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Yamaha WOLVERINE 350 YFM25XX Owner's Manual

Summary of WOLVERINE 350 YFM25XX

  • Page 1

    Yfm35xx owner’s manual manuel du propriÉtaire manual del propietario 3d5-f8199-62 dic183.

  • Page 2

    Printed in usa 2007.07-0.3 ×1 cr (e,f,s) yamaha motor co., ltd. Dic183.

  • Page 3: Owner’S Manual

    Owner’s manual yfm35xx 3d5-f8199-62-e0 u3d562e0.Book page 1 wednesday, june 6, 2007 12:58 pm.

  • Page 4

    U3d562e0.Book page 2 wednesday, june 6, 2007 12:58 pm.

  • Page 5

    Ebu17170 introduction ebu17320 congratulations on your purchase of the yamaha yfm35xx. This atv represents the result of many years of yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this yamaha, you can now appreciate the high deg...

  • Page 6

    Ebu17330 important manual information ebu17341 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 ebu17370 welcome to the yamaha world of motor sports! 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 bef...

  • Page 8

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

  • Page 9

    Operating the drive select lever and driving in reverse ...................................... 6-3 engine break-in .......................................... 6-4 parking ....................................................... 6-5 parking on a slope ..................................... 6-5 accessori...

  • Page 10

    Axle boots ................................................ 8-31 brake light switches ................................. 8-31 checking and lubricating the cables ........ 8-32 checking and lubricating the front and rear brake levers .................................... 8-32 checking and lubricating t...

  • Page 11

    1-1 1 ebu17430 safety information ebu17534 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 12

    1-2 1 ● 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 13

    1-3 1 hill. If you stall or roll backwards, follow the spe- cial procedure for braking described in this man- ual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the atv around and remount, following the procedure described in this manual. ● always check for obstacles befo...

  • Page 14

    1-4 1 ● when transporting the atv in another vehi- cle, be sure it is kept upright and that the fuel cock is in the “off” position. Otherwise, fuel may leak out of the carburetor or fuel tank. ● gasoline is poisonous. If you should swal- low some gasoline or inhale a lot of gasoline vapor, or get so...

  • Page 15

    2-1 2 ebu17660 location of the warning and specification labels u3d562e0.Book page 1 wednesday, june 6, 2007 12:58 pm.

  • Page 16

    2-2 2 ebu17670 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 replace- ment label from your yamaha dealer. U3d562e0.Book p...

  • Page 17

    2-3 2 u3d562e0.Book page 3 wednesday, june 6, 2007 12:58 pm.

  • Page 18

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Front shock absorber assembly spring preload adjusting ring 2. Fuel cock 3. Air filter case 4. Fuses 5. Storage compartment and tool kit 6. Seat lock lever 7. Rear shock absorber assembly spring preload adjusting ring 8. Engine oil...

  • Page 19

    3-2 3 ebu17712 controls and instruments note: the atv you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Drive select lever 5. Main switch 6. Fuel tank cap 7. Front brake lever 8. Throttle lever u3d562e0.Book ...

  • Page 20

    4-1 4 ebu17731 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 21

    4-2 4 ebu17813 indicator lights and warning light ebu17830 reverse indicator light “ ” this indicator light comes on when the transmis- sion is in the reverse position. Ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu26931 oil...

  • Page 22

    4-3 4 ebu18061 handlebar switches ebu18080 engine stop switch “ / ” set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run ...

  • Page 23

    4-4 4 ebu18280 throttle lever once the engine is running, movement of the throt- tle lever will increase the engine speed. Regulate the speed of the atv by varying the throttle position. Because the throttle is spring- loaded, the atv will decelerate, and the engine will return to an idle any time t...

  • Page 24

    4-5 4 3. Tighten the locknut. Warning ewb00240 improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle...

  • Page 25

    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 26

    4-7 4 ● always be sure you have released the park- ing brake before you begin to ride. The brake could overheat if you ride the atv without re- leasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely. Ebu18581 drive ...

  • Page 27

    4-8 4 ebu18752 fuel make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 1. Fuel tank cap 1. Fuel level 2. Fuel tank filler tube recommended fuel: unleaded gasoline only for europe: regular unleaded gasoline only with a research octane nu...

  • Page 28

    4-9 4 note: if knocking or pinging occurs, use a different brand of gasoline or higher octane grade. Caution: ecb00070 use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Warn...

  • Page 29

    4-10 4 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 and riding. Res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to thi...

  • Page 30

    4-11 4 move the starter (choke) in direction (b) to turn off the starter (choke). See the “starting a cold engine” section on page 6-1 for proper operation. Ebu26981 seat to remove the seat push the seat lock lever backward and pull up the seat at the rear. 1. Starter (choke) “ ” 1. Seat 1. Seat loc...

  • Page 31

    4-12 4 to install the seat fit the slot in the seat onto the projection on the front cowling, insert the projections on the front of the seat into the seat holders, and then push on the seat at the rear. Note: make sure that the seat is securely fitted. Ebu26551 storage compartment the storage compa...

  • Page 32

    4-13 4 ● do not exceed the maximum load of 100.0 kg (220 lb) for the atv. Note: drain plugs are fitted at the bottom of the storage compartment. If any water collects in the storage compartment, remove the drain plugs, drain the water, and then install the drain plugs. Ebu18990 adjusting the front s...

  • Page 33

    4-14 4 warning ewb00400 always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. Ebu19020 adjusting the rear shock absorber as- sembly the spring preload can be adju...

  • Page 34

    4-15 4 note: a special wrench can be obtained at a yamaha dealer to make this adjustment. 1. Spring preload adjusting ring 2. Position indicator 1. Special wrench spring preload setting: minimum (soft): 1 standard: 2 maximum (hard): 5 u3d562e0.Book page 15 wednesday, june 6, 2007 12:58 pm.

  • Page 35

    5-1 5 ebu19200 pre-operation checks ebu19222 pre-operation check list before operating this atv, be sure to check the items listed in the following table. Warning ewb00480 always inspect your atv each time you use it to make sure it is in safe operating condition. Always follow the inspection and ma...

  • Page 36

    5-2 5 rear brake • check operation, and correct if necessary. • lubricate cables if necessary. • check lever and pedal free play, and adjust if necessary. 5-3, 8-25, 8-28 throttle lever • make sure that operation is smooth. Lubricate cable and lever hous- ing if necessary. • check cable free play, a...

  • Page 37

    5-3 5 ebu19540 fuel make sure that there is sufficient fuel in the tank. (see page 4-8.) warning ewb00520 ● do not overfill the fuel tank. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the en- gine or the sun. ● be careful not to spill fuel, esp...

  • Page 38

    5-4 5 lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be checked by a yamaha dealer. Brake operation test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braki...

  • Page 39

    5-5 5 ● the tires should be set to the recommended pressure: recommended tire pressure: front: 25.0 kpa (3.6 psi) (0.250 kgf/cm²) rear: 25.0 kpa (3.6 psi) (0.250 kgf/cm²) • check and adjust tire pressures when the tires are cold. • tire pressures must be equal on both sides. • tire pressure below th...

  • Page 40

    5-6 5 set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: ebu19830 tire wear limit replace the tire when the tire groove decreases to 3 mm (0.12 in). Ebu19840 chassis fasteners make sure that all nuts, bolts and screws are prop- erly tightened. Ebu1...

  • Page 41

    6-1 6 ebu19880 operation ebu19900 read the owner’s manual carefully before riding the atv. Warning ewb00630 read the owner’s manual carefully to become familiar with all controls in order to help pre- vent any loss of control, which could cause an accident or injury. If there is a control or func- t...

  • Page 42

    6-2 6 5. Use the starter (choke) in reference to the fig- ure: position (1): cold engine start with ambient temperature below 5 °c (40 °f). Position (2): cold engine start with ambient temperature between 0 °c (30 °f) and 30 °c (90 °f). Position (3): cold engine start with ambient temperature above ...

  • Page 43

    6-3 6 note: the engine is warm when it responds normally to the throttle with the starter (choke) turned off. 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 t...

  • Page 44

    6-4 6 3. Shift from neutral to reverse and vice versa by moving the drive select lever along the shift guide. Note: when in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a yamaha dealer check the electrical circuit. 4. Check behind for people or o...

  • Page 45

    6-5 6 polish themselves to the correct operating clear- ances. During this period, prolonged full-throttle operation or any condition that might result in en- gine overheating must be avoided. 0–160 km (0–100 mi) or 0–10 hours avoid prolonged operation above 1/2 throttle. Vary the speed of the atv r...

  • Page 46

    6-6 6 3. With the rear brake lever and pedal applied, apply the parking brake, and then slowly re- lease the brake pedal. Ebu20910 accessories and loading ebu20920 accessories accessories can affect the handling and control of your atv. Keep the following in mind when consid- ering an accessory or o...

  • Page 47

    6-7 6 judgment as the stability and handling of an atv can be changed. When adding accessories, keep the following points in mind: ● never exceed the weight limits shown. An over- loaded atv can be unstable. ● if you are carrying cargo and towing a trailer, in- clude the tongue weight in the maximum...

  • Page 48

    7-1 7 ebu21141 riding your atv u3d562e0.Book page 1 wednesday, june 6, 2007 12:58 pm.

  • Page 49

    7-2 7 ebu26970 getting to know your atv this atv is intended for recreational use by expe- rienced operators only. Even if you are an experi- enced operator of all other all terrain atvs or motorcycles, riding the atv requires special skills acquired through practice. Take your time to fully learn t...

  • Page 50

    7-3 7 not recommended for children under 16 years of age. Warning ewb01390 a child under 16 should never operate an atv with engine size greater than 90 cc. Use by chil- dren of atvs that are not recommended for their age can lead to severe injury or death of the child. This atv is designed to carry...

  • Page 51

    7-4 7 apparel always wear an approved motorcycle helmet that fits properly. You should also wear: ● eye protection (goggles or face shield) ● gloves ● boots ● long-sleeved shirt or jacket ● long pants 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet u3d562e0.Book page 4 wednesday, june...

  • Page 52

    7-5 7 warning ewb01410 never operate this atv without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protecti...

  • Page 53

    7-6 7 in the owner’s manual. Failure to inspect the atv before operating or failure to properly maintain the atv increases the possibility of an accident or equipment damage. Warning ewb01440 always use the size and type tires specified in the owner’s manual for this atv on page 5-4. Always maintain...

  • Page 54

    7-7 7 loading and accessories as originally equipped, this atv is not designed to carry cargo or tow a trailer. If you choose to add ac- cessories so that you can carry cargo or tow a trail- er, you must use common sense and good judgment. Use extra caution when riding the atv with addi- tional load...

  • Page 55

    7-8 7 foot can reduce your ability to control the atv or could cause you to lose your balance and fall off of the atv. If you remove a foot from a footboard, your foot or leg may come into con- tact with the rear wheels, which could injure you or cause an accident. Avoid wheelies and jumping. You ma...

  • Page 56

    7-9 7 ● do not park the atv during or after operation in a place where others might be likely to touch it. ● do not operate, idle, or park the atv in dry grass, dry ground cover, or combustible ma- terials. Be careful where you ride this atv is designed for use on unpaved surfaces only. Riding on pa...

  • Page 57

    7-10 7 while riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles. Watch carefully for other vehicles. Make sure you know your country’s laws and regulations before you ride on unpaved public streets or roads. Do...

  • Page 58

    7-11 7 warning ewb01540 do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the atv on such terrain. Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction o...

  • Page 59

    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, and turning tech- niques in this area before trying more difficult ter- rain. Always avoid riding on pave...

  • Page 60

    7-13 7 warning ewb01570 always follow proper procedures for turning as described in this owner’s manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions. As you approach a curve, slow down and begin to turn t...

  • Page 61

    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 62

    7-15 7 ● never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 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...

  • Page 63

    7-16 7 if your atv has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the atv on the up- hill side. Physically turn the atv aro...

  • Page 64

    7-17 7 riding downhill when riding your atv downhill, shift your weight as far to the rear and uphill side of the atv as pos- sible. Move back on the seat and sit with your arms straight. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfac...

  • Page 65

    7-18 7 crossing a slope traversing a sloping surface on your atv requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slip- pery surfaces or rough...

  • Page 66

    7-19 7 crossing through shallow water 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 ups...

  • Page 67

    7-20 7 test your brakes after leaving the water. Do not continue to ride your atv without verifying that you have regained proper braking ability. Caution: ecb00730 after riding your atv in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the...

  • Page 68

    7-21 7 1. V-belt cooling duct check hose (left front side of atv) 1. Drive select lever box check hose 1. Storage compartment drain plug 1. V-belt case drain plug u3d562e0.Book page 21 wednesday, june 6, 2007 12:58 pm.

  • Page 69

    7-22 7 riding over rough terrain riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the atv or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the atv as loss of cont...

  • Page 70

    7-23 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 71

    7-24 7 ● if your atv can’t make it up a hill you are trying to climb: turn the atv around if you still have forward speed. If not, stop, dismount on the uphill side of the atv and physically turn the atv around. If the atv starts to slip backwards, do not use the rear brake – the atv may tip over on...

  • Page 72

    8-1 8 ebu28781 periodic maintenance and minor repair ebu21670 safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your atv in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are expla...

  • Page 73

    8-2 8 the service information included in this manual and the tools provided in the owner’s tool kit are in- tended to assist you in the performance of preven- tive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work c...

  • Page 74

    8-3 8 ebu21742 periodic maintenance chart for the emission control system note: ● 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...

  • Page 75

    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 76

    8-5 8 ebu21864 general maintenance and lubrication chart no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 air filter element • clean and replace if necessary. Every 20–4...

  • Page 77

    8-6 8 9 * v-belt • check for wear, cracks or other damage, and re- place if necessary. √ √ √ √ 10 * chassis fasteners • make sure that all nuts, bolts, and screws are properly tightened. √ √ √ √ √ 11 * shock absorber as- semblies • check operation and correct if necessary. • check for oil leakage an...

  • Page 78

    8-7 8 ebu28390 note: ● the air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal components of the brake master cylinder and calipe...

  • Page 79

    8-8 8 ebu23080 removing and installing the panel the panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. Ebu23111 panel a to remove the panel remove the bolt, and then take the...

  • Page 80

    8-9 8 plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart. In addition, the condition of the spark plug can reveal the condition of the engine. To remove the spark plug 1. Remove the spark plug cap. 2. Remove the spark plug as shown, with the spar...

  • Page 81

    8-10 8 to install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification. 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug wi...

  • Page 82

    8-11 8 2. Check the engine oil level on a cold engine. Note: if the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. 3. Remove the engine oil filler cap, and then wipe the...

  • Page 83

    8-12 8 to change the engine oil (with or without oil fil- ter cartridge replacement) 1. Place the atv on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, an...

  • Page 84

    8-13 8 note: an oil filter wrench is available at a nearby yamaha dealer. 6. Apply a thin coat of engine oil to the o-ring of the new oil filter cartridge. Note: make sure that the o-ring is properly seated. 7. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to ...

  • Page 85

    8-14 8 note: be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. Caution: ecb00300 ● in order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of...

  • Page 86

    8-15 8 note: the oil level should be at the brim of the filler hole. 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 4. Install the oil filler bolt, and then tighten it to the specified torque. To change the final gear ...

  • Page 87

    8-16 8 5. Install the drain bolt, and then tighten it to the specified torque. 6. Add the recommended final gear oil to the brim of the filler hole as shown. Caution: ecb00420 be sure no foreign material enters the final gear case. 7. Install the oil filler bolt, and then tighten it to the specified...

  • Page 88

    8-17 8 8. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 9. Install the final gear case guard by installing the bolts and tightening them to the specified torque. Ebu23641 cleaning the air filter element the air filter element should be cleaned at the in- tervals ...

  • Page 89

    8-18 8 3. Pull the air filter element out of the air filter case. 4. Pull off the lock plate, and then remove the sponge material from the air filter element frame. 1. Air filter case cover holder 2. Air filter case cover 1. Air filter element u3d562e0.Book page 18 wednesday, june 6, 2007 12:58 pm.

  • Page 90

    8-19 8 5. Wash the sponge material gently but thor- oughly in solvent. Warning ewb01940 always use parts cleaning solvent to clean the sponge material. Never use low-flash-point solvents or gasoline to clean the sponge mate- rial because the engine could catch fire or ex- plode. 6. Squeeze the exces...

  • Page 91

    8-20 8 10. Insert the air filter element into the air filter case, and then install the air filter case cover by hooking the holders onto the air filter case. 11. Install the seat. Note: the air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if th...

  • Page 92

    8-21 8 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the tailpipe cover by installing the bolts, and...

  • Page 93

    8-22 8 ebu23930 v-belt case drain plug after riding in water deep enough to allow it to en- ter the v-belt case, remove this plug to drain the water from the case. Note: if water drains from the v-belt case after removing the plug, have a yamaha dealer check the atv as the water may affect other eng...

  • Page 94

    8-23 8 note: a diagnostic tachometer is needed to make this adjustment. 1. Start the engine and warm it up. Note: the engine is warm when it quickly responds to the throttle. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces- sary, adjust it to specifica...

  • Page 95

    8-24 8 ebu24043 adjusting the throttle cable free play the throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in the periodic maintenance and lubrication chart. The throttle cable free play should measure 3.0– 5.0 mm (0.12–0.20 in) at the throttle lev...

  • Page 96

    8-25 8 ebu24070 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 at the intervals specified in the periodic maintenance and lu...

  • Page 97

    8-26 8 ebu24251 checking the brake fluid level insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary. A low brake fluid level may indicate w...

  • Page 98

    8-27 8 ● be careful that water does not enter the brake fluid reservoir when refilling. Water will signifi- cantly lower the boiling point of the fluid and may result in vapor lock. ● brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid imme- diately. ● as the...

  • Page 99

    8-28 8 ● make sure the brakes operate smoothly and that the free play is correct. ● make sure the brakes do not drag. ● make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be perform...

  • Page 100

    8-29 8 adjusting the brake lever free play the brake lever free play should measure 3.0–5.0 mm (0.12–0.20 in) as shown. If the free play is in- correct, adjust it as follows. 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 2. Turn the brake lever ...

  • Page 101

    8-30 8 3. Turn the brake lever free play adjusting bolt at the brake lever in direction (a) to increase the free play, and in direction (b) to decrease it. 4. Tighten the locknut at the brake lever. Note: when adjusting the rear brake lever free play: ● be sure not to step on the brake pedal. ● make...

  • Page 102

    8-31 8 warning ewb02080 operating with improperly serviced or adjust- ed brakes could cause loss of braking ability, which could lead to an accident. After servicing: ● make sure the brakes operate smoothly and that the free play is correct. ● make sure the brakes do not drag. Replacement of brake c...

  • Page 103

    8-32 8 2. Turn the adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direc- tion (a). To make the brake light come on lat- er, turn the adjusting nut in direction (b). 3. Install the panel. Ebu24900 checking and lubricatin...

  • Page 104

    8-33 8 ebu28831 checking and lubricating the brake pedal the operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. Note: to access the brake pedal pivot, remove panel a. (see page 8-8.) ebu24962 checking the wheel hub bearings the fro...

  • Page 105

    8-34 8 in a wheel hub or if a wheel does not turn smoothly, have a yamaha dealer check the wheel hub bear- ings. Ebu25100 lubricating the steering shaft the steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Ebu25222 battery this model...

  • Page 106

    8-35 8 to store the battery 1. 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. 2. If the battery will be stored for more than two months, check it at least once a month and ful- ly charge it if necessary. To install th...

  • Page 107

    8-36 8 ebu25324 replacing a fuse the main fuse and the fuse box are located under the seat. (see page 4-11.) if a fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Caution: ecb00640 to prevent accidental short-circuiting, turn off the main switch wh...

  • Page 108

    8-37 8 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Warning ewb02171 always use a fuse of the specified rating, and never use a substitute object in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical sys- tem, whic...

  • Page 109

    8-38 8 3. Remove the defective bulb from the headlight unit by pulling it out. Warning ewb02220 a headlight bulb is hot when it is on and imme- diately after it is turned off. Wait for the bulb to cool before touching or removing it. You can be burned or a fire could start if the bulb touch- es some...

  • Page 110

    8-39 8 6. Install the headlight bulb holder cover at the rear of the headlight. Caution: ecb00670 make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 7. Adjust the headlight beam if necessary. Ebu25560 adjusting a headlight beam caution: ecb00690 it...

  • Page 111

    8-40 8 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. Caution: ecb00700 do not overtighten the screws, otherwise the lens may bre...

  • Page 112

    8-41 8 4. Remove the wheel. Ebu25700 installing a wheel 1. Install the wheel and the nuts. Note: ● the arrow mark on the tire must point toward the rotating direction of the wheel. ● tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the whee...

  • Page 113

    8-42 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 114

    8-43 8 ebu25751 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 115

    9-1 9 ebu25860 cleaning and storage ebu25880 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 116

    9-2 9 warning ewb02310 wet brakes may have reduced stopping ability, increasing the chance of an accident. Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. Ebu25932 storage short-term always store your atv in a cool, dry place and, if ...

  • Page 117

    9-3 9 c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (this will limit sparking during the next step.) d. Turn the engine over several times with the starter. (this will coat the cylinder wall with oil.) e. Re...

  • Page 118

    10-1 10 ebu25960 specifications dimensions: overall length: 1978 mm (77.9 in) overall width: 1063 mm (41.9 in) overall height: 1095 mm (43.1 in) seat height: 840 mm (33.1 in) wheelbase: 1233 mm (48.5 in) ground clearance: 220 mm (8.7 in) minimum turning radius: 3000 mm (118 in) weight: with oil and ...

  • Page 119

    10-2 10 engine oil quantity: without oil filter cartridge replacement: 2.20 l (2.33 us qt) (1.94 imp.Qt) with oil filter cartridge replacement: 2.30 l (2.43 us qt) (2.02 imp.Qt) final gear oil: type: sae80 api gl-4 hypoid gear oil quantity: 0.23 l (0.24 us qt) (0.20 imp.Qt) air filter: air filter el...

  • Page 120

    10-3 10 manufacturer/model: maxxis/m937 rear tire: type: tubeless size: at23 x 10-12 manufacturer/model: maxxis/m938 loading: maximum loading limit: 100.0 kg (220 lb) (total weight of rider, cargo, accessories, and tongue) tire air pressure (measured on cold tires): recommended: front: 25.0 kpa (3.6...

  • Page 121

    10-4 10 rear suspension: type: swingarm (monocross) spring/shock absorber type: coil spring/oil damper wheel travel: 180 mm (7.1 in) electrical system: ignition system: dc. Cdi charging system: ac magneto battery: model: ytx14ah voltage, capacity: 12 v, 12.0 ah headlight: bulb type: krypton bulb bul...

  • Page 122

    11-1 11 ebu26000 consumer information ebu26011 identification numbers record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a yamaha dealer or for ref- erence in case the atv is s...

  • Page 123

    11-2 11 note: 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 d...

  • Page 124

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning ............................................ 8-17 axle boots .................................................................... 8-31 b battery ............................................

  • Page 125

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

  • Page 126

    Yamaha motor co., ltd. Printed in usa 2007.07-0.3 ×1 cr (e) u3d562e0.Book page 1 wednesday, june 6, 2007 12:58 pm.