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Yamaha BANSHEE YFZ350W Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFZ350W
This A
3B5-28199-61

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Summary of Contents for Yamaha BANSHEE YFZ350W

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFZ350W This A 3B5-28199-61...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN 2006.07-0.7x1 ! (E,F,S)
  • Page 3 OWNER’S MANUAL YFZ350W This A 3B5-28199-61-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 WARNING...
  • 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 cock ........... 4-9 Starter (choke) ......... 4-10 Seat ............4-11 LOCATION OF THE WARNING AND Adjusting the front shock absorber SPECIFICATION LABELS ......2-1 assemblies ..........4-12 Adjusting the rear shock absorber DESCRIPTION ..........
  • Page 9 Engine break-in ......... 6-4 Cleaning the air filter element ....8-16 Parking ............6-5 Cleaning the spark arrester ..... 8-19 Parking on a slope ........6-6 Changing the carburetor settings ..... 8-21 Accessories and loading ......6-6 Adjusting the engine idling speed .... 8-28 Adjusting the throttle cable free play ..
  • Page 10 Adjusting a headlight beam ..... 8-47 Replacing the tail/brake light bulb ... 8-47 Removing a wheel ........8-48 Installing a wheel ........8-49 Troubleshooting ........8-49 Troubleshooting charts ......8-51 CLEANING AND STORAGE......9-1 Cleaning ............ 9-1 Storage ............9-2 SPECIFICATIONS ........

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU17591 does not have the abilities to operate it safely. Never carry a passenger on an ATV. AN ATV IS NOT A TOY AND CAN BE HAZARD- Always avoid operating an ATV on any paved OUS TO OPERATE.
  • Page 12 that is proper for the terrain, visibility, operating before attempting larger hills. conditions, and your experience. Always follow proper procedures for climbing Never attempt wheelies, jumps, or other stunts. hills as described in this manual. Check the ter- Always inspect your ATV each time you use it to rain carefully before you start up any hill.
  • Page 13 ing, use the proper gear and maintain a steady Always use the size and type of tires specified in speed when climbing a hill. If you stall or roll this manual. backwards, follow the special procedure for Always maintain proper tire pressure as de- braking described in this manual.
  • Page 14 cock is in the “OFF” position. Otherwise, fuel and may cause loss of consciousness and may leak out of the carburetor or fuel tank. death within a short time. Gasoline is poisonous. If you should swal- low some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately.

  • 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 21: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly 1. Tail/brake light 2. Radiator 2. Seat 3. Fuel cock 3. Kickstarter 4. Rear shock absorber assembly 4. Fuel tank cap 5. Spark arrester 5. Headlight 6. Starter (choke) 6.

  • Page 22: Controls And Instruments

    EBU17712 Controls and instruments 1. Clutch lever 2. Parking brake lock plate 3. Main switch 4. Brake lever 5. Throttle lever 6. Handlebar switches NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 23: Instrument And Control Functions

    EBU17731 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 24: Handlebar Switches

    EBU18061 EBU18140 Handlebar switches Light switch “LIGHTS” Set this switch to “LO” to turn on the low beams and the taillight. Set the switch to “HI” to turn on the high beams and the taillight. Set the switch to “OFF” to turn off all the lights. ECB00040 CAUTION: Do not use the headlights with the engine...

  • Page 25: Throttle Override System

    ATV, turn check for the cause. Correct the problem be- the adjusting screw in direction (a). To de- fore riding the ATV or consult a Yamaha dealer. crease the maximum engine power available...

  • Page 26: Clutch Lever

    and the maximum speed of the ATV, turn the aged. Always make sure the throttle lever free adjusting screw in direction (b). play is adjusted to 4.0–6.0 mm (0.16–0.24 in). (See page 8-30.) EBU18372 Clutch lever The clutch lever is located on the left handlebar. To disengage the clutch, pull the clutch lever toward the handlebar grip.

  • 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 EBU18500 Parking brake Use the parking brake before starting the engine or 1.
  • Page 28 wise, the engine will misfire, preventing normal op- eration. 1. Locked position EWB00220 1. Button WARNING 2. Parking brake lock plate Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied.

  • Page 29: Shift Pedal

    prematurely. push it down smoothly but forcefully. This model is equipped with a primary kickstarter, allowing the engine to be started in any gear if the clutch is dis- EBU18530 Shift pedal engaged. However, shifting the transmission into the neutral position before starting is recommend- This ATV is equipped with a constant-mesh 6- speed transmission.

  • Page 30: Fuel

    1. Fuel level 1. Fuel tank cap 2. Filler tube EBU18770 Fuel Recommended fuel: Make sure that there is sufficient fuel in the tank. PREMIUM UNLEADED GASOLINE ONLY Fill the fuel tank to the bottom of the filler tube as For Europe: PREMIUM UNLEADED GASO- shown.

  • Page 31: Fuel Cock

    of gasoline or higher octane grade. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. ECB00060 CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the piston rings, as well as to the exhaust system.

  • Page 32: Starter (Choke)

    FUEL FUEL 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetors. Turn the fuel cock lever to this this position, the fuel reserve is made available.

  • Page 33: Seat

    the starter (choke). Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Seat lock lever To install the seat Insert the projection on the front of the seat into the seat holder and push down on the seat at the rear.

  • Page 34: Adjusting The Front Shock Absorber Assemblies

    2. Position indicator EBU18990 NOTE: Adjusting the front shock absorber A special wrench can be obtained at a Yamaha assemblies 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

    Do not dispose of a damaged or worn out Uneven adjustment can cause poor handling shock absorber assembly yourself. Take the and loss of stability, which could lead to an ac- shock absorber assembly to a Yamaha deal- cident. er for any service. EBU19100...
  • Page 36 2. Spring preload adjusting nut Spring preload setting: NOTE: Minimum (hard): A special wrench can be obtained at a Yamaha Distance A = 213.5 mm (8.4 in) dealer to make this adjustment. Standard: The spring preload setting is determined by Distance A = 220.5 mm (8.7 in)
  • Page 37 ECB00080 Rebound damping setting: CAUTION: Minimum (soft): Always tighten the locknut against the adjust- 20 click(s) in direction (b)* ing nut, and then tighten it to the specified Standard: torque. 12 click(s) in direction (b)* Maximum (hard): Rebound damping force 3 click(s) in direction (b)* Turn the adjusting dial in direction (a) to increase * With the adjusting dial fully turned in direc-...
  • Page 38 the minimum and maximum settings. NOTE: Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always rep- resents the entire adjusting range. To obtain a pre- cise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as...

  • Page 39: 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 40 ITEM ROUTINE PAGE Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Rear brake 5-4, 8-31, 8-32, 8-34 Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.
  • Page 41 EWB00480 WARNING Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. Failure to inspect increases the possibility of an accident or equipment damage.

  • Page 42: Fuel And 2-Stroke Engine Oil Mixing Ratio

    EBU19580 Transmission oil Check that there is no free play in the brake le- ver. If there is free play, have a Yamaha dealer Make sure that the transmission oil is at the speci- check the brake system. fied level. Add oil as necessary. (See page 8-9.)

  • Page 43: Throttle Lever

    If there is any leak- EBU19770 Drive chain age, have a Yamaha dealer check the brake sys- tem. Check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the Brake operation drive chain as necessary.

  • Page 44: Tires

    Pay attention to the following. tires are cold. The tires listed below have been approved Tire pressures must be equal on both by Yamaha Motor Co., Ltd. for this model. sides. Other tire combinations are not recommend- Tire pressure below the minimum speci-...

  • Page 45: Measuring The Tire Pressure

    Higher pressures and fast inflation may Set the tire pressure when the tires are cold. Set cause a tire to burst. Inflate the tires very the tire pressures to the following specifications: slowly and carefully. Recommended pressure: Front EBU19820 30.0 kPa (4.4 psi) (0.300 kgf/cm Measuring the tire pressure Rear Use the low-pressure tire gauge.

  • Page 46: 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 47: Operation

    4. Shift the transmission into neutral. accident or injury. If there is a control or func- 5. Use the starter (choke) in reference to the fig- tion you do not understand, ask your Yamaha ure: dealer. Position (1):...

  • Page 48: Starting A Warm Engine

    Ambient temp./starter (choke) position ECB00160 CAUTION: °C 0° 10° 20° 30° For maximum engine life, always warm the en- gine up before starting off. Never accelerate 90° °F 30° 50° 70° hard when the engine is cold! 8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to position (3) before riding.

  • Page 49: Shifting

    EBU20520 EBU20570 Shifting To start out and accelerate 1. Release the throttle lever. This ATV has a 6-speed forward transmission. The ECB00200 transmission allows you to control the amount of CAUTION: power you have available at a given speed or for Always close the throttle before shifting gears, starting, accelerating, climbing hills, etc.

  • Page 50: Engine Break-In

    wheelie, which would increase the chance of for long distances. The transmission is prop- an accident, including an overturn. erly lubricated only when the engine is run- ning. Inadequate lubrication may damage the transmission. EBU20650 To decelerate Always use the clutch when changing gears. When slowing down or stopping, release the throt- The engine, transmission and drive train are tle and apply the brakes smoothly and evenly.

  • Page 51: Parking

    ECB00220 CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. EBU20721 Parking When parking the ATV, stop the engine, shift into first gear, apply the parking brake, and then turn...

  • Page 52: Parking On A Slope

    steep you could not walk up them easily. 1. Bring the ATV to a stop by applying the brakes in first gear. 2. Stop the engine and release the clutch lever. 3. With the rear brake applied, apply the parking brake and slowly release the brake pedal.
  • Page 53 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- the following points in mind: ity or suitability.
  • Page 54 The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail- Allow more braking distance. A heavier ATV takes longer to stop.

  • Page 55: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 56: 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 57 with engine size greater than 90 cc. Use by chil- harm to you and/or your passenger. dren of ATVs that are not recommended for their age can lead to severe injury or death of the child. Apparel This ATV is designed to carry operator only – Always wear an approved motorcycle helmet that passengers prohibited.
  • Page 58 event of an accident. Operating without protec- tive clothing increases your chances of severe injury in the event of an accident. Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. 1.
  • Page 59 page 5-1 before riding for proper care of the ATV Do not operate at speeds too fast for your and to ensure safety. skills or the conditions. EWB01430 EWB01450 WARNING WARNING Always inspect your ATV each time you use it Always go at a speed that is proper for the ter- to make sure the ATV is in safe operating con- rain, visibility and operating conditions, and...
  • Page 60 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 100.0 kg (220 lb) EWB01460 WARNING Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- 1. Adjusting screw curely attached. Reduce speed when carrying cargo or pull- Loading and accessories ing a trailer.
  • Page 61 All parts and Avoid wheelies and jumping. You may lose control accessories added to this ATV should be gen- of the ATV or overturn. uine Yamaha or equivalent components de- signed for use on this ATV and should be...

  • Page 62: Be Careful Where You Ride

    installed and used according to instructions. Improper installation of accessories or modifi- cation of this ATV may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized ATV dealer. Exhaust system The exhaust system on the ATV is very hot during and following operation.
  • Page 63 paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. While riding on unpaved public streets or roads may be legal in your area, such operation can in- Know the terrain where you ride.
  • Page 64 ing terrain conditions when operating the ATV. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution EWB01540 WARNING flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the...
  • Page 65 Select a large, flat, unpaved area to become famil- EWB01550 iar with your ATV. Make sure that this area is free WARNING of obstacles and other riders. You should practice Always mount a caution flag on the ATV to control of the throttle, brakes, shifting procedures, make you more visible when operating in areas and turning techniques in this area before trying where you might not be seen by other vehicles.

  • Page 66: Turning Your Atv

    these components. ECB00230 CAUTION: With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then Do not shift gears without releasing the throt- release the parking brake. Open the throttle grad- tle.
  • Page 67 used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. EWB01570 WARNING Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds.

  • Page 68: Climbing Uphill

    changes, excessive braking, incorrect body move- It is important when climbing a hill to make sure ments, or too much speed for the sharpness of the that your weight is transferred forward on the ATV. turn may cause the ATV to tip. If the ATV begins to This can be accomplished by leaning forward and, tip over to the outside while negotiating a turn, lean on steeper inclines, standing on the footboards...
  • Page 69 scribed in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. 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 70: Riding Downhill

    ply the front brake gradually, or dismount the ATV immediately on the uphill side. 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.

  • Page 71: Crossing A Slope

    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 down hills as described in this Owner’s Manu- Note: a special technique is required when braking as you go down a hill.

  • Page 72: Crossing Through Shallow Water

    in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel. EWB01631 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.
  • Page 73 them several times to let friction dry out the lin- ings. If the ATV is operated through deep or fast flowing water, the tires may float, causing loss of traction and loss of control, which could lead to an accident. ECB00240 CAUTION: After riding your ATV in water, be sure to drain...

  • Page 74: Riding Over Rough Terrain

    you go over obstacles, always follow proper procedures as described in the Owner’s Manu- SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident.

  • Page 75: What To Do If

    slide. Applying the brakes or accelerating is not go slowly and be very cautious in order to re- recommended until you have corrected the slide. duce the chance of skidding or sliding out of control. WHAT TO DO IF... This section is designed to be a reference guide only.
  • Page 76 to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE – the ATV may tip over on top of you.

  • Page 77: Periodic Maintenance And Minor Repair

    1. Owner’s manual can cause shocks or start fires. Turn off the en- 2. Low-pressure tire gauge gine when performing maintenance unless 3. Owner’s tool kit otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with...
  • Page 78 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 79: 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 80 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Check operation and correct if necessary. Check brake pedal free play and adjust if neces- √ √ √ √...
  • Page 81 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Make sure that all nuts, bolts, and screws are √ √ √ √ √ 15 * Chassis fasteners properly tightened.
  • Page 82 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Check for leakage and replace gasket(s) if neces- sary. √ √ √ 24 * Exhaust system Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 83: Checking The Spark Plugs

    EBU28320 kit. Checking the spark plugs The spark plugs are important engine compo- nents, which are easy to check. Since heat and de- posits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lu- brication chart.
  • Page 84 Yamaha dealer check the ATV. 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/BR8ES To install a spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

  • Page 85: Transmission Oil

    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. Install the spark plug cap. EBU23341 Transmission oil The transmission oil level should be checked be- fore each ride.
  • Page 86 2. Start the engine, warm it up for several min- 6. Add the specified amount of the recommend- utes, and then turn it off. ed transmission oil, and then install and tight- 3. Place an oil pan under the transmission to col- en the oil filler cap.

  • Page 87: Coolant

    EBU23470 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. EBU23501 To check the coolant level 1. Place the ATV on a level surface. NOTE: The coolant level must be checked on a cold en- 1.
  • Page 88 If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- erwise the effectiveness of the coolant will be reduced.
  • Page 89 when opening. Allow any remaining pressure to escape before completely removing the cap. 1. Place the ATV on a level surface. 2. Remove the radiator cover by removing the bolts. 1. Coolant drain bolt 4. Remove the radiator cap. 1. Radiator cover 2.
  • Page 90 1. Radiator cap 1. Coolant reservoir cap 5. Remove the coolant reservoir cap. 6. Disconnect the hose on the coolant reservoir side and drain the coolant from the coolant reservoir. 8-14...
  • Page 91 voir to the maximum level mark, and then in- stall the reservoir cap. 11. Pour the recommended coolant into the radia- tor until it is full. Antifreeze/water mixture ratio: Recommended antifreeze: High-quality ethylene glycol antifreeze con- taining corrosion inhibitors for aluminum en- gines Coolant quantity: 1.

  • Page 92: Cleaning The Air Filter Element

    14. Start the engine, and then check for coolant leakage. NOTE: If any leakage is found, have a Yamaha dealer check the cooling system. 15. Install the radiator cover by installing the bolts. 1. Air filter case check hose EBU23620 1.
  • Page 93 1. Air filter case cover 1. Air filter element lock plate 2. Air filter case cover holder 4. Remove the lock plate by turning it, and then 3. Pull the air filter element out of the air filter remove the sponge material from the air filter case.
  • Page 94 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 95: Cleaning The Spark Arrester

    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. Never operate the engine with the air filter el- ement removed.
  • Page 96 1. Screw 1. Tailpipe 2. Spark arrester 3. Gasket 2. Remove the tailpipe by pulling it out of the muffler. 4. Make sure the gasket is properly positioned, 3. Tap the tailpipe lightly, and then use a wire then insert the tailpipe into the muffler and brush to remove any carbon deposits from the align the screw holes.

  • Page 97: Changing The Carburetor Settings

    Carburetor adjustments should only be per- formed by a Yamaha dealer. Do not attempt to perform these procedures unless you have mechanical knowledge and the neces- 1. Main jet number sary tools.
  • Page 98 1. Standard position: Groove 3 Carburetor setting chart Altitude Temperature 0–1500 m (5000 ft) Above 1500 m (5000 ft) Main jet Jet needle Pilot air screw Main jet Jet needle Pilot air screw Above 0°C (32°F) #200 3rd groove 2.0 turns out #190 3rd groove 2 1/2 turns out...
  • Page 99 Changing the settings of the carburetors 5. Disconnect the fuel hoses. To change the settings of the carburetors, you 6. Remove the fuel tank by removing the bolts. need to disassemble and remove them. Follow the procedures for both carburetors. Disassembling and removing the carburetors 1.
  • Page 100 1. Air filter case cover 1. Mixing chamber cap securing plate 2. Air filter case cover holder 2. Screw 8. Remove the mixing chamber cap securing 9. Loosen the carburetor joint screws. plate by removing the screw. 8-24...
  • Page 101 1. Joint screw 1. Throttle cable 2. Throttle valve 3. Throttle cable holder 10. Remove the mixing chamber cap. 4. Screw 11. Remove the throttle cable from the throttle valve, and then remove the throttle cable hold- er by removing the screws. 8-25...
  • Page 102 3. Main jet 14. Change the main jet and the jet needle clip po- sition. NOTE: Optional main jets can be obtained at a Yamaha dealer. After the jet needle clip position is changed, the throttle cables may need to be adjusted.
  • Page 103 Assembling and installing the carburetors Assemble and install both carburetors by the fol- lowing steps. 1. Install the needle valve and float. 2. Install the float chamber by installing the screws. 3. Install the carburetor and tighten the joint screws. 4.

  • Page 104: Adjusting The Engine Idling Speed

    2. Push the throttle lever forward until it stops and hold it in this position. 3. Check through each carburetor window to see if the punch mark on the throttle valve is at the specified position. 1. Adjusting nut 2. Locknut 5.
  • Page 105 tion chart. NOTE: A diagnostic tachometer is needed to make this adjustment. The carburetor synchronization and the throttle cable free play must be checked, and adjusted if necessary, before adjusting the engine idling speed. 1. Start the engine and warm it up. NOTE: 1.

  • Page 106: Adjusting The Throttle Cable Free Play

    NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 7. Install the seat. (b) (a) EBU24043 Adjusting the throttle cable free play The throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- 1.

  • Page 107: Checking The Front And Rear Brake Pads

    If a brake pad has worn to the point that the wear indicator almost touches the brake disc, have a Yamaha dealer re- place the brake pads as a set. 1. Throttle lever free play adjusting bolt 2.

  • Page 108: Checking The Brake Fluid Level

    Yamaha dealer re- Front brake place the brake pads as a set.

  • Page 109: Changing The Brake Fluid

    Yamaha dealer check the cause. EBU24290 1. Minimum level mark Changing the brake fluid Have a Yamaha dealer change the brake fluid at Observe these precautions: the intervals specified in the NOTE after the peri- When checking the fluid level, make sure that odic maintenance and lubrication chart.

  • Page 110: Checking The Brake Pedal Position

    Make sure the brakes are not spongy. All air free play of zero mm (zero in) as shown. If the free must be bled from the brake system. play is incorrect, have a Yamaha dealer check the Replacement of brake components requires brake system.

  • Page 111: Adjusting The Parking Brake Free Play

    Yamaha dealer. EBU24670 Adjusting the parking brake free play The parking brake free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Cable length “A” should measure 46–50 mm (1.81–1.97 in).
  • Page 112 If the cable length cannot be adjusted to specifica- ECB00520 CAUTION: tion, consult a Yamaha dealer. When tightening the locknut, hold the adjust- 5. Tighten the locknut at the clutch lever. ing bolt with a wrench so that it does not turn 6.

  • Page 113: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light EBU24810 switches should be adjusted by a Yamaha dealer. Adjusting the clutch lever free play NOTE: The clutch lever free play must be checked and, if...

  • Page 114: Drive Chain Slack

    If the free play is incorrect, adjust it as fol- rectly, have a Yamaha dealer check the internal lows. clutch mechanism. EBU24851 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary.
  • Page 115 1. Axle holding nut (upper) 1. Drive chain slack 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 116: Lubricating The Drive Chain

    Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) Axle holding nut (upper): 120 Nm (12.0 m·kgf, 85 ft·lbf) Axle holding nut (lower): 60 Nm (6.0 m·kgf, 43 ft·lbf) EBU24880 Lubricating the drive chain 1. Locknut The drive chain must be cleaned and lubricated at 2.

  • Page 117: Checking And Lubricating The Cables

    If a cable is damaged or does not move ECB00560 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.

  • Page 118: Checking And Lubricating The Brake And Clutch Levers

    EBU24920 in a wheel hub or if a wheel does not turn smoothly, Checking and lubricating the brake and have a Yamaha dealer check the wheel bearings. clutch levers EBU25001 The operation of the brake and clutch levers Lubricating the rear suspension relay...

  • Page 119: Lubricating The Upper And Lower Arm Pivots

    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 Left side 1.

  • Page 120: Replacing A Headlight Bulb

    Right side 1. Screw 1. Grease nipple 2. Remove the headlight bulb holder cover. EBU26881 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the screw. 8-44...
  • Page 121 1. Headlight bulb holder cover 1. Headlight bulb holder 3. Remove the bulb holder by turning it counter- 4. Remove the defective bulb. clockwise. EWB02200 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.
  • Page 122 1. Do not touch the glass part of the bulb. 1. Headlight bulb holder cover 2. Headlight bulb holder 3. Headlight unit ECB00650 CAUTION: ECB00680 Do not touch the glass part of the headlight CAUTION: bulb to keep it free from oil, otherwise the Make sure the bulb holder cover is securely fit- transparency of the glass, the luminosity of the ted over the bulb holder and seated against the...

  • Page 123: Adjusting A Headlight Beam

    1. Remove the bulb holder (together with the ECB00690 bulb) by turning it counterclockwise. CAUTION: It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).

  • Page 124: Removing A Wheel

    Front 1. Tail/brake light bulb holder 1. Wheel nut 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. 4. Install the bulb holder (together with the bulb) by turning it clockwise.

  • Page 125: Installing A Wheel

    3. Remove the nuts from the wheel. systems yourself. However, should your ATV re- 4. Remove the wheel. quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- EBU25660 Installing a wheel rience, and know-how to service the ATV properly.
  • Page 126 EWB02280 WARNING Do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. 8-50...

  • Page 127: Troubleshooting Charts

    Wipe off with a dry cloth and correct the the kickstarter. spark plug gaps, or replace the spark plugs. Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Have a Yamaha dealer check the ATV. 8-51...
  • Page 128 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.

  • Page 129: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25920 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 130: Storage

    increasing the chance of an accident. Test the section of this chapter. brakes after washing. Apply the brakes several 2. Turn the fuel cock lever to “OFF”. times at slow speeds to let friction dry out the 3. Drain the carburetor float chamber by loosen- linings.
  • Page 131 with oil.) e. Remove the spark plug caps from the spark plugs, and then install the spark plugs and the spark plug caps. 6. Lubricate all control cables and the pivoting points of all levers and pedals. 7. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground.

  • Page 132: Specifications

    EBU25960 SPECIFICATIONS EBU25977 Compression ratio: Dimensions: 6.50 :1 Overall length: Starting system: 1855 mm (73.0 in) Kickstarter Overall width: Lubrication system: 1100 mm (43.3 in) Premix Overall height: Type: 1080 mm (42.5 in) YAMALUBE 2-R, Castrol R30, A545, A747 Seat height: Engine oil quantity: 800 mm (31.5 in) Mixing ratio:...
  • Page 133 Fuel: Operation: Left foot operation Recommended fuel: 1st: Premium unleaded gasoline only 32/13 (2.461) Fuel tank capacity: 2nd: 12.0 L (3.17 US gal) (2.64 Imp.gal) 29/16 (1.812) Fuel reserve amount: 3rd: 2.5 L (0.66 US gal) (0.55 Imp.gal) 27/18 (1.500) Carburetor: 4th: Manufacturer:...
  • Page 134 Size: Rear wheel: AT20 x 10-9 Wheel type: Manufacturer/model: Panel wheel DUNLOP/KT877A Rim size: Loading: 9 x 8.5AT Maximum loading limit: Front brake: 100.0 kg (220 lb) Type: (Total weight of rider, cargo, accessories, and tongue) Dual disc brake Tire air pressure (measured on cold tires): Operation: Recommended: Right hand operation...
  • Page 135 Wheel travel: 220 mm (8.7 in) Electrical system: Ignition system: Charging system: AC magneto Headlight: Bulb type: Krypton bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 30.0/30.0 W × 2 Tail/brake light: 12 V, 5.0/21.0 W × 1 10-4...

  • Page 136: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 137 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 138 INDEX Drive chain slack ............8-38 Accessories and loading ..........6-6 Air filter element, cleaning..........8-16 Engine break-in .............. 6-4 Engine, cold start ............6-1 Engine idling speed............8-28 Brake and clutch levers, checking and lubricating ..8-42 Engine, starting a warm ..........6-2 Brake and shift pedals, checking and lubricating ..
  • Page 139 Suspension relay arm and connecting arm pivoting points, lubricating the rear ......... 8-42 Main switch ..............4-1 Model label..............11-2 Tail/brake light bulb, replacing ........8-47 Throttle cable free play, adjusting ........ 8-30 Owner’s manual and tool kit..........8-1 Throttle lever ............4-2 Throttle OverRide System..........4-3 Parking................6-5 Tire pressure, measuring ..........
  • Page 140 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2006.07-0.7x1 !

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