Yamaha YFM250 Owner's Manual
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Yamaha YFM250 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
OWNER'S MANUAL
YFM25RD
YFM250RD
1BT-28199-63

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Summary of Contents for Yamaha YFM250

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM25RD YFM250RD 1BT-28199-63...
  • Page 2 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2012.03-0.3×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM25RD YFM250RD WARNING This ATV should not be ridden by anyone under 16 years of age. 1BT-28199-63-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM250R (YFM25R) (JY4AG03W0C0010257–)
  • Page 5 Congratulations on your purchase of the Yamaha YFM25RD/YFM250RD. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing ma- chines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 Please check your local riding laws and regulations before operating this ATV. EBU17390 YFM25RD/YFM250RD OWNER’S MANUAL ©2012 by Yamaha Motor Co., Ltd. 1st edition, February 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel cock ............4-9 SPECIFICATION LABELS ......1-1 Starter (choke) ..........4-11 Seat ............4-11 SAFETY INFORMATION ......2-1 Adjusting the front shock absorber assemblies ..........4-12 DESCRIPTION ..........3-1 Adjusting the rear shock absorber Left view ............
  • Page 9 Parking on a slope ........6-5 Engine oil and oil filter element ....8-11 Accessories and loading ......6-6 Cleaning the air filter element ....8-14 Cleaning the spark arrester ......8-18 RIDING YOUR ATV ........7-1 Adjusting the carburetor ......8-20 GETTING TO KNOW YOUR ATV....7-2 Adjusting the engine idling speed .....8-20 RIDE WITH CARE AND GOOD Adjusting the throttle lever free play ..8-21...
  • Page 10 Lubricating the upper and lower arm pivots ............8-34 Lubricating the steering shaft ....8-35 Battery ............8-35 Replacing the fuse ........8-38 Replacing a headlight bulb ....... 8-39 Adjusting a headlight beam ...... 8-41 Replacing the tail/brake light bulb .... 8-41 Removing a wheel ........

  • Page 11: Location Of The Warning And Specification Labels

    Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. For Europe...
  • Page 12 1PD-2811R-00 43P-2816P-00 43P-2816R-01...
  • Page 13 4AA-22259-40 27.5 kPa 27.5 kPa 0.275 kgf/cm² 0.275 kgf/cm² 4.0 psi 4.0 psi 4D3-2816M-M0 YFM250R 2012 14.0 kW 150 kg YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 4D3-2156A-10 8AC-2817L-00...
  • Page 14 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
  • Page 15 This unit contains high-pressure nitrogen Turning 4WD-LOCK gas. (“DIFF.LOCK”) takes more effort. Mishandling can cause an explosion. Do not Operate at a slow speed and allow extra incinerate, puncture or open. time and distance for maneuvers to avoid loss of control. This pictogram shows the loading limits and/or maximum load capacity for this ATV.
  • Page 16 Model Name ****** Max. Power *** kW *** kg Mass In Running Order 1 Year of construction **** YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN...
  • Page 17 For Oceania...
  • Page 18 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate : • without proper training or instruction. •...
  • Page 19 WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. OPERATING TIRE PRESSURE: Set with tires cold • Recommended : Front : 27.5 kPa, 4.0 psi Rear : 27.5 kPa, 4.0 psi •...

  • Page 20: Safety Information

    EBU17431 SAFETY INFORMATION ● EBU17595 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 21 ● Never operate at speeds too fast for your skills ● Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 22 ● Always use proper procedures if you stall or roll reduced stopping ability. Test your brakes after backwards when climbing a hill. To avoid stall- leaving water. If necessary, apply them several ing, use the proper gear and maintain a steady times to let friction dry out the linings.
  • Page 23 In the event of an accident tion. If necessary, contact your riding party or 1. If serious injuries are incurred, you may be local authorities to let them know where you safer staying next to your vehicle; it may are and what has happened. shield you from oncoming riders.
  • Page 24 This im- While you may find aftermarket products similar in proper position limits the freedom of movement design and quality to genuine Yamaha accesso- of the operator and may limit control ability, ries, recognize that some aftermarket accessories...
  • Page 25 ● Do not run engine outdoors where engine EWB00072 WARNING exhaust can be drawn into a building through openings such as windows and Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, doors. a deadly gas. Breathing carbon monoxide can EWB02591 cause headaches, dizziness, drowsiness, nau- WARNING...

  • Page 26: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 3 4 5 6 7 1. Front shock absorber assembly spring preload adjusting 1. Spark arrester ring 2. Fuse 2. Spark plug 3. Battery 3. Fuel cock 4. Air filter case 4. Starter (choke) 5.

  • Page 27: Controls And Instruments

    EBU17712 Controls and instruments 1. Clutch lever 2. Handlebar switches 3. Parking brake lever 4. Main switch 5. Front brake fluid reservoir 6. Throttle lever 7. Brake lever The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 28: Instrument And Control Functions

    EBU17734 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

  • Page 29: Indicator Light

    EBU17783 EBU18061 Indicator light Handlebar switches 1. Neutral indicator light “N” 1. Light switch “ /OFF” 2. Engine stop switch “ ” EBU17860 3. Start switch “ ” Neutral indicator light “ ” This indicator light comes on when the transmis- EBU18080 sion is in the neutral position.

  • Page 30: Throttle Lever

    Regulate the speed of the ATV by varying the EBU18101 Start switch “ ” throttle position. Because the throttle is spring- Push this switch to crank the engine with the start- loaded, the ATV will decelerate, and the engine will er.

  • Page 31: Speed Limiter

    EBU18323 Speed limiter Your ATV is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 32: Brake Lever

    1. Brake lever 1. Clutch lever EBU18432 EBU18411 Brake pedal Brake lever The brake pedal is located on the right side of the The brake lever is located at the right handlebar ATV. To apply the rear brake, push down on the grip.

  • Page 33: Parking Brake Lever

    1. Brake pedal 1. Parking brake lever (locked position) EBU18520 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a).

  • Page 34: Shift Pedal

    EWB00220 WARNING ● Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. ● Always be sure you have released the park- ing brake before you begin to ride.

  • Page 35: Fuel

    of sparks, open flames, or other sources of ig- nition such as the pilot lights of water heaters and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole.

  • Page 36: Fuel Cock

    1.0 L (0.26 US gal, 0.22 Imp.gal) rings, as well as to the exhaust system. 3. Wipe up any spilled fuel immediately. Your Yamaha engine has been designed to use NOTICE: Immediately wipe off spilled fuel regular unleaded gasoline with a research octane with a clean, dry, soft cloth, since fuel may number of 91 or higher (95 or higher for Europe).
  • Page 37 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 38: Starter (Choke)

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 39: Adjusting The Front Shock Absorber Assemblies

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat Insert the projections on the front of the seat into EBU18993 Adjusting the front shock absorber as- the seat holders and push down on the seat at the semblies rear.

  • Page 40: Adjusting The Rear Shock Absorber Assembly

    (a) to increase the spring preload and thereby harden the suspension, and in direc- tion (b) to decrease the spring preload and A special wrench can be obtained at a Yamaha thereby soften the suspension. dealer to make this adjustment.
  • Page 41 2. Spring preload adjusting nut 3. Distance A Tightening torque: Locknut: 42 Nm (4.2 m·kgf, 30 ft·lbf) ● A special wrench can be obtained at a Yamaha dealer to make this adjustment. EWB00450 ● The spring preload setting is determined by WARNING measuring distance A, shown in the illustration.
  • Page 42 ● Do not deform or damage the cylinder in any way. ● Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- er for any service. 4-15...

  • Page 43: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 44 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Rear brake 5-3, 8-22, 8-23, 8-25 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.

  • Page 45: Fuel

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

  • Page 46: Specifications

    EBU19770 Recommended tire pressure: Drive chain Front Check the condition of the drive chain and check 27.5 kPa (0.275 kgf/cm², 4.0 psi) the drive chain slack. Lubricate and adjust the Rear drive chain as necessary. (See page 8-29.) 27.5 kPa (0.275 kgf/cm², 4.0 psi) Minimum tire pressure: EBU19794 Tires...
  • Page 47 EWB02551 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

  • Page 48: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are DURO/DI-K102 working properly. Correct if necessary. Size: AT20 x 7-10 Type: Tubeless Rear: Manufacturer/model: DURO/DI-K502A Size: AT19 x 10-9 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling,...

  • Page 49: Operation

    If the indicator Read the Owner’s Manual carefully before riding light does not come on, have a Yamaha deal- the ATV. If there is a control or function you do not er check the electrical circuit.

  • Page 50: Starting A Warm Engine

    Ambient temp./starter (choke) position 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine. If the engine is started with the starter (choke) in position (2), keep the starter (choke) in this position to warm up the engine.

  • Page 51: Shifting

    EBU20522 EBU20593 To start out and accelerate Shifting 1. Release the throttle lever, apply the front or This ATV has a 5-speed forward transmission. The rear brake, and then release the parking transmission allows you to control the amount of brake.

  • Page 52: Engine Break-In

    8. Follow the same procedure when shifting to for long distances. The transmission is prop- the next higher gear. erly lubricated only when the engine is run- ning. Inadequate lubrication may damage EBU20650 the transmission. To decelerate ● Always use the clutch when changing gears. When slowing down or stopping, release the throt- The engine, transmission and drive train are tle and apply the brakes smoothly and evenly.

  • Page 53: Parking

    If any engine trouble should occur during the EWB00851 engine break-in period, immediately have a WARNING Yamaha dealer check the ATV. Avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the ATV to roll out of control, increasing the chance of an accident.

  • Page 54: Accessories And Loading

    Yamaha 3. Release the front and rear brakes. vehicles. Yamaha is not in a position to test the 4. Turn the fuel cock to “OFF”. products that these aftermarket companies pro- duce.
  • Page 55 market products or having other modifications EBU20941 Loading performed to your ATV that change any of the ve- EWB00820 hicle’s design or operation characteristics can put WARNING you and others at greater risk of serious injury or Never exceed the stated load capacity for this death.
  • Page 56 ● If you are carrying cargo and towing a trailer, in- clude the tongue weight in the maximum ATV load limit. ● Load cargo on the carriers as close to the center of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it.

  • Page 57: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 58: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EBU21617 Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is intended for recreational use by expe- WARNING rienced operators only. This section, Riding your ● Do not operate this ATV or allow anyone else ATV, provides general ATV riding instructions for to operate it without proper instruction.
  • Page 59 Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
  • Page 60 proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. [EWB01411] Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision.
  • Page 61 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 62 opening, even when the throttle lever is pushed to ● Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see “MAXIMUM LOADING the maximum engine power available and de- LIMIT” below or vehicle labeling). ●...
  • Page 63 All parts and accessories added to this ATV should be genuine Yamaha or equivalent components de- signed for use on this ATV and should be installed and used according to instructions. If you have...
  • Page 64 questions, consult an authorized ATV dealer. other hot parts. Check under the vehicle after op- WARNING! Operating this ATV with improper erating in areas where combustible materials may modifications may cause changes in handling have collected. Do not idle or park the vehicle in which in some situations could lead to an acci- long dry grass or other dry ground cover.

  • Page 65: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE Watch carefully for other vehicles. Make sure you This ATV is designed for use on unpaved surfaces know your country’s laws and regulations before only. WARNING! Paved surfaces may seriously you ride on unpaved public streets or roads. Do not affect handling and control of the ATV, and ride on any paved public street, road or motorway.
  • Page 66 have enough time to react to hidden rocks, loose terrain could cause loss of traction or bumps, or holes. Go slowly and be extra care- ATV control, which could result in an accident, ful when operating on unfamiliar terrain. Al- including an overturn.
  • Page 67 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.

  • Page 68: Turning Your Atv

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

  • Page 69: Climbing Uphill

    Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.
  • Page 70 ● Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards. ● Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
  • Page 71 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footrests and leaning forward over the handlebars. Whenever possible, ride straight up hills.

  • Page 72: Riding Downhill

    If you start to roll backwards, DO NOT apply the rear brake, and apply the front brake gradually. The ATV could easily tip over backwards. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount the ATV im- mediately on the uphill side or to a side if pointed straight uphill.
  • Page 73 ● Never operate the ATV on hills too steep for Whenever possible, ride your ATV straight down- the ATV or for your abilities. The ATV can hill. Avoid sharp angles which could allow the ATV overturn more easily on extremely steep hills to tip or roll over.

  • Page 74: Crossing A Slope

    CROSSING A SLOPE As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the EWB01632 WARNING steering when riding on loose surfaces by pointing Improperly crossing hills or turning on hills the front wheels slightly uphill.

  • Page 75: Crossing Through Shallow Water

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

  • Page 76: Riding Over Rough Terrain

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

  • Page 77: Sliding And Skidding

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

  • Page 78: What To Do If

    WHAT TO DO... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footrest to the outside of the turn. Position your weight over the front wheels for better control.
  • Page 79 ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 80: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 81: Owner's Manual And Tool Kit

    If you do not have the tools or experience required owner’s tool kit under the seat. for a particular job, have a Yamaha dealer perform it for you. 1. Low-pressure tire gauge 2.

  • Page 82: 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. INITIAL...
  • Page 83 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 84: General Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL...
  • Page 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years √...
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Make sure that all nuts, bolts, and screws are √ √ √ √ √ Chassis fasteners properly tightened. Shock absorber as- •...
  • Page 87 EBU23071 ● Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 88: Checking The Spark Plug

    (the ideal color when the ATV is ridden normally). 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.
  • Page 89 2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.

  • Page 90: Engine Oil And Oil Filter Element

    EBU28957 Engine oil and oil filter element The engine oil should be between the minimum The engine oil level should be checked before and maximum level marks. each ride. In addition, the oil must be changed and the oil filter element must be replaced at the inter- vals specified in the periodic maintenance and lu- brication chart.
  • Page 91 6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. Skip steps 5–7 if the oil filter element is not being replaced. To change the engine oil (with or without oil fil- ter element replacement) 5.
  • Page 92 8. Install the engine oil drain bolt and its new gasket, and then tighten the bolt to the speci- fied torque. Tightening torque: Engine oil drain bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) 9. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap.

  • Page 93: Cleaning The Air Filter Element

    ECB00300 NOTICE There is a check hose at the bottom of the air filter ● In order to prevent clutch slippage (since the case. If dust or water collects in this hose, empty engine oil also lubricates the clutch), do not the hose and clean the air filter element and air fil- mix any chemical additives.
  • Page 94 1. Air filter element 1. Air filter case cover 2. Washer 2. Air filter case cover holder 3. Wing bolt 4. Loosen the wing bolt. 6. Remove the wing bolt and washer from the air 5. Remove the air filter element together with the filter element.
  • Page 95 2. Air filter element frame damaged. 8. Wash the sponge material gently but thor- 11. Apply Yamaha foam air filter oil or other qual- oughly in solvent. WARNING! Always use ity foam air filter oil to the sponge material. parts cleaning solvent to clean the sponge material.
  • Page 96 1. Air filter element seat 1. Washer 14. Install the washer onto the air filter element 15. Insert the air filter element into the air filter frame, and then insert the wing bolt into the case, and then tighten the wing bolt. NOTICE: hole in the air filter element frame.

  • Page 97: Cleaning The Spark Arrester

    17. Install the seat. The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar- eas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions.
  • Page 98 1. Tailpipe 1. Gasket 2. Spark arrester 2. Tailpipe 3. Tailpipe bolt 4. Check the gasket for damage, and replace it if 6. Install the bolts and tighten them to the speci- necessary. fied torque. 5. Make sure the gasket is properly positioned, then insert the tailpipe into the muffler and Tightening torque: align the bolt holes.

  • Page 99: Adjusting The Carburetor

    Therefore, 1. Start the engine and warm it up. most carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- The engine is warm when it quickly responds to the sional knowledge and experience. The adjustment throttle.

  • Page 100: Adjusting The Throttle Lever Free Play

    (a). To decrease the throttle lever free 1500–1600 r/min play, turn the adjusting bolt in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EBU24047 Adjusting the throttle lever free play...

  • Page 101: Valve Clearance

    If a brake pad has worn to the point that must be adjusted by a Yamaha dealer at the inter- the wear indicator groove has almost disappeared, vals specified in the periodic maintenance and lu- have a Yamaha dealer replace the brake pads as brication chart.

  • Page 102: Checking The Brake Fluid Level

    To check the brake pad wear, check the wear indica- tor grooves. If a brake pad has worn to the point that a wear indicator groove almost appears, have a Yamaha dealer replace the brake pads as a set. 8-23...
  • Page 103 Front brake Specified brake fluid: DOT 4 EWB02720 WARNING Improper maintenance can result in loss of braking ability. Observe these precautions: ● Insufficient brake fluid may allow air to enter the brake system, reducing braking perfor- mance. ● Clean the filler cap before removing. Use only DOT 4 brake fluid from a sealed contain- 1.

  • Page 104: Changing The Brake Fluid

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

  • Page 105: Adjusting The Parking Brake Free Play

    The top of the brake pedal should be positioned 40.0 mm (1.57 in) above the top of the frame as shown. If the brake pedal is not positioned as spec- ified, have a Yamaha dealer adjust it. 1. Cable length “A” 2. Locknut 3.

  • Page 106: Brake Light Switches

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

  • Page 107: Adjusting The Clutch Lever Free Play

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

  • Page 108: Drive Chain Slack

    5. Slide the rubber cover back to its original po- sition. If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal clutch mechanism. EBU26864 Drive chain slack The drive chain slack should be checked before 1.
  • Page 109 1. Rear wheel axle pinch bolt 2. Rod 3. Drive chain tensioner 4. Hole A rod can be obtained at a Yamaha dealer to make this adjustment. Tightening torque: Rear axle pinch bolt: 4. Shift the transmission into neutral.

  • Page 110: Lubricating The Drive Chain

    EBU24882 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. ECB00561 NOTICE The drive chain must be lubricated after wash-...

  • Page 111: Checking And Lubricating The Brake And Clutch Levers

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

  • Page 112: Checking The Shift Pedal

    If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- ings. EBUM0170 Checking the shift pedal The operation of the shift pedal should be checked before each ride.

  • Page 113: Lubricating The Swingarm Pivots

    Lubricating the swingarm pivots For parts equipped with a grease nipple, use a The swingarm pivots must be lubricated by a grease gun. Yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart. Recommended lubricant: Recommended lubricant:...

  • Page 114: Lubricating The Steering Shaft

    EBU25092 when working near batteries. Lubricating the steering shaft Antidote: The steering shaft must be lubricated by a Yamaha EXTERNAL: Flush with water. dealer at the intervals specified in the periodic INTERNAL: Drink large quantities of water or maintenance and lubrication chart.
  • Page 115 KEEP OUT OF REACH OF CHILDREN. 3. Disconnect the negative battery lead first, then the positive battery lead by removing ECB00620 their bolt. NOTICE: When removing the bat- NOTICE tery, the main switch must be off, and the Never attempt to remove the battery cell seals, negative lead must be disconnected be- as this would permanently damage the battery.
  • Page 116 To charge the battery To install the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in Be sure the battery is fully charged. mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- 1.

  • Page 117: Replacing The Fuse

    3. Install the battery holding plate by installing the bolts, and then hook the band to secure the owner’s tool kit. 4. Install the seat. (See page 4-11.) EBUM0183 Replacing the fuse The fuse holder is located beside the battery and can be accessed as follows: 1.

  • Page 118: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a 1. Headlight unit Yamaha dealer check the electrical system. 2. Bolt 5. Install the battery holding plate by installing 2. Disconnect the headlight coupler.
  • Page 119 1. Headlight bulb holder cover 1. Headlight bulb holder 2. Headlight coupler 5. Place a new headlight bulb into position. 4. Remove the headlight bulb holder by pushing NOTICE: Do not touch the glass part of the it in and turning it counterclockwise, and then headlight bulb to keep it free from oil, oth- remove the burnt-out bulb.

  • Page 120: Adjusting A Headlight Beam

    Yamaha dealer replace it. EBU25561 Adjusting a headlight beam EBU25651 Removing a wheel ECB00690 NOTICE 1. Place the ATV on a level surface. 2. Loosen the wheel nuts. It is advisable to have a Yamaha dealer make this adjustment. 8-41...

  • Page 121: Installing A Wheel

    Front 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. EBU27481 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts. When installing the wheel, make sure its arrow mark points toward the rotating direction of the...

  • Page 122: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 123: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 124: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE may cause water seepage and deteriora- EBU25902 Cleaning tion of wheel bearings, brakes, transmis- Frequent, thorough cleaning of your ATV will not sion seals and electrical devices. Many only enhance its appearance but will improve its expensive repair bills have resulted from general performance and extend the useful life of improper high-pressure detergent applica-...

  • Page 125: Storage

    EBU25933 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inder, piston rings, etc.
  • Page 126 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.

  • Page 127: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 1625 mm (64.0 in) Air cooled 4-stroke, SOHC Overall width: Cylinder arrangement: 1072 mm (42.2 in) Single cylinder Overall height: Displacement: 1040 mm (40.9 in) 249 cm³ Bore × stroke: Seat height: 74.0 ×...
  • Page 128 Type: Fuel tank capacity: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- 9.0 L (2.38 US gal, 1.98 Imp.gal) Fuel reserve amount: 1.0 L (0.26 US gal, 0.22 Imp.gal) Carburetor: 130 ˚F Type × quantity: BSR29 x 1 SAE 5W-30 Spark plug (s): SAE 10W-30 Manufacturer/model:...
  • Page 129 Gear ratio: Loading: 1st: Maximum loading limit: 37/13 (2.846) 100.0 kg (220 lb) 2nd: (Total weight of rider, cargo, accessories, and tongue) 33/18 (1.833) Tire air pressure (measured on cold tires): 3rd: Recommended: 29/21 (1.381) Front: 4th: 27.5 kPa (0.275 kgf/cm², 4.0 psi) 27/24 (1.125) Rear: 5th:...
  • Page 130 Specified brake fluid: Voltage, capacity: DOT 4 12 V, 6.0 Ah Rear brake: Headlight: Type: Bulb type: Disc brake Krypton bulb Bulb voltage, wattage × quantity: Operation: Right foot operation Headlight: 12 V, 30.0/30.0 W × 2 Specified brake fluid: DOT 4 Tail/brake light: 12 V, 5.0/21.0 W ×...
  • Page 131 exposed to the noise. Also the permissible expo- sure level can vary from country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk. 10-5...

  • Page 132: Consumer Information

    Record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 133 1. Model label 11-2...
  • Page 134 INDEX Accessories and loading ..........6-6 Engine break-in .............. 6-4 Air filter element, cleaning ..........8-14 Engine, cold start ............6-1 Engine idling speed ............8-20 Engine oil ............... 5-3 Battery ................8-35 Engine oil and oil filter element ........8-11 Brake and clutch levers, checking and lubricating ..
  • Page 135 Model label ..............11-1 Tail/brake light bulb, replacing ........8-41 Neutral indicator light ............. 4-2 Throttle lever ............4-3, 5-3 Throttle lever free play, adjusting ......... 8-21 Tires ................5-4 Owner’s manual and tool kit ........... 8-2 Troubleshooting ............8-43 Troubleshooting chart ..........
  • Page 136 EBU26162 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER CARRY NEVER USE NEVER USE AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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