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  5. Owner's Manual

Yamaha big bear 250 YFM250A Owner's Manual

Summary of big bear 250 YFM250A

  • Page 1

    Yfm25ba yfm250a owner’s manual manuel du propriÉtaire manual del propietario 1p0-f8199-66 read this manual carefully! It contains important safety information. Lire attentivement ce manuel! Il comprend d’importantes informations de sécurité. ¡lea este manual atentamente! Contiene indicaciones import...

  • Page 2

    Printed in usa 2010.08-0.3 × 1 cr (e,f,s) yamaha motor co., ltd. Dic183.

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Owner’s manual yfm25ba yfm250a 1p0-f8199-66-e0 u1p066e0.Book page 1 thursday, august 5, 2010 4:15 pm.

  • Page 4

    Ebu17114 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. Ansi/svia 1-2007 general manager rv engineering division mc operations yamaha motor co., ltd. 9 march, 2010 yfm250 (yfm25b) (5y4ag01w0a0518901–) we, yamaha motor co., ltd. 25...

  • Page 5

    Ebu17170 introduction ebu17292 congratulations on your purchase of the yamaha yfm25ba/yfm250a. This atv represents the result of many years of yamaha experience in the production of fine sporting, touring, and pacesetting racing ma- chines. With the purchase of this yamaha, you can now appreciate th...

  • Page 6

    Ebu17330 important manual information ebu17342 failure to follow the warnings contained in this manual can result in serious in- jury or death. Particularly important information is distinguished in this manual by the following notations: * product and specifications are subject to change without no...

  • Page 7

    Ebu17350 important notice ebu17372 this atv is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this atv on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations before operating this atv. Ebu17410 yfm25ba/yfm2...

  • Page 8

    Ebu17420 table of contents location of the warning and specification labels ............................ 1-1 safety information .............................. 2-1 description .............................................. 3-1 left view ...................................................... 3-1 right...

  • Page 9

    Operating the drive select lever and driving in reverse ...................................... 6-3 shifting ....................................................... 6-4 engine break-in .......................................... 6-6 parking ....................................................... 6-7 p...

  • Page 10

    Checking and lubricating the front and rear brake levers .................................... 8-36 checking the shift pedal ........................... 8-37 checking and lubricating the brake pedal ...................................................... 8-37 checking the wheel hub bearings .............

  • Page 11

    1-1 1 ebu29680 location of the warning and specification labels ebu30290 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a re...

  • Page 12

    1-2 1 1p0-f817r-00 30 kg ( 66 lbs) 1p0-f817r-10 45 kg ( 99 lbs) 20.0 kpa 0.20 kgf/cm² 2.9 psi 25.0 kpa 0.25 kgf/cm² 3.6 psi 4xe-f816m-m0 1p0-f816p-20 3230 n 330 kgf 727 lbf 147 n 15 kgf 33 lbf 1p0-f817s-00 1 3 4 5 2 u1p066e0.Book page 2 thursday, august 5, 2010 4:15 pm.

  • Page 13

    1-3 1 1p0-f816l-20 1p0-f816r-00 yamaha motor co., ltd. 2500 shingai, iwata, japan yfm250 12.2 kw 216 kg 2010 1p0-f155a-30 6 7 8 9 u1p066e0.Book page 3 thursday, august 5, 2010 4:15 pm.

  • Page 14

    1-4 1 familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the owner’s manual. Always use an approved helmet and protective gear. Never permit children under age 6 to operate this atv. Operation of thi...

  • Page 15

    1-5 1 **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi never use with drugs or alcohol. Never store fuel or flammable liquids. This unit contains high-pressure nitrogen gas. Mishandling can cause an explosion. Do not incinerate, puncture or open. Use unleaded gasoline only. Measure the ti...

  • Page 16

    1-6 1 yamaha motor co., ltd. 2500 shingai, iwata, japan ****** *** kw *** kg **** 1 2 3 4 this pictogram shows trailer hitch tow weight limit. (combined weight of the trailer and all cargo in the trailer.) overloading can cause loss of control. Loss of control can result in severe injury or death. T...

  • Page 17

    1-7 1 for oceania u1p066e0.Book page 7 thursday, august 5, 2010 4:15 pm.

  • Page 18

    1-8 1 3230 n 727 ( 3 3 0 k g f ) ( 1 5 k g f ) 4xe-f151k-00 4xe-f816m-20 20 kpa, (2.9 psi) 25 kpa, (3.6 psi) 17 kpa, (2.5 psi) 22 kpa, (3.2 psi) 165 kg, (364 lbs) 30 kg (66 lbs) 4xe-f4877-20 45 kg (99 lbs) 4xe-f4897-20 1 3 4 5 2 u1p066e0.Book page 8 thursday, august 5, 2010 4:15 pm.

  • Page 19

    1-9 1 16 under 7 6 u1p066e0.Book page 9 thursday, august 5, 2010 4:15 pm.

  • Page 20

    2-1 2 ebu17431 safety information ebu17463 an atv is not a toy and can be hazard- ous to operate. An atv handles differently from other vehicles, in- cluding motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over o...

  • Page 21

    2-2 2 ● always inspect your atv each time you use it to make sure it is in safe operating condition. Al- ways follow the inspection and maintenance procedures and schedules described in this manual. ● always keep both hands on the handlebars and both feet on the footboards of the atv during operatio...

  • Page 22

    2-3 2 speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill. Turn the atv around and remount, following the procedure described in this manual. ● always chec...

  • Page 23

    2-4 2 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and seek medical ...

  • Page 24

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Headlights 2. Fuel cock 3. Recoil starter 4. Fuses 5. Battery 6. Tail/brake light 7. Rear shock absorber assembly spring preload adjusting ring 8. Engine oil drain bolt 9. Shift pedal 9 1. Spark arrester 2. Storage compartment and ...

  • Page 25

    3-2 3 ebu17712 controls and instruments tip the atv you have purchased may differ slightly from the figures shown in this manual. 1. Drive select lever 2. Rear brake lever 3. Handlebar switches 4. Parking brake lock plate 5. Horn switch 6. Starter (choke) 7. Main switch 8. Brake fluid reservoir 9. T...

  • Page 26

    4-1 4 ebu17733 instrument and control functions ebu17760 main switch the positions of the main switch are as follows: on all electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. Off all...

  • Page 27

    4-2 4 ebu17793 indicator lights ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu17830 reverse indicator light “ ” this indicator light comes on when the transmis- sion is in the reverse position. Ebu18061 handlebar switches eb...

  • Page 28

    4-3 4 ebu18101 start switch “ ” push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. Ebu18152 light switch “ / /off” set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to turn on the hig...

  • Page 29

    4-4 4 ebu18323 speed limiter your atv is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the ...

  • Page 30

    4-5 4 ebu18442 brake pedal and rear brake lever the brake pedal is located on the right side of the atv and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. 1. Front brake lever 1. Brake pe...

  • Page 31

    4-6 4 ebu18460 parking brake use the parking brake before starting the engine or parking the atv, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. Warning ewb00220 ● always set the pa...

  • Page 32

    4-7 4 ebu18571 drive select lever the drive select lever is used for driving the atv either forward or in reverse. See the “operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. Ebu27610 recoil starter firmly grasp the handle and pull slig...

  • Page 33

    4-8 4 ebu18754 fuel make sure there is sufficient gasoline in the tank. Warning ewb02521 gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, fol- low these instructions. 1. Before refueling, turn off the engine and be s...

  • Page 34

    4-9 4 3. Wipe up any spilled fuel immediately. Notice: immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. [ecb00981] 4. Turn the fuel tank cap fully clockwise to make sure it is securely closed. Warning ewb02531 gasoline is ...

  • Page 35

    4-10 4 off with the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. On with the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine an...

  • Page 36

    4-11 4 res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to “on”! Ebu18850...

  • Page 37

    4-12 4 to install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Make sure that the seat is securely fitted. Ebu18921 storage compartment notice ecb00130 do not store metal or sharply edged objects, like tools, in the storage com...

  • Page 38

    4-13 4 when storing any documents in the storage com- partment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the atv, be careful not to let any water enter the storage compartment. Tip there is a check hose at the bottom of the storage compartment. If any water c...

  • Page 39

    4-14 4 ebu19023 adjusting the rear shock absorber as- sembly the spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Notice ecb01090 never turn the adjusting mechanism beyond the minimum and maximum settings. Adjust the spring preload as follows. Turn the spring pr...

  • Page 40

    4-15 4 1. Special wrench spring preload setting: minimum (soft): 1 standard: 2 maximum (hard): 5 u1p066e0.Book page 15 thursday, august 5, 2010 4:15 pm.

  • Page 41

    5-1 5 ebu19201 pre-operation checks ebu19224 inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual. Warning ewb00481 failure to inspect or maintain the v...

  • Page 42

    5-2 5 rear brake • check operation, and correct if necessary. • lubricate cable if necessary. • check lever and pedal free play, and adjust if necessary. 5-3, 8-28, 8-31 throttle lever • make sure that operation is smooth. Lubricate cable and lever hous- ing if necessary. • check lever free play, an...

  • Page 43

    5-3 5 ebu19541 fuel make sure that there is sufficient fuel in the tank. (see page 4-8.) ebu19560 engine oil make sure that the engine oil is at the specified lev- el. Add oil as necessary. (see page 8-11.) ebu19590 final gear oil make sure that the final gear oil is at the specified level. Add oil ...

  • Page 44

    5-4 5 ebu19761 throttle lever check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a yamaha dealer correct if necessary. Ebu19814 tires check tire pressure regularly to make sure it is at the recommended specifications. Also check ...

  • Page 45

    5-5 5 tire wear limit when the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. Tire information this atv is equipped with tubeless tires with valves. Warning ewb02551 use of improper tires on this atv may cause loss of control, increasing your risk of an acci- dent. After exte...

  • Page 46

    5-6 5 aftermarket tires and rims the tires and rims that came with your atv were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Ebu19840 chassis fasteners make su...

  • Page 47

    6-1 6 ebu19881 operation ebu19901 read the owner’s manual carefully before riding the atv. If there is a control or function you do not understand, ask your yamaha dealer. Warning ewb00631 read the owner’s manual carefully to become familiar with all controls in order to help pre- vent any loss of c...

  • Page 48

    6-2 6 ambient temp./starter (choke) position 6. Completely close the throttle lever and start the engine by pushing the start switch. Tip ● if the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as pos...

  • Page 49

    6-3 6 ebu20291 starting a warm engine follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. Ebu20321 operating the drive select lever and driving in reve...

  • Page 50

    6-4 6 tip to shift into reverse, the transmission must be in first gear. 1. Bring the atv to a complete stop. 2. Apply the brake pedal. 3. Shift the transmission into first gear. 4. Move the drive select lever to the rear until it completely stops. Tip when in reverse, the reverse indicator light sh...

  • Page 51

    6-5 6 ebu20611 to start out and accelerate 1. Release the throttle lever. Notice ecb00200 always close the throttle before shifting gears, otherwise damage to the engine and drive train may result. 2. Shift into first gear and release the shift pedal. 3. Open the throttle gradually. Warning! Al- way...

  • Page 52

    6-6 6 could make the wheels stop rotating and lose traction. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. Notice ecb00190 even with the transmission in the neutral posi- tion, do not coast for long periods of time with the engine off, an...

  • Page 53

    6-7 6 notice ecb00220 if any engine trouble should occur during the engine break-in period, immediately have a yamaha dealer check the atv. Ebu20722 parking when parking the atv, shift into first gear, stop the engine, apply the parking brake, and then turn the fuel cock to “off”. Ebu20844 parking o...

  • Page 54

    6-8 6 ebu20910 accessories and loading ebu20921 genuine yamaha accessories choosing accessories for your atv is an important decision. Genuine yamaha accessories, which are available only from a yamaha dealer, have been designed, tested, and approved by yamaha for use on your atv. Many companies wit...

  • Page 55

    6-9 6 bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view. ● use extra caution when riding an atv with ac- cessories. The atv may handle differently than it does without accessorie...

  • Page 56

    6-10 6 ● load cargo on the carriers as close to the center of the atv as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it. ● tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an a...

  • Page 57

    7-1 7 ebu21141 riding your atv u1p066e0.Book page 1 thursday, august 5, 2010 4:15 pm.

  • Page 58

    7-2 7 ebu21346 getting to know your atv this atv is for recreation and utility use. This sec- tion, riding your atv, provides general atv riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your at...

  • Page 59

    7-3 7 riding your atv requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the atv’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more di...

  • Page 60

    7-4 7 apparel always wear the following to reduce risk of injury in an accident: ● approved motorcycle helmet that fits properly ● eye protection (goggles, helmet face shield, or protective eyewear) ● over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants an approved helmet and o...

  • Page 61

    7-5 7 do not operate after or while consuming alco- hol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. Consuming al- cohol or drugs could seriously affect your judg- ment, cause you to react more slowly, and affect your balance and perception. Warnin...

  • Page 62

    7-6 7 opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and de- creases the maximum speed of the atv. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (see page 4-4.) loa...

  • Page 63

    7-7 7 drive more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice to drive slowly (shift into first gear or low drive if avail- able on this model) whenever you are carrying heavier loads or when towing a trailer...

  • Page 64

    7-8 7 an overturn. Never attempt stunts, such as wheelies or jumps. Don’t try to show off. [ewb01481] modifications and accessories never modify this atv through improper installa- tion or use of accessories or other modification. All parts and accessories added to this atv should be genuine yamaha ...

  • Page 65

    7-9 7 to prevent burns, avoid touching the exhaust sys- tem. Park the atv in a place where pedestrians or children are not likely to touch it. Be careful where you ride this atv is designed for use on unpaved surfaces only. Warning! Paved surfaces may seriously affect handling and control of the atv...

  • Page 66

    7-10 7 know your country’s laws and regulations before you ride on unpaved public streets or roads. Do not ride on any paved public street, road or motorway. Warning! Never operate this atv on any paved street, paved road or motorway. You can collide with another vehicle. [ewb01521] know the terrain...

  • Page 67

    7-11 7 loose terrain could cause loss of traction or atv control, which could result in an accident, including an overturn. [ewb01541] when riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the atv. Do not use the flag pole bracket as a trailer hit...

  • Page 68

    7-12 7 select a large, flat, unpaved area to become famil- iar with your atv. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Set the pa...

  • Page 69

    7-13 7 the atv will resist turning. A special turning tech- nique must be used to allow the atv to make turns quickly and easily. It is essential that this skill be learned first at low speed. As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so,...

  • Page 70

    7-14 7 improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the atv to tip. If the atv begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be n...

  • Page 71

    7-15 7 do not attempt to climb hills until you have mas- tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. To climb a hill, you need trac...

  • Page 72

    7-16 7 if you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the atv around while you still have forward motion (provided you have the room to do so) and go down the hill. If your atv has stalled or stopped and you believe you c...

  • Page 73

    7-17 7 ● shift your weight backward and to the up side of the hill. ● never go down a hill at high speed. ● avoid going down a hill at an angle that would cause the atv to lean sharply to one side. Go straight down the hill where possi- ble. ● improper braking can cause the wheels on the uphill side...

  • Page 74

    7-18 7 ● shift your weight to the uphill side of the atv. ● never attempt to turn the atv around on any hill until you have mastered the turning tech- nique as described in the owner’s manual on level ground. Be very careful when turning on any hill. Traversing a sloping surface on your atv requires...

  • Page 75

    7-19 7 the atv can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the atv. Drive slowly and ca...

  • Page 76

    7-20 7 riding over rough terrain warning ewb01651 riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always fo...

  • Page 77

    7-21 7 cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the atv as loss of control and damage to the atv may re- sult. Sliding and skidding warning ewb01662 skidding or sliding improperly may cause you to lose control of this atv. You may also re- gain t...

  • Page 78

    7-22 7 with practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are re- duced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery sur...

  • Page 79

    7-23 7 ● if your atv is traversing a sloping surface: be sure to ride with your weight positioned to- wards the uphill side of the atv to maintain proper balance. If the atv starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the atv is ...

  • Page 80

    8-1 8 ebu28783 periodic maintenance and adjustment ebu21673 periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most effi- cient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustmen...

  • Page 81

    8-2 8 ebu21731 owner’s manual and tool kit be sure to put this owner’s manual in the plastic bag and always carry it on the bottom of the seat as shown. Put the owner’s tool kit and low-pres- sure tire gauge under the seat. The service information included in this manual and the tools provided in th...

  • Page 82

    8-3 8 ebu21743 periodic maintenance chart for the emission control system tip ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep i...

  • Page 83

    8-4 8 6 * exhaust system • check for leakage and replace gasket(s) if neces- sary. • check for looseness and tighten all screw clamps and joints if necessary. √ √ √ 7 spark arrester • clean. √ √ √ no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (2...

  • Page 84

    8-5 8 ebu21865 general maintenance and lubrication chart tip ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep in mind that if th...

  • Page 85

    8-6 8 5 * brake hoses • check for cracks or other damage, and replace if necessary. √ √ √ √ • replace. Every 4 years 6 * wheels • check runout and for damage, and replace if nec- essary. √ √ √ √ 7 * tires • check tread depth and for damage, and replace if necessary. • check air pressure and balance,...

  • Page 86

    8-7 8 14 engine oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ √ √ 15 engine oil filter ele- ment • clean or replace if necessary. √ √ √ 16 engine oil strainer • clean. √ √ √ 17 final gear oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ 18 * mov...

  • Page 87

    8-8 8 ebu28391 tip ● some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal components...

  • Page 88

    8-9 8 ebu23213 checking the spark plug the spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart. In ad...

  • Page 89

    8-10 8 tip if the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a yamaha dealer check the atv. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and repla...

  • Page 90

    8-11 8 tip if a torque wrench is not available when installing the spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 3. Install the spark plug cap. Ebu2329g engine oil and oil ...

  • Page 91

    8-12 8 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level. Notice: be sure the engine oil is at the correct level, otherwise engine damage may result. [ecb00851] 6. Insert the dipstick into the oil filler hole, an...

  • Page 92

    8-13 8 tip skip steps 5–12, 18, and 19 if the oil filter element is not being cleaned. 5. Remove the footboard by removing the bolts. 6. Fully loosen the brake pedal free play adjust- ing nut, and push the brake pedal downward. 1. Engine oil drain bolt 2. O-ring 3. Compression spring 4. Oil strainer...

  • Page 93

    8-14 8 7. Move the drive select lever safety system ca- ble away from the oil filter element cover. 8. Remove the oil filter element cover by remov- ing the bolts, and then remove the oil filter el- ement and the o-ring. Notice: do not loosen the adjusting nuts shown when re- moving the oil filter e...

  • Page 94

    8-15 8 9. Clean the oil strainer and oil filter element with solvent. 10. Install the oil filter element and a new o-ring. Tip make sure that the o-ring is properly seated. 11. Apply a thin coat of clean engine oil to the o- ring. 12. Install the oil filter element cover by installing the bolts, and...

  • Page 95

    8-16 8 13. Apply a thin coat of clean engine oil to a new o-ring. 14. Install the oil strainer, the compression spring, the new o-ring and the engine oil drain bolt, and then tighten the engine oil drain bolt to the specified torque. Notice: before installing the engine oil drain bolt, be sure to in...

  • Page 96

    8-17 8 a higher quality than specified. In addition, do not use oils labeled “energy conserv- ing ii” or higher. ● make sure that no foreign material enters the crankcase. 16. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately...

  • Page 97

    8-18 8 ebu23386 final gear oil the final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a yamaha dealer check and repair the atv. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the peri...

  • Page 98

    8-19 8 to change the final gear oil 1. Place the atv on a level surface. 2. Remove the final gear case guard by remov- ing the bolts. 3. Place an oil pan under the final gear case to collect the used oil. 4. Remove the final gear oil filler bolt, the final gear oil drain bolt, and their gasket to dr...

  • Page 99

    8-20 8 7. Check the oil filler bolt gasket for damage, and replace it if necessary. 8. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque. 9. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 10. Install the final gear case ...

  • Page 100

    8-21 8 1. Place the atv on a level surface. 2. Remove the seat. (see page 4-11.) 3. Remove the air filter case cover by unhooking the holders. 4. Pull the air filter element assembly out of the air filter case. 1. Air filter case check hose 1. Air filter case cover 2. Air filter case cover holder u1...

  • Page 101

    8-22 8 5. Remove the sponge material from the air filter element. 6. Clean the sponge material with water or sol- vent. Warning! When using solvent to clean the sponge material, always use parts cleaning solvent or water. Never use low-flash-point solvents or gasoline to clean the sponge material be...

  • Page 102

    8-23 8 8. Check the sponge material and replace it if damaged. 9. Tap the air filter element lightly to remove most of the dust and dirt. Blow out the remain- ing dirt with compressed air as shown. If the air filter element is damaged, replace it. 10. Pull the sponge material over the air filter ele...

  • Page 103

    8-24 8 12. Install the seat. Tip the air filter element should be cleaned every 20– 40 hours. It should be cleaned more often if the atv is operated in extremely dusty areas. Each time the air filter element maintenance is per- formed, check the air inlet of the air filter case for obstructions. Che...

  • Page 104

    8-25 8 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the tailpipe bolts and tighten them to the specified torque. Warning ewb02340 do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing,...

  • Page 105

    8-26 8 notice ecb00480 the carburetor has been set and extensively tested at the yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performance of or damage to the engine. Ebu24000 adjusting the engine idling speed the engine idling speed must be chec...

  • Page 106

    8-27 8 tip if the specified idling speed cannot be obtained as described above, have a yamaha dealer make the adjustment. Ebu24047 adjusting the throttle lever free play the throttle lever free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance ...

  • Page 107

    8-28 8 ebu24071 adjusting the drive select lever safety system cable the drive select lever safety system cable stretch- es with use, which can result in improper function. Therefore, the safety system cable should be checked and adjusted by a yamaha dealer at the intervals specified in the periodic...

  • Page 108

    8-29 8 ebu24180 rear brake shoes the rear brake is provided with a wear indicator, which allows you to check the brake shoe wear without having to disassemble the brake. To check the brake shoe wear, check the position of the wear indicator while applying the brake. If a brake shoe has worn to the p...

  • Page 109

    8-30 8 ● use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. ● refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. ● be careful that...

  • Page 110

    8-31 8 ebu24575 adjusting the brake pedal height and free play, and the rear brake lever free play the brake pedal height and free play, and the brake lever free play must be checked and, if nec- essary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Tip ● alw...

  • Page 111

    8-32 8 the brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) as shown. If the free play is incorrect, adjust it as follows. A. Fully loosen the brake lever free play ad- justing nut on the brake cable at the rear wheel hub. B. Turn the brake pedal free play adjusting nut on the brake ...

  • Page 112

    8-33 8 a. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjust- ing bolt. B. Turn the brake lever free play adjusting nut on the brake cable at the rear wheel hub so that the distance between the brake cam- shaft lever and the pin, gap “a”, measures 0–1 mm (0–0.04...

  • Page 113

    8-34 8 d. Tighten the locknut at the brake lever. E. Install the footboard. Tip when adjusting the rear brake lever free play: ● be sure not to step on the brake pedal. ● make sure the brake pedal does not move. Ebu24762 brake light switches the brake light, which is activated by the brake pedal and...

  • Page 114

    8-35 8 ebu24803 adjusting the clutch free play the clutch free play must be adjusted periodically. Adjust the free play as follows. 1. Remove the footboard. (see “engine oil” on page 8-11 for removal and installation proce- dures.) 2. Loosen the locknut. 3. Slowly turn the clutch adjusting screw in ...

  • Page 115

    8-36 8 warning ewb02581 ● inspect cables frequently and replace if dam- aged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury. ● always make sure all control cabl...

  • Page 116

    8-37 8 rear brake lever ebum0170 checking the shift pedal the operation of the shift pedal should be checked before each ride. If operation is not smooth, have a yamaha dealer check the vehicle. Ebu30310 checking and lubricating the brake pedal the operation of the brake pedal should be checked befo...

  • Page 117

    8-38 8 in a wheel hub or if a wheel does not turn smoothly, have a yamaha dealer check the wheel hub bear- ings. Ebu24995 lubricating the swingarm pivots the swingarm pivots must be lubricated by a yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart. Ebu25092...

  • Page 118

    8-39 8 ebu30350 battery the battery is located behind the seat. A poorly maintained battery will corrode and dis- charge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance an...

  • Page 119

    8-40 8 tip the electrolyte should be between the minimum and maximum level marks. 4. If the electrolyte is at or below the minimum level mark, add distilled water to raise it to the maximum level mark. Notice: use only dis- tilled water, as tap water contains minerals that are harmful to the battery...

  • Page 120

    8-41 8 5. Remove the battery. To store the battery ● if the atv will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. ● if the battery will be stored for more than two months, check the specific gravity of the electro- lyte at least on...

  • Page 121

    8-42 8 posed to electrolyte or gas expelled from the battery, the frame could suffer struc- tural and external damages. [ecb00611] 6. Install the battery cover. Ebu25243 replacing the fuse the fuse holder is located under the seat. (see page 4-11.) if the fuse is blown, replace it as follows. 1. Tur...

  • Page 122

    8-43 8 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Warning! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical system, which coul...

  • Page 123

    8-44 8 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 4. Remove the burnt-out bulb by pulling it out. 5. Insert a new headlight bulb into the bulb hold- er by pushing it in. Notice: do not touch the glass part of the headlight bulb to keep it free from oil, oth...

  • Page 124

    8-45 8 ebu25551 adjusting a headlight beam notice ecb00690 it is advisable to have a yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b). Ebu25611 replacing the t...

  • Page 125

    8-46 8 3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 4. Install the bulb holder (together with the bulb) by turning it clockwise. Ebu25651 removing a wheel 1. Place the atv on a level surface. 2. Loosen the wheel nuts. 3. Elevate the atv and place ...

  • Page 126

    8-47 8 ● tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 3. Lower the atv to the ground. 4. Tighten the wheel nuts to the specified torques. 1. Arrow mark 1 1. Tapered nut tightening torques: front wheel nut: 55 nm (5.5 m·kgf, 4...

  • Page 127

    8-48 8 ebu25720 troubleshooting although yamaha atvs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshootin...

  • Page 128

    8-49 8 ebu25791 troubleshooting chart check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compression. Operate the electric starter. 2. Compression there is compression. There is no compressio...

  • Page 129

    9-1 9 ebu25860 cleaning and storage ebu25881 cleaning frequent, thorough cleaning of your atv will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the atv: a. Block off the end of the exhaust pipe to prevent w...

  • Page 130

    9-2 9 ebu25933 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a porous cover. Notice: storing the atv in a poorly ven- tilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust...

  • Page 131

    9-3 9 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. D...

  • Page 132

    10-1 10 ebu25960 specifications dimensions: overall length: 1916 mm (75.4 in) overall width: 1038 mm (40.9 in) overall height: 1118 mm (44.0 in) seat height: 772 mm (30.4 in) wheelbase: 1170 mm (46.1 in) ground clearance: 150 mm (5.9 in) minimum turning radius: 2900 mm (114 in) weight: with oil and ...

  • Page 133

    10-2 10 type: sae 5w-30, 10w-30, 10w-40, 15w-40, 20w-40 or 20w- 50 recommended engine oil grade: api service sg type or higher, jaso standard ma engine oil quantity: without oil filter element removal: 1.50 l (1.59 us qt, 1.32 imp.Qt) with oil filter element removal: 1.60 l (1.69 us qt, 1.41 imp.Qt)...

  • Page 134

    10-3 10 transmission type: constant mesh 5-speed.Forward, 1-speed.Reverse operation: left foot operation gear ratio: 1st: 34/12 (2.833) 2nd: 34/19 (1.789) 3rd: 29/22 (1.318) 4th: 26/25 (1.040) 5th: 23/28 (0.821) reverse gear: 73/22 × 34/12 × 19/18 (9.924) chassis: frame type: steel tube frame caster...

  • Page 135

    10-4 10 rim size: 10 x 8.0at front brake: type: disc brake operation: right hand operation recommended fluid: dot 4 rear brake: type: drum brake operation: left hand and right foot operation front suspension: type: strut spring/shock absorber type: coil spring/oil damper wheel travel: 125 mm (5.0 in...

  • Page 136

    11-1 11 ebu26000 consumer information ebu28200 identification numbers record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a yamaha dealer or for reference in case the atv is stolen. Vehicle identification n...

  • Page 137

    11-2 11 tip the vehicle identification number is used to identify your atv. Ebu26050 model label the model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a yamaha dea...

  • Page 138

    Index a accessories and loading ................................................ 6-8 air filter element, cleaning ............................................ 8-20 b battery ...................................................................5-6, 8-39 brake fluid, changing ..............................

  • Page 139

    M main switch .................................................................... 4-1 maintenance and lubrication chart ................................. 8-5 maintenance chart, emission control system ................. 8-3 model label ...................................................................

  • Page 140

    Yamaha motor co., ltd. Printed in usa 2010.08-0.3 × 1 cr (e) u1p066e0.Book page 1 thursday, august 5, 2010 4:15 pm.