Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35GW WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-20-19 5WH-F8199-14...
Page 2 EBU17091...
Page 3 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 ....4-6 Parking brake ..........4-7 Indicates a potential hazard that could result in serious injury or death. Drive select lever ........4-7 Recoil starter ..........4-8 Fuel tank cap ..........4-9 Fuel .............4-9 EBU17420 Fuel cock ..........4-10 TABLE OF CONTENTS...
Page 7 Tire wear limit ..........5-8 WHAT TO DO IF........7-32 Chassis fasteners ........5-8 WHAT TO DO..........7-32 Instruments, lights and switches ....5-8 PERIODIC MAINTENANCE AND MINOR OPERATION ..........6-1 REPAIR ............8-1 Starting a cold engine ........ 6-1 Owner’s manual and tool kit .......8-1 Starting a warm engine ......
Page 8 ......8-32 Noise regulation ........11-3 Checking and lubricating the brake Maintenance record ........11-4 pedal ............8-33 YAMAHA MOTOR CORPORATION, Checking the wheel bearings ....8-33 U.S.A. ATV LIMITED WARRANTY ..11-5 Lubricating the drive shaft universal YAMAHA EXTENDED SERVICE joint ............
Page 9: Safety Information
EBU17430 SAFETY INFORMATION EBU17542 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 roll backwards, follow the special procedure for Always be sure there are no obstacles or people braking described in this manual. Dismount on behind you when you operate in reverse. When the uphill side or to a side if pointed straight up- 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. WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident.
Page 18: Description
EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Fuel cock 1. Rear shock absorber assembly spring preload adjusting ring 2. Throttle stop screw 2. Spark arrester 3. Air filter case 3. Storage compartment and tool kit 4. Fuses 4. Spark plug 5.
Page 19: Controls And Instruments
EBU17712 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Parking brake lock plate 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 And Warning Light
If the warning light stays on, allow the engine to 1. Neutral indicator light “N” cool. If the warning light stays on when the engine 2. Reverse indicator light “R” is cool, have a Yamaha dealer check the electrical 3. Oil temperature warning light “ ” circuit.
Page 22: Handlebar Switches
EBU18060 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 23: 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 24: 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 25: 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 26: 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 27: Recoil Starter
1. Drive select lever 1. Recoil starter EWB00300 EBU18660 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 without shifting into the careful not to pull the rope all the way out. neutral position.
Page 28: Fuel Tank Cap
EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Fuel level 2. Fuel tank filler tube Recommended fuel: 1. Fuel tank cap UNLEADED GASOLINE ONLY Fuel tank capacity: EBU18730 13.5 L (3.57 US gal) (2.97 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 pointing to “OFF” 1. Arrow mark pointing to “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 pointing to “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 EBU18911 Storage compartment Insert the projections on the front of the seat into ECB00130 the seat holders and push down on the seat at the CAUTION: rear.
Page 33: Front Carrier
1. Storage compartment 1. Storage compartment check hose Do not exceed the load limit of 2.0 kg (4 lb) EBU18960 Front carrier for the storage compartment. Do not exceed the maximum load of 210.0 kg Do not exceed the load limit of 40.0 kg (88 lb) for (463 lb) for the ATV.
Page 34: Adjusting The Front Shock Absorber Assemblies
EBU18980 NOTE: Adjusting the front shock absorber as- A special wrench can be obtained at a Yamaha semblies 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: Adjusting The Rear Shock Absorber Assembly
NOTE: EBU19020 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.
Page 36 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4-17...
Page 37: Pre-Operation Checks
Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
Page 38 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary. 5-4, 8-24 • Check cable free play, and adjust if necessary. Control cables • Make sure that operation is smooth. Lubricate if necessary. 8-32 •...
Page 39: 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 40: 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 42: 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 43: Measuring The Tire Pressure
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 44: 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 45: 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 46 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 47: 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 48 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 49: Engine Break-In
There is never a more important period in the life of engine break-in period, immediately have a your engine than the first 20 hours of riding. For Yamaha dealer check the ATV. this reason, you should read the following material carefully.
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 the drive select lever to the forward position, 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
Keep the may also be available on the market. However, following points in mind: it is not possible for Yamaha to test all non- Never exceed the weight limits shown. An over- Yamaha accessories, nor control over their qual-...
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 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 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 1-5. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. EBU21621 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. 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 61 EWB00950 WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or opera- tion of this ATV with improper or uneven tire pressure, may cause loss of control, in- creasing your risk of an accident.
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- 210.0 kg (463 lb) curely attached. Front carrier: Reduce speed when carrying cargo or pull- 40.0 kg (88 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: 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 71 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 72: 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 73 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 74 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 75 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 76: 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 77 7-24...
Page 78: 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 79 7-26...
Page 80: 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 81 1. Air filter case check hose ECB00280 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 check hose.
Page 82: Riding Over Rough Terrain
1. V-belt case drain plug 1. Drive select lever box check hose 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 83 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 84: Sliding And Skidding
SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.
Page 85: What To Do If
WHAT CAN HAPPEN If your ATV begins to tip while turning: You may lose control of this ATV. You may Lean more into the turn to regain balance. If nec- also regain traction unexpectedly, which essary, gradually let off the throttle and/or steer may cause the ATV to overturn.
Page 86 If your ATV encounters shallow water: 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 87: 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 88 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 89: 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 90 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 91: General Maintenance And Lubrication Chart
EBU21863 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 92 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Upper and lower √ √ √ • Lubricate with lithium-soap-based grease. arm pivots • Check for wear, cracks or other damage, and re- √...
Page 93 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Moving parts and √ √ √ √ 21 * • Lubricate. cables Drive select lever • Check operation and adjust or replace if neces- √...
Page 94: 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 95: 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 96: To Install The Spark Plug
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 97: Engine Oil And Oil Filter Cartridge
NOTE: 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. 4.
Page 98: To Change The Engine Oil
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 99 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 100 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) ECB00300 CAUTION: In order to prevent clutch slippage (since the 1.
Page 101: 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 102 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 103: 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 104 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 holder 2.
Page 105 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 106 CAUTION: damaged. Make sure that the air filter element is prop- 8. Apply Yamaha foam air filter oil or other qual- erly seated in the air filter case. ity foam air filter oil to the sponge material. Never operate the engine with the air filter el- NOTE: ement removed.
Page 107: Cleaning The Spark Arrester
will affect carburetor jetting with subsequent 3. Tap the tailpipe lightly, and then use a wire poor performance and possible engine over- brush to remove any carbon deposits from the heating. spark arrester portion of the tailpipe and inside of the tailpipe housing. EBU23881 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be-...
Page 108: V-Belt Cooling Duct Check Hose
If water drains from the V-belt case after removing If dust or water collects in the V-belt cooling duct the plug, have a Yamaha dealer check the ATV as check hose, remove the hose and clean it. the water may affect other engine parts.
Page 109: Adjusting The Carburetor
ECB00480 CAUTION: The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performance of or damage to the engine. EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals 1.
Page 110: Adjusting The Throttle Cable Free Play
(a). To decrease 1450–1550 r/min the throttle cable free play, turn the adjusting bolt in direction (b). NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 8-24...
Page 111: Valve Clearance
1.0 mm prevent this from occurring, the valve clearance (0.04 in), have a Yamaha dealer replace the brake must be adjusted by a Yamaha dealer at the inter- pads as a set. vals specified in the periodic maintenance and lu- brication chart.
Page 112: Checking The Brake Fluid Level
Yamaha dealer replace the brake shoes as a set. 1. Brake pad 2. Lining thickness NOTE: 1. Wear limit line The wheels need to be removed to check the 2.
Page 113: Changing The Brake Fluid
Changing the brake fluid Observe these precautions: When checking the fluid level, make sure that Have a Yamaha dealer change the brake fluid at the top of the brake fluid reservoir is level. the intervals specified in the NOTE after the peri- Use only the recommended quality brake fluid, odic maintenance and lubrication chart.
Page 114: 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 115 Before adjusting the brake lever and brake pedal free play, check the rear brake shoes for wear. Adjusting the brake pedal free play The brake pedal free play should measure 20.0– 30.0 mm (0.79–1.18 in) as shown. If the free play is incorrect, adjust it as follows.
Page 116 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 117: Brake Light Switches
The brake light switch for the brake pedal can be Make sure the brake pedal does not move. adjusted as follows, but the other brake light EWB02020 switches should be adjusted by a Yamaha dealer. WARNING 1. Remove panel A. (See page 8-8.) POTENTIAL HAZARD...
Page 118: Checking And Lubricating The Cables
If a cable is damaged or does not move light switch in place. To make the brake light smoothly, have a Yamaha dealer check or replace come on earlier, turn the adjusting nut in direc- tion (a). To make the brake light come on lat- Recommended lubricant: er, turn the adjusting nut in direction (b).
Page 119: Checking And Lubricating The Brake Pedal
Yamaha dealer check the wheel bearings. NOTE: To access the brake pedal pivot, remove panel A.
Page 120: Lubricating The Drive Shaft Universal Joint
EBU24980 Recommended lubricant: Lubricating the drive shaft universal Lithium-soap-based grease joint The drive shaft universal joint must be lubricated at EBU25100 the intervals specified in the periodic maintenance Lubricating the steering shaft and lubrication chart. The steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- Recommended lubricant: brication chart.
Page 121 EWB02140 To charge the battery WARNING Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in POTENTIAL HAZARD mind that the battery tends to discharge more Failure to handle batteries or battery electro- quickly if the ATV is equipped with optional electri- lyte carefully.
Page 122: Replacing A Fuse
To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat- tery. 8-36...
Page 123 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Ignition fuse: 15.0 A Signaling system fuse: 10.0 A 1. Headlight fuse 2. Ignition fuse EWB02151 3.
Page 124: Replacing A Headlight Bulb
4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU26892 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the bulb holder cover at the rear of the headlight by pulling it off.
Page 125 NOTE: The headlight bulb cannot be removed from the headlight bulb holder. To replace the headlight bulb, replace the headlight bulb holder assembly. EWB02180 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and im- mediately after it is turned off. WHAT CAN HAPPEN 1.
Page 126: Adjusting A Headlight Beam
7. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make 1. Headlight beam adjusting screw this adjustment. EBU25580 Replacing the tail/brake light bulb To raise a headlight beam, turn the adjusting screw in direction (a).
Page 127: 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 128: 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 129 HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys- tem. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces. 8-43...
Page 130: 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 131: 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 132: 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 133 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 8-34.
Page 134: Specifications
EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 1984 mm (78.1 in) Electric and recoil starter Overall width: Lubrication system: 1085 mm (42.7 in) Wet sump Overall height: Engine oil: 1120 mm (44.1 in) Seat height: Type: 827 mm (32.6 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase:...
Page 135 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 136 Rear tire: Rim size: 12 x 6.0AT Type: Rear wheel: Tubeless Size: Wheel type: AT25 x 10-12 Panel wheel Manufacturer/model: Rim size: MAXXIS/M980 12 x 7.5AT Loading: Front brake: Maximum loading limit: Type: 210.0 kg (463 lb) Dual disc brake (Total weight of rider, cargo, accessories, and tongue) Operation: Tire air pressure (measured on cold tires):...
Page 137 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: Halogen bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 30.0/30.0 W ×...
Page 138: Consumer Information
Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
Page 139 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 140: 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 141: 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 142: 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 143 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 144: 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 145 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 146 EBU26132 11-9...
Page 147 INDEX Drive shaft universal joint, lubricating ......8-34 Accessories and loading ..........6-7 Air filter element, cleaning ..........8-17 Engine break-in .............. 6-5 Engine, cold start ............6-1 Engine idling speed ............. 8-23 Battery ................8-34 Engine oil ............... 5-3 Brake fluid, changing ...........
Page 148 Light switch ..............4-3 Speed limiter ..............4-4 Starter (choke) ............. 4-12 Start switch ..............4-3 Main switch ..............4-1 Steering shaft, lubricating ..........8-34 Maintenance and lubrication chart ......... 8-5 Storage ................9-2 Maintenance chart, emission control system ....8-3 Storage compartment ...........
Page 149 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 2006.05-1.3×1 CR...

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