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  5. Owner's Manual

Yamaha YFM125GZ Owner's Manual

Summary of YFM125GZ

  • Page 1

    This a this atv should not be ridden by anyone under 16 years of age. Owner’s manual lit-11626-23-13 1c5-28199-16 yfm125gz warning read this manual carefully! It contains important safety information..

  • Page 2

    Ebu17092 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. ✤✰✬✤✩ ✤.

  • Page 3

    Ebu17170 introduction ebu17272 congratulations on your purchase of the yamaha yfm125gz. This atv represents the result of many years of yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this yamaha, you can now appreciate the high d...

  • Page 4

    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 5

    Ebu17350 important notice ebu17362 this atv is designed and manufactured for off-road use only. It is illegal and unsafe to operate this atv on any public street, road or highway. This atv complies with all applicable off-road noise level and spark arrester laws and regulations in effect at the time...

  • Page 6

    Warning ewb00011 indicates a hazardous situation which, if not avoided, could result in death or serious injury. Ebu17420 table of contents location of the warning and specification labels ............................ 1-1 safety information .............................. 2-1 description ...............

  • Page 7

    Parking ...................................................... 6-5 parking on a slope .................................... 6-5 accessories and loading ........................... 6-6 riding your atv ...................................... 7-1 getting to know your atv.............. 7-2 ride with care ...

  • Page 8

    Adjusting a headlight beam ..................... 8-45 replacing the tail/brake light bulb ........... 8-45 removing a wheel ................................... 8-46 installing a wheel ..................................... 8-47 troubleshooting ...................................... 8-48 troubleshooti...

  • Page 9

    1-1 1 2 3 4 5 6 7 8 9 10 11 ebu17660 location of the warning and specification labels 1 2 6 5 4 3 9 8 7 10 ✤✰✬✤✩ ✤.

  • Page 10

    1-2 1 2 3 4 5 6 7 8 9 10 11 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 d...

  • Page 11: Load Limit

    1-3 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 load limit 3ld-24877-u0 11 ibs. ( 5 kg) warning never sit here. 3mx-24875-a0 warning never sit here. 3mx-24875-a0 load limit 1c5-24877-u0 22 ibs. ( 10 kg) 6 wa r n in g imprope r tire pressure or overloading can cause loss of cont rol. Loss of control can result...

  • Page 12

    1-4 1 2 3 4 5 6 7 8 9 10 11 7 8 9 10 read owner's manual carefully before operating. When shifting the drive select lever, always be sure to stop the atv and apply the rear brake. Drive select lever 5yt-2151e-30 warning improper at v use can result in severe injury or death. Always use an approved h...

  • Page 13

    2-1 1 2 3 4 5 6 7 8 9 10 11 ebu17431 safety information safety information ebu17445 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...

  • Page 14

    2-2 1 2 3 4 5 6 7 8 9 10 11 ● never attempt wheelies, jumps, or other stunts. ● 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 t...

  • Page 15

    2-3 1 2 3 4 5 6 7 8 9 10 11 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 check for obstacles before oper...

  • Page 16

    2-4 1 2 3 4 5 6 7 8 9 10 11 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 treatment. ● do not run engine indoors. Even if you try to ventilate ...

  • Page 17

    3-1 1 2 3 4 5 6 7 8 9 10 11 ebu17680 description ebu17690 left view ebu17700 right view 1. Front carrier 2. Starter (choke) 3. Fuel cock 4. Tail/brake light 5. Rear carrier 6. Spark arrester 7. Footboard 1 2 3 4 5 6 7 1. Seat 2. Drive select lever 3. Headlight 1 2 3 ✤✰✬✤✩ ✤.

  • Page 18

    3-2 1 2 3 4 5 6 7 8 9 10 11 ebu17712 controls and instruments tip the atv you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Parking brake 3. Reverse indicator light 4. Neutral indicator light 5. Front brake lever 6. Throttle lever 7. Main switch 8. ...

  • Page 19

    4-1 1 2 3 4 5 6 7 8 9 10 11 ebu17725 instrument and control functions warning ewb00011 indicates a hazardous situation which, if not avoided, could result in death or serious injury. Ebu17740 main switch the positions of the main switch are as follows: on all electrical systems are supplied with pow...

  • Page 20

    4-2 1 2 3 4 5 6 7 8 9 10 11 ebu17792 indicator lights 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. Ebu18061...

  • Page 21

    4-3 1 2 3 4 5 6 7 8 9 10 11 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 ...

  • Page 22

    4-4 1 2 3 4 5 6 7 8 9 10 11 pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the atv, turn the adjusting screw in direction (a). To de- crease the maximum engine power available and the maximum speed of the atv, turn the adjus...

  • Page 23

    4-5 1 2 3 4 5 6 7 8 9 10 11 ebu18401 rear brake lever the rear brake lever is located on the left handle- bar. To apply the rear brake, pull the brake lever to- ward the handlebar grip. Ebu18460 parking brake use the parking brake before starting the engine or parking the atv, especially on a slope....

  • Page 24

    4-6 1 2 3 4 5 6 7 8 9 10 11 warning ewb00220 ● always set the parking brake before starting the engine. The atv could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. ● always be sure you have released the park- ing brake before you ...

  • Page 25

    4-7 1 2 3 4 5 6 7 8 9 10 11 ebu18720 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. Ebu18731 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 ...

  • Page 26

    4-8 1 2 3 4 5 6 7 8 9 10 11 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...

  • Page 27

    4-9 1 2 3 4 5 6 7 8 9 10 11 buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. 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...

  • Page 28

    4-10 1 2 3 4 5 6 7 8 9 10 11 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 ...

  • Page 29

    4-11 1 2 3 4 5 6 7 8 9 10 11 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. Ebu18962 front carrier ● do not exceed the load limit of 5.0 kg (11 lb) for the front carrier. ● d...

  • Page 30

    4-12 1 2 3 4 5 6 7 8 9 10 11 warning ewb00011 indicates a hazardous situation which, if not avoided, could result in death or serious injury. ✤✰✬✤✩ ✤✥.

  • Page 31

    5-1 1 2 3 4 5 6 7 8 9 10 11 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 ins...

  • Page 32

    5-2 1 2 3 4 5 6 7 8 9 10 11 throttle lever ● make sure that operation is smooth. Lubricate cable and lever hous- ing if necessary. ● check cable free play, and adjust if necessary. 5-3, 8-25 control cables ● make sure that operation is smooth. Lubricate if necessary. 8-36 drive chain ● check chain s...

  • Page 33

    5-3 1 2 3 4 5 6 7 8 9 10 11 ebu19541 fuel make sure that there is sufficient fuel in the tank. (see page 4-7.) ebu19560 engine oil make sure that the engine oil is at the specified lev- el. Add oil as necessary. (see page 8-10.) ebu19580 transmission oil make sure that the transmission oil is at the...

  • Page 34

    5-4 1 2 3 4 5 6 7 8 9 10 11 pressures must be equal on both sides. Warning! Operation of this vehicle with im- proper tire pressure may cause severe injury or death from loss of control or rollover. Tire pressure below the minimum specified could also cause the tire to dislodge from the rim un- der ...

  • Page 35

    5-5 1 2 3 4 5 6 7 8 9 10 11 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 extensive tests, only the tires listed below have been approved for this model...

  • Page 36

    5-6 1 2 3 4 5 6 7 8 9 10 11 ebu19850 instruments, lights and switches check that all instruments, lights and switches are working properly. Correct if necessary. Ebu19860 battery check the fluid level in the battery. Fill with distilled water if necessary. (see page 8-39.) ✤✰✬✤✩ ✩.

  • Page 37

    6-1 1 2 3 4 5 6 7 8 9 10 11 ebu19872 operation warning ewb00011 indicates a hazardous situation which, if not avoided, could result in death or serious injury. 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 d...

  • Page 38

    6-2 1 2 3 4 5 6 7 8 9 10 11 ambient temp./starter (choke) position 6. Completely close the throttle lever and start the engine by pushing the start switch. Notice: for maximum engine life, never accelerate hard when the engine is cold! [ecb00162] tip if the engine fails to start, release the start s...

  • Page 39

    6-3 1 2 3 4 5 6 7 8 9 10 11 ebu20361 operating the drive select lever and driving in reverse notice ecb00170 before shifting, stop the atv, otherwise the transmission may be damaged. Shifting: forward 1. Bring the atv to a complete stop. 2. Shift from neutral to forward and vice versa by moving the ...

  • Page 40

    6-4 1 2 3 4 5 6 7 8 9 10 11 go slowly. 1. Bring the atv to a complete stop. 2. Apply the parking brake. 3. Shift from neutral to reverse and vice versa by moving the drive select lever along the shift guide. Tip when in reverse, the reverse indicator light should come on. If the indicator light does...

  • Page 41

    6-5 1 2 3 4 5 6 7 8 9 10 11 320 km (200 mi) or 20 hours and beyond the atv can now be operated normally. Notice ecb00220 if any engine trouble should occur during the engine break-in period, immediately have a yamaha dealer check the atv. Ebu20700 parking when parking the atv, stop the engine, shift...

  • Page 42

    6-6 1 2 3 4 5 6 7 8 9 10 11 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 a...

  • Page 43

    6-7 1 2 3 4 5 6 7 8 9 10 11 ples include (but are not limited to) a heavy or 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- ce...

  • Page 44

    6-8 1 2 3 4 5 6 7 8 9 10 11 ● allow more braking distance. A heavier atv takes longer to stop. ● avoid making sharp turns unless at very slow speeds. ● avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the atv. Warning ewb00011 indicates a ha...

  • Page 45

    7-1 1 2 3 4 5 6 7 8 9 10 11 ebu21132 riding your atv ✤✰✬✤✩ ✤.

  • Page 46

    7-2 1 2 3 4 5 6 7 8 9 10 11 warning ewb00011 indicates a hazardous situation which, if not avoided, could result in death or serious injury. Ebu21294 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 rec...

  • Page 47

    7-3 1 2 3 4 5 6 7 8 9 10 11 information about the training course, contact an authorized atv dealer or call 1-800-887-2887. 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’...

  • Page 48

    7-4 1 2 3 4 5 6 7 8 9 10 11 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...

  • Page 49

    7-5 1 2 3 4 5 6 7 8 9 10 11 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 ...

  • Page 50

    7-6 1 2 3 4 5 6 7 8 9 10 11 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 4-3.) loading and accessories take ext...

  • Page 51

    7-7 1 2 3 4 5 6 7 8 9 10 11 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...

  • Page 52

    7-8 1 2 3 4 5 6 7 8 9 10 11 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 or equivalent components de- signed for use on this atv and should be inst...

  • Page 53

    7-9 1 2 3 4 5 6 7 8 9 10 11 children are not likely to touch it. Be careful where you ride this atv is designed for off-road use only. Warning! Paved surfaces may seriously af- fect handling and control of the atv, and may cause the atv to go out of control. Always avoid paved surfaces, including si...

  • Page 54

    7-10 1 2 3 4 5 6 7 8 9 10 11 know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the atv to upset. Warning! The atv could go out of control if you do not have enough time to react to hidd...

  • Page 55

    7-11 1 2 3 4 5 6 7 8 9 10 11 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 hitch. Warning! You could collide with another vehicle if operating in off-road ar- eas where you cannot easi...

  • Page 56

    7-12 1 2 3 4 5 6 7 8 9 10 11 select a large, flat area off-road to become familiar 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...

  • Page 57

    7-13 1 2 3 4 5 6 7 8 9 10 11 as you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the out- side of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintai...

  • Page 58

    7-14 1 2 3 4 5 6 7 8 9 10 11 ● never operate the atv on hills too steep for the atv or for your abilities. The atv can overturn more easily on extremely steep hills than on level surfaces or small hills. ● always check the terrain carefully before you start up any hill. Never climb hills with excess...

  • Page 59

    7-15 1 2 3 4 5 6 7 8 9 10 11 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...

  • Page 60

    7-16 1 2 3 4 5 6 7 8 9 10 11 riding downhill warning ewb01131 going down a hill improperly could cause overturns or loss of control. Always follow proper procedures for going down hills as de- scribed in this owner’s manual. ● always check the terrain carefully before you start down any hill. ● neve...

  • Page 61

    7-17 1 2 3 4 5 6 7 8 9 10 11 crossing a slope warning ewb01632 improperly crossing hills or turning on hills could cause loss of control or cause the atv to overturn. ● always follow proper procedures as de- scribed in the owner’s manual. ● avoid hills with excessively slippery or loose surfaces. ● ...

  • Page 62

    7-18 1 2 3 4 5 6 7 8 9 10 11 crossing through shallow water warning ewb01641 operating this vehicle through deep or fast- flowing water can lead to loss of control or an overturn. To reduce your risk of drowning or other injuries, use care when crossing through water. Never operate this atv water de...

  • Page 63

    7-19 1 2 3 4 5 6 7 8 9 10 11 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. Also, remove the v-belt case drain plug to drain any water that may have accumulated. Notice: undrained water can cause damage or improper ...

  • Page 64

    7-20 1 2 3 4 5 6 7 8 9 10 11 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 ove...

  • Page 65

    7-21 1 2 3 4 5 6 7 8 9 10 11 ways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide. With practice, over a period of time, skill at con- trolled sliding can...

  • Page 66

    7-22 1 2 3 4 5 6 7 8 9 10 11 (see page 7-13.) ● 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 ba...

  • Page 67

    8-1 1 2 3 4 5 6 7 8 9 10 11 ebu2164a periodic maintenance and adjustment ebu21671 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...

  • Page 68

    8-2 1 2 3 4 5 6 7 8 9 10 11 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 cert...

  • Page 69

    8-3 1 2 3 4 5 6 7 8 9 10 11 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-...

  • Page 70

    8-4 1 2 3 4 5 6 7 8 9 10 11 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...

  • Page 71

    8-5 1 2 3 4 5 6 7 8 9 10 11 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 engine and v-belt case air filter ele- me...

  • Page 72

    8-6 1 2 3 4 5 6 7 8 9 10 11 8 drive chain ● check chain slack and adjust if necessary. ● check rear wheel alignment and correct if neces- sary. ● clean and lubricate. √ √ √ √ √ 9 * v-belt ● check for wear, cracks or other damage, and replace if necessary. √ √ 10 * chassis fasteners ● make sure that ...

  • Page 73

    8-7 1 2 3 4 5 6 7 8 9 10 11 ebu23061 tip some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. 19 * throttle lever hous- ing and cable ● check operation and correct if necessary. ● check throttle cable free play and ad...

  • Page 74

    8-8 1 2 3 4 5 6 7 8 9 10 11 warning ewb00011 indicates a hazardous situation which, if not avoided, could result in death or serious injury. Ebu23211 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 ...

  • Page 75

    8-9 1 2 3 4 5 6 7 8 9 10 11 to check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medi- um-to-light tan (the ideal color when the atv is ridden normally). Tip if the spark plug shows a distinctly different color, the engine could be operatin...

  • Page 76

    8-10 1 2 3 4 5 6 7 8 9 10 11 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 with the spark plug wrench, and then tighten it to the specified torque. Tip if a torque wrench is not available when ...

  • Page 77

    8-11 1 2 3 4 5 6 7 8 9 10 11 4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level. Tip the engine oil should be between the minimum and maximum level marks. 5. If the engine oil is at or below the minimum level mark, add sufficient oil...

  • Page 78

    8-12 1 2 3 4 5 6 7 8 9 10 11 5. Clean the oil strainer with solvent. 6. Check the o-ring for damage and replace it if necessary. 7. Install the o-ring, oil strainer, compression spring and drain bolt. Tighten the engine oil drain bolt to the specified torque. Notice: before installing the engine oil...

  • Page 79

    8-13 1 2 3 4 5 6 7 8 9 10 11 is leaking, immediately turn the engine off and check for the cause. 10. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. Ebu27025 transmission oil the transmission oil level should be checked be- fore each ride. I...

  • Page 80

    8-14 1 2 3 4 5 6 7 8 9 10 11 5. Pour the recommended type of oil in the trans- mission oil filler hole until it flows out of the check screw hole. 6. Install the transmission oil check screw and transmission oil filler bolt, and then tighten them to the specified torques. To change the transmission ...

  • Page 81

    8-15 1 2 3 4 5 6 7 8 9 10 11 6. Refill with the specified amount of the recom- mended transmission oil, and then install and tighten the oil filler bolt. Notice: make sure that no foreign material enters the trans- mission case. [ecb00791] notice ecb01061 make sure that no oil gets on the tires or w...

  • Page 82

    8-16 1 2 3 4 5 6 7 8 9 10 11 1. Place the atv on a level surface. 2. Remove the seat. (see page 4-10.) 3. Remove the breather hose, and then loosen the clamp screw. 4. Remove the air filter case cover by removing the screws. 1. Check hose 1 1. Breather hose 2. Clamp screw 1 2 ✤✰✬✤✩ ✤✩.

  • Page 83

    8-17 1 2 3 4 5 6 7 8 9 10 11 5. Pull the air filter element out of the air filter case. 6. Remove the bolt and washer shown, and then pull the sponge material off from the air filter element frame. 7. Wash the sponge material gently but thor- oughly in solvent. Warning! Always use parts cleaning sol...

  • Page 84

    8-18 1 2 3 4 5 6 7 8 9 10 11 9. Check the sponge material and replace it if damaged. 10. Apply yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. Tip the sponge material should be wet but not drip- ping. 11. Pull the sponge material over the air filter ele- men...

  • Page 85

    8-19 1 2 3 4 5 6 7 8 9 10 11 15. Install the breather hose and then tighten the clamp screw. 16. Install the seat. Tip the air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the atv is operated in extremely dusty ar- eas. Each time the air filt...

  • Page 86

    8-20 1 2 3 4 5 6 7 8 9 10 11 4. Disconnect the coupler shown. 5. Remove the air filter case cover by removing the screw. 1. Panel 2. Quick fastener 1 2 2 1 1. Panel 2. Coupler 1 2 ✤✰✬✤✩ ✥✣.

  • Page 87

    8-21 1 2 3 4 5 6 7 8 9 10 11 6. Remove the air filter element. 7. 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. 1. Air filter case cover 2. Screw 1 2 1. Air filter element 1 ✤✰✬✤✩ ✥✤.

  • Page 88

    8-22 1 2 3 4 5 6 7 8 9 10 11 8. Check the air filter element and replace it if damaged. 9. Install the air filter element into the air filter case. 10. Install the air filter case cover by installing the screw. 11. Connect the coupler, and then install the pan- el by installing the quick fasteners. ...

  • Page 89

    8-23 1 2 3 4 5 6 7 8 9 10 11 4. Insert the tailpipe into the muffler and align the screw holes. 5. Install the screws and tighten them. 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, possibly...

  • Page 90

    8-24 1 2 3 4 5 6 7 8 9 10 11 ebu23940 adjusting the carburetor the carburetor should be checked and, if neces- sary, adjusted at the intervals specified in the peri- odic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adjustment. ...

  • Page 91

    8-25 1 2 3 4 5 6 7 8 9 10 11 tip if the specified idling speed cannot be obtained as described above, have a yamaha dealer make the adjustment. Ebu24045 adjusting the throttle cable free play the throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in t...

  • Page 92

    8-26 1 2 3 4 5 6 7 8 9 10 11 4. Tighten the locknut. 5. Slide the rubber cover to its original position. Ebu24060 valve clearance the valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by ...

  • Page 93

    8-27 1 2 3 4 5 6 7 8 9 10 11 front brake rear brake ebu24371 adjusting the front brake lever free play the brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Tip before adjusting the brake lever free play, c...

  • Page 94

    8-28 1 2 3 4 5 6 7 8 9 10 11 the brake lever free play should measure 5.0–8.0 mm (0.20–0.31 in) as shown. If the free play is in- correct, adjust it as follows. 1. Remove the front carrier by removing the bolts. 2. Remove the panel shown by removing the quick fasteners, then disconnect the coupler s...

  • Page 95

    8-29 1 2 3 4 5 6 7 8 9 10 11 3. Remove the v-belt air filter element cover by removing the screw. 1. Panel 2. Quick fastener 1 2 2 1 1. Panel 2. Coupler 1 2 ✤✰✬✤✩ ✥✬.

  • Page 96

    8-30 1 2 3 4 5 6 7 8 9 10 11 4. Loosen the locknut and fully turn in the adjust- ing bolt at the brake lever. 5. Make sure the brake cable joint in the equaliz- er is straight when the brake is applied. If the cable joint isn’t straight, loosen the locknuts, and then turn the adjusting nuts on the f...

  • Page 97

    8-31 1 2 3 4 5 6 7 8 9 10 11 6. Tighten the locknut on each brake cable. 7. Turn the adjusting bolt in direction (a) to in- crease the free play, and in direction (b) to de- crease it. 1. Brake equalizer 2. Cable joint a a' a=a' 1 2 1. Locknut 2. Adjusting nut 1 2 2 1 ✤✰✬✤✩ ✦✤.

  • Page 98

    8-32 1 2 3 4 5 6 7 8 9 10 11 8. Tighten the locknut at the brake lever. 9. Install the v-belt air filter element cover by in- stalling the screw. 10. Connect the coupler, and then install the pan- el by installing the quick fasteners. 11. Install the front carrier by installing the bolts. Ebu24492 a...

  • Page 99

    8-33 1 2 3 4 5 6 7 8 9 10 11 ebu24873 drive chain slack the drive chain slack should be checked before each ride and adjusted if necessary. To check the drive chain slack 1. Place the atv on a level surface. Tip when checking and adjusting the drive chain slack, there should be no weight on the atv ...

  • Page 100

    8-34 1 2 3 4 5 6 7 8 9 10 11 the hub stopper bolt. 3. Loosen the axle holding bolts. 4. Loosen the chain adjusting bolt locknut. To tighten the drive chain, turn the adjusting bolt in direction (a). To loosen the drive chain, turn the adjusting bolt in direction (b), and then push the wheels forward...

  • Page 101

    8-35 1 2 3 4 5 6 7 8 9 10 11 notice ecb00550 if measurement “a” of the drive chain adjust- ing bolt is less than 27 mm (1.06 in), have a yamaha dealer replace the drive chain. 6. Tighten the hub stopper bolt, and then its lock- nut. Ebu24881 lubricating the drive chain the drive chain must be cleane...

  • Page 102

    8-36 1 2 3 4 5 6 7 8 9 10 11 notice ecb00560 the drive chain must be lubricated after wash- ing the atv or riding in the rain. 1. Clean the drive chain with kerosene and a small soft brush. Notice: to prevent dam- aging the o-rings, do not clean the drive chain with steam cleaners, high-pressure was...

  • Page 103

    8-37 1 2 3 4 5 6 7 8 9 10 11 front brake lever rear brake lever ebu24962 checking the wheel hub bearings the front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smo...

  • Page 104

    8-38 1 2 3 4 5 6 7 8 9 10 11 left side right side ebu28822 lubricating the front knuckle pivots the front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Lubricate the front knuckle pivots using a grease gun. 1. Grease nipple 1 1 1. Gre...

  • Page 105

    8-39 1 2 3 4 5 6 7 8 9 10 11 ebu25090 lubricating the steering shaft the steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Lubricate the steering shaft using a grease gun. Ebu25122 battery a poorly maintained battery will corrode and ...

  • Page 106

    8-40 1 2 3 4 5 6 7 8 9 10 11 tip the electrolyte should be between the minimum and maximum level marks. 3. 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 ...

  • Page 107

    8-41 1 2 3 4 5 6 7 8 9 10 11 eyes: flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ig- nition away. Ventilate when charging or using in an enclosed space. Keep out of reach of children. 4. Check a...

  • Page 108

    8-42 1 2 3 4 5 6 7 8 9 10 11 to install the battery tip be sure the battery is fully charged. 1. Install the battery. 2. Connect the positive lead first, and then con- nect the negative lead. 3. Make sure that the breather hose is properly routed, in good condition, and not obstructed. Notice: if th...

  • Page 109

    8-43 1 2 3 4 5 6 7 8 9 10 11 ebu25263 replacing the fuse the fuse holder is located on the right side of the atv. If the fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Notice ecb00640 to prevent accidental short-circuiting, turn off the main swit...

  • Page 110

    8-44 1 2 3 4 5 6 7 8 9 10 11 2. Remove the headlight bulb holder cover by pulling it off. 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. Noti...

  • Page 111

    8-45 1 2 3 4 5 6 7 8 9 10 11 6. Install the bulb holder by pushing it in and turn- ing it clockwise. 7. Install the bulb holder cover and the cover at the rear of the headlight. Notice: make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. [ecb00671] ...

  • Page 112

    8-46 1 2 3 4 5 6 7 8 9 10 11 follows. 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 2. Remove the burnt-out bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 4....

  • Page 113

    8-47 1 2 3 4 5 6 7 8 9 10 11 3. Elevate the atv and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. Ebu25692 installing a wheel 1. Place the atv on a level surface. 2. Elevate the atv and place a suitable stand under the frame. 3. Install the wheel and...

  • Page 114

    8-48 1 2 3 4 5 6 7 8 9 10 11 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 fo...

  • Page 115

    8-49 1 2 3 4 5 6 7 8 9 10 11 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. ...

  • Page 116

    9-1 1 2 3 4 5 6 7 8 9 10 11 ebu25860 cleaning and storage ebu25902 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 exh...

  • Page 117

    9-2 1 2 3 4 5 6 7 8 9 10 11 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 ...

  • Page 118

    9-3 1 2 3 4 5 6 7 8 9 10 11 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 cha...

  • Page 119

    10-1 1 2 3 4 5 6 7 8 9 10 11 ebu25960 specifications ebu2597e dimensions: overall length: 1700 mm (66.9 in) overall width: 990 mm (39.0 in) overall height: 980 mm (38.6 in) seat height: 685 mm (27.0 in) wheelbase: 1080 mm (42.5 in) ground clearance: 145 mm (5.7 in) minimum turning radius: 2900 mm (1...

  • Page 120

    10-2 1 2 3 4 5 6 7 8 9 10 11 transmission oil: quantity: 0.6 l (0.63 us qt, 0.53 imp.Qt) air filter: air filter element: wet element fuel: recommended fuel: unleaded gasoline only fuel tank capacity: 7.0 l (1.85 us gal, 1.54 imp.Gal) fuel reserve amount: 1.3 l (0.34 us gal, 0.29 imp.Gal) carburetor:...

  • Page 121

    10-3 1 2 3 4 5 6 7 8 9 10 11 loading: maximum loading limit: 105.0 kg (231 lb) (total weight of rider, cargo, accessories, and tongue) tire air pressure (measured on cold tires): recommended: front: 20.0 kpa (0.200 kgf/cm 2 , 2.9 psi) rear: 25.0 kpa (0.250 kgf/cm 2 , 3.6 psi) minimum: front: 17.0 kp...

  • Page 122

    10-4 1 2 3 4 5 6 7 8 9 10 11 headlight: bulb type: krypton bulb bulb voltage, wattage ×××× quantity: headlight: 12 v, 30/30 w × 2 tail/brake light: 12 v, 5.0/21.0 w × 1 neutral indicator light: 12 v, 1.7 w × 1 reverse indicator light: 12 v, 1.7 w × 1 fuses: main fuse: 15.0 a ✤✰✬✤✩ ✧.

  • Page 123

    11-1 1 2 3 4 5 6 7 8 9 10 11 ebu25981 consumer information ebu26012 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...

  • Page 124

    11-2 1 2 3 4 5 6 7 8 9 10 11 tip the vehicle identification number is used to identi- fy 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 ...

  • Page 125

    11-3 1 2 3 4 5 6 7 8 9 10 11 1. Vehicle emission control information label 1 ✤✰✬✤✩ ✦.

  • Page 126

    11-4 1 2 3 4 5 6 7 8 9 10 11 ebu26060 noise regulation tampering with noise control system prohibited: federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device ...

  • Page 127

    11-5 1 2 3 4 5 6 7 8 9 10 11 ebu26080 maintenance record copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is require...

  • Page 128

    11-6 1 2 3 4 5 6 7 8 9 10 11 ebu26501 yamaha motor corporation, u.S.A. Atv limited warranty yamaha motor corporation, u.S.A. Hereby warrants that new yamaha atvs purchased from an authorized yamaha atv dealer in the continental united states will be free from defects in material and workmanship for ...

  • Page 129

    11-7 1 2 3 4 5 6 7 8 9 10 11 warranty questions and answers q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spa...

  • Page 130

    11-8 1 2 3 4 5 6 7 8 9 10 11 ebu26123 yamaha extended service (y.E.S.) keep your yamaha protected even after your warranty expires with genuine yamaha extended ser vice (y.E.S.). Y.E.S. Is designed and administered by yamaha motor corporation to provide maximum owner satisfaction. You get uninterr u...

  • Page 131

    11-9 1 2 3 4 5 6 7 8 9 10 11 we urge you to act now. You’ll get the excellent benefits of trip coverage r ight away, and you’ll rest easy knowing you’ll have strong factor y-backed protection even after your ya m a h a l i m i t e d wa r ra n t y ex p i r e s. Yo u c a n a l s o s ave money: y.E.S. ...

  • Page 132

    11-10 1 2 3 4 5 6 7 8 9 10 11 ebu26132 ✤✰✬✤✩ ✤✣.

  • Page 133

    Index a accessories and loading ................................................ 6-6 air filter elements, engine and v-belt filter cleaning ..... 8-15 b battery.................................................................. 5-6 , 8-39 brake lever free play, adjusting the front.......................

  • Page 134

    M main switch .................................................................... 4-1 maintenance and lubrication chart ................................. 8-5 maintenance chart, emission control system ................. 8-3 maintenance record ..................................................... 11-...

  • Page 136

    Printed in japan 2009.03-0.4x1 ! (e) yamaha motor co., ltd. Printed on recycled paper locate and read owner’s manual. Follow all instructions and warnings. (for replacement manual, call 1-800-532-1558) warning always : use proper riding techniques to avoid vehicle overturns on hills and rough terrai...

  • Page 137: Read    Carefull

    Dear new yamaha atv owner: congratulations on the purchase of your new yamaha atv. You have purchased a quality yamaha product that, with proper use and care, will provide hours of riding pleasure. Before you operate your new atv, yamaha recommends these important points: 8 read your owner’s manual ...

  • Page 138

    No postage necessary if mailed in the united states first class permit no. 4 cypress, ca postage will be paid by addressee yamaha motor corporation u.S.A. P.O. Box 6555 cypress, california 90630-9989 attn: sales administration atv card for us 08/12/2 10:24 am page 2.