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Yamaha YFM250RZ 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
YFM25RZ
YFM250RZ
1BT-28199-60

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Summary of Contents for Yamaha YFM250RZ

  • 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 YFM25RZ YFM250RZ 1BT-28199-60...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2009.04-0.3×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM25RZ YFM250RZ 1BT-28199-60-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, 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM250R (YFM25R) (JY4AG03W090006627–)
  • Page 5 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 YFM25RZ/YFM250RZ OWNER’S MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st edition, April 2009 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 ....8-10 Accessories and loading ......6-6 Cleaning the air filter element ....8-13 Cleaning the spark arrester ......8-17 RIDING YOUR ATV ........7-1 Adjusting the carburetor ......8-19 GETTING TO KNOW YOUR ATV....7-2 Adjusting the engine idling speed .....8-20 RIDE WITH CARE AND GOOD Adjusting the throttle cable 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 4D3-2816L-20 43P-2816R-00 43P-2816P-00...
  • Page 13 27.5 kPa 0.275 kgf/cm² 0.275 kgf/cm² 4.0 psi 4.0 psi 4D3-2816M-M0 MODEL : YFM250R MAX. POWER : 14.0 kW MASS IN RUNNING ORDER : 150 kg 4D3-2156A-00 YEAR OF CONSTRUCTION : 2009 YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 5PG-2817L-10...
  • 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 permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
  • Page 15 NEVER use with drugs or alcohol. Adjust tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids. Turning 4WD-LOCK (“DIFF.LOCK”) takes more effort.
  • Page 16 This pictogram shows trailer Hitch Tow weight limit. (Combined weight of the trailer and all cargo in the trailer.) Overloading can cause loss of control. Loss of control can result in severe injury or death. This pictogram shows trailer Hitch Tongue weight limit.
  • 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 EBU17593 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 21 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 22 speed when climbing a hill. If you stall or roll Always use the size and type of tires specified in backwards, follow the special procedure for this manual. braking described in this manual. Dismount on Always maintain proper tire pressure as de- the uphill side or to a side if pointed straight up- scribed in this manual.
  • Page 23 closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT. Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels.

  • Page 24: 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 25: 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 26: Instrument And Control Functions

    EBU17733 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 27: Indicator Light

    EBU17782 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 28: Throttle Lever

    EBU18101 Regulate the speed of the ATV by varying the 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 29: Speed Limiter

    EBU18322 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. 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 30: 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 31: 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 32: 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 33: 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 34: Fuel Cock

    doctor immediately. If gasoline spills on your Recommended fuel: skin, wash with soap and water. If gasoline UNLEADED GASOLINE ONLY spills on your clothing, change your clothes. For Europe: Regular unleaded gasoline only with a research octane number of 91 or high- ECB00070 NOTICE Fuel tank capacity:...
  • Page 35 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 36: 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 37: 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 EBU18992 Adjusting the front shock absorber as- the seat holders and push down on the seat at the semblies rear.

  • Page 38: Adjusting The Rear Shock Absorber Assembly

    1. Loosen the locknut. 2. Turn the spring preload adjusting nut in direc- tion (a) to increase the spring preload and A special wrench can be obtained at a Yamaha thereby harden the suspension, and in direc- dealer to make this adjustment.
  • Page 39 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 40 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 41: 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 42 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 recommended brake fluid to specified level if necessary.

  • Page 43: 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 44: Drive Chain

    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 45 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 46: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are DUNLOP/KT201 working properly. Correct if necessary. Size: AT20 x 7-10 Type: Tubeless Rear: Manufacturer/model: DUNLOP/KT205A 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 47: 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 48: Starting A Warm Engine

    Ambient temp./starter (choke) position as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. 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.

  • Page 49: Shifting

    EBU20520 EBU20591 To start out and accelerate Shifting 1. Release the throttle lever, and then release This ATV has a 5-speed forward transmission. The the parking brake. transmission allows you to control the amount of ECB00200 power you have available at a given speed or for NOTICE starting, accelerating, climbing hills, etc.

  • Page 50: 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 51: Parking

    If any engine trouble should occur during the EWB00850 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 52: Accessories And Loading

    Yamaha 3. Release the rear brake. vehicles. Yamaha is not in a position to test the products that these aftermarket companies pro- duce. Therefore, Yamaha can neither endorse nor...
  • Page 53 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 54 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 55: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 56: Getting To Know Your Atv

    EBU21616 RIDE WITH CARE AND GOOD JUDGMENT 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 57 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 58 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 59 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 60 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 box in this section or ve- the maximum engine power available and de- hicle labeling).
  • Page 61 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 62 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 63: 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 64 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 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 control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.

  • Page 66: 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 67: 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 68 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 69 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 70: 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 71 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 72: 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 the front wheels slightly uphill. When riding on Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to slopes, be sure not to make sharp turns either up...

  • Page 73: 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 74: 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 75: 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 76: 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 77 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 78: Periodic Maintenance And Adjustment

    If you are not fa- EBU21691 miliar with vehicle service, have a Yamaha Owner’s manual and tool kit dealer perform the service. Be sure to put this owner’s manual and the low-...
  • Page 79 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. 1. Low-pressure tire gauge 2. Owner’s tool kit 3. Owner’s manual 4. Manual cover The service information included in this manual and the tools provided in the owner’s tool kit are in-...

  • Page 80: 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 81 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 82: 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 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 looseness or damage, and replace if √ √ √ √ Wheel hub bearings necessary. • Check operation and for excessive play, and re- √...
  • Page 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Moving parts and √ √ √ √ • Lubricate. cables • Check operation and correct if necessary. Throttle lever hous- •...

  • Page 85: 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 86 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DR7EA To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

  • Page 87: Engine Oil And Oil Filter Element

    3. Remove the engine oil filler cap, and then wipe the engine oil dipstick off with a clean If a torque wrench is not available when installing rag. a spark plug, a good estimate of the correct torque 4. Insert the dipstick into the filler hole (without is 1/4–1/2 turn past finger tight.
  • Page 88 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level. NOTICE: Be sure the engine oil is at the correct level, otherwise engine damage may result.
  • Page 89 1. Oil filter element cover 1. Oil filter element 2. Bolt 2. O-ring 6. Check the O-rings for damage and replace 7. Install a new oil filter element. them if necessary. Make sure that the O-rings are properly seated. 8. Install the oil filter element cover by installing the bolts, and then tighten them to the speci- fied torque.

  • Page 90: Cleaning The Air Filter Element

    9. Install the engine oil drain bolt and tighten it to ECB00300 NOTICE the specified torque. In order to prevent clutch slippage (since the Tightening torque: engine oil also lubricates the clutch), do not Engine oil drain bolt: mix any chemical additives. Do not use oils 20 Nm (2.0 m·kgf, 14 ft·lbf) with a diesel specification of “CD”...
  • Page 91 There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air fil- ter case. 1. Air filter case cover 2.
  • Page 92 1. Wing bolt 1. Sponge material 2. Air filter element 2. Air filter element frame 3. Washer 8. Wash the sponge material gently but thor- 6. Remove the wing bolt and washer from the air oughly in solvent. WARNING! Always use filter element.
  • Page 93 14. Install the washer onto the air filter element damaged. frame, and then insert the wing bolt into the 11. Apply Yamaha foam air filter oil or other qual- hole in the air filter element frame. NOTICE: ity foam air filter oil to the sponge material.

  • Page 94: 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 95 1. Bolt 1. Tailpipe 2. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 4. Make sure the gasket is properly positioned, muffler, and then remove the gasket. then insert the tailpipe into the muffler and 3.

  • Page 96: Adjusting The Carburetor

    Therefore, 1. Gasket most carburetor adjustments should be left to a 2. Tailpipe Yamaha dealer, who has the necessary profes- 3. Bolt sional knowledge and experience. The adjustment described in the following section, however, may 5. Install the bolts and tighten them to the speci- be performed by the owner as part of routine main- fied torque.

  • Page 97: Adjusting The Engine Idling Speed

    3. Check the engine idling speed and, if neces- If the specified idling speed cannot be obtained as sary, adjust it to specification by turning the described above, have a Yamaha dealer make the throttle stop screw at the carburetor. To in- adjustment.

  • Page 98: Adjusting The Throttle Cable Free Play

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

  • Page 99: Brakes

    If a brake pad has worn to the point the wear indicator groove has almost disappeared, that a wear indicator groove almost appears, have have a Yamaha dealer replace the brake pads as a Yamaha dealer replace the brake pads as a set. a set. 8-22...

  • Page 100: Checking The Brake Fluid Level

    Front brake 1. Wear indicator groove 1. Minimum level mark EBU28930 Rear brake 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 101 If the rear brake fluid level is low, replenish as fol- lows. 1. Remove the brake fluid reservoir cap cover by removing the bolt. 1. Brake fluid reservoir cap 3. Refill with brake fluid. 4. Install the brake fluid reservoir cap. 5.

  • Page 102: 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. No free play maintenance and lubrication chart. In addition,...

  • Page 103: 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. Adjusting bolt 2. Cable length “A”...

  • Page 104: Brake Light Switches

    The brake light switch for the brake pedal can be that it does not turn together with the lock- adjusted as follows, but the other brake light nut. [ECB00521] switches should be adjusted by a Yamaha dealer. 8-27...

  • Page 105: Adjusting The Clutch Lever Free Play

    EBU24811 Adjusting the clutch lever free play The brake light switch is properly adjusted when The clutch lever free play must be checked and, if the brake light comes on just before braking takes necessary, adjusted at the intervals specified in the effect.

  • Page 106: Drive Chain Slack

    5. Slide the rubber cover to its original position. 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...
  • Page 107 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 108: Lubricating The Drive Chain

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

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

    EWB02581 Recommended lubricants: WARNING Brake lever: Inspect cables frequently and replace if dam- Silicone grease aged. Corrosion can result when the cable Clutch lever: sheaths become damaged, and cables can Lithium-soap-based grease also become frayed or kinked, which could restrict the operation of controls and lead to Brake lever an accident or injury.

  • Page 110: 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. EBU24994 EBUM0170...

  • Page 111: Lubricating The Upper And Lower Arm Pivots

    Left side EBU25032 1. Upper grease nipple Lubricating the upper and lower arm 2. Lower grease nipple pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun. Recommended lubricant: Lithium-soap-based grease 8-34...

  • Page 112: Lubricating The Steering Shaft

    Right side EBU2522A Battery This model is equipped with a VRLA (Valve Regu- lated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened. ECB00620 NOTICE Never attempt to remove the battery cell seals,...
  • Page 113 Batteries produce explosive gases. Keep 3. Disconnect the negative battery lead first, sparks, flame, cigarettes or other sources of ig- then the positive battery lead by removing nition away. Ventilate when charging or using their bolt. NOTICE: When removing the bat- in an enclosed space.
  • Page 114 To charge the battery ECB00940 NOTICE Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in Always keep the battery charged. Storing a dis- mind that the battery tends to discharge more...

  • Page 115: Replacing The Fuse

    1. Battery holding plate 1. Battery holding plate 2. Bolt 2. Bolt EBUM0182 Replacing the fuse The fuse holder is located beside the battery and can be accessed as follows: 1. Remove the seat. (See page 4-11.) 2. Unhook the band securing the owner’s tool kit, and then remove the battery holding plate by removing the bolts.

  • Page 116: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 2. Disconnect the headlight coupler. 4. If the fuse immediately blows again, have a 3. Remove the headlight bulb holder cover. Yamaha dealer check the electrical system. 8-39...
  • Page 117 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 118: Adjusting A Headlight Beam

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

  • Page 119: 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 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 EBU25902 may cause water seepage and deteriora- 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 123: 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 124 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 125: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Cylinder arrangement: Forward-inclined single cylinder Overall length: Displacement: 1625 mm (64.0 in) 249 cm³ Overall width: Bore × stroke: 1070 mm (42.1 in) 74.0 × 58.0 mm (2.91 × 2.28 in) Overall height: Compression ratio: 1040 mm (40.9 in) 9.50 :1 Seat height: Starting system:...
  • Page 126 1.35 L (1.43 US qt, 1.19 Imp.qt) Secondary reduction ratio: Air filter: 38/14 (2.714) Air filter element: Transmission type: Wet element Constant mesh 5-speed Fuel: Operation: Recommended fuel: Left foot operation YFM250RZ Unleaded gasoline only YFM25RZ Regular unleaded gasoline only 10-2...
  • 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/cm², 4.0 psi) 27/24 (1.125) Rear: 5th:...
  • 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, 30/30 W × 2 Recommended fluid: DOT 4 Tail/brake light: 12 V, 5.0/21.0 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 Accessories and loading ..........6-6 Engine break-in .............. 6-4 Air filter element, cleaning ..........8-13 Engine, cold start ............6-1 Engine idling speed ............8-20 Engine oil ............... 5-3 Battery ................8-35 Engine oil and oil filter element ........8-10 Brake and clutch levers, checking and lubricating ..
  • Page 133 Maintenance and lubrication chart ......... 8-5 Suspension, lubricating the upper and lower arm Maintenance chart, emission control system ....8-3 pivots ................. 8-34 Model label ..............11-2 Swingarm pivots, lubricating ........8-33 Neutral indicator light ............. 4-2 Tail/brake light bulb, replacing ........8-41 Throttle cable free play, adjusting ........
  • Page 134 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009.04-0.3×1 CR...

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