Yamaha BANSHEE YFZ350Y Owner's Manual
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Yamaha BANSHEE YFZ350Y Owner's Manual

Yamaha BANSHEE YFZ350Y 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
This A
OWNER'S MANUAL
YFZ350Y
3B5-28199-63

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Summary of Contents for Yamaha BANSHEE YFZ350Y

  • 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 YFZ350Y This A 3B5-28199-63...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN 2008.06-0.6x2 ! (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFZ350Y This A 3B5-28199-63-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 98 / 37 /EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product ( JY43GG00080295001...
  • Page 5 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 degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • 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: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 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.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Fuel cock ........... 4-9 Starter (choke) ......... 4-10 Seat ............4-11 LOCATION OF THE WARNING AND Adjusting the front shock absorber SPECIFICATION LABELS ......2-1 assemblies ..........4-12 Adjusting the rear shock absorber DESCRIPTION ..........
  • Page 9 Shifting ............6-3 Checking the spark plugs ......8-8 Engine break-in ......... 6-4 Transmission oil ........8-10 Parking ............6-5 Coolant ............ 8-12 Parking on a slope ........6-6 Cleaning the air filter element ....8-17 Accessories and loading ......6-6 Cleaning the spark arrester .....
  • Page 10 Lubricating the steering shaft ....8-45 Replacing a headlight bulb ...... 8-45 Adjusting a headlight beam ..... 8-48 Replacing the tail/brake light bulb ... 8-49 Removing a wheel ........8-49 Installing a wheel ........8-50 Troubleshooting ........8-51 Troubleshooting charts ......8-52 CLEANING AND STORAGE......

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION continued use of an ATV by a child if he or she EBU17592 does not have the abilities to operate it safely. AN ATV IS NOT A TOY AND CAN BE HAZARD- Never carry a passenger on an ATV. OUS TO OPERATE.
  • Page 12 or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills. conditions, and your experience. Always follow proper procedures for climbing Never attempt wheelies, jumps, or other stunts.
  • Page 13 backwards when climbing a hill. To avoid stall- times to let friction dry out the linings. ing, use the proper gear and maintain a steady Always use the size and type of tires specified in speed when climbing a hill. If you stall or roll this manual.
  • Page 14 cle, be sure it is kept upright and that the fuel in a closed area. Exhaust fumes are poisonous cock is in the “OFF” position. Otherwise, fuel and may cause loss of consciousness and may leak out of the carburetor or fuel tank. death within a short time.

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 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.
  • Page 17 Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. Front : 30.0 kPa, (4.4 psi) Rear : 30.0 kPa, (4.4 psi) Front : 27.0 kPa, (4.0 psi) Rear : 27.0 kPa, (4.0 psi) Maximum weight capacity 3B5-2816M-00...
  • Page 19 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. 4D3-2816L-00...

  • Page 21: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly 1. Tail/brake light 2. Radiator 2. Seat 3. Fuel cock 3. Kickstarter 4. Rear shock absorber assembly 4. Fuel tank cap 5. Spark arrester 5. Headlight 6. Starter (choke) 6.

  • Page 22: Controls And Instruments

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

  • Page 23: Instrument And Control Functions

    EBU17732 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 24: Handlebar Switches

    EBU18061 EBU18151 Handlebar switches Light switch “ /OFF” Set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to turn on the high beams and the taillight. Set the switch to “OFF”...

  • Page 25: Throttle Override System

    ATV, turn check for the cause. Correct the problem be- the adjusting screw in direction (a). To de- fore riding the ATV or consult a Yamaha dealer. crease the maximum engine power available...

  • Page 26: Clutch Lever

    and the maximum speed of the ATV, turn the aged. Always make sure the throttle lever free adjusting screw in direction (b). play is adjusted to 4.0–6.0 mm (0.16–0.24 in). (See page 8-32.) EBU18372 Clutch lever The clutch lever is located on the left handlebar. To disengage the clutch, pull the clutch lever toward the handlebar grip.

  • Page 27: Brake Lever

    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. 1. Brake pedal EBU18500 Parking brake Use the parking brake before starting the engine or parking the ATV, especially on a slope.
  • Page 28 wise, the engine will misfire, preventing normal op- eration. 1. Locked position EWB00220 1. Button WARNING 2. Parking brake lock plate Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied.

  • Page 29: Shift Pedal

    prematurely. push it down smoothly but forcefully. This model is equipped with a primary kickstarter, allowing the engine to be started in any gear if the clutch is dis- EBU18530 Shift pedal engaged. However, shifting the transmission into the neutral position before starting is recommend- This ATV is equipped with a constant-mesh 6- speed transmission.

  • Page 30: Fuel

    1. Fuel level 1. Fuel tank cap 2. Filler tube EBU18772 Fuel Recommended fuel: Make sure that there is sufficient fuel in the tank. PREMIUM UNLEADED GASOLINE ONLY Fill the fuel tank to the bottom of the filler tube as For Europe: PREMIUM UNLEADED GASO- shown.

  • Page 31: Fuel Cock

    of gasoline or higher octane grade. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. ECB00060 NOTICE Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the piston rings, as well as to the exhaust system.

  • Page 32: Starter (Choke)

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

  • Page 33: Seat

    the 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. Seat lock lever To install the seat Insert the projection on the front of the seat into the seat holder and push down on the seat at the rear.

  • Page 34: Adjusting The Front Shock Absorber Assemblies

    2. Seat holder 2. Position indicator EBU18991 Adjusting the front shock absorber A special wrench can be obtained at a Yamaha assemblies dealer to make this adjustment. The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions.

  • Page 35: Adjusting The Rear Shock Absorber Assembly

    Do not dispose of a damaged or worn out Uneven adjustment can cause poor handling shock absorber assembly yourself. Take the and loss of stability, which could lead to an ac- shock absorber assembly to a Yamaha deal- cident. er for any service. EBU19100...
  • Page 36 1. Locknut 2. Spring preload adjusting nut Spring preload setting: Minimum (hard): A special wrench can be obtained at a Yamaha Distance A = 213.5 mm (8.4 in) dealer to make this adjustment. Standard: The spring preload setting is determined by Distance A = 220.5 mm (8.7 in)
  • Page 37 ECB00080 Rebound damping setting: NOTICE Minimum (soft): Always tighten the locknut against the adjust- 20 click(s) in direction (b)* ing nut, and then tighten it to the specified Standard: torque. 12 click(s) in direction (b)* Maximum (hard): Rebound damping force 3 click(s) in direction (b)* Turn the adjusting dial in direction (a) to increase * With the adjusting dial fully turned in direc-...

  • Page 38: Specifications

    the minimum and maximum settings. Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always rep- resents the entire adjusting range. To obtain a pre- cise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as...

  • Page 39: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 40 ITEM ROUTINE PAGE Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-32, 8-33, 8-35 Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 41: Fuel And 2-Stroke Engine Oil Mixing Ratio

    EBU19580 Transmission oil Check that there is no free play in the brake le- ver. If there is free play, have a Yamaha dealer Make sure that the transmission oil is at the speci- check the brake system. fied level. Add oil as necessary. (See page 8-10.)

  • Page 42: Throttle Lever

    If there is any leak- EBU19770 Drive chain age, have a Yamaha dealer check the brake sys- tem. Check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the Brake operation drive chain as necessary.

  • Page 43: Tires

    Pay attention to the following. tires are cold. The tires listed below have been approved Tire pressures must be equal on both by Yamaha Motor Co., Ltd. for this model. sides. Other tire combinations are not recommend- Tire pressure below the minimum speci-...

  • Page 44: Measuring The Tire Pressure

    Higher pressures and fast inflation may Set the tire pressure when the tires are cold. Set cause a tire to burst. Inflate the tires very the tire pressures to the following specifications: slowly and carefully. Recommended pressure: Front EBU19821 30.0 kPa (0.300 kgf/cm , 4.4 psi) Measuring the tire pressure Rear...

  • Page 45: Chassis Fasteners

    1. Tire wear limit 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.

  • Page 46: Operation

    4. Shift the transmission into neutral. accident or injury. If there is a control or func- 5. Use the starter (choke) in reference to the fig- tion you do not understand, ask your Yamaha ure: dealer. Position (1):...

  • Page 47: Starting A Warm Engine

    Ambient temp./starter (choke) position ECB00160 NOTICE °C 0° 10° 20° 30° For maximum engine life, always warm the en- gine up before starting off. Never accelerate 90° °F 30° 50° 70° hard when the engine is cold! 8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to position (3) before riding.

  • Page 48: Shifting

    EBU20520 EBU20590 Shifting To start out and accelerate 1. Release the throttle lever, and then release This ATV has a 6-speed forward transmission. The the parking brake. transmission allows you to control the amount of ECB00200 power you have available at a given speed or for NOTICE starting, accelerating, climbing hills, etc.

  • Page 49: Engine Break-In

    clutch lever too quickly could make the ATV with the engine off, and do not tow the ATV wheelie, which would increase the chance of for long distances. The transmission is prop- an accident, including an overturn. erly lubricated only when the engine is run- ning.

  • Page 50: Parking

    320 km (200 mi) or 20 hours and beyond The ATV can now be operated normally. ECB00220 NOTICE If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. EBU20721 Parking When parking the ATV, stop the engine, shift into...

  • Page 51: Parking On A Slope

    steep you could not walk up them easily. 1. Bring the ATV to a stop by applying the brakes in first gear. 2. Stop the engine and release the clutch lever. 3. With the rear brake applied, apply the parking brake and slowly release the brake pedal.
  • Page 52 However, cessories so that you can carry cargo or tow a trail- it is not possible for Yamaha to test all non- er, you must use common sense and good Yamaha accessories, nor control over their qual- judgment as the stability and handling of an ATV ity or suitability.
  • Page 53 Make sure the load does not interfere with con- trols or your ability to see where you are going. Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail- Allow more braking distance.

  • Page 54: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 55: Getting To Know Your Atv

    EBU21613 Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum performance until GETTING TO KNOW YOUR ATV you are totally familiar with the ATV’s handling and This ATV is intended for recreational use by expe- performance characteristics.
  • Page 56 with engine size greater than 90 cc. Use by chil- harm to you and/or your passenger. dren of ATVs that are not recommended for their age can lead to severe injury or death of the child. Apparel This ATV is designed to carry operator only – Always wear an approved motorcycle helmet that passengers prohibited.
  • Page 57 event of an accident. Operating without protec- tive clothing increases your chances of severe injury in the event of an accident. Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. 1.
  • Page 58 page 5-1 before riding for proper care of the ATV Do not operate at speeds too fast for your and to ensure safety. skills or the conditions. EWB01430 EWB01450 WARNING WARNING Always inspect your ATV each time you use it Always go at a speed that is proper for the ter- to make sure the ATV is in safe operating con- rain, visibility and operating conditions, and...
  • Page 59 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 100.0 kg (220 lb) EWB01460 WARNING Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- 1. Adjusting screw curely attached. Reduce speed when carrying cargo or pull- Loading and accessories ing a trailer.
  • Page 60 All parts and Avoid wheelies and jumping. You may lose control accessories added to this ATV should be gen- of the ATV or overturn. uine Yamaha or equivalent components de- signed for use on this ATV and should be...

  • Page 61: Be Careful Where You Ride

    installed and used according to instructions. Improper installation of accessories or modifi- cation of this ATV may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized ATV dealer. Exhaust system The exhaust system on the ATV is very hot during and following operation.
  • Page 62 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. While riding on unpaved public streets or roads may be legal in your area, such operation can in- Know the terrain where you ride.
  • Page 63 ing terrain conditions when operating the ATV. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution EWB01540 WARNING flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the...
  • Page 64 Select a large, flat, unpaved area to become famil- EWB01550 iar with your ATV. Make sure that this area is free WARNING of obstacles and other riders. You should practice Always mount a caution flag on the ATV to control of the throttle, brakes, shifting procedures, make you more visible when operating in areas and turning techniques in this area before trying where you might not be seen by other vehicles.

  • Page 65: Turning Your Atv

    these components. ECB00230 NOTICE With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then Do not shift gears without releasing the throt- release the parking brake. Open the throttle grad- tle.
  • Page 66 used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. EWB01570 WARNING Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds.

  • Page 67: Climbing Uphill

    changes, excessive braking, incorrect body move- It is important when climbing a hill to make sure ments, or too much speed for the sharpness of the that your weight is transferred forward on the ATV. turn may cause the ATV to tip. If the ATV begins to This can be accomplished by leaning forward and, tip over to the outside while negotiating a turn, lean on steeper inclines, standing on the footboards...
  • Page 68 scribed in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. 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 69: Riding Downhill

    ply the front brake gradually, or dismount the ATV immediately on the uphill side. EWB01731 WARNING 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.

  • Page 70: Crossing A Slope

    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. EWB01620 WARNING Always follow proper procedures for going down hills as described in this Owner’s Manu- Note: a special technique is required when braking as you go down a hill.

  • Page 71: Crossing Through Shallow Water

    in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel. EWB01631 WARNING 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.
  • Page 72 them several times to let friction dry out the lin- ings. If the ATV is operated through deep or fast flowing water, the tires may float, causing loss of traction and loss of control, which could lead to an accident. ECB00240 NOTICE After riding your ATV in water, be sure to drain...

  • Page 73: Riding Over Rough Terrain

    you go over obstacles, always follow proper procedures as described in the Owner’s Manu- 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.

  • Page 74: What To Do If

    slide. Applying the brakes or accelerating is not go slowly and be very cautious in order to re- recommended until you have corrected the slide. duce the chance of skidding or sliding out of control. WHAT TO DO IF... This section is designed to be a reference guide only.
  • Page 75 to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE – the ATV may tip over on top of you.

  • Page 76: Periodic Maintenance And Minor Repair

    1. Owner’s manual can cause shocks or start fires. Turn off the en- 2. Low-pressure tire gauge gine when performing maintenance unless 3. Owner’s tool kit otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with...
  • Page 77 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING...

  • Page 78: 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 79 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours √ √ √ Spark arrester Clean.

  • Page 80: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element Clean and replace if necessary. dusty areas) √...
  • Page 81 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check for looseness or damage, and replace if √ √ √ √ Wheel hub bearings necessary. Upper and lower √...
  • Page 82 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Moving parts and √ √ √ √ 19 * Lubricate. cables Check operation and correct if necessary. Throttle lever hous- Check throttle cable free play and adjust if neces- √...

  • Page 83: Checking The Spark Plugs

    EBU28320 kit. Checking the spark plugs The spark plugs are important engine compo- nents, which are easy to check. Since heat and de- posits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lu- brication chart.
  • Page 84 Yamaha dealer check the ATV. 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/BR8ES To install a spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

  • Page 85: Transmission Oil

    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. EBU23343 Transmission oil The transmission oil level should be checked be- fore each ride.
  • Page 86 To change the transmission oil 1. Place the ATV on a level surface. Tightening torque: 2. Start the engine, warm it up for several min- Transmission oil drain bolt: utes, and then turn it off. 20 Nm (2.0 m·kgf, 14 ft·lbf) 3.

  • Page 87: Coolant

    EBU23501 To check the coolant level 1. Place the ATV on a level surface. The coolant level must be checked on a cold en- gine since the level varies with engine tempera- ture. 2. Check the coolant level in the coolant reser- voir.
  • Page 88 1. Maximum level mark 1. Coolant reservoir cover 2. Minimum level mark 2. Coolant reservoir cap 3. If the coolant is at or below the minimum level 5. Remove the reservoir cap, add coolant or dis- mark, remove the seat. (See page 4-11.) tilled water to the maximum level mark, and 4.
  • Page 89 If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- erwise the effectiveness of the coolant will be reduced.
  • Page 90 1. Coolant drain bolt 1. Radiator cap 4. Remove the radiator cap. 5. Remove the coolant reservoir cap. 8-15...
  • Page 91 1. Coolant reservoir hose 1. Coolant reservoir cap 2. Coolant reservoir 6. Disconnect the hose on the coolant reservoir 7. After draining the coolant, thoroughly flush the side and drain the coolant from the coolant cooling system with clean tap water. reservoir.

  • Page 92: Cleaning The Air Filter Element

    Coolant reservoir capacity (up to the maxi- mum level mark): 0.28 L (0.30 US qt, 0.25 Imp.qt) If any leakage is found, have a Yamaha dealer check the cooling system. ECB00401 NOTICE 15. Install the radiator cover by installing the bolts.
  • Page 93 areas. There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air fil- ter case. 1. Air filter case cover 2.
  • Page 94 1. Air filter element lock plate 1. Sponge material 2. Air filter element frame 3. Air filter element lock plate 5. Remove the lock plate by turning it, and then remove the sponge material from the air filter 6. Wash the sponge material gently but thor- element frame.
  • Page 95 ECB00440 turning it. NOTICE Do not twist the sponge material when squeez- ing it. 1. Air filter element 11. Insert the air filter element into the air filter case, and then install the air filter case cover 8. Check the sponge material and replace it if damaged.

  • Page 96: Cleaning The Spark Arrester

    joint to the carburetor fittings and the rubber joint manifold fittings for an air-tight seal. Tighten all fit- tings securely to avoid the possibility of unfiltered air entering the engine. ECB00460 NOTICE Make sure that the air filter element is prop- erly seated in the air filter case.

  • Page 97: Changing The Carburetor Settings

    Carburetor adjustments should only be per- 4. Make sure the gasket is properly positioned, formed by a Yamaha dealer. Do not attempt then insert the tailpipe into the muffler and to perform these procedures unless you align the screw holes.
  • Page 98 erating the ATV to make sure it is working correctly. Standard settings Main jet #200 Jet needle clip position 3rd groove Pilot air screw 2.0 turns out 1. Standard position: Groove 3 1. Main jet number 8-23...
  • Page 99 Carburetor setting chart Altitude Temperature 0–1500 m (5000 ft) Above 1500 m (5000 ft) Main jet Jet needle Pilot air screw Main jet Jet needle Pilot air screw Above 0°C (32°F) #200 3rd groove 2.0 turns out #190 3rd groove 2 1/2 turns out from +5 °C (41 °F) to #220...
  • Page 100 6. Remove the fuel tank by removing the bolts. 1. Air filter case cover 2. Air filter case cover holder 1. Fuel tank 2. Bolt 8. Remove the mixing chamber cap securing 7. Remove the air filter case cover by unhooking plate by removing the screw.
  • Page 101 1. Mixing chamber cap securing plate 1. Joint screw 2. Screw 10. Remove the mixing chamber cap. 9. Loosen the carburetor joint screws. 11. Remove the throttle cable from the throttle valve, and then remove the throttle cable hold- er by removing the screws. 8-26...
  • Page 102 12. Remove the carburetor, and then remove the 1. Throttle cable float chamber by removing the screws. 2. Throttle valve 3. Throttle cable holder 4. Screw 1. Float chamber 2. Screw 8-27...
  • Page 103 ECB00501 NOTICE Be sure to match one of the projections on the Optional main jets can be obtained at a Yamaha carburetor cap with one of the slots on the se- dealer. curing plate. If the securing plate does not...
  • Page 104 Adjusting the throttle cables 1. Move the throttle lever a few times. 2. Push the throttle lever forward until it stops and hold it in this position. 3. Check through each carburetor window to see if the punch mark on the throttle valve is at the specified position.

  • Page 105: Adjusting The Engine Idling Speed

    tion chart. A diagnostic tachometer is needed to make this adjustment. The carburetor synchronization and the throttle cable free play must be checked, and adjusted if necessary, before adjusting the engine idling speed. 1. Start the engine and warm it up. 1.
  • Page 106 (b) (a) 1. Throttle stop screw 1. Pilot air screw 5. Remove the seat. (See page 4-11.) Engine idling speed: 6. Check the engine idling speed and, if neces- 1450–1550 r/min sary, adjust it to specification by turning the ECB00510 throttle stop screws at the carburetors.

  • Page 107: Adjusting The Throttle Cable Free Play

    (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 7. Install the seat. EBU24044...

  • Page 108: Checking The Brake Fluid Level

    To check touches the brake disc, have a Yamaha dealer re- the brake pad wear, check the position of the wear place the brake pads as a set.
  • Page 109 sary. A low brake fluid level may indicate worn Rear brake brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Front brake LOWER 1.

  • Page 110: Changing The Brake Fluid

    Yamaha dealer check the cause. 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- 1.

  • Page 111: Checking The Brake Pedal Position

    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 by a Yamaha dealer. EBU24611 Checking the brake pedal position The brake pedal position must be checked and, if 1.

  • Page 112: Adjusting The Parking Brake Free Play

    Yamaha dealer. 3. Loosen the locknut and the adjusting bolt at the rear brake caliper. 4. Turn the adjusting bolt at the clutch lever in di- EBU24670 Adjusting the parking brake free play rection (a) to increase the cable length, and in direction (b) to decrease it.

  • Page 113: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light ECB00520 switches should be adjusted by a Yamaha dealer. NOTICE When tightening the locknut, hold the adjust- ing bolt with a wrench so that it does not turn The brake light switch is properly adjusted when together with the locknut.

  • Page 114: Adjusting The Clutch Lever Free Play

    effect. shown. If the free play is incorrect, adjust it as fol- lows. Turn the adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjust- ing nut in direction (b).

  • Page 115: Drive Chain Slack

    Yamaha dealer check the internal clutch mechanism. EBU24852 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. To check the drive chain slack 1. Place the ATV on a level surface.
  • Page 116 1. Axle holding nut (upper) 1. Locknut 2. Axle holding nut (lower) 2. Drive chain slack adjusting bolt 3. Alignment marks 3. Loosen the locknut on each side of the swing- ECB00541 arm. To tighten the drive chain, turn the ad- NOTICE justing bolts in direction (a).

  • Page 117: Lubricating The Drive Chain

    Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) Axle holding nut (upper): 120 Nm (12.0 m·kgf, 85 ft·lbf) Axle holding nut (lower): 60 Nm (6.0 m·kgf, 43 ft·lbf) 1. O-ring EBU24880 Lubricating the drive chain ECB00560 The drive chain must be cleaned and lubricated at NOTICE the intervals specified in the periodic maintenance The drive chain must be lubricated after wash-...

  • Page 118: Checking And Lubricating The Cables

    Lithium-soap-based grease essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace EBUM0170 Checking the shift pedal The operation of the shift pedal should be checked Recommended lubricant: before each ride.

  • Page 119: Checking The Wheel Hub Bearings

    If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- 1. Grease nipple ings.

  • Page 120: Lubricating The Upper And Lower Arm Pivots

    EBU25032 Right side 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. Recommended lubricant: Lithium-soap-based grease Left side 1.
  • Page 121 screw. 1. Headlight bulb holder cover 1. Screw 3. Remove the bulb holder by turning it counter- clockwise. 2. Remove the headlight bulb holder cover. 8-46...
  • Page 122 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. 4. Remove the defective bulb. ECB00650 NOTICE EWB02200 WARNING Do not touch the glass part of the headlight A headlight bulb is hot when it is on and imme- bulb to keep it free from oil, otherwise the diately after it is turned off.

  • Page 123: Adjusting A Headlight Beam

    EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).

  • Page 124: Replacing The Tail/Brake Light Bulb

    EBU25610 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 1. Tail/brake light bulb holder 2. Tail/brake light bulb 3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops.

  • Page 125: Installing A Wheel

    Front Rear 1. Wheel nut 1. Wheel nut 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.

  • Page 126: 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 127: Troubleshooting Charts

    Wipe off with a dry cloth and correct the the kickstarter. spark plug gaps, or replace the spark plugs. Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Have a Yamaha dealer check the ATV. 8-52...

  • Page 128: Engine Overheating

    Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.

  • Page 129: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25920 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 130: Storage

    increasing the chance of an accident. Test the section of this chapter. brakes after washing. Apply the brakes several 2. Turn the fuel cock lever to “OFF”. times at slow speeds to let friction dry out the 3. Drain the carburetor float chamber by loosen- linings.
  • Page 131 with oil.) e. Remove the spark plug caps from the spark plugs, and then install the spark plugs and the spark plug caps. 6. Lubricate all control cables and the pivoting points of all levers and pedals. 7. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground.

  • Page 132: Specifications

    EBU25960 SPECIFICATIONS EBU2597B Engine: Engine type: Liquid cooled 2-stroke Dimensions: Cylinder arrangement: Overall length: Forward-inclined parallel 2-cylinder 1855 mm (73.0 in) Displacement: Overall width: 347.0 cm 1100 mm (43.3 in) Bore × stroke: Overall height: 64.0 × 54.0 mm (2.52 × 2.13 in) 1080 mm (42.5 in) Compression ratio: Seat height:...
  • Page 133 Cooling system: Primary reduction ratio: 66/23 (2.869) Coolant reservoir capacity (up to the maximum level mark): Secondary reduction system: 0.28 L (0.30 US qt, 0.25 Imp.qt) Chain drive Radiator capacity (including all routes): Secondary reduction ratio: 1.50 L (1.59 US qt, 1.32 Imp.qt) 41/14 (2.929) Air filter: Transmission type:...
  • Page 134 Size: Rear wheel: AT21 x 7-10 Wheel type: Manufacturer/model: Panel wheel DUNLOP/KT851B Rim size: Rear tire: 9 x 8.5AT Type: Front brake: Tubeless Type: Size: Dual disc brake AT20 x 10-9 Operation: Manufacturer/model: Right hand operation DUNLOP/KT877A Recommended fluid: Loading: DOT 4 Rear brake: Maximum loading limit:...
  • Page 135 Wheel travel: 220 mm (8.7 in) Electrical system: Ignition system: Charging system: AC magneto Headlight: Bulb type: Krypton bulb Bulb voltage, wattage × quantity: Headlight: 12 V, 30.0/30.0 W × 2 Tail/brake light: 12 V, 5.0/21.0 W × 1 10-4...

  • Page 136: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • 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 1. Model label 11-3...
  • Page 139 INDEX Drive chain slack ............8-40 Accessories and loading ..........6-6 Air filter element, cleaning..........8-17 Engine break-in .............. 6-4 Engine, cold start ............6-1 Engine idling speed............8-30 Brake and clutch levers, checking and lubricating ..8-43 Engine, starting a warm ..........6-2 Brake fluid, changing............
  • Page 140 Suspension, lubricating the upper and lower arm pivots................8-45 Main switch ..............4-1 Suspension relay arm and connecting arm pivoting Maintenance and lubrication chart ......... 8-5 points, lubricating the rear.......... 8-44 Maintenance chart, emission control system ....8-3 Model label..............11-2 Tail/brake light bulb, replacing ........
  • Page 142 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2008.06-0.6x2 !

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