Table of Contents


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It contains important safety information.
Il comprend d'importantes informations de sécurité.
Contiene indicaciones importantes acerca de la seguridad.


Table of Contents

Summary of Contents for Yamaha BIG BEAR 250 YFM25BZ

  • 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 YFM25BZ YFM250Z 1P0-F8199-65...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2009.08-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM25BZ YFM250Z 1P0-F8199-65-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 YFM250 (YFM25B) (5Y4AG01W090518201–)
  • 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. EBU17410 YFM25BZ/YFM250Z OWNER’S MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st edition, May 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 .............4-8 SPECIFICATION LABELS ......1-1 Fuel cock ............4-9 Starter (choke) ..........4-11 SAFETY INFORMATION ......2-1 Seat ............4-11 Storage compartment .......4-12 DESCRIPTION ..........3-1 Front carrier ..........4-13 Left view ............3-1 Rear carrier ..........4-13 Right view............
  • Page 9 Operating the drive select lever and Periodic maintenance chart for driving in reverse ........6-3 the emission control system .....8-3 Shifting ............6-4 General maintenance and lubrication Engine break-in .......... 6-6 chart ............8-5 Parking ............6-7 Checking the spark plug ......8-9 Parking on a slope ........
  • Page 10 Checking and lubricating the front and rear brake levers ........8-35 Checking the shift pedal ......8-36 Checking and lubricating the brake pedal ............8-36 Checking the wheel hub bearings .... 8-37 Lubricating the swingarm pivots ....8-37 Lubricating the steering shaft ....8-37 Battery ............
  • 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 < 30 kg ( 66 lbs) 1P0-F817R-00 1P0-F816P-20 < 45 kg ( 99 lbs) 20.0 kPa 25.0 kPa 1P0-F817R-10 0.20 kgf/cm² 0.25 kgf/cm² 2.9 psi 3.6 psi 4XE-F816M-M0 < 3230 N < 330 kgf < 727 lbf < 147 N <...
  • Page 13 1P0-F816L-20 YEAR OF CONSTRUCTION : 2009 MODEL : YFM250 YAMAHA MOTOR CO., LTD. MAX.POWER : 12.2 kW 2500 SHINGAI, IWATA, JAPAN MASS IN RUNNING ORDER : 216 kg 1P0-F816R-00 1P0-F155A-20...
  • 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 30 kg (66 lbs) 4XE-F4877-20 20 kPa, (2.9 psi) 25 kPa, (3.6 psi) 45 kg (99 lbs) 17 kPa, (2.5 psi) 22 kPa, (3.2 psi) 4XE-F4897-20 165 kg, (364 lbs) ( 3 3 0 k g f ) 3230 N 4XE-F816M-20 ( 1 5 k g f ) 4XE-F151K-00...
  • Page 19 UNDER...
  • Page 20: Safety Information

    EBU17431 SAFETY INFORMATION EBU17463 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 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 23 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- 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.
  • Page 24: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Headlights 1. Spark arrester 2. Fuel cock 2. Storage compartment and tool kit 3. Recoil starter 3. Air filter case 4. Fuses 4. Engine oil filler cap 5. Battery 5. Brake pedal 6.
  • Page 25: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 3 4 5 6 1. Drive select lever 2. Rear brake lever 3. Handlebar switches 4. Parking brake lock plate 5. Horn switch 6.
  • 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 Lights

    EBU17793 EBU18061 Indicator lights Handlebar switches 1. Neutral indicator light “N” 1. Light switch “ /OFF” 2. Reverse indicator light “R” 2. Engine stop switch “ ” 3. Start switch “ ” EBU17860 4. Horn switch “ ” Neutral indicator light “ ”...
  • Page 28: Throttle Lever

    EBU18101 EBU18282 Start switch “ ” Throttle lever Push this switch to crank the engine with the start- Once the engine is running, pushing the throttle le- er. See the starting instructions on page 6-1 prior ver will increase the engine speed. to starting the engine.
  • Page 29: Speed Limiter

    EBU18323 Speed limiter Your ATV is equipped 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 Pedal And Rear Brake Lever

    1. Front brake lever 1. Brake pedal EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.
  • Page 31: Parking Brake

    EBU18460 Always be sure you have released the park- Parking brake ing brake before you begin to ride. The brake Use the parking brake before starting the engine or could overheat if you ride the ATV without re- parking the ATV, especially on a slope. Apply the leasing the parking brake.
  • Page 32: Drive Select Lever

    EBU18571 Drive select lever The drive select lever is used for driving the ATV either forward or in reverse. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. 1.
  • 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

    1.6 L (0.42 US gal, 0.35 rings, as well as to the exhaust system. 3. Wipe up any spilled fuel immediately. Your Yamaha engine has been designed to use NOTICE: Immediately wipe off spilled fuel regular unleaded gasoline with a research octane with a clean, dry, soft cloth, since fuel may number of 91 or higher.
  • 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: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18921 Storage compartment Insert the projections on the front of the seat into the seat holders and push down on the seat at the ECB00130 NOTICE rear.
  • Page 38: Front Carrier

    When storing any documents in the storage com- partment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartment. 1.
  • Page 39: Adjusting The Rear Shock Absorber Assembly

    (a) to increase the spring preload and thereby 2. Position indicator harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension. A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-14...
  • Page 40 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): 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, and correct if necessary. Rear brake • Lubricate cable if necessary. 5-3, 8-27, 8-30 • Check lever and pedal free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary.
  • Page 43: Fuel

    If there is any leakage, the brake Check that there is no free play in the front brake system should be checked by a Yamaha dealer. lever. If there is free play, have a Yamaha dealer check the brake system. Brake operation...
  • Page 44: Throttle Lever

    Check the operation of the throttle lever. It must 20.0 kPa (0.200 kgf/cm², 2.9 psi) open smoothly and spring back to the idle position Rear when released. Have a Yamaha dealer correct if 25.0 kPa (0.250 kgf/cm², 3.6 psi) necessary. Minimum tire pressure:...
  • Page 45 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 Manufacturing Corporation of America.
  • Page 46: Chassis Fasteners

    EBU19840 Front: Chassis fasteners Manufacturer/model: Make sure that all nuts, bolts and screws are prop- YFM250Z CARLISLE/TRAIL WOLF erly tightened. YFM25BZ MAXXIS/M905 Size: EBU19850 Instruments, lights and switches AT22 x 7.00-10 Type: Check that all instruments, lights and switches are Tubeless working properly.
  • 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 be as short as possible to preserve battery ener- gy. Do not crank the engine more than 10 sec- onds on each attempt. If the battery is discharged, pull the recoil starter to start the engine. 7.
  • Page 49: Operating The Drive Select Lever And Driving In Reverse

    EBU20321 Operating the drive select lever and driving in reverse ECB00170 NOTICE Before shifting, stop the ATV, otherwise the transmission may be damaged. Shifting: Reverse to Forward 1. Bring the ATV to a complete stop. 2. Apply the brake pedal. 1.
  • Page 50: Shifting

    When in reverse, the reverse indicator light should first gear. be on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 1. Bring the ATV to a complete stop. 2. Apply the brake pedal.
  • Page 51 3. Open the throttle gradually. WARNING! Al- ways open the throttle gradually. Opening the throttle abruptly would increase the chance of an accident. It could make the ATV wheelie or overturn. [EWB00741] 4. Once the ATV has attained adequate speed, release the throttle lever.
  • Page 52: Engine Break-In

    could make the wheels stop rotating and lose There is never a more important period in the life of traction. This could cause loss of control, an your engine than the first 320 km (200 mi) or 20 accident and injury. It could also cause engine hours of riding.
  • Page 53: Parking

    If any engine trouble should occur during the WARNING engine break-in period, immediately have a Avoid parking on hills or other inclines. Park- Yamaha dealer check the ATV. ing on a hill or other incline could cause the ATV to roll out of control, increasing the EBU20722 chance of an accident.
  • Page 54: Accessories And Loading

    Yamaha ability to control the ATV. vehicles. Yamaha is not in a position to test the Do not mount an accessory where it could inter- products that these aftermarket companies pro- fere with your ability to control the ATV.
  • Page 55 bulky object attached to the handlebars which Never exceed the weight limits shown. An over- could make steering difficult, an accessory that loaded ATV can be unstable. limits your ability to move around on the seat, or MAXIMUM LOADING LIMIT one that limits your view.
  • Page 56 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. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around.
  • Page 57: Riding Your Atv

  • Page 58: Getting To Know Your Atv

    EBU21345 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding Do not operate this ATV or allow anyone else instructions for recreational riding.
  • Page 59 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 60 Apparel Always wear the following to reduce risk of injury in an accident: Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 61 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 62 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 63 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of cargo, rider, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 165.0 kg (364 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
  • Page 64 ATV should be during operation or after leaving the ATV, do not let genuine Yamaha or equivalent components de- brush, grass and other materials collect under the signed for use on this ATV and should be installed vehicle, near the muffler or exhaust pipe, or next to and used according to instructions.
  • Page 65: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 66 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do not ways be alert to changing terrain conditions ride on any paved public street, road or motorway. when operating the ATV.
  • Page 67 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.
  • Page 68: Turning Your Atv

    Select a large, flat, unpaved area to become famil- Use this same procedure as you move into the iar with your ATV. Make sure that this area is free higher gears. Be sure to coordinate the use of the of obstacles and other riders. You should practice throttle and shift pedal properly.
  • Page 69 the ATV will resist turning. A special turning tech- nique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. As you approach a curve, slow down and begin to turn the handlebars in the desired direction.
  • Page 70: Climbing Uphill

    Improper riding procedures such as abrupt throttle Never open the throttle suddenly or make changes, excessive braking, incorrect body move- sudden gear changes. The ATV could flip ments, or too much speed for the sharpness of the over backwards. turn may cause the ATV to tip. If the ATV begins to Never go over the top of any hill at high tip over to the outside while negotiating a turn, lean speed.
  • Page 71 Do not attempt to climb hills until you have mas- tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
  • Page 72: Riding Downhill

    If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.
  • Page 73: Crossing A Slope

    Shift your weight backward and to the up side of the hill. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possi- ble.
  • Page 74: Crossing Through Shallow Water

    Shift your weight to the uphill side of the ATV. 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.
  • Page 75 The ATV can be used to cross slow moving, shal- ability. WARNING! Wet brakes may have re- low water of up to a maximum of 35 cm (14 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.
  • Page 76: Riding Over Rough Terrain

    1. Air filter case check hose 1. Storage compartment check hose RIDING OVER ROUGH TERRAIN EWB01651 WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees.
  • Page 77: Sliding And Skidding

    cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may re- sult. SLIDING AND SKIDDING EWB01662 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.
  • Page 78: 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 footboard to the outside of the turn.
  • Page 79 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 80: Periodic Maintenance And Adjustment

    If you are not fa- EBU21731 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 in the plastic...
  • Page 81 However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.
  • Page 82: 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 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 leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.
  • Page 84: General 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 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years •...
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Change. √ √ √ √ Engine oil • Check ATV for oil leakage, and correct if neces- sary.
  • Page 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check electrolyte level and specific gravity, and correct if necessary. √ √ √ √ √ 23 * Battery •...
  • Page 88: Checking The Spark Plug

    EBU23213 2. Remove the spark plug as shown, with the Checking the spark plug spark plug wrench included in the owner’s tool The spark plug is an important engine component, kit. which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica-...
  • Page 89 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.
  • Page 90: Engine Oil And Oil Filter Element

    Tightening torque: Spark plug: If the engine was started before checking the oil 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. If a torque wrench is not available when installing 3.
  • Page 91 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. 3. Place an oil pan under the engine to collect the used oil.
  • Page 92 1. Engine oil drain bolt 1. Footboard 2. O-ring 2. Bolt 3. Compression spring 6. Fully loosen the brake pedal free play adjust- 4. Oil strainer ing nut, and push the brake pedal downward. Skip steps 5–11, 16, and 17 if the oil filter element is not being cleaned.
  • Page 93 1. Brake pedal free play adjusting nut 1. Drive select lever safety system cable 2. Oil filter element cover 7. Move the drive select lever safety system ca- 8. Remove the oil filter element cover by remov- ble away from the oil filter element cover. ing the bolts, and then remove the oil filter el- ement and the O-ring.
  • Page 94 1. Oil filter element 1. Adjusting nut 2. O-ring 2. Oil filter element cover 3. Bolt 10. Install the oil filter element and a new O-ring. 9. Clean the oil strainer and oil filter element with solvent. Make sure that the O-ring is properly seated. 11.
  • Page 95 12. Install the oil strainer, the compression spring, a new O-ring and the engine oil drain bolt, and Be sure to wipe off spilled oil on any parts after the then tighten the engine oil drain bolt to the engine and exhaust system have cooled down. specified torque.
  • Page 96: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 97 To change the final gear oil 1. Place the ATV on a level surface. 2. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil filler bolt 2. Gasket 3. Final gear oil 4. Correct oil level 1.
  • Page 98 1. Final gear oil drain bolt 1. Final gear oil filler bolt 2. Gasket 2. Gasket 3. Final gear oil 5. Install the drain bolt and its new gasket, and 4. Correct oil level then tighten the bolt to the specified torque. Recommended final gear oil: Tightening torque: See page 10-1.
  • Page 99: Cleaning The Air Filter Element

    9. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 10. Install the final gear case guard by installing the bolts and tightening them to the specified torque. Tightening torque: Final gear case guard bolt: 17 Nm (1.7 m·kgf, 12 ft·lbf) EBU23686 Cleaning the air filter element...
  • Page 100 1. Air filter case cover 1. Air filter element assembly 2. Air filter case cover holder 5. Remove the sponge material from the air filter 4. Pull the air filter element assembly out of the element. air filter case. 8-21...
  • Page 101 1. Air filter element 8. Check the sponge material and replace it if 2. Sponge material damaged. 6. Clean the sponge material with water or sol- 9. Tap the air filter element lightly to remove vent. WARNING! When using solvent to most of the dust and dirt.
  • Page 102: Cleaning The Spark Arrester

    12. Install the seat. The air filter element should be cleaned every 20– 40 hours. It should be cleaned more often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance is per- formed, check the air inlet of the air filter case for obstructions.
  • Page 103 1. Bolt 1. Tailpipe 2. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 4. Insert the tailpipe into the muffler and align the muffler. bolt holes. 3. Tap the tailpipe lightly, and then use a wire 5.
  • Page 104: Adjusting The Carburetor

    Do not start the engine when cleaning the The carburetor has been set and extensively spark arrester, otherwise it could cause injury tested at the Yamaha factory. Changing these to the eyes, burns, carbon monoxide poison- settings without sufficient technical knowl- ing, possibly leading to death, and start a fire.
  • Page 105: Adjusting The Throttle Cable Free Play

    If the specified idling speed cannot be obtained as throttle stop screw at the carburetor. To in- described above, have a Yamaha dealer make the crease the engine idling speed, turn the throt- adjustment.
  • Page 106: Valve Clearance

    Checking the front brake pads and rear prevent this from occurring, the valve clearance brake shoes must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- The front brake pads and the rear brake shoes brication chart.
  • Page 107 1.0 mm without having to disassemble the brake. To check (0.04 in), have a Yamaha dealer replace the brake the brake shoe wear, check the position of the pads as a set.
  • Page 108: Checking The Brake Fluid Level

    1. Minimum level mark Changing the brake fluid Observe these precautions: Have a Yamaha dealer change the brake fluid at When checking the fluid level, make sure that the intervals specified in the TIP after the periodic the top of the brake fluid reservoir is level.
  • Page 109: Checking The Front Brake Lever Free Play

    If there is free play, have a brake. Yamaha dealer check the brake system. Before adjusting the brake lever free play and the brake pedal free play and position, check the rear brake shoes for wear.
  • Page 110 The brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) as shown. If the free play is incorrect, adjust it as follows. 1. Locknut 2. Brake pedal position adjusting bolt 3. Brake pedal position 1. Brake pedal free play a.
  • Page 111 1. Brake lever free play adjusting nut 1. Brake lever free play 2. Brake pedal free play adjusting nut 2. Locknut 3. Brake lever free play adjusting bolt 3. Adjusting the brake lever free play a. Loosen the locknut at the brake lever and The brake lever free play should measure fully turn in the brake lever free play adjust- 5.0–7.0 mm (0.20–0.28 in) as shown.
  • Page 112: Brake Light Switches

    1. Locknut 1. Brake lever free play adjusting nut 2. Brake lever free play adjusting bolt 2. Brake camshaft lever 3. Pin d. Tighten the locknut at the brake lever. 4. Gap “A” e. Install the footboard. c. Turn the brake lever free play adjusting bolt at the brake lever in direction (a) to in- When adjusting the rear brake lever free play: crease the free play, and in direction (b) to...
  • Page 113: Adjusting The Clutch Free Play

    Adjusting the clutch free play adjusted as follows, but the other brake light The clutch free play must be adjusted periodically. switches should be adjusted by a Yamaha dealer. Adjust the free play as follows. 1. Remove the footboard. (See “Engine oil” on 1.
  • Page 114: Checking And Lubricating The Cables

    If a cable is damaged or does not move pivots should be lubricated if necessary. smoothly, have a Yamaha dealer check or replace 8-35...
  • Page 115: Checking The Shift Pedal

    EBUM0170 Checking the shift pedal The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle. EBU28871 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.
  • Page 116: Checking The Wheel Hub Bearings

    Lithium-soap-based grease EBU24995 Lubricating the swingarm pivots The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the pe- EBU24963 riodic maintenance and lubrication chart. Checking the wheel hub bearings The front and rear wheel hub bearings must be...
  • Page 117: Battery

    EWB02160 Recommended lubricant: WARNING Lithium-soap-based grease Battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk.
  • Page 118 1. Battery cover 1. Battery 2. Maximum level mark 3. Check the electrolyte level in the battery. 3. Minimum level mark The electrolyte should be between the minimum and maximum level marks. 4. If the electrolyte is at or below the minimum level mark, add distilled water to raise it to the maximum level mark.
  • Page 119 5. Check and, if necessary, tighten the battery lead connections and correct the breather hose routing as explained in step 5 of “To in- stall the battery”. 6. Install the battery cover. To remove the battery 1. Remove the battery cover by pulling it upward. 2.
  • Page 120 ECB01100 NOTICE Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. Do not leave or store the battery on its side. To install the battery Be sure the battery is fully charged. 1. Battery 1. Install the battery. 2.
  • Page 121: Replacing The Fuse

    1. Fuse 4. If the fuse immediately blows again, have a 2. Spare fuse Yamaha dealer check the electrical system. The fuse holder is located under the seat. (See page 4-11.) EBU25481 If the fuse is blown, replace it as follows.
  • Page 122 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 1. Cover at the rear of the headlight 2. Remove the headlight bulb holder cover by 1. Headlight bulb holder pulling it off. 4. Remove the burnt-out bulb by pulling it out. 5.
  • Page 123: Adjusting A Headlight Beam

    EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).
  • Page 124: Replacing The Tail/Brake Light Bulb

    EBU25611 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 1. Tail/brake light bulb holder 2. Tail/brake light bulb 3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops.
  • Page 125: Installing A Wheel

    Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Wheel nut 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 1.
  • Page 126: Troubleshooting

    The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- 1. Tapered nut rience, and know-how to service the ATV properly.
  • Page 127: 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 128: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25881 tion of wheel bearings, brakes, transmis- Cleaning sion seals and electrical devices. Many Frequent, thorough cleaning of your ATV will not expensive repair bills have resulted from only enhance its appearance but will improve its improper high-pressure detergent applica- general performance and extend the useful life of tions such as those available in coin-oper-...
  • Page 129: 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 130 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 131: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Cylinder arrangement: Forward-inclined single cylinder Overall length: Displacement: 1916 mm (75.4 in) 229 cm³ Overall width: Bore × stroke: 1038 mm (40.9 in) 71.0 × 58.0 mm (2.80 × 2.28 in) Overall height: Compression ratio: 1118 mm (44.0 in) 8.70 :1 Seat height: Starting system:...
  • Page 132 Type: Air filter: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- Air filter element: Dry element Fuel: Recommended fuel: 130 ˚F YFM250Z Unleaded gasoline only YFM25BZ Regular unleaded gasoline only SAE 5W-30 Fuel tank capacity: SAE 10W-30 12.0 L (3.17 US gal, 2.64 Fuel reserve amount: SAE 10W-40 1.6 L (0.42 US gal, 0.35
  • Page 133 Transmission type: Rear tire: Constant mesh 5-speed.forward, 1-speed.reverse Type: Operation: Tubeless Left foot operation Size: Gear ratio: AT22 x 10.00-10 1st: Manufacturer/model: 34/12 (2.833) YFM250Z CARLISLE/TRAIL WOLF 2nd: YFM25BZ MAXXIS/M906 34/19 (1.789) Loading: 3rd: Maximum loading limit: 29/22 (1.318) 165.0 kg (364 lb) 4th: (Total weight of rider, cargo, accessories, and tongue) 26/25 (1.040)
  • Page 134 Rim size: Charging system: 10 x 8.0AT AC magneto Front brake: Battery: Type: Model: Dual disc brake CB14A-A2 Operation: Voltage, capacity: Right hand operation 12 V, 14.0 Ah Recommended fluid: Headlight: DOT 4 Bulb type: Rear brake: Krypton bulb Bulb voltage, wattage × quantity: Type: Drum brake Headlight:...
  • Page 135: 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 136 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 137 INDEX Drive select lever and driving in reverse ......6-3 Drive select lever safety system cable, adjusting ..8-27 Accessories and loading ..........6-8 Air filter element, cleaning ..........8-20 Engine break-in .............. 6-6 Engine, cold start ............6-1 Battery ..............5-6, 8-38 Engine idling speed .............
  • Page 138 Storage ................9-2 Storage compartment ........... 4-12 Main switch ..............4-1 Swingarm pivots, lubricating ........8-37 Maintenance and lubrication chart ......... 8-5 Maintenance chart, emission control system ....8-3 Model label ..............11-2 Tail/brake light bulb, replacing ........8-45 Throttle cable free play, adjusting ........ 8-26 Throttle lever ............
  • Page 140 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2009.08-0.3×1 CR...

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