Yamaha YFM25BX Owner's Manual
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Yamaha YFM25BX Owner's Manual

Yamaha YFM25BX Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM25BX
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-21-16
1P0-F8199-13

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Summary of Contents for Yamaha YFM25BX

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM25BX WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-21-16 1P0-F8199-13...
  • Page 2 EBU17091...
  • Page 3 INTRODUCTION EBU17270 Congratulations on your purchase of the Yamaha YFM25BX. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting 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 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 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 ....4-5 Parking brake ..........4-6 Indicates a potential hazard that could result in serious injury or death. Shift pedal ...........4-7 Drive select lever ........4-7 Recoil starter ..........4-8 Fuel tank cap ..........4-9 EBU17420 Fuel .............4-9 TABLE OF CONTENTS...
  • Page 7 Chassis fasteners ........5-7 SLIDING AND SKIDDING ......7-31 Instruments, lights and switches ....5-7 WHAT TO DO IF........7-33 Battery ............5-7 WHAT TO DO..........7-33 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 the...
  • Page 8 Noise regulation ........11-3 Checking and lubricating the cables ..8-33 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 EBU17442 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 speed when climbing a hill. If you stall or roll Always be sure there are no obstacles or people backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 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 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Headlights 1. Spark arrester 2. Fuel cock 2. Storage compartment and tool kit 3. Recoil starter 3. Air filter case 4. Fuses 4. Engine oil filler cap 5. Battery 5. Front brake fluid reservoir 6.

  • Page 19: Controls And Instruments

    EBU17712 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Parking brake lock plate 4. Starter (choke) 5. Drive select lever 6. Main switch 7. Fuel tank cap 8. Throttle lever 9. Front 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. 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 21: Indicator Lights

    EBU17791 EBU18061 Indicator lights Handlebar switches 1. Reverse indicator light “R” 1. Light switch “ /OFF” 2. Neutral indicator light “N” 2. Engine stop switch “ ” 3. Start switch “ ” EBU17830 Reverse indicator light “ ” EBU18080 Engine stop switch “ ”...

  • Page 22: Throttle Lever

    EBU18100 EBU18270 Start switch “ ” Throttle lever Push this switch to crank the engine with the start- Once the engine is running, movement of the throt- tle lever will increase the engine speed. ECB00050 Regulate the speed of the ATV by varying the CAUTION: throttle position.

  • Page 23: Speed Limiter

    If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a 1. Locknut Yamaha dealer if you can’t find or solve the 2. Adjusting screw problem yourself. 3. No more than 12 mm (0.47 in) EBU18311 3.

  • Page 24: Front Brake Lever

    EWB00190 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 1.

  • Page 25: Parking Brake

    EBU18450 Parking brake Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. 1.

  • 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: Recoil Starter

    1. Drive select lever 1. Recoil starter EWB02361 EBU27371 WARNING Recoil starter Firmly grasp the handle and pull slightly until en- POTENTIAL HAZARD gagement can be felt. Then pull forcefully, being Starting the engine in gear or starting the careful not to pull the rope all the way out. engine without applying the parking brake.

  • Page 28: Fuel Tank Cap

    EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Fuel tank filler tube 2. Fuel level Recommended fuel: 1. Fuel tank cap UNLEADED GASOLINE ONLY Fuel tank capacity: EBU18730 12.0 L (3.17 US gal) (2.64 Imp.gal) Fuel Fuel reserve amount: Make sure that there is sufficient fuel in the tank.

  • Page 29: Fuel Cock

    HOW TO AVOID THE HAZARD Your Yamaha engine has been designed to use Do not overfill the fuel tank. Be careful not to regular unleaded gasoline with a pump octane...
  • Page 30 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 31: Starter (Choke)

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 32: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18920 Storage compartment Insert the projections on the front of the seat into the seat holders and push down on the seat at the The storage compartment is located under the rear.

  • Page 33: Front Carrier

    ECB00130 CAUTION: Do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartment. 1. Storage compartment check hose EBU18960 Front carrier Do not exceed the load limit of 30.0 kg (66 lb) for the front carrier.

  • Page 34: Adjusting The Rear Shock Absorber Assembly

    EBU19020 NOTE: Adjusting the rear shock absorber as- A special wrench can be obtained at a Yamaha sembly 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 35 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4-16...

  • Page 36: 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 37 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 5-3, 8-25, 8-26, 8-27 •...

  • Page 38: Fuel

    WHAT CAN HAPPEN Check that there is no free play in the front brake Fuel can spill, which can cause a fire and se- lever. If there is free play, have a Yamaha dealer vere injury. check the brake system.

  • Page 39: Throttle Lever

    If there is any leakage, the brake vided in this manual, have a Yamaha dealer system should be checked by a Yamaha dealer. check for the cause.

  • 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 17.0 kPa (2.5 psi) (0.170 kgf/cm²)

  • Page 42: Tire Wear Limit

    Recommended pressure: Front 20.0 kPa (2.9 psi) (0.200 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 17.0 kPa (2.5 psi) (0.170 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Tire wear limit Front 23.0 kPa (3.3 psi) (0.230 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 transmission into neutral. The neutral Ambient temp./starter (choke) position indicator light should come on. If the indicator light does not come on, have a Yamaha deal- er check the electrical circuit. NOTE: The engine can be started under the following con- ditions: The transmission is in neutral.

  • Page 45: Starting A Warm Engine

    If the battery is discharged, pull the recoil starter EBU20291 Starting a warm engine to start the engine. Follow the same procedure as for starting a cold 7. If the engine is started with the starter (choke) engine, with the exception that the starter (choke) in position (1), the starter (choke) should be is not required when the engine is warm.
  • Page 46 NOTE: be on. If the indicator light does not come on, have To shift into reverse, the transmission must be in a Yamaha dealer check the electrical circuit. first gear. 5. Check behind you for people or obstacles, 1. Bring the ATV to a complete stop.

  • Page 47: Shifting

    EWB00660 WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or even a person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no people or obstacles behind you. When it is safe to proceed, go slowly.
  • Page 48 5. Shift into second gear and release the shift EWB00650 WARNING pedal. 6. Open the throttle gradually. POTENTIAL HAZARD 7. Follow the same procedure when shifting to Engaging a lower gear when the engine the next higher gear. speed is too high. EWB00690 WHAT CAN HAPPEN WARNING...

  • Page 49: Engine Break-In

    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. Since the engine is brand new, do not put an ex-...

  • Page 50: Parking On A Slope

    HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV transversely across the incline, shift into first gear, stop the engine, apply the parking brake, and then block the front and rear wheels with rocks or other objects.

  • Page 51: Accessories And Loading

    You must use common sense and good judgment may also be available on the market. However, when carrying cargo or towing a trailer. Keep the it is not possible for Yamaha to test all non- following points in mind: Yamaha accessories, nor control over their qual- Never exceed the weight limits shown.
  • Page 52 Load cargo on the carriers as close to the center MAXIMUM LOADING LIMIT of the ATV as possible. Put cargo at the rear of ATV loading limit (total weight of rider, cargo, the front carrier, at the front of the rear carrier, accessories, and tongue): and center it.
  • Page 53 EWB00750 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. 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.

  • Page 54: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 55: Getting To Know Your Atv

    EWB00010 ular attention to the safety information on pages WARNING 1-1–1-5. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. EBU21321 GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use.

  • Page 56: Ride With Care And Good Judgement

    Beginners should get training from a certified in- course offered by Yamaha. They should then structor. regularly practice the skills learned in the Become familiar with this ATV at slow speeds first, course and the operating techniques de- even if you are an experienced operator.
  • Page 57 WHAT CAN HAPPEN Use by children of ATVs that are not recom- mended for their age can lead to severe inju- ry or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.
  • Page 58 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 59 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 60 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. EWB00930 WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs.
  • Page 61 Pre-operation checks WHAT CAN HAPPEN Always perform the pre-operation checks listed on Use of improper tires on this ATV, or opera- page 5-1 before riding for proper care of the ATV tion of this ATV with improper or uneven tire and to ensure safety.
  • Page 62 EWB00010 the maximum engine power available and de- WARNING creases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and Indicates a potential hazard that could result in turning it out increases top speed. (See page 4-4.) serious injury or death.
  • Page 63 HOW TO AVOID THE HAZARD MAXIMUM LOADING LIMIT Never exceed the stated load capacity for ATV loading limit (total weight of cargo, rider, this ATV. accessories, and tongue): Cargo should be properly distributed and se- 165.0 kg (364 lb) curely attached. Front carrier: Reduce speed when carrying cargo or pull- 30.0 kg (66 lb)
  • Page 64 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 wheels. cause you to lose your balance and fall off of the ATV.
  • Page 65 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 66: 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 67 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 68 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 69 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 70 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 71 When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an accident.

  • Page 72: Turning Your Atv

    TURNING YOUR ATV As you approach a curve, slow down and begin to To achieve maximum traction while riding off-road, turn the handlebars in the desired direction. As you the two rear wheels are mounted solidly on one do so, put your weight on the footboard to the out- axle and turn together at the same speed.
  • Page 73 may continue to go straight. If the ATV doesn’t turn, come to a stop and then practice the proce- dure again. If the riding surface is slippery or loose, it may help to position more of your weight over the front wheels by moving forward on the seat.

  • Page 74: Climbing Uphill

    CLIMBING UPHILL EWB01100 WARNING Use proper riding techniques to avoid ATV over- turns on hills. Be sure that you can maneuver your POTENTIAL HAZARD ATV well on flat ground before attempting any in- Climbing hills improperly. cline and then practice riding first on gentle slopes. WHAT CAN HAPPEN Try more difficult climbs only after you have devel- Could cause loss of control or cause the...
  • Page 75 7-22...
  • Page 76 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 77 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 78: 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 79 7-26...

  • Page 80: 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 81 7-28...

  • Page 82: 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 83 1. Air filter case check hose ECB00290 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 drive se- lect lever box check hose, and the storage compartment check hose.

  • Page 84: 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 procedures as described in the Owner’s Manual.
  • Page 85 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 slide. Applying the brakes or accelerating is not recommended until you have corrected the slide. 7-32...

  • Page 86: What To Do If

    With practice, over a period of time, skill at con- WHAT TO DO IF... trolled sliding can be developed. The terrain This section is designed to be a reference guide should be chosen carefully before attempting such only. Be sure to read each section on riding tech- maneuvers, since both stability and control are re- niques completely.
  • Page 87 THE REAR BRAKE – the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See page 7-21.) If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance.

  • Page 88: 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 89 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 90: 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 91 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 92: 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 93 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and for excessive play, and re- √ √ √ Swingarm pivots place bearings if necessary. •...
  • Page 94 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. Throttle lever hous- • Check throttle cable free play and adjust if neces- √...

  • Page 95: 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 96 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 gap 2. Check the spark plug for electrode erosion 2.

  • Page 97: Engine Oil And Oil Filter Element

    3. Install the spark plug with the spark plug 2. Check the engine oil level on a cold engine. wrench, and then tighten it to the specified NOTE: torque. If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, Tightening torque: and then wait at least ten minutes until the oil set- Spark plug:...

  • Page 98: To Change The Engine Oil

    4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the minimum and maximum level marks. 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level.
  • Page 99 1. Footboard 1. Brake pedal free play adjusting nut 2. Bolt 7. Move the drive select lever safety system ca- 6. Fully loosen the brake pedal free play adjust- ble away from the oil filter element cover. ing nut, and push the brake pedal downward. 8.
  • Page 100 1. Oil filter element cover 1. Oil filter element 2. Adjusting nut 2. O-ring 3. Bolt 10. Check the O-rings for damage and replace it if 4. Drive select lever safety system cable necessary. ECB00340 11. Install the oil filter element and the O-ring. CAUTION: NOTE: Do not loosen the adjusting nuts shown when...
  • Page 101 13. Install the oil strainer, compression spring, O- NOTE: ring and engine oil drain bolt, and then tighten Be sure to wipe off spilled oil on any parts after the the engine oil drain bolt to the specified engine and exhaust system have cooled down. torque.

  • Page 102: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 103 To change the final gear oil 1. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil 2. Correct oil level 3. Final gear oil filler bolt 1. Final gear case guard 3. If the oil is below the brim of the filler hole, add 2.
  • Page 104 1. Final gear oil drain bolt 1. Final gear oil 2. Correct oil level 5. Install the drain bolt, and then tighten it to the 3. Final gear oil filler bolt specified torque. Recommended final gear oil: Tightening torque: See page 10-1. Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) ECB00420...

  • Page 105: Cleaning The Air Filter Element

    Tightening torque: NOTE: Final gear oil filler bolt: There is a check hose at the bottom of the air filter 23 Nm (2.3 m·kgf, 17 ft·lbf) case. If dust or water collects in this hose, empty the hose and clean the air filter element and air fil- 8.
  • Page 106 1. Air filter case cover 1. Air filter element assembly 2. Air filter case cover holder 4. Remove the sponge material from the air filter 3. Pull the air filter element assembly out of the element. air filter case. 8-19...
  • Page 107 6. Squeeze the excess water or solvent out of the sponge material and let it dry. ECB00470 CAUTION: Do not twist the sponge material when squeezing it. Do not apply oil to the sponge material. 1. Air filter element 2. Sponge material 5.

  • Page 108: Cleaning The Spark Arrester

    fold fittings for an air-tight seal. Tighten all fittings securely to avoid the possibility of unfiltered air en- tering 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 109: Adjusting The Carburetor

    EWB01930 WARNING POTENTIAL HAZARD Improperly purging the exhaust system. 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. Purging bolt HOW TO AVOID THE HAZARD When purging the exhaust system: 2.

  • Page 110: Adjusting The Engine Idling Speed

    NOTE: most carburetor adjustments should be left to a The engine is warm when it quickly responds to the Yamaha dealer, who has the necessary profes- throttle. sional knowledge and experience. The adjustment 2. Attach the tachometer to the spark plug lead.

  • Page 111: Adjusting The Throttle Cable Free Play

    1. Loosen the locknut. must be adjusted by a Yamaha dealer at the inter- 2. To increase the throttle cable free play, turn vals specified in the periodic maintenance and lu- the adjusting bolt in direction (a).

  • Page 112: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm The rear brake is provided with a wear indicator, (0.04 in), have a Yamaha dealer replace the brake which allows you to check the brake shoe wear pads as a set.

  • Page 113: Checking The Brake Fluid Level

    Yamaha dealer replace the brake shoes as a set. pads for wear and the brake system for leakage. 1. Wear indicator 1.

  • Page 114: Changing The Brake Fluid

    Water will signifi- free play of zero mm (zero in) as shown. If the free cantly lower the boiling point of the fluid and may play is incorrect, have a Yamaha dealer check the result in vapor lock. brake system.

  • Page 115: Adjusting The Brake Pedal Position, Free Play And The Rear Brake Lever Free Play

    Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24562 Adjusting the brake pedal position, free play and the rear brake lever free...
  • Page 116 2. Loosen the locknuts at the brake pedal. 2. Turn the brake pedal free play adjusting nut 3. Turn the brake pedal position adjusting bolt at on the brake rod at the rear wheel hub in direc- the brake pedal in direction (a) to raise the tion (a) to increase the free play, and in direc- brake pedal, and in direction (b) to lower it.
  • Page 117 1. Brake lever free play 1. Brake lever free play adjusting nut 2. Locknut 2. Brake camshaft lever 3. Brake lever free play adjusting bolt 3. Pin 4. Gap “A” 1. Loosen the locknut at the brake lever and fully 3.

  • Page 118: Axle Boots

    Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 1. Locknut EBU24230 2. Brake lever free play adjusting bolt Axle boots 4.

  • Page 119: Adjusting The Clutch Free Play

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. 1. Remove the footboard. (See “Engine oil” on page 8-10 for removal and installation proce- dures.)

  • Page 120: Checking And Lubricating The Cables

    1. Locknut essary. If a cable is damaged or does not move 2. Clutch adjusting screw smoothly, have a Yamaha dealer check or replace NOTE: Turning the clutch adjusting screw in direction (a) Recommended lubricant:...

  • Page 121: Checking And Lubricating The Front And Rear Brake Levers

    WHAT CAN HAPPEN Front brake lever Corrosion can result when the cable sheaths become damaged, and cables can also be- come frayed or kinked, which could restrict the operation of controls and lead to an acci- dent or injury. HOW TO AVOID THE HAZARD Inspect cables frequently.

  • Page 122: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel hub bear- ings. Recommended lubricant: Lithium-soap-based grease (all-purpose...

  • Page 123: Battery

    1. Grease nipple 1. Battery cover 3. Check the electrolyte level in the battery. EBU25191 Battery A poorly maintained battery will corrode and dis- charge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica- tion chart.
  • Page 124 EWB02140 WARNING POTENTIAL HAZARD Failure to handle batteries or battery electro- lyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be se- verely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gas- HOW TO AVOID THE HAZARD 1.
  • Page 125 5. Check and, if necessary, tighten the battery lead connections and correct the breather hose routing. 6. Install the battery cover. To store the battery If the ATV will not be used for more than one month, the battery will need to be removed and stored as follows.

  • Page 126: Replacing The Fuse

    To install the battery ECB00610 CAUTION: NOTE: If the breather hose is positioned in such a way Be sure the battery is fully charged. that the frame is exposed to electrolyte or gas 1. Install the battery. expelled from the battery, the frame could suf- 2.

  • Page 127: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a ECB00640 CAUTION: Yamaha dealer check the electrical system. To prevent accidental short-circuiting, turn off EBU25470 the main switch when checking or replacing a Replacing a headlight bulb fuse.
  • Page 128 4. Remove the defective bulb by pulling it out. EWB02180 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and im- mediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable.

  • Page 129: Adjusting A Headlight Beam

    EBU25550 Adjusting a headlight beam ECB00690 CAUTION: 1. Do not touch the glass part of the bulb. It is advisable to have a Yamaha dealer make this adjustment. ECB00650 CAUTION: To raise a headlight beam, turn the adjusting Do not touch the glass part of the headlight screw in direction (a).

  • Page 130: Replacing The Tail/Brake Light Bulb

    1. Headlight beam adjusting screw 1. Tail/brake light bulb holder 2. Remove the defective bulb by pushing it in EBU25610 Replacing the tail/brake light bulb and turning it counterclockwise. If the tail/brake light bulb burns out, replace it as follows. 1.

  • Page 131: Removing A Wheel

    1. Tail/brake light bulb holder 1. Wheel nut 2. Tail/brake light bulb 2. Elevate the ATV and place a suitable stand 3. Insert a new bulb into the bulb holder, push it under the frame. in, and then turn it clockwise until it stops. 3.
  • Page 132 Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Tapered nut 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques.

  • Page 133: 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 134: 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 135: 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 136: Storage

    EWB02300 To prevent corrosion, avoid damp cellars, WARNING stables (because of the presence of ammo- nia) and areas where strong chemicals are POTENTIAL HAZARD stored. Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping abil- Long-term ity, increasing the chance of an accident.
  • Page 137 b. Pour a teaspoonful of engine oil into the sively cold or warm place [less than 0 °C (30 spark plug bore. °F) or more than 30 °C (90 °F)]. For more in- c. Install the spark plug cap onto the spark formation on storing the battery, see page plug, and then place the spark plug on the 8-36.

  • Page 138: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 8.70 :1 Overall length: Starting system: 1916 mm (75.4 in) Electric and recoil starter Overall width: Lubrication system: 1038 mm (40.9 in) Wet sump Overall height: Engine oil: 1118 mm (44.0 in) Seat height: Type: 772 mm (30.4 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase:...
  • Page 139 With oil filter element removal: Transmission: 1.60 L (1.69 US qt) (1.41 Imp.qt) Primary reduction system: Final gear oil: Spur gear Type: Primary reduction ratio: SAE80 API GL-4 Hypoid gear oil 73/22 (3.318) Quantity: Secondary reduction system: 0.25 L (0.26 US qt) (0.22 Imp.qt) Shaft drive Air filter: Secondary reduction ratio:...
  • Page 140 Trail: Maximum: 20.0 mm (0.79 in) Front: Front tire: 23.0 kPa (3.3 psi) (0.230 kgf/cm²) Rear: Type: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Tubeless Front wheel: Size: AT22 x 7.00-10 Wheel type: Manufacturer/model: Panel wheel MAXXIS/M905 Rim size: Rear tire: 10 x 6.0AT Rear wheel: Type:...
  • Page 141 Spring/shock absorber type: Reverse indicator light: 12 V, 1.7 W × 1 Coil spring/oil damper Wheel travel: Fuse: 125 mm (5.0 in) Fuse: Rear suspension: 20.0 A Type: Swingarm (monocross) Spring/shock absorber type: Coil spring/oil damper Wheel travel: 135 mm (5.3 in) Electrical system: Ignition system: DC.

  • Page 142: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 143 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 144: 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 145: 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 146: 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 147 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 148: 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 149 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 150 EBU26132 11-9...
  • Page 151 INDEX Drive select lever and driving in reverse ......6-3 Drive select lever safety system cable, adjusting ..8-25 Accessories and loading ..........6-9 Air filter element, cleaning ..........8-18 Axle boots ..............8-31 Engine break-in .............. 6-7 Engine, cold start ............6-1 Engine idling speed .............
  • Page 152 Light switch ..............4-3 Starter (choke) ............. 4-12 Start switch ..............4-3 Steering shaft, lubricating ..........8-35 Main switch ..............4-1 Storage ................9-2 Maintenance and lubrication chart ......... 8-5 Storage compartment ........... 4-13 Maintenance chart, emission control system ....8-3 Swingarm pivots, lubricating ........
  • Page 154 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 2007.05-0.7×1 CR...

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