Yamaha BRUIN 250 Owner's Manual
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Yamaha BRUIN 250 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM250BT
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-18-41
1P0-F8199-10

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  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM250BT WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-18-41 1P0-F8199-10...
  • Page 2 EBU00776...
  • Page 3 Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of crafts- manship and reliability that have made Yamaha a leader in these fields.

  • Page 4: Warning

    EBU00801 I MPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe WARNING...
  • Page 5 Please check your local riding laws and regulations before operating this ATV. EBU13340 YFM250BT OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, AFFIX DEALER U.S.A. 1st edition, June 2004 LABEL HERE All rights reserved. Any reprinting or...

  • Page 6: Table Of Contents

    EBU00014 CONTROL FUNCTIONS....4-1 WARNING Main switch ........4-1 Indicates a potential hazard that could Indicator lights........4-2 result in serious injury or death. Handlebar switches ......4-2 Throttle lever ........4-4 Speed limiter ........4-5 CONTENTS Front brake lever......4-6 Brake pedal and rear brake lever ..........4-6 LOCATION OF THE WARNING Parking brake........4-8 AND SPECIFICATION LABELS..
  • Page 7 PRE-OPERATION CHECKS ... 5-1 Engine break-in ....... 6-7 Front and rear brakes ..... 5-3 Parking..........6-8 Fuel ..........5-5 Parking on a slope......6-9 Engine oil ........5-7 Accessories and loading ....6-10 Final gear oil........5-7 Throttle lever ........5-7 RIDING YOUR ATV ......
  • Page 8 PERIODIC MAINTENANCE AND Adjusting the rear brake light ADJUSTMENT........8-1 switch ...........8-34 Owner’s manual and tool kit.... 8-1 Clutch adjustment ......8-35 Periodic maintenance/ Cable inspection and lubrication ........8-3 lubrication........8-35 Engine oil and oil filter element ..8-6 Brake lever and brake pedal Final gear oil ........
  • Page 9 SPECIFICATIONS......10-1 NOISE REGULATION....11-1 MAINTENANCE RECORD .... 12-1 ATV LIMITED WARRANTY.... 13-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ........... 14-1...

  • Page 10: Location Of The Warning And Specification Labels

    EBU00464 L OCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 11 Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident.
  • Page 12 WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum rear cargo limit of : 45kg (99 lbs) NEVER sit on the carrier. Refer to instructions in the Owner’s Manual.

  • Page 14: Safety Information

    EBU13351 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.
  • Page 15 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions.
  • Page 16 Always follow proper procedures for climbing hills as described in this manual. Check the ter- rain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes.
  • Page 17 Always be careful when skidding or sliding. Learn to safely control skidding or sliding by prac- ticing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con- trol.
  • Page 18 WARNING When transporting the ATV in another vehicle, be sure it is kept upright and POTENTIAL HAZARD that the fuel cock is in the “OFF” posi- Improper handling of gasoline. tion. Otherwise, fuel may leak out of the WHAT CAN HAPPEN carburetor or fuel tank.
  • Page 19 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.

  • Page 20: Description And Machine Identification

    EBU00032 D ESCRIPTION AND MACHINE IDENTIFICATION 1. Spark arrester 15. Tail/brake light 2. Storage compartment 16. Rear shock absorber spring 3. Air filter case preload adjusting ring 4. Engine oil dipstick 17. Engine oil drain bolt 5. Front brake fluid reservoir 18.

  • Page 21: Identification Number Records

    This number can be used for ordering a new when ordering spare parts from a Yamaha key. dealer or for reference in case the vehicle is stolen.

  • Page 22: Vehicle Identification Number

    Record the information on this la- bel in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to 1.

  • Page 23: Control Functions

    EBU00039 CONTROL FUNCTIONS WARNING Indicates a potential hazard that could result in serious injury or death. EBU00942 Main switch Functions of the respective switch positions are as follows: The engine can be started only at this position and the headlights and taillight come on when the light switch is on.

  • Page 24: Indicator Lights

    EBU00043 EBU00053 Indicator lights Handlebar switches 1. Reverse indicator light “R” 1. Light switch “OFF/ ” 2. Neutral indicator light “N” 2. Engine stop switch “ ” 3. Start switch “ ” EBU12500 EBU12050 Reverse indicator light “R” Engine stop switch “ ”...
  • Page 25 EBU12040 EBU06070 Light switch “OFF/ ” Start switch “ ” Set the switch to “ ” to turn on the low beam The starter motor cranks the engine when this and the taillight. switch is pushed. Set the switch to “ ”...

  • Page 26: Throttle Lever

    If it does not ver is released. work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. 1. Throttle lever...

  • Page 27: Speed Limiter

    EBU11590 Speed limiter WARNING The speed limiter keeps the throttle from fully POTENTIAL HAZARD opening, even when the throttle lever is Improper adjustment of the speed limit- pushed to the maximum. Turning in the ad- er and throttle. justing screw limits the maximum engine pow- WHAT CAN HAPPEN er available and decreases the maximum The throttle cable could be damaged.

  • Page 28: Front Brake Lever

    EBU00070 EBU00732 Front brake lever Brake pedal and rear brake lever The front brake lever is located on the right The brake pedal is located on the right side of handlebar. Pull it toward the handlebar to ap- the ATV and the rear brake lever is located on ply the front brake.
  • Page 29 1. Rear brake lever...

  • Page 30: Parking Brake

    EBU00074 Parking brake WARNING Use the parking brake when you have to start POTENTIAL HAZARD the engine or park the machine, especially on Improper use of the parking brake. a slope. Apply the rear brake lever and push WHAT CAN HAPPEN down the lock plate to apply the parking The ATV could start moving unexpect- brake.

  • Page 31: Shift Pedal

    EBU00083 EBU00085 Shift pedal Drive select lever This machine is equipped with a constant- The drive select lever is used for driving the mesh 5-speed transmission. The shift pedal is machine either forward or in reverse. Refer to located on the left side of the engine. Neutral page 6-4 for drive select lever operation.

  • Page 32: Recoil Starter

    EBU00590 Recoil starter WARNING Firmly grasp the handle and pull slightly until POTENTIAL HAZARD engagement can be felt. Then pull forcefully, Starting the engine in gear and/or start- being careful not to pull the rope all the way ing the engine without setting the park- out.

  • Page 33: Fuel Tank Cap

    EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun- terclockwise. 1. Fuel tank cap 4-11...

  • Page 34: Fuel Cock

    EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor.

  • Page 35: Starter (Choke)

    EBU00950 Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke).

  • Page 36: Seat

    EBU00567 Seat To install the seat, insert the projections on To remove the seat, pull the seat lock lever the front of the seat into the seat holders and upward and pull up the seat at the rear. push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted.

  • Page 37: Storage Compartment

    EBU10620 Storage compartment The storage compartment is located under the seat. (See page 4-14 for seat removal and installation procedures.) When storing any documents in the storage compartment, be sure to wrap them in a plas- tic bag so that they will not get wet. When washing the ATV, be careful not to let any wa- ter enter the storage compartment.

  • Page 38: Front Carrier

    NOTE: A special wrench can be obtained at a The spring preload can be adjusted to suit the Yamaha dealer to make this adjustment. rider’s weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the ad- justing ring in direction a.
  • Page 39 1. Special wrench Standard position: 2 1 - Minimum (soft) 5 - Maximum (hard) EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death. 4-17...

  • Page 40: Pre-Operation Checks

    P RE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE • Check operation, free play, fluid level and fluid leakage. Front brake 5-3–5-4, 8-26–8-29 • Fill with DOT 4 brake fluid if necessary. • Check operation, condition and free play. 5-3–5-4, 8-26, Rear brake •...
  • Page 41 WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op- erating condition.

  • Page 42: Front And Rear Brakes

    Brake operation should be a firm feeling when the brake is Test the brakes at slow speed after starting applied. If not, have a Yamaha dealer in- out to make sure they are working properly. If spect them. the brakes do not provide proper braking per-...
  • Page 43 Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the ad- justment procedures provided in this manual, have a Yamaha dealer check for the cause.

  • Page 44: Fuel

    EBU01085 Fuel Your Yamaha engine has been designed to Make sure there is sufficient gasoline in the use regular unleaded gasoline with a pump tank. octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If...
  • Page 45 Fuel can spill, which can cause a fire hol containing methanol is not recommended and severe injury. by Yamaha because it may cause fuel system Fuel expands when it heats up. If the damage or vehicle performance problems. fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun.

  • Page 46: Engine Oil

    Recommended engine oil type and Check to see that the throttle lever operates quantity: correctly. It must open smoothly and spring See page 10-2. back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation.

  • Page 47: Fittings And Fasteners

    EBU11620 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. EBU10030 Lights Check the headlights and tail/brake light to make sure they are in working condition.

  • Page 48: Tires

    HOW TO AVOID THE HAZARD specified could cause the tire to 1. The tires listed below have been ap- dislodge from the rim under severe proved by Yamaha Motor Co., Ltd. riding conditions. for this model. Other tire combina- The following are minimums: tions are not recommended.
  • Page 49 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm , 36 psi) Rear 250 kPa (2.5 kgf/cm , 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully.

  • Page 50: How To Measure Tire Pressure

    EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measure- ments of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.

  • Page 51: Tire Wear Limit

    EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit 5-12...

  • Page 52: Operation

    Read the Owner’s Manual carefully. If 3. Turn the main switch to “ON” and the en- there is a control or function you do not gine stop switch to “ ”. understand, ask your Yamaha dealer. 4. Shift the transmission into neutral.
  • Page 53 25°C (80°F) and warm engine the light does not come on, ask a start position. Yamaha dealer to inspect it. The engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral be- fore starting the engine.

  • Page 54: Starting A Warm Engine

    NOTE: CAUTION: If the engine fails to start, release the See the “Engine break-in” section prior to start switch, then push the start switch operating the engine for the first time. again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery en- EBU00180 ergy.

  • Page 55: Drive Select Lever Operation And Reverse Driving

    1. Bring the ATV to a complete stop and re- should be on. If the light does not come on, turn the throttle lever to the closed posi- ask a Yamaha dealer to inspect the ATV. tion. 2. Apply the brake pedal.

  • Page 56: Shifting

    EBU02000 Shifting WARNING This model has a 5-speed forward transmis- POTENTIAL HAZARD sion with centrifugal automatic clutch. The Improperly operating in reverse. transmission allows you to control the amount WHAT CAN HAPPEN of power you have available at a given speed You could hit an obstacle or person be- or for starting accelerating, climbing, etc.

  • Page 57: To Start Out And Accelerate

    4. Once the machine has attained adequate CAUTION: speed, release the throttle lever. Do not coast for long periods with the en- 5. Shift into second gear and release the gine off, and do not tow the machine a shift pedal. long distance.

  • Page 58: To Decelerate

    EBU00207 EBU02092 To decelerate: Engine break-in When slowing down or stopping, release the There is never a more important period in the throttle and apply the brakes smoothly and life of your machine than the period between evenly. As you slow down, shift to a lower zero and 20 hours.

  • Page 59: Parking

    EBU00211 If any abnormality is noticed during this peri- Parking od, consult a Yamaha dealer. When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF” and apply 0–10 hours: the parking brake. Avoid continuous operation above half throt- tle.

  • Page 60: Parking On A Slope

    EBU12960 Parking on a slope 1. Bring the ATV to a stop by applying the brakes in low gear. WARNING 2. Stop the engine. POTENTIAL HAZARD 3. With the rear brake lever and pedal ap- Parking on a hill or other incline. plied, apply the parking brake and slowly WHAT CAN HAPPEN release the brake pedal.

  • Page 61: Accessories And Loading

    Choose only accessories designed for your dlebars which could make steering difficult, ATV. Your Yamaha dealer has a variety of an accessory that limits your ability to move genuine Yamaha accessories. Other ac-...
  • Page 62 EBU15510 Loading Do not exceed the maximum tongue Cargo or a trailer can change the stability and weight. You can measure tongue weight handling of an ATV. with a bathroom scale. Put the tongue of You must use common sense and good judg- the loaded trailer on the scale with the ment when carrying cargo or towing a trailer.
  • Page 63 Ride more slowly than you would without a WARNING load. The more weight you carry, the slow- POTENTIAL HAZARD er you should go. Although conditions vary, Overloading this ATV or carrying or tow- it is good practice not to exceed 2nd gear ing cargo improperly.
  • Page 64 EBU15540 WARNING Indicates a potential hazard that could result in serious injury or death. 6-13...

  • Page 65: Riding Your Atv

    R iding Your...

  • Page 66: Getting To Know Your Atv

    WARNING Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV Owner’s Manual completely and understand This ATV is for recreation and utility use. This the operation of the controls. Pay particular at- section, Riding your ATV, provides general tention to the safety information on pages ATV riding instructions for recreational riding.

  • Page 67: Ride With Care And Good Judgement

    JUDGEMENT Beginning and inexperienced operators should complete the certified training Get training if you are inexperienced. course offered by Yamaha. They should Beginners should get training from a certified then regularly practice the skills learned instructor. in the course and the operating tech- Become familiar with this ATV at slow speeds niques described in this Owner’s Manu-...
  • Page 68 Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommenda- tions for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended for their age can lead to se- vere injury or death of the child.
  • Page 69 This ATV is designed to carry operator and cargo only - passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger.
  • Page 70 Apparel Operating without protective clothing WARNING increases your chances of severe injury in the event of an accident. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an Always wear an approved motorcycle approved motorcycle helmet, eye pro- helmet that fits properly.
  • Page 71 Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator’s performance capability is reduced Operating this ATV after consuming al- by the influence of alcohol or drugs. cohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly.
  • Page 72 Pre-operation checks WARNING Always perform the pre-operation checks list- POTENTIAL HAZARD ed on page 5-1 before riding for safety and Operating this ATV with improper tires, proper care of the ATV. or with improper or uneven tire pres- WARNING sure. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before oper-...
  • Page 73 Speed limiter WARNING For riders less experienced with this model, Indicates a potential hazard that could this model is equipped with a speed limiter in result in serious injury or death. the throttle lever housing. The speed limiter keeps the throttle from fully opening, even Do not operate at speeds too fast for your when the throttle lever is pushed to the maxi- skills or the conditions.
  • Page 74 Loading and accessories WARNING Use extra caution when riding the ATV with POTENTIAL HAZARD additional loads, such as accessories or car- Overloading this ATV or carrying or tow- go. The ATV’s handling may be adversely af- ing cargo improperly. fected. Reduce your speed when adding WHAT CAN HAPPEN additional loads.
  • Page 75 During operation WARNING Always keep your feet on the footboards dur- POTENTIAL HAZARD ing operation. Otherwise your feet may con- Removing hands from handlebars or tact the rear wheels. feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re- duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
  • Page 76 Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, in- cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.
  • Page 77 Never modify this ATV through improp- er installation or use of accessories. All parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized ATV dealer.
  • Page 78 Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system.

  • Page 79: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of con-...
  • Page 80 Do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or...
  • Page 81 Know the terrain where you ride. Ride cau- tiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and oth- er hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 82 WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an acci- dent, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills neces-...
  • Page 83 When riding in an area where you might not WHAT CAN HAPPEN easily be seen, such as desert terrain, mount You could be in a collision. You could a caution flag on the ATV. DO NOT use the be injured. flag pole bracket as a trailer hitch.
  • Page 84 Select a large, flat area off-road to become fa- With the engine idling, lift the shift pedal to the miliar with your ATV. Make sure that this area 1st gear position and then release the parking is free of obstacles and other riders. You brake.
  • Page 85 CAUTION: WARNING Do not shift gears without releasing the POTENTIAL HAZARD throttle. Damage to the engine or drive Engaging a lower gear when the engine train may occur. speed is too high. WHAT CAN HAPPEN When slowing down or stopping, release the The wheels could stop rotating.

  • Page 86: Turning Your Atv

    TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for road, the two rear wheels are mounted solidly turning as described in this Owner’s on one axle and turn together at the same Manual.
  • Page 87 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 movements, or too much speed for the sharpness of the turn may cause the ATV to tip.

  • Page 88: Climbing Uphill

    CLIMBING UPHILL HOW TO AVOID THE HAZARD Use proper riding techniques to avoid vehicle Never operate the ATV on hills too steep overturns on hills. Be sure that you can ma- for the ATV or for your abilities. neuver your ATV well on flat ground before at- Practice on smaller hills before attempt- tempting any incline and then practice riding ing large hills.
  • Page 89 WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other POTENTIAL HAZARD side of the hill. Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Own- er’s Manual.
  • Page 90 If you are climbing a hill and you find that you When crossing the side of a hill: have not properly judged your ability to make Always follow proper procedures as de- it to the top, you should turn the ATV around scribed in the Owner’s Manual.
  • Page 91 If your ATV has stalled or stopped and you WARNING believe you can continue up the hill, restart POTENTIAL HAZARD carefully to make sure you do not lift the front Stalling, rolling backwards or improper- wheels which could cause you to lose control. ly dismounting while climbing a hill.
  • Page 92 Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the pro- cedure described in the Owner’s Manu- 7-29...

  • Page 93: Riding Downhill

    RIDING DOWNHILL WARNING When riding your ATV downhill, shift your POTENTIAL HAZARD weight as far to the rear and uphill side of the Going down a hill improperly. ATV as possible. Move back on the seat and WHAT CAN HAPPEN sit with your arms straight.
  • Page 94 7-31...

  • Page 95: Crossing A Slope

    CROSSING A SLOPE If your ATV does begin to tip over, gradually Traversing a sloping surface on your ATV re- steer in the downhill direction if there are no quires you to properly position your weight to obstacles in your path. As you regain proper maintain proper balance.
  • Page 96 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. 7-33...

  • Page 97: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have re- The ATV can be used to cross slow moving, duced stopping ability. Test your brakes shallow water of up to a maximum of 35 cm after leaving water. If necessary, apply (14 in) in depth.
  • Page 98 Test your brakes after leaving the water. Do CAUTION: not continue to ride your ATV without verifying After riding your ATV in water, be sure to that you have regained proper braking ability. drain the trapped water by removing the check hose at the bottom of the air filter case, the drive select lever box check hose, and the storage compartment check...

  • Page 99: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result.

  • Page 100: Sliding And Skidding

    SLIDING AND SKIDDING WARNING Care should be used when riding on loose or POTENTIAL HAZARD slippery surfaces since the ATV may slide. If Improperly operating over obstacles. unexpected and uncorrected, sliding could WHAT CAN HAPPEN lead to an accident. Could cause loss of control or a colli- To reduce the tendency for the front wheels to sion.
  • Page 101 If the rear wheels of your ATV start to slide With practice, over a period of time, skill at sideways, control can usually be regained (if controlled sliding can be developed. The ter- there is room to do so) by steering in the direc- rain should be chosen carefully before at- tion of the slide.

  • Page 102: What To Do If

    WHAT TO DO IF ... WARNING This section is designed to be a reference POTENTIAL HAZARD guide only. Be sure to read each section on Skidding or sliding improperly. riding techniques completely. WHAT CAN HAPPEN You may lose control of this ATV. You WHAT TO DO ...
  • Page 103 If your ATV starts to slide sideways: If your ATV is traversing a sloping surface: Steer in the direction of the slide if you have Be sure to ride with your weight positioned the room. towards the uphill side of the ATV to main- Applying the brakes or accelerating is not tain proper balance.

  • Page 104: Periodic Maintenance And Adjustment

    EBU00515 P ERIODIC MAINTENANCE AND Have a Yamaha dealer perform service if ADJUSTMENT you are not familiar with machine service. Periodic inspection, adjustment and lubrica- tion will keep your machine in the safest and most efficient condition possible. Safety is an EBU14510 obligation of the machine owner.
  • Page 105 HOW TO AVOID THE HAZARD during a service operation requiring one, take Never modify this ATV through improp- your machine to a Yamaha dealer to check er installation or use of accessories. All the torque settings and adjust them as neces- parts and accessories added to this ve- sary.

  • Page 106: Periodic Maintenance/Lubrication

    EBU02611 PERIODIC MAINTENANCE/LUBRICATION NOTE: For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. How- ever, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
  • Page 107 INITIAL EVERY month Whichever ITEM ROUTINE comes first 1,200 2,400 2,400 4,800 (mi) (200) (750) (1,500) (1,500) (3,000) hours Engine oil • Replace (Warm engine before draining). Engine oil filter element • Clean. Engine oil strainer • Clean. • Check oil level/oil leakage. Final gear oil •...
  • Page 108 • Correct if necessary. • Check operation. Lights and switches* • Adjust headlight beams. It is recommended that these items be serviced by a Yamaha dealer. NOTE: • Recommended brake fluid: DOT 4 • Brake fluid replacement: 1. When disassembling the master cylinder or cali- per, replace the brake fluid.

  • Page 109: Engine Oil And Oil Filter Element

    EBU11004 Engine oil and oil filter element 5. If the engine oil is at or below the mini- The engine oil level should be checked before mum level mark, add sufficient oil of the each ride. In addition, the oil must be changed recommended type to raise it to the cor- and the oil filter element cleaned at the inter- rect level.
  • Page 110 To change the engine oil (with or without oil filter element cleaning) 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes, and then turn it off. 3. Place a container under the engine to collect the used oil.
  • Page 111 5. Remove the footboard by removing the 6. Loosen the brake pedal free play adjust- bolts. ing nut, and then remove the oil filter ele- ment cover bolts. 1. Footrest 2. Bolt (× 8) 1. Adjusting nut (brake rod)
  • Page 112 7. Remove the oil filter element cover and oil filter element. NOTE: To remove or install the oil filter element cover and oil filter element, move the select lever safety system cable away from the cover. CAUTION: Do not loosen the adjusting nuts shown when removing the oil filter element cover 1.
  • Page 113 8. Clean the oil strainer and oil filter element CAUTION: with solvent. Before installing the engine oil drain bolt, 9. Check the O-ring for damage and re- be sure to install the O-ring, compression place it if necessary. spring and oil strainer. NOTE: Make sure the O-ring is seated properly.
  • Page 114 CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a high- er quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II”...

  • Page 115: Final Gear Oil

    EBU11453 Final gear oil Checking the final gear oil 1. Place the ATV on a level surface. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. NOTE: The oil level should be at the brim of the filler hole.
  • Page 116 Replacing the final gear oil 2. Place the ATV on a level surface. 1. Remove the final gear case cover by re- 3. Place a container under the final gear moving the bolts. case to collect the used oil. 4. Remove the oil filler bolt and the drain bolt to drain the oil.
  • Page 117 6. Add the recommended final gear oil to 9. Install the final gear case cover bolts, and the brim of the filler hole. then tighten them to the specified torque. Recommended oil: Tightening torque: SAE 80 API GL-4 Hypoid gear oil Final gear case cover bolt: Oil quantity: 17 Nm (1.7 m·kgf, 12 ft·lbf)

  • Page 118: Spark Plug Inspection

    EBU14550 Spark plug inspection 2. Use the spark plug wrench in the owner’s Removal tool kit to remove the spark plug as 1. Remove the spark plug cap. shown. 1. Spark plug cap 1. Spark plug wrench 8-15...
  • Page 119 ATV that is being ridden normally. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.
  • Page 120 2. Clean the surface of the spark plug gas- ket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug and tighten it to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.5 ft·lbf) NOTE: If a torque wrench is not available when you...

  • Page 121: Air Filter Element Cleaning

    EBU13010 Air filter element cleaning 1. Remove the seat. (See page 4-14 for seat removal and installation proce- NOTE: dures.) There is a check hose at the bottom of the air 2. Remove the air filter case cover by un- filter case.
  • Page 122 3. Pull the air filter element out. 4. Remove the foam cover from the air filter element. 1. Air filter element 2. Foam cover 1. Air filter element 8-19...
  • Page 123 5. Tap the element lightly to remove most of WARNING the dust and dirt. Blow out the remaining POTENTIAL HAZARD dirt with compressed air as shown. If the Using low flash point solvents or gaso- air filter element is damaged, replace it. line to clean the foam cover.
  • Page 124 10. Install the air filter element. CAUTION: 11. Install the air filter case cover by fasten- Never operate the engine with the air filter ing the holders. element removed. This will allow unfiltered 12. Install the seat. air to enter, causing rapid engine wear and NOTE: possible engine damage.

  • Page 125: Spark Arrester Cleaning

    EBU13620 Spark arrester cleaning 3. Stop the engine and allow the exhaust Select a well-ventilated area free of combusti- pipe to cool. ble materials and make sure the exhaust pipe 4. Install the purging bolt and tighten it. and muffler are cool. 1.

  • Page 126: Carburetor Adjustment

    The carburetor is a vital part of the engine and POTENTIAL HAZARD requires very sophisticated adjustment. Most Improperly purging the exhaust system. adjusting should be left to a Yamaha dealer Hot exhaust system. who has the professional knowledge and ex- WHAT CAN HAPPEN perience to do so.

  • Page 127: Idle Speed Adjustment

    To prevent this, the valve clear- tion b to decrease the engine speed. ance must be adjusted regularly. This adjust- ment however, should be left to a professional Specified idle speed: Yamaha service technician. 1,400–1,500 r/min 8-24...

  • Page 128: Throttle Lever Adjustment

    This adjustment, however, should be left 1. Loosen the locknut. to a Yamaha dealer. 2. Turn the adjusting bolt until the throttle le- ver free play is 3.0–5.0 mm (0.12– 0.20 in).

  • Page 129: Front Brake Pad Check

    If the indicator reaches the wear limit line, ask a Yamaha dealer to replace shoes as a set. 1. Brake pad (× 2) a. Brake pad thickness...

  • Page 130: Brake Fluid Level Check

    EBU13040 Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indi- cate worn brake pads and/or brake system leakage.

  • Page 131: Brake Fluid Replacement

    EBU11870 Have a Yamaha dealer check the cause if Front brake lever free play the brake fluid level goes down. The front brake lever should have a free play of zero mm (zero in) at the lever end. If not,...
  • Page 132 Make sure the brakes do not drag. Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components re- quires professional knowledge. These procedures should be performed by a Yamaha dealer. 8-29...

  • Page 133: Adjusting The Brake Pedal And Rear Brake Lever

    EBU15432 Adjusting the brake pedal and rear brake Adjusting the brake pedal free play lever 1. Fully loosen the brake cable adjusting Adjusting the brake pedal height nut. 1. Remove the footboard. (See page 8-8.) 2. Loosen the adjusting bolt locknuts. 3.
  • Page 134 2. Turn the adjusting nut on the brake rod Adjusting the rear brake lever free play until the free play is 20.0–30.0 mm (0.79– 1. Loosen the locknut and fully turn in the 1.18 in). adjusting bolt at the brake lever. a.
  • Page 135 2. Turn in the adjusting nut on the brake ca- 3. Turn the adjusting bolt until the free play ble to provide a gap of 0–1 mm (0– at the brake lever pivot is 5.0–7.0 mm 0.04 in) between the lever and the pin. (0.20–0.28 in).
  • Page 136 After servicing: Make sure the brakes operate smoothly and that the free play is correct. Make sure the brakes do not drag. Replacement of brake components re- quires professional knowledge. These procedures should be performed by a Yamaha dealer. 8-33...

  • Page 137: Adjusting The Rear Brake Light Switch

    EBU15420 Adjusting the rear brake light switch 2. Turn the adjusting nut while holding the The rear brake light switch, which is activated rear brake light switch in place. To make by the brake pedal and rear brake lever, is the brake light come on earlier, turn the adjusting nut in direction a.

  • Page 138: Clutch Adjustment

    EBU15470 Clutch adjustment NOTE: Turn the adjusting bolt counterclockwise to 1. Remove the footboard. (See page 8-8.) decrease the clutch free play and turn it clock- 2. Loosen the locknut. wise to increase the free play. 3. Slowly turn the adjusting bolt counter- clockwise until resistance is felt.

  • Page 139: Brake Lever And Brake Pedal Lubrication

    Brake lever and brake pedal lubrication If the cables do not operate smoothly, ask a Lubricate the pivoting parts. Yamaha dealer to replace them. Recommended lubricant: Recommended lubricant: Lithium-soap-based grease Yamaha chain and cable lube or (all-purpose grease) SAE 10W30 motor oil 8-36...

  • Page 140: Steering Shaft Lubrication

    EBU14060 Steering shaft lubrication Lubricate the pivot point with a grease gun. Recommended lubricant: Lithium-soap-based grease (all purpose grease) 1. Grease nipple 8-37...

  • Page 141: Wheel Removal

    EBU01112 EBU11211 Wheel removal Wheel installation 1. Loosen the wheel nuts. 1. Install the wheel and the nuts. 2. Elevate the ATV and place a suitable NOTE: stand under the frame. The arrow mark on the tire must point 3. Remove the nuts from the wheel. toward the rotating direction of the wheel.
  • Page 142 1. Tapered nut 2. Lower the ATV so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf) 8-39...

  • Page 143: Battery

    EBU00378 Battery Check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low. CAUTION: Do not leave or store the battery on its side. When inspecting the battery, be sure the breather hose is routed correctly.
  • Page 144 WARNING EYES: Flush with water for 15 minutes and get prompt medical attention. Keep POTENTIAL HAZARD batteries away from sparks, flames, cig- Failure to handle batteries or battery arettes or other sources of ignition. Ven- electrolyte carefully. tilate when charging or using in a closed WHAT CAN HAPPEN space.

  • Page 145: Replenishing The Battery Fluid

    EBU15400 Replenishing the battery fluid 2. The electrolyte level should be between A poorly maintained battery will corrode and the upper and lower level marks. Use discharge quickly. The battery fluid should be only distilled water if refilling is neces- checked at least once a month.
  • Page 146 3. Disconnect the negative (-) lead. 4. Disconnect the positive (+) lead. 5. Remove the battery bracket bolts, brack- et and battery. 6. When the ATV is not to be used for a month or longer, remove the battery and store it in a cool, dark place.

  • Page 147: Fuse Replacement

    Then turn on the switch- An improper fuse can cause damage to es. If the fuse immediately blows again, the electrical system which could lead consult a Yamaha dealer. to a fire. Specified fuse: 20.0 A HOW TO AVOID THE HAZARD Always use a fuse of the specified rat- ing.

  • Page 148: Replacing A Headlight Bulb

    EBU14560 Replacing a headlight bulb 2. Remove the headlight bulb holder by If a headlight bulb burns out, replace it as fol- turning it counterclockwise. lows. 1. Remove the bulb holder cover at the rear of the headlight by pulling it off. 1.
  • Page 149 3. Remove the defective bulb by unhooking WARNING the headlight bulb holder tabs. POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flamma- ble.
  • Page 150 4. Insert a new headlight bulb into the bulb CAUTION: holder, and then secure the bulb by Do not touch the glass part of the head- hooking the tabs onto the bulb. light bulb to keep it free from oil, otherwise the transparency of the glass, the luminos- ity of the bulb, and the bulb life will be ad- versely affected.

  • Page 151: Headlight Beam Adjustment

    Tail/brake light bulb replacement 1. Remove the bulb holder (together with CAUTION: the bulb) by turning it counterclockwise. It is advisable to have a Yamaha dealer make this adjustment. To raise the beam, turn the adjusting screw in direction a.
  • Page 152 1. Bulb holder 2. Bulb 3. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 4. Install the bulb holder (together with the bulb) by turning it clockwise. 8-49...

  • Page 153: Troubleshooting

    EBU00412 Troubleshooting WARNING Although Yamaha machines receive a rigid in- POTENTIAL HAZARD spection before shipment from the factory, Checking the fuel system while smok- trouble may occur during operation. Any prob- ing or near an open flame. lem in the fuel, compression, or ignition sys-...

  • Page 154: Troubleshooting Chart

    Clean fuel cock. 2. Compression There is compression. Compression normal. Use electric starter to see if there is compression. Ask a Yamaha dealer to No compression. inspect. 3. Ignition Wipe clean with dry cloth. Ignition system Spark good. normal. Remove spark plug and check electrodes.

  • Page 155: Cleaning And Storage

    EBU00419 CLEANING AND STORAGE CAUTION: Excessive water pressure may cause wa- A. CLEANING ter seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend bills have resulted from improper high the useful life of many components.
  • Page 156 6. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after wash- 7. Automotive type wax may be applied to ing. all painted and chrome plated surfaces. WHAT CAN HAPPEN Avoid combination cleaner-waxes.

  • Page 157: Storage

    Do not apply oil to any rubber parts or the seat cover. NOTE: Use of fuel stabilizer and conditioner elimi- nates the need to drain the fuel system. Con- sult a Yamaha dealer if the fuel system needs to be drained instead.
  • Page 158 7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an ex- cessively warm or cold place (less than 0°C (30°F) or more than 30°C (90°F)). NOTE: Make any necessary repairs before storing the machine.

  • Page 159: Specifications

    EBU00428 S PECIFICATIONS MODEL YFM250B Dimension: Overall length 1,916 mm ( 75.4 in) Overall width 1,038 mm ( 40.9 in) Overall height 1,118 mm ( 44.0 in) Seat height 772 mm ( 30.4 in) Wheel base 1,170 mm ( 46.1 in) Minimum ground clearance 150 mm ( 5.91 in) Minimum turning radius...

  • Page 160: Recommended Engine Oil Classification

    MODEL YFM250B Engine oil: 0˚ 10˚ 30˚ 70˚ 90˚ 110˚ 130˚F 50˚ Type YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C Recommended engine oil classification: API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the en- gine oil also lubricates the clutch), do not mix any...
  • Page 161 MODEL YFM250B Final gear case oil: Type SAE 80 API GL-4 Hypoid gear oil Quantity: Periodic oil change 0.25 L (0.22 Imp qt, 0.26 US qt) Air filter: Dry element Fuel: Type UNLEADED GASOLINE ONLY Tank capacity 12.0 L (2.64 Imp gal, 3.17 US gal) Reserve amount 1.6 L (0.35 Imp gal, 0.42 US gal) Carburetor:...
  • Page 162 MODEL YFM250B Gear ratio: 34/12 (2.833) 34/19 (1.789) 29/22 (1.318) 26/25 (1.040) 23/28 (0.821) × × Reverse 73/22 34/12 19/18 (9.924) Chassis: Frame type Steel tube frame ° Caster angle Trail 20.0 mm (0.79 in) Tire: Type Tubeless AT22 × 7.00-10 Size: Front AT22 ×...
  • Page 163 MODEL YFM250B Wheel travel: Front 125.0 mm (4.92 in) Rear 135.0 mm (5.31 in) Electrical: Ignition system DC. C.D.I. Generator system A.C. magneto Battery type/voltage, capacity CB14A-A2/12V 14.0 Ah Headlight type: Incandescence Bulb voltage, wattage × quantity: 12 V 30 W/30.0 W × 2 Headlight 12 V 5 W/21.0 W ×...

  • Page 164: Noise Regulation

    EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 165: Maintenance Record

    EBU13653 M AINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

  • Page 166: Atv Limited Warranty

    EBU00432 Y AMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1...
  • Page 167 13-2...

  • Page 168: Yamaha Extended Service (Y.e.s.)

    EBU00435 Y AMAHA EXTENDED SERVICE (Y.E.S.) 14-1...
  • Page 169 14-2...
  • Page 170 EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death.
  • Page 171 EBU00437...
  • Page 172 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN USA 2004.06-2.6×1 CR...

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