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Yamaha YFM250R Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
This A
OWNER'S MANUAL
YFM25RSEY
4D3-28199-63

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Summary of Contents for Yamaha YFM250R

  • 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 YFM25RSEY This A 4D3-28199-63...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2008.05-0.7x2 ! IMPRIMÉ SUR PAPIER RECYCLÉ (E,F,S) IMPRESO EN PAPEL RECICLADO...
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM25RSEY This A 4D3-28199-63-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 98 / 37 /EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM250R ( YFM25R )
  • 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 EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Starter (choke) ......... 4-10 Seat ............4-10 Adjusting the front shock absorber LOCATION OF THE WARNING AND assemblies ..........4-11 SPECIFICATION LABELS ......2-1 Adjusting the rear shock absorber assembly ..........4-16 DESCRIPTION ..........
  • Page 9 Parking on a slope ........6-6 Cleaning the spark arrester ..... 8-17 Accessories and loading ......6-6 Adjusting the carburetor ......8-19 Adjusting the engine idling speed .... 8-19 RIDING YOUR ATV ........7-1 Adjusting the throttle cable free play ..8-20 Valve clearance ........
  • Page 10 Replacing the fuse ........8-38 Replacing a headlight bulb ...... 8-39 Adjusting a headlight beam ..... 8-42 Replacing the tail/brake light bulb ... 8-42 Removing a wheel ........8-42 Installing a wheel ........8-43 Troubleshooting ........8-44 Troubleshooting chart ......8-45 CLEANING AND STORAGE......

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION 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 4D3-2816L-00 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 0.275 kgf/cm 0.275 kgf/cm death. OPERATING TIRE PRESSURE : Set with tires cold 4.0 psi 4.0 psi 0 Recommended : Front...

  • Page 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 The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 21: Instrument And Control Functions

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

  • Page 22: Handlebar Switches

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

  • Page 23: Speed Limiter

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

  • Page 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 NOTICE Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. EWB00310 WARNING Do not overfill the fuel tank.
  • Page 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 EBU29300 Adjusting the front shock absorber the seat holders and push down on the seat at the assemblies rear.
  • Page 32 Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- A special wrench can be obtained at a Yamaha er for any service. dealer to make this adjustment.
  • Page 33 (0.06 in). 3. Tighten the locknut to the specified torque. Tightening torque: Spring preload setting: Locknut: Minimum (hard): 42 Nm (4.2 m·kgf, 30 ft·lbf) Distance A = 197.6 mm (7.78 in) Standard: ECB00080 Distance A = 206.0 mm (8.11 in) NOTICE Maximum (soft): Always tighten the locknut against the adjust-...
  • Page 34 Compression damping force Compression damping force (for fast compression damping) 1. To increase the compression damping force and thereby harden the compression damp- ing, turn the adjusting bolt in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting bolt in direction (b).
  • Page 35 Compression damping setting (for fast com- pression damping): Minimum (soft): 4 turn(s) out from the fully turned in position Standard: 2 turn(s) out from the fully turned in position Maximum (hard): Fully turned in Make sure that the position indicator marks are aligned when the shock absorber assembly is set 1.

  • Page 36: Adjusting The Rear Shock Absorber Assembly

    ECB00090 Uneven adjustment can cause poor handling NOTICE and loss of stability, which could lead to an accident. Never turn an adjusting mechanism beyond the minimum and maximum settings. EBU29310 Adjusting the rear shock absorber assembly Although the total number of clicks of a damping force adjusting mechanism may not exactly match The spring preload, rebound damping and com- the above specifications due to small differences in...
  • Page 37 Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the A special wrench can be obtained at a Yamaha shock absorber assembly to a Yamaha deal- dealer to make this adjustment. er for any service.
  • Page 38 Spring preload setting: Minimum (hard): Distance A = 220.0 mm (8.66 in) Standard: Distance A = 228.0 mm (8.98 in) Maximum (soft): Distance A = 232.0 mm (9.13 in) 3. Tighten the locknut to the specified torque. Tightening torque: Locknut: 1.
  • Page 39 the compression damping force and thereby hard- Compression damping setting: en the damping, and in direction (b) to decrease Minimum (soft): the compression damping force and thereby soft- 12 click(s) in direction (b)* en the damping. Standard: 7 click(s) in direction (b)* Maximum (hard): 2 click(s) in direction (b)* * With the adjusting screw fully turned in di-...
  • Page 40 EWB02500 WARNING Suspension components become hot during operation. Never touch the compression damping force adjusting screw, the rebound damping force adjusting dial or the oil reser- voir with your bare hand or skin until suspen- sion components have cooled. 4-20...

  • Page 41: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 42 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, 8-21, 8-22, 8-26 Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 43: Fuel

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

  • Page 44: 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 45: Measuring The Tire Pressure

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

  • Page 46: Tire Wear Limit

    EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). 1. Low-pressure tire gauge Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: 1. Tire wear limit Recommended pressure: Front EBU19840...

  • Page 47: 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 48 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 49: 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 50 EBU20590 wheelie, which would increase the chance of To start out and accelerate an accident, including an overturn. 1. Release the throttle lever, and then release the parking brake. EBU20650 ECB00200 To decelerate NOTICE When slowing down or stopping, release the throt- Always close the throttle before shifting gears, tle and apply the brakes smoothly and evenly.

  • Page 51: 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 52: 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 53 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 54 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 55: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 56: Getting To Know Your Atv

    EBU21613 Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum performance until GETTING TO KNOW YOUR ATV you are totally familiar with the ATV’s handling and This ATV is intended for recreational use by expe- performance characteristics.
  • Page 57 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 58 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 59 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 60 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 61 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 62: 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 63 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 64 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 65 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 66: Turning Your Atv

    these components. ECB00230 NOTICE With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then Do not shift gears without releasing the throt- release the parking brake. Open the throttle grad- tle.
  • Page 67 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 68: 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 69 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 70: 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 71: 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 72: 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 73 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 74: 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 75: 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 76 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 77: Periodic Maintenance And Minor Repair

    1. Low-pressure tire gauge can cause shocks or start fires. Turn off the en- 2. Owner’s tool kit gine when performing maintenance unless 3. Owner’s manual otherwise specified. Have a Yamaha dealer 4. Panel perform the service if you are not familiar with...
  • Page 78 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING...

  • Page 79: 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 80 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 81: 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 82 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 83 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Moving parts and √ √ √ √ 21 * Lubricate. cables Check operation and correct if necessary. Throttle lever hous- Check throttle cable free play and adjust if neces- √...

  • Page 84: 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 85: 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 86 To check the engine oil level 1. Place the ATV on a level surface. 2. Check the engine oil level on a cold engine. If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading.
  • Page 87 To change the engine oil (with or without oil ing the bolts, and then remove the oil filter el- filter element replacement) ement. 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil.
  • Page 88 8. Install the engine oil drain bolt and tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 20 Nm (2.0 m·kgf, 14.5 ft·lbf) 9. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap.

  • Page 89: Cleaning The Air Filter Element

    with a diesel specification of “CD” or oils of necessary. a higher quality than specified. In addition, EBU23704 do not use oils labeled “ENERGY CONSERV- Cleaning the air filter element ING II” or higher. The air filter element should be cleaned at the in- Make sure that no foreign material enters the tervals specified in the periodic maintenance and crankcase.
  • Page 90 1. Air filter case check hose 1. Air filter case cover 2. Air filter case cover holder 1. Place the ATV on a level surface. 4. Loosen the wing bolt. 2. Remove the seat. (See page 4-10.) 5. Remove the air filter element together with the 3.
  • Page 91 1. Wing bolt 1. Sponge material 2. Air filter element 2. Air filter element frame 6. Remove the wing bolt and washer from the air 8. Wash the sponge material gently but thor- filter element. oughly in solvent. 7. Remove the sponge material from the air filter EWB01940 WARNING element frame.
  • Page 92 ECB00440 13. Install the washer onto the air filter element NOTICE frame, and then insert the wing bolt into the hole in the air filter element frame. Do not twist the sponge material when squeez- ECB00451 ing it. NOTICE Be sure to install the washer with the bent edge facing outward as shown.

  • Page 93: Cleaning The Spark Arrester

    EBU28900 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 94 1. Tailpipe 1. Gasket 2. Spark arrester 2. Tailpipe 3. Bolt 4. Make sure the gasket is properly positioned, 5. Install the bolts and tighten them to the speci- then insert the tailpipe into the muffler and fied torque. align the bolt holes. Tightening torque: Tailpipe bolt: 11 Nm (1.1 m·kgf, 8.0 ft·lbf)

  • Page 95: Adjusting The Carburetor

    1. Start the engine and warm it up. requires very sophisticated adjustment. Therefore, 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 96: Adjusting The Throttle Cable Free Play

    Engine idling speed: play, turn the adjusting bolt in direction (b). 1500–1600 r/min If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EBU24044 Adjusting the throttle cable free play The throttle cable free play should be checked...

  • Page 97: 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 98: Checking The Brake Fluid Level

    If a brake pad pads for wear and the brake system for leakage. has worn to the point that the wear indicator almost touches the brake disc, have a Yamaha dealer re- 8-22...
  • Page 99 Front brake Rear brake 1. Minimum level mark 1. Minimum level mark If the rear brake fluid level is low, replenish as fol- lows. 1. Remove the brake fluid reservoir cap cover by removing the bolt. 8-23...
  • Page 100 1. Bolt 1. Brake fluid reservoir cap 2. Brake fluid reservoir cap cover 3. Refill with brake fluid. 2. Remove the brake fluid reservoir cap. 4. Install the brake fluid reservoir cap. 5. Install the brake fluid reservoir cap cover by installing the bolt.

  • Page 101: Changing The Brake Fluid

    Yamaha dealer check the cause. EBU24291 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic 1. Brake lever free play maintenance and lubrication chart. In addition,...

  • Page 102: Checking The Brake Pedal Position

    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. EBU24591 Checking the brake pedal position The brake pedal position must be checked and, if 1.

  • Page 103: Adjusting The Parking Brake Free Play

    Yamaha dealer. parking brake lever to the right. 2. Fully loosen the locknut and the adjusting bolt at the rear brake caliper. EBU24710 Adjusting the parking brake free play 3. Loosen the locknut on the brake cable.

  • Page 104: Brake Light Switches

    The brake light switch for the brake pedal can be together with the locknut. adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. Tightening torque: Locknut (rear brake caliper): 16 Nm (1.6 m·kgf, 11.6 ft·lbf)

  • Page 105: Adjusting The Clutch Lever Free Play

    10.0 mm (0.20–0.39 in) as shown. If the free play is incorrect, adjust it as follows. 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. 8-29...

  • Page 106: Drive Chain Slack

    EBU26862 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. To check the drive chain slack 1. Place the ATV on a level surface. When checking and adjusting the drive chain slack, there should be no weight on the ATV and all tires must be touching the ground.

  • Page 107: Lubricating The Drive Chain

    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: 4. Shift the transmission into neutral. Rear axle pinch bolt: 5.

  • Page 108: Checking And Lubricating The Cables

    ECB00560 essary. If a cable is damaged or does not move NOTICE smoothly, have a Yamaha dealer check or replace The drive chain must be lubricated after wash- ing the ATV or riding in the rain. Recommended lubricant: 1.

  • Page 109: Checking And Lubricating The Brake And Clutch Levers

    aged. Corrosion can result when the cable Brake lever sheaths become damaged, and cables can also become frayed or kinked, which could re- strict the operation of controls and lead to an accident or injury. EBU24922 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever...

  • Page 110: Checking The Shift Pedal

    If there is play EBU25032 in a wheel hub or if a wheel does not turn smoothly, Lubricating the upper and lower arm have a Yamaha dealer check the wheel hub bear- pivots ings. The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart.

  • Page 111: Lubricating The Steering Shaft

    Lubricate the pivoting points using a grease gun. Right side Recommended lubricant: Lithium-soap-based grease Left side 1. Upper grease nipple 2. Lower grease nipple EBU25102 Lubricating the steering shaft 1. Upper grease nipple The steering shaft must be lubricated at the inter- 2.
  • Page 112 lated Lead Acid) battery. There is no need to check KEEP OUT OF REACH OF CHILDREN. the electrolyte or to add distilled water. However, the battery lead connections need to be checked To remove the battery and, if necessary, tightened. 1.
  • Page 113 4. Pull the battery out of its compartment. 4. Install the seat. (See page 4-10.) 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 114: Replacing The Fuse

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

  • Page 115: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a If the fuse is blown, replace it as follows. Yamaha dealer check the electrical system. 1. Turn the key to “OFF” and turn off all electrical 5. Install the battery cover by installing the bat- circuits.
  • Page 116 1. Headlight unit 1. Headlight bulb holder cover 2. Bolt 2. Headlight coupler 2. Disconnect the headlight coupler. 4. Remove the headlight bulb holder by pushing 3. Remove the headlight bulb holder cover. it in and turning it counterclockwise, and then remove the defective bulb.
  • Page 117 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. EWB02230 ECB00650 WARNING NOTICE Do not touch a headlight bulb when it is on or Do not touch the glass part of the headlight immediately after it is turned off. You can be bulb to keep it free from oil, otherwise the burned or a fire could start if the bulb touches transparency of the glass, the luminosity of the...

  • Page 118: Adjusting A Headlight Beam

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

  • Page 119: Installing A Wheel

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

  • Page 120: 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 121: 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 122: 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 123: 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 124 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 125: Specifications

    EBU25960 SPECIFICATIONS EBU2597B Engine: Engine type: Air cooled 4-stroke, SOHC Dimensions: Cylinder arrangement: Overall length: Forward-inclined single cylinder 1625 mm (64.0 in) Displacement: Overall width: 249.0 cm 1070 mm (42.1 in) Bore × stroke: Overall height: 74.0 × 58.0 mm (2.91 × 2.28 in) 1040 mm (40.9 in) Compression ratio: Seat height:...
  • Page 126 Fuel reserve amount: 50 ˚C 1.0 L (0.26 US gal, 0.22 Imp.gal) Carburetor: Manufacturer: SAE 5W-30 MIKUNI SAE 10W-30 Type × quantity: BSR29 x 1 SAE 10W-40 Spark plug (s): SAE 15W-40 Manufacturer/model: NGK/DR7EA SAE 20W-40 Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) SAE 20W-50 Clutch: Clutch type:...
  • Page 127 Gear ratio: Loading: 1st: Maximum loading limit: 37/13 (2.846) 100.0 kg (220 lb) 2nd: (Total weight of rider, cargo, accessories, and tongue) 33/18 (1.833) Tire air pressure (measured on cold tires): 3rd: Recommended: 29/21 (1.381) Front: 4th: 27.5 kPa (0.275 kgf/cm , 4.0 psi) 27/24 (1.125) Rear:...
  • Page 128 Recommended fluid: Voltage, capacity: DOT 4 12 V, 6.0 Ah Rear brake: Headlight: Type: Bulb type: Single disc brake Krypton bulb Bulb voltage, wattage × quantity: Operation: Right foot operation Headlight: 12 V, 30.0/30.0 W × 2 Recommended fluid: DOT 4 Tail/brake light: 12 V, 0.5/3.9 W ×...

  • Page 129: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 130 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 131 1. Model label 11-3...
  • Page 132 INDEX Drive chain, lubricating..........8-31 Drive chain slack ............8-30 Accessories and loading ..........6-6 Air filter element, cleaning..........8-13 Engine break-in .............. 6-5 Engine, cold start ............6-1 Battery................8-35 Engine idling speed............8-19 Brake and clutch levers, checking and Engine oil ...............
  • Page 133 Specifications............... 10-1 Speed limiter ..............4-3 Label locations ..............2-1 Starter (choke) ............. 4-10 Light switch ..............4-2 Start switch ..............4-2 Steering shaft, lubricating ..........8-35 Main switch ..............4-1 Storage ................9-2 Maintenance and lubrication chart ........8-5 Suspension, lubricating the upper and lower arm Maintenance chart, emission control system ....8-3 pivots .................
  • Page 134 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2008.05-0.7x2 !

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