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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM35RW
10P-28199-60

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Summary of Contents for Yamaha YFM35RW

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM35RW 10P-28199-60...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2006.06-0.7×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 OWNER’S MANUAL YFM35RW 10P-28199-60-E0...
  • Page 5 INTRODUCTION EBU17320 Congratulations on your purchase of the Yamaha YFM35RW. This ATV represents the result of many years of 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 or death to the ATV operator, a bystander, or a person inspecting or...
  • 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 Fuel tank cap ..........4-9 Fuel ............4-10 LOCATION OF THE WARNING AND Fuel cock ..........4-11 SPECIFICATION LABELS ......2-1 Starter (choke) ..........4-12 Steering lock ..........4-13 DESCRIPTION ..........3-1 Seat ............4-14 Left view ............3-1 Adjusting the front shock absorber Right view............
  • Page 9 OPERATION ..........6-1 PERIODIC MAINTENANCE AND MINOR Starting a cold engine ........ 6-1 REPAIR ............8-1 Starting a warm engine ......6-3 Owner’s manual and tool kit .......8-1 Operating the drive select lever and Periodic maintenance and lubrication driving in reverse ........6-3 chart ............8-3 Shifting ............
  • Page 10 Checking and lubricating the brake and SPECIFICATIONS ........10-1 shift pedals ..........8-32 Checking the wheel bearings ....8-32 CONSUMER INFORMATION.......11-1 Lubricating the swingarm pivots ....8-32 Identification numbers .......11-1 Lubricating the rear suspension relay arm and connecting arm pivoting points ..8-33 Lubricating the upper and lower arm pivots ............
  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION EBU17462 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 12 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 13 speed when climbing a hill. If you stall or roll Always be sure there are no obstacles or people backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 14 nition such as the pilot lights of water heat- EWB00070 WARNING ers and clothes dryers. Gasoline can catch fire and you could be burned. Always operate your ATV in an area with ade- When transporting the ATV in another vehi- quate ventilation.
  • 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.
  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Headlight 1. Spark arrester 2. Front wheel 2. Seat 3. Fuel cock 3. Drive select lever 4. Rear wheel 4. Fuel tank cap 5. Shift pedal 5. Main switch 6. Brake pedal...
  • Page 19: Controls And Instruments

    EBU17712 Controls and instruments 1. Clutch lever 2. Parking brake lever 3. Speedometer unit 4. Brake lever 5. Throttle lever 6. Engine stop switch 7. Starter (choke) 8. Handlebar switches NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual.
  • Page 20: Instrument And Control Functions

    EBU17731 INSTRUMENT AND CONTROL FUNCTIONS EBU28040 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The auxiliary light, taillight and license plate light come on, and the engine can be started. The key cannot be removed.
  • Page 21: Indicator Lights

    EBU17791 EBU17860 Indicator lights Neutral indicator light “ ” This indicator light comes on when the transmis- sion is in the neutral position. EBU27980 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. EBU28050 Speedometer The speedometer shows the riding speed.
  • Page 22: Handlebar Switches

    EBU18061 Handlebar switches 1. Engine stop switch “ ” EBU18080 1. Light switch “ / ” Engine stop switch “ ” 2. Hazard switch “ ” Set this switch to “ ” before starting the engine. 3. Turn signal switch “ ”...
  • Page 23: Throttle Lever

    ECB00050 EBU18170 Horn switch “ ” CAUTION: Press the switch to sound the horn. See the starting instructions on page 6-1 prior to starting the engine. EBU28000 Hazard switch “ ” With the key in the “ON” position, turn this switch to EBU28061 Light switch “...
  • Page 24: Speed Limiter

    If the throttle does not work smoothly, check for the cause. Correct the problem be- fore riding the ATV or consult a Yamaha dealer. 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in)
  • Page 25: Clutch Lever

    3. Tighten the locknut. EWB00240 WARNING Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be dam- aged.
  • Page 26: Brake Pedal

    1. Brake lever 1. Brake pedal EBU28070 EBU18520 Brake pedal Parking brake lever The brake pedal is located on the right side of the Use the parking brake before starting the engine or ATV. parking the ATV, especially on a slope. To apply This model is equipped with a unified brake sys- the parking brake, move the parking brake lever in tem.
  • Page 27: 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 28: Drive Select Lever

    1. Shift pedal 1. Drive select lever EBU18571 EBU18720 Drive select lever Fuel tank cap The drive select lever is used for driving the ATV Remove the fuel tank cap by turning it counter- either forward or in reverse. See the “Operating the clockwise.
  • Page 29: Fuel

    1. Fuel tank filler tube 2. Fuel level 1. Fuel tank cap Recommended fuel: UNLEADED GASOLINE ONLY EBU18750 Fuel For Europe: Regular unleaded gasoline only with a research octane number of 91 or high- Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as Fuel tank capacity: shown.
  • Page 30: Fuel Cock

    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. Fuel expands when it heats up.
  • Page 31: Starter (Choke)

    1. Arrow mark pointing to “ON” 1. Arrow mark pointing to “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.
  • Page 32: Steering Lock

    Move the starter (choke) in direction (b) to turn off EBU28010 Steering lock the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Steering lock cap 2. Steering lock 1. Starter (choke) “ ”...
  • Page 33: Seat

    To unlock the steering To install the seat 1. Open the steering lock cap, and then insert Insert the projections on the front of the seat into the key. the seat holders and push down on the seat at the 2.
  • Page 34 1. Special wrench Spring preload setting: Minimum (soft): 1. Spring preload adjusting ring Standard: 2. Position indicator Maximum (hard): NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-15...
  • Page 35: Adjusting The Rear Shock Absorber Assembly

    Adjust the spring preload as follows. NOTE: 1. Loosen the locknut. A special wrench can be obtained at a Yamaha 2. Turn the adjusting nut in direction (a) to in- dealer to make this adjustment. crease the spring preload and thereby harden...
  • Page 36 1. Special wrench 1. Distance A 3. Tighten the locknut to the specified torque. Spring preload setting: Minimum (hard): Tightening torque: Distance A = 218.5 mm (8.6 in) Locknut: Standard: 42 Nm (4.2 m·kgf, 30 ft·lbf) Distance A = 228.5 mm (9.0 in) Maximum (soft): ECB00080 Distance A = 233.5 mm (9.2 in)
  • Page 37 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. 4-18...
  • Page 38: Pre-Operation Checks

    Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 39 ITEM ROUTINE PAGE • Check operation, and correct if necessary. Clutch • Lubricate cable if necessary. 8-26 • Check lever free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary.
  • Page 40: Fuel

    Brake lever and brake pedal (See page 4-10.) Check that there is no free play in the brake le- EWB00520 ver. If there is free play, have a Yamaha dealer WARNING check the brake system. Do not overfill the fuel tank. Fuel expands Check for correct brake pedal height.
  • Page 41: Throttle Lever

    Apply the open smoothly and spring back to the idle position brakes firmly for one minute. If there is any leak- when released. Have a Yamaha dealer correct if age, have a Yamaha dealer check the brake sys- necessary. tem. EBU19770...
  • Page 42: Measuring The Tire Pressure

    Size: Minimum tire pressure: AT21 x 7-10 Front: Type: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Tubeless Rear: Rear: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Manufacturer: • Use no more than the following pressures MAXXIS when seating the tire beads. Size: Maximum tire seating pressure: AT20 x 10-9 Front:...
  • Page 43: Tire Wear Limit

    Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Low-pressure tire gauge Front Set the tire pressure when the tires are cold. Set 28.0 kPa (4.1 psi) (0.280 kgf/cm²) the tire pressures to the following specifications: Rear...
  • Page 44: 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 45: 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 46 5. Use the starter (choke) in reference to the fig- Ambient temp./starter (choke) position ure: NOTE: Be sure to move the starter lever gently to keep the correct starter lever assembly position. Position (1): Cold engine start with ambient temperature below 5 °C (40 °F).
  • Page 47: Starting A Warm Engine

    7. If the engine is started with the starter (choke) EBU20340 Operating the drive select lever and in position (1), the starter (choke) should be driving in reverse returned to position (2) to warm up the engine. ECB00170 If the engine is started with the starter (choke) CAUTION: in position (2), keep the starter (choke) in this Before shifting, stop the ATV, otherwise the...
  • Page 48: Shifting

    When in reverse, the reverse indicator light should be on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 5. Check behind you for people or obstacles, and then release the brake pedal.
  • Page 49 To shift into neutral, return the throttle lever to the ECB00200 CAUTION: closed position, apply the clutch, and then repeat- edly depress the shift pedal until it stops. Always close the throttle before shifting gears, When it stops, it will be in first gear. Raise the pedal otherwise damage to the engine and drive train slightly to reach the neutral position.
  • Page 50: Engine Break-In

    EWB00730 ECB00180 WARNING CAUTION: Opening the throttle abruptly or releasing the Even with the transmission in the neutral po- clutch lever too quickly could make the ATV sition, do not coast for long periods of time wheelie, which would increase the chance of with the engine off, and do not tow the ATV an accident, including an overturn.
  • Page 51: Parking

    Since the engine is brand new, do not put an ex- Yamaha dealer check the ATV. cessive load on it for the first 320 km (200 mi) or 20 hours. The various parts in the engine wear and...
  • Page 52: Parking On A Slope

    EBU20900 4. With the front and rear brakes applied, pull the Parking on a slope clutch lever, shift into first gear, and then re- EWB00870 lease the clutch lever, brake lever and brake WARNING pedal. Avoid parking on hills or other inclines. Park- NOTE: ing on a hill or other incline could cause the Make sure that the neutral indicator light goes off.
  • Page 53: Accessories And Loading

    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 Load cargo on the carriers as close to the center EWB00820 WARNING of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, Never exceed the stated load capacity for this and center it.
  • Page 55: Riding Your Atv

    EBU21141 RIDING YOUR ATV...
  • Page 56: Getting To Know Your Atv

    EBU28120 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 Not recommended for children under 16 years This ATV is designed to carry operator only – of age. passengers prohibited. EWB01390 EWB01400 WARNING WARNING A child under 16 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 90 cc.
  • Page 58 Apparel EWB01410 WARNING Always wear an approved motorcycle helmet that fits properly. Never operate this ATV without wearing an ap- You should also wear: proved motorcycle helmet, eye protection and eye protection (goggles or face shield) protective clothing. Operating without an ap- gloves proved motorcycle helmet increases your boots...
  • Page 59 in the Owner’s Manual. Failure to inspect the ATV before operating or failure to properly maintain the ATV increases the possibility of an accident or equipment damage. EWB01440 WARNING Always use the size and type tires specified in the Owner’s Manual for this ATV on page 5-4. Always maintain proper tire pressure as de- scribed in the Owner’s Manual on page 5-5.
  • Page 60 Speed limiter Loading and accessories For riders less experienced with this model, the As originally equipped, this ATV is not designed to throttle lever housing is equipped with a speed lim- carry cargo or tow a trailer. If you choose to add ac- iter.
  • Page 61 Always follow the instructions in your Own- EWB01470 WARNING er’s Manual for carrying cargo or pulling a trailer. Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation. Removing even one hand or During operation foot can reduce your ability to control the ATV Always keep your feet on the footboards during op-...
  • Page 62 ATV should be gen- Do not operate, idle, or park the ATV in dry uine Yamaha or equivalent components de- grass, dry ground cover, or combustible ma- signed for use on this ATV and should be terials.
  • Page 63: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE This ATV is designed for use on unpaved surfaces only. Riding on paved surfaces can cause loss of control. EWB01510 WARNING While riding on unpaved public streets or roads Always avoid paved surfaces, including side- may be legal in your area, such operation can in- walks, driveways, parking lots and streets.
  • Page 64 EWB01520 EWB01530 WARNING WARNING Never operate this ATV on any paved street, Go slowly and be extra careful when operating paved road or motorway. You can collide with on unfamiliar terrain. Always be alert to chang- another vehicle. In many areas, it is illegal to ing terrain conditions when operating the ATV.
  • Page 65 when operating on excessively rough, slippery or loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. EWB01550 WARNING Always mount a caution flag on the ATV to make you more visible when operating in areas where you might not be seen by other vehicles.
  • Page 66 haust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then release the parking brake.
  • Page 67: Turning Your Atv

    EWB01720 TURNING YOUR ATV WARNING To achieve maximum traction on unpaved surfac- es, the two rear wheels are mounted solidly on one Always open the throttle gradually and release axle and turn together at the same speed. There- the clutch lever slowly. Otherwise, the ATV could wheelie which would increase the fore, unless the wheel on the inside of the turn is al- chance of an accident.
  • Page 68: Climbing Uphill

    Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. 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.
  • Page 69 EWB01580 Never go over the top of any hill at high WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never operate the ATV on hills too steep for the of the hill. ATV or for your abilities.
  • Page 70 EWB01600 WARNING Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.
  • Page 71: Riding Downhill

    EWB02410 WARNING Use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock the parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill.
  • Page 72: Crossing A Slope

    Whenever possible, ride your ATV straight down- hill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear. EWB01620 WARNING Always follow proper procedures for going...
  • Page 73: Crossing Through Shallow Water

    As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the 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.
  • Page 74 EWB01640 WARNING Never operate this ATV in fast flowing water or in water deeper than that specified in your 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 75: Riding Over Rough Terrain

    1. Air filter case check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- ECB00240 tion. Look out for obstacles which could cause CAUTION: damage to the ATV or could lead to an upset or ac- After riding your ATV in water, be sure to drain cident.
  • Page 76: Sliding And Skidding

    you go over obstacles, always follow proper If the rear wheels of your ATV start to slide side- procedures as described in the Owner’s Manu- ways, control can usually be regained (if there is room to do so) by steering in the direction of the slide.
  • Page 77: What To Do If

    EWB01661 If your ATV starts to slide sideways: WARNING Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not Learn to safely control skidding or sliding by recommended until you have corrected the practicing at low speeds and on level, smooth terrain.
  • Page 78 BRAKES AND ELECTRICAL EQUIPMENT (turn signals, horn, headlight, etc.) FOR PROP- ER OPERATION when you come out of the wa- ter. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-19.) 7-24...
  • Page 79: Periodic Maintenance And Minor Repair

    EBU21654 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21670 otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with Safety is an obligation of the owner. Periodic in- maintenance work. spection, adjustment and lubrication will keep your...
  • Page 80 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 81: Periodic Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 82 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours • Check operation and correct if necessary. √ √ √ √ √ • Check fluid level and ATV for fluid leakage, and Rear brake correct if necessary.
  • Page 83 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours √ √ √ 16 * Drive chain rollers • Check for wear and replace if necessary. • Make sure that all nuts, bolts, and screws are √...
  • Page 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Moving parts and √ √ √ √ • Lubricate. cables • Check operation and correct if necessary. Throttle lever hous- •...
  • Page 85 • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Every two years replace the piston seals and O-ring of the brake equalizer. • Replace the brake hoses every four years and if cracked or damaged.
  • Page 86: Checking The Spark Plug

    NOTE: If the spark plug shows a distinctly different color, 1. Spark plug cap the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV.
  • Page 87 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DR8EA To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.
  • Page 88: Engine Oil And Oil Filter Element

    NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4.
  • Page 89 7. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. To change the engine oil (with or without oil fil- ter element cleaning) 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 90 5. Remove the oil filter element cover by remov- 9. Install the oil filter element cover by installing ing the bolts, and then remove the oil filter el- the bolts, and then tighten them to the speci- ement. fied torque. Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 91: Cleaning The Air Filter Element

    EBU23740 Recommended oil: Cleaning the air filter element See page 10-1. The air filter element should be cleaned at the in- Oil quantity: tervals specified in the periodic maintenance and Without oil filter element replacement: lubrication chart. Clean the air filter element more 2.50 L (2.64 US qt) (2.20 Imp.qt) frequently if you are riding in unusually wet or dusty With oil filter element replacement:...
  • Page 92 2. Remove the air filter case cover by unhooking the holders. 1. Air filter element assembly 4. Remove the sponge material from the air filter 1. Air filter case cover element frame. 2. Air filter case holder 3. Pull the air filter element out of the air filter case.
  • Page 93 ECB00440 CAUTION: Do not twist the sponge material when squeez- ing it. 7. Check the sponge material and replace it if damaged. 8. Apply a quality foam air filter oil to the sponge material. NOTE: The sponge material should be wet but not drip- ping.
  • Page 94: Cleaning The Spark Arrester

    for obstructions. Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air-tight seal. Tighten all fit- tings securely to avoid the possibility of unfiltered air entering the engine. ECB00460 CAUTION: Make sure that the air filter element is prop- erly seated in the air filter case.
  • Page 95: Adjusting The Carburetor

    Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment described in the following section, however, may 1.
  • Page 96 Engine idling speed: tle stop screw in direction (a), and to decrease 1450–1550 r/min it, turn the screw in direction (b). NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 8-18...
  • Page 97: Adjusting The Throttle Cable Free Play

    (b). must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. 8-19...
  • Page 98: Checking The Front And Rear Brake Pads

    If a brake pad has worn to the point that the wear indicator groove is almost in contact with NOTE: the disc plate, have a Yamaha dealer replace the The wheels need to be removed to check the brake pads as a set.
  • Page 99: Checking The Brake Fluid Level

    Front brake 1. Wear indicator groove 1. Minimum level mark EBU24251 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 100: Changing The Brake Fluid

    EBU24290 Changing the brake fluid When checking the fluid level, make sure that Have a Yamaha dealer change the brake fluid at the top of the brake fluid reservoir is level. the intervals specified in the NOTE after the peri- Use only the recommended quality brake fluid, odic maintenance and lubrication chart.
  • Page 101: Checking The Brake Pedal Position

    The top of the brake pedal should be positioned 50.2 mm (1.98 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. Brake lever free play EWB02070...
  • Page 102: Adjusting The Parking Brake Free Play

    Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24710 Adjusting the parking brake free play 1. Locknut 2.
  • Page 103: Brake Light Switches

    The brake light switch for the brake pedal can be When tightening the locknut, hold the adjust- adjusted as follows, but the other brake light ing bolt with a wrench so that it does not turn switches should be adjusted by a Yamaha dealer. together with the locknut. 8-25...
  • Page 104: Adjusting The Clutch Lever Free Play

    EBU24820 NOTE: 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 105: Drive Chain Slack

    3. Tighten the locknut at the clutch lever. scribed above or if the clutch does not operate cor- If the specified free play cannot be obtained, rectly, have a Yamaha dealer check the internal proceed with the following steps. clutch mechanism.
  • Page 106 1. Drive chain slack 1. Axle holding nut (upper) 2. Axle holding nut (lower) 3. If the drive chain slack is incorrect, adjust it as 2. Loosen the locknut on each side of the swing- follows. arm. To tighten the drive chain, turn the ad- To adjust the drive chain slack justing bolts in direction (a).
  • Page 107 mark on both drive chain pullers with the alignment 3. Tighten the locknuts and the axle holding nuts mark on either side of the swingarm for proper to the specified torques. wheel alignment. NOTE: Make sure that the curved edge of the speed sen- sor bracket touches the rear wheel hub when tight- ening the axle holding nuts.
  • Page 108: Lubricating The Drive Chain

    ECB00560 Tightening torques: CAUTION: Locknut: The drive chain must be lubricated after wash- 16 Nm (1.6 m·kgf, 11 ft·lbf) ing the ATV or riding in the rain. Axle holding nut (upper): 120 Nm (12.0 m·kgf, 85 ft·lbf) 1. Clean the drive chain with kerosene and a Axle holding nut (lower): small soft brush.
  • Page 109: Checking And Lubricating The Brake And Clutch Levers

    If a cable is damaged or does not move Brake lever smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil EWB02130 WARNING Inspect cables frequently and replace if dam- aged. Corrosion can result when the cable...
  • Page 110: 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 bearings. EBU24992 Lubricating the swingarm pivots...
  • Page 111: Lubricating The Rear Suspension Relay Arm And Connecting Arm Pivoting Points

    Recommended lubricant: Lithium-soap-based grease EBU25001 Lubricating the rear suspension relay arm and connecting arm pivoting points The rear suspension relay arm and connecting arm pivoting points must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart.
  • Page 112: Lubricating The Upper And Lower Arm Pivots

    Left side 1. Grease nipple 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. Lubricate the pivoting points using a grease gun.
  • Page 113: Lubricating The Steering Shaft

    Right side EBU25222 Battery This model is equipped with a sealed-type (MF) 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,...
  • Page 114 KEEP OUT OF REACH OF CHILDREN. 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 115: Replacing A Fuse

    ECB00640 CAUTION: er, have a Yamaha dealer charge your bat- tery. To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. EBU28151 Replacing a fuse 2. Remove the blown fuse, and then install a new fuse of the specified amperage.
  • Page 116: Headlight Bulb

    EBU28160 2. Remove the defective bulb by pushing it in Headlight bulb and turning it counterclockwise. If the headlight bulb burns out, have a Yamaha dealer replace it. EBU28170 Headlight beam If a headlight beam adjustment is necessary, have a Yamaha dealer perform it.
  • Page 117: Replacing The License Plate Light Bulb

    1. Remove the license plate light body by remov- ing the screw. 1. Screw 2. Remove the defective bulb by pushing it in 1. Screw and turning it counterclockwise. 2. License plate light body 3. Insert a new bulb into the socket, push it in, 2.
  • Page 118: Auxiliary Light Bulb

    Do not overtighten the screw as the license plate light body may break. EBU28020 Auxiliary light bulb If the auxiliary light bulb burns out, have a Yamaha dealer replace it. 1. License plate light bulb socket 3. Remove the defective bulb by pulling it out.
  • Page 119: Installing A Wheel

    1. Nut 1. Arrow mark 2. Elevate the ATV and place a suitable stand 2. Lower the ATV to the ground. under the frame. 3. Tighten the wheel nuts to the specified 3. Remove the nuts from the wheel. torques. 4.
  • 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 EBU28190 ECB00710 Cleaning CAUTION: Frequent, thorough cleaning of your ATV will not Excessive water pressure may cause water only enhance its appearance but will improve its seepage and deterioration of wheel bearings, general performance and extend the useful life of brakes, transmission seals and electrical de- many components.
  • Page 123: Storage

    abrasives which may mar the paint or protec- To prevent corrosion, avoid damp cellars, tive finish. When finished cleaning, start the stables (because of the presence of ammo- engine and let it idle for several minutes. nia) and areas where strong chemicals are stored.
  • Page 124 b. Pour a teaspoonful of engine oil into the sively cold or warm place [less than 0 °C (30 spark plug bore. °F) or more than 30 °C (90 °F)]. For more in- c. Install the spark plug cap onto the spark formation on storing the battery, see page plug, and then place the spark plug on the 8-35.
  • Page 125: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 1780 mm (70.1 in) Electric starter Overall width: Lubrication system: 1095 mm (43.1 in) Wet sump Overall height: Engine oil: 1095 mm (43.1 in) Seat height: Type: 820 mm (32.3 in) SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 Wheelbase: or SAE20W40 or SAE20W50...
  • Page 126 Engine oil quantity: Transmission: Without oil filter element replacement: Primary reduction system: 2.50 L (2.64 US qt) (2.20 Imp.qt) Spur gear With oil filter element replacement: Primary reduction ratio: 2.60 L (2.75 US qt) (2.29 Imp.qt) 76/24 (3.166) Air filter: Secondary reduction system: Air filter element: Chain drive...
  • Page 127 Caster angle: Rear: 6.0 ° 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Trail: Maximum: 26.0 mm (1.02 in) Front: Front tire: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Rear: Type: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Tubeless Front wheel: Size: AT21 x 7-10 Wheel type: Manufacturer: Panel wheel...
  • Page 128 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Front turn signal light: Double wishbone 12 V, 10.0 W Spring/shock absorber type: Rear turn signal light: Coil spring/oil damper 12 V, 10.0 W Wheel travel: Auxiliary light: 200 mm (7.9 in) 12 V, 5.0 W Rear suspension: License plate light:...
  • Page 129: Consumer Information

    Record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 130 1. Model label 11-2...
  • Page 131 INDEX Drive select lever ............4-9 Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-9 Air filter element, cleaning ..........8-13 Auxiliary light bulb ............8-40 Engine break-in .............. 6-6 Engine, cold start ............6-1 Engine idling speed .............
  • Page 132 License plate light bulb, replacing ........ 8-39 Starter (choke) ............. 4-12 Light switch ..............4-4 Start switch ..............4-3 Steering lock ..............4-13 Steering shaft, lubricating ..........8-35 Main switch ..............4-1 Storage ................9-2 Model label ..............11-1 Suspension, lubricating the upper and lower arm pivots .................
  • Page 134 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.06-0.7×1 CR...

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