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Yamaha YFM250R Owner's Manual

Other manuals for YFM250R: Owner's Manual

Summary of YFM250R

  • Page 1

    This a manual del propietario 4d3-28199-60 yfm25rx manuel du propriÉtaire owner’s manual.

  • Page 2

    Printed in japan 2007.05-1.5x1 ! (e,f,s) yamaha motor co., ltd. Printed on recycled paper imprimÉ sur papier recyclÉ impreso en papel reciclado.

  • Page 3: Yfm25Rx

    This a 4d3-28199-60-e0 yfm25rx owner’s manual.

  • Page 5

    Ebu17170 introduction ebu17320 congratulations on your purchase of the yamaha yfm25rx. 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

    Riding your atv ...................................... 7-1 getting to know your atv.............. 7-2 ride with care and good judgement........................................... 7-2 be careful where you ride............ 7-8 turning your atv ............................. 7-12 climbing uphill ..........

  • Page 10

    Removing a wheel ................................... 8-42 installing a wheel ..................................... 8-42 troubleshooting ...................................... 8-43 troubleshooting chart ............................. 8-44 cleaning and storage.......................... 9-1 cleaning ......

  • Page 11

    1-1 1 2 3 4 5 6 7 8 9 10 11 ebu17430 safety information safety information ebu17592 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 12

    1-2 1 2 3 4 5 6 7 8 9 10 11 conditions, and your experience. ● 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 manu...

  • Page 13

    1-3 1 2 3 4 5 6 7 8 9 10 11 speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill. Turn the atv around and remount, following the procedure described in this...

  • Page 14

    1-4 1 2 3 4 5 6 7 8 9 10 11 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 some gasoline in your eyes, seek medical help immediately. If gasoline spills on your skin, wash with soap and wa- ter. If...

  • Page 15

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

  • Page 16

    2-2 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 17

    2-3 1 2 3 4 5 6 7 8 9 10 11 16 5fk-21697-00 warning under 16 operating this atv if you are under the age of 16 increases your chance of severe injury or death. Never operate this atv if you are under age 16. 5fe-21697-01 for europe for oceania 3 3 3b4-2151h-10 warning never never ride as a passenger...

  • Page 18

    2-4 1 2 3 4 5 6 7 8 9 10 11 5 5lp-21696-m0 27.5 kpa 0.275 kgf/cm 2 4.0 psi 27.5 kpa 0.275 kgf/cm 2 4.0 psi gb d e f i nl p s set with tires cold. Pneus à froid. Bei kalten reifen. Ajuste con los neumáticos an frío. Impostare a pneumatici freddi. Ställ in med kalla däck. Wanneer de banden koud zijn. ...

  • Page 19

    3-1 1 2 3 4 5 6 7 8 9 10 11 ebu17680 description ebu17690 left view ebu17700 right view 1. Headlights 2. Fuel cock 3. Starter (choke) 4. Throttle stop screw 5. Fuse 6. Tail/brake light 7. Shift pedal 7 1 2 3 4 5 6 1. Spark arrester 2. Seat 3. Fuel tank cap 4. Oil filter element 5. Brake pedal 4 1 2 ...

  • Page 20

    3-2 1 2 3 4 5 6 7 8 9 10 11 ebu17712 controls and instruments note: 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. Throttle lever 6. Brake lever 1 2 3 4 5 6.

  • Page 21

    4-1 1 2 3 4 5 6 7 8 9 10 11 ebu17731 instrument and control functions ebu17740 main switch the positions of the main switch are as follows: on all electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved. Off all electrical systems are off. The key can b...

  • Page 22

    4-2 1 2 3 4 5 6 7 8 9 10 11 ebu18061 handlebar switches ebu18070 engine stop switch “eng. Stop” set this switch to “run” 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...

  • Page 23

    4-3 1 2 3 4 5 6 7 8 9 10 11 return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. Warning ewb00250 malfunction of the thro...

  • Page 24

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

  • Page 25

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

  • Page 26

    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 27

    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. 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. Shift pedal 1 1. Fuel tank cap 1.

  • Page 28

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

  • Page 29

    4-9 1 2 3 4 5 6 7 8 9 10 11 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 with the fuel cock lever in this...

  • Page 30

    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 31

    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. Note: make sure that the seat is securely fitted. Ebu18990 adjusting the front shock absorber assemblies the spring preload can be adjusted to...

  • Page 32

    4-12 1 2 3 4 5 6 7 8 9 10 11 note: a special wrench can be obtained at a yamaha dealer to make this adjustment. 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 le...

  • Page 33

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

  • Page 34

    5-2 1 2 3 4 5 6 7 8 9 10 11 rear brake ● check operation. If soft or spongy, have yamaha dealer bleed hydraulic system. ● check brake pads for wear, and replace if necessary. ● check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary. ● check hydraulic sy...

  • Page 35

    5-3 1 2 3 4 5 6 7 8 9 10 11 ebu19540 fuel make sure that there is sufficient fuel in the tank. (see page 4-7.) 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 ...

  • Page 36

    5-4 1 2 3 4 5 6 7 8 9 10 11 tem. 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 braking performance, check the brake pads for wear. (see page 8-22.) warning ewb00580 always check the brakes at the start of ...

  • Page 37

    5-5 1 2 3 4 5 6 7 8 9 10 11 size: at19 x 10-9 type: tubeless ● the tires should be set to the recommended pressure: recommended tire pressure: front: 27.5 kpa (4.0 psi) (0.275 kgf/cm 2 ) rear: 27.5 kpa (4.0 psi) (0.275 kgf/cm 2 ) ● check and adjust tire pressures when the tires are cold. ● tire pres...

  • Page 38

    5-6 1 2 3 4 5 6 7 8 9 10 11 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). 1. Low-pressure tire gauge recommended pressure: front 27.5 kpa (4.0 psi) (0....

  • Page 39

    5-7 1 2 3 4 5 6 7 8 9 10 11 ebu19840 chassis fasteners make sure that all nuts, bolts and screws are prop- erly tightened. Ebu19850 instruments, lights and switches check that all instruments, lights and switches are working properly. Correct if necessary. 1. Tire wear limit.

  • Page 40

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

  • Page 41

    6-2 1 2 3 4 5 6 7 8 9 10 11 position (1): ● cold engine start with ambient temperature be- low 5 °c (40 °f). Position (2): ● cold engine start with ambient temperature be- tween 0 °c (30 °f) and 30 °c (90 °f). Position (3): ● cold engine start with ambient temperature above 25 °c (80 °f). Ambient te...

  • Page 42

    6-3 1 2 3 4 5 6 7 8 9 10 11 attempt. 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine. If the engine is started with the starter (choke) in position (2), keep the starter (choke) in this position to war...

  • Page 43

    6-4 1 2 3 4 5 6 7 8 9 10 11 ebu20570 to start out and accelerate 1. Release the throttle lever. Caution: ecb00200 always close the throttle before shifting gears, otherwise damage to the engine and drive train may result. 2. Pull the clutch lever to disengage the clutch. 3. Shift into first gear. 4....

  • Page 44

    6-5 1 2 3 4 5 6 7 8 9 10 11 for long distances. The transmission is prop- erly lubricated only when the engine is run- ning. Inadequate lubrication may damage the transmission. ● always use the clutch when changing gears. The engine, transmission and drive train are not designed to withstand the sho...

  • Page 45

    6-6 1 2 3 4 5 6 7 8 9 10 11 the fuel cock to “off”. Ebu20860 parking on a slope warning ewb00850 avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the atv to roll out of control, increasing the chance of an accident. If you must park on an incline, place the ...

  • Page 46

    6-7 1 2 3 4 5 6 7 8 9 10 11 accessories. ● choose only accessories designed for your atv. Your yamaha dealer has a variety of gen- uine yamaha accessories. Other accessories may also be available on the market. However, it is not possible for yamaha to test all non- yamaha accessories, nor control o...

  • Page 47

    6-8 1 2 3 4 5 6 7 8 9 10 11 ● make sure the load does not interfere with con- trols or your ability to see where you are going. ● ride 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 not to exceed 2nd gear ...

  • Page 48

    7-1 1 2 3 4 5 6 7 8 9 10 11 ebu21141 riding your atv.

  • Page 49

    7-2 1 2 3 4 5 6 7 8 9 10 11 ebu21611 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...

  • Page 50

    7-3 1 2 3 4 5 6 7 8 9 10 11 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 operator only – passengers prohibited. Warning ewb01400 never carry a passenger. The long s...

  • Page 51

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

  • Page 52

    7-5 1 2 3 4 5 6 7 8 9 10 11 page 5-1 before riding for proper care of the atv and to ensure safety. Warning ewb01430 always inspect your atv each time you use it to make sure the atv is in safe operating con- dition. Always follow the inspection and main- tenance procedures and schedules described i...

  • Page 53

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

  • Page 54

    7-7 1 2 3 4 5 6 7 8 9 10 11 warning ewb01470 always keep both hands on the handlebars and both feet on the footboards of your atv during operation. 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...

  • Page 55

    7-8 1 2 3 4 5 6 7 8 9 10 11 signed for use on this atv and should be installed and used according to instructions. Improper installation of accessories or modifi- cation of this atv may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an ...

  • Page 56

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

  • Page 57

    7-10 1 2 3 4 5 6 7 8 9 10 11 on unfamiliar terrain. Always be alert to chang- ing terrain conditions when operating the atv. 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. F...

  • Page 58

    7-11 1 2 3 4 5 6 7 8 9 10 11 warning ewb01550 always mount a caution flag on the atv to make you more visible when operating in areas where you might not be seen by other vehicles. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”. Do not ride on private property witho...

  • Page 59

    7-12 1 2 3 4 5 6 7 8 9 10 11 these components. With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then release the parking brake. Open the throttle grad- ually, and at the same time, release the clutch le- ver slowly. Once the atv has attained adequa...

  • Page 60

    7-13 1 2 3 4 5 6 7 8 9 10 11 used to allow the atv to make turns quickly and easily. It is essential that this skill be learned first at low speed. Warning ewb01570 always follow proper procedures for turning as described in this owner’s manual. Practice turning at low speeds before attempting to tu...

  • Page 61

    7-14 1 2 3 4 5 6 7 8 9 10 11 curves. 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 t...

  • Page 62

    7-15 1 2 3 4 5 6 7 8 9 10 11 if you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the atv around while you still have forward motion (provided you have the room to do so) and go down the hill. Warning ewb01600 never attempt to ...

  • Page 63

    7-16 1 2 3 4 5 6 7 8 9 10 11 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 around and then descend the hill. If you start to roll backwards, do not apply the ...

  • Page 64

    7-17 1 2 3 4 5 6 7 8 9 10 11 tion. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. Whenever possible, ride your atv straight down- hill. Avoid sharp angl...

  • Page 65

    7-18 1 2 3 4 5 6 7 8 9 10 11 steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill. If your atv does begin to tip over, gradually steer in the downhill direction if there are no obstacles in ...

  • Page 66

    7-19 1 2 3 4 5 6 7 8 9 10 11 in water deeper than that specified in your owner’s manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the lin- ings. If the atv is operated through deep...

  • Page 67

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

  • Page 68

    7-21 1 2 3 4 5 6 7 8 9 10 11 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 be developed. The terrain should be chosen carefully before attempting such maneuvers, since both sta...

  • Page 69

    7-22 1 2 3 4 5 6 7 8 9 10 11 slide. (see page 7-20.) ● 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 no...

  • Page 70

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

  • Page 71

    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 72

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

  • Page 73

    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 74

    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 air filter element ● clean and replace if...

  • Page 75

    8-6 1 2 3 4 5 6 7 8 9 10 11 10 * swingarm pivots ● check operation and for excessive play, and replace bearings if necessary. ● lubricate with lithium-soap-based grease. √ √ √ 11 * upper and lower arm pivots ● lubricate with lithium-soap-based grease. √ √ √ 12 drive chain ● check chain slack and adj...

  • Page 76

    8-7 1 2 3 4 5 6 7 8 9 10 11 20 engine oil ● change. ● check atv for oil leakage, and correct if neces- sary. √ √ √ √ 21 engine oil filter ele- ment ● clean or replace if necessary. √ √ √ 22 * moving parts and cables ● lubricate. √ √ √ √ 23 * throttle lever hous- ing and cable ● check operation and c...

  • Page 77

    8-8 1 2 3 4 5 6 7 8 9 10 11 ebu23070 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 mast...

  • Page 78

    8-9 1 2 3 4 5 6 7 8 9 10 11 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 slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubr...

  • Page 79

    8-10 1 2 3 4 5 6 7 8 9 10 11 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. 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 surfa...

  • Page 80

    8-11 1 2 3 4 5 6 7 8 9 10 11 to check the engine oil level 1. Place the atv on a level surface. 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 ...

  • Page 81

    8-12 1 2 3 4 5 6 7 8 9 10 11 to change the engine oil (with or without oil filter element cleaning) 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...

  • Page 82

    8-13 1 2 3 4 5 6 7 8 9 10 11 8. Install the oil filter element and o-ring. Note: make sure that the o-ring is properly seated. 9. Install the oil filter element cover by installing the bolts, and then tighten them to the speci- fied torque. 10. Install the engine oil drain bolt and tighten it to the...

  • Page 83

    8-14 1 2 3 4 5 6 7 8 9 10 11 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 “cd” or oils of a higher quality than ...

  • Page 84

    8-15 1 2 3 4 5 6 7 8 9 10 11 3. Loosen the wing bolt. 4. Remove the air filter element together with the wing bolt and washer. 5. Remove the wing bolt and washer from the air filter element. 6. Remove the sponge material from the air filter element frame. 1. Air filter case cover 2. Air filter case ...

  • Page 85

    8-16 1 2 3 4 5 6 7 8 9 10 11 7. 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...

  • Page 86

    8-17 1 2 3 4 5 6 7 8 9 10 11 12. Install the washer onto the air filter element frame, and then insert the wing bolt into the hole in the air filter element frame. Caution: ecb00451 be sure to install the washer with the bent edge facing outward as shown. 13. Insert the air filter element into the a...

  • Page 87

    8-18 1 2 3 4 5 6 7 8 9 10 11 ebu28900 cleaning the spark arrester be sure the exhaust pipe and muffler are cool be- fore cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any car...

  • Page 88

    8-19 1 2 3 4 5 6 7 8 9 10 11 5. Install the bolts and tighten them to the speci- fied torque. Warning ewb02340 do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire. Alway...

  • Page 89

    8-20 1 2 3 4 5 6 7 8 9 10 11 ebu24000 adjusting the engine idling speed the engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrica- tion chart. Note: a diagnostic tachometer is needed to make this adjustment. 1. S...

  • Page 90

    8-21 1 2 3 4 5 6 7 8 9 10 11 chart. The throttle cable free play should measure 2.0– 4.0 mm (0.08–0.16 in) at the throttle lever. Period- ically check the throttle cable free play and, if nec- essary, adjust it as follows. Note: the engine idling speed must be checked, and ad- justed if necessary, b...

  • Page 91

    8-22 1 2 3 4 5 6 7 8 9 10 11 ebu24130 checking the front and rear brake pads the front and rear brake pads must be checked for wear at the intervals specified in the periodic main- tenance and lubrication chart. Ebu27711 front brake pads each brake pad is provided with wear indicator grooves, which ...

  • Page 92

    8-23 1 2 3 4 5 6 7 8 9 10 11 place the brake pads as a set. Ebu28930 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 i...

  • Page 93

    8-24 1 2 3 4 5 6 7 8 9 10 11 rear brake if the rear brake fluid level is low, replenish as fol- lows. 1. Remove the brake fluid reservoir cap cover by removing the bolt. 2. Remove the brake fluid reservoir cap. 1. Minimum level mark 1 1. Bolt 2. Brake fluid reservoir cap cover 1 2.

  • Page 94

    8-25 1 2 3 4 5 6 7 8 9 10 11 3. Refill with brake fluid. 4. Install the brake fluid reservoir cap. 5. Install the brake fluid reservoir cap cover by installing the bolt. Observe these precautions: ● when checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● use on...

  • Page 95

    8-26 1 2 3 4 5 6 7 8 9 10 11 ebu24390 checking the front brake lever free play the brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake lever should have a free play of zero mm (zero in) as shown. If the free play is incorrect,...

  • Page 96

    8-27 1 2 3 4 5 6 7 8 9 10 11 warning ewb02110 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 brake pedal position is correct. ● make sure the brakes do...

  • Page 97

    8-28 1 2 3 4 5 6 7 8 9 10 11 parking brake lever to the right. 2. Fully loosen the locknut and the adjusting bolt at the rear brake caliper. 3. Loosen the locknut on the brake cable. 4. Turn the adjusting nut on the brake cable in di- rection (a) to increase the cable length, and in direction (b) to...

  • Page 98

    8-29 1 2 3 4 5 6 7 8 9 10 11 ebu24740 brake light switches the operation of the brake light switches must be checked and, if necessary, adjusted at the inter- vals specified in the periodic maintenance and lu- brication chart. The brake light switch for the brake pedal can be adjusted as follows, bu...

  • Page 99

    8-30 1 2 3 4 5 6 7 8 9 10 11 1. Loosen the locknut at the clutch lever. 2. To increase the clutch lever free play, turn the adjusting bolt in direction (a), and to decrease it, turn the bolt in direction (b). 3. Tighten the locknut. Note: if the specified free play cannot be obtained as de- scribed ...

  • Page 100

    8-31 1 2 3 4 5 6 7 8 9 10 11 3. If the drive chain slack is incorrect, adjust it as follows. To adjust the drive chain slack 1. Loosen the rear axle pinch bolts. 2. Insert a rod of a diameter of 8 mm (0.3 in) and a length of 10 cm (4 in) into one of the holes in the drive chain tensioner as shown. N...

  • Page 101

    8-32 1 2 3 4 5 6 7 8 9 10 11 gine as well as other vital parts of the atv and can lead to drive chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits. 5. Pull the rod out, and then tighten the rear axle pinch bolts to the specified torque ...

  • Page 102

    8-33 1 2 3 4 5 6 7 8 9 10 11 the drive chain with steam cleaners, high-pres- sure washers or inappropriate solvents. 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special o-ring chain lubricant. Caution: ecb00580 do not use engine oil or any other lubricants for the dri...

  • Page 103

    8-34 1 2 3 4 5 6 7 8 9 10 11 brake lever clutch lever ebu24931 checking and lubricating the brake and shift pedals the operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Ebu24962 checking the wheel hub bearings the fron...

  • Page 104

    8-35 1 2 3 4 5 6 7 8 9 10 11 lubrication chart. Ebu25030 lubricating the upper and lower arm pivots the upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun. Left side recommende...

  • Page 105

    8-36 1 2 3 4 5 6 7 8 9 10 11 right side 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 is equipped with a sealed-type (mf) battery, which does not require any ...

  • Page 106

    8-37 1 2 3 4 5 6 7 8 9 10 11 keep out of reach of children. 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. T...

  • Page 107

    8-38 1 2 3 4 5 6 7 8 9 10 11 if the 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 when checking or replacing a fuse. 2. Remove the blown fuse, and then install a ...

  • Page 108

    8-39 1 2 3 4 5 6 7 8 9 10 11 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, which could lead to a fire. 3. Turn the key to “on” and turn on...

  • Page 109

    8-40 1 2 3 4 5 6 7 8 9 10 11 4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the defective bulb. Warning ewb02230 do not touch a headlight bulb when it is on or immediately after it is turned off. You can be burned or a fire could start if the bu...

  • Page 110

    8-41 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00650 do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affect- ed. Thoroughly clean off any dirt and finger- prints on the head...

  • Page 111

    8-42 1 2 3 4 5 6 7 8 9 10 11 ebu25580 replacing the tail/brake light bulb if the tail/brake light bulb burns out, have a yamaha dealer replace it. Ebu25650 removing a wheel 1. Loosen the wheel nuts. Front rear 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the...

  • Page 112

    8-43 1 2 3 4 5 6 7 8 9 10 11 front 2. Lower the atv to the ground. 3. 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, compre...

  • Page 113

    8-44 1 2 3 4 5 6 7 8 9 10 11 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. ...

  • Page 114

    9-1 1 2 3 4 5 6 7 8 9 10 11 ebu25860 cleaning and storage ebu25900 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 115

    9-2 1 2 3 4 5 6 7 8 9 10 11 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 necessary, protect it against dust with a...

  • Page 116

    9-3 1 2 3 4 5 6 7 8 9 10 11 with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. 6. Lubricate all control cables and the pivoting points of all levers and pedals. 7. Check and, if necessary, correct the tire air pressure, and then block...

  • Page 117

    10-1 1 2 3 4 5 6 7 8 9 10 11 ebu25960 specifications ebu2597a dimensions: overall length: 1625 mm (64.0 in) overall width: 1070 mm (42.1 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 ...

  • Page 118

    10-2 1 2 3 4 5 6 7 8 9 10 11 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 imp.Qt) air filter: air filter element: wet element fuel: recommended fuel: regular unleaded gasoline only (eur) ...

  • Page 119

    10-3 1 2 3 4 5 6 7 8 9 10 11 front tire: type: tubeless size: at20 x 7-10 manufacturer/model: dunlop/kt201 rear tire: type: tubeless size: at19 x 10-9 manufacturer/model: dunlop/kt205a loading: maximum loading limit: 100.0 kg (220 lb) (total weight of rider, cargo, accessories, and tongue) tire air ...

  • Page 120

    10-4 1 2 3 4 5 6 7 8 9 10 11 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 absorber type: coil spring/gas-oil damper wheel travel: 200 mm (7.9 in) electrical system: ignition syste...

  • Page 121

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

  • Page 122

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

  • Page 123

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning............................................ 8-14 b battery.......................................................................... 8-36 brake and clutch levers, checking and lubricatin...

  • Page 124

    Light switch .................................................................... 4-2 m main switch .................................................................... 4-1 maintenance and lubrication chart ................................. 8-5 maintenance chart, emission control system ...............

  • Page 126

    Printed in japan 2007.05-1.5x1 ! (e) yamaha motor co., ltd. Printed on recycled paper.