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Yamaha YFM350RY Owner's Manual - Owner’S Manual

Summary of YFM350RY

  • Page 1

    Yfm35ry owner’s manual manuel du propriÉtaire manual del propietario 5yt-28199-65 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 importantes ac...

  • Page 2

    Printed in japan 2008.03-0.6 ×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 yfm35ry 5yt-28199-65-e0 u5yt65e0.Book page 1 tuesday, march 18, 2008 11:39 am.

  • Page 4

    Ebu28990 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. Ec declaration of conformity conforming to directive 98/37/ec (make, model) to which this declaration applies, conforms to the essential health and safety requirements of dir...

  • Page 5

    Ebu17170 introduction ebu17321 congratulations on your purchase of the yamaha yfm35ry. 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 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 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 clutch levers ........................................... 8-33 checking and lubricating the brake and shift pedals ............................................. 8-33 checking the wheel hub bearings ............ 8-34 lubricating the swingarm pivots ................

  • 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 u5yt65e0.Book page 1 tuesday, march 18, 2008 11:39 am.

  • 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 u5yt65e0.Book page 4 tuesday, march 18, 2008 11:39 am.

  • Page 19

    2-5 2 for oceania warning improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. Operating tire pressure : set with tires cold • recommended : front : 25.0 kpa (3.6 psi) rear : 25.0 kpa (3.6 psi) • minimum : front : 22.0 kpa (3.2 psi) r...

  • Page 20

    2-6 2 for oceania under warning 4d3-2816l-00 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. 6 u5yt65e0.Book page 6 tuesday, march 18, 2008 11:39 am.

  • Page 21

    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 22

    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 u5yt65e0.Book page 2 tuesday, ...

  • Page 23

    4-1 4 ebu17732 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 ebu17791 indicator lights ebu17830 reverse indicator light “ ” this indicator light comes on when the transmis- sion is in the reverse position. Ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu18061 handlebar switches eb...

  • Page 25

    4-3 4 ebu18100 start switch “ ” push this switch to crank the engine with the start- er. Notice ecb00050 see the starting instructions on page 6-1 prior to starting the engine. Ebu18151 light switch “ / /off” set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to...

  • Page 26

    4-4 4 eration of the throttle lever before you start the engine. If the throttle does not work smoothly, check for the cause. Correct the problem be- fore riding the atv or consult a yamaha dealer. Ebu18321 speed limiter your atv was delivered with an adjustable speed limiter. The speed limiter keep...

  • Page 27

    4-5 4 ebu18382 clutch lever the clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporat- ed in the clutch lever holder. To disengage the clutch, pull the clutch lever toward the handlebar grip. To engage the clutch, release the clutch lever. The clutch lev...

  • Page 28

    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 29

    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 30

    4-8 4 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. Drive select lever 1. Fuel tank cap u5yt65e0.Book page 8 tuesday, march 18, 2008...

  • Page 31

    4-9 4 tip if knocking or pinging occurs, use a different brand of gasoline or higher octane grade. 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 rings, as well as to the exhaust system. Warning ...

  • Page 32

    4-10 4 off with the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. On with the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine an...

  • Page 33

    4-11 4 res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to “on”! Ebu18850...

  • Page 34

    4-12 4 to install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Tip make sure that the seat is securely fitted. Ebu18991 adjusting the front shock absorber as- semblies the spring preload can be adjusted to suit the rid- er’s we...

  • Page 35

    4-13 4 tip a special wrench can be obtained at a yamaha dealer to make this adjustment. 1. Spring preload adjusting ring 2. Position indicator 1. Special wrench spring preload setting: minimum (soft): 1 standard: 3 maximum (hard): 5 u5yt65e0.Book page 13 tuesday, march 18, 2008 11:39 am.

  • Page 36

    4-14 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. Ebu19041 adjusting the rear shock absorber as- sembly the spring preload can be adju...

  • Page 37

    4-15 4 notice ecb00090 never turn an adjusting mechanism beyond the minimum and maximum settings. 3. Tighten the locknut to the specified torque. Notice ecb00080 always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque. 1. Special wrench spring preload sett...

  • Page 38

    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 39

    5-1 5 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 the inspection and ma...

  • Page 40

    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 41

    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 42

    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 43

    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 (0.250 kgf/cm², 3.6 psi) rear: 25.0 kpa (0.250 kg...

  • Page 44

    5-6 5 tip 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 foll...

  • Page 45

    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 u5yt65e0.Book page 7 tuesday, march 18, 2008 1...

  • Page 46

    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 47

    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 48

    6-3 6 tip 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 the...

  • Page 49

    6-4 6 tip 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 clutch ...

  • Page 50

    6-5 6 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 disengage the clutch. 3. Shift into first gear. 4. Open the throttle gradually and at the same time, release the clutch lever slowly. 5. Once ...

  • Page 51

    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 52

    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 53

    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 54

    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 55

    7-1 7 ebu21141 riding your atv u5yt65e0.Book page 1 tuesday, march 18, 2008 11:39 am.

  • Page 56

    7-2 7 ebu21613 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 57

    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 58

    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 59

    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 60

    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 61

    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 62

    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 63

    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 64

    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 65

    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 66

    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 67

    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. Notice ecb00230 do not shift gears without releasing the throt- tle. Damage to the engine or drive train may oc- cur. When ...

  • Page 68

    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 69

    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 70

    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 71

    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 72

    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 73

    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 74

    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 75

    7-21 7 notice 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 should...

  • Page 76

    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 77

    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 78

    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.) u5yt65e0.Book page 24 tuesday, march 18, 2008 11:39 am.

  • Page 79

    8-1 8 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 lubrication are expla...

  • Page 80

    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 81

    8-3 8 ebu21742 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 82

    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 83

    8-5 8 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 necessary. Every 20–4...

  • Page 84

    8-6 8 10 * swingarm pivots • check operation and for excessive play, and re- place 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 adjust if necessary. • ...

  • Page 85

    8-7 8 ebu23070 tip ● 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 master cylinders and caliper...

  • Page 86

    8-8 8 • replace the brake hoses every four years and if cracked or damaged. U5yt65e0.Book page 8 tuesday, march 18, 2008 11:39 am.

  • Page 87

    8-9 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 88

    8-10 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 g...

  • Page 89

    8-11 8 tip 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. Ebu2327a engine oil and oil fi...

  • Page 90

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

  • Page 91

    8-13 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 them if necessary. 8. Install the oil filter element and o-ring. Tip make sure t...

  • Page 92

    8-14 8 tip be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. Notice ecb00300 ● in order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “cd...

  • Page 93

    8-15 8 ebu23742 cleaning the air filter element the air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. Tip there is a check hose at the bo...

  • Page 94

    8-16 8 5. Remove the sponge material from the air filter element frame. 6. 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 becau...

  • Page 95

    8-17 8 notice ecb00440 do not twist the sponge material when squeez- ing it. 8. Check the sponge material and replace it if damaged. 9. Apply a quality foam air filter oil to the sponge material. Tip the sponge material should be wet but not drip- ping. 10. Pull the sponge material over the air filt...

  • Page 96

    8-18 8 will affect carburetor jetting with subsequent poor performance and possible engine over- heating. Ebu27701 cleaning the spark arrester select a well-ventilated area free of combustible materials and make sure the exhaust and muffler are cool. 1. Remove the bolt. 2. Remove the tailpipe by pul...

  • Page 97

    8-19 8 7. Start the engine and rev it up approximately twenty times while momentarily creating ex- haust system back pressure by blocking the end of the muffler with a shop towel. 8. Stop the engine and allow the exhaust pipe to cool. 9. Install the purging bolt and tighten it to the specified torqu...

  • Page 98

    8-20 8 described in the following section, however, may be performed by the owner as part of routine main- tenance. Notice ecb00480 the carburetor has been set and extensively tested at the yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performanc...

  • Page 99

    8-21 8 ebu24044 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 100

    8-22 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. Ebu28790 front brake pads each brake pad is provided with two wear indicator grooves, which allow you to check...

  • Page 101

    8-23 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 102

    8-24 8 ● be careful that water does not enter the brake fluid reservoir when refilling. Water will signifi- cantly lower the boiling point of the fluid and may result in vapor lock. ● brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid imme- diately. ● as the...

  • Page 103

    8-25 8 ● make sure the brakes operate smoothly and that there is no free play. ● 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 procedures should be performed ...

  • Page 104

    8-26 8 ebu24710 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 105

    8-27 8 notice ecb00520 when tightening the locknut, hold the adjust- ing bolt with a wrench so that it does not turn together with the locknut. Warning ewb02090 operating with improperly serviced or adjust- ed brakes could cause the brakes to malfunc- tion, resulting in reduced braking performance. ...

  • Page 106

    8-28 8 ebu24820 adjusting the clutch lever free play the clutch lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The clutch lever free play should measure 5.0– 10.0 mm (0.20–0.39 in) as shown. If the free play i...

  • Page 107

    8-29 8 7. To increase the clutch lever free play, turn the adjusting nut at the crankcase in direction (a), and to decrease it, turn the nut in direction (b). 8. Tighten the locknut at the crankcase and the clutch lever. Tip if the specified free play cannot be obtained as de- scribed above or if th...

  • Page 108

    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 109

    8-31 8 mark on both drive chain pullers with the alignment mark on either side of the swingarm for proper wheel alignment. Notice 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 f...

  • Page 110

    8-32 8 notice ecb00560 the drive chain must be lubricated after wash- ing the atv or riding in the rain. 1. Clean the drive chain with kerosene and a small soft brush. Notice ecb00570 to prevent damaging the o-rings, do not clean the drive chain with steam cleaners, high-pres- sure washers or inappr...

  • Page 111

    8-33 8 ebu24922 checking and lubricating the brake and clutch levers the operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Brake lever clutch lever ebu28841 checking and lubricating the brake and shift pedals the oper...

  • Page 112

    8-34 8 brake pedal shift pedal ebu24962 checking the wheel hub bearings the front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a yamaha dealer check...

  • Page 113

    8-35 8 recommended lubricant: lithium-soap-based grease 1. Grease nipple 1. Grease nipple 1. Grease nipple u5yt65e0.Book page 35 tuesday, march 18, 2008 11:39 am.

  • Page 114

    8-36 8 ebu25032 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 right side ebu25102 lubricating the steering shaft ...

  • Page 115

    8-37 8 ebu25225 battery this model is equipped with a vrla (valve regu- lated lead acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened. Notice ecb00620 never attempt to remove the ba...

  • Page 116

    8-38 8 4. Pull the battery out of its compartment. 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. To store t...

  • Page 117

    8-39 8 3. Install the battery holding plate by installing the bolts, and then hook the band to secure the owner’s tool kit. 4. Install the seat. (see page 4-11.) notice ecb00632 ● always keep the battery charged. Storing a discharged battery can cause permanent battery damage. ● to charge a vrla (va...

  • Page 118

    8-40 8 notice 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 new fuse of the specified amperage. Warning ewb02171 always use a fuse of the specified rating, and never use a substitute object in...

  • Page 119

    8-41 8 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 touching or removing it. You can be burned or a fire could start if the bulb touch- es some...

  • Page 120

    8-42 8 6. Install the headlight bulb holder cover at the rear of the headlight. Notice ecb00670 make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 7. Adjust the headlight beam if necessary. Ebu25560 adjusting a headlight beam notice ecb00690 it is ...

  • Page 121

    8-43 8 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 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. Notice ecb00700 do not overtighten the screws, otherwise the lens may break...

  • Page 122

    8-44 8 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 torques. Ebu25720 troubleshooting although yamaha atvs receive...

  • Page 123

    8-45 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 124

    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 125

    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 126

    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 127

    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 128

    10-2 10 engine oil: type: sae 5w-30 or sae 10w-30 or sae 10w-40 or sae 15w-40 or sae 20w-40 or sae 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 elemen...

  • Page 129

    10-3 10 secondary reduction ratio: 38/13 (2.923) transmission type: constant mesh 6-speed.Forward, 1-speed.Reverse operation: left foot operation gear ratio: 1st: 36/16 × 20/27 × 29/18 (2.685) 2nd: 33/20 × 20/27 × 29/18 (1.969) 3rd: 29/23 × 20/27 × 29/18 (1.504) 4th: 27/26 × 20/27 × 29/18 (1.239) 5t...

  • Page 130

    10-4 10 front wheel: wheel type: panel wheel rim size: 10 x 5.5at rear wheel: wheel type: panel wheel rim size: 9 x 8.5at 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:...

  • Page 131

    10-5 10 fuse: fuse: 15.0 a u5yt65e0.Book page 5 tuesday, march 18, 2008 11:39 am.

  • Page 132

    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 133

    11-2 11 the year of manufacture is listed in the vehicle identification number as shown in the illustration. 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...

  • Page 134

    11-3 11 1. Model label u5yt65e0.Book page 3 tuesday, march 18, 2008 11:39 am.

  • Page 135

    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 136

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

  • Page 137

    U5yt65e0.Book page 3 tuesday, march 18, 2008 11:39 am.

  • Page 138

    Yamaha motor co., ltd. Printed on recycled paper printed in japan 2008.03-0.6 ×1 cr (e) u5yt65e0.Book page 1 tuesday, march 18, 2008 11:39 am.