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Yamaha YFM35XX Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM35XX
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-21-18
3D5-F8199-12

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Summary of Contents for Yamaha YFM35XX

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35XX WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-21-18 3D5-F8199-12...
  • Page 2 EBU17091...
  • Page 3 INTRODUCTION EBU17300 Congratulations on your purchase of the Yamaha YFM35XX. 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 or death to the ATV operator, a bystander, or a person inspecting or...

  • 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

    Front brake lever .........4-5 EWB00010 WARNING Brake pedal and rear brake lever ....4-6 Parking brake ..........4-7 Indicates a potential hazard that could result in serious injury or death. Drive select lever ........4-7 Fuel tank cap ..........4-8 Fuel .............4-8 Fuel cock ..........4-10 EBU17420 Starter (choke) ..........4-11 TABLE OF CONTENTS...
  • Page 7 OPERATION ..........6-1 PERIODIC MAINTENANCE AND MINOR Starting a cold engine ........ 6-1 REPAIR ............8-1 Starting a warm engine ......6-3 Owner’s manual and tool kit .......8-1 Operating the drive select lever and Periodic maintenance chart for driving in reverse ........6-3 the emission control system .....8-3 Engine break-in ..........
  • Page 8 Noise regulation ........11-3 Checking and lubricating the cables ..8-34 Maintenance record ........11-4 Checking and lubricating the front and YAMAHA MOTOR CORPORATION, rear brake levers ........8-34 U.S.A. ATV LIMITED WARRANTY ..11-5 Checking and lubricating the brake YAMAHA EXTENDED SERVICE pedal ............

  • Page 9: Safety Information

    EBU17430 SAFETY INFORMATION EBU17513 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 10 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 11 hill. If you stall or roll backwards, follow the spe- Always be sure there are no obstacles or people cial procedure for braking described in this man- behind you when you operate in reverse. When ual. Dismount on the uphill side or to a side if it is safe to proceed in reverse, go slowly.
  • Page 12 EWB00021 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- POTENTIAL HAZARD oline in your eyes, seek medical help Improper handling of gasoline. immediately. If gasoline spills on your skin, WHAT CAN HAPPEN wash with soap and water.
  • Page 13 WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within 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: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly spring preload adjusting 1. Spark arrester ring 2. Tail/brake light 2. Fuel cock 3. Spark plug 3. Air filter case 4. Front shock absorber assembly spring preload adjusting 4.

  • Page 18: Controls And Instruments

    EBU17712 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Drive select lever 5. Main switch 6. Fuel tank cap 7. Front brake lever 8. Throttle lever NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 19: Instrument And Control Functions

    EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 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 1.

  • Page 20: Indicator Lights And Warning Light

    If the warning light stays on, allow the engine to 1. Reverse indicator light “R” cool. If the warning light stays on when the engine 2. Neutral indicator light “N” is cool, have a Yamaha dealer check the electrical 3. Oil temperature warning light “ ” circuit.

  • Page 21: Handlebar Switches

    EBU18061 EBU18100 Handlebar switches Start switch “ ” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18151 Light switch “ /OFF” Set this switch to “ ”...

  • Page 22: Throttle Lever

    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 1.

  • Page 23: Front Brake Lever

    crease the maximum engine power available WHAT CAN HAPPEN and the maximum speed of the ATV, turn the The throttle cable could be damaged. Im- adjusting screw in direction (b). proper throttle operation could result. You could lose control, have an accident or be in- jured.

  • Page 24: 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 25: Parking Brake

    EBU18450 WHAT CAN HAPPEN Parking brake The ATV could start moving unexpectedly if Use the parking brake before starting the engine or the parking brake is not applied before start- parking the ATV, especially on a slope. Apply the ing the engine. This could cause loss of con- rear brake lever and push down the lock plate to trol or a collision.

  • Page 26: Fuel Tank Cap

    1. Drive select lever 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 27 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.

  • Page 28: Fuel Cock

    EWB00270 WARNING POTENTIAL HAZARD Improper care when refueling. 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.

  • Page 29: 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 30: Seat

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Seat 1. Starter (choke) “ ” EBU26981 Seat To remove the seat Push the seat lock lever backward and pull up the seat at the rear.

  • Page 31: Storage Compartment

    To install the seat When storing any documents in the storage com- Fit the slot in the seat onto the projection on the partment, be sure to wrap them in a plastic bag so front cowling, insert the projections on the front of that they will not get wet.

  • Page 32: Adjusting The Front Shock Absorber Assemblies

    1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha 1. Storage compartment drain plug dealer to make this adjustment. EBU18980 Adjusting the front shock absorber as-...

  • Page 33: Adjusting The Rear Shock Absorber Assembly

    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 1. Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: Maximum (hard): EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.

  • Page 35: Pre-Operation Checks

    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. ITEM...
  • Page 36 Final gear oil • Check ATV for oil leakage. Correct if necessary. 5-3, 8-15 • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-4, 8-26, 8-27, 8-28 •...

  • Page 37: Fuel

    EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. Make sure that the final gear oil is at the specified (See page 4-8.) level. Add oil as necessary. (See page 8-15.) EWB00500 WARNING POTENTIAL HAZARD Improper care when refueling.

  • Page 38: Front And Rear Brakes

    Brake levers and brake pedal Check that there is no free play in the front brake Brake operation lever. If there is free play, have a Yamaha dealer Test the brakes at slow speed after starting out to check the brake system.

  • Page 39: Throttle Lever

    EBU19761 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary.

  • Page 40: Tires

    HOW TO AVOID THE HAZARD Rear: The tires listed below have been approved 25.0 kPa (3.6 psi) (0.250 kgf/cm²) by Yamaha Motor Manufacturing Corpora- • Check and adjust tire pressures when tion of America for this model. Other tire the tires are cold.

  • Page 41: Specifications

    Tire pressure below the minimum speci- NOTE: fied could cause the tire to dislodge from The low-pressure tire gauge is included as stan- the rim under severe riding conditions. dard equipment. Make two measurements of the Minimum tire pressure: tire pressure and use the second reading. Dust or Front: dirt in the gauge could cause the first reading to be 22.0 kPa (3.2 psi) (0.220 kgf/cm²)

  • Page 42: Tire Wear Limit

    Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Tire wear limit Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) EBU19840 Chassis fasteners Rear...

  • Page 43: Operation

    Read the Owner’s Manual carefully. If there is prior to operating the engine for the first time. a control or function you do not understand, ask your Yamaha dealer. 1. Set the parking brake. 2. Turn the fuel cock to “ON”.
  • Page 44 4. Shift the drive select lever into the neutral po- Ambient temp./starter (choke) position sition. The neutral indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical cir- cuit. NOTE: The engine can be started under the following con- ditions: The drive select lever is in the neutral position.

  • Page 45: Starting A Warm Engine

    7. If the engine is started with the starter (choke) EBU20370 Operating the drive select lever and in position (1), the starter (choke) should be driving in reverse returned to position (2) to warm up the engine. ECB00170 If the engine is started with the starter (choke) CAUTION: in position (2), keep the starter (choke) in this Before shifting, stop the ATV, otherwise the...
  • Page 46 NOTE: When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 1. Drive select lever 2. F (Forward) 3. N (Neutral) 4. R (Reverse) 3.

  • Page 47: Engine Break-In

    If any engine trouble should occur during the your engine than the first 320 km (200 mi) or 20 engine break-in period, immediately have a hours of riding. For this reason, you should read Yamaha dealer check the ATV. the following material carefully.

  • Page 48: Parking

    EBU20700 1. Bring the ATV to a stop by applying the brakes Parking in the forward position. When parking the ATV, stop the engine, shift the 2. Stop the engine. drive select lever into the forward position, apply 3. With the rear brake lever and pedal applied, the parking brake, and then turn the fuel cock to apply the parking brake, and then slowly re- “OFF”.
  • Page 49 However, cessories so that you can carry cargo or tow a trail- it is not possible for Yamaha to test all non- er, you must use common sense and good Yamaha accessories, nor control over their qual- judgment as the stability and handling of an ATV ity or suitability.
  • Page 50 Tie down cargo securely to the carriers. Make HOW TO AVOID THE HAZARD sure cargo in the trailer cannot move around. A Never exceed the stated load capacity for shifting load can cause an accident. this ATV. Make sure the load does not interfere with con- Cargo should be properly distributed and se- trols or your ability to see where you are going.

  • Page 51: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 52: 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, EBU26960 even if you are an experienced operator.
  • Page 53 Yamaha. They should then ry or death of the child. regularly practice the skills learned in the HOW TO AVOID THE HAZARD course and the operating techniques de- A child under 16 should never operate an scribed in this Owner’s Manual.
  • Page 54 This ATV is designed to carry operator and car- go 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 55 Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet EWB00920 WARNING that fits properly. You should also wear: POTENTIAL HAZARD eye protection (goggles or face shield) Operating this ATV without wearing an ap- gloves proved motorcycle helmet, eye protection boots and protective clothing.
  • Page 56 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 57 EWB00950 Do not operate at speeds too fast for your skills WARNING 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 58 Speed limiter Loading and accessories For riders less experienced with this model, the As originally equipped, this ATV is not designed to throttle lever housing is equipped with a speed lim- carry cargo or tow a trailer. If you choose to add ac- iter.
  • Page 59 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. Allow greater distance for brak- ing. Always follow the instructions in your Own- er’s Manual for carrying cargo or pulling a trailer.
  • Page 60 EWB00980 WHAT CAN HAPPEN WARNING Increases the chance of an accident, includ- ing an overturn. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Removing hands from handlebars or feet Never attempt stunts, such as wheelies or from footboards during operation. jumps. Don’t try to show off. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could...
  • 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 compo- nents designed for use on this ATV and should be installed and used according to instructions.

  • Page 62: Be Careful Where You Ride

    Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system.
  • Page 63 HOW TO AVOID THE HAZARD EWB01030 WARNING Always avoid paved surfaces, including sidewalks, driveways, parking lots and POTENTIAL HAZARD streets. Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one.
  • Page 64 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • 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: Turning Your Atv

    Do not ride in areas posted “no trespassing”. hot when riding and afterwards; do not allow skin Do not ride on private property without getting per- or clothing to come in contact with these compo- mission. nents. With the engine idling, return the starter (choke) to the closed position and shift the drive select lever into the forward position, then release the parking brake.
  • 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. EWB01080 WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a colli- sion or overturn.

  • Page 68: Climbing Uphill

    Improper riding procedures such as abrupt throttle WHAT CAN HAPPEN changes, excessive braking, incorrect body move- The ATV can overturn more easily on ex- ments, or too much speed for the sharpness of the tremely steep hills than on level surfaces or turn may cause the ATV to tip.
  • Page 69 HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing hills as described in this Owner’s Manu- Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly.
  • Page 70 If you are climbing a hill and you find that you have When crossing the side of a hill: not properly judged your ability to make it to the Always follow proper procedures as de- top, you should turn the ATV around while you still scribed in the Owner’s Manual.
  • Page 71 If you start to roll backwards, DO NOT apply the If you begin rolling backwards: rear brake to stop or try to put the ATV in gear. The Keep weight uphill. ATV could easily tip over backwards. Instead, ap- Never apply the rear brake while rolling ply the front brake gradually, or dismount the ATV backwards.

  • Page 72: Riding Downhill

    RIDING DOWNHILL HOW TO AVOID THE HAZARD When riding your ATV downhill, shift your weight Always follow proper procedures for going as far to the rear and uphill side of the ATV as pos- down hills as described in this Owner’s Man- sible.
  • Page 73 7-23...

  • Page 74: Crossing A Slope

    CROSSING A SLOPE HOW TO AVOID THE HAZARD Traversing a sloping surface on your ATV requires Never attempt to turn the ATV around on any you to properly position your weight to maintain hill until you have mastered the turning tech- proper balance.
  • Page 75 7-25...

  • Page 76: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
  • Page 77 1. Air filter case check hose ECB00730 CAUTION: After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the storage compartment drain plugs.

  • Page 78: Riding Over Rough Terrain

    1. Drive select lever box check hose 1. V-belt case drain plug RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident.

  • Page 79: Sliding And Skidding

    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 procedures as described in the Owner’s Manual.

  • Page 80: What To Do If

    WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.
  • Page 81 If your ATV begins to tip while turning: If your ATV encounters shallow water: Lean more into the turn to regain balance. If nec- Ride slowly and carefully through slow moving essary, gradually let off the throttle and/or steer water, watching for obstacles. Be sure to let wa- to the outside of the turn.

  • Page 82: 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 83 Yamaha ATV dealer. additional tools such as a torque wrench may be 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 it for you.

  • Page 84: 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 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 leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 86: 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 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for wear, cracks or other damage, and re- √ √ √ √ V-belt place if necessary. •...
  • Page 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Drive select lever • Check operation and adjust or replace if neces- √ √ √ safety system cable sary.

  • Page 89: Removing And Installing The Panel

    EWB00010 EBU23111 Panel A WARNING Indicates a potential hazard that could result in To remove the panel serious injury or death. Remove the bolt, and then take the panel off. EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter.

  • Page 90: Checking The Spark Plug

    NOTE: If the spark plug shows a distinctly different color, 1. Spark plug cap the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV.
  • Page 91 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DR8EA To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

  • Page 92: Engine Oil And Oil Filter Cartridge

    3. Remove the engine oil filler cap, and then NOTE: wipe the dipstick off with a clean rag. If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
  • Page 93 To change the engine oil (with or without oil fil- ter cartridge 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 94 5. Remove the oil filter cartridge with an oil filter NOTE: wrench. An oil filter wrench is available at a nearby Yamaha dealer. 6. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
  • Page 95 Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.20 L (2.33 US qt) (1.94 Imp.qt) With oil filter cartridge replacement: 2.30 L (2.43 US qt) (2.02 Imp.qt) NOTE: Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down.

  • 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 1.
  • Page 97 To change the final gear oil 1. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 1. Final gear case guard 2.

  • Page 98: Cleaning The Air Filter Element

    Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 8. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 9. Install the final gear case guard by installing the bolts and tightening them to the specified torque.
  • Page 99 NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air fil- ter case. 1. Air filter case cover holder 2.
  • Page 100 1. Air filter element 1. Air filter element frame 2. Sponge material 4. Pull off the lock plate, and then remove the 3. Air filter element lock plate sponge material from the air filter element 5. Wash the sponge material gently but thor- frame.
  • Page 101 7. Check the sponge material and replace it if ECB00460 damaged. CAUTION: 8. Apply Yamaha foam air filter oil or other qual- Make sure that the air filter element is prop- ity foam air filter oil to the sponge material. erly seated in the air filter case.

  • Page 102: Cleaning The Spark Arrester

    Never operate the engine with the air filter el- ement removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage. Addition- ally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine over- heating.

  • Page 103: V-Belt Cooling Duct Check Hose

    EWB01910 WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. 1. Tailpipe HOW TO AVOID THE HAZARD 2.

  • Page 104: V-Belt Case Drain Plug

    If water drains from the V-belt case after removing most carburetor adjustments should be left to a the plug, have a Yamaha dealer check the ATV as Yamaha dealer, who has the necessary profes- the water may affect other engine parts.

  • Page 105: Adjusting The Engine Idling Speed

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

  • Page 106: Adjusting The Throttle Cable Free Play

    The valve clearance changes with use, resulting in bolt in direction (b). 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. 8-25...

  • Page 107: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm which allows you to check the brake shoe wear (0.04 in), have a Yamaha dealer replace the brake without having to disassemble the brake. To check pads as a set.

  • Page 108: Checking The Brake Fluid Level

    1. Wear limit line 1. Minimum level mark 2. Wear indicator Observe these precautions: When checking the fluid level, make sure that EBU24251 Checking the brake fluid level the top of the brake fluid reservoir is level. Insufficient brake fluid may allow air to enter the Use only the recommended quality brake fluid, brake system, possibly causing it to become inef- otherwise the rubber seals may deteriorate,...

  • Page 109: Changing The Brake Fluid

    Brake fluid may deteriorate painted surfaces or free play of zero mm (zero in) as shown. If the free plastic parts. Always clean up spilled fluid imme- play is incorrect, have a Yamaha dealer check the diately. brake system. As the brake pads wear, it is normal for the brake fluid level to gradually go down.

  • Page 110: Adjusting The Brake Pedal And Rear Brake Lever Free Play And Checking The Brake Pedal Position

    Adjusting the brake pedal free play professional knowledge. These procedures The brake pedal free play should measure 20.0– should be performed by a Yamaha dealer. 30.0 mm (0.79–1.18 in) as shown. If the free play is incorrect, adjust it as follows.
  • Page 111 1. Brake pedal free play 1. Brake pedal free play adjusting nut 2. Brake lever free play adjusting nut 1. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the rear wheel Adjusting the brake lever free play hub.
  • Page 112 1. Brake lever free play 1. Brake lever free play adjusting nut 2. Locknut 2. Gap “A” 3. Brake lever free play adjusting bolt 3. Turn the brake lever free play adjusting bolt at 1. Loosen the locknut at the brake lever and fully the brake lever in direction (a) to increase the turn in the brake lever free play adjusting bolt.
  • Page 113 Make sure the brake pedal does not move. Checking the brake pedal position The top of the brake pedal should be positioned 72.0–82.0 mm (2.83–3.23 in) above the footboard bracket. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 8-32...

  • Page 114: Axle Boots

    You could lose braking ability, which could adjusted as follows, but the other brake light lead to an accident. switches should be adjusted by a Yamaha dealer. HOW TO AVOID THE HAZARD 1. Remove panel A. (See page 8-8.) After servicing:...

  • Page 115: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil 8-34...

  • Page 116: Checking And Lubricating The Brake Pedal

    Recommended lubricants: NOTE: Front brake lever: To access the brake pedal pivot, remove panel A. Silicone grease (See page 8-8.) Rear brake lever: Lithium-soap-based grease (all-purpose Recommended lubricant: grease) Lithium-soap-based grease (all-purpose grease) EBU28831 Checking and lubricating the brake EBU24962 pedal Checking the wheel hub bearings The operation of the brake pedal should be...

  • Page 117: Lubricating The Steering Shaft

    EWB02140 WARNING have a Yamaha dealer check the wheel hub bear- ings. POTENTIAL HAZARD Failure to handle batteries or battery electro- EBU25100 lyte carefully. Lubricating the steering shaft...
  • Page 118 To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.

  • Page 119: Replacing A Fuse

    EBU25313 Replacing a fuse 1. Headlight fuse 2. Ignition fuse 1. Main fuse 3. Signaling system fuse 2. Spare main fuse 4. Spare fuse 3. Fuse box The main fuse and the fuse box are located under the seat. (See page 4-12.) If a fuse is blown, replace it as follows.

  • Page 120: Replacing A Headlight Bulb

    2. Remove the blown fuse, and then install a 4. If the fuse immediately blows again, have a new fuse of the specified amperage. Yamaha dealer check the electrical system. EBU25531 Specified fuses: Replacing a headlight bulb Main fuse: If a headlight bulb burns out, replace it as follows.
  • Page 121 4. Install a new headlight bulb into the headlight unit by aligning the projection on the bulb with the groove in the headlight unit. 1. Headlight bulb holder 3. Remove the defective bulb from the headlight unit by pulling it out. 1.

  • Page 122: Adjusting A Headlight Beam

    ECB00690 pushing it inward, and turning it clockwise until CAUTION: it stops. It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the adjusting bolt in direction (a). To lower a headlight beam, turn the adjusting bolt in direction (b).

  • Page 123: Removing A Wheel

    1. Remove the lens by removing the screws. 1. Tail/brake light bulb 1. Screw 3. Insert a new bulb into the socket, push it in, 2. Remove the defective bulb by pushing it in and then turn it clockwise until it stops. and turning it counterclockwise.

  • Page 124: 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 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 1.

  • Page 125: 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 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 injury 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 EBU25870 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

    WHAT CAN HAPPEN Long-term Wet brakes may have reduced stopping abil- Before storing your ATV for several months: ity, increasing the chance of an accident. 1. Follow all the instructions in the “Cleaning” HOW TO AVOID THE HAZARD section of this chapter. Test the brakes after washing.
  • Page 130 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-36.

  • Page 131: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 1978 mm (77.9 in) Electric starter Overall width: Lubrication system: 1063 mm (41.9 in) Wet sump Overall height: Engine oil: 1095 mm (43.1 in) Seat height: Type: 840 mm (33.1 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase: 1233 mm (48.5 in)
  • Page 132 With oil filter cartridge replacement: Transmission: 2.30 L (2.43 US qt) (2.02 Imp.qt) Primary reduction system: Final gear oil: V-belt Type: Secondary reduction system: SAE80 API GL-4 Hypoid gear oil Shaft drive Quantity: Secondary reduction ratio: 41/21 × 24/18 × 33/9 (9.545) 0.23 L (0.24 US qt) (0.20 Imp.qt) Air filter: Transmission type:...
  • Page 133 Rear tire: Rim size: 12 x 6.0AT Type: Rear wheel: Tubeless Size: Wheel type: AT23 x 10-12 Panel wheel Manufacturer/model: Rim size: MAXXIS/M938 12 x 7.5AT Loading: Front brake: Maximum loading limit: Type: 100.0 kg (220 lb) Dual disc brake (Total weight of rider, cargo, accessories, and tongue) Operation: Tire air pressure (measured on cold tires):...
  • Page 134 Wheel travel: Signaling system fuse: 180 mm (7.1 in) 10.0 A Electrical system: Ignition fuse: 15.0 A Ignition system: DC. CDI Charging system: AC magneto Battery: Model: YTX14AH Voltage, capacity: 12 V, 12.0 Ah Headlight: Bulb type: Krypton bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 30.0/30.0 W ×...

  • 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 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 ul- timate 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 Accessories and loading ..........6-6 Engine break-in .............. 6-5 Air filter element, cleaning ..........8-17 Engine, cold start ............6-1 Axle boots ..............8-33 Engine idling speed ............8-24 Engine oil ............... 5-3 Engine oil and oil filter cartridge ........8-11 Battery ................
  • Page 145 Start switch ..............4-3 Steering shaft, lubricating ..........8-36 Main switch ..............4-1 Storage ................9-2 Maintenance and lubrication chart ......... 8-5 Storage compartment ..........4-13 Maintenance chart, emission control system ....8-3 Maintenance record ............. 11-4 Model label ..............11-2 Tail/brake light bulb, replacing ........
  • Page 148 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 USA 2007.05-0.1×1 CR...

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