Yamaha big bear 250 YFM25BA Owner's Manual
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Yamaha big bear 250 YFM25BA Owner's Manual

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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 acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
OWNER'S MANUAL
YFM25BA
YFM250A
1P0-F8199-66

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Summary of Contents for Yamaha big bear 250 YFM25BA

  • Page 1 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 acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM25BA YFM250A 1P0-F8199-66...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2010.08-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM25BA YFM250A 1P0-F8199-66-E0...
  • Page 4 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 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM250 (YFM25B) (5Y4AG01W0A0518901–)
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting racing ma- chines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

  • Page 6: Important Manual Information

    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: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.

  • Page 7: Important Notice

    Please check your local riding laws and regulations before operating this ATV. EBU17410 YFM25BA/YFM250A OWNER’S MANUAL ©2010 by Yamaha Motor Co., Ltd. 1st edition, July 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel .............4-8 SPECIFICATION LABELS ......1-1 Fuel cock ............4-9 Starter (choke) ..........4-11 SAFETY INFORMATION ......2-1 Seat ............4-11 Storage compartment .......4-12 DESCRIPTION ..........3-1 Front carrier ..........4-13 Left view ............3-1 Rear carrier ..........4-13 Right view............
  • Page 9 Operating the drive select lever and Periodic maintenance chart for the driving in reverse ........6-3 emission control system ......8-3 Shifting ............6-4 General maintenance and lubrication Engine break-in .......... 6-6 chart ............8-5 Parking ............6-7 Checking the spark plug ......8-9 Parking on a slope ........
  • Page 10 Checking and lubricating the front and rear brake levers ........8-36 Checking the shift pedal ......8-37 Checking and lubricating the brake pedal ............8-37 Checking the wheel hub bearings .... 8-37 Lubricating the swingarm pivots ....8-38 Lubricating the steering shaft ....8-38 Battery ............

  • Page 11: Location Of The Warning And Specification Labels

    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...
  • Page 12 < 30 kg ( 66 lbs) 1P0-F817R-00 1P0-F816P-20 < 45 kg ( 99 lbs) 20.0 kPa 25.0 kPa 1P0-F817R-10 0.20 kgf/cm² 0.25 kgf/cm² 2.9 psi 3.6 psi 4XE-F816M-M0 < 3230 N < 330 kgf < 727 lbf < 147 N <...
  • Page 13 1P0-F816L-20 YFM250 2010 12.2 kW YAMAHA MOTOR CO., LTD. 216 kg 1P0-F816R-00 2500 SHINGAI, IWATA, JAPAN 1P0-F155A-30...
  • Page 14 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. NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
  • Page 15 NEVER use with drugs or alcohol. Adjust the tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids.
  • Page 16 Overloading can cause loss of control. Loss of control can result in severe injury or death. Year of construction Model Name **** ****** *** kW YAMAHA MOTOR CO., LTD. Max. Power *** kg 2500 SHINGAI, IWATA, JAPAN Mass In Running Order...
  • Page 17 For Oceania...
  • Page 18 30 kg (66 lbs) 4XE-F4877-20 20 kPa, (2.9 psi) 25 kPa, (3.6 psi) 45 kg (99 lbs) 17 kPa, (2.5 psi) 22 kPa, (3.2 psi) 4XE-F4897-20 165 kg, (364 lbs) ( 3 3 0 k g f ) 3230 N 4XE-F816M-20 ( 1 5 k g f ) 4XE-F151K-00...
  • Page 19 UNDER...

  • Page 20: Safety Information

    EBU17431 SAFETY INFORMATION EBU17463 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 21 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 22 speed when climbing a hill. If you stall or roll Always be sure there are no obstacles or people backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 23 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 TREATMENT.

  • Page 24: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Headlights 1. Spark arrester 2. Fuel cock 2. Storage compartment and tool kit 3. Recoil starter 3. Air filter case 4. Fuses 4. Engine oil filler cap 5. Battery 5. Brake pedal 6.

  • Page 25: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 3 4 5 6 1. Drive select lever 2. Rear brake lever 3. Handlebar switches 4. Parking brake lock plate 5. Horn switch 6.

  • Page 26: Instrument And Control Functions

    EBU17733 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: 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.

  • Page 27: Indicator Lights

    EBU17793 EBU18061 Indicator lights Handlebar switches 1. Neutral indicator light “N” 1. Light switch “ /OFF” 2. Reverse indicator light “R” 2. Engine stop switch “ ” 3. Start switch “ ” EBU17860 4. Horn switch “ ” Neutral indicator light “ ”...

  • Page 28: Throttle Lever

    EBU18101 EBU18282 Start switch “ ” Throttle lever Push this switch to crank the engine with the start- Once the engine is running, pushing the throttle le- er. See the starting instructions on page 6-1 prior ver will increase the engine speed. to starting the engine.

  • Page 29: Speed Limiter

    EBU18323 Speed limiter Your ATV is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 30: Brake Pedal And Rear Brake Lever

    1. Front brake lever 1. Brake pedal EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.

  • Page 31: Parking Brake

    EBU18460 Always be sure you have released the park- Parking brake ing brake before you begin to ride. The brake Use the parking brake before starting the engine or could overheat if you ride the ATV without re- parking the ATV, especially on a slope. Apply the leasing the parking brake.

  • Page 32: Drive Select Lever

    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. 1.

  • Page 33: Fuel

    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.

  • Page 34: Fuel Cock

    1.6 L (0.42 US gal, 0.35 Imp.gal) rings, as well as to the exhaust system. 3. Wipe up any spilled fuel immediately. Your Yamaha engine has been designed to use NOTICE: Immediately wipe off spilled fuel regular unleaded gasoline with a research octane with a clean, dry, soft cloth, since fuel may number of 91 or higher.
  • Page 35 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 36: Starter (Choke)

    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. 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 37: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18921 Storage compartment Insert the projections on the front of the seat into the seat holders and push down on the seat at the ECB00130 NOTICE rear.

  • Page 38: Front Carrier

    When storing any documents in the storage com- partment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartment. 1.

  • Page 39: Adjusting The Rear Shock Absorber Assembly

    (a) to increase the spring preload and thereby 2. Position indicator harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension. A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-14...
  • Page 40 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): 4-15...

  • Page 41: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 42 ITEM ROUTINE PAGE • Check operation, and correct if necessary. Rear brake • Lubricate cable if necessary. 5-3, 8-28, 8-31 • Check lever and pedal free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary.

  • Page 43: Fuel

    If there is any leakage, the brake Check that there is no free play in the front brake system should be checked by a Yamaha dealer. lever. If there is free play, have a Yamaha dealer check the brake system. Brake operation...

  • Page 44: Throttle Lever

    Check the operation of the throttle lever. It must 20.0 kPa (0.200 kgf/cm², 2.9 psi) open smoothly and spring back to the idle position Rear when released. Have a Yamaha dealer correct if 25.0 kPa (0.250 kgf/cm², 3.6 psi) necessary. Minimum tire pressure:...
  • Page 45 Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Manufacturing Corporation of America.

  • Page 46: Chassis Fasteners

    EBU19840 Front: Chassis fasteners Manufacturer/model: Make sure that all nuts, bolts and screws are prop- YFM250A CARLISLE/TRAIL WOLF erly tightened. YFM25BA MAXXIS/M905 Size: EBU19850 Instruments, lights and switches AT22 x 7.00-10 Type: Check that all instruments, lights and switches are Tubeless working properly.

  • Page 47: Operation

    If the indicator Read the Owner’s Manual carefully before riding light does not come on, have a Yamaha deal- the ATV. If there is a control or function you do not er check the electrical circuit.
  • Page 48 Ambient temp./starter (choke) position If the battery is discharged, pull the recoil starter to start the engine. 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine. If the engine is started with the starter (choke) in position (2), keep the starter (choke) in this position to warm up the engine.

  • Page 49: Starting A Warm Engine

    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. EBU20321 Operating the drive select lever and driving in reverse ECB00170...

  • Page 50: Shifting

    When in reverse, the reverse indicator light should first gear. be on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 1. Bring the ATV to a complete stop. 2. Apply the brake pedal.
  • Page 51 3. Open the throttle gradually. WARNING! Al- ways open the throttle gradually. Opening the throttle abruptly would increase the chance of an accident. It could make the ATV wheelie or overturn. [EWB00741] 4. Once the ATV has attained adequate speed, release the throttle lever.

  • Page 52: Engine Break-In

    could make the wheels stop rotating and lose There is never a more important period in the life of traction. This could cause loss of control, an your engine than the first 320 km (200 mi) or 20 accident and injury. It could also cause engine hours of riding.

  • Page 53: Parking

    If any engine trouble should occur during the WARNING engine break-in period, immediately have a Avoid parking on hills or other inclines. Park- Yamaha dealer check the ATV. ing on a hill or other incline could cause the ATV to roll out of control, increasing the EBU20722 chance of an accident.

  • Page 54: Accessories And Loading

    Yamaha ability to control the ATV. vehicles. Yamaha is not in a position to test the Do not mount an accessory where it could inter- products that these aftermarket companies pro- fere with your ability to control the ATV.
  • Page 55 bulky object attached to the handlebars which Never exceed the weight limits shown. An over- could make steering difficult, an accessory that loaded ATV can be unstable. limits your ability to move around on the seat, or MAXIMUM LOADING LIMIT one that limits your view.
  • Page 56 Load cargo on the carriers as close to the center of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around.

  • Page 57: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 58: Getting To Know Your Atv

    EBU21346 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding Do not operate this ATV or allow anyone else instructions for recreational riding.
  • Page 59 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 difficult maneuvers.
  • Page 60 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 other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 61 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 62 opening, even when the throttle lever is pushed to Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see “MAXIMUM LOADING the maximum engine power available and de- LIMIT” in this section or vehicle labeling). creases the maximum speed of the ATV.
  • Page 63 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of cargo, rider, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 165.0 kg (364 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
  • Page 64 ATV should be during operation or after leaving the ATV, do not let genuine Yamaha or equivalent components de- brush, grass and other materials collect under the signed for use on this ATV and should be installed vehicle, near the muffler or exhaust pipe, or next to and used according to instructions.

  • Page 65: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 66 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do not ways be alert to changing terrain conditions ride on any paved public street, road or motorway. when operating the ATV.
  • Page 67 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 68: Turning Your Atv

    Select a large, flat, unpaved area to become famil- Use this same procedure as you move into the iar with your ATV. Make sure that this area is free higher gears. Be sure to coordinate the use of the of obstacles and other riders. You should practice throttle and shift pedal properly.
  • Page 69 the ATV will resist turning. A special turning tech- nique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. As you approach a curve, slow down and begin to turn the handlebars in the desired direction.

  • Page 70: Climbing Uphill

    Improper riding procedures such as abrupt throttle Never open the throttle suddenly or make changes, excessive braking, incorrect body move- sudden gear changes. The ATV could flip ments, or too much speed for the sharpness of the over backwards. turn may cause the ATV to tip. If the ATV begins to Never go over the top of any hill at high tip over to the outside while negotiating a turn, lean speed.
  • Page 71 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.

  • Page 72: Riding Downhill

    If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.

  • Page 73: Crossing A Slope

    Shift your weight backward and to the up side of the hill. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possi- ble.

  • Page 74: Crossing Through Shallow Water

    Shift your weight to the uphill side of the ATV. 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.
  • Page 75 The ATV can be used to cross slow moving, shal- ability. WARNING! Wet brakes may have re- low water of up to a maximum of 35 cm (14 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.

  • Page 76: Riding Over Rough Terrain

    1. Air filter case check hose 1. Storage compartment check hose RIDING OVER ROUGH TERRAIN EWB01651 WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees.

  • Page 77: Sliding And Skidding

    cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may re- sult. SLIDING AND SKIDDING EWB01662 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 78: What To Do If

    WHAT TO DO... If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn.
  • Page 79 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.

  • Page 80: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 81: Owner's Manual And Tool Kit

    Put the owner’s tool kit and low-pres- If you do not have the tools or experience required sure tire gauge under the seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s manual 2.

  • Page 82: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 83 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 84: General Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years •...
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Change. √ √ √ √ Engine oil • Check ATV for oil leakage, and correct if neces- sary.
  • Page 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check electrolyte level and specific gravity, and correct if necessary. √ √ √ √ √ 23 * Battery •...

  • Page 88: Checking The Spark Plug

    EBU23213 2. Remove the spark plug as shown, with the Checking the spark plug spark plug wrench included in the owner’s tool The spark plug is an important engine component, kit. 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-...
  • Page 89 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 replace it if necessary.

  • Page 90: Engine Oil And Oil Filter Element

    Tightening torque: Spark plug: If the engine was started before checking the oil 18 Nm (1.8 m·kgf, 13 ft·lbf) level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. If a torque wrench is not available when installing 3.
  • Page 91 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 oil pan under the engine to collect the used oil.
  • Page 92 1. Engine oil drain bolt 1. Footboard 2. O-ring 2. Bolt 3. Compression spring 6. Fully loosen the brake pedal free play adjust- 4. Oil strainer ing nut, and push the brake pedal downward. Skip steps 5–12, 18, and 19 if the oil filter element is not being cleaned.
  • Page 93 1. Brake pedal free play adjusting nut 1. Drive select lever safety system cable 2. Oil filter element cover 7. Move the drive select lever safety system ca- 8. Remove the oil filter element cover by remov- ble away from the oil filter element cover. ing the bolts, and then remove the oil filter el- ement and the O-ring.
  • Page 94 1. Oil filter element 1. Adjusting nut 2. O-ring 2. Oil filter element cover 3. Bolt 10. Install the oil filter element and a new O-ring. 9. Clean the oil strainer and oil filter element with solvent. Make sure that the O-ring is properly seated. 11.
  • Page 95 13. Apply a thin coat of clean engine oil to a new Tightening torque: O-ring. Engine oil drain bolt: 43 Nm (4.3 m·kgf, 31 ft·lbf) 15. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap.
  • Page 96 a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERV- ING II” or higher. Make sure that no foreign material enters the crankcase. 16. 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.

  • Page 97: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 98 To change the final gear oil 1. Place the ATV on a level surface. 2. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil drain bolt 2. Gasket 5. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque.

  • Page 99: Cleaning The Air Filter Element

    9. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 10. Install the final gear case guard by installing the bolts and tightening them to the specified torque. Tightening torque: Final gear case guard bolt: 17 Nm (1.7 m·kgf, 12 ft·lbf) EBU23686 Cleaning the air filter element...
  • Page 100 1. Air filter case check hose 1. Air filter case cover 2. Air filter case cover holder 1. Place the ATV on a level surface. 4. Pull the air filter element assembly out of the 2. Remove the seat. (See page 4-11.) air filter case.
  • Page 101 1. Air filter element assembly 1. Air filter element 2. Sponge material 5. Remove the sponge material from the air filter 6. Clean the sponge material with water or sol- element. vent. WARNING! When using solvent to clean the sponge material, always use parts cleaning solvent or water.
  • Page 102 10. Pull the sponge material over the air filter ele- 8. Check the sponge material and replace it if ment. damaged. 11. Insert the air filter element assembly into the 9. Tap the air filter element lightly to remove air filter case, and then install the air filter case most of the dust and dirt.

  • Page 103: Cleaning The Spark Arrester

    12. Install the seat. The air filter element should be cleaned every 20– 40 hours. It should be cleaned more often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance is per- formed, check the air inlet of the air filter case for obstructions.

  • Page 104: Adjusting The Carburetor

    5. Install the tailpipe bolts and tighten them to the most carburetor adjustments should be left to a specified torque. Yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment Tightening torque: described in the following section, however, may...

  • Page 105: Adjusting The Engine Idling Speed

    To in- The carburetor has been set and extensively crease the engine idling speed, turn the throt- tested at the Yamaha factory. Changing these settings without sufficient technical knowl- tle stop screw in direction (a), and to decrease edge may result in poor performance of or it, turn the screw in direction (b).

  • Page 106: Adjusting The Throttle Lever Free Play

    3. To increase the throttle lever free play, turn must be adjusted by a Yamaha dealer at the inter- the throttle lever free play adjusting bolt in di- rection (a). To decrease the throttle lever free vals specified in the periodic maintenance and lu- play, turn the adjusting bolt in direction (b).

  • Page 107: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm es with use, which can result in improper function. (0.04 in), have a Yamaha dealer replace the brake Therefore, the safety system cable should be pads as a set.

  • Page 108: Checking The Brake Fluid Level

    If the Yamaha dealer replace the brake shoes as a set. brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.

  • Page 109: Changing The Brake Fluid

    Yamaha dealer check the cause. EBU24281 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic 1. No brake lever free play maintenance and lubrication chart. In addition,...

  • Page 110: Adjusting The Brake Pedal Height And Free Play, And The Rear Brake Lever Free Play

    EBU24575 Adjusting the brake pedal height and free play, and the rear brake lever free play The brake pedal height and free play, and the brake lever free play must be checked and, if nec- essary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 111 The brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) as shown. If the free play is incorrect, adjust it as follows. 1. Brake lever free play adjusting nut 2. Brake pedal free play adjusting nut 3. Adjusting the brake lever free play 1.
  • Page 112 1. Brake lever free play 1. Brake lever free play adjusting nut 2. Locknut 2. Brake camshaft lever 3. Brake lever free play adjusting bolt 3. Pin 4. Gap “A” a. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjust- c.

  • Page 113: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. 1. Remove the footboard. (See “Engine oil” on page 8-11 for removal and installation proce- dures.)

  • Page 114: Adjusting The Clutch Free Play

    1. Locknut cables and cable ends should be lubricated if nec- 2. Clutch adjusting screw essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace 8-35...

  • Page 115: Checking And Lubricating The Front And Rear Brake Levers

    Recommended lubricant: Recommended lubricants: Engine oil Front brake lever: Silicone grease EWB02581 Rear brake lever: WARNING Lithium-soap-based grease Inspect cables frequently and replace if dam- Front brake lever aged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury.

  • Page 116: Checking The Shift Pedal

    Lithium-soap-based grease EBUM0170 Checking the shift pedal The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle. EBU30310 Checking and lubricating the brake pedal EBU24963 Checking the wheel hub bearings...

  • Page 117: Lubricating The Swingarm Pivots

    EBU25092 Lubricating the steering shaft have a Yamaha dealer check the wheel hub bear- The steering shaft must be lubricated by a Yamaha ings. dealer at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 118: Battery

    EBU30350 KEEP OUT OF REACH OF CHILDREN. Battery The battery is located behind the seat. To check the electrolyte level A poorly maintained battery will corrode and dis- 1. Place the ATV on a level surface. charge quickly. The electrolyte level, battery lead 2.
  • Page 119 5. Check and, if necessary, tighten the battery lead connections and correct the breather hose routing as explained in step 5 of “To in- stall the battery”. 6. Install the battery cover. To remove the battery 1. Remove the battery cover by pulling it upward. 2.
  • Page 120 ECB01100 NOTICE Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. Do not leave or store the battery on its side. To install the battery Be sure the battery is fully charged. 1. Battery 1. Install the battery. 2.

  • Page 121: Replacing The Fuse

    posed to electrolyte or gas expelled from EBU25243 Replacing the fuse the battery, the frame could suffer struc- tural and external damages. [ECB00611] 1. Fuse 2. Spare fuse 1. Battery 2. Battery breather hose The fuse holder is located under the seat. (See 3.

  • Page 122: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25481 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 123 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 1. Do not touch the glass part of the bulb. 6. Install the bulb holder by pushing it in and turn- 1. Headlight bulb holder ing it clockwise. 4.

  • Page 124: Adjusting A Headlight Beam

    ECB00690 If the tail/brake light bulb burns out, replace it as NOTICE follows. It is advisable to have a Yamaha dealer make 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a).

  • Page 125: Removing A Wheel

    1. Tail/brake light bulb holder 1. Wheel nut 2. Tail/brake light bulb 3. Elevate the ATV and place a suitable stand 3. Insert a new bulb into the bulb holder, push it under the frame. in, and then turn it clockwise until it stops. 4.
  • Page 126 Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Tapered nut 3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified torques.

  • Page 127: Troubleshooting

    However, should your ATV re- 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.

  • Page 128: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 129: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25881 tion of wheel bearings, brakes, transmis- Cleaning sion seals and electrical devices. Many Frequent, thorough cleaning of your ATV will not expensive repair bills have resulted from only enhance its appearance but will improve its improper high-pressure detergent applica- general performance and extend the useful life of tions such as those available in coin-oper-...

  • Page 130: Storage

    EBU25933 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inder, piston rings, etc.
  • Page 131 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.

  • Page 132: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Cylinder arrangement: Forward-inclined single cylinder Overall length: Displacement: 1916 mm (75.4 in) 229 cm³ Overall width: Bore × stroke: 1038 mm (40.9 in) 71.0 × 58.0 mm (2.80 × 2.28 in) Overall height: Compression ratio: 1118 mm (44.0 in) 8.70 :1 Seat height: Starting system:...
  • Page 133 Type: Air filter: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- Air filter element: Dry element Fuel: Recommended fuel: 130 ˚F YFM250A Unleaded gasoline only YFM25BA Regular unleaded gasoline only SAE 5W-30 Fuel tank capacity: SAE 10W-30 12.0 L (3.17 US gal, 2.64 Imp.gal) Fuel reserve amount: SAE 10W-40 1.6 L (0.42 US gal, 0.35 Imp.gal)
  • Page 134 Transmission type: Rear tire: Constant mesh 5-speed.forward, 1-speed.reverse Type: Operation: Tubeless Left foot operation Size: Gear ratio: AT22 x 10.00-10 1st: Manufacturer/model: 34/12 (2.833) YFM250A CARLISLE/TRAIL WOLF 2nd: YFM25BA MAXXIS/M906 34/19 (1.789) Loading: 3rd: Maximum loading limit: 29/22 (1.318) 165.0 kg (364 lb) 4th: (Total weight of rider, cargo, accessories, and tongue) 26/25 (1.040)
  • Page 135 Rim size: Charging system: 10 x 8.0AT AC magneto Front brake: Battery: Type: Model: Disc brake CB14A-A2 Operation: Voltage, capacity: Right hand operation 12 V, 14.0 Ah Recommended fluid: Headlight: DOT 4 Bulb type: Rear brake: Krypton bulb Bulb voltage, wattage × quantity: Type: Drum brake Headlight:...

  • Page 136: Consumer Information

    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 NUMBER: 1. Vehicle identification number...
  • Page 137 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 deal- 11-2...
  • Page 138 INDEX Drive select lever and driving in reverse ......6-3 Drive select lever safety system cable, adjusting ..8-28 Accessories and loading ..........6-8 Air filter element, cleaning ..........8-20 Engine break-in .............. 6-6 Engine, cold start ............6-1 Battery ..............5-6, 8-39 Engine idling speed ............
  • Page 139 Storage ................9-2 Storage compartment ..........4-12 Main switch ..............4-1 Swingarm pivots, lubricating ........8-38 Maintenance and lubrication chart ......... 8-5 Maintenance chart, emission control system ....8-3 Model label ..............11-2 Tail/brake light bulb, replacing ........8-45 Throttle lever ............4-3, 5-4 Throttle lever free play, adjusting .........
  • Page 140 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2010.08-0.3×1 CR...

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Big bear 250 yfm250a

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