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Yamaha YFM35FGW Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM35FGW
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-20-18
5UH-F8199-14

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Summary of Contents for Yamaha YFM35FGW

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35FGW WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-20-18 5UH-F8199-14...
  • Page 2 EBU17091...
  • 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 craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 4 EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 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: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or...
  • Page 5 EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 6: Table Of Contents

    Front brake lever .........4-7 EWB00010 WARNING Brake pedal and rear brake lever ....4-7 Parking brake ..........4-8 Indicates a potential hazard that could result in serious injury or death. Drive select lever ........4-9 Recoil starter ..........4-9 Fuel tank cap ..........4-10 Fuel ............4-10 EBU17420 Fuel cock ..........4-12 TABLE OF CONTENTS...
  • Page 7 Measuring the tire pressure ....... 5-6 SLIDING AND SKIDDING ......7-31 Tire wear limit ..........5-7 WHAT TO DO IF........7-32 Chassis fasteners ........5-7 WHAT TO DO..........7-32 Instruments, lights and switches ....5-7 PERIODIC MAINTENANCE AND MINOR OPERATION ..........6-1 REPAIR ............8-1 Starting a cold engine ........
  • Page 8 Checking and lubricating the brake Noise regulation ........11-3 pedal ............8-36 Maintenance record ........11-4 Checking the wheel bearings ....8-37 YAMAHA MOTOR CORPORATION, Lubricating the drive shaft universal U.S.A. ATV LIMITED WARRANTY ..11-5 joint ............8-37 YAMAHA EXTENDED SERVICE Lubricating the upper and lower arm (Y.E.S.) ...........11-7...

  • Page 9: Safety Information

    EBU17430 SAFETY INFORMATION EBU17542 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 10 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 11 roll backwards, follow the special procedure for Always be sure there are no obstacles or people braking described in this manual. Dismount on behind you when you operate in reverse. When the uphill side or to a side if pointed straight up- it is safe to proceed in reverse, go slowly.
  • Page 12 EWB00021 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- POTENTIAL HAZARD oline in your eyes, seek medical help Improper handling of gasoline. immediately. If gasoline spills on your skin, WHAT CAN HAPPEN wash with soap and water.
  • Page 13 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 ad- equate ventilation.

  • Page 14: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 15 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. WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident.

  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Fuel cock 1. Rear shock absorber assembly spring preload adjusting ring 2. Throttle stop screw 2. Spark arrester 3. Air filter case 3. Storage compartment and tool kit 4. Fuses 4. Spark plug 5.

  • Page 19: Controls And Instruments

    EBU17712 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Parking brake lock plate 5. Drive select lever 6. Main switch 7. Fuel tank cap 8. On-Command four-wheel-drive switch 9. Throttle lever 10.Front brake lever NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 20: Instrument And Control Functions

    EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light 1.

  • Page 21: Indicator Lights And Warning Light

    1. Neutral indicator light “N” cool. If the warning light stays on when the engine 2. Reverse indicator light “R” is cool, have a Yamaha dealer check the electrical 3. On-Command four-wheel-drive indicator light “ ” 4. Oil temperature warning light “...

  • Page 22: Handlebar Switches

    EBU17952 EBU18080 On-Command four-wheel-drive indicator light Engine stop switch “ ” “ ” Set this switch to “ ” before starting the engine. This indicator light comes on when the On-Com- The engine stop switch controls the ignition and mand four-wheel-drive switch is set to the “4WD” stops the engine when it is running.
  • Page 23 ECB00040 CAUTION: Do not use the headlights with the engine turned off for an extended period of time, oth- erwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it.

  • Page 24: Throttle Lever

    EWB00120 Regulate the speed of the ATV by varying the WARNING throttle position. Because the throttle is spring- loaded, the ATV will decelerate, and the engine will POTENTIAL HAZARD return to an idle any time the hand is removed from Changing from two-wheel drive to four- the throttle lever.

  • Page 25: Speed Limiter

    If it does not 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. Locknut 2. Adjusting screw EBU18311 3.

  • Page 26: Front Brake Lever

    EWB00190 WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result. You could lose control, have an accident or be in- jured. HOW TO AVOID THE HAZARD 1.

  • Page 27: Parking Brake

    EBU18450 Parking brake Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. 1.

  • Page 28: Drive Select Lever

    EWB00170 WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start- ing the engine. This could cause loss of con- trol or a collision. The brake could overheat if you ride the ATV without releasing the parking brake.

  • Page 29: Fuel Tank Cap

    EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Recoil starter EWB00300 WARNING POTENTIAL HAZARD 1. Fuel tank cap Starting the engine without shifting into the EBU18730 neutral position. Fuel WHAT CAN HAPPEN Make sure that there is sufficient fuel in the tank. The ATV could start to move unexpectedly, Fill the fuel tank to the bottom of the filler tube as which could cause an accident.
  • Page 30 Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher.

  • Page 31: Fuel Cock

    WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank.

  • 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: Seat

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Seat 2. Seat lock lever To install the seat Insert the projections on the front of the seat into 1.

  • Page 34: Storage Compartment

    1. Projection 1. Storage compartment 2. Seat holder Do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment. EBU18911 Storage compartment Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. ECB00130 CAUTION: NOTE:...

  • Page 35: Front Carrier

    EBU18980 Adjusting the front shock absorber as- semblies The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspen- sion, and in direction (b) to decrease the spring preload and thereby soften the suspension.

  • Page 36: Adjusting The Rear Shock Absorber Assembly

    EWB00350 NOTE: WARNING A special wrench can be obtained at a Yamaha POTENTIAL HAZARD dealer to make this adjustment. Improper shock absorber assembly adjust- ment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident.
  • Page 37 1. Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: Maximum (hard): EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.

  • Page 38: Pre-Operation Checks

    Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 39 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary. 5-4, 8-27 • Check cable free play, and adjust if necessary. Control cables • Make sure that operation is smooth. Lubricate if necessary. 8-35 •...

  • Page 40: Fuel

    Check that there is no free play in the front brake HOW TO AVOID THE HAZARD lever. If there is free play, have a Yamaha dealer Do not overfill the fuel tank. Be careful not to check the brake system.

  • Page 41: Throttle Lever

    If a problem cannot be corrected by the adjustment procedures pro- Brake fluid leakage (front brake) vided in this manual, have a Yamaha dealer Check to see if any brake fluid is leaking out of the check for the cause.

  • Page 42: Tires

    HOW TO AVOID THE HAZARD Rear: The tires listed below have been approved 25.0 kPa (3.6 psi) (0.250 kgf/cm²) by Yamaha Motor Manufacturing Corpora- • Check and adjust tire pressures when tion of America for this model. Other tire the tires are cold.

  • Page 43: Specifications

    Tire pressure below the minimum speci- NOTE: fied could cause the tire to dislodge from The low-pressure tire gauge is included as stan- the rim under severe riding conditions. dard equipment. Make two measurements of the Minimum tire pressure: tire pressure and use the second reading. Dust or Front: dirt in the gauge could cause the first reading to be 22.0 kPa (3.2 psi) (0.220 kgf/cm²)

  • Page 44: Tire Wear Limit

    Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Tire wear limit Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) EBU19840 Chassis fasteners Rear...

  • Page 45: Operation

    Read the Owner’s Manual carefully. If there is prior to operating the engine for the first time. a control or function you do not understand, ask your Yamaha dealer. 1. Set the parking brake. 2. Turn the fuel cock to “ON”.
  • Page 46 4. Shift the drive select lever into the neutral po- Ambient temp./starter (choke) position sition. The neutral indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical cir- cuit. NOTE: The engine can be started under the following con- ditions: The drive select lever is in the neutral position.

  • Page 47: Starting A Warm Engine

    If the battery is discharged, pull the recoil starter EBU20291 Starting a warm engine to start the engine. Follow the same procedure as for starting a cold 7. If the engine is started with the starter (choke) engine, with the exception that the starter (choke) in position (1), the starter (choke) should be is not required when the engine is warm.
  • Page 48 NOTE: When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 1. Drive select lever 2. F (Forward) 3. N (Neutral) 4. R (Reverse) 3.

  • Page 49: 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 20 hours of riding. For Yamaha dealer check the ATV. this reason, you should read the following material carefully.

  • Page 50: Parking On A Slope

    HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV transversely across the incline, shift the drive select lever to the forward position, stop the engine, apply the parking brake, and then block the front and rear wheels with rocks or other objects.

  • Page 51: Accessories And Loading

    Keep the may also be available on the market. However, following points in mind: it is not possible for Yamaha to test all non- Never exceed the weight limits shown. An over- Yamaha accessories, nor control over their qual-...
  • Page 52 Load cargo on the carriers as close to the center MAXIMUM LOADING LIMIT of the ATV as possible. Put cargo at the rear of ATV loading limit (total weight of rider, cargo, the front carrier, at the front of the rear carrier, accessories, and tongue): and center it.
  • Page 53 WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo or pull- ing a trailer.

  • Page 54: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 55: Getting To Know Your Atv

    EWB00010 ular attention to the safety information on pages WARNING 1-1–1-5. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. EBU21441 GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use.

  • Page 56: Ride With Care And Good Judgement

    Beginners should get training from a certified in- course offered by Yamaha. They should then structor. regularly practice the skills learned in the Become familiar with this ATV at slow speeds first, course and the operating techniques de- even if you are an experienced operator.
  • Page 57 WHAT CAN HAPPEN Use by children of ATVs that are not recom- mended for their age can lead to severe inju- ry or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.
  • Page 58 This ATV is designed to carry operator and car- go only – passengers prohibited. EWB00910 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 passen- ger.
  • Page 59 Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet EWB00920 WARNING that fits properly. You should also wear: POTENTIAL HAZARD eye protection (goggles or face shield) Operating this ATV without wearing an ap- gloves proved motorcycle helmet, eye protection boots and protective clothing.
  • Page 60 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. by the influence of alcohol or drugs. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.
  • Page 61 EWB00950 Do not operate at speeds too fast for your skills WARNING or the conditions. EWB00960 POTENTIAL HAZARD WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Operating this ATV at speeds too fast for Use of improper tires on this ATV, or opera- your skills or the conditions.
  • Page 62 Speed limiter Loading and accessories For riders less experienced with this model, the Use extra caution when riding the ATV with addi- throttle lever housing is equipped with a speed lim- tional loads, such as accessories or cargo. The iter. The speed limiter keeps the throttle from fully ATV’s handling may be adversely affected.
  • Page 63 EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
  • Page 64 During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op- Removing even one hand or foot can reduce eration, otherwise they may contact the rear your ability to control the ATV or could wheels. cause you to lose your balance and fall off of the ATV.
  • Page 65 Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo- nents designed for use on this ATV and should be installed and used according to instructions.

  • Page 66: Be Careful Where You Ride

    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. EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system.
  • Page 67 HOW TO AVOID THE HAZARD EWB01030 WARNING Always avoid paved surfaces, including sidewalks, driveways, parking lots and POTENTIAL HAZARD streets. 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 gravel one.
  • Page 68 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 69 HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. EWB01060 WARNING POTENTIAL HAZARD...

  • Page 70: Turning Your Atv

    Do not ride in areas posted “no trespassing”. hot when riding and afterwards; do not allow skin Do not ride on private property without getting per- or clothing to come in contact with these compo- mission. nents. With the engine idling, return the starter (choke) to the closed position, shift the drive select lever into the forward position, and then release the parking brake.
  • Page 71 used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. EWB01080 WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a colli- sion or overturn.

  • Page 72: Climbing Uphill

    Improper riding procedures such as abrupt throttle WHAT CAN HAPPEN changes, excessive braking, incorrect body move- The ATV can overturn more easily on ex- ments, or too much speed for the sharpness of the tremely steep hills than on level surfaces or turn may cause the ATV to tip.
  • Page 73 HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing hills as described in this Owner’s Manu- Always check the terrain 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.
  • Page 74 If you are climbing a hill and you find that you have When crossing the side of a hill: not properly judged your ability to make it to the Always follow proper procedures as de- top, you should turn the ATV around while you still scribed in the Owner’s Manual.
  • Page 75 If you start to roll backwards, DO NOT apply either If you begin rolling backwards: brake abruptly. If you are in 2WD, apply only the Keep weight uphill. front brake. If you are in 4WD, because all wheels 2WD: Never apply the rear brake while roll- are interconnected by the drive train, applying ei- ing backwards.

  • Page 76: Riding Downhill

    RIDING DOWNHILL Whenever possible, ride your ATV straight down- When riding your ATV downhill, shift your weight hill. Avoid sharp angles which could allow the ATV as far to the rear and uphill side of the ATV as pos- to tip or roll over. Carefully choose your path and sible.
  • Page 77 7-24...

  • Page 78: Crossing A Slope

    CROSSING A SLOPE HOW TO AVOID THE HAZARD Traversing a sloping surface on your ATV requires Never attempt to turn the ATV around on any you to properly position your weight to maintain hill until you have mastered the turning tech- proper balance.
  • Page 79 7-26...

  • Page 80: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
  • Page 81 1. Air filter case check hose ECB00280 CAUTION: After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the storage compartment check hose.

  • Page 82: Riding Over Rough Terrain

    1. V-belt case drain plug 1. Drive select lever box check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident.
  • Page 83 WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.

  • Page 84: Sliding And Skidding

    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. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.

  • Page 85: What To Do If

    WHAT CAN HAPPEN If your ATV begins to tip while turning: You may lose control of this ATV. You may Lean more into the turn to regain balance. If nec- also regain traction unexpectedly, which essary, gradually let off the throttle and/or steer may cause the ATV to overturn.
  • Page 86 If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let wa- ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability.

  • Page 87: Periodic Maintenance And Minor Repair

    Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.
  • Page 88 Yamaha ATV dealer. additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

  • Page 89: 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 90 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 91: General Maintenance And Lubrication Chart

    EBU21862 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 92 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Upper and lower √ √ √ • Lubricate with lithium-soap-based grease. arm pivots • Check for wear, cracks or other damage, and re- √...
  • Page 93 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Change. √ √ Differential gear oil • Check ATV for oil leakage, and correct if neces- sary. •...
  • Page 94 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. • Replace the brake hoses every four years and if cracked or damaged.

  • Page 95: Removing And Installing The Panel

    EWB00010 EBU23111 Panel A WARNING Indicates a potential hazard that could result in To remove the panel serious injury or death. Remove the bolt, and then take the panel off. EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter.

  • Page 96: Checking The Spark Plug

    NOTE: If the spark plug shows a distinctly different color, 1. Spark plug cap the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-10...

  • Page 97: To Install The Spark Plug

    2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DR8EA To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

  • Page 98: Engine Oil And Oil Filter Cartridge

    NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4.

  • Page 99: To Change The Engine Oil

    To change the engine oil (with or without oil fil- ter cartridge replacement) 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 100 5. Remove the oil filter cartridge with an oil filter NOTE: wrench. An oil filter wrench is available at a nearby Yamaha dealer. 6. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
  • Page 101 Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.20 L (2.33 US qt) (1.94 Imp.qt) With oil filter cartridge replacement: 2.30 L (2.43 US qt) (2.02 Imp.qt) ECB00300 CAUTION: In order to prevent clutch slippage (since the 1.

  • Page 102: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 103 To change the final gear oil 1. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 1. Final gear case guard 2.

  • Page 104: Changing The Differential Gear Oil

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, ECB00420 have a Yamaha dealer check and repair the ATV. CAUTION: In addition, the differential gear oil must be Be sure no foreign material enters the final changed as follows at the intervals specified in the gear case.
  • Page 105 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case. 1. Differential gear oil drain bolt 4. Install the drain bolt, and then tighten it to the specified torque.

  • Page 106: Cleaning The Air Filter Element

    The differential gear case capacity is greater EBU23630 Cleaning the air filter element than the recommended oil quantity, therefore The air filter element should be cleaned at the in- the oil level cannot be accurately checked from tervals specified in the periodic maintenance and the oil filler hole.
  • Page 107 2. Remove the air filter case cover by unhooking the holders. 1. Air filter element 4. Pull off the lock plate, and then remove the 1. Air filter case holder sponge material from the air filter element 2. Air filter case cover frame.
  • Page 108 1. Air filter element frame 2. Sponge material 8. Apply Yamaha foam air filter oil or other qual- 3. Air filter element lock plate ity foam air filter oil to the sponge material. 5. Wash the sponge material gently but thor- NOTE: oughly in solvent.

  • Page 109: Cleaning The Spark Arrester

    EBU23881 NOTE: Cleaning the spark arrester The air filter element should be cleaned every 20– Be sure the exhaust pipe and muffler are cool be- 40 hours. It should be cleaned and lubricated more fore cleaning the spark arrester. often if the ATV is operated in extremely dusty ar- 1.

  • Page 110: V-Belt Cooling Duct Check Hose

    WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components.

  • Page 111: V-Belt Case Drain Plug

    If water drains from the V-belt case after removing most carburetor adjustments should be left to a the plug, have a Yamaha dealer check the ATV as Yamaha dealer, who has the necessary profes- the water may affect other engine parts.

  • Page 112: Adjusting The Engine Idling Speed

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

  • Page 113: Adjusting The Throttle Cable Free Play

    The valve clearance changes with use, resulting in bolt in direction (b). 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. 8-27...

  • Page 114: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm The rear brake is provided with a wear indicator, (0.04 in), have a Yamaha dealer replace the brake which allows you to check the brake shoe wear pads as a set.

  • Page 115: Checking The Brake Fluid Level

    Yamaha dealer replace the brake shoes as a set. pads for wear and the brake system for leakage. 1. Wear limit line 1.

  • Page 116: Changing The Brake Fluid

    Water will signifi- free play of zero mm (zero in) as shown. If the free cantly lower the boiling point of the fluid and may play is incorrect, have a Yamaha dealer check the result in vapor lock. brake system.

  • Page 117: Adjusting The Brake Pedal And Rear Brake Lever Free Play

    Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24501 Adjusting the brake pedal and rear brake lever free play...
  • Page 118 1. Brake pedal free play adjusting nut 1. Brake lever free play 2. Brake lever free play adjusting nut 2. Locknut 3. Brake lever free play adjusting bolt Adjusting the brake lever free play 1. Loosen the locknut at the brake lever and fully The brake lever free play should measure 3.0–5.0 turn in the brake lever free play adjusting bolt.
  • Page 119 1. Brake lever free play adjusting nut 1. Locknut 2. Gap “A” 2. Brake lever free play adjusting bolt 3. Turn the brake lever free play adjusting bolt at 4. Tighten the locknut at the brake lever. the brake lever in direction (a) to increase the NOTE: free play, and in direction (b) to decrease it.

  • Page 120: Axle Boots

    The axle boots must be checked for damage at the adjusted as follows, but the other brake light intervals specified in the periodic maintenance and switches should be adjusted by a Yamaha dealer. lubrication chart. Check the axle boots for tears or 1. Remove panel A. (See page 8-9.) damage.

  • Page 121: Checking And Lubricating The Cables

    If a cable is damaged or does not move 2. Turn the adjusting nut while holding the brake smoothly, have a Yamaha dealer check or replace light switch in place. To make the brake light come on earlier, turn the adjusting nut in direc- tion (a).

  • Page 122: Checking And Lubricating The Front And Rear Brake Levers

    EBU24911 EBU24950 Checking and lubricating the front and Checking and lubricating the brake rear brake levers pedal The operation of the front and rear brake levers The operation of the brake pedal should be should be checked before each ride, and the lever checked before each ride, and the pedal pivot pivots should be lubricated if necessary.

  • Page 123: Checking The Wheel Bearings

    If there is play brication chart. in a wheel hub or if a wheel does not turn smoothly, Recommended lubricant: have a Yamaha dealer check the wheel bearings. Lithium-soap-based grease EBU24980 Lubricating the drive shaft universal...
  • Page 124 Ventilate when charg- ing or using in a closed space. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.
  • Page 125 If you do not have 2. Make sure to properly connect the battery access to a constant-voltage battery charg- leads to the battery terminals. er, have a Yamaha dealer charge your bat- tery. 1. Positive battery terminal 2. Negative battery terminal...

  • Page 126: Replacing A Fuse

    EBU25313 Replacing a fuse 1. Headlight fuse 2. Ignition fuse 1. Main fuse 3. Four-wheel-drive motor fuse 2. Spare main fuse 4. Signaling system fuse 3. Fuse box 5. Spare fuse The main fuse and the fuse box are located under the seat.

  • Page 127: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical new fuse of the specified amperage. circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Specified fuses: Yamaha dealer check the electrical system. Main fuse: EBU26892 30.0 A Replacing a headlight bulb Headlight fuse: If a headlight bulb burns out, replace it as follows.
  • Page 128 NOTE: The headlight bulb cannot be removed from the headlight bulb holder. To replace the headlight bulb, replace the headlight bulb holder assembly. EWB02180 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and im- mediately after it is turned off. WHAT CAN HAPPEN 1.

  • Page 129: Adjusting A Headlight Beam

    EBU25550 Adjusting a headlight beam ECB00690 CAUTION: 1. Do not touch the glass part of the bulb. It is advisable to have a Yamaha dealer make this adjustment. ECB00650 CAUTION: To raise a headlight beam, turn the adjusting Do not touch the glass part of the headlight screw in direction (a).

  • Page 130: Replacing The Tail/Brake Light Bulb

    Replacing the tail/brake light bulb under the frame. 3. Remove the nuts from the wheel. If the tail/brake light bulb burns out, have a 4. Remove the wheel. Yamaha dealer replace it. EBU25700 EBU25650 Installing a wheel Removing a wheel 1.
  • Page 131 Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Tapered nut 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques.

  • Page 132: 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 133: 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 134: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25870 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 135: Storage

    WHAT CAN HAPPEN Long-term Wet brakes may have reduced stopping abil- Before storing your ATV for several months: ity, increasing the chance of an accident. 1. Follow all the instructions in the “Cleaning” HOW TO AVOID THE HAZARD section of this chapter. Test the brakes after washing.
  • Page 136 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-37.

  • Page 137: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 1984 mm (78.1 in) Electric and recoil starter Overall width: Lubrication system: 1085 mm (42.7 in) Wet sump Overall height: Engine oil: 1120 mm (44.1 in) Seat height: Type: 827 mm (32.6 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase:...
  • Page 138 With oil filter cartridge replacement: Spark plug gap: 2.30 L (2.43 US qt) (2.02 Imp.qt) 0.6–0.7 mm (0.024–0.028 in) Final gear oil: Clutch: Type: Clutch type: SAE80 API GL-4 Hypoid gear oil Wet, centrifugal automatic Quantity: Transmission: 0.23 L (0.24 US qt) (0.20 Imp.qt) Primary reduction system: Differential gear oil: V-belt...
  • Page 139 Size: Front wheel: AT25 x 8-12 Wheel type: Manufacturer/model: Panel wheel MAXXIS/M979 Rim size: Rear tire: 12 x 6.0AT Type: Rear wheel: Tubeless Wheel type: Size: Panel wheel AT25 x 10-12 Rim size: Manufacturer/model: 12 x 7.5AT MAXXIS/M980 Front brake: Loading: Type: Maximum loading limit:...
  • Page 140 Rear suspension: Four-wheel-drive indicator light: 12 V, 1.7 W × 1 Type: Fuses: Swingarm (monocross) Spring/shock absorber type: Main fuse: Coil spring/oil damper 30.0 A Wheel travel: Headlight fuse: 180 mm (7.1 in) 15.0 A Electrical system: Signaling system fuse: 10.0 A Ignition system: Ignition fuse:...

  • Page 141: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 142 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 143: Noise Regulation

    EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ul- timate 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 144: Maintenance Record

    EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 145: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 146 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 147: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”...
  • Page 148 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 149 EBU26132 11-9...
  • Page 150 INDEX Drive select lever ............4-9 Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-7 Drive select lever safety system cable, adjusting ..8-28 Air filter element, cleaning ..........8-20 Drive shaft universal joint, lubricating ......8-37 Axle boots ..............
  • Page 151 Key identification number ..........11-1 Safety information ............1-1 Knuckle shafts, lubricating ........... 8-37 Seat ................4-14 Shock absorber assemblies, adjusting the front ..4-16 Shock absorber assembly, adjusting the rear ....4-17 Label locations ............... 2-1 Spark arrester, cleaning ..........8-23 Light switch ..............
  • Page 152 Warranty, limited ............11-5 Wheel bearings, checking ..........8-37 Wheel, installing ............8-44 Wheel, removing ............8-44...
  • Page 153 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 2006.05-1.6×1 CR...

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