Yamaha YFM25RX Owner's Manual
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Yamaha YFM25RX Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM25RX
This A
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-21-39
4D3-28199-11

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  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM25RX This A WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-21-39 4D3-28199-11...
  • Page 2 EBU17091...
  • Page 3 INTRODUCTION EBU17300 Congratulations on your purchase of the Yamaha YFM25RX. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

  • Page 4: Important Manual Information

    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 5: Important Notice

    EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 6: Table Of Contents

    EWB00010 Clutch lever ..........4-5 WARNING Brake lever ..........4-5 Brake pedal ..........4-6 Indicates a potential hazard that could result in Parking brake lever ........4-6 serious injury or death. Shift pedal ..........4-7 Fuel tank cap ..........4-8 Fuel ............
  • Page 7 Shifting ............6-3 Checking the spark plug ......8-9 Engine break-in ......... 6-5 Engine oil and oil filter element ....8-11 Parking ............6-6 Cleaning the air filter element ....8-15 Parking on a slope ........6-6 Cleaning the spark arrester ..... 8-19 Accessories and loading ......
  • Page 8 Cleaning ............ 9-1 Storage ............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ...... 11-1 Identification numbers ......11-1 Noise regulation ........11-3 Maintenance record ........ 11-4 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY ..11-5 YAMAHA EXTENDED SERVICE (Y.E.S.) ..........11-7...

  • Page 9: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU17572 – A child under 16 years old should never oper- ate an ATV with engine size greater than 90 cc. AN ATV IS NOT A TOY AND CAN BE HAZARD- Never allow a child under age 16 to operate an OUS TO OPERATE.
  • Page 10 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 11 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 12 EWB00021 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- POTENTIAL HAZARD hale a lot of gasoline vapor, or get some gas- Improper handling of gasoline. oline in your eyes, seek medical help WHAT CAN HAPPEN immediately.
  • Page 13 WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death with- in a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad- equate ventilation.

  • Page 14: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 15 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 17 NEVER NEVER...

  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 2 3 4 1. Headlights 1. Spark arrester 2. Fuel cock 2. Seat 3. Starter (choke) 3. Fuel tank cap 4. Throttle stop screw 4. Oil filter element 5. Fuse 5. Brake pedal 6.

  • Page 19: Controls And Instruments

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

  • Page 20: Instrument And Control Functions

    EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17740 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved.

  • Page 21: Indicator Light

    EBU17781 EBU18061 Indicator light Handlebar switches 1. Neutral indicator light “N” 1. Light switch “LIGHTS” 2. Engine stop switch “ENG. STOP” EBU17860 3. Start switch “START” Neutral indicator light “ ” This indicator light comes on when the transmis- EBU18070 sion is in the neutral position.

  • Page 22: Throttle Lever

    EBU18090 return to an idle any time the hand is removed from Start switch “START” the throttle lever. 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. EBU18120 Light switch “LIGHTS”...

  • Page 23: Speed Limiter

    Check the operation of the throttle lever be- fore you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. EBU18311 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 24: Clutch Lever

    EWB00190 off system.) WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result. You could lose control, have an accident or be in- jured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in).

  • Page 25: Brake Pedal

    1. Brake lever 1. Brake pedal 2. Locknut 3. Brake lever position adjusting bolt EBU18510 Parking brake lever 4. Distance between brake lever and handlebar grip Use the parking brake before starting the engine or EBU18432 parking the ATV, especially on a slope. To apply Brake pedal the parking brake, move the parking brake lever in The brake pedal is located on the right side of the...

  • Page 26: Shift Pedal

    EWB00170 WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start- ing the engine. This could cause loss of con- trol or a collision. The brake could overheat if you ride the ATV without releasing the parking brake.

  • Page 27: Fuel Tank Cap

    1. Shift pedal 1. Fuel tank cap EBU18720 EBU18730 Fuel tank cap Fuel Remove the fuel tank cap by turning it counter- Make sure that there is sufficient fuel in the tank. clockwise. Fill the fuel tank to the bottom of the filler tube as shown.
  • Page 28 Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premi- um unleaded fuel.

  • Page 29: Fuel Cock

    WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank.

  • Page 30: Starter (Choke)

    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 carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.

  • Page 31: 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 projections on the front of the seat into the seat holders and push down on the seat at the rear.

  • Page 32: Adjusting The Front Shock Absorber Assemblies

    EBU18980 Adjusting the front shock absorber NOTE: assemblies A special wrench can be obtained at a Yamaha dealer to make this adjustment. The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Adjust the spring preload as follows.
  • Page 33 EWB00350 WARNING POTENTIAL HAZARD Improper shock absorber assembly adjust- ment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorber assem- blies on the left and right side to the same setting.

  • Page 34: Pre-Operation Checks

    Always follow the inspection and maintenance procedures and schedules described in the Own- er’s Manual. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.

  • Page 35: Fuel

    Engine oil level if necessary. 5-4, 8-11 Check ATV for oil leakage. Correct if necessary. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Front brake 5-4, 8-23, 8-24, 8-27 Check brake fluid level in reservoir, and add recommended brake...
  • Page 36 ITEM ROUTINE PAGE Make sure that operation is smooth. Lubricate pedal pivoting points Brake and shift pedals 8-36 if necessary. Make sure that operation is smooth. Lubricate lever pivoting points Brake and clutch levers 8-35 if necessary. Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. Instruments, lights and Check operation, and correct if necessary.

  • Page 37: Front And Rear Brakes

    (See page 4-8.) Check that there is no free play in the brake le- EWB00500 WARNING ver. If there is free play, have a Yamaha dealer check the brake system. POTENTIAL HAZARD Check for correct brake pedal height. (See Improper care when refueling.

  • Page 38: Throttle Lever

    Do not ride the ATV if you find any prob- lem with the brakes. If a problem cannot be corrected by the adjustment procedures pro- vided in this manual, have a Yamaha dealer check for the cause. EBU19761 Throttle lever Check the operation of the throttle lever.

  • Page 40: Tires

    HOW TO AVOID THE HAZARD Rear: The tires listed below have been approved 27.5 kPa (4.0 psi) (0.275 kgf/cm by Yamaha Motor Co., Ltd. for this model. Check and adjust tire pressures when Other tire combinations are not recom- the tires are cold.

  • Page 41: Specifications

    dirt in the gauge could cause the first reading to be Tire pressure below the minimum speci- incorrect. fied could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 24.5 kPa (3.5 psi) (0.245 kgf/cm Rear: 24.5 kPa (3.5 psi) (0.245 kgf/cm Use no more than the following pressures...

  • Page 42: Tire Wear Limit

    Recommended pressure: Front 27.5 kPa (4.0 psi) (0.275 kgf/cm Rear 27.5 kPa (4.0 psi) (0.275 kgf/cm Minimum: Front 24.5 kPa (3.5 psi) (0.245 kgf/cm Rear 24.5 kPa (3.5 psi) (0.245 kgf/cm 1. Tire wear limit Maximum: Front EBU19840 30.5 kPa (4.4 psi) (0.305 kgf/cm Chassis fasteners Rear Make sure that all nuts, bolts and screws are prop-...

  • Page 43: Operation

    See the “Engine break-in” section on page 6-5 a control or function you do not understand, prior to operating the engine for the first time. ask your Yamaha dealer. 1. Set the parking brake. 2. Turn the fuel cock to “ON”.
  • Page 44 Yamaha deal- Ambient temp./starter (choke) position er check the electrical circuit. NOTE: This model is equipped with an ignition circuit cut- off system. The engine can be started under the following conditions. The transmission is in neutral.

  • Page 45: Starting A Warm Engine

    attempt. EBU20520 Shifting 7. If the engine is started with the starter (choke) This ATV has a 5-speed forward transmission. The in position (1), the starter (choke) should be transmission allows you to control the amount of returned to position (2) to warm up the engine. power you have available at a given speed or for If the engine is started with the starter (choke) starting, accelerating, climbing hills, etc.
  • Page 46 EBU20560 EWB00680 To start out and accelerate WARNING 1. Release the throttle lever. POTENTIAL HAZARD ECB00200 Opening the throttle abruptly or releasing the CAUTION: clutch lever too quickly. Always close the throttle before shifting gears, WHAT CAN HAPPEN otherwise damage to the engine and drive train The ATV could wheelie.

  • Page 47: Engine Break-In

    EBU20672 WHAT CAN HAPPEN Engine break-in The wheels could stop rotating and lose trac- tion. This could cause loss of control, an ac- NOTE: cident and injury. It could also cause engine For ATVs equipped with an odometer or an hour or drive train damage.

  • Page 48: Parking

    320 km (200 mi) or 20 hours and beyond The ATV can now be operated normally. ECB00220 CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. 1. Locked position EBU20721 EBU20850 Parking Parking on a slope...

  • Page 49: Accessories And Loading

    However, 2. Stop the engine and release the clutch lever. it is not possible for Yamaha to test all non- 3. With the rear brake applied, apply the parking Yamaha accessories, nor control over their qual- brake and slowly release the brake pedal.
  • Page 50 limits your ability to move around on the seat, or of the ATV as possible. Put cargo at the rear of one that limits your view. the front carrier, at the front of the rear carrier, Use extra caution when riding an ATV with ac- and center it.
  • Page 51 WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo or pull- ing a trailer.

  • Page 52: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 53: Getting To Know Your Atv

    EWB00010 RIDE WITH CARE AND GOOD JUDGEMENT WARNING Get training if you are inexperienced. Indicates a potential hazard that could result in Beginners should get training from a certified in- serious injury or death. structor. Become familiar with this ATV at slow speeds first, EBU21591 even if you are an experienced operator.
  • Page 54 HOW TO AVOID THE HAZARD should complete the certified training course A child under 16 should never operate an offered by Yamaha. They should then regu- ATV with engine size greater than 90 cc. larly practice the skills learned in the course and the operating techniques described in this Owner’s Manual.
  • Page 55 This ATV is designed to carry operator only – passengers prohibited. EWB00910 WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger.
  • Page 56 Apparel HOW TO AVOID THE HAZARD EWB00920 Always wear an approved motorcycle helmet WARNING that fits properly. POTENTIAL HAZARD You should also wear: Operating this ATV without wearing an ap- eye protection (goggles or face shield) proved motorcycle helmet, eye protection gloves and protective clothing.
  • Page 57 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. by the influence of alcohol or drugs. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.
  • Page 58 EWB00950 Do not operate at speeds too fast for your WARNING skills or the conditions. EWB00960 POTENTIAL HAZARD WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Operating this ATV at speeds too fast for Use of improper tires on this ATV, or opera- your skills or the conditions.
  • Page 59 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 100.0 kg (220 lb) EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. 1. Adjusting screw WHAT CAN HAPPEN 2. Locknut Could cause changes in ATV handling which could lead to an accident.
  • Page 60 During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op- Removing even one hand or foot can reduce eration, otherwise they may contact the rear your ability to control the ATV or could cause wheels. you to lose your balance and fall off of the ATV.
  • Page 61 Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions.

  • Page 62: Be Careful Where You Ride

    EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible ma- terial accumulated around the engine area could catch fire. Someone touching the exhaust system dur- ing or after operation could be burned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry BE CAREFUL WHERE YOU RIDE...
  • Page 63 HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways. Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles.
  • Page 64 EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.
  • Page 65 HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. EWB01060 WARNING POTENTIAL HAZARD...
  • Page 66 Do not ride in areas posted “no trespassing”. the shift pedal. Remember that the engine and ex- Do not ride on private property without getting per- haust pipe will be hot when riding and afterwards; mission. do not allow skin or clothing to come in contact with these components.

  • Page 67: Turning Your Atv

    EWB01240 EWB01070 WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Opening the throttle abruptly or releasing the Engaging a lower gear when the engine clutch lever too quickly. speed is too high. WHAT CAN HAPPEN WHAT CAN HAPPEN The ATV could wheelie. This would increase The wheels could stop rotating.
  • Page 68 EWB01220 WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN The ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner’s Manual. Prac- tice turning at low speeds before attempting to turn at faster speeds.

  • Page 69: Climbing Uphill

    curves. WHAT CAN HAPPEN Improper riding procedures such as abrupt throttle The ATV can overturn more easily on ex- changes, excessive braking, incorrect body move- tremely steep hills than on level surfaces or ments, or too much speed for the sharpness of the small hills.
  • Page 70 EWB01100 WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill.
  • Page 71 WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD 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 72: Riding Downhill

    immediately on the uphill side. EWB01251 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning. HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill.
  • Page 73 braking may also cause a loss of traction. HOW TO AVOID THE HAZARD Whenever possible, ride your ATV straight down- Always follow proper procedures for going hill. Avoid sharp angles which could allow the ATV down hills as described in this Owner’s Man- to tip or roll over.

  • Page 74: Crossing A Slope

    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. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path.

  • Page 75: Crossing Through Shallow Water

    depth. Before entering the water, choose your path When crossing the side of a hill: carefully. Enter where there is no sharp drop off, Always follow proper procedures as de- and avoid rocks or other obstacles which may be scribed in the Owner’s Manual. slippery or upset the ATV.
  • Page 76 ECB00240 Test your brakes after leaving the water. Do not CAUTION: continue to ride your ATV without verifying that you After riding your ATV in water, be sure to drain have regained proper braking ability. the trapped water by removing the check hose at the bottom of the air filter case.

  • Page 77: Riding Over Rough Terrain

    WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper pro- cedures as described in the Owner’s Manual.
  • Page 78 If the rear wheels of your ATV start to slide side- ways, control can usually be regained (if there is room to do so) by steering in the direction of the With practice, over a period of time, skill at con- slide.

  • Page 79: What To Do If

    Lean more into the turn to regain balance. If nec- WHAT CAN HAPPEN essary, gradually let off the throttle and/or steer You may lose control of this ATV. You may to the outside of the turn. (See page 7-16.) also regain traction unexpectedly, which If your ATV starts to slide sideways: may cause the ATV to overturn.
  • Page 80 Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let wa- ter drain from the ATV and CHECK YOUR 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.

  • Page 81: Periodic Maintenance And Minor Repair

    Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.
  • Page 82 If you have questions, consult an authorized additional tools such as a torque wrench may be Yamaha ATV dealer. necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform...

  • Page 83: 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 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 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 85: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element Clean and replace if necessary. dusty areas) √...
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check operation and for excessive play, and √ √ √ 10 * Swingarm pivots replace bearings if necessary. Lubricate with lithium-soap-based grease.
  • Page 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 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. Engine oil filter ele- √...
  • Page 88 EBU23070 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 89: Checking The Spark Plug

    EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23211 Checking the spark plug The spark plug is an important engine component, 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- 1.
  • Page 90 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. 1. Spark plug cap 2. Check the spark plug for electrode erosion...

  • Page 91: Engine Oil And Oil Filter Element

    2. Clean the surface of the spark plug gasket To check the engine oil level and its mating surface, and then wipe off any 1. Place the ATV on a level surface. grime from the spark plug threads. 2. Check the engine oil level on a cold engine. 3.
  • Page 92 To change the engine oil (with or without oil filter element replacement) 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 93 5. Remove the oil filter element cover by remov- 6. Check the O-rings for damage and replace ing the bolts, and then remove the oil filter el- them if necessary. ement. 1. Oil filter element 2. O-ring 1. Oil filter element cover 2.
  • Page 94 7. Install a new oil filter element. NOTE: Recommended oil: Make sure that the O-rings are properly seated. See page 10-1. Oil quantity: 8. Install the oil filter element cover by installing Without oil filter element replacement: the bolts, and then tighten them to the speci- 1.25 L (1.32 US qt) (1.10 Imp.qt) fied torque.

  • Page 95: Cleaning The Air Filter Element

    is leaking, immediately turn the engine off and check for the cause. 12. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. EBU23692 Cleaning the air filter element The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart.
  • Page 96 1. Air filter case cover 1. Wing bolt 2. Air filter case cover holder 2. Air filter element 3. Loosen the wing bolt. 5. Remove the wing bolt and washer from the air 4. Remove the air filter element together with the filter element.
  • Page 97 WHAT CAN HAPPEN 9. Check the sponge material and replace it if Low-flash-point solvents or gasoline can damaged. catch fire or explode. 10. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. 8-17...
  • Page 98 13. Insert the air filter element into the air filter NOTE: case, and then tighten the wing bolt. The sponge material should be wet but not drip- 14. Install the air filter case cover by hooking the ping. holders onto the air filter case. 11.

  • Page 99: Cleaning The Spark Arrester

    will affect carburetor jetting with subsequent brush to remove any carbon deposits from the poor performance and possible engine over- spark arrester portion of the tailpipe and inside heating. of the tailpipe housing. EBU28890 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be- fore cleaning the spark arrester.

  • Page 100: Adjusting The Carburetor

    Tailpipe bolt: requires very sophisticated adjustment. Therefore, 11 Nm (1.1 m·kgf, 8.0 ft·lbf) most carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- EWB01910 sional knowledge and experience. The adjustment WARNING described in the following section, however, may...

  • Page 101: Adjusting The Engine Idling Speed

    The engine is warm when it quickly responds to the If the specified idling speed cannot be obtained as throttle. described above, have a Yamaha dealer make the 2. Attach the tachometer to the spark plug lead. adjustment. 3. Check the engine idling speed and, if neces-...

  • Page 102: Adjusting The Throttle Cable Free Play

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

  • Page 103: Checking The Front And Rear Brake Pads

    If a brake pad has worn to the point 1. Wear indicator groove that the wear indicator grooves are almost in con- tact with the disc plate, have a Yamaha dealer re- NOTE: place the brake pads as a set.

  • Page 104: Checking The Brake Fluid Level

    place the brake pads as a set. Front brake 1. Minimum level mark 1. Wear indicator EBU28930 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 105 Rear brake 1. Bolt 1. Minimum level mark 2. Brake fluid reservoir cap cover If the rear brake fluid level is low, replenish as fol- 2. Remove the brake fluid reservoir cap. lows. 1. Remove the brake fluid reservoir cap cover by removing the bolt.

  • Page 106: Changing The Brake Fluid

    5. Install the brake fluid reservoir cap cover by Changing the brake fluid installing the bolt. 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 107: Checking The Front Brake Lever Free Play

    After servicing: free play of zero mm (zero in) as shown. If the free Make sure the brakes operate smoothly play is incorrect, have a Yamaha dealer check the and that the free play is correct. brake system. Make sure the brakes do not drag.

  • Page 108: 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. 1. Brake pedal position EBU24700 Adjusting the parking brake free play...
  • Page 109 1. Release the parking brake by moving the If the cable length cannot be adjusted to specifica- parking brake lever to the right. tion, consult a Yamaha dealer. 2. Fully loosen the locknut and the adjusting bolt 5. Tighten the locknut on the brake cable.

  • Page 110: Brake Light Switches

    The brake light switch for the brake pedal can be Tightening torque: adjusted as follows, but the other brake light Locknut (rear brake caliper): switches should be adjusted by a Yamaha dealer. 16 Nm (1.6 m·kgf, 11.6 ft·lbf) NOTE: EWB02030...

  • Page 111: Adjusting The Clutch Lever Free Play

    10.0 mm (0.20–0.39 in) as shown. If the free play NOTE: is incorrect, adjust it as follows. If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal clutch mechanism. 8-31...

  • Page 112: Drive Chain Slack

    EBU26861 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. To check the drive chain slack 1. Place the ATV on a level surface. NOTE: When checking and adjusting the drive chain slack, there should be no weight on the ATV and all tires must be touching the ground.

  • Page 113: Lubricating The Drive Chain

    1. Rear wheel axle pinch bolt 2. Rod 3. Drive chain tensioner 4. Hole NOTE: A rod can be obtained at a Yamaha dealer to make this adjustment. Tightening torque: 3. Shift the transmission into neutral. Rear axle pinch bolt: 4.

  • Page 114: 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 115: Checking And Lubricating The Brake And Clutch Levers

    EWB02120 WARNING Recommended lubricants: POTENTIAL HAZARD Brake lever: Damaged control cables. Silicone grease WHAT CAN HAPPEN Clutch lever: Corrosion can result when the cable sheaths Lithium-soap-based grease (all-purpose become damaged, and cables can also be- grease) come frayed or kinked, which could restrict the operation of controls and lead to an acci- Brake lever dent or injury.

  • Page 116: Checking And Lubricating The Brake And Shift Pedals

    If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- ings. EBU24993 Lubricating the swingarm pivots...

  • Page 117: Lubricating The Upper And Lower Arm Pivots

    Left side EBU25031 1. Upper grease nipple Lubricating the upper and lower arm 2. Lower grease nipple pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun. Recommended lubricant: Lithium-soap-based grease (all-purpose grease)

  • Page 118: Lubricating The Steering Shaft

    Right side EBU25212 Battery This model is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections. ECB00620 CAUTION: Never attempt to remove the battery cell seals,...
  • Page 119 To charge the battery To charge a sealed-type (MF) battery, a spe- Have a Yamaha dealer charge the battery as soon cial constant-voltage battery charger is re- as possible if it seems to have discharged. Keep in quired. Using a conventional battery charger mind that the battery tends to discharge more will damage the battery.

  • Page 120: Replacing The Fuse

    EBU28911 Replacing the fuse The fuse holder is located beside the battery and can be accessed as follows: 1. Remove the seat. (See page 4-12.) 2. Unhook the band, and then take out the own- er’s tool kit and the low-pressure tire gauge. 3.

  • Page 121: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a 2. Disconnect the headlight coupler. Yamaha dealer check the electrical system. 3. Remove the headlight bulb holder cover. 5. Install the battery cover by installing the bat- tery cover bracket bolts.
  • Page 122 1. Headlight bulb holder cover 1. Headlight bulb holder 2. Headlight coupler EWB02180 WARNING 4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then POTENTIAL HAZARD remove the defective bulb. A headlight bulb is hot when it is on and im- mediately after it is turned off.

  • Page 123: Adjusting A Headlight Beam

    EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the adjusting screw in direction (a). 1. Do not touch the glass part of the bulb.

  • Page 124: Replacing The Tail/Brake Light Bulb

    EBU25580 Rear Replacing the tail/brake light bulb If the tail/brake light bulb burns out, have a Yamaha dealer replace it. EBU25650 Removing a wheel 1. Loosen the wheel nuts. Front 1. Nut 2. Elevate the ATV and place a suitable stand under the frame.

  • Page 125: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.
  • Page 126 EWB02260 WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe in- jury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys- tem.

  • 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 EBU25890 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 129: Storage

    EWB02300 nia) and areas where strong chemicals are WARNING stored. POTENTIAL HAZARD Operation with wet brakes after washing. Long-term WHAT CAN HAPPEN Before storing your ATV for several months: Wet brakes may have reduced stopping abil- 1. Follow all the instructions in the “Cleaning” ity, increasing the chance of an accident.
  • Page 130 plug, and then place the spark plug on the 8-38. cylinder head so that the electrodes are NOTE: grounded. (This will limit sparking during Make any necessary repairs before storing the the next step.) ATV. d. Turn the engine over several times with the starter.

  • Page 131: Specifications

    EBU25960 SPECIFICATIONS Bore × stroke: EBU2597A 74.0 × 58.0 mm (2.91 × 2.28 in) Compression ratio: Dimensions: 9.50 :1 Overall length: Starting system: 1625 mm (64.0 in) Electric starter Overall width: Lubrication system: 1070 mm (42.1 in) Wet sump Overall height: Engine oil: 1040 mm (40.9 in) Type:...
  • Page 132 Engine oil quantity: Transmission: Without oil filter element replacement: Primary reduction system: 1.25 L (1.32 US qt) (1.10 Imp.qt) Spur gear With oil filter element replacement: Primary reduction ratio: 1.35 L (1.43 US qt) (1.19 Imp.qt) 76/22 (3.455) Air filter: Secondary reduction system: Air filter element: Chain drive...
  • Page 133 Front tire: Maximum: Front: Type: 30.5 kPa (4.4 psi) (0.305 kgf/cm Tubeless Rear: Size: 30.5 kPa (4.4 psi) (0.305 kgf/cm AT20 x 7-10 Front wheel: Manufacturer/model: DUNLOP/KT201 Wheel type: Rear tire: Panel wheel Rim size: Type: 10 x 5.5AT Tubeless Rear wheel: Size: AT19 x 10-9...
  • Page 134 Front suspension: Tail/brake light: 12 V, 0.5/3.9 W × 1 Type: Neutral indicator light: Double wishbone 12 V, 1.7 W × 1 Spring/shock absorber type: Fuse: Coil spring/oil damper Wheel travel: Fuse: 190 mm (7.5 in) 15.0 A Rear suspension: Type: Swingarm Spring/shock absorber type:...

  • Page 135: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.

  • Page 136: Model Label

    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: Noise Regulation

    EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 138: Maintenance Record

    EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 139: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 140 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 141: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”...
  • Page 142 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 143 EBU26132 11-9...
  • Page 144 INDEX Drive chain slack ............8-32 Accessories and loading ..........6-7 Air filter element, cleaning..........8-15 Engine break-in .............. 6-5 Engine, cold start ............6-1 Engine idling speed............8-21 Battery................8-38 Engine oil ............... 5-4 Brake and clutch levers, checking and lubricating ..8-35 Engine oil and oil filter element ........
  • Page 145 Light switch ..............4-3 Starter (choke) ............. 4-11 Start switch ..............4-3 Steering shaft, lubricating ..........8-38 Main switch ..............4-1 Storage ................9-2 Maintenance and lubrication chart ........8-5 Suspension, lubricating the upper and lower arm Maintenance chart, emission control system ....8-3 pivots .................
  • Page 146 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2007.06-2.4x1 !
  • Page 147 8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA – ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887 If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to yamaha today.
  • Page 148 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U.S.A. P.O. BOX 6555 CYPRESS, CALIFORNIA 90630-9989 ATTN: SALES ADMINISTRATION...

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