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  5. Owner's Manual

Yamaha YFM250 Owner's Manual

Summary of YFM250

  • Page 1

    Yfm25rd yfm250rd owner’s manual manuel du propriÉtaire manual del propietario 1bt-28199-63 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 impor...

  • Page 2

    Printed in japan 2012.03-0.3 ×1 cr (e,f,s) dic183 printed on recycled paper imprimÉ sur papier recyclÉ impreso en papel reciclado.

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Warning owner’s manual yfm25rd yfm250rd this atv should not be ridden by anyone under 16 years of age. 1bt-28199-63-e0 u1bt63e0.Book page 1 friday, march 9, 2012 11:22 am.

  • Page 4

    Ebu29104 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. En15997, ansi/svia 1-2010 general manager rv engineering division recreational vehicle business unit business development operations yamaha motor co., ltd. Yfm250r (yfm25r) (...

  • Page 5

    Ebu17170 introduction ebu17322 congratulations on your purchase of the yamaha yfm25rd/yfm250rd. 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 t...

  • 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. Ebu17390 yfm25rd/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

    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 and good judgment .................................................

  • Page 10

    Lubricating the upper and lower arm pivots ...................................................... 8-34 lubricating the steering shaft ................... 8-35 battery ...................................................... 8-35 replacing the fuse ................................... 8-38 replacing a h...

  • Page 11

    1-1 1 ebu29680 location of the warning and specification labels ebu29992 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 43p-2816p-00 43p-2816r-01 1pd-2811r-00 1 2 3 u1bt63e0.Book page 2 friday, march 9, 2012 11:22 am.

  • Page 13

    1-3 1 4d3-2816m-m0 27.5 kpa 0.275 kgf/cm² 4.0 psi 27.5 kpa 0.275 kgf/cm² 4.0 psi 4d3-2156a-10 yfm250r 14.0 kw 150 kg 4aa-22259-40 8ac-2817l-00 yamaha motor co., ltd. 2500 shingai, iwata, japan 2012 4 5 6 7 u1bt63e0.Book page 3 friday, march 9, 2012 11:22 am.

  • 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. For atv type 1 category y12, use from 12 years old. Operation of this a...

  • Page 15

    1-5 1 **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi 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. This unit contains high-p...

  • Page 16

    1-6 1 ****** *** kw *** kg 1 2 3 yamaha motor co., ltd. 2500 shingai, iwata, japan **** 1 1 2 3 model name max. Power mass in running order 1 year of construction u1bt63e0.Book page 6 friday, march 9, 2012 11:22 am.

  • Page 17

    1-7 1 for oceania 5 1 2 4 3 u1bt63e0.Book page 7 friday, march 9, 2012 11:22 am.

  • Page 18

    1-8 1 3b4-2151h-00 warning never ride as a passenger. Passengers can cause a loss of control, resulting in severe injury or death. Warning improper atv use can result in severe injury or death. Always use never use never carry never use an approved on public passengers with drugs helmet and roads or...

  • Page 19

    1-9 1 warning operating tire pressure: set with tires cold • recommended : front : 27.5 kpa, rear : 27.5 kpa, • minimum : front : 24.5 kpa, rear : 24.5 kpa, • never set tire pressure below minimum. It could cause the tire to dislodge from the rim. Loading • maximum weight capacity : 100 kg, (220 lbs...

  • Page 20

    2-1 2 ebu17431 safety information ebu17595 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 ● never operate at speeds too fast for your skills or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. ● never attempt wheelies, jumps, or other stunts. ● always inspect your atv each time you use it to make sure...

  • Page 22

    2-3 2 ● always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall- ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphi...

  • Page 23

    2-4 2 in the event of an accident 1. If serious injuries are incurred, you may be safer staying next to your vehicle; it may shield you from oncoming riders. Depending on your injuries and position in the trail; you must make a judgment call as to whether you should move to a position off the trail....

  • Page 24

    2-5 2 4. Once immediate safety hazards are con- firmed not to exist, you may remove your hel- met to more closely inspect your vehicle. Check for external signs of wear, broken parts, fluid leaks, cracks in the frame, suspen- sion damage, wheel damage, and so on. Fuel, oil, and coolant usually give ...

  • Page 25

    2-6 2 warning ewb00072 avoid carbon monoxide poisoning all engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nau- sea, confusion, and eventually death. Carbon monoxide is a colorless, odorless, tasteless gas which may be pres...

  • Page 26

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Front shock absorber assembly spring preload adjusting ring 2. Spark plug 3. Fuel cock 4. Starter (choke) 5. Throttle stop screw 6. Rear shock absorber assembly spring preload adjusting nut 7. Owner’s tool kit 8. Engine oil drain b...

  • Page 27

    3-2 3 ebu17712 controls and instruments tip the atv you have purchased may differ slightly from the figures shown in this manual. 1. Clutch lever 2. Handlebar switches 3. Parking brake lever 4. Main switch 5. Front brake fluid reservoir 6. Throttle lever 7. Brake lever 1 2 3 4 6 7 5 u1bt63e0.Book pa...

  • Page 28

    4-1 4 ebu17734 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 29

    4-2 4 ebu17783 indicator light ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu18061 handlebar switches ebu18080 engine stop switch “ / ” set this switch to “ ” before starting the engine. The engine stop switch controls the i...

  • Page 30

    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. Ebu18154 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 31

    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 32

    4-5 4 ebu18411 brake lever the brake lever is located at the right handlebar grip. To apply the front brake, pull the brake lever toward the handlebar grip. Ebu18432 brake pedal the brake pedal is located on the right side of the atv. To apply the rear brake, push down on the brake pedal. 1. Clutch ...

  • Page 33

    4-6 4 ebu18520 parking brake lever use the parking brake before starting the engine or parking the atv, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a). To release the parking brake, move the parking brake lever in direction (b). 1. Brake pedal 1 1. P...

  • Page 34

    4-7 4 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 begin to ride. The bra...

  • Page 35

    4-8 4 ebu18755 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 36

    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 37

    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 38

    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”! Ebu18840...

  • Page 39

    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. Ebu18993 adjusting the front shock absorber as- semblies the spring preload can be adjusted to suit the rid- er’s weight...

  • Page 40

    4-13 4 adjust the spring preload as follows. Turn the spring preload adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension. Align the appropriate notch in the adjusting...

  • Page 41

    4-14 4 tip ● a special wrench can be obtained at a yamaha dealer to make this adjustment. ● the spring preload setting is determined by measuring distance a, shown in the illustration. The shorter distance a is, the higher the spring preload; the longer distance a is, the lower the spring preload. W...

  • Page 42

    4-15 4 ● do not tamper with or attempt to open the cylinder assembly. ● do not subject the shock absorber assembly to an open flame or other high heat. ● do not deform or damage the cylinder in any way. ● do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorb...

  • Page 43

    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 44

    5-2 5 rear brake • check operation. If soft or spongy, have yamaha dealer bleed hy- draulic system. • check brake pads for wear, and replace if necessary. • check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary. • check hydraulic system for leakage. Corr...

  • Page 45

    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.) ebu19712 front and rear brakes brake lever and brake pedal ● check that there is no free play...

  • Page 46

    5-4 5 ebu19770 drive chain check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the drive chain as necessary. (see page 8-29.) ebu19794 tires check tire pressure regularly to make sure it is at the recommended specifications. Also check for wear and damage. Ti...

  • Page 47

    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 48

    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 49

    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 50

    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 possi...

  • Page 51

    6-3 6 ebu20522 shifting this atv has a 5-speed forward transmission. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, release the throttle lever, ap- ply the clutch, and then repe...

  • Page 52

    6-4 6 8. Follow the same procedure when shifting to the next higher gear. Ebu20650 to decelerate when slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a ...

  • Page 53

    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 54

    6-6 6 incline, shift into first gear, stop the engine, ap- ply the parking brake, and then block the front and rear wheels with rocks or other objects. Never park the atv on hills that are too steep to walk up easily. 1. Bring the atv to a stop by applying the front brake, shift into first gear, and...

  • Page 55

    6-7 6 market products or having other modifications performed to your atv that change any of the ve- hicle’s design or operation characteristics can put you and others at greater risk of serious injury or death. You are responsible for injuries related to changes in the vehicle. Keep the following i...

  • Page 56

    6-8 6 ● if you are carrying cargo and towing a trailer, in- clude the tongue weight in the maximum atv load limit. ● 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...

  • Page 57

    7-1 7 ebu21141 riding your atv u1bt63e0.Book page 1 friday, march 9, 2012 11:22 am.

  • Page 58

    7-2 7 ebu21617 getting to know your atv this atv is intended for recreational use by expe- rienced operators only. This section, riding your atv, provides general atv riding instructions for recreational riding. The skills and techniques de- scribed in this section, however, are appropriate for all ...

  • 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 during operation always keep your feet on the footrests during op- eration; otherwise, they may contact the rear wheels. Warning! Removing even one hand or 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...

  • Page 64

    7-8 7 questions, consult an authorized atv dealer. Warning! Operating this atv with improper modifications may cause changes in handling which in some situations could lead to an acci- dent. [ewb01491] exhaust system warning ewb01501 ● dry grass or brush or other combustible ma- terial accumulated a...

  • Page 65

    7-9 7 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, and may cause the atv to go out of control. Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. [ewb...

  • Page 66

    7-10 7 have enough time to react to hidden rocks, bumps, or holes. Go slowly and be extra care- ful when operating on unfamiliar terrain. Al- ways be alert to changing terrain conditions when operating the atv. [ewb01531] do not operate on rough, slippery, or loose terrain until you have learned and...

  • Page 67

    7-11 7 do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. 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, brake...

  • Page 68

    7-12 7 trol. [ewb02631] notice: do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. [ecb01071] use this same procedure as you move into the higher gears. Be sure to coordinate the use of the throttle and shift pedal properly. Avoid higher speeds until yo...

  • Page 69

    7-13 7 this procedure should be practiced at slow speed many times in a large unpaved area with no obsta- cles. If an incorrect technique is used, your atv may continue to go straight. If the atv doesn’t turn, come to a stop and then practice the proce- dure again. If the riding surface is slippery ...

  • Page 70

    7-14 7 ● never open the throttle suddenly or make sudden gear changes. The atv could flip over backwards. ● 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. ● never attempt to turn the atv around on any h...

  • 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 start to roll backwards, do not apply the rear brake, and apply the front brake gradually. The atv could easily tip over backwards. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount the atv im- mediately on the uphill side or to a side if point...

  • Page 73

    7-17 7 ● 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. ● shift your weight backward and to the up side of the hill. ● never go down a hill at high speed. ● avoid going down ...

  • Page 74

    7-18 7 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. ● avoid crossing the sid...

  • Page 75

    7-19 7 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 deeper than the depth sp...

  • Page 76

    7-20 7 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. Notice: undrained water can cause damage or improper opera- tion. [ecb00841] wash the atv in fresh water if it has been operat- ed in salt water or muddy conditi...

  • Page 77

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

  • 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 ebu21674 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 ebu29792 owner’s manual and tool kit make sure to protect the owner’s manual by put- ting it in the plastic bag, then by placing the bag in the manual cover. Always carry the owner’s man- ual along with the low-pressure tire gauge and the owner’s tool kit under the seat. The service informatio...

  • 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 * parking brake • check operation and adjust if necessary. √ √ √ √ √ 7 * wheels • check runout and for damage, and replace if nec- essary. √ √ √ √ 8 * tires • check tread depth and ...

  • Page 86

    8-7 8 14 * chassis fasteners • make sure that all nuts, bolts, and screws are properly tightened. √ √ √ √ √ 15 * shock absorber as- semblies • check operation and correct if necessary. • check for oil leakage and replace if necessary. √ √ √ 16 * steering shaft • lubricate with lithium-soap-based gre...

  • Page 87

    8-8 8 ebu23071 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 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. 3. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification. To install the spark plug 1. Clean the surface of the spark plug g...

  • Page 90

    8-11 8 ebu28957 engine oil and oil filter element the engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element must be replaced at the inter- vals specified in the periodic maintenance and lu- brication chart. To check the engine oil level ...

  • Page 91

    8-12 8 6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. To change the engine oil (with or without oil fil- ter element 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 a...

  • Page 92

    8-13 8 6. Install a new oil filter element and new o- rings. Tip make sure that the o-rings are properly seated. 7. Install the oil filter element cover by installing the bolts, and then tighten them to the speci- fied torque. 8. Install the engine oil drain bolt and its new gasket, and then tighten...

  • Page 93

    8-14 8 notice 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 “cd” or oils of a higher quality than specified. In addition, do not use oils labeled “energy conserv- ing...

  • Page 94

    8-15 8 4. Loosen the wing bolt. 5. Remove the air filter element together with the wing bolt and washer. 6. Remove the wing bolt and washer from the air filter element. 7. Remove the sponge material from the air filter element frame. 1. Air filter case cover 2. Air filter case cover holder 1 2 1. Ai...

  • Page 95

    8-16 8 8. Wash the sponge material gently but thor- oughly in solvent. Warning! Always use parts cleaning solvent to clean the sponge material. Never use low-flash-point sol- vents or gasoline to clean the sponge ma- terial because the engine could catch fire or explode. [ewb01941] 9. Squeeze the ex...

  • Page 96

    8-17 8 14. Install the washer onto the air filter element frame, and then insert the wing bolt into the hole in the air filter element frame. Notice: be sure to install the washer with its curved side facing outward as shown. [ecb00453] 15. Insert the air filter element into the air filter case, and...

  • Page 97

    8-18 8 17. 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 filter element maintenance is performed, check the air inlet of the air filter case for ob...

  • Page 98

    8-19 8 4. Check the gasket for damage, and replace it if necessary. 5. Make sure the gasket is properly positioned, then insert the tailpipe into the muffler and align the bolt holes. 6. Install the bolts and tighten them to the speci- fied torque. Warning ewb02340 do not start the engine when clean...

  • Page 99

    8-20 8 ing, possibly leading to death, and start a fire. Always let the exhaust system cool prior to touching exhaust components. 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 ...

  • Page 100

    8-21 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 101

    8-22 8 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 a yamaha dealer at the...

  • Page 102

    8-23 8 tip the wheels need to be removed to check the brake pads. (see page 8-41.) ebu28801 rear brake pads each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indica-...

  • Page 103

    8-24 8 front brake rear brake warning ewb02720 improper maintenance can result in loss of braking ability. Observe these precautions: ● insufficient brake fluid may allow air to enter the brake system, reducing braking perfor- mance. ● clean the filler cap before removing. Use only dot 4 brake fluid...

  • Page 104

    8-25 8 notice ecb01160 brake fluid may damage painted surfaces or plastic parts. Always clean up spilled fluid im- mediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. A low brake fluid level may indicate worn brake pads and/or brake system leakage; therefo...

  • Page 105

    8-26 8 the top of the brake pedal should be positioned 40.0 mm (1.57 in) above the top of the frame as shown. If the brake pedal is not positioned as spec- ified, have a yamaha dealer adjust it. Ebu24715 adjusting the parking brake free play the parking brake free play must be checked and, if necess...

  • Page 106

    8-27 8 tip if the cable length cannot be adjusted to specifica- tion, consult a yamaha dealer. 6. Tighten the locknut on the brake cable. 7. Slide the rubber cover to its original position. 8. Turn in the adjusting bolt at the rear brake cal- iper until it feels tight, then turn it out 1/8 turn and ...

  • Page 107

    8-28 8 the brake light switch for the brake pedal can be adjusted as follows, but the front brake light switch should be adjusted by a yamaha dealer. Turn the rear brake light switch adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjust...

  • Page 108

    8-29 8 5. Slide the rubber cover back to its original po- sition. Tip if the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a yamaha dealer check the internal clutch mechanism. Ebu26864 drive chain slack the drive chain slack should be...

  • Page 109

    8-30 8 tip a rod can be obtained at a yamaha dealer to make this adjustment. 4. Shift the transmission into neutral. 5. To tighten the drive chain, push the atv back- ward. To loosen the drive chain, push the atv forward. Notice: improper drive chain slack will overload the engine as well as other v...

  • Page 110

    8-31 8 ebu24882 lubricating the drive chain the drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. Notice ecb005...

  • Page 111

    8-32 8 essary. If a cable is damaged or does not move smoothly, have a yamaha dealer check or replace it. 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 restri...

  • Page 112

    8-33 8 clutch 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. Ebu28871 checking and lubricating the brake pedal the operation of the brake pedal should be checked before e...

  • Page 113

    8-34 8 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. Ebu25033 lubricating the upper and lower arm pivots the upper and lower arm pivots must be lubricated at the inter...

  • Page 114

    8-35 8 right side ebu25092 lubricating the steering shaft the steering shaft must be lubricated by a yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Tip for parts equipped with a grease nipple, use a grease gun. Ebu2522e battery the battery is located unde...

  • Page 115

    8-36 8 keep out of reach of children. Notice ecb00620 never attempt to remove the battery cell seals, as this would permanently damage the battery. To remove the battery 1. Remove the seat. (see page 4-11.) 2. Unhook the band securing the owner’s tool kit, and then remove the battery holding plate b...

  • Page 116

    8-37 8 to charge the battery have a yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the atv is equipped with optional electri- cal accessories. Notice ecb00931 to charge a vrla (valve regulated lead...

  • Page 117

    8-38 8 3. Install the battery holding plate by installing the bolts, and then hook the band to secure the owner’s tool kit. 4. Install the seat. (see page 4-11.) ebum0183 replacing the fuse the fuse holder is located beside the battery and can be accessed as follows: 1. Remove the seat. (see page 4-...

  • Page 118

    8-39 8 ject in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical system, which could lead to a fire. [ewb02172] 3. Turn the key to “on” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have...

  • Page 119

    8-40 8 4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the burnt-out bulb. 5. Place a new headlight bulb into position. Notice: do not touch the glass part of the headlight bulb to keep it free from oil, oth- erwise the transparency of the glass,...

  • Page 120

    8-41 8 6. Install the headlight bulb holder by pushing it in and turning it clockwise. 7. Install the headlight bulb holder cover. 8. Connect the headlight coupler. 9. Place the headlight unit in the original posi- tion, and then install the bolt. 10. Adjust the headlight beam if necessary. Ebu25561...

  • Page 121

    8-42 8 front rear 3. Elevate the atv and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. Ebu27481 installing a wheel 1. Place the atv on a level surface. 2. Install the wheel and the nuts. Tip when installing the wheel, make sure its arrow mark points ...

  • Page 122

    8-43 8 3. Lower the atv to the ground. 4. Tighten the wheel nuts to the specified torques. 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, ...

  • Page 123

    8-44 8 ebu25752 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 124

    9-1 9 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 exhaust pipe to prevent w...

  • Page 125

    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 126

    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 127

    10-1 10 ebu25961 specifications dimensions: overall length: 1625 mm (64.0 in) overall width: 1072 mm (42.2 in) overall height: 1040 mm (40.9 in) seat height: 730 mm (28.7 in) wheelbase: 1110 mm (43.7 in) ground clearance: 100 mm (3.9 in) minimum turning radius: 2900 mm (114 in) weight: with oil and ...

  • Page 128

    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 replacement: 1.25 l (1.32 us qt, 1.10 imp.Qt) with oil filter element replacement: 1.35 l (1.43 us qt, 1.19...

  • Page 129

    10-3 10 gear ratio: 1st: 37/13 (2.846) 2nd: 33/18 (1.833) 3rd: 29/21 (1.381) 4th: 27/24 (1.125) 5th: 28/29 (0.966) chassis: frame type: steel tube frame caster angle: 6.0 ° trail: 23.0 mm (0.91 in) front tire: type: tubeless size: at20 x 7-10 manufacturer/model: duro/di-k102 rear tire: type: tubeles...

  • Page 130

    10-4 10 specified brake fluid: dot 4 rear brake: type: disc brake operation: right foot operation specified brake fluid: dot 4 front suspension: type: double wishbone spring/shock absorber type: coil spring/oil damper wheel travel: 190 mm (7.5 in) rear suspension: type: swingarm spring/shock absorbe...

  • Page 131

    10-5 10 exposed to the noise. Also the permissible expo- sure level can vary from country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk. U1bt63e0.Book page 5 friday, march 9, 2012 11:22 am.

  • Page 132

    11-1 11 ebu26000 consumer information ebu28201 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 133

    11-2 11 1. Model label 1 u1bt63e0.Book page 2 friday, march 9, 2012 11:22 am.

  • Page 134

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning ............................................ 8-14 b battery .......................................................................... 8-35 brake and clutch levers, checking and lubricat...

  • Page 135

    Model label ................................................................... 11-1 n neutral indicator light ..................................................... 4-2 o owner’s manual and tool kit ........................................... 8-2 p parking ..............................................

  • Page 136

    Ebu26162 warning always : • use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. • avoid paved surfaces—pavement may seriously affect handling and control. Improper atv use can result in severe injury or death. Never use with drugs or alcohol always use an...