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  5. Owner's Manual

Yamaha YFM350R-W Owner's Manual

Summary of YFM350R-W

  • Page 1

    Yfm35rw owner’s manual manuel du propriÉtaire manual del propietario 5yt-28199-63.

  • Page 2

    Printed in japan 2006.04-0.4 ×1 cr (e,f,s) printed on recycled paper imprimÉ sur papier recyclÉ impreso en papel reciclado yamaha motor co., ltd..

  • Page 3: Owner’S Manual

    Owner’s manual yfm35rw 5yt-28199-63-e0 u5yt63e0.Book page 1 wednesday, april 12, 2006 3:20 pm.

  • Page 4

    U5yt63e0.Book page 2 wednesday, april 12, 2006 3:20 pm.

  • Page 5

    Ebu17170 introduction ebu17320 congratulations on your purchase of the yamaha yfm35rw. 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

    Starting a warm engine .............................. 6-3 operating the drive select lever and driving in reverse ...................................... 6-3 shifting ....................................................... 6-4 engine break-in .......................................... 6-6 parking ......

  • Page 10

    Checking and lubricating the brake and shift pedals ............................................. 8-31 checking the wheel bearings ................... 8-32 lubricating the swingarm pivots ............... 8-32 lubricating the rear suspension relay arm and connecting arm pivoting points ........ 8-32 ...

  • Page 11

    1-1 1 ebu17430 safety information ebu17462 an atv is not a toy and can be hazard- ous to operate. An atv handles differently from other vehicles, in- cluding motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over o...

  • Page 12

    1-2 1 ● always inspect your atv each time you use it to make sure it is in safe operating condition. Al- ways follow the inspection and maintenance procedures and schedules described in this manual. ● always keep both hands on the handlebars and both feet on the footboards of the atv during operatio...

  • Page 13

    1-3 1 speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill. Turn the atv around and remount, following the procedure described in this manual. ● always chec...

  • Page 14

    1-4 1 nition such as the pilot lights of water heat- ers and clothes dryers. Gasoline can catch fire and you could be burned. ● when transporting the atv in another vehi- cle, be sure it is kept upright and that the fuel cock is in the “off” position. Otherwise, fuel may leak out of the carburetor o...

  • Page 15

    2-1 2 ebu17660 location of the warning and specification labels u5yt63e0.Book page 1 wednesday, april 12, 2006 3:20 pm.

  • Page 16

    2-2 2 ebu27150 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a replace- ment label from your yamaha dealer. For europe and ...

  • Page 17

    2-3 2 for europe 2 3 4 5fk-2151h-00 5nf-21696-m0 25 kpa 0.25 kgf/cm 2 3.6 psi 25 kpa 0.25 kgf/cm 2 3.6 psi gb d e f i nl p s set with tires cold. Pneus à froid. Bei kalten reifen. Ajuste con los neumáticos en frío. Impostare a pneumatici freddi. Ställ in med kalla däck. Wanneer de banden koud zijn. ...

  • Page 18

    2-4 2 for europe u5yt63e0.Book page 4 wednesday, april 12, 2006 3:20 pm.

  • Page 19

    2-5 2 for oceania u5yt63e0.Book page 5 wednesday, april 12, 2006 3:20 pm.

  • Page 20

    2-6 2 for oceania 6 under warning 5fe-21697-01 never operate this atv if you are under age 16. Operating this atv if you are under the age of 16 increases your chance of severe injury or death. U5yt63e0.Book page 6 wednesday, april 12, 2006 3:20 pm.

  • Page 21

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Headlights 2. Front wheel 3. Fuel cock 4. Rear wheel 5. Shift pedal 1. Spark arrester 2. Seat 3. Drive select lever 4. Fuel tank cap 5. Main switch 6. Brake pedal u5yt63e0.Book page 1 wednesday, april 12, 2006 3:20 pm.

  • Page 22

    3-2 3 ebu17712 controls and instruments note: the atv you have purchased may differ slightly from the figures shown in this manual. 1. Clutch lever 2. Parking brake lever 3. Brake lever 4. Throttle lever 5. Handlebar switches u5yt63e0.Book page 2 wednesday, april 12, 2006 3:20 pm.

  • Page 23

    4-1 4 ebu17730 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 24

    4-2 4 ebu18060 handlebar switches ebu18080 engine stop switch “ / ” set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run ...

  • Page 25

    4-3 4 ebu18280 throttle lever once the engine is running, movement of the throt- tle lever will increase the engine speed. Regulate the speed of the atv by varying the throttle position. Because the throttle is spring- loaded, the atv will decelerate, and the engine will return to an idle any time t...

  • Page 26

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

  • Page 27

    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. Ebu18520 p...

  • Page 28

    4-6 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 29

    4-7 4 ebu18571 drive select lever the drive select lever is used for driving the atv either forward or in reverse. See the “operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. Ebu18720 fuel tank cap remove the fuel tank cap by turning it...

  • Page 30

    4-8 4 ebu18750 fuel make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Note: if knocking or pinging occurs, use a different brand of gasoline or higher octane grade. 1. Fuel tank cap 1. Fuel tank filler tube 2. Fuel level recommended fu...

  • Page 31

    4-9 4 caution: ecb00070 use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Warning ewb00310 ● do not overfill the fuel tank. Fuel expands when it heats up. If the fuel tank i...

  • Page 32

    4-10 4 on with the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding. Res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to thi...

  • Page 33

    4-11 4 move the starter (choke) in direction (b) to turn off the starter (choke). See the “starting a cold engine” section on page 6-1 for proper operation. Ebu18880 seat to remove the seat pull the seat lock lever upward and pull up the seat at the rear. To install the seat insert the projections o...

  • Page 34

    4-12 4 ebu18990 adjusting the front shock absorber as- semblies the spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspen- sion...

  • Page 35

    4-13 4 warning ewb00400 always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. Ebu19040 adjusting the rear shock absorber as- sembly the spring preload can be adju...

  • Page 36

    4-14 4 note: ● 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....

  • Page 37

    4-15 4 3. Tighten the locknut to the specified torque. Caution: ecb00080 always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque. Warning ewb00450 this shock absorber assembly contains highly pressurized nitrogen gas. If the shock absorb- er assembly is da...

  • Page 38

    5-1 5 ebu19200 pre-operation checks ebu19220 pre-operation check list before operating this atv, be sure to check the items listed in the following table. Note: the maintenance of some items in the table has to be performed by a yamaha dealer. Refer to the “periodic maintenance and lubrication chart...

  • Page 39

    5-2 5 warning ewb00480 always inspect your atv each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual. Failure to inspect increases the possibility of an accident or equipment damage. ...

  • Page 40

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

  • Page 41

    5-4 5 brake fluid leakage check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If there is any leak- age, have a yamaha dealer check the brake sys- tem. Brake operation test the brakes at slow speed after starting out to...

  • Page 42

    5-5 5 front: manufacturer/model: dunlop/kt851b size: at21 x 7-10 type: tubeless rear: manufacturer/model: dunlop/kt877a size: at20 x 10-9 type: tubeless ● the tires should be set to the recommended pressure: recommended tire pressure: front: 25.0 kpa (3.6 psi) (0.250 kgf/cm²) rear: 25.0 kpa (3.6 psi...

  • Page 43

    5-6 5 note: the low-pressure tire gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set the tire pressure when the tires are cold. Set the tire pressures to the fo...

  • Page 44

    5-7 5 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 u5yt63e0.Book page 7 wednesday, april 12, 2006...

  • Page 45

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

  • Page 46

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

  • Page 47

    6-3 6 note: the engine is warm when it responds normally to the throttle with the starter (choke) turned off. Ebu20291 starting a warm engine follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start t...

  • Page 48

    6-4 6 note: when in reverse, the reverse indicator light should be on. If the indicator light does not come on, have a yamaha dealer check the electrical circuit. 5. Check behind you for people or obstacles, and then release the brake pedal. 6. Open the throttle lever gradually and release the clutc...

  • Page 49

    6-5 6 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. Open the throttle gradually and at the same time, release the clutch lever slowly. 5. Onc...

  • Page 50

    6-6 6 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 shock of forced shifting and can be damaged by shift- ing without using...

  • Page 51

    6-7 6 ebu20900 parking on a slope warning ewb00870 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 atv transversely across the incline, apply the...

  • Page 52

    6-8 6 ebu20910 accessories and loading ebu20920 accessories accessories can affect the handling and control of your atv. Keep the following in mind when consid- ering an accessory or operating an atv which has accessories. ● choose only accessories designed for your atv. Your yamaha dealer has a var...

  • Page 53

    6-9 6 ● never exceed the weight limits shown. An over- loaded atv can be unstable. ● if you are carrying cargo and towing a trailer, in- clude the tongue weight in the maximum 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 fro...

  • Page 54

    7-1 7 ebu21141 riding your atv u5yt63e0.Book page 1 wednesday, april 12, 2006 3:20 pm.

  • Page 55

    7-2 7 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 time to fully learn t...

  • Page 56

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

  • Page 57

    7-4 7 apparel always wear an approved motorcycle helmet that fits properly. You should also wear: ● eye protection (goggles or face shield) ● gloves ● boots ● long-sleeved shirt or jacket ● long pants warning ewb01410 never operate this atv without wearing an ap- proved motorcycle helmet, eye protec...

  • Page 58

    7-5 7 warning ewb01420 never consume alcohol or drugs before or while driving this atv. Pre-operation checks always perform the pre-operation checks listed on 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...

  • Page 59

    7-6 7 speed limiter for riders less experienced with this model, the throttle lever housing is equipped with a speed lim- iter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine pow...

  • Page 60

    7-7 7 ● always follow the instructions in your own- er’s manual for carrying cargo or pulling a trailer. During operation always keep your feet on the footboards during op- eration, otherwise they may contact the rear wheels. Warning ewb01470 always keep both hands on the handlebars and both feet on...

  • Page 61

    7-8 7 modifications warning ewb01490 never modify this atv through improper in- stallation or use of accessories. All parts and accessories added to this atv should be gen- uine yamaha or equivalent components de- signed for use on this atv and should be installed and used according to instructions....

  • Page 62

    7-9 7 be careful where you ride this atv is designed for use on unpaved surfaces only. Riding on paved surfaces can cause loss of control. Warning ewb01510 always avoid paved surfaces, including side- walks, driveways, parking lots and streets. Atvs are designed for use on unpaved surfac- es only. P...

  • Page 63

    7-10 7 warning ewb01520 never operate this atv on any paved street, paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate atvs on public streets, roads and highways. Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for h...

  • Page 64

    7-11 7 when operating on excessively rough, slippery or loose terrain could cause loss of traction or atv control, which could result in an accident, including an overturn. 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 ...

  • Page 65

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

  • Page 66

    7-13 7 warning ewb01720 always open the throttle gradually and release the clutch lever slowly. Otherwise, the atv could wheelie which would increase the chance of an accident. Caution: ecb00230 do not shift gears without releasing the throt- tle. Damage to the engine or drive train may oc- cur. Whe...

  • Page 67

    7-14 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 68

    7-15 7 warning ewb01580 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. Practice on small- er hills before attempting large hills. It is important when climbing a hill to make...

  • Page 69

    7-16 7 warning ewb01600 never attempt to turn the atv around on any hill until you have mastered the turning tech- nique as described in the owner’s manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill...

  • Page 70

    7-17 7 warning ewb01731 use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: ● keep weight uphill. ● apply the brakes. ● lock the parking brake after you are stopped. If you begin rolling backwards: ● keep weight uphill. ● never apply the rear brake wh...

  • Page 71

    7-18 7 whenever possible, ride your atv straight down- hill. Avoid sharp angles which could allow the atv to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear. Warning ewb01620 always follow proper procedures for going down...

  • Page 72

    7-19 7 as you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the 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 t...

  • Page 73

    7-20 7 warning ewb01640 never operate this atv in fast flowing water or 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...

  • Page 74

    7-21 7 caution: ecb00240 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. Wash the atv in fresh water if it has been operated in salt water or muddy conditions. Riding over rough terrain riding over rough terrain shou...

  • Page 75

    7-22 7 you go over obstacles, always follow proper procedures as described in the owner’s manu- al. Sliding and skidding care should be used when riding on loose or slip- pery surfaces since the atv may slide. If unex- pected and uncorrected, sliding could lead to an accident. To reduce the tendency...

  • Page 76

    7-23 7 warning ewb01661 learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control. What to do if... This secti...

  • Page 77

    7-24 7 brakes for proper operation when you come out of the water. Do not continue to ride your atv until you have regained adequate braking ability. (see page 7-19.) u5yt63e0.Book page 24 wednesday, april 12, 2006 3:20 pm.

  • Page 78

    8-1 8 ebu21652 periodic maintenance and minor repair ebu21670 safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your atv in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are expla...

  • Page 79

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

  • Page 80

    8-3 8 ebu22402 periodic maintenance and lubrication chart note: ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep in mind that if...

  • Page 81

    8-4 8 7 * rear brake • check operation and correct if necessary. • check fluid level and atv for fluid leakage, and correct if necessary. √ √ √ √ √ • replace brake pads. Whenever worn to the limit 8 * brake hoses • check for cracks or other damage, and replace if necessary. √ √ √ √ • replace. Every ...

  • Page 82

    8-5 8 16 * drive chain rollers • check for wear and replace if necessary. √ √ √ 17 * chassis fasteners • make sure that all nuts, bolts, and screws are properly tightened. √ √ √ √ √ 18 * shock absorber as- semblies • check operation and correct if necessary. • check for oil leakage and replace if ne...

  • Page 83

    8-6 8 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. 28 * moving parts and cables • lubricate. √ √ √ √ 29 * throttle lever hous- ing and cable...

  • Page 84

    8-7 8 • every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • replace the brake hoses every four years and if cracked or damaged. U5yt63e0.Book page 7 wednesday, april 12, 2006 3:20 pm.

  • Page 85

    8-8 8 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 lubrica- tion chart. In ad...

  • Page 86

    8-9 8 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 surface of the spark plug ga...

  • Page 87

    8-10 8 note: if a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4. Install the spark plug cap. Ebu23273 engine oil and oil ...

  • Page 88

    8-11 8 7. 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 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 o...

  • Page 89

    8-12 8 5. Remove the oil filter element cover by remov- ing the bolts, and then remove the oil filter el- ement. 6. Clean the oil strainer and oil filter element with solvent. 7. Check the o-rings for damage and replace it if necessary. 8. Install the oil filter element and o-ring. Note: make sure t...

  • Page 90

    8-13 8 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 specified. In addition, do not use oils labeled “energy conserv- i...

  • Page 91

    8-14 8 2. Remove the air filter case cover by unhooking the holders. 3. Pull the air filter element out of the air filter case. 4. Remove the sponge material from the air filter element frame. 1. Air filter case cover 2. Air filter case holder 1. Air filter element assembly 1. Unlock. U5yt63e0.Book ...

  • Page 92

    8-15 8 5. Wash the sponge material gently but thor- oughly in solvent. Warning ewb01940 always use parts cleaning solvent to clean the sponge material. Never use low-flash-point solvents or gasoline to clean the sponge mate- rial because the engine could catch fire or ex- plode. 6. Squeeze the exces...

  • Page 93

    8-16 8 for obstructions. Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air-tight seal. Tighten all fit- tings securely to avoid the possibility of unfiltered air entering the engine. Caution: ecb00460 ● make sure that the air filter e...

  • Page 94

    8-17 8 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install and tighten the bolt. 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...

  • Page 95

    8-18 8 note: a diagnostic tachometer is needed to make this adjustment. 1. Start the engine and warm it up. Note: the engine is warm when it quickly responds to the throttle. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces- sary, adjust it to specifica...

  • Page 96

    8-19 8 ebu24043 adjusting the throttle cable free play the throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in the periodic maintenance and lubrication chart. The throttle cable free play should measure 2.0– 4.0 mm (0.08–0.16 in) at the throttle lev...

  • Page 97

    8-20 8 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. Ebu24150 front brake pads each brake pad is provided with a wear indicator groove, which allows you to check t...

  • Page 98

    8-21 8 ebu24251 checking the brake fluid level insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary. A low brake fluid level may indicate w...

  • Page 99

    8-22 8 observe these precautions: ● when checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. ● refill with the same type of br...

  • Page 100

    8-23 8 warning ewb02070 operating with improperly serviced or adjust- ed brakes could cause loss of braking ability, which could lead to an accident. After servicing: ● make sure the brakes operate smoothly and that the free play is correct. ● make sure the brakes do not drag. ● make sure the brakes...

  • Page 101

    8-24 8 after servicing: ● make sure the brakes operate smoothly and that the brake pedal position is correct. ● make sure the brakes do not drag. ● make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These ...

  • Page 102

    8-25 8 note: if the cable length cannot be adjusted to specifica- tion, consult a yamaha dealer. 5. Tighten the locknut on the brake cable. 6. Turn in the adjusting bolt at the rear brake cal- iper until it feels tight, then turn it out 1/8 turn and tighten its locknut to the specified torque. Cauti...

  • Page 103

    8-26 8 note: the brake light switch is properly adjusted when the brake light comes on just before braking takes effect. Turn the adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light com...

  • Page 104

    8-27 8 2. To increase the clutch lever free play, turn the adjusting bolt at the clutch lever in direction (a), and to decrease it, turn the bolt in direction (b). 3. Tighten the locknut at the clutch lever. If the specified free play cannot be obtained, proceed with the following steps. 4. Loosen t...

  • Page 105

    8-28 8 3. If the drive chain slack is incorrect, adjust it as follows. To adjust the drive chain slack 1. Loosen the axle holding bolts. 2. Loosen the locknut on each side of the swing- arm. To tighten the drive chain, turn the ad- justing bolts in direction (a). To loosen the drive chain, turn the ...

  • Page 106

    8-29 8 caution: ecb00541 improper drive chain slack will overload the en- 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. 3. Tighten the locknuts and the axle holdin...

  • Page 107

    8-30 8 caution: 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. Caution: ecb00570 to prevent damaging the o-rings, do not clean the drive chain with steam cleaners, high-pres- sure washers or in...

  • Page 108

    8-31 8 brake lever clutch lever ebu24930 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. Brake pedal recommended lubricant: lithium-soap-based grease (all-purpo...

  • Page 109

    8-32 8 shift pedal ebu24961 checking the wheel bearings the front and rear wheel 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 smoothly, have a yamaha dealer check the wheel bearings....

  • Page 110

    8-33 8 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. 1. Grease nipple 1. Grease nipple 1. Grease nipple recommende...

  • Page 111

    8-34 8 left side right side ebu25080 lubricating the knuckle shafts the knuckle shafts must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. 1. Upper grease nipple 2. Lower grease nipple 1. Upper grease nipple 2. Lower grease nipple recommended lubrican...

  • Page 112

    8-35 8 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 maintenance. There is no need to ...

  • Page 113

    8-36 8 to store the battery 1. If the atv will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check it at least once a month and ful- ly charge it if necessary. To install th...

  • Page 114

    8-37 8 ebu25242 replacing the fuse the fuse holder is located under the seat. (see page 4-11.) if the fuse is blown, replace it as follows. 1. 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 ...

  • Page 115

    8-38 8 2. Remove the headlight bulb holder by pushing it inward and turning it counterclockwise. 3. Remove the defective bulb from the headlight unit by pulling it out. Warning ewb02220 a headlight bulb is hot when it is on and imme- diately after it is turned off. Wait for the bulb to cool before t...

  • Page 116

    8-39 8 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 headlight bulb using a clo...

  • Page 117

    8-40 8 ebu25600 replacing the tail/brake light bulb if the tail/brake light bulb burns out, replace it as follows. 1. Remove the lens by removing the screws. 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 1. Headlight beam adjusting bolt 1. Screw 1. Tail/brake light b...

  • Page 118

    8-41 8 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. Caution: ecb00700 do not overtighten the screws, otherwise the lens may break. Ebu25650 removing a wheel 1. Loosen the wheel nuts. 2. Elevate the atv and ...

  • Page 119

    8-42 8 quire any repair, take it to a yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the atv properly. Use only genuine yamaha replacement parts. Im- itation parts may look like yamaha parts, but they are often inferior, have a shorter servic...

  • Page 120

    8-43 8 ebu25751 troubleshooting chart check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compression. Operate the electric starter. 2. Compression there is compression. There is no compressio...

  • Page 121

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

  • Page 122

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

  • Page 123

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

  • Page 124

    10-1 10 ebu25960 specifications dimensions: overall length: 1780 mm (70.1 in) overall width: 1095 mm (43.1 in) overall height: 1080 mm (42.5 in) seat height: 820 mm (32.3 in) wheelbase: 1210 mm (47.6 in) ground clearance: 115 mm (4.5 in) minimum turning radius: 3100 mm (122 in) weight: with oil and ...

  • Page 125

    10-2 10 engine oil quantity: without oil filter element replacement: 2.50 l (2.64 us qt) (2.20 imp.Qt) with oil filter element replacement: 2.60 l (2.75 us qt) (2.29 imp.Qt) air filter: air filter element: wet element fuel: recommended fuel: regular unleaded gasoline only (eur) unleaded gasoline onl...

  • Page 126

    10-3 10 caster angle: 6.0 ° trail: 26.0 mm (1.02 in) front tire: type: tubeless size: at21 x 7-10 manufacturer/model: dunlop/kt851b rear tire: type: tubeless size: at20 x 10-9 manufacturer/model: dunlop/kt877a loading: maximum loading limit: 100.0 kg (220 lb) (total weight of rider, cargo, accessori...

  • Page 127

    10-4 10 front suspension: type: double wishbone spring/shock absorber type: coil spring/oil damper wheel travel: 200 mm (7.9 in) rear suspension: type: swingarm (link suspension) spring/shock absorber type: coil spring/gas-oil damper wheel travel: 210 mm (8.3 in) electrical system: ignition system: ...

  • Page 128

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

  • Page 129

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

  • Page 130

    Index a accessories and loading ................................................ 6-8 air filter element, cleaning ............................................ 8-13 b battery .......................................................................... 8-35 brake and clutch levers, checking and lubricat...

  • Page 131

    M main switch .................................................................... 4-1 model label ................................................................... 11-2 n neutral indicator light ..................................................... 4-1 o owner’s manual and tool kit .................

  • Page 132

    Yamaha motor co., ltd. Printed on recycled paper printed in japan 2006.04-0.4 ×1 cr (e) u5yt63e0.Book page 1 wednesday, april 12, 2006 3:20 pm.