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Yamaha YFM350RW Owner's Manual

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Download this manual See also: Supplementary Service Manual, Owner's Manual
OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM35RW
5YT-28199-63

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  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM35RW 5YT-28199-63...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2006.04-0.4×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 OWNER’S MANUAL YFM35RW 5YT-28199-63-E0...
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury 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 .............4-8 Fuel cock ............4-9 LOCATION OF THE WARNING AND Starter (choke) ..........4-10 SPECIFICATION LABELS ......2-1 Seat ............4-11 Adjusting the front shock absorber DESCRIPTION ..........3-1 assemblies ..........4-12 Left view ............3-1 Adjusting the rear shock absorber Right view............
  • Page 9 Starting a warm engine ......6-3 PERIODIC MAINTENANCE AND MINOR Operating the drive select lever and REPAIR ............8-1 driving in reverse ........6-3 Owner’s manual and tool kit .......8-1 Shifting ............6-4 Periodic maintenance and lubrication Engine break-in .......... 6-6 chart ............8-3 Parking ............
  • Page 10 Checking and lubricating the brake and SPECIFICATIONS ........10-1 shift pedals ..........8-31 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 ..8-32 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. For Europe and Oceania...
  • Page 17 Impostare a pneumatici freddi. Bei kalten Reifen. Wanneer de banden koud zijn. Ajuste con los Regular com pneus 5FK-2151H-00 neumáticos en frío. frios. Pneus à froid. Ställ in med kalla däck. 5NF-21696-M0 YAMAHA MOTOR CO., LTD. SHIZUOKA JAPAN YAMAHA 4GB-2155A-00...
  • Page 18 For Europe...
  • Page 19 For Oceania...
  • Page 20 For Oceania WARNING UNDER 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. 5FE-21697-01...

  • Page 21: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Headlights 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 22: Controls And Instruments

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

  • Page 23: Instrument And Control Functions

    EBU17730 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 EBU17790 Main switch Indicator lights 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 24: Handlebar Switches

    EBU18060 EBU18100 Handlebar switches Start switch “ ” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18151 Light switch “ /OFF” Set this switch to “ ”...

  • Page 25: Throttle Lever

    Correct the problem be- tle lever will increase the engine speed. fore riding the ATV or consult a Yamaha dealer. Regulate the speed of the ATV by varying the throttle position. Because the throttle is spring-...

  • Page 26: Clutch Lever

    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. To engage the clutch, release the clutch lever. The clutch lever should be pulled rapidly and re- leased slowly for smooth clutch operation.

  • Page 27: 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 28: 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 29: 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 30: 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 31: 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 32: 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 33: Seat

    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. Seat lock lever To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the 1.

  • Page 34: Adjusting The Front Shock Absorber Assemblies

    2. Position indicator EBU18990 NOTE: Adjusting the front shock absorber as- A special wrench can be obtained at a Yamaha semblies dealer to make this adjustment. The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions.

  • Page 35: Adjusting The Rear Shock Absorber Assembly

    EWB00400 WARNING Always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. EBU19040 Adjusting the rear shock absorber as- sembly 1.
  • Page 36 Spring preload setting: Minimum (hard): NOTE: Distance A = 218.5 mm (8.6 in) A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: The spring preload setting is determined by Distance A = 228.5 mm (9.0 in) measuring distance A, shown in the illustration.
  • Page 37 Do not dispose of a damaged or worn out Tightening torque: shock absorber assembly yourself. Take the Locknut: shock absorber assembly to a Yamaha deal- 42 Nm (4.2 m·kgf, 30 ft·lbf) er for any service. ECB00080 CAUTION: Always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque.

  • 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 4-8.) 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

    Front: • Tire pressure below the minimum speci- Manufacturer/model: fied could cause the tire to dislodge from DUNLOP/KT851B the rim under severe riding conditions. 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)

  • Page 43: Tire Wear Limit

    Recommended pressure: NOTE: Front The low-pressure tire gauge is included as stan- 25.0 kPa (3.6 psi) (0.250 kgf/cm²) dard equipment. Make two measurements of the Rear tire pressure and use the second reading. Dust or 25.0 kPa (3.6 psi) (0.250 kgf/cm²) dirt in the gauge could cause the first reading to be Minimum: incorrect.

  • 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- 6. Completely close the throttle lever and start ure: the engine by pushing the start switch. Position (1): NOTE: Cold engine start with ambient temperature If the engine fails to start, release the start switch, below 5 °C (40 °F).

  • Page 47: Starting A Warm Engine

    NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm.

  • Page 48: Shifting

    If the indicator light does not come on, have When it stops, it will be in first gear. Raise the pedal a Yamaha dealer check the electrical circuit. slightly to reach the neutral position. 5. Check behind you for people or obstacles, and then release the brake pedal.
  • Page 49 ECB00200 EBU20650 To decelerate CAUTION: When slowing down or stopping, release the throt- Always close the throttle before shifting gears, tle and apply the brakes smoothly and evenly. As otherwise damage to the engine and drive train you slow down, shift to a lower gear. Be sure that may result.

  • Page 50: Engine Break-In

    EBU20670 Engine break-in engine break-in period, immediately have a Yamaha dealer check the ATV. There is never a more important period in the life of your engine than the first 20 hours of riding. For this reason, you should read the following material...

  • Page 51: Parking On A Slope

    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 front brake. 2. With the front and rear brake applied, pull the clutch lever, shift into the neutral position, re- lease the clutch lever, and then apply the parking brake.

  • Page 52: Accessories And Loading

    However, judgment as the stability and handling of an ATV it is not possible for Yamaha to test all non- can be changed. When adding accessories, keep Yamaha accessories, nor control over their qual-...
  • Page 53 Never exceed the weight limits shown. An over- Allow more braking distance. A heavier ATV loaded ATV can be unstable. takes longer to stop. Avoid making sharp turns unless at very slow MAXIMUM LOADING LIMIT speeds. ATV loading limit (total weight of rider, cargo, Avoid hills and rough terrain.

  • Page 54: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 55: Getting To Know Your Atv

    EBU21611 Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum performance until GETTING TO KNOW YOUR ATV you are totally familiar with the ATV’s handling and This ATV is intended for recreational use by expe- performance characteristics.
  • Page 56 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 57 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 58 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 59 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 60 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 61 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 62: 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 63 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 64 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 65 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 66: 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 67: 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 68 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 69 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 70: Riding Downhill

    EWB01731 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 71: 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 72: 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 73 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 74: 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 75: 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 76: 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 77 BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-19.) 7-24...

  • Page 78: Periodic Maintenance And Minor Repair

    EBU21652 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 79 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 80: 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 81 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 82 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours √ √ √ Drive chain rollers • Check for wear and replace if necessary. • Make sure that all nuts, bolts, and screws are √...
  • Page 83 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 √ √ √ √ 28 * • Lubricate. cables • Check operation and correct if necessary. Throttle lever hous- •...
  • Page 84 • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.

  • Page 85: 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 86 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 87: 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 88 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 89 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 90: 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 91 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 92 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 93: 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 94: 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 95 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 96: 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 97: 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 98: 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 99: 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 100: 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 101: 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 102: 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 103: 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 104: 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 105 1. Drive chain slack 1. Axle holding bolt (upper) 2. Axle holding bolt (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 106: Lubricating The Drive Chain

    Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) Axle holding bolt (upper): 120 Nm (12.0 m·kgf, 87 ft·lbf) Axle holding bolt (lower): 73 Nm (7.3 m·kgf, 53 ft·lbf) EBU24880 Lubricating the drive chain The drive chain must be cleaned and lubricated at 1.

  • Page 107: Checking And Lubricating The Cables

    ECB00560 essary. If a cable is damaged or does not move CAUTION: 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. Clean the drive chain with kerosene and a Engine oil small soft brush.

  • Page 108: Checking And Lubricating The Brake And Shift Pedals

    Brake lever EBU24930 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Brake pedal Clutch lever 8-31...

  • Page 109: Checking The Wheel Bearings

    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 110: Lubricating The Upper And Lower Arm Pivots

    1. Grease nipple 1. 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. Recommended lubricant: Lithium-soap-based grease 1.

  • Page 111: Lubricating The Knuckle Shafts

    Left side Right side 1. Upper grease nipple 1. Upper grease nipple 2. Lower grease nipple 2. Lower grease nipple EBU25080 Lubricating the knuckle shafts The knuckle shafts must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart.

  • Page 112: Lubricating The Steering Shaft

    KEEP OUT OF REACH OF CHILDREN. as this would permanently damage the battery. 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 113 To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat- tery. 8-36...

  • Page 114: Replacing The Fuse

    The fuse holder is located under the seat. (See 4. If the fuse immediately blows again, have a page 4-11.) Yamaha dealer check the electrical system. If the fuse is blown, replace it as follows. EBU25541 1. Turn the key to “OFF” and turn off all electrical Replacing a headlight bulb circuits.
  • Page 115 3. Remove the defective bulb from the headlight unit by pulling it out. EWB02220 WARNING A headlight bulb is hot when it is on and imme- diately after it is turned off. Wait for the bulb to cool before touching or removing it. You can be burned or a fire could start if the bulb touch- es something flammable.

  • Page 116: Adjusting A Headlight Beam

    ECB00690 5. Install the headlight bulb holder by aligning the CAUTION: projections with the holes in the headlight unit, It is advisable to have a Yamaha dealer make pushing it inward, and turning it clockwise until this adjustment. it stops.

  • Page 117: Replacing The Tail/Brake Light Bulb

    1. Headlight beam adjusting bolt 1. Screw 2. Remove the defective bulb by pushing it in EBU25600 Replacing the tail/brake light bulb and turning it counterclockwise. If the tail/brake light bulb burns out, replace it as follows. 1. Remove the lens by removing the screws. 1.

  • Page 118: Removing A Wheel

    Rear wheel nut: 45 Nm (4.5 m·kgf, 32 ft·lbf) EBU25720 Troubleshooting Although Yamaha ATVs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power.
  • Page 119 Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly. Use only genuine Yamaha replacement parts. Im- itation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

  • Page 120: 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 121: 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 122: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the brakes after washing. Apply the brakes several 2.
  • Page 123 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-35.

  • Page 124: 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: 1080 mm (42.5 in) Seat height: Type: 820 mm (32.3 in) SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 Wheelbase: or SAE20W40 or SAE20W50...
  • Page 125 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 126 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/model: Panel wheel...
  • Page 127 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Neutral indicator light: Double wishbone 12 V, 1.7 W × 1 Spring/shock absorber type: Reverse indicator light: Coil spring/oil damper 12 V, 1.7 W × 1 Wheel travel: Fuse: 200 mm (7.9 in) Rear suspension: Fuse:...

  • Page 128: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 129 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 130 INDEX Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-8 Air filter element, cleaning ..........8-13 Engine break-in .............. 6-6 Engine, cold start ............6-1 Engine idling speed ............8-17 Battery ................8-35 Engine oil ............... 5-3 Brake and clutch levers, checking and lubricating ..
  • Page 131 Storage ................9-2 Suspension, lubricating the upper and lower Main switch ..............4-1 arm pivots ..............8-33 Model label ..............11-2 Suspension relay arm and connecting arm pivoting points, lubricating the rear ......8-32 Neutral indicator light ............. 4-1 Swingarm pivots, lubricating ........8-32 Owner’s manual and tool kit ...........
  • Page 132 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.04-0.4×1 CR...

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