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Yamaha YFM350R Owner's Manual - Owner’S Manual

Other manuals for YFM350R: Owner's Manual, Owner's Manual

Summary of YFM350R

  • Page 1

    Yfm35ra yfm350ra owner’s manual manuel du propriÉtaire manual del propietario 1bs-28199-61 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 2010.04-0.3 ×1 cr (e,f,s) printed on recycled paper imprimÉ sur papier recyclÉ impreso en papel reciclado yamaha motor co., ltd. Dic183.

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Owner’s manual yfm35ra yfm350ra 1bs-28199-61-e0 u1bs61e0.Book page 1 tuesday, april 13, 2010 10:25 am.

  • Page 4

    Ebu28992 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. Ansi/svia 1-2007 general manager rv engineering division mc operations 6 january, 2010 yfm350 (yfm35r) (jy4ah18w0a0005519–) we, yamaha motor co., ltd. 2500 shingai, iwata, ja...

  • Page 5

    Ebu17170 introduction ebu17322 congratulations on your purchase of the yamaha yfm35ra/yfm350ra. 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 yfm35ra/yfm3...

  • 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

    Shifting ....................................................... 6-4 engine break-in .......................................... 6-6 parking ....................................................... 6-7 parking on a slope ..................................... 6-7 accessories and loading ..................

  • Page 10

    Lubricating the swingarm pivots ............... 8-34 lubricating the rear suspension relay arm and connecting arm pivoting points ........ 8-35 lubricating the upper and lower arm pivots ..................................... 8-36 lubricating the steering shaft ................... 8-37 battery .........

  • Page 11

    1-1 1 ebu29680 location of the warning and specification labels ebu29991 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 4d3-2816l-20 43p-2816r-01 1 2 u1bs61e0.Book page 2 tuesday, april 13, 2010 10:25 am.

  • Page 13

    1-3 1 25.0 kpa 0.25 kgf/cm² 3.6 psi 25.0 kpa 0.25 kgf/cm² 3.6 psi 5yt-2816m-m0 1as-2816p-00 5yt-2156a-10 yfm350 20.0 kw 180 kg 8ac-2817l-00 yamaha motor co., ltd. 2500 shingai, iwata, japan 2010 4aa-22259-40 4 6 7 5 3 u1bs61e0.Book page 3 tuesday, april 13, 2010 10:25 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. Never permit children under age 6 to operate this atv. Operation of thi...

  • Page 15

    1-5 1 **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi never use with drugs or alcohol. Never store fuel or flammable liquids. This unit contains high-pressure nitrogen gas. Mishandling can cause an explosion. Do not incinerate, puncture or open. Use unleaded gasoline only. Measure the ti...

  • Page 16

    1-6 1 ****** *** kw *** kg 1 2 3 yamaha motor co., ltd. 2500 shingai, iwata, japan **** 1 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. T...

  • Page 17

    1-7 1 for oceania 1 3 2 4 5 6 u1bs61e0.Book page 7 tuesday, april 13, 2010 10:25 am.

  • Page 18

    1-8 1 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 alcohol protective gear never operate : • without proper training or instruction. • at speeds too fast for your skills or th...

  • Page 19

    1-9 1 warning operating tire pressure: set with tires cold • recommended : front : 25.0 kpa, rear : 25.0 kpa, • minimum : front : 22.0 kpa, rear : 22.0 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 ebu17463 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 ● 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 22

    2-3 2 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 23

    2-4 2 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and seek medical ...

  • Page 24

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Front shock absorber assembly spring preload adjusting ring 2. Fuel cock 3. Throttle stop screw 4. Air filter case 5. Battery 6. Owner’s tool kit 7. Oil filter element 8. Shift pedal 1. Spark arrester 2. Fuse 3. Rear shock absorber...

  • Page 25

    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. Parking brake lever 3. Front brake fluid reservoir 4. Brake lever 5. Throttle lever 6. Main switch 7. Handlebar switches u1bs61e0.Book page 2 tuesday, ...

  • Page 26

    4-1 4 ebu17733 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 27

    4-2 4 ebu17793 indicator lights ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu17830 reverse indicator light “ ” this indicator light comes on when the transmis- sion is in the reverse position. Ebu18061 handlebar switches eb...

  • Page 28

    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. Ebu18152 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 29

    4-4 4 2. To increase the maximum engine power avail- able and the maximum speed of the atv, turn the adjusting screw in direction (a). To de- crease the maximum engine power available and the maximum speed of the atv, turn the adjusting screw in direction (b). Do not turn the adjusting screw out mor...

  • Page 30

    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 31

    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. Par...

  • Page 32

    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 33

    4-8 4 ebu18720 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. Ebu18754 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 refueli...

  • Page 34

    4-9 4 of sparks, open flames, or other sources of ig- nition such as the pilot lights of water heaters and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole. Stop filling when the fuel reach- es the bottom of the filler...

  • Page 35

    4-10 4 doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. Notice ecb00070 use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston ring...

  • Page 36

    4-11 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 37

    4-12 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. Ebu18881 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 38

    4-13 4 ebu18992 adjusting the front shock absorber as- semblies the spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Warning ewb00400 always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor han...

  • Page 39

    4-14 4 ebu19044 adjusting the rear shock absorber as- sembly the spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Notice ecb01090 never turn the adjusting mechanism beyond the minimum and maximum settings. Adjust the spring preload as follows. 1. Loosen the lock...

  • Page 40

    4-15 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 41

    4-16 4 warning ewb00450 this shock absorber assembly contains highly pressurized nitrogen gas. If the shock absorb- er assembly is damaged, it could explode causing injury or property damage. Shock ab- sorber cylinder damage could also result in poor handling which could cause an accident. ● do not ...

  • Page 42

    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 43

    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 recommended brake fluid to specified level if necessary. • check hydraulic system for leakage. Co...

  • Page 44

    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.) ebu19711 front and rear brakes brake lever and brake pedal ● check that there is no free play...

  • Page 45

    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 46

    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 47

    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 48

    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 49

    6-2 6 position (3): cold engine start with ambient temperature above 25 °c (80 °f). Ambient temp./starter (choke) position 6. Completely close the throttle lever and start the engine by pushing the start switch. Notice: for maximum engine life, never accelerate hard when the engine is cold! [ecb0016...

  • Page 50

    6-3 6 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 the engine with the throttle slightly open. Ebu20341 operating the drive select lever and driving in reve...

  • Page 51

    6-4 6 reverse, make sure there are no people or ob- stacles behind you. When it is safe to proceed, go slowly. 1. Bring the atv to a complete stop. 2. Pull in the clutch lever to disengage the clutch. 3. Apply the brake pedal. 4. While pulling the drive select lever handle up- ward, move the drive s...

  • Page 52

    6-5 6 ebu20592 to start out and accelerate 1. Release the throttle lever, apply the front or rear brake, and then release the parking brake. Notice ecb00200 always close the throttle before shifting gears, otherwise damage to the engine and drive train may result. 2. Pull the clutch lever to disenga...

  • Page 53

    6-6 6 notice ecb00180 ● even with the transmission in the neutral po- sition, do not coast for long periods of time with the engine off, and do not tow the atv for long distances. The transmission is prop- erly lubricated only when the engine is run- ning. Inadequate lubrication may damage the trans...

  • Page 54

    6-7 6 notice ecb00220 if any engine trouble should occur during the engine break-in period, immediately have a yamaha dealer check the atv. Ebu20722 parking when parking the atv, shift into first gear, stop the engine, apply the parking brake, and then turn the fuel cock to “off”. Ebu20865 parking o...

  • Page 55

    6-8 6 ebu20910 accessories and loading ebu20921 genuine yamaha accessories choosing accessories for your atv is an important decision. Genuine yamaha accessories, which are available only from a yamaha dealer, have been designed, tested, and approved by yamaha for use on your atv. Many companies wit...

  • Page 56

    6-9 6 bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view. ● use extra caution when riding an atv with ac- cessories. The atv may handle differently than it does without accessorie...

  • Page 57

    6-10 6 practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail- er. ● allow more braking distance. A heavier atv takes longer to stop. ● avoid making sharp turns unless at very slow speeds. ● avoid hills and rough terrain. Choose terrain carefully. Added weight...

  • Page 58

    7-1 7 ebu21141 riding your atv u1bs61e0.Book page 1 tuesday, april 13, 2010 10:25 am.

  • Page 59

    7-2 7 ebu21616 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 60

    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 61

    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 62

    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 63

    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 4-3.) loa...

  • Page 64

    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 65

    7-8 7 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 around the engine area could catch fire. Do no...

  • Page 66

    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 67

    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 68

    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 69

    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 70

    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 71

    7-14 7 ● shift your weight forward. ● 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...

  • Page 72

    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 73

    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 74

    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 75

    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 76

    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 77

    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 78

    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 79

    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 80

    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 81

    8-1 8 ebu28783 periodic maintenance and adjustment ebu21672 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 82

    8-2 8 ebu21691 owner’s manual and tool kit be sure to put this owner’s manual and the low- pressure tire gauge in the plastic bag and always carry them along with the owner’s tool kit under the seat. The service information included in this manual and the tools provided in the owner’s tool kit are i...

  • Page 83

    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 84

    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 85

    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 86

    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 87

    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 * rear suspension re- lay arm and con- necting arm pivot...

  • Page 88

    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 89

    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 90

    8-10 8 tip if the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a yamaha dealer check the atv. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and repla...

  • Page 91

    8-11 8 tip if a torque wrench is not available when installing the 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. 3. Install the spark plug cap. Ebu2327d engine oil and oil ...

  • Page 92

    8-12 8 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level. Notice: be sure the engine oil is at the correct level, otherwise engine damage may result. [ecb00851] 6. Insert the dipstick into the oil filler hole, an...

  • Page 93

    8-13 8 tip skip steps 5–8 if the oil filter element is not being cleaned. 5. Remove the oil filter element cover by remov- ing the bolts, and then remove the oil filter el- ement and the o-ring. 6. Clean the oil strainer and oil filter element with solvent. 7. Install the oil filter element and a ne...

  • Page 94

    8-14 8 9. Install the oil strainer, the compression spring, a new o-ring and the engine oil drain bolt. Tighten the engine oil drain bolt to the speci- fied torque. Notice: before installing the engine oil drain bolt, be sure to install the o-ring, compression spring and oil strain- er. [ecb00321] 1...

  • Page 95

    8-15 8 11. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 12. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. Ebu23743 ...

  • Page 96

    8-16 8 4. Pull the air filter element out of the air filter case. 5. Remove the sponge material from the air filter element frame. 1. Air filter case cover 2. Air filter case cover holder 1. Air filter element 1. Unlock. U1bs61e0.Book page 16 tuesday, april 13, 2010 10:25 am.

  • Page 97

    8-17 8 6. 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] 7. Squeeze the ex...

  • Page 98

    8-18 8 notice: make sure that the air filter ele- ment is properly seated in the air filter case. Never operate the engine with the air filter element removed. This will allow un- filtered air to enter the engine, causing rap- id engine wear and possible engine damage. Additionally, operation withou...

  • Page 99

    8-19 8 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the bolt and tighten it to the specified torque. 6. Remove the purging bolt and the gasket. 7. Start the engine and rev it up approximately twenty times while momentarily creating ex- haust system back pressure by bl...

  • Page 100

    8-20 8 warning ewb02380 never run the engine in an enclosed area when purging the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monox- ide poisoning, possibly leading to death, and start a fire. ● always let the exhaust system cool prior to touching exhaust components. ●...

  • Page 101

    8-21 8 tip 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 specification by turning the throttle stop screw at the carburetor. To in- crease the engine idling speed, turn ...

  • Page 102

    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 103

    8-23 8 tip the wheels need to be removed to check the brake pads. (see page 8-43.) ebu28800 rear brake pads each brake pad is provided with two 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 ind...

  • Page 104

    8-24 8 front brake rear brake 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 w...

  • Page 105

    8-25 8 ebu24291 changing the brake fluid have a yamaha dealer change the brake fluid at the intervals specified in the tip after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and cali- pers as well as the brake hoses replaced at the in- terva...

  • Page 106

    8-26 8 ebu24712 adjusting the parking brake free play the parking brake free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Cable length “a” should measure 64–68 mm (2.52–2.68 in). Adjust the parking brake free play as f...

  • Page 107

    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 108

    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 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)...

  • Page 109

    8-29 8 tip if the specified clutch lever free play could be ob- tained as described above, skip steps 4–8. 4. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable. 5. Slide the rubber cover back at the crankcase. 6. Loosen the locknut. 7. To increase the clut...

  • Page 110

    8-30 8 3. If the drive chain slack is incorrect, adjust it as follows. To adjust the drive chain slack 1. Place the atv on a level surface. 2. Loosen the axle holding bolts. 3. Loosen the locknut on each side of the swing- arm. To tighten the drive chain, turn the ad- justing bolts in direction (a)....

  • Page 111

    8-31 8 tip there are alignment marks on both drive chain pullers and an alignment mark on each side of the swingarm. Make sure to align the same alignment mark on both drive chain pullers with the alignment mark on either side of the swingarm for proper wheel alignment. 4. Tighten the locknuts and t...

  • Page 112

    8-32 8 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special o-ring chain lubricant. Notice: do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the o- rings. [ecb00581] ebu24901 checking and lubricating th...

  • Page 113

    8-33 8 brake lever clutch lever ebu28841 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. Recommended lubricants: brake lever: silicone grease clutch lever: lith...

  • Page 114

    8-34 8 brake pedal shift pedal ebu24963 checking the wheel hub bearings the front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a yamaha dealer check...

  • Page 115

    8-35 8 ebu25004 lubricating the rear suspension relay arm and connecting arm pivoting points the rear suspension relay arm and connecting arm pivoting points must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Tip for parts equipped with a grease nipp...

  • Page 116

    8-36 8 ebu25033 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. Tip for parts equipped with a grease nipple, use a grease gun. Left side 1. Grease nipple recommended lubricant...

  • Page 117

    8-37 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. Ebu2522b battery this model is equipped with...

  • Page 118

    8-38 8 batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ig- nition away. Ventilate when charging or using in an enclosed space. Keep out of reach of children. To remove the battery 1. Remove the seat. (see page 4-12.) 2. Unhook the band securing the owner’s tool ...

  • Page 119

    8-39 8 notice ecb00931 to charge a vrla (valve regulated lead acid) battery, a special (constant-voltage) battery charger is required. Using a conventional bat- tery charger will damage the battery. To store the battery ● if the atv will not be used for more than one month, remove the battery, fully...

  • Page 120

    8-40 8 ebu25243 replacing the fuse the fuse holder is located under the seat. (see page 4-12.) if the fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Notice ecb00640 to prevent accidental short-circuiting, turn off the main switch when checking or...

  • Page 121

    8-41 8 2. Remove the headlight bulb holder by pushing it inward and turning it counterclockwise. 3. Remove the burnt-out bulb from the headlight unit by pulling it out. 4. Install a new headlight bulb into the headlight unit by aligning the projection on the bulb with the groove in the headlight uni...

  • Page 122

    8-42 8 5. Install the headlight bulb holder by aligning the projections with the holes in the headlight unit, pushing it inward, and turning it clockwise until it stops. 6. Install the headlight bulb holder cover at the rear of the headlight. Notice: make sure the headlight bulb holder cover is secu...

  • Page 123

    8-43 8 ebu25601 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 burnt-out bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn...

  • Page 124

    8-44 8 3. Elevate the atv and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. Ebu25661 installing a wheel 1. Place the atv on a level surface. 2. Install the wheel and the nuts. 3. Lower the atv to the ground. 4. Tighten the wheel nuts to the specified...

  • Page 125

    8-45 8 warning ewb02280 do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. U1bs61e0.Book page 45 tuesday, april 13, 2010...

  • Page 126

    8-46 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 127

    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 128

    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 129

    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 130

    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 131

    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: 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...

  • Page 132

    10-3 10 gear ratio: 1st: 36/16 (2.685) 2nd: 33/20 (1.969) 3rd: 29/23 (1.504) 4th: 27/26 (1.239) 5th: 25/28 (1.065) 6th: 23/29 (0.946) forward gear: 20/27 × 29/18 reverse gear: 33/16 × 33/10 (6.806) chassis: frame type: steel tube frame caster angle: 6.0 ° trail: 26.0 mm (1.02 in) front tire: type: t...

  • Page 133

    10-4 10 rim size: 9 x 8.0at front brake: type: dual disc brake operation: right hand operation recommended fluid: dot 4 rear brake: type: single disc brake operation: right foot operation recommended fluid: dot 4 front suspension: type: double wishbone spring/shock absorber type: coil spring/oil dam...

  • Page 134

    11-1 11 ebu26000 consumer information ebu28200 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 135

    11-2 11 tip 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 dea...

  • Page 136

    Index a accessories and loading ................................................ 6-8 air filter element, cleaning ............................................ 8-15 b battery .......................................................................... 8-37 brake and clutch levers, checking and lubricat...

  • Page 137

    Maintenance and lubrication chart ................................. 8-5 maintenance chart, emission control system ................. 8-3 model label ................................................................... 11-2 n neutral indicator light .......................................................

  • Page 138

    Yamaha motor co., ltd. Printed on recycled paper printed in japan 2010.04-0.3 ×1 cr (e) u1bs61e0.Book page 1 tuesday, april 13, 2010 10:25 am.