Yamaha YFM25RY Owner's Manual
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Yamaha YFM25RY Owner's Manual

Yamaha YFM25RY 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
YFM25RY
4D3-28199-62

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Summary of Contents for Yamaha YFM25RY

  • 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 YFM25RY This A 4D3-28199-62...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2008.03-0.8x2 ! IMPRIMÉ SUR PAPIER RECYCLÉ (E,F,S) IMPRESO EN PAPEL RECICLADO...
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM25RY This A 4D3-28199-62-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 YFM250R ( YFM25R )
  • Page 5 INTRODUCTION EBU17321 Congratulations on your purchase of the Yamaha YFM25RY. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high 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 Starter (choke) ......... 4-10 Seat ............4-10 Adjusting the front shock absorber LOCATION OF THE WARNING AND assemblies ..........4-11 SPECIFICATION LABELS ......2-1 Adjusting the rear shock absorber assembly ..........4-12 DESCRIPTION ..........
  • Page 9 Parking on a slope ........6-6 Cleaning the spark arrester ..... 8-18 Accessories and loading ......6-6 Adjusting the carburetor ......8-19 Adjusting the engine idling speed .... 8-20 RIDING YOUR ATV ........7-1 Adjusting the throttle cable free play ..8-20 Valve clearance ........
  • Page 10 Replacing the fuse ........8-38 Replacing a headlight bulb ...... 8-39 Adjusting a headlight beam ..... 8-42 Replacing the tail/brake light bulb ... 8-42 Removing a wheel ........8-42 Installing a wheel ........8-43 Troubleshooting ........8-44 Troubleshooting chart ......8-45 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 EWB00070 WARNING cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank. Always operate your ATV in an area with ade- Gasoline is poisonous. If you should swal- quate ventilation.

  • 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 For Europe For Europe For Oceania WARNING Improper ATV use can result in SEVERE INJURY or DEATH. YAMAHA MOTOR CO., LTD. SHIZUOKA JAPAN 4GB-2155A-00 ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND...
  • Page 18 For Oceania For Europe WARNING UNDER < 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 5FK-21697-00 4D3-2816L-00 For Europe For Oceania WARNING NEVER...
  • Page 19 For Europe For Oceania WARNING Improper tire pressure or overloading can cause loss of control. 27.5 kPa 27.5 kPa Loss of control can result in severe injury or 0.275 kgf/cm 0.275 kgf/cm death. OPERATING TIRE PRESSURE : Set with tires cold 4.0 psi 4.0 psi 0 Recommended : Front...

  • Page 20: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 2 3 4 1. Headlights 1. Spark arrester 2. Fuel cock 2. Seat 3. Starter (choke) 3. Fuel tank cap 4. Throttle stop screw 4. Oil filter element 5. Fuse 5. Brake pedal 6.

  • Page 21: Controls And Instruments

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

  • Page 22: Instrument And Control Functions

    EBU17732 INSTRUMENT AND CONTROL FUNCTIONS EBU17740 EBU17781 Main switch Indicator light The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved. All electrical systems are off. The key can be re- moved.

  • Page 23: Handlebar Switches

    EBU18061 EBU18100 Handlebar switches Start switch “ ” Push this switch to crank the engine with the start- ECB00050 NOTICE See the starting instructions on page 6-1 prior to starting the engine. EBU18151 Light switch “ /OFF” Set this switch to “ ”...

  • Page 24: Throttle Lever

    ATV will decelerate, and the engine will check for the cause. Correct the problem be- return to an idle any time the hand is removed from fore riding the ATV or consult a Yamaha dealer. the throttle lever. EBU18321...

  • Page 25: Clutch Lever

    (See page 8-20.) EBU18382 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporat- ed in the clutch lever holder. To disengage the clutch, pull the clutch lever toward the handlebar grip.

  • Page 26: 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 EBU18520 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope.
  • Page 27 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 28: Shift Pedal

    1. Shift pedal 1. Fuel tank cap EBU18720 EBU18752 Fuel tank cap Fuel Remove the fuel tank cap by turning it counter- Make sure that there is sufficient fuel in the tank. clockwise. Fill the fuel tank to the bottom of the filler tube as shown.

  • Page 29: Fuel Cock

    of gasoline or higher octane grade. ECB00070 NOTICE Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. EWB00310 WARNING Do not overfill the fuel tank.
  • Page 30 The fuel cock lever positions are explained as fol- lows and shown in the illustrations. 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel flows 1. Arrow mark positioned over “OFF” to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding.

  • Page 31: Starter (Choke)

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

  • Page 32: Adjusting The Front Shock Absorber Assemblies

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat Insert the projections on the front of the seat into EBU18990 Adjusting the front shock absorber the seat holders and push down on the seat at the assemblies rear.

  • Page 33: Adjusting The Rear Shock Absorber Assembly

    Adjust the spring preload as follows. 1. Loosen the locknut. 2. Turn the adjusting nut in direction (a) to in- A special wrench can be obtained at a Yamaha crease the spring preload and thereby harden dealer to make this adjustment.
  • Page 34 2. Adjusting nut the minimum and maximum settings. 3. Distance A 3. Tighten the locknut to the specified torque. A special wrench can be obtained at a Yamaha Tightening torque: dealer to make this adjustment. Locknut: The spring preload setting is determined by 42 Nm (4.2 m·kgf, 31.0 ft·lbf)
  • Page 35 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. 4-14...

  • Page 36: 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 37 ITEM ROUTINE PAGE Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Rear brake 5-3, 8-22, 8-23, 8-26 Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 38: Fuel

    Check that there is no free play in the brake le- EWB00520 WARNING ver. If there is free play, have a Yamaha dealer check the brake system. Do not overfill the fuel tank. Fuel expands Check for correct brake pedal height. (See when it heats up.

  • Page 39: Throttle Lever

    The tires listed below have been approved ability, which could lead to an accident. If a by Yamaha Motor Co., Ltd. for this model. problem cannot be corrected by the adjust- Other tire combinations are not recommend- ment procedures provided in this manual, have a Yamaha dealer check for the cause.

  • Page 40: Measuring The Tire Pressure

    Size: Maximum tire seating pressure: AT19 x 10-9 Front: Type: 250 kPa (2.5 kgf/cm , 36 psi) Tubeless Rear: The tires should be set to the recommended 250 kPa (2.5 kgf/cm , 36 psi) pressure: Higher pressures and fast inflation may Recommended tire pressure: cause a tire to burst.

  • Page 41: Tire Wear Limit

    EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). 1. Low-pressure tire gauge Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: 1. Tire wear limit Recommended pressure: Front 27.5 kPa (0.275 kgf/cm...

  • Page 42: Chassis Fasteners

    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 43: Operation

    If there is a control or func- indicator light should come on. If the indicator tion you do not understand, ask your Yamaha light does not come on, have a Yamaha deal- dealer. er check the electrical circuit.
  • Page 44 Position (1): Ambient temp./starter (choke) position Cold engine start with ambient temperature be- low 5 °C (40 °F). Position (2): Cold engine start with ambient temperature be- tween 0 °C (30 °F) and 30 °C (90 °F). Position (3): Cold engine start with ambient temperature above 25 °C (80 °F).

  • Page 45: Starting A Warm Engine

    attempt. EBU20520 Shifting 7. If the engine is started with the starter (choke) This ATV has a 5-speed forward transmission. The in position (1), the starter (choke) should be transmission allows you to control the amount of returned to position (2) to warm up the engine. power you have available at a given speed or for If the engine is started with the starter (choke) starting, accelerating, climbing hills, etc.
  • Page 46 EBU20590 wheelie, which would increase the chance of To start out and accelerate an accident, including an overturn. 1. Release the throttle lever, and then release the parking brake. EBU20650 ECB00200 To decelerate NOTICE When slowing down or stopping, release the throt- Always close the throttle before shifting gears, tle and apply the brakes smoothly and evenly.

  • Page 47: Engine Break-In

    There is never a more important period in the life of engine break-in period, immediately have a your engine than the first 320 km (200 mi) or 20 Yamaha dealer check the ATV. hours of riding. For this reason, you should read the following material carefully.

  • Page 48: Parking On A Slope

    the fuel cock to “OFF”. Do not park the ATV at all on hills that are so 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.
  • Page 49 However, er, you must use common sense and good it is not possible for Yamaha to test all non- judgment as the stability and handling of an ATV Yamaha accessories, nor control over their qual- can be changed.
  • Page 50 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 51: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 52: 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 53 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 54 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 55 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 56 duce your speed when adding additional loads. 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.
  • Page 57 All parts and tact with the rear wheels, which could injure accessories added to this ATV should be gen- you or cause an accident. uine Yamaha or equivalent components de-...

  • Page 58: Be Careful Where You Ride

    signed for use on this ATV and should be 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.
  • Page 59 EWB01520 WARNING Never operate this ATV on any paved street, paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. While riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles.
  • Page 60 EWB01530 when operating on excessively rough, slippery WARNING or loose terrain could cause loss of traction or ATV control, which could result in an accident, Go slowly and be extra careful when operating including an overturn. on unfamiliar terrain. Always be alert to chang- ing terrain conditions when operating the ATV.
  • Page 61 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 EWB01550 control of the throttle, brakes, shifting procedures, WARNING and turning techniques in this area before trying Always mount a caution flag on the ATV to more difficult terrain.

  • Page 62: 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 63 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 64: Climbing Uphill

    curves. er hills before attempting large hills. Improper riding procedures such as abrupt throttle It is important when climbing a hill to make sure changes, excessive braking, incorrect body move- that your weight is transferred forward on the ATV. ments, or too much speed for the sharpness of the This can be accomplished by leaning forward and, turn may cause the ATV to tip.
  • Page 65 any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

  • Page 66: Riding Downhill

    make sure you do not lift the front wheels which straight uphill. Turn the ATV around and re- could cause you to lose control. If you are unable mount, following the procedure described in to continue up the hill, dismount the ATV on the up- the Owner’s Manual.

  • Page 67: Crossing A Slope

    tion. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. Whenever possible, ride your ATV straight down- hill. Avoid sharp angles which could allow the ATV to tip or roll over.

  • Page 68: Crossing Through Shallow Water

    steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path.
  • Page 69 in water deeper than that specified in your have regained proper braking ability. Owner’s Manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the lin- ings.

  • Page 70: 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 71: What To Do If

    slide. Applying the brakes or accelerating is not terrain. recommended until you have corrected the slide. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control.
  • Page 72 slide. (See page 7-20.) If your ATV can’t make it up a hill you are trying 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 –...

  • Page 73: Periodic Maintenance And Minor Repair

    1. Low-pressure tire gauge can cause shocks or start fires. Turn off the en- 2. Owner’s tool kit gine when performing maintenance unless 3. Owner’s manual otherwise specified. Have a Yamaha dealer 4. Panel perform the service if you are not familiar with...
  • Page 74 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 75: 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 76 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 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 77: 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 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check operation and for excessive play, and √ √ √ 10 * Swingarm pivots replace bearings if necessary. Lubricate with lithium-soap-based grease.
  • Page 79 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 √ √ √ √ 21 * Lubricate. cables Check operation and correct if necessary. Throttle lever hous- Check throttle cable free play and adjust if neces- √...
  • Page 80 EBU23070 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 81: Checking The Spark Plug

    If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not 1. Spark plug cap attempt to diagnose such problems yourself. In- 2. Remove the spark plug as shown, with the stead, have a Yamaha dealer check the ATV.

  • Page 82: Engine Oil And Oil Filter Element

    2. Check the spark plug for electrode erosion 2. Clean the surface of the spark plug gasket and excessive carbon or other deposits, and and its mating surface, and then wipe off any replace it if necessary. grime from the spark plug threads. 3.
  • Page 83 To check the engine oil level 1. Place the ATV on a level surface. 2. Check the engine oil level on a cold engine. If the engine was started before checking the oil 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.
  • Page 84 To change the engine oil (with or without oil 4. Remove the oil filter element cover by remov- filter element replacement) ing the bolts, and then remove the oil filter el- 1. Start the engine, warm it up for several min- ement.
  • Page 85 8. Install the engine oil drain bolt and tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 20 Nm (2.0 m·kgf, 14.5 ft·lbf) 9. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap.

  • Page 86: Cleaning The Air Filter Element

    with a diesel specification of “CD” or oils of EBU23703 Cleaning the air filter element a higher quality than specified. In addition, The air filter element should be cleaned at the in- do not use oils labeled “ENERGY CONSERV- tervals specified in the periodic maintenance and ING II”...
  • Page 87 1. Place the ATV on a level surface. 2. Remove the seat. (See page 4-10.) 3. Remove the air filter case cover by unhooking the holders. 1. Wing bolt 2. Air filter element 6. Remove the wing bolt and washer from the air filter element.
  • Page 88 ECB00440 NOTICE Do not twist the sponge material when squeez- ing it. 1. Sponge material 2. Air filter element frame 8. Wash the sponge material gently but thor- oughly in solvent. 10. Check the sponge material and replace it if EWB01940 damaged.
  • Page 89 13. Install the washer onto the air filter element frame, and then insert the wing bolt into the The air filter element should be cleaned every 20– hole in the air filter element frame. 40 hours. It should be cleaned and lubricated more ECB00451 often if the ATV is operated in extremely dusty ar- NOTICE...

  • Page 90: Cleaning The Spark Arrester

    EBU28900 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be- fore cleaning the spark arrester. 1. Remove the bolts. 1. Tailpipe 2. Spark arrester 4. Make sure the gasket is properly positioned, then insert the tailpipe into the muffler and 1.

  • Page 91: Adjusting The Carburetor

    Therefore, 1. Gasket most carburetor adjustments should be left to a 2. Tailpipe Yamaha dealer, who has the necessary profes- 3. Bolt sional knowledge and experience. The adjustment described in the following section, however, may 5. Install the bolts and tighten them to the speci- be performed by the owner as part of routine main- fied torque.

  • Page 92: Adjusting The Engine Idling Speed

    If the specified idling speed cannot be obtained as throttle stop screw at the carburetor. To in- described above, have a Yamaha dealer make the crease the engine idling speed, turn the throt- adjustment.

  • Page 93: Valve Clearance

    The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.

  • Page 94: Checking The Front And Rear Brake Pads

    If a brake pad has worn to the point that 1. Wear indicator groove the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. The wheels need to be removed to check the brake pads.

  • Page 95: Checking The Brake Fluid Level

    place the brake pads as a set. Front brake 1. Minimum level mark 1. Wear indicator EBU28930 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary.
  • Page 96 Rear brake 1. Bolt 1. Minimum level mark 2. Brake fluid reservoir cap cover If the rear brake fluid level is low, replenish as fol- 2. Remove the brake fluid reservoir cap. lows. 1. Remove the brake fluid reservoir cap cover by removing the bolt.

  • Page 97: Changing The Brake Fluid

    5. Install the brake fluid reservoir cap cover by Changing the brake fluid installing the bolt. Have a Yamaha dealer change the brake fluid at Observe these precautions: the intervals specified in the TIP after the periodic When checking the fluid level, make sure that maintenance and lubrication chart.

  • Page 98: Checking The Front Brake Lever Free Play

    If there is free play, have a Replacement of brake components requires Yamaha dealer check the brake system. professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24591 Checking the brake pedal position The brake pedal position must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 99: Adjusting The Parking Brake Free Play

    Yamaha dealer. EBU24710 Adjusting the parking brake free play The parking brake free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Cable length “A” should measure 64–68 mm (2.52–2.68 in).
  • Page 100 Check to make sure there is no brake drag. If If the cable length cannot be adjusted to specifica- brake drag is noticed, perform the adjustment tion, consult a Yamaha dealer. again. 5. Tighten the locknut on the brake cable.

  • Page 101: 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. The brake light switch is properly adjusted when the brake light comes on just before braking takes 1.

  • Page 102: Drive Chain Slack

    (b). 3. Tighten the locknut. If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal clutch mechanism. 8-30...
  • Page 103 4. Hole To adjust the drive chain slack 1. Place the ATV on a level surface. A rod can be obtained at a Yamaha dealer to make 2. Loosen the rear wheel axle pinch bolts. this adjustment. 3. Insert a rod of a diameter of 8 mm (0.3 in) and 4.

  • Page 104: Lubricating The Drive Chain

    ECB00541 EBU24880 Lubricating the drive chain NOTICE The drive chain must be cleaned and lubricated at Improper drive chain slack will overload the en- the intervals specified in the periodic maintenance gine as well as other vital parts of the ATV and and lubrication chart, otherwise it will quickly wear can lead to drive chain slippage or breakage.

  • Page 105: Checking And Lubricating The Cables

    Clutch lever: cables and cable ends should be lubricated if nec- Lithium-soap-based grease essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil 8-33...

  • Page 106: Checking The Shift Pedal

    The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- ings. 8-34...

  • Page 107: Lubricating The Swingarm Pivots

    EBU24994 Lubricate the pivoting points using a grease gun. Lubricating the swingarm pivots Recommended lubricant: The swingarm pivots must be lubricated at the in- Lithium-soap-based grease tervals specified in the periodic maintenance and lubrication chart. Left side Recommended lubricant: Lithium-soap-based grease 1.

  • Page 108: Lubricating The Steering Shaft

    Right side lated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened. ECB00620 NOTICE Never attempt to remove the battery cell seals, as this would permanently damage the battery.
  • Page 109 KEEP OUT OF REACH OF CHILDREN. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in To remove the battery mind that the battery tends to discharge more 1.

  • Page 110: Replacing The Fuse

    Yamaha dealer charge your battery. EBU28924 Replacing the fuse The fuse holder is located beside the battery and can be accessed as follows: 1. Remove the seat. (See page 4-10.) 2. Unhook the band securing the owner’s tool kit, and then remove the battery holding plate by removing the bolts.

  • Page 111: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a If the fuse is blown, replace it as follows. Yamaha dealer check the electrical system. 1. Turn the key to “OFF” and turn off all electrical 5. Install the battery cover by installing the bat- circuits.
  • Page 112 1. Headlight assembly 1. Headlight bulb holder cover 2. Bolt 2. Headlight coupler 2. Disconnect the headlight coupler. 4. Remove the headlight bulb holder by pushing 3. Remove the headlight bulb holder cover. it in and turning it counterclockwise, and then remove the defective bulb.
  • Page 113 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. EWB02230 ECB00650 WARNING NOTICE Do not touch a headlight bulb when it is on or Do not touch the glass part of the headlight immediately after it is turned off. You can be bulb to keep it free from oil, otherwise the burned or a fire could start if the bulb touches transparency of the glass, the luminosity of the...

  • Page 114: Adjusting A Headlight Beam

    ECB00690 NOTICE 1. Place the ATV on a level surface. 2. Loosen the wheel nuts. It is advisable to have a Yamaha dealer make Front this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a).

  • Page 115: Installing A Wheel

    Rear wheel. Front 1. Nut 1. Arrow mark 3. Elevate the ATV and place a suitable stand under the frame. 3. Lower the ATV to the ground. 4. Remove the nuts from the wheel. 4. Tighten the wheel nuts to the specified 5.

  • Page 116: 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 117: 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 118: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25900 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 119: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the 2. Turn the fuel cock lever to “OFF”. brakes after washing.
  • Page 120 the next step.) ATV. d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. 6.

  • Page 121: Specifications

    EBU25960 SPECIFICATIONS EBU2597B Engine: Engine type: Air cooled 4-stroke, SOHC Dimensions: Cylinder arrangement: Overall length: Forward-inclined single cylinder 1625 mm (64.0 in) Displacement: Overall width: 249.0 cm 1070 mm (42.1 in) Bore × stroke: Overall height: 74.0 × 58.0 mm (2.91 × 2.28 in) 1040 mm (40.9 in) Compression ratio: Seat height:...
  • Page 122 Fuel reserve amount: 50 ˚C 1.0 L (0.26 US gal, 0.22 Imp.gal) Carburetor: Manufacturer: SAE 5W-30 MIKUNI SAE 10W-30 Type × quantity: BSR29 x 1 SAE 10W-40 Spark plug (s): SAE 15W-40 Manufacturer/model: NGK/DR7EA SAE 20W-40 Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) SAE 20W-50 Clutch: Clutch type:...
  • Page 123 Gear ratio: Loading: 1st: Maximum loading limit: 37/13 (2.846) 100.0 kg (220 lb) 2nd: (Total weight of rider, cargo, accessories, and tongue) 33/18 (1.833) Tire air pressure (measured on cold tires): 3rd: Recommended: 29/21 (1.381) Front: 4th: 27.5 kPa (0.275 kgf/cm , 4.0 psi) 27/24 (1.125) Rear:...
  • Page 124 Recommended fluid: Voltage, capacity: DOT 4 12 V, 6.0 Ah Rear brake: Headlight: Type: Bulb type: Single disc brake Krypton bulb Bulb voltage, wattage × quantity: Operation: Right foot operation Headlight: 12 V, 30.0/30.0 W × 2 Recommended fluid: DOT 4 Tail/brake light: 12 V, 5.0/21.0 W ×...

  • Page 125: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 126 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 127 1. Model label 11-3...
  • Page 128 INDEX Drive chain slack ............8-30 Accessories and loading ..........6-6 Air filter element, cleaning..........8-14 Engine break-in .............. 6-5 Engine, cold start ............6-1 Engine idling speed............8-20 Battery................8-36 Engine oil ............... 5-3 Brake and clutch levers, checking and lubricating ..8-33 Engine oil and oil filter element ........
  • Page 129 Light switch ..............4-2 Starter (choke) ............. 4-10 Start switch ..............4-2 Steering shaft, lubricating ..........8-36 Main switch ..............4-1 Storage ................9-2 Maintenance and lubrication chart ........8-5 Suspension, lubricating the upper and lower arm Maintenance chart, emission control system ....8-3 pivots .................
  • Page 130 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2008.03-0.8x2 !

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