Yamaha YFM250R Owner's Manual
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Yamaha YFM250R Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM25RX
This A
4D3-28199-60

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  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM25RX This A 4D3-28199-60...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2007.05-1.5x1 ! IMPRIMÉ SUR PAPIER RECYCLÉ (E,F,S) IMPRESO EN PAPEL RECICLADO...
  • Page 3 OWNER’S MANUAL YFM25RX This A 4D3-28199-60-E0...
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 EBU17330 IMPORTANT MANUAL INFORMATION 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 WARNING...
  • Page 7 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Starter (choke) ......... 4-10 Seat ............4-10 Adjusting the front shock absorber LOCATION OF THE WARNING AND assemblies ..........4-11 SPECIFICATION LABELS ......2-1 PRE-OPERATION CHECKS ......5-1 DESCRIPTION ..........3-1 Pre-operation check list ......5-1 Left view .............
  • Page 9 RIDING YOUR ATV ........7-1 Adjusting the throttle cable free play ..8-20 Valve clearance ........8-21 GETTING TO KNOW YOUR ATV....7-2 Checking the front and rear brake RIDE WITH CARE AND GOOD pads ............8-22 JUDGEMENT........... 7-2 Checking the brake fluid level ....8-23 BE CAREFUL WHERE YOU RIDE....
  • Page 10 Removing a wheel ........8-42 Installing a wheel ........8-42 Troubleshooting ........8-43 Troubleshooting chart ......8-44 CLEANING AND STORAGE......9-1 Cleaning ............ 9-1 Storage ............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ...... 11-1 Identification numbers ......11-1...

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU17592 does not have the abilities to operate it safely. Never carry a passenger on an ATV. AN ATV IS NOT A TOY AND CAN BE HAZARD- Always avoid operating an ATV on any paved OUS TO OPERATE.
  • Page 12 conditions, and your experience. Always follow proper procedures for climbing Never attempt wheelies, jumps, or other stunts. hills as described in this manual. Check the ter- Always inspect your ATV each time you use it to rain carefully before you start up any hill. Never make sure it is in safe operating condition.
  • Page 13 speed when climbing a hill. If you stall or roll this manual. backwards, follow the special procedure for Always maintain proper tire pressure as de- braking described in this manual. Dismount on scribed in this manual. the uphill side or to a side if pointed straight up- Never modify an ATV through improper installa- hill.
  • Page 14 may leak out of the carburetor or fuel tank. in a closed area. Exhaust fumes are poisonous Gasoline is poisonous. If you should swal- and may cause loss of consciousness and low some gasoline or inhale a lot of gasoline death within a short time.

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. For Europe For Europe...
  • Page 17 For Oceania For Europe WARNING UNDER < 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 5FK-21697-00 5FE-21697-01 For Europe For Oceania WARNING NEVER...
  • Page 18 For Europe For Oceania WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. 27.5 kPa 27.5 kPa LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. 0.275 kgf/cm 0.275 kgf/cm OPERATING TIRE PRESSURE : Set with tires cold 4.0 psi 4.0 psi 0 Recommended : FRONT : 27.5kPa, {0.275kgf/cm...

  • Page 19: Description

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

  • Page 20: Controls And Instruments

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

  • Page 21: Instrument And Control Functions

    EBU17731 INSTRUMENT AND CONTROL FUNCTIONS EBU17740 EBU17781 Main switch Indicator light The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved. All electrical systems are off. The key can be re- moved.

  • Page 22: Handlebar Switches

    EBU18061 EBU18090 Handlebar switches Start switch “START” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18120 Light switch “LIGHTS” Set this switch to “LO” to turn on the low beams and the taillight.

  • Page 23: Speed Limiter

    ATV or consult a Yamaha dealer. the throttle lever. EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum.

  • Page 24: Clutch Lever

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

  • Page 25: Brake Lever

    EBU18411 Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the brake lever toward the handlebar grip. 1. Brake pedal EBU18520 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope.

  • Page 26: 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 27: Fuel Tank Cap

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

  • Page 28: Fuel Cock

    of gasoline or higher octane grade. ECB00070 CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. EWB00310 WARNING Do not overfill the fuel tank.
  • Page 29 The fuel cock lever positions are explained as fol- lows and shown in the illustrations. 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel flows 1. Arrow mark positioned over “OFF” to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding.

  • Page 30: Starter (Choke)

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

  • Page 31: Adjusting The Front Shock Absorber Assemblies

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat Insert the projections on the front of the seat into EBU18990 Adjusting the front shock absorber the seat holders and push down on the seat at the assemblies rear.
  • Page 32 1. Spring preload adjusting ring 2. Special wrench 3. Position indicator NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Spring preload setting: Minimum (soft): Standard: Maximum (hard):...

  • Page 33: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 34 ITEM ROUTINE PAGE Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Rear brake 5-3, 8-22, 8-23, 8-26 Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 35: Front And Rear Brakes

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

  • Page 36: Throttle Lever

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

  • Page 37: Measuring The Tire Pressure

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

  • Page 38: Tire Wear Limit

    Recommended pressure: Front 27.5 kPa (4.0 psi) (0.275 kgf/cm Rear 27.5 kPa (4.0 psi) (0.275 kgf/cm Minimum: Front 24.5 kPa (3.5 psi) (0.245 kgf/cm Rear 24.5 kPa (3.5 psi) (0.245 kgf/cm 1. Low-pressure tire gauge Maximum: Front Set the tire pressure when the tires are cold. Set 30.5 kPa (4.4 psi) (0.305 kgf/cm the tire pressures to the following specifications: Rear...

  • Page 39: Chassis Fasteners

    1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.

  • Page 40: Operation

    If there is a control or func- indicator light should come on. If the indicator tion you do not understand, ask your Yamaha light does not come on, have a Yamaha deal- dealer. er check the electrical circuit.
  • Page 41 Position (1): Ambient temp./starter (choke) position Cold engine start with ambient temperature be- low 5 °C (40 °F). Position (2): Cold engine start with ambient temperature be- tween 0 °C (30 °F) and 30 °C (90 °F). Position (3): Cold engine start with ambient temperature above 25 °C (80 °F).

  • Page 42: Starting A Warm Engine

    attempt. EBU20520 Shifting 7. If the engine is started with the starter (choke) This ATV has a 5-speed forward transmission. The in position (1), the starter (choke) should be transmission allows you to control the amount of returned to position (2) to warm up the engine. power you have available at a given speed or for If the engine is started with the starter (choke) starting, accelerating, climbing hills, etc.
  • Page 43 EBU20570 wheelie, which would increase the chance of To start out and accelerate an accident, including an overturn. 1. Release the throttle lever. ECB00200 EBU20650 CAUTION: To decelerate Always close the throttle before shifting gears, When slowing down or stopping, release the throt- otherwise damage to the engine and drive train tle and apply the brakes smoothly and evenly.

  • Page 44: Engine Break-In

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

  • Page 45: Parking On A Slope

    the fuel cock to “OFF”. Do not park the ATV at all on hills that are so steep you could not walk up them easily. 1. Bring the ATV to a stop by applying the brakes in first gear. 2. Stop the engine and release the clutch lever. 3.
  • Page 46 However, er, you must use common sense and good it is not possible for Yamaha to test all non- judgment as the stability and handling of an ATV Yamaha accessories, nor control over their qual- can be changed.
  • Page 47 Make sure the load does not interfere with con- trols or your ability to see where you are going. Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail- Allow more braking distance.

  • Page 48: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 49: Getting To Know Your Atv

    EBU21611 Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum performance until GETTING TO KNOW YOUR ATV you are totally familiar with the ATV’s handling and This ATV is intended for recreational use by expe- performance characteristics.
  • Page 50 with engine size greater than 90 cc. Use by chil- harm to you and/or your passenger. dren of ATVs that are not recommended for their age can lead to severe injury or death of the child. Apparel This ATV is designed to carry operator only – Always wear an approved motorcycle helmet that passengers prohibited.
  • Page 51 event of an accident. Operating without protec- tive clothing increases your chances of severe injury in the event of an accident. Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. 1.
  • Page 52 page 5-1 before riding for proper care of the ATV Do not operate at speeds too fast for your and to ensure safety. skills or the conditions. EWB01430 EWB01450 WARNING WARNING Always inspect your ATV each time you use it Always go at a speed that is proper for the ter- to make sure the ATV is in safe operating con- rain, visibility and operating conditions, and...
  • Page 53 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 100.0 kg (220 lb) EWB01460 WARNING Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- 1. Adjusting screw curely attached. 2.
  • Page 54 All parts and tact with the rear wheels, which could injure accessories added to this ATV should be gen- you or cause an accident. uine Yamaha or equivalent components de-...

  • Page 55: Be Careful Where You Ride

    signed for use on this ATV and should be installed and used according to instructions. Improper installation of accessories or modifi- cation of this ATV may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized ATV dealer.
  • Page 56 paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. While riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles.
  • Page 57 on unfamiliar terrain. Always be alert to chang- including an overturn. ing terrain conditions when operating the ATV. When riding in an area where you might not easily EWB01540 be seen, such as desert terrain, mount a caution WARNING flag on the ATV. DO NOT use the flag pole bracket Do not operate on excessively rough, slippery as a trailer hitch.
  • Page 58 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice EWB01550 control of the throttle, brakes, shifting procedures, WARNING and turning techniques in this area before trying Always mount a caution flag on the ATV to more difficult terrain.

  • Page 59: Turning Your Atv

    these components. ECB00230 CAUTION: With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then Do not shift gears without releasing the throt- release the parking brake. Open the throttle grad- tle.
  • Page 60 used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. EWB01570 WARNING Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds.

  • Page 61: Climbing Uphill

    curves. er hills before attempting large hills. Improper riding procedures such as abrupt throttle It is important when climbing a hill to make sure changes, excessive braking, incorrect body move- that your weight is transferred forward on the ATV. ments, or too much speed for the sharpness of the This can be accomplished by leaning forward and, turn may cause the ATV to tip.
  • Page 62 any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

  • Page 63: Riding Downhill

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

  • Page 64: Crossing A Slope

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

  • Page 65: Crossing Through Shallow Water

    steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path.
  • Page 66 in water deeper than that specified in your have regained proper braking ability. Owner’s Manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the lin- ings.

  • Page 67: Riding Over Rough Terrain

    you go over obstacles, always follow proper procedures as described in the Owner’s Manu- SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident.

  • Page 68: What To Do If

    slide. Applying the brakes or accelerating is not terrain. recommended until you have corrected the slide. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control.
  • Page 69 slide. (See page 7-20.) If your ATV can’t make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE –...

  • Page 70: Periodic Maintenance And Minor Repair

    1. Low-pressure tire gauge can cause shocks or start fires. Turn off the en- 2. Owner’s tool kit gine when performing maintenance unless 3. Owner’s manual otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with...
  • Page 71 NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING Never modify this ATV through improper in-...

  • Page 72: 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 73 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 74: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element Clean and replace if necessary. dusty areas) √...
  • Page 75 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check operation and for excessive play, and √ √ √ 10 * Swingarm pivots replace bearings if necessary. Lubricate with lithium-soap-based grease.
  • Page 76 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Change. √ √ √ √ Engine oil Check ATV for oil leakage, and correct if neces- sary. Engine oil filter ele- √...
  • Page 77 EBU23070 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 78: Checking The Spark Plug

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

  • Page 79: Engine Oil And Oil Filter Element

    2. Check the spark plug for electrode erosion 2. Clean the surface of the spark plug gasket and excessive carbon or other deposits, and and its mating surface, and then wipe off any replace it if necessary. grime from the spark plug threads. 3.
  • Page 80 To check the engine oil level 1. Place the ATV on a level surface. 2. Check the engine oil level on a cold engine. NOTE: If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading.
  • Page 81 To change the engine oil (with or without oil compression spring, oil strainer and O-ring will filter element cleaning) fall out. Take care not to lose these parts. 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- NOTE: utes, and then turn it off.
  • Page 82 10. Install the engine oil drain bolt and tighten it to the specified torque. ECB00320 CAUTION: Before installing the engine oil drain bolt, be sure to install the O-ring, compression spring and oil strainer. Tightening torque: Engine oil drain bolt: 20 Nm (2.0 m·kgf, 14.5 ft·lbf) 1.

  • Page 83: Cleaning The Air Filter Element

    engine and exhaust system have cooled down. areas. ECB00300 NOTE: CAUTION: 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 84 1. Air filter case cover 1. Wing bolt 2. Air filter case cover holder 2. Air filter element 3. Loosen the wing bolt. 5. Remove the wing bolt and washer from the air 4. Remove the air filter element together with the filter element.
  • Page 85 ECB00440 CAUTION: Do not twist the sponge material when squeez- ing it. 1. Sponge material 2. Air filter element frame 7. Wash the sponge material gently but thor- oughly in solvent. 9. Check the sponge material and replace it if EWB01940 damaged.
  • Page 86 12. Install the washer onto the air filter element NOTE: frame, and then insert the wing bolt into the The air filter element should be cleaned every 20– hole in the air filter element frame. 40 hours. It should be cleaned and lubricated more ECB00451 often if the ATV is operated in extremely dusty ar- CAUTION:...

  • Page 87: Cleaning The Spark Arrester

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

  • Page 88: Adjusting The Carburetor

    Therefore, most carburetor adjustments should be left to a 1. Gasket Yamaha dealer, who has the necessary profes- 2. Tailpipe sional knowledge and experience. The adjustment 3. Bolt...

  • Page 89: Adjusting The Engine Idling Speed

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

  • Page 90: Valve Clearance

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

  • Page 91: Checking The Front And Rear Brake Pads

    If a brake pad has worn to the point 1. Wear indicator groove that the wear indicator grooves are almost in con- tact with the disc plate, have a Yamaha dealer re- NOTE: place the brake pads as a set.

  • Page 92: Checking The Brake Fluid Level

    place the brake pads as a set. Front brake 1. Minimum level mark 1. Wear indicator EBU28930 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary.
  • Page 93 Rear brake 1. Bolt 1. Minimum level mark 2. Brake fluid reservoir cap cover If the rear brake fluid level is low, replenish as fol- 2. Remove the brake fluid reservoir cap. lows. 1. Remove the brake fluid reservoir cap cover by removing the bolt.

  • Page 94: Changing The Brake Fluid

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

  • Page 95: Checking The Front Brake Lever Free Play

    Make sure the brakes are not spongy. All air free play of zero mm (zero in) as shown. If the free must be bled from the brake system. play is incorrect, have a Yamaha dealer check the Replacement of brake components requires brake system.

  • Page 96: Adjusting The Parking Brake Free Play

    Yamaha dealer. EBU24710 Adjusting the parking brake free play The parking brake free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Cable length “A” should measure 64–68 mm (2.52–2.60 in).
  • Page 97 If the cable length cannot be adjusted to specifica- again. tion, consult a Yamaha dealer. 5. Tighten the locknut on the brake cable. 6. Turn in the adjusting bolt at the rear brake cal-...

  • Page 98: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. NOTE: The brake light switch is properly adjusted when 1. Brake light switch the brake light comes on just before braking takes 2.

  • Page 99: Drive Chain Slack

    (b). 3. Tighten the locknut. NOTE: If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal clutch mechanism. 8-30...
  • Page 100 To adjust the drive chain slack NOTE: 1. Loosen the rear axle pinch bolts. A rod can be obtained at a Yamaha dealer to make 2. Insert a rod of a diameter of 8 mm (0.3 in) and this adjustment.

  • Page 101: Lubricating The Drive Chain

    gine as well as other vital parts of the ATV and and lubrication chart, otherwise it will quickly wear can lead to drive chain slippage or breakage. out, especially when riding in dusty or wet areas. To prevent this from occurring, keep the drive Service the drive chain as follows.

  • Page 102: Checking And Lubricating The Cables

    Silicone grease cables and cable ends should be lubricated if nec- Clutch lever: essary. If a cable is damaged or does not move Lithium-soap-based grease (all-purpose smoothly, have a Yamaha dealer check or replace grease) Recommended lubricant: Engine oil EWB02130...

  • Page 103: Checking And Lubricating The Brake And Shift Pedals

    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. EBU24992 Lubricating the swingarm pivots...

  • Page 104: Lubricating The Upper And Lower Arm Pivots

    lubrication chart. Left side Recommended lubricant: Lithium-soap-based grease 1. Upper grease nipple 2. Lower grease nipple EBU25030 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart.

  • Page 105: Lubricating The Steering Shaft

    Right side battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections. ECB00620 CAUTION: Never attempt to remove the battery cell seals, as this would permanently damage the battery.

  • Page 106: Replacing The Fuse

    Always keep the battery charged. Storing a To charge the battery discharged battery can cause permanent Have a Yamaha dealer charge the battery as soon battery damage. as possible if it seems to have discharged. Keep in To charge a sealed-type (MF) battery, a spe-...
  • Page 107 1. Low-pressure tire gauge 1. Main fuse 2. Owner’s tool kit 2. Spare fuse 3. Bolt 4. Battery cover If the fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off all electrical circuits. ECB00640 CAUTION: To prevent accidental short-circuiting, turn off...

  • Page 108: Replacing A Headlight Bulb

    2. Bolt 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 2. Disconnect the headlight coupler. 5. Install the battery cover by installing the bat- 3. Remove the headlight bulb holder cover.
  • Page 109 1. Headlight bulb holder cover 1. Headlight bulb holder 2. Headlight coupler EWB02230 WARNING 4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then Do not touch a headlight bulb when it is on or remove the defective bulb.

  • Page 110: Adjusting A Headlight Beam

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

  • Page 111: Replacing The Tail/Brake Light Bulb

    EBU25580 Rear Replacing the tail/brake light bulb If the tail/brake light bulb burns out, have a Yamaha dealer replace it. EBU25650 Removing a wheel 1. Loosen the wheel nuts. Front 1. Nut 2. Elevate the ATV and place a suitable stand under the frame.

  • Page 112: 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 113: 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 114: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25900 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 115: Storage

    increasing the chance of an accident. Test the section of this chapter. brakes after washing. Apply the brakes several 2. Turn the fuel cock lever to “OFF”. times at slow speeds to let friction dry out the 3. Drain the carburetor float chamber by loosen- linings.
  • Page 116 with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. 6. Lubricate all control cables and the pivoting points of all levers and pedals. 7. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground.

  • Page 117: Specifications

    EBU25960 SPECIFICATIONS Bore × stroke: EBU2597A 74.0 × 58.0 mm (2.91 × 2.28 in) Compression ratio: Dimensions: 9.50 :1 Overall length: Starting system: 1625 mm (64.0 in) Electric starter Overall width: Lubrication system: 1070 mm (42.1 in) Wet sump Overall height: Engine oil: 1040 mm (40.9 in) Type:...
  • Page 118 Engine oil quantity: Transmission: Without oil filter element replacement: Primary reduction system: 1.25 L (1.32 US qt) (1.10 Imp.qt) Spur gear With oil filter element replacement: Primary reduction ratio: 1.35 L (1.43 US qt) (1.19 Imp.qt) 76/22 (3.455) Air filter: Secondary reduction system: Air filter element: Chain drive...
  • Page 119 Front tire: Maximum: Front: Type: 30.5 kPa (4.4 psi) (0.305 kgf/cm Tubeless Rear: Size: 30.5 kPa (4.4 psi) (0.305 kgf/cm AT20 x 7-10 Front wheel: Manufacturer/model: DUNLOP/KT201 Wheel type: Rear tire: Panel wheel Rim size: Type: 10 x 5.5AT Tubeless Rear wheel: Size: AT19 x 10-9...
  • Page 120 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Neutral indicator light: Double wishbone 12 V, 1.7 W × 1 Spring/shock absorber type: Fuse: Coil spring/oil damper Wheel travel: Fuse: 190 mm (7.5 in) 15.0 A Rear suspension: Type: Swingarm Spring/shock absorber type:...

  • Page 121: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 122 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 123 INDEX Drive chain slack ............8-30 Accessories and loading ..........6-6 Air filter element, cleaning..........8-14 Engine break-in .............. 6-5 Engine, cold start ............6-1 Engine idling speed............8-20 Battery................8-36 Engine oil ............... 5-3 Brake and clutch levers, checking and lubricating ..8-33 Engine oil and oil filter element ........
  • Page 124 Light switch ..............4-2 Steering shaft, lubricating..........8-36 Storage................9-2 Suspension, lubricating the upper and lower arm Main switch ..............4-1 pivots................8-35 Maintenance and lubrication chart ......... 8-5 Swingarm pivots, lubricating ........8-34 Maintenance chart, emission control system ....8-3 Model label..............
  • Page 126 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2007.05-1.5x1 !

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