Yamaha YFM350R-W Owner's Manual
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Yamaha YFM350R-W Owner's Manual

Yamaha YFM350R-W Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM35R-W
10P-F8199-70

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Summary of Contents for Yamaha YFM350R-W

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35R-W 10P-F8199-70...
  • Page 2 EBU28980 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 3 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 4 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 5 EBU17350 IMPORTANT NOTICE EBU17372 This ATV is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations before operating this ATV. EBUM0010 YFM35R-W OWNER’S MANUAL...

  • Page 6: Table Of Contents

    EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel tank cap ..........4-9 SPECIFICATION LABELS ......1-1 Fuel .............4-9 Fuel cock ..........4-11 SAFETY INFORMATION ......2-1 Starter (choke) ..........4-12 Steering lock ..........4-13 DESCRIPTION ..........3-1 Seat ............4-14 Left view ............3-1 Adjusting the front shock absorber Right view............
  • Page 7 Operating the drive select lever and Periodic maintenance chart for driving in reverse ........6-3 the 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 8 Checking and lubricating the brake and SPECIFICATIONS ........10-1 shift pedals ..........8-34 Checking the wheel hub bearings .... 8-35 CONSUMER INFORMATION.......11-1 Lubricating the swingarm pivots ....8-35 Identification numbers .......11-1 Lubricating the rear suspension relay arm and connecting arm pivoting points ..8-35 Lubricating the upper and lower arm pivots ............

  • Page 9: 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.
  • Page 10 4AA-22259-40 25.0 kPa 25.0 kPa 0.25 kgf/cm² 0.25 kgf/cm² 3.6 psi 3.6 psi 5YT-2816M-M0 1AS-2816P-00...
  • Page 11 4D3-2816L-20 2011 YAMAHA MOTOR CO., LTD. 43P-2816R-01 2500 SHINGAI, IWATA, JAPAN 8AC-2817L-00...
  • Page 12 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 13 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 14 Overloading can cause loss of control. Loss of control can result in severe injury or death. Model Name ****** Max. Power *** kW *** kg Mass In Running Order **** 1 Year of construction YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN...

  • Page 15: Safety Information

    EBU17431 SAFETY INFORMATION EBU17464 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 16 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 17 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 18 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 19: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 3 4 5 1. Headlight 1. Spark arrester 2. Front shock absorber assembly spring preload adjusting 2. Fuse ring 3. Rear shock absorber assembly spring preload adjusting 3. Fuel cock 4. Throttle stop screw 4.

  • Page 20: Controls And Instruments

    EBU17712 Controls and instruments 1. Clutch lever 2. Parking brake lever 3. Speedometer unit 4. Front brake fluid reservoir 5. Brake lever 6. Throttle lever 7. Engine stop switch 8. Main switch 9. Starter (choke) 10.Handlebar switches The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 21: Instrument And Control Functions

    EBU17733 INSTRUMENT AND CONTROL FUNCTIONS EBU28040 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The auxiliary light, taillight and license plate light come on, and the engine can be started. The key cannot be removed.

  • Page 22: Indicator Lights

    EBU17793 EBU17830 Reverse indicator light “ ” Indicator lights This indicator light comes on when the transmis- sion is in the reverse position. EBU27980 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. EBU28051 Speedometer This speedometer is equipped with an odometer.

  • Page 23: Handlebar Switches

    EBU18061 Handlebar switches 1. Engine stop switch “ ” EBU18080 1. Light switch “ / ” Engine stop switch “ ” 2. Hazard switch “ ” Set this switch to “ ” before starting the engine. 3. Turn signal switch “ ”...

  • Page 24: Throttle Lever

    EBU28063 EBU28001 Light switch “ / ” Hazard switch “ ” Set the switch to “ ” to turn on the high beam. With the key in the “ON” position, use this switch to Set this switch to “ ” to turn on the low beam. turn on the hazard lights (simultaneous flashing of Set the switch to “...

  • Page 25: Speed Limiter

    the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be dam- aged. Always make sure the throttle lever free play is adjusted to 2.0–4.0 mm (0.08–0.16 in). (See page 8-21.) WARNING! Improper ad- justment of the speed limiter and throttle could cause throttle cable damage or im- proper throttle operation.

  • Page 26: Clutch Lever

    EBU18382 EBU18411 Clutch lever Brake lever The clutch lever is located on the left handlebar The brake lever is located at the right handlebar and the ignition circuit cut-off system is incorporat- grip. To apply the front brake, pull the brake lever ed in the clutch lever holder.

  • Page 27: Parking Brake Lever

    When pressing down on the brake pedal, the brak- ing force is applied to the rear brake and a portion of the front brakes. For full braking performance, apply both the brake lever and the brake pedal si- multaneously. 1. Parking brake lever (locked position) 1.

  • Page 28: Shift Pedal

    EWB00220 WARNING 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.

  • Page 29: Fuel Tank Cap

    1. Drive select lever 1. Fuel tank cap EBU18720 EBU28942 Fuel tank cap Fuel Remove the fuel tank cap by turning it counter- Make sure there is sufficient gasoline in the tank. clockwise. EWB02521 WARNING Gasoline and gasoline vapors are extremely flammable.
  • Page 30 of sparks, open flames, or other sources of ig- Recommended fuel: nition such as the pilot lights of water heaters Regular unleaded gasoline only with a re- and clothes dryers. search octane number of 91 or higher 2. Do not overfill the fuel tank. When refueling, Fuel tank capacity: be sure to insert the pump nozzle into the fuel 9.0 L (2.38 US gal, 1.98 Imp.gal)

  • Page 31: Fuel Cock

    Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of 91 or higher. If knocking (or pinging) oc- curs, use a gasoline of a different brand.

  • Page 32: Starter (Choke)

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

  • Page 33: Steering Lock

    Move the starter (choke) in direction (b) to turn off EBU28010 Steering lock the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Steering lock cap 2. Steering lock 1. Starter (choke) “ ”...

  • Page 34: Seat

    To unlock the steering To install the seat 1. Open the steering lock cap, and then insert Insert the projections on the front of the seat into the key. the seat holders and push down on the seat at the 2.
  • Page 35 2. Position indicator suspension. Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-15...

  • Page 36: Adjusting The Rear Shock Absorber Assembly

    ECB01090 NOTICE Never turn the adjusting mechanism beyond the minimum and maximum settings. Adjust the spring preload as follows. 1. Loosen the locknut. 2. Turn the spring preload adjusting nut in direc- tion (a) to increase the spring preload and thereby harden the suspension, and in direc- tion (b) to decrease the spring preload and thereby soften the suspension.
  • Page 37 Spring preload setting: Minimum (soft): A special wrench can be obtained at a Yamaha Distance A = 233.5 mm (9.19 in) dealer to make this adjustment. Standard: The spring preload setting is determined by Distance A = 228.5 mm (9.00 in) measuring distance A, shown in the illustration.
  • Page 38 Do not deform or damage the cylinder in any way. Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- er for any service. 4-18...

  • Page 39: 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 40 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Rear brake 5-3, 8-22, 8-23, 8-25 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.

  • Page 41: Fuel

    Check that there is no free play in the brake le- do not provide proper braking performance, check ver. If there is free play, have a Yamaha dealer the brake pads for wear. (See page 8-22.) check the brake system.

  • Page 42: Drive Chain

    EBU19770 Recommended tire pressure: Drive chain Front Check the condition of the drive chain and check 25.0 kPa (0.250 kgf/cm², 3.6 psi) the drive chain slack. Lubricate and adjust the Rear drive chain as necessary. (See page 8-29.) 25.0 kPa (0.250 kgf/cm², 3.6 psi) Minimum tire pressure: EBU28083 Tires...
  • Page 43 1. Low-pressure tire gauge 1. Tire wear limit Tire wear limit Tire information When the tire groove decreases to 3 mm (0.12 in) This ATV is equipped with tubeless tires with due to wear, replace the tire. valves. EWB02551 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent.

  • Page 44: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are MAXXIS/C9207 working properly. Correct if necessary. Size: AT21 x 7-10 Type: Tubeless Rear: Manufacturer/model: MAXXIS/M976 Size: AT20 x 10-9 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling,...

  • Page 45: 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 46 Position (2): Cold engine start with ambient temperature If the engine fails to start, release the start switch, between 0 °C (30 °F) and 30 °C (90 °F). then push it again. Pause a few seconds before Position (3): the next attempt. Each cranking should be as short Cold engine start with ambient temperature as possible to preserve battery energy.

  • Page 47: 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. EBU20341 Operating the drive select lever and driving in reverse ECB00170...

  • Page 48: Shifting

    When in reverse, the reverse indicator light should lease the clutch. 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.
  • Page 49 EBU28112 5. Once the ATV has attained adequate speed, To start out and accelerate release the throttle, and at the same time, 1. Release the throttle lever, and then release quickly pull in the clutch lever. the parking brake. 6. Shift the transmission into second gear. ECB00200 (Make sure not to shift the transmission into NOTICE...

  • Page 50: Engine Break-In

    traction. This could cause loss of control, an For ATVs not equipped with an odometer or accident and injury. It could also cause engine hour meter, follow the figures given in hours. or drive train damage. There is never a more important period in the life of your engine than the first 320 km (200 mi) or 20 ECB00180 NOTICE...

  • Page 51: 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 52: Accessories And Loading

    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- duce.
  • Page 53 bulky object attached to the handlebars which judgment as the stability and handling of an ATV could make steering difficult, an accessory that can be changed. When adding accessories, keep limits your ability to move around on the seat, or the following points in mind: one that limits your view.
  • Page 54 practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail- Allow more braking distance. A heavier ATV takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully.

  • Page 55: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 56: Getting To Know Your Atv

    EBU28125 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is intended for recreational use by expe- WARNING rienced operators only. This section, Riding your Do not operate this ATV or allow anyone else ATV, provides general ATV riding instructions for to operate it without proper instruction.
  • Page 57 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 58 proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. [EWB01411] Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision.
  • Page 59 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 60 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” below or vehicle labeling). creases the maximum speed of the ATV.
  • Page 61 All parts and accessories added to this ATV should be genuine Yamaha or equivalent components de- signed for use on this ATV and should be installed and used according to instructions. If you have...
  • Page 62 WARNING! Operating this ATV with improper erating in areas where combustible materials may modifications may cause changes in handling have collected. Do not idle or park the vehicle in which in some situations could lead to an acci- long dry grass or other dry ground cover. dent.

  • Page 63: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE Watch carefully for other vehicles. Make sure you This ATV is designed for use on unpaved surfaces know your country’s laws and regulations before only. WARNING! Paved surfaces may seriously you ride on unpaved public streets or roads. Do not affect handling and control of the ATV, and ride on any paved public street, road or motorway.
  • Page 64 have enough time to react to hidden rocks, loose terrain could cause loss of traction or bumps, or holes. Go slowly and be extra care- ATV control, which could result in an accident, ful when operating on unfamiliar terrain. Al- including an overturn.
  • Page 65 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.

  • Page 66: Turning Your Atv

    trol. NOTICE: Do not shift gears without To achieve maximum traction on unpaved surfac- [EWB02631] releasing the throttle. Damage to the engine or es, the two rear wheels turn together at the same drive train may occur. speed. Therefore, unless the wheel on the inside [ECB01071] Use this same procedure as you move into the of the turn is allowed to slip or lose some traction,...

  • Page 67: Climbing Uphill

    Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip.
  • Page 68 Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
  • Page 69 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footrests and leaning forward over the handlebars. Whenever possible, ride straight up hills.

  • Page 70: Riding Downhill

    If you start to roll backwards, DO NOT apply the brake pedal, and apply the front brake gradually. The ATV could easily tip over backwards. When fully stopped, apply the brake pedal as well, and then lock the parking brake. Dismount the ATV im- mediately on the uphill side or to a side if pointed straight uphill.
  • Page 71 Never operate the ATV on hills too steep for Whenever possible, ride your ATV straight down- the ATV or for your abilities. The ATV can hill. Avoid sharp angles which could allow the ATV overturn more easily on extremely steep hills to tip or roll over.

  • Page 72: Crossing A Slope

    CROSSING A SLOPE As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the EWB01632 WARNING steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to slopes, be sure not to make sharp turns either up...

  • Page 73: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER EWB01641 WARNING Operating this vehicle through deep or fast- flowing water can lead to loss of control or an overturn. To reduce your risk of drowning or other injuries, use care when crossing through water. Never operate this ATV water deeper than the depth specified in your Owner’s Man- ual, as tires may float, increasing the risk of an overturn.

  • Page 74: Riding Over Rough Terrain

    1. Air filter case check hose RIDING OVER ROUGH TERRAIN EWB01651 After riding your ATV in water, be sure to drain the WARNING trapped water by removing the check hose at the Riding improperly over obstacles could cause bottom of the air filter case. NOTICE: Undrained loss of control or a collision.

  • Page 75: Sliding And Skidding

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

  • Page 76: 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 footrest to the outside of the turn. Position your weight over the front wheels for better control.
  • Page 77 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 78: 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 79: Owner's Manual And Tool Kit

    If you do not have the tools or experience required seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s manual 2. Owner’s tool kit 3.

  • Page 80: 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 81 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 82: 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 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 cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years √...
  • Page 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Make sure that all nuts, bolts, and screws are √ √ √ √ √ Chassis fasteners properly tightened. Shock absorber as- •...
  • 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 operation. • Check throttle lever free play, and adjust if neces- √ √ √ √ √ 23 * Throttle lever sary.

  • Page 86: 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 87 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 88: 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 89 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 90 1. Oil filter element cover 1. Engine oil drain bolt 2. Bolt 2. O-ring 3. Oil filter element 3. Compression spring 4. O-ring 4. Oil strainer 6. Clean the oil strainer and oil filter element with solvent. Skip steps 5–9 if the oil filter element is not being 7.
  • Page 91 engine oil drain bolt, be sure to install the Tightening torque: O-ring, compression spring and oil strain- Oil filter element cover bolt: [ECB00321] 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tightening torque: 10. Apply a thin coat of clean engine oil to a new Engine oil drain bolt: O-ring.

  • Page 92: Cleaning The Air Filter Element

    ECB00300 NOTICE There is a check hose at the bottom of the air filter In order to prevent clutch slippage (since the case. If dust or water collects in this hose, empty engine oil also lubricates the clutch), do not the hose and clean the air filter element and air fil- mix any chemical additives.
  • Page 93 1. Air filter case cover 1. Air filter element 2. Air filter case cover holder 5. Remove the sponge material from the air filter 4. Pull the air filter element out of the air filter element frame. case. 1. Unlock. 8-16...
  • Page 94 2. Air filter element frame damaged. 3. Sponge material 9. Apply Yamaha foam air filter oil or other qual- 4. Air filter element seat ity foam air filter oil to the sponge material. 6. Wash the sponge material gently but thor- oughly in solvent.

  • Page 95: Cleaning The Spark Arrester

    NOTICE: Make sure that the air filter ele- EBU27703 Cleaning the spark arrester ment is properly seated in the air filter Select a well-ventilated area free of combustible case. Never operate the engine with the air materials and make sure the exhaust and muffler filter element removed.
  • Page 96 1. Tailpipe 1. Purging bolt 2. Spark arrester 2. Gasket 4. Insert the tailpipe into the muffler and align the 7. Start the engine and rev it up approximately bolt holes. twenty times while momentarily creating ex- 5. Install the bolt and tighten it to the specified haust system back pressure by blocking the torque.

  • Page 97: Adjusting The Carburetor

    Yamaha dealer, who has the necessary profes- Tightening torque: sional knowledge and experience. The adjustment Purging bolt: described in the following section, however, may 27 Nm (2.7 m·kgf, 20 ft·lbf) be performed by the owner as part of routine main- tenance.

  • Page 98: Adjusting The Throttle Lever Free Play

    The engine is warm when it quickly responds to the If the specified idling speed cannot be obtained as throttle. described above, have a Yamaha dealer make the adjustment. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces-...

  • Page 99: Valve Clearance

    To must be adjusted by a Yamaha dealer at the inter- check the brake pad wear, check the wear indica- vals specified in the periodic maintenance and lu- tor grooves.

  • Page 100: Checking The Brake Fluid Level

    To check the brake pad wear, check the wear indica- tor grooves. If a brake pad has worn to the point that a wear indicator groove almost appears, have a Yamaha dealer replace the brake pads as a set. 8-23...
  • Page 101 Front brake Specified brake fluid: DOT 4 EWB02720 WARNING Improper maintenance can result in loss of braking ability. Observe these precautions: Insufficient brake fluid may allow air to enter the brake system, reducing braking perfor- mance. Clean the filler cap before removing. Use only DOT 4 brake fluid from a sealed contain- 1.

  • Page 102: Changing The Brake Fluid

    If the brake fluid level goes down suddenly, have a Yamaha dealer check the cause before fur- ther riding. EBU24291 Changing the brake fluid...

  • Page 103: Adjusting The Parking Brake Free Play

    The top of the brake pedal should be positioned 50.2 mm (1.98 in) above the top of the frame as shown. If the brake pedal is not positioned as spec- ified, have a Yamaha dealer adjust it. 1. Locknut 2. Adjusting bolt 3.

  • Page 104: Brake Light Switches

    ATV off the ground and spin the rear wheels. If the cable length cannot be adjusted to specifica- Check to make sure there is no brake drag. If tion, consult a Yamaha dealer. brake drag is noticed, perform the adjustment 6. Tighten the locknut on the brake cable.

  • Page 105: Adjusting The Clutch Lever Free Play

    10.0 mm (0.20–0.39 in) as shown. If the free play should be adjusted by a Yamaha dealer. is incorrect, adjust it as follows. Turn the rear brake light switch adjusting nut while 1.

  • Page 106: Drive Chain Slack

    6. Loosen the locknut. scribed above or if the clutch does not operate cor- 7. To increase the clutch lever free play, turn the rectly, have a Yamaha dealer check the internal adjusting nut at the crankcase in direction (a), clutch mechanism.
  • Page 107 Drive chain slack: 25.0–35.0 mm (0.98–1.38 in) 1. Axle holding bolt (upper) 2. Axle holding bolt (lower) 3. Loosen the locknut on each side of the swing- 1. Drive chain slack arm. To tighten the drive chain, turn the ad- justing bolts in direction (a).
  • Page 108 There are alignment marks on both drive chain Make sure that the curved edge of the speed sen- pullers and an alignment mark on each side of the sor bracket touches the rear wheel hub when tight- swingarm. Make sure to align the same alignment ening the axle holding nuts.

  • Page 109: Lubricating The Drive Chain

    Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf) Axle holding nut (upper): 120 Nm (12 m·kgf, 87 ft·lbf) Axle holding nut (lower): 73 Nm (7.3 m·kgf, 53 ft·lbf) EBU24882 Lubricating the drive chain The drive chain must be cleaned and lubricated at 1.

  • Page 110: Checking And Lubricating The Brake And Clutch Levers

    If a cable is damaged or does not move EBU24922 Checking and lubricating the brake and smoothly, have a Yamaha dealer check or replace clutch levers The operation of the brake and clutch levers Recommended lubricant: should be checked before each ride, and the lever Yamaha Chain and Cable Lube or engine oil pivots should be lubricated if necessary.

  • Page 111: Checking And Lubricating The Brake And Shift Pedals

    Clutch lever Brake pedal Shift pedal EBU28841 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease 8-34...

  • Page 112: Checking The Wheel Hub Bearings

    Lubricating the rear suspension relay in a wheel hub or if a wheel does not turn smoothly, arm and connecting arm pivoting have a Yamaha dealer check the wheel hub bear- points ings. The rear suspension relay arm and connecting...

  • Page 113: Lubricating The Upper And Lower Arm Pivots

    1. Grease nipple 1. Grease nipple EBU25033 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. For parts equipped with a grease nipple, use a grease gun.

  • Page 114: Lubricating The Steering Shaft

    2. Lower grease nipple 2. Lower grease nipple EBU25092 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. For parts equipped with a grease nipple, use a grease gun.

  • Page 115: Battery

    EBU2522E KEEP OUT OF REACH OF CHILDREN. Battery ECB00620 The battery is located under the seat. (See page NOTICE 4-14.) Never attempt to remove the battery cell seals, This model is equipped with a VRLA (Valve Regu- as this would permanently damage the battery. lated Lead Acid) battery.
  • Page 116 To charge the battery damage. Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in To install the battery mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.

  • Page 117: Replacing A Fuse

    2. Connect the positive battery lead first, then EBU28153 Replacing a fuse connect the negative battery lead by installing their bolt. NOTICE: When installing the bat- tery, the main switch must be off, and the positive lead must be connected before the negative lead.

  • Page 118: Headlight Bulb

    4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU28160 Headlight bulb 1. Screw If the headlight bulb burns out, have a Yamaha 2. Remove the burnt-out bulb by pushing it in dealer replace it. and turning it counterclockwise. 8-41...

  • Page 119: Replacing A Turn Signal Light Bulb

    1. Tail/brake light bulb 1. Screw 3. Insert a new bulb into the socket, push it in, 2. Remove the burnt-out bulb by pushing it in and then turn it clockwise until it stops. and turning it counterclockwise. 4. Install the lens by installing the screws. 3.
  • Page 120 1. Screw 1. License plate light bulb socket 2. License plate light body 3. Remove the burnt-out bulb by pulling it out. 2. Remove the license plate light bulb socket (to- gether with the bulb). 1. License plate light bulb 4.

  • Page 121: Auxiliary Light Bulb

    EBU28020 Auxiliary light bulb 1. Place the ATV on a level surface. If the auxiliary light bulb burns out, have a Yamaha 2. Install the wheel and the nuts. dealer replace it. When installing the wheel, make sure its arrow...

  • Page 122: 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 123: 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 124: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU28191 speeds to let friction dry out the linings. Cleaning NOTICE: Excessive water pressure [EWB02311] Frequent, thorough cleaning of your ATV will not may cause water seepage and deteriora- only enhance its appearance but will improve its tion of wheel bearings, brakes, transmis- general performance and extend the useful life of sion seals and electrical devices.

  • Page 125: Storage

    abrasives which may mar the paint or protec- 4. Fill up the fuel tank and add fuel stabilizer (if tive finish. When finished cleaning, start the available) to prevent the fuel from deteriorat- engine and let it idle for several minutes. ing.
  • Page 126 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. Alternative- ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.

  • Page 127: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Compression ratio: 9.20 : 1 Overall length: Starting system: 1780 mm (70.1 in) Electric starter Overall width: Lubrication system: 1095 mm (43.1 in) Wet sump Overall height: Engine oil: 1095 mm (43.1 in) Seat height: Recommended brand: 820 mm (32.3 in) YAMALUBE Wheelbase:...
  • Page 128 Engine oil quantity: Primary reduction ratio: Without oil filter element replacement: 76/24 (3.166) 2.50 L (2.64 US qt, 2.20 Imp.qt) Secondary reduction system: With oil filter element replacement: Chain drive 2.60 L (2.75 US qt, 2.29 Imp.qt) Secondary reduction ratio: Air filter: 38/13 (2.923) Transmission type:...
  • Page 129 Trail: Front wheel: 26.0 mm (1.02 in) Wheel type: Front tire: Panel wheel Type: Rim size: Tubeless 10 x 5.5AT Size: Rear wheel: AT21 x 7-10 Wheel type: Manufacturer/model: Panel wheel MAXXIS/C9207 Rim size: Rear tire: 9 x 8.0AT Type: Front brake: Tubeless Type:...
  • Page 130 Rear suspension: License plate light: 12 V, 5.0 W × 1 Type: Neutral indicator light: Swingarm (link suspension) 12 V, 1.7 W × 1 Spring/shock absorber type: High beam indicator light: Coil spring/gas-oil damper Wheel travel: Turn signal indicator light: 210 mm (8.3 in) Electrical system: Reverse indicator light:...

  • Page 131: 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 132 1. Model label 11-2...
  • Page 133 INDEX Drive chain slack ............8-29 Drive select lever ............4-8 Accessories and loading ..........6-8 Drive select lever and driving in reverse ......6-3 Air filter element, cleaning ..........8-15 Auxiliary light bulb ............8-44 Engine break-in .............. 6-6 Engine, cold start ............
  • Page 134 Speed limiter ..............4-5 Speedometer ..............4-2 Label locations ............... 1-1 Starter (choke) ............. 4-12 License plate light bulb, replacing ........ 8-42 Start switch ..............4-3 Light switch ..............4-4 Steering lock ..............4-13 Steering shaft, lubricating ..........8-37 Main switch ..............4-1 Storage ................
  • Page 136 PRINTED IN FRANCE 2011.07 (E)

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