Home

Yamaha YFM25RX Offroad Vehicle User Manual

1. Dear New Yamaha ATV Owner CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV You have purchased a quality Yamaha product that with proper use and care will provide hours of riding pleasure BEFORE YOU OPERATE YOUR NEW ATV Yamaha recommends these important points READ YOUR OWNER S MANUAL A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC TAKE THE FREE HANDS ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1 800 887 2887 If you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership please fill out the information below and mail this card to yamaha today Name ATV Model Purchase Date Le MO DAY YR Address Primary 1 D Engine Number L J E t ft t i Dealer Name amp Address Telephone CAREFULLY READ BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 4 CYPRESS CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U S A P O BOX 6555 CYPRESS CALIFORNIA 90630 9989 ATTN SALES ADMINISTRATION NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES
2. WARNING POTENTIAL HAZARD Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding Loss of control which could cause an acci ECBO00150 dent or injury HOW TO AVOID THE HAZARD CAUTION Read the Owner s Manual carefully If there is See the Engine break in section on page 6 5 a control or function you do not understand prior to operating the engine for the first time ask your Yamaha dealer a Suaepaanesee a SSS Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to RUN 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator 6 1 light does not come on have a Yamaha deal er check the electrical circuit NOTE gt This model is equipped with an ignition circuit cut off system The engine can be started under the following conditions The transmission is in neutral The clutch is disengaged with the transmission in gear However it is recommended to shift into neutral before starting the engine BEM 5 Use the starter choke in reference to the fig ure Position 1 Cold engine start with ambient temperature be low 5 C 40 F Position
3. 4 5 off system 1 Clutch lever EBU18411 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the brake lever toward the handlebar grip 1 Brake lever EBU18432 Brake pedal The brake pedal is located on the right side of the ATV To apply the rear brake push down on the brake pedal 4 6 1 Brake pedal EBU18510 Parking brake lever Use the parking brake before starting the engine or parking the ATV especially on a slope To apply the parking brake move the parking brake lever in direction a To release the parking brake move the parking brake lever in direction b EWB00170 A 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 You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure you have released the park ing brake before you begin to ride EBU18530 Shift pedal This ATV is equipped with a constant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in combina 1 Parkin
4. 0 7 mm 0 024 0 028 in m 1 Spark plug cap 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads Install the spark plug with the spark plug wrench and then tighten it to the specified torque Tightening torque Spark plug 18 Nm 1 8 m kof 13 ft lbf NOTE SSS 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 Install the spark plug cap EBU28881 Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter element cleaned at the intervals speci fied in the periodic maintenance and lubrication chart 8 11 To check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine NOTE gt If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil set tles for an accurate reading 3 Remove the engine oil filler cap and then wipe the dipstick off with a clean rag Insert the dipstick into the filler hole without screwing it in and then remove it again to check the oil level 4 1 Engine oil filler cap 2 Dipstick 3 Ma
5. Compression ratio 9 50 1 Starting system Electric starter Lubrication system Wet sump Engine oll Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 0 10 30 50 70 90 110 130 F ee a a a a YAMALUBE 4 ee or SAE Dow40 E aes YAMALUBE 4 10W30 or SAE 10W30 YAMALUBE 4 CW 5W30 or SAE 5W30 3 20 10 0 10 20 30 40 50 C Recommended engine oil grade API service SG type or higher JASO standard MA 10 1 Engine oil quantity Without oil filter element replacement 1 25 L 1 32 US qt 1 10 Imp qt With oil filter element replacement 1 35 L 1 43 US qt 1 19 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 9 0 L 2 38 US gal 1 98 Imp gal Fuel reserve amount 1 0 L 0 26 US gal 0 22 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BSR29 x 1 Spark plug s Manufacturer model NGK DR7EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet multiple disc Operation Left hand operation 10 2 Transmission Primary reduction system Spur gear Primary reduction ratio 76 22 3 455 Secondary reduction system Chain drive Secondary reduction ratio 38 14 2 714 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 37 13 2 846 2nd 33 18 1 833 3rd 29 21 1 381 Ath 27 24 1 125 5th
6. Lubricating the swingarm pivots The swingarm pivots must be lubricated at the in tervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease ER EBU25030 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte nance and lubrication chart Lubricate the pivoting points using a grease gun Recommended lubricant Lithium soap based grease 8 37 Left side 1 Upper grease nipple 2 Lower grease nipple Right side 1 Upper grease nipple 2 Lower grease nipple EBU25100 Lubricating the steering shaft The steering shaft must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart Recommended lubricant Lithium soap based grease 8 38 EBU25212 Battery This model is equipped with a sealed type MF battery which does not require any maintenance There is no need to check the electrolyte or to add distilled water Check and if necessary tighten the battery lead connections ECB00620 CAUTION Never attempt to remove the battery cell seals as this would permanently damage the battery EWB02140 A WARNING POTENTIAL HAZARD Failure to handle batteries or battery electro lyte carefully WHAT CAN HAPPEN You could be poisoned You could be severe ly burned by the sulfuric acid in battery elec troly
7. VAMAHA EBU17091 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 EBU17170 INTRODUCTION EBU17300 Congratulations on your purchase of the Yamaha YFM25RxX 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 This manual will provide you with a good basic understanding of the features and operation of this ATV This manual includes important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV CALL 1 800 887 2887 FOR MORE INFORMA TION THIS ATV AND ANY OTHE
8. 28 29 0 966 Chassis Frame type Steel tube frame Caster angle 6 0 Trail 23 0 mm 0 91 in Front tire Type Tubeless Size AT20 x 7 10 Manufacturer model DUNLOP KT201 Rear tire Type Tubeless Size AT19 x 10 9 Manufacturer model DUNLOP KT205A Loading Maximum loading limit 100 0 kg 220 Ib Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 27 5 kPa 4 0 psi 0 275 kgf cm Rear 27 5 kPa 4 0 psi 0 275 kgf cm Minimum Front 24 5 kPa 3 5 psi 0 245 kgf cm Rear 24 5 kPa 3 5 psi 0 245 kgf cm Maximum Front 30 5 kPa 4 4 psi 0 305 kgf cm Rear 30 5 kPa 4 4 psi 0 305 kgf cm Front wheel Wheel type Panel wheel Rim size 10 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 9 x 8 5AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 10 3 Front suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 190 mm 7 5 in Rear suspension Type Swingarm Spring shock absorber type Coil spring gas oil damper Wheel travel 200 mm 7 9 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model YTZ7S Voltage capacity 12 V 6 0 Ah Headlight Bulb type Krypton bulb
9. And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs e n addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period e Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S coverage is transferable to a new owner if you sell or trade in your ATV That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service We urge you to act now You ll get the excellent benefits
10. POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN OFF Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot 1 Arrow mark positioned over OFF EBU18820 Fuel cock With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this position The fuel cock supplies fuel from the tank to the car when the engine is not running buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations 4 10 ON RES 1 Arrow mark positioned over ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 4 11 1 Arrow mark positioned over RES This indicates reserve With the fuel cock lever in this position the fuel reserve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fue
11. Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum 1 Loosen the locknut 2 Toincrease the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in direction b 4 4 1 Locknut 2 Adjusting screw 3 No more than 12 mm 0 47 in 3 Tighten the locknut EWB00190 A WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Im proper throttle operation could result You could lose control have an accident or be in jured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjusted to 2 0 4 0 mm 0 08 0 16 in See page 8 22 EBU18382 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut off system is incorporat ed in the clutch lever holder To disengage the clutch pull the clutch lever toward the handlebar grip To engage the clutch release the clutch lever The clutch lever should be pulled rapidly and re leased slowly for smooth clutch operation See page 6 1 for a description of the ignition circuit cut
12. ing use the proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to a side if pointed straight up hill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating ina new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obsta cles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to re duce the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribed in this manual Never modify an ATV through improper installa tion or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attache
13. possibly causing it to become inef fective Before riding check that the brake fluid is above the minimum level mark and replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage 8 24 Rear brake JE ip EA SDN Si cue 2 o 1 Bolt 1 Minimum level mark 2 Brake fluid reservoir cap cover If the rear brake fluid level is low replenish as fol 2 Remove the brake fluid reservoir cap lows 1 Remove the brake fluid reservoir cap cover by removing the bolt 8 25 N 1 Brake fluid reservoir cap 3 Refill with brake fluid 4 Install the brake fluid reservoir cap 5 Install the brake fluid reservoir cap cover by installing the bolt Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking performance Recommended brake fluid DOT 4 8 26 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock Brake
14. Exhaust fumes are poisonous and may cause loss of consciousness and death with in a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad equate ventilation EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 3 Ea PA _ EF Nk NA FE i EBU17670 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 mas ment label from your Yamaha dealer 2 2 A WARNING A WARNING Improper ATV use can result in SEVERE INJURY or DEATH poe te Operating this ATV if you are under the age of 16 increases your chance AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS of severe injury or death HELMET AND ROADS OR ALCOHOL PROTECTIVE NEVER operate this ATV if you are GEAR under ape 1B NEVER operate See without proper training or instruction 5FE 21697 01 e at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTI
15. after the engine has been running and is still very hot Brake fluid level Check the brake fluid level Add fluid if necessary See page 8 24 Recommended brake fluid DOT 4 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If there is any leak age have a Yamaha dealer check the brake sys EBU19560 Engine oil Make sure that the engine oil is at the specified lev el Add oil as necessary See page 8 11 5 4 tem Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake pads for wear See page 8 23 EWB00540 A WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any prob lem with the brakes If a problem cannot be corrected by the adjustment procedures pro vided in this manual have a Yamaha dealer check for the cause EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if 5 5 necessary EBU19770 Drive chain Check the condition of the dr
16. changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer 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 ina place where pedestrians or children are not likely 7 11 to touch it EWB01010 A WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible ma terial accumulated around the engine area could catch fire Someone touching the exhaust system dur ing or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it Sy ESON SH SEE ee CLE ene BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Riding on paved surfaces can cause loss of control EWB01020 A WARNING POTENTIAL HAZARD Do not ride on any public road street or
17. engine off and VO a check for the cause TN 3 13 Turn the engine off wait at least ten minutes P by L and then check the oil level and correct it if lt 72 SS AIT necessary Ve g PEN N A EBU23692 Z A Cleaning the air filter element SS Gy The air filter element should be cleaned at the in Z tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas 1 Remove the seat See page 4 12 2 Remove the air filter case cover by unhooking 8 NOTE the holders 1 Air filter case check hose 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 8 15 1 Wing bolt 2 Air filter element 1 Air filter case cover 2 Air filter case cover holder 3 Loosen the wing bolt 5 Remove the wing bolt and washer from the air 4 Remove the air filter element together with the filter element wing bolt and washer 6 Remove the sponge material from the air filter element frame 8 16 HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material 8 Squeeze the excess solvent out of the sponge material and let it dry ECB00440 CAUTION Do not twist the sponge material when squeez ing it 1 Sponge material 2 Air filter element frame E 7 Wash the spon
18. filter element cover by installing the bolts and then tighten them to the speci fied torque Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kof 7 2 ft lbf 10 Install the engine oil drain bolt and tighten it to the specified torque ECB00320 CAUTION Before installing the engine oil drain bolt be sure to install the O ring compression spring and oil strainer Tightening torque Engine oil drain bolt 20 Nm 2 0 m kof 14 5 ft lbf 11 Add the specified amount of the recommend ed engine oil and then install and tighten the engine oil filler cap 8 14 Recommended oil See page 10 1 Oil quantity Without oil filter element replacement 1 25 L 1 32 US qt 1 10 Imp qt With oil filter element replacement 1 35 L 1 43 US qt 1 19 Imp qt NOTE Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down ECB00300 CAUTION e In order to prevent clutch slippage since the a engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 12 Start the engine and then let it idle for several ZA minutes while checking it for oil leakage If oil ye ra is leaking immediately turn the
19. for fluid otek and ATV or iting ad and y y V y ear brake correct if F Skeet tu vei ane ATV or iting and e Replace brake pads si e Replace brake pads si brake pads Whenever worn to the limit e Check for cracks or other eee and replace if r J n J Brake hoses eee e Replace esses e Replace esses aes 4 ee Parking brake e Check operation and adjust if necessary e Check runout and for damage and replace if nec essary e Check tread depth and for damage and replace if necessary N K y N e Check air pressure and balance and correct if necessary e Check for looseness or damage and replace if 8 5 ji e iid INITIAL EVERY CHECK OR MAINTENANCE Whichev month 1 3 6 6 2 JOB ercomes km 320 1300 2500 2500 5000 first on 200 800 1600 1600 3200 e Check operation and for excessive play jon Swingarm pivots replace bearings if necessary e Lubricate with lithium soap based grease aay Upper ANAJOWEI e Lubricate with lithium soap based grease ee arm pivots e Check chain slack and adjust if necessary Drive chain as rear wheel alignment and correct if necess T r J N e Clean and lubricate Ag Drive chain rollers e Check for wear and replace if necessary Chassis fasteners e Make sure that all nuts bolts and screws are properly tightened aa Shock absorber e Check operation and correct if necessary J assemblies e Check for oil leakage and replace if necessary Re
20. highway Operating this ATV on paved surfaces Riding on public roads can result in collisions with WHAT CAN HAPPEN other vehicles ATVs are designed for off road use only Paved surfaces may seriously affect han dling and control of the ATV and may cause the ATV to go out of control HOW TO AVOID THE HAZARD Always avoid paved surfaces including side walks driveways parking lots and streets EWB01030 A WARNING POTENTIAL HAZARD 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 In many states it is illegal to operate ATVs on public streets roads and highways 7 13 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 EWBO01040 POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV 7 14 EWB01050 WARNING POTENTIAL HAZARD Fa
21. manual Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ve hicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose sur faces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stall
22. of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires You can also save money 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 Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 11 8 Y YAMAHA EXTENDED SERVICE Indicates a potential hazard that could result in serious injury or death EBU26132 PROTECT YOUR INVESTMENT Use Genuine YAMAHA parts and Accessories See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual INDEX A Drive chain SIAR eta ci citaciicixaceneacempsaundnidadalen Anirna 8 32 Accessories and loading ccccsssccssccssscecesseesseeeeeees 6 7 E Air filter element Cleaning ccccceeeeeeeeeeeeeeseeeeeees 8 15 Engine breakiin isacieecettecasot nce cecieveretecnteederedeceendesatametesennans 6 5 B Engine cold STATT ceciecccettestcoccsrtenestttienneenss aes 6 1 Batle esena A R 8 38 ENGING Amg SPC CO enses sia 8 21 Brake and clutch levers checking and lubricating 8 35 SEES NEE E EEA P AE E rae nme Py 5 4 Brake and shift pedals checking and lubricating 8 36 Engine oil and oil filter element ccseeeee
23. paved surfaces the ATV is designed for off road use only and handling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruction on page 6 1 to start the engine Once it has warmed up you are ready to begin riding your ATV As you get on the ATV be sure not to accidentally move 7 16 the shift pedal Remember that the engine and ex haust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling pull the clutch lever to dis engage the clutch and shift into 1st gear and then release the parking brake Open the throttle grad ually and at the same time release the clutch le ver slowly Once the ATV has attained adequate speed release the throttle lever and at the same time quickly pull in the clutch lever and shift into 2nd gear Open the throttle part way and gradually release the clutch Use this same procedure as you move into the higher gears Be sure to coordi nate the use of the throttle and shift pedal properly If the throttle is applied too abruptly or if the throttle is not released during shifting or if the shift pedal is not released before applying the throttle the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds un til you are thoroughly familiar with the operation of your ATV EWB01240 A WARNING POTENTIAL HAZARD Opening the throt
24. pivoting points Brake and clutch levers e Make sure that operation is smooth Lubricate lever pivoting points if necessary 5 2 Front brake 5 4 8 23 8 24 8 27 ITEM ROUTINE Chassis fasteners e Make sure that all nuts bolts and screws are properly tightened eh leit nants ane e Check operation and correct if necessary 5 9 5 3 EBU19530 Fuel Make sure that there is sufficient fuel in the tank See page 4 8 EWB00500 EBU19700 Front and rear brakes Brake lever and brake pedal Check that there is no free play in the brake le ver If there is free play have a Yamaha dealer check the brake system Check for correct brake pedal height See page 8 27 If the pedal height is incorrect have a Yamaha dealer adjust it Check the operation of the lever and pedal They A 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 should move smoothly and there should be a firm feeling when the brakes are applied If not have a Yamaha dealer check the brake system HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right
25. stability and control are re duced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost EWB01170 POTENTIAL HAZARD Skidding or sliding improperly 7 29 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 On extremely slippery surfaces such as ice go slowly and be very cautious in order to re duce the chance of skidding or sliding out of control WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding tech niques completely WHAT TO DO f your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See page 7 17 f your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off the throttle and or steer to the outside of the turn See page 7 17 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected
26. the ATV and can lead to drive chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 5 Pull the rod out and then tighten the rear axle pinch bolts to the specified torque in the order shown Tightening torque Rear axle pinch bolt 21 Nm 2 1 m kof 15 2 ft lbf EBU24880 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart otherwise it will quickly wear the drive chain with steam cleaners high pres out especially when riding in dusty or wet areas sure washers or inappropriate solvents Service the drive chain as follows 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECB00580 CAUTION Do not use engine oil or any other lubricants for the drive chain as they may contain sub stances that could damage the O rings EBU24890 Checking and lubricating the cables The operation and the condition of all control ca 1 O rings bles should be checked before each ride and the a cables and cable ends should be lubricated if nec ECB00560 essary If a cable is damaged or does not move CAUTION smoothly have a Yamaha dealer check or replace The drive chain must be lubricated after wash it ing the ATV or riding in the rain 1 Clean the drive chain with kerosene and a Engine oil small soft b
27. visibility and operating conditions ing your risk of an accident and your experience 7 7 Speed limiter For riders less experienced with this model the throttle lever housing is equipped with a speed lim iter The speed limiter Keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Turning in the adjusting screw limits the maximum engine power available and de creases the maximum speed of the ATV Turning in the adjusting screw decreases top speed and turning it out increases top speed See page 4 4 1 Adjusting screw 2 Locknut Loading and accessories As originally equipped this ATV is not designed to 7 8 carry cargo or tow a trailer If you choose to add ac cessories so that you can carry cargo or tow a trail er you must use common sense and good judgment Use extra caution when riding the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Re duce your speed when adding additional loads MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 100 0 kg 220 Ib EWB00970 A 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 Cargo should be properly distribut
28. 00050 CAUTION See the starting instructions on page 6 1 prior to starting the engine EBU18120 Light switch LIGHTS Set this switch to LO to turn on the low beams and the taillight Set the switch to HI to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTE gt The headlights and the taillight can be turned on only when the engine is running EBU18270 Throttle lever Once the engine is running movement of the throt tle lever will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will 4 3 return to an idle any time the hand is removed from the throttle lever 1 Throttle lever Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released EWB00200 POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD 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
29. 1 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter choke is not required when the engine is warm Instead start the engine with the throttle slightly open 6 3 EBU20520 Shifting This ATV has a 5 speed forward transmission The transmission allows you to control the amount of power you have available at a given speed or for starting accelerating climbing hills etc To shift into neutral return the throttle lever to the closed position apply the clutch and then repeat edly depress the shift pedal until it stops When it stops it will be in first gear Raise the pedal slightly to reach the neutral position 1 Shift pedal 2 Neutral position EBU20560 To start out and accelerate 1 Release the throttle lever ECB00200 CAUTION Always close the throttle before shifting gears otherwise damage to the engine and drive train may result 2 Pull the clutch lever to disengage the clutch 3 Shift into first gear 4 Open the throttle gradually and at the same time release the clutch lever slowly 5 Once the ATV has attained adequate speed release the throttle and at the same time quickly pull in the clutch lever 6 Shift the transmission into second gear Make sure not to shift the transmission into neutral 7 Open the throttle part way and gradually re lease the clutch lever 8 Follow the same procedure when shifting to the nex
30. 2 Cold engine start with ambient temperature be tween 0 C 30 F and 30 C 90 F Position 3 Cold engine start with ambient temperature above 25 C 80 F 6 2 Ambient temp starter choke position AMBIENT TEMP STARTER CHOKE POSITION 0 10 20 30 C S oa o a a 50 70 90 F 3 2 4 maa IO OOK lo o rrr 1 2 3 1 Fully open 2 Half open 3 Closed 4 Starter choke 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE gt If the engine fails to start release the start switch then push it again Pause a few seconds before the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt 7 Ifthe engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine ECB00160 CAUTION For maximum engine life always warm the en gine up before starting off Never accelerate hard when the engine is cold 8 Continue warming up the engine until it idles smoothly then return the starter choke to position 3 before riding NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EBU2029
31. 200 S S 48 20000 12800 1280 TP a a a 60 25000 16000 1600 d S S S EBU26501 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein sub ject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha ATVs shall be six 6 months from the date of purchase DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corp U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts Damage due to improper transportation Q 4 0 AO SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance such as spark plugs oil oil fi
32. B Maximum hard E EWB00350 A WARNING POTENTIAL HAZARD Improper shock absorber assembly adjust ment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorber assem blies on the left and right side to the same setting EWB00010 A WARNING Indicates a potential hazard that could result in serious injury or death 4 14 EBU19200 PRE OPERATION CHECKS EBU19212 Pre operation check list Before operating this ATV be sure to check the items listed in the following table EWB00470 A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual NOTE gt 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 e Check fuel level in fuel tank and add recommended fuel if neces sary 4 8 5 4 e Check fuel line for leakage Correct if necessary e Check oil level in engine and add recommende
33. Bulb voltage wattage x quantity Headlight 12 V 30 0 30 0 W x 2 10 4 Tail brake light 12 V 5 0 21 0 W x 1 Neutral indicator light 12V 1 7Wx1 Fuse Fuse 15 0A EBU25981 CONSUMER INFORMATION EBU26011 Identification numbers Record the key identification number vehicle iden tification number and model label information in the spaces provided below for assistance when or dering spare parts from a Yamaha dealer or for ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER Se VEHICLE IDENTIFICATION NUMBER So MODEL LABEL INFORMATION 11 1 EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key 1 Key identification number EBU26030 o Vehicle identification number The vehicle identification number is stamped into the frame Ua KE 2 y 3 eS ne a ae LNO OS N A goe AD A Or ca a O_o e vo 1 i oe 1 SEE 1 Vehicle identification number 1 Model label NOTE gt The vehicle identification number is used to identi fy your ATV 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 er 11 2 EBU26060 Noise regulation TAMPERING
34. Check the engine idling speed and if neces sary adjust it to specification by turning the 8 21 throttle stop screw at the carburetor To in crease the engine idling speed turn the throt tle stop screw in direction a and to decrease it turn the screw in direction b 1 Throttle stop screw Engine idling speed 1500 1600 r min NOTE gt If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EBU24043 Adjusting the throttle cable free play The throttle cable free play should be checked and if necessary adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The throttle cable free play should measure 2 0 4 0 mm 0 08 0 16 in at the throttle lever Period ically check the throttle cable free play and if nec essary adjust it as follows NOTE The engine idling speed must be checked and ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle cable free play turn the adjusting bolt in direction b 1 Locknut 2 Throttle cable free play adjusting bolt 3 Throttle lever free play 3 Tighten the locknut EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this fr
35. 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 EBU28911 Replacing the fuse The fuse holder is located beside the battery and can be accessed as follows 1 Remove the seat See page 4 12 2 Unhook the band and then take out the own er s tool kit and the low pressure tire gauge 3 Remove the battery cover by removing the battery cover bracket bolts 8 40 1 Low pressure tire gauge 2 Owner s tool kit 3 Bolt 4 Battery cover oe Specified fuse yor x Ne 15 0A H aly EWB02151 Fi A WARNING POTENTIAL HAZARD Using an improper fuse hh Bibs WHAT CAN HAPPEN iL An improper fuse can cause damage to the electrical system which could lead to a fire le Main Iuse HOW TO AVOID THE HAZARD 2 Spare fuse Always use a fuse of the specified rating Never use a material in place of the proper If the fuse is blown replace it as follows fuse 8 1 Turn the key to OFF and turn off all electrical circuits 3 Turn the key to ON and turn on the electrical sees circuits to check if the devices operate CAUTION ee 4 If the fuse immediately blows again have a To prevent accidental short circuiting turn off Yamaha dealer check the electrical system the main switch when checking or replacing a 5 Install
36. ONS AND WARNINGS For replacement manual call 1 800 532 1558 5FE 21568 01 2 3 4 WARNING EW ride IMPROPER TIRE PRESSURE OR OVERLOADING CAN NEVER ride as a CAUSE LOSS OF CONTROL passenger LOSS OF CONTROL CAN RESULT IN SEVERE Passengers can cause INJURY OR DEATH a loss af control OPERATING TIRE PRESSURE Set with tires cold f ce tae Recommended FRONT 27 5kPa 0 275kgf crn 4 0psi resulting in SEVERE REAR 27 5kPa 0 275kgt cm 4 0psi INJURY or DEATH Minimum FRONT 24 5kPa 0 245kgf cm 3 5psi ee ee REAR 24 5kPa 0 245kgf cm 3 5psi 3B4 2151H 00 Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING Maximum Vehicle Load 100kg 220lbs Includes weight of operator cargo and accessories LP 21696 00 A WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 4AA 22259 00_ 2 4 EBU17680 DESCRIPTION Right view EBU17700 Left view EBU17690 AN 9 vai WARS g Oz q e Yn OK 1 Spark arrester 2 Seat 1 Headlights 2 Fuel cock 3 Fuel tank cap 4 Throttle stop screw 5 Fuse choke 3 Starter 4 Oil filter element 5 Brake pedal 6 Tail brake light 7 Shift pedal 3 1 EBU17712 Controls and instruments 12 3 e eal FL GS Wiss Al NA
37. R ATV OVER 90 cc SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF ROAD USE ONLY FOR SPORT TYPE REC REATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS 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 A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury AA WARNING or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid CAUTION damage to the ATV NOTE A NOTE provides key information to make procedures easier or clearer Product and specifications are subject to change without 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 Please check your local riding laws and regulations before operating this ATV EBU17381 YFM25RX OWNER S MANUAL 2007 by Yamaha M
38. WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of de sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system e Muffler e Exhaust pipe e Silencer Intake system e Air cleaner case e Air cleaner element e Intake duct 11 3 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 It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF EERE SERVICING DEALER km km mi SERVICE NAME AND ADDRESS ee arf a amaaa 500 860 8 S S 12 50003200 320 o e e 7500 a 480 e T G O 24 10000 6400 640 12500 co Eo Se 36 150009600 960 3750
39. aivactubcemiabatindsaczadicnsenschagedinanedl 4 2 Ba WOVE E A EE 4 5 Instruments lights and switches c cccccsseceesteeeens 5 9 Clutch lever free play adjusting eccceeeeeseeeeeeeees 8 31 K D Key identification NUMDEL cecceceeesseeeeeeeeeeneeeeees 11 1 Drive Chai eset haters ict Gah ote ct eames EAEE EE EREE 5 5 L Drive chain MUDNCALUING wnacnsccscndonntdennadadapeecaderanmiyetanencids 8 33 Label locations cccccccccscccceeecceescececseececssceeecsaeeernecens 2 1 OPS Vy EGY toes eeetence ries ce reect eneinio 4 3 M Malih SWUNG annissa ennan a tnmstnsuanncracecnednessaseniecnsencaescecena 4 1 Maintenance and lubrication chart cccccecseeeeeeeee es 8 5 Maintenance chart emission control system 8 3 Maintenance record c ccccccssseeeesseseeeesneeeeessaeeeeesees 11 4 Model TAD Cl sinc siavenwss oiccinvsaticenwancanutndomnetsdsidneeiauticnteaneses 11 2 N Neutral indicator light aces idecaacetieeeechaaatdecesecuonseneeanden tia tes 4 2 Noise regulation escien tes detec 11 3 O Owner s manual and tool Kit ccccsseeseeeeeeeeeeseeeeeeees 8 1 P E e EEEE ASI E E E A aes 6 6 Parking brake free play AdjUStING eeeeeeeee eens 8 28 Parking Brake Jever sinisisi 4 6 Parking On a SOS eisio 6 6 Pan TOC AU OIG eocena anenai n RnR 3 1 Pre operation check liSt cccsseecesseseeeeseeeeeesseeeeenees 5 1 R Rdn YOUR EY cienie Eao et 7 1 Safet
40. ar suspension relay arm and con e Check operation and correct if necessary necting arm pivot e Lubricate with lithium soap based grease ing points 17 Steering shaft e Lubricate with lihium soap based grease af emmma srann See rane e Check toe in and adjust if necessary 19 Eneine mount recossay nn nare TE necessary 8 6 INITIAL EVERY 5 sHecicon mainvenance iene e e ITE JOB ercomes km 320 1300 2500 2500 5000 first mi 200 800 1600 1600 3200 pais 2 a deo ast e Change e Check ATV for oil leakage and correct if neces y y y sary engine ON NNETEE Gisan or replace if necessary y y ment l Moving parts and ing and cable sary e Lubricate throttle lever housing and cable Front and rear brake e Check operation and correct if necessary y T ge i e Check operation and correct if necessary PMES Ane SWCRES e Adjust headlight beams e Check operation and correct if necessary Throttle lever hous e Check throttle cable free play and adjust if neces r J EZS 8 7 EBU23070 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake service e Regularly check and if necessary correct the brake fluid level e Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if
41. ause the tires to lose traction reducing con trol and increasing the possibility of an accident 7 17 EWB01220 A WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The ATV could go out of control causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Prac tice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the condi tions As you approach a curve slow down and begin to turn the handlebars in the desired direction As you do so put your weight on the footboard to the out side of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly 7 18 1 Lean towards inside of turn 2 Support your weight on the outer footrest This procedure should be practiced at slow speed many times in a large off road area with no obsta cles If an incorrect technique is used your ATV 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 Once you have learned this tech
42. be accomplished by leaning forward and on steeper inclines standing on the footboards and leaning forward over the handlebars EWB01 100 POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climb ing hills as described in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 7 20 If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill EWB01190 WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a s
43. ccident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regu larly practice the skills learned in the course and the operating techniques described in this Owner s Manual For more information about the training course contact an autho rized ATV dealer or call 1 800 887 2887 A WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV 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 Riding your ATV requires skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers 7 3 This ATV is designed to carry operator only passengers prohibited EWBO00910 A 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 HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as ne
44. ccsceeeeeeeeeeees 11 1 Noise regulation ccccceseeeeseeeeseeeneees 11 3 Maintenance record ccccccceseeeeseeeneees 11 4 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY 11 5 YAMAHA EXTENDED SERVICE YE S ccccccsessecsssssssessesvssessesssstseseveeeeeee ii EBU17430 4d SAFETY INFORMATION EBU17572 AN ATV IS NOT A TOY AND CAN BE HAZARD OUS TO OPERATE An ATV handles differently from other vehicles in cluding motorcycles and cars A collision or roll over can occur quickly even during routine maneuvers such as turning and riding on hills or over obstacles if you fail to take proper precau tions SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and all labels carefully and fol low the operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instruc tor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV A
45. cracked or damaged 8 8 EWB00010 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 e a O dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine a 1 Spark plug cap 2 Remove the spark plug as shown with the To remove the spark plug spark plug wrench included in the owner s tool 1 Remove the spark plug cap kit 8 9 A A 77D 1 Spark plug wrench To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally NOTE y 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 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and 8 10 replace it if necessary Specified spark plug NGK DR7EA 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 Spark plug gap 0 6
46. d Reduce speed and follow in structions in this manual for carrying cargo or pulling a trailer Allow greater distance for brak ing FOR MORE INFORMATION ABOUT ATV SAFE TY call the Consumer Products Safety Commis sion at 1 800 638 2772 or the ATV Distributors Safety Hotline at 1 800 852 5344 Suen HOW TO AVOID THE HAZARD If you should swallow some gasoline or in gy POTENTIAL HAZARD hale a lot of gasoline vapor or get some gas Improper handling of gasoline oline in your eyes seek medical help WHAT CAN HAPPEN immediately If gasoline spills on your skin Gasoline can catch fire and you could be wash with soap and water If gasoline spills burned on your clothing change your clothes HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel right after the engine has been running and is still very hot Do not spill gasoline on the engine or ex haust pipe muffler when refueling Never refuel while smoking or in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers and clothes dryers When transporting the ATV in another vehi cle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN EWB00030 Gasoline is poisonous and can cause inju ait POTENTIAL HAZARD Starting or running the engine in a closed ar ea WHAT CAN HAPPEN
47. d oil to specified level if necessary e Check ATV for oil leakage Correct if necessary e Check operation If soft or spongy have Yamaha dealer bleed hydraulic system e Check brake pads for wear and replace if necessary e Check brake fluid level in reservoir and add recommended brake fluid to specified level if necessary e Check hydraulic system for leakage Correct if necessary e Check operation If soft or spongy have Yamaha dealer bleed hydraulic system e Check brake pads for wear and replace if necessary te ee f Rear brake e Check brake fluid level in reservoir and add recommended brake 6 O20 0 2G bet fluid to specified level if necessary e Check hydraulic system for leakage Correct if necessary e Check operation and correct if necessary Clutch e Lubricate cable if necessary 8 31 e Check lever free play and adjust if necessary e Make sure that operation is smooth Lubricate cable and lever hous Throttle lever ing if necessary 5 5 8 22 e Check cable free play and adjust if necessary Control cables e Make sure that operation is smooth Lubricate if necessary f e Check chain slack and adjust if necessary E e Check chain condition Lubricate if necessary prone Sep e ae e Check wheel condition and replace if damaged Wheels and tires e Check tire condition and tread depth Replace if necessary 5 7 5 8 5 9 e Check air pressure Correct if necessary e Make sure that operation is smooth Lubricate pedal
48. damage and replace if necessary Valves e Check valve clearance and adjust if necessary Oyo pot te e Check starter choke operation and correct if nec Carburetor eka y y V e Check engine idling speed and adjust if neces sary Crankcase breather e Check breather hose for cracks or other damage J J system and replace if necessary 8 3 e Check condition and clean regap or replace if Spark plug necessary i INITIAL EVERY CHECK OR MAINTENANCE Whichev month 1 3 6 6 12 JOB ercomes km 320 1300 2500 2500 5000 first mi 200 800 1600 1600 3200 e Check for leakage and replace gasket s if neces 7 sary EXNAUStEYSIEM e Check for looseness and tighten all screw clamps y y and joints if necessary 7 Spark arrester Clean aa 8 4 EBU21864 General maintenance and lubrication chart INITIAL EVERY JOB oo a 320 1300 2500 2500 EE first a a _ a 3200 Caa 20 40 E ECRECH often in wet or Air filter element e Clean and replace if necessary dusty areas e Check operation and adjust if necessary e Check operation and correct if necessary E k e Check fluid level and ATV for fluid F Greek ia evei ana Yor stage and and ront brake correct if F Greek ia evei ana ATV for tud stage and e Replace brake pads 0 e Replace brake pads 0 brake pads Whenever worn to the limit e Check operation and correct if necessary m 7 e Check fluid level and ATV
49. e back on the seat and sit with your arms When fully stopped apply the rear brake straight Choose a low gear which will allow the en as well and then lock the parking brake gine compression to do most of the braking for Dismount on uphill side or to a side if pointed you Improper braking may cause a loss of trac straight uphill Turn the ATV around and re tion mount following the procedure described in Use caution while descending a hill with loose or the Owner s Manual slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper RIDING DOWNHILL 7 22 braking may also cause a loss of traction HOW TO AVOID THE HAZARD Whenever possible ride your ATV straight down Always follow proper procedures for going hill Avoid sharp angles which could allow the ATV down hills as described in this Owner s Man to tip or roll over Carefully choose your path and ual ride no faster than you will be able to react to ob Note a special technique is required when stacles which may appear braking as you go down a hill Sa Always check the terrain carefully before you start down any hill POTENTIAL HAZARD Shift your weight backward Going down a hill improperly Never go down a hill at high speed WHAT CAN HAPPEN Avoid going down a hill at an angle that Could cause loss of control or cause the ATV would cause the ATV to lean sharply to one to overturn side Go straight down the hill where po
50. e cylinder wall with oil e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap Lubricate all control cables and the pivoting points of all levers and pedals Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot Cover the muffler outlet with a plastic bag to prevent moisture from entering it Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery see page 9 3 8 38 NOTE gt Make any necessary repairs before storing the ATV EBU25960 EBU2597A Dimensions Overall length 1625 mm 64 0 in Overall width 1070 mm 42 1 in Overall height 1040 mm 40 9 in Seat height 730 mm 28 7 in Wheelbase 1110 mm 48 7 in Ground clearance 100 mm 3 9 in Minimum turning radius 2900 mm 114 in Weight With oil and fuel 150 0 kg 331 Ib Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 249 0 cm SPECIFICATIONS Bore x stroke 74 0 x 58 0 mm 2 91 x 2 28 in
51. e general and overlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttle operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transportation and or tie down If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be done by a Yamaha ATV dealer Will the warranty be void or cancelled if do not operate or maintain my new ATV exactly as specified in the Owner s Manual A No The warranty on a new ATV cannot be voided or cancelled However PO gt O if a particular failure is caused by operation or maintenance other than as described in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha ATV dealer is expected to 1 Completely set up every new machine before sale 2 Exp
52. ed 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 POTENTIAL HAZARD trailer Removing hands from handlebars or feet from footboards during operation EWB00980 During operation Always keep your feet on the footboards during op eration otherwise they may contact the rear wheels 7 9 WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation Avoid wheelies and jumping You may lose control of the ATV or overturn EWBO00990 A WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident includ ing an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off 7 10 Modifications EWB01000 A WARNING POTENTIAL HAZARD Operating this ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause
53. ed free play cannot be obtained as de scribed above or if the clutch does not operate cor rectly have a Yamaha dealer check the internal clutch mechanism EBU26861 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the ATV ona level surface NOTE When checking and adjusting the drive chain slack there should be no weight on the ATV and all tires must be touching the ground 2 Move the ATV back and forth to locate the tightest portion of the drive chain and then measure the drive chain slack as shown Drive chain slack 45 0 55 0 mm 1 77 2 17 in 8 32 1 Drive chain slack 3 If the drive chain slack is incorrect adjust it as follows To adjust the drive chain slack 1 2 Loosen the rear axle pinch bolts Insert a rod of a diameter of 8 mm 0 3 in and a length of 10 cm 4 in into one of the holes in the drive chain tensioner as shown X at rag ai lt lt ES 1 Rear wheel axle pinch bolt 2 Rod 3 Drive chain tensioner 4 Hole NOTE gt A rod can be obtained at a Yamaha dealer to make this adjustment 3 Shift the transmission into neutral 4 To tighten the drive chain push the ATV back ward To loosen the drive chain push the ATV forward ECB00541 CAUTION Improper drive chain slack will overload the en 8 33 gine as well as other vital parts of
54. eded during operation It is not for carrying pas sengers 7 4 Apparel EWB00920 POTENTIAL HAZARD Operating this ATV without wearing an ap proved motorcycle helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci dent Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases your chances of severe injury in the event of an accident 3 2 3 Gloves 4 5 HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants Protective clothing Goggles Boots Helmet Do not operate after consuming alcohol or drugs The operators performance capability is reduced by the influence of alcohol or drugs EWB00930 POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident 7 6 HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV Pre operation checks Al
55. eeeeeeeeees 8 11 Brake fluid ChANGING cccccssccceesseeeesseeeeeseeeesseeees 8 26 Engmestanng A WEIN serere a 6 3 Brake fluid level ChECKING cccsccesseceereesereeeeeees 8 24 ENgINS SIO SVU coarse aetna aaae eeeeeseeebeseses 4 2 Brake lever cccccccesccccesscecessceceesseececseeceeeseeeecsaneeersateeens 4 5 F Brake lever free play checking the front 0006 8 27 3 ET cena tres anneaines sea E E E E 4 8 5 4 Brake light switches wccescccceestendecesnentanieseancecnesetuneeeneseses 8 30 FUEN OCR iei 4 10 Brake pads checking the front and rear 008 8 23 Fueltank CA ote ces tetera a 4 8 Brake DCU All prne prenra DETO 4 6 FUSS TEpIACINO ersin AER ERIR 8 40 Brake pedal position checking cccceeeeeeeeeeeeeeeees 8 27 H Bip e S ONEAN TOAT iion reer a rerrrerrer eer cater terre ee 5 4 Handlebar switches oe cc cesasoesiansesddsncectdabynaoutenideceadauehventers 4 2 C Headlight beam AdjUStING ccccccecccsseseseeesseeeeteees 8 44 Cables checking and lubricating cccccsseeeeeeeees 8 34 Headlight bulb replacing ccccssssecessesseeeseeseeeenees 8 42 Carburetor AjUStING cceeccceeteeeteseeeeeeeeeeeeeeeaeaees 8 20 I Chassis TASTES S scaui evacsencusinsdestrrensiuaieeeinsdacdanehedanhiedentind 5 9 Identification NUMDELSS cccccccccecececcucececccceceeeuueeeeeeeee 11 1 GICAW ING E E P TE E E A TT TT 9 1 indicator Mohl os scceracincna tccnisiadnc
56. es All parts and accessories added to this ATV should be The service information included in this manual and the tools provided in the owner s tool kit are in tended to assist you in the performance of preven installed and used according to instructions tive maintenance and minor repairs However If you have questions consult an authorized additional tools such as a torque wrench may be Yamaha ATV dealer necessary to perform certain maintenance work correctly NOTE y If you do not have the tools or experience required for a particular job have a Yamaha dealer perform genuine Yamaha or equivalent components designed for use on this ATV and should be 8 2 EBU21742 Periodic maintenance chart for the emission control system NOTE For ATVs not equipped with an odometer or an hour meter follow the month maintenance intervals For ATVs equipped with an odometer or an hour meter follow the km mi or hours maintenance inter vals 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 INITIAL EVERY wey CHECK OR MAINTENANCE Whichev month 1 3 6 6 12_ JOB ercomes km 320 1300 2500 2500 5000 first mi 200 800 1600 1600 3200 5 e Check fuel hoses for cracks or other
57. eseeeeeeeeeees 11 1 W Warranty extended ois cssiic cxeiavancdewarnessncdetaseendebbonsuarddenares 11 7 Warranty limited ainciedsusaacdadsonandacndsacsnGediussmumembarsenscadeonan 11 5 Wheel hub bearings checking 2 ccccsseeeeeeeee ees 8 36 Wheel installing ccccceseeeeeeeceeeeeeeeeeeeeeaeeeeeeeeeeaas 8 45 Wheel removing sdeistc desticeseerssaieet eeheaniede ene setlenien 8 44 EBU26141 AWARNING Improper ATV use can result in SEVERE INJURY or DEATH NEVER USE ON PUBLIC ROADS ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions eon public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For replacement manual call 1 800 532 1558 YAMAHA YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2007 05 1 8x1 A E Dear Yamaha ATV Owner Please Review this IMPORTANT SAFETY CARD before operating your ATV If card is not attached call 1 800 344 6418
58. fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid imme diately As the brake pads wear it is normal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24290 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the peri odic maintenance and lubrication chart In addi tion have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are dam aged or leaking Oil seals Replace every two years Brake hoses Replace every four years EBU24380 Checking the front brake lever free play The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart The brake lever should have a free play of zero mm zero in as shown If the free play is incorrect have a Yamaha dealer check the brake system 1 Brake lever free play EWB02010 POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes 8 27 WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air mus
59. g brake lever unlocked position tion with the clutch when shifting 4 7 1 Shift pedal EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise 4 8 aie L AN AN K O 1 Fuel tank cap EBU18730 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel level 2 Filler tube Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 9 0 L 2 38 US gal 1 98 Imp gal Fuel reserve amount 1 0 L 0 26 US gal 0 22 Imp gal ECB00070 CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston 4 9 rings as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or a research oc tane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premi um unleaded fuel Unleaded fuel will give you long er spark plug life and reduced maintenance cost Gasohol There are two types of gasohol gasohol contain ing ethanol and that containing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ATV performance problems EWB00270
60. gainst the possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new ATV please advise us of your new address by sending a postcard listing your ATV model name V I N frame number dealer number or dealers name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law EBU26122 YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service Y E S e YE S is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind Y E S is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans
61. ge material gently but thor oughly in solvent EWB01900 POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode 9 Check the sponge material and replace it if damaged 10 Apply Yamaha foam air filter oil or other qual ity foam air filter oil to the sponge material 8 17 NOTE The sponge material should be wet but not drip ping 11 Pull the sponge material over the air filter ele ment frame 12 Install the washer onto the air filter element frame and then insert the wing bolt into the hole in the air filter element frame ECB00451 CAUTION Be sure to install the washer with the bent edge facing outward as shown 1 Washer 13 Insert the air filter element into the air filter case and then tighten the wing bolt 14 Install the air filter case cover by hooking the holders onto the air filter case 15 Install the seat NOTE gt The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air tight seal Tighten all fit tings securely to avoid the p
62. hose Use only enough pressure to do the job ECB00710 CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result 9 1 ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places 5 Rinse the ATV off immediately with clean wa ter and dry all surfaces with a chamois clean towel or soft absorbing cloth 6 Dry the chain and lubricate it to prevent it from rusting 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protec tive finish When finished cleaning start the engine and let it idle for several minutes EWB02300 A WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping abil ity increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings EBU25932 Storage Short term Al
63. i 7 2 BE CAREFUL WHERE YOU RIDE 7 12 TURNING YOUR ATV cccceeeeeeteeeeees 7 17 CLIMBING UPHILL sanissenissrtenvensinseciicantiuns 7 19 RIDING DOWNHILL 7 22 CROSSING A SLOPE ox sitet asicrisvansiunsamenesn 7 24 CROSSING THROUGH SHALLOW WATE Plocice anes eae 7 25 RIDING OVER ROUGH TERRAIN 7 27 SLIDING AND SKIDDING asnissneensnennnn 7 28 WHAT TO DO IF wctsccanisuancctrtnenirermcncnesce 7 29 WHAF TO DO ecese nioi 7 29 PERIODIC MAINTENANCE AND MINOR REPAIR ees a E 8 1 Owners manual and tool Kit 005 8 1 Periodic maintenance chart for the emission control system ccceeeeeeeeees 8 3 General maintenance and lubrication CTO eae ne E ANE E EEE 8 5 Checking the spark plug cccseeeeeeeeees 8 9 Engine oil and oil filter element 8 11 Cleaning the air filter element 8 15 Cleaning the spark arrester 00 8 19 Adjusting the carburetor cccseceees 8 20 Adjusting the engine idling speed 8 21 Adjusting the throttle cable free play 8 22 Valve clearance chisis ccsentniescewncusnsoesncedctendess 8 22 Checking the front and rear brake 0 219 ane nee ae eee ere eee eee 8 23 Checking the brake fluid level 8 24 Changing the brake fluid 00000 8 26 Checking the front brake lever free DIA Y ea a nied 8 27 Checking the brake pedal position 8 27 Adjus
64. ilure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Could cause loss of traction or ATV control which could result in an accident including an overturn 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 aL Yi Pe i va Pe mail When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch 7 15 EWB01060 A WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be in jured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles Do not ride in areas posted no trespassing Do not ride on private property without getting per mission i ir a re Select a large flat area off road to become familiar with your ATV Make sure that this area is free of obstacles and other riders You should practice control of the throttle brakes shifting procedures and turning techniques in this area before trying more difficult terrain Always avoid riding on
65. ion There is compression Check the ignition Check the fuel level in the fuel tank 2 Compression Operate the electric starter Have a Yamaha dealer check the ATV Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV There is no compression 3 Ignition Open the throttle halfway and operate the electric starter The engine does not start Check the battery The engine turns over quickly The engine does not start Operate the electric starter Have a Yamaha dealer The engine turns over Check the battery lead connections check the ATV slowly and charge the battery if necessary Remove the spark plug and check the electrodes 4 Battery The battery is good 8 47 EBU25860 CLEANING AND STORAGE EBU25890 Cleaning Frequent thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many componenis 1 Before cleaning the ATV a Block off the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used b Make sure the spark plug and all filler caps are properly installed 2 Ifthe engine case is excessively greasy apply degreaser with a paint brush Do not apply de greaser to the chain sprockets or wheel ax les 3 Rinse the dirt and degreaser off with a garden
66. ise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affect ed Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth moistened with alcohol or thinner 6 Install the headlight bulb holder by pushing it in and turning it clockwise 7 Install the headlight bulb holder cover 8 Connect the headlight coupler 9 Install the headlight unit by installing the bolts 10 Adjust the headlight beam if necessary EBU25550 Adjusting a headlight beam ECBO0690 CAUTION It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b 1 Headlight beam adjusting screw 8 44 EBU25580 Replacing the tail brake light bulb If the tail orake light bulb burns out have a Yamaha dealer replace it EBU25650 Removing a wheel 1 Loosen the wheel nuts cy gh 1 e T lt E 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut EBU25670 Installing a wheel 1 Install the wheel and the nuts NOTE When installing a front wheel make sure its arrow mark gt points toward the rotating direction of the wheel 8 45 1 Arrow mark 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified to
67. ition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that 1 Bring the ATV toa stop by applying the brakes in first gear 2 Stop the engine and release the clutch lever 3 With the rear brake applied apply the parking brake and slowly release the brake pedal 6 7 limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU20930 Loading As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add ac cessories so that you can carry cargo or tow a trail er you must use common sense and good judgment as the stability and handling of an ATV can be changed When adding accessories keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable MAXIMUM LOADING LIMIT ATV loading limit total weight of rider cargo accessories and tongue 100 0 kg 220 Ib f you are carrying cargo and towing a trailer in clude the tongue weight in the maximum ATV load limit Load cargo on the carriers as close to the cen
68. ive chain and check the drive chain slack Lubricate and adjust the drive chain as necessary See page 8 32 5 6 EBU19781 k Rear Tires HOPA Manufacturer model DUNLOP KT205A Size POTENTIAL HAZARD AT19 x 10 9 Operating this ATV with improper tires or Type with improper or uneven tire pressure Tubeless WHAT CAN HAPPEN The tires should be set to the recommend Use of improper tires on this ATV or opera ed pressure tion of this ATV with improper or uneven tire Recommended tire pressure pressure may cause loss of control increas Front ing your risk of accident 27 5 kPa 4 0 psi 0 275 kgf cm HOW TO AVOID THE HAZARD Rear The tires listed below have been approved 27 5 kPa 4 0 psi 0 275 kgf cm by Yamaha Motor Co Ltd for this model o Check and adjust tire pressures when Other tire combinations are not recom the tires are cold mended e Tire pressures must be equal on both Front sides Manufacturer model DUNLOP KT201 Size AT20 x 7 10 Type Tubeless 5 7 Tire pressure below the minimum speci dirt in the gauge could cause the first reading to be fied could cause the tire to dislodge from incorrect the rim under severe riding conditions Minimum tire pressure Front 24 5 kPa 3 5 psi 0 245 kgf cm Rear 24 5 kPa 3 5 psi 0 245 kgf cm Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf c
69. l cock lever back to ON EBU18840 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke Move the starter choke in direction b to turn off the starter choke See the Starting a cold engine section on page 6 1 for proper operation 1 Starter choke EBU18890 Seat To remove the seat Insert your hand between the rear of the seat and the rear fender pull the seat lock lever upward and pull up the seat at the rear 4 12 1 Seat lock lever To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely fitted 1 Projection 2 Seat holder EBU18980 Adjusting the front shock absorber assemblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension 1 Spring preload adjusting ring 2 Special wrench 3 Position indicator NOTE gt A special wrench can be obtained at a Yamaha dealer to make this adjustment Spring preload setting Minimum soft A Standard
70. lain the operation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha ATV dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding warranty first contact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers a
71. lter air filter and brake shoes THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the ATV as specified in the appropriate owner s manual 2 Give notice to an authorized Yamaha ATV dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealers place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also warrants to the ultimate purchaser and each subsequent pur chaser of each 2006 and later model Yamaha ATV covered by this warranty that the vehicle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below Failures other than those resulting from defects in material or workmanship which arise solely as a result of
72. lways avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Never operate an ATV on any public street road or highway even a dirt or gravel one Never operate an ATV without wearing an ap proved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots a long sleeved shirt or a jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at speeds too fast for your skills or the riding conditions Always go at a speed that is proper for the terrain visibility operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Al ways follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footpegs of the ATV during op eration Always go slowly and be extra careful when op erating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never operate on excessively rough slippery or loose terrain until you have learned and prac ticed the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Always follow proper procedures for turning as described in this
73. m Rear 250 kPa 36 psi 2 5 kgf cm 1 Low pressure tire gauge Higher pressures and fast inflation may cause a tire to burst Inflate the tires very set the tire pressure when the tires are cold Set slowly and carefully the tire pressures to the following specifications EBU19820 Measuring the tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or 5 8 Recommended pressure Front 27 5 kPa 4 0 psi 0 275 kgf cm Rear 27 5 kPa 4 0 psi 0 275 kgf cm Minimum Front 24 5 kPa 3 5 psi 0 245 kgf cm Rear 24 5 kPa 3 5 psi 0 245 kgf cm Maximum Front 30 5 kPa 4 4 psi 0 305 kgf cm Rear 30 5 kPa 4 4 psi 0 305 kgf cm EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm 0 12 in 5 9 1 Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary EBU19870 OPERATION EWBO00010 EBU20091 A WARNING Starting a cold engine Indicates a potential hazard that could result in meen serious injury or death EBU19890 EWB00610 A WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN
74. n adjustment and lubrication are explained on the following pages The intervals given in the periodic maintenance and lubrication chart should be considered as a general guide under normal riding conditions However DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED EWB01820 POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires HOW TO AVOID THE HAZARD Turn off the engine when performing mainte nance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with maintenance work EBU21720 Owner s manual and tool kit Be sure to put this owners manual in the plastic bag and always carry it on the bottom of the seat as shown Put the owner s tool kit and low pres sure tire gauge under the seat it for you A EWB01830 A WARNING ee lof POTENTIAL HAZARD 2 il this ATV with improper modifica ions 1 WHAT CAN HAPPEN oe p Improper installation of accessories or mod i AN gy ification of this ATV may cause changes in i at handling which in some situations could lead to an accident 1 Low pressure tire gauge HOW TO AVOID THE HAZARD 2 Owners toolkit Never modify this ATV through improper in 3 Owner s manual stallation or use of accessori
75. nique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid ATV over turns on hills Be sure that you can maneuver your ATV well on flat ground before attempting any in cline and then practice riding first on gentle slopes Try more difficult climbs only after you have devel oped your skill In all cases avoid inclines with slip pery or loose surfaces or obstacles that might cause you to lose control EWBO01090 POTENTIAL HAZARD Operating on excessively steep hills 7 19 WHAT CAN HAPPEN The ATV can overturn more easily on ex tremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can
76. ok out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult EWB01160 POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for ob stacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper pro cedures as described in the Owner s Manual 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 7 28 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 aa With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both
77. om occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance and lu brication chart EBU24130 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EBU27711 Front brake pads Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indica tor grooves If a brake pad has worn to the point that the wear indicator grooves are almost in con tact with the disc plate have a Yamaha dealer re e place the brake pads as a set 8 23 1 Wear indicator groove NOTE gt gt The wheels need to be removed to check the brake pads See page 8 44 EBU24190 Rear brake pads Each brake pad is provided with a wear indicator which allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the position of the wear indicator while applying the brake If a brake pad has worn to the point that the wear indicator almost touches the brake disc have a Yamaha dealer re place the brake pads as a set Front brake 1 Wear indicator 1 Minimum level mark EBU28930 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system
78. ossibility of unfiltered air entering the engine ECB00460 CAUTION Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed 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 EBU28890 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the bolts oe es JTE B Ly 0 my a Ney SDT i 1 Bolt 2 Tailpipe 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing Tailpipe 2 Spark arrester 4 Make sure the gasket is properly positioned then insert the tailpipe into the muffler and align the bolt holes WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the ex 1 Gasket hau
79. otor Corporation U S A 1st edition May 2007 AFFIX DEALER All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 21 22 LABEL HERE EWB00010 Indicates a potential hazard that could result in serious injury or death EBU17420 TABLE OF CONTENTS SAFETY INFORMATION c cceeeeeeee 1 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS c 0c0ceceee 2 1 DESCRIPTION sssciccsdcaccceetacconcdecnconeseceechecdoass 3 1 Left WICW scccioccsas docednwntannadewanenebeeeecdabeadeeee dimes 3 1 RIONU WIC WY soosis aaa 3 1 Controls and instruments c0cceceeeees 3 2 INSTRUMENT AND CONTROL FUNG TIONS wiesisinsnccccutenacestetervcacvitiemcnds Ved ORN 4 1 Main switch casicsicticccu deca uvesu seat den tsamavonieaese 4 1 IGIGATOMILGIN sssrin ngnacvareance 4 2 Handlebar switches cceeceseeeeceeeeeeeeeens 4 2 Throttle lever oo eeeecececececeseeeeeeeeseeeeeees 4 3 Speed limiter sececssendensmusasstesesnesessserosenedeeeu 4 4 Clutch lever wcccoisissceannsiscacbiceiansaetoaariwnndannnden 4 5 Brake lever scatsuuseechsaussiive aassincvensaimonteesmaieneas 4 5 Brake pedal cccccsecssseecsseeenseeenseeenaees 4 6 Parking brake lever cccessseeeesseerensserens 4 6 SNN pedal geet azeeseeiocaeecslastedesae asaieesnnesanceean 4 7 Fuel tank cap siieccece
80. owner abuse and or lack of proper maintenance are not covered by this warranty All Models Thirty 30 months from the original purchase date YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 gt O gt O gt O gt O O WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customers responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damages and oil oil filters air filters spark plugs and brake shoes What are some examples of abnormal strain neglect or abuse These terms ar
81. pes a 1 Clutch lever 2 Handlebar switches 3 Parking brake lever 4 5 6 Main switch Throttle lever Brake lever NOTE The ATV you have purchased may differ slightly from the figures shown in this manual 3 2 EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 Indicates a potential hazard that could result in serious injury or death EBU17740 Main switch The positions of the main switch are as follows ON All electrical systems are supplied with power and the engine can be started The key cannot be re moved OFF All electrical systems are off The key can be re moved 4 1 1 Main switch OFF i ON x 1 EBU17781 Indicator light q LE TE T 1 Neutral indicator light N EBU17860 Neutral indicator light N This indicator light comes on when the transmis sion is in the neutral position 4 2 EBU18061 Handlebar switches 1 Light switch LIGHTS 2 Engine stop switch ENG STOP 3 Start switch START EBU18070 Engine stop switch ENG STOP Set this switch to RUN before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to OFP EBU18090 Start switch START Push this switch to crank the engine with the start er ECBO
82. riod immediately have a Yamaha dealer check the ATV EBU20721 Parking When parking the ATV stop the engine shift into first gear apply the parking brake and then turn the fuel cock to OFF 6 6 1 Locked position EBU20850 Parking on a slope EWB00790 POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident Avoid parking on hills or other inclines Ifyou Ssories and loading must park on an incline place the ATV trans auipesee versely across the incline shift into first Accessories gear stop the engine apply the parking Accessories can affect the handling and control of brake and then block the front and rear your ATV Keep the following in mind when consid wheels with rocks or other objects ering an accessory or operating an ATV which has Do not park the ATV at all on hills that are so accessories steep you could not walk up them easily Choose only accessories designed for your ATV Your Yamaha dealer has a variety of gen uine Yamaha accessories Other accessories may also be available on the market However it is not possible for Yamaha to test all non Yamaha accessories nor control over their qual ity or suitability Choose a genuine Yamaha ac cessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift pos
83. rques Tightening torques Front wheel nut 45 Nm 4 5 m kof 32 5 ft lbf Rear wheel nut 45 Nm 4 5 m kof 32 5 ft lbf EBU25710 Troubleshooting Although Yamaha ATVs receive a thorough in spection before shipment from the factory trouble may occur during operation Any problem in the fu el compression or ignition systems for example can cause poor starting and loss of power 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 toa Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills EWB02260 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe in jury or property damage 8 46 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 EBU25751 Troubleshooting chart 1 Fuel There is enough fuel Check the compression The engine does not start There is no fuel Parnes Supe IUBI Check the compress
84. rs The engine transmission and drive train are not designed to withstand the shock of forced shifting and can be damaged by shift ing without using the clutch 6 5 EBU20672 Engine break in NOTE For ATVs equipped with an odometer or an hour meter follow the figures given in km mi or the figures given in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various parts in the engine wear and polish themselves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided 0 160 km 0 100 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 160 320 km 100 200 mi or 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine through the gears freely but do not use full throttle at any time 320 km 200 mi or 20 hours and beyond The ATV can now be operated normally ECB00220 CAUTION If any engine trouble should occur during the engine break in pe
85. rush ECB00570 CAUTION To prevent damaging the O rings do not clean 8 34 EWB02120 A WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cables can also be Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease all purpose grease 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 Replace damaged cables Brake lever EBU24921 8 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lubricated if necessary 8 35 Clutch lever 62 EBU24931 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary Recommended lubricants Brake pedal Silicone grease Shift pedal Lithium soap based grease all purpose grease 8 36 EBU24962 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU24992
86. scerseenaencsidebemaeiceceanonie 4 8 FS E E E PE E TE ee 4 8 UST COG sirenerne nr bean a 4 10 Starter choke ccccceceeeeeeeeeeeeeeeeeeees 4 11 SE EEEE 4 12 Adjusting the front shock absorber assemblies ccccceccceeeceeeceseeceeeseeesaees 4 13 PRE OPERATION CHECKS 0cccceees 5 1 Pre operation Check list cccecceseeeeeeees 5 1 PUC e seen 5 4 ENGINE OIl ssstenerpainnp an e 5 4 Front and rear brakes cccceseeeeeeeeeees 5 4 Throttle lever oo cccecccecceeeeeecseeeeeeseeeeeeeaes 5 5 Drive chain acsdv dans tascucacsscesncusneninantaniasedanans 5 5 WEES sc ccnsissteaunnaetyssiuawingeatesttneneaisadeieannteuis sient 5 7 Measuring the tire pressure a se 5 8 Tire wear limit oo ceecceeeceeceeeeeeeeeeeeeeeees 5 9 Chassis fasteners ccccceeeeeeseseeeeseeeees 5 9 Instruments lights and switches 5 9 OPERA TOWN ciniisaivicssanddndeanborsiesennsescemnedeesd condeee 6 1 Starting a cold engine c eeeeeeesseeeeeees 6 1 Starting a warm engine ceeeeeeseeeeeeees 6 3 FMLA T A E A E E E T 6 3 Engine break in svsacoscainniecncsamndvanseauscetwencauas 6 5 PAULING siiperi a nA r E n 6 6 Parking on a slope sicnssissoraceeiecatanieowonnenuas 6 6 Accessories and loading cccceeeeeeeees 6 7 RIDING YOUR ATV ou cceecccseeeeeeeeeeeeeeeeenees 7 1 GETTING TO KNOW YOUR ATV 7 2 RIDE WITH CARE AND GOOD JUDGEMENT seieren
87. ssi ble 7 23 CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the 7 24 steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel EWB01141 A WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de CROSSING THROUGH SHALLOW WATER scribed in the Owner s Manual Avoid hills with excessively slipper
88. st system 2 Tailpipe 3 Bolt EBU23940 Adjusting the carburetor 5 Install the bolts and tighten them to the speci The carburetor should be checked and if neces ER fied torque sary adjusted at the intervals specified in the peri odic maintenance and lubrication chart The Tightening torque carburetor is an important part of the engine and Tailpipe bolt requires very sophisticated adjustment Therefore 11 Nm 1 1 m kgf 8 0 ft Ibf most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment described in the following section however may POTENTIAL HAZARD be performed by the owner as part of routine main Improper cleaning of the spark arrester tenance Hot exhaust system EWB01910 8 20 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 specified in the periodic maintenance and lubrica tion chart NOTE SSS A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it up NOTE The engine is warm when it quickly responds to the throttle 2 Attach the tachometer to the spark plug lead 3
89. t be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24581 Checking the brake pedal position The brake pedal position must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The top of the brake pedal should be positioned 40 0 mm 1 57 in above the top of the frame as shown If the brake pedal is not positioned as spec ified have a Yamaha dealer adjust it RY TESS YS es A chr E gt 1 Brake pedal position EWB02060 POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident 8 28 HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the brake pedal position is cor rect Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24700 Adjusting the parking brake free play The parking brake free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart Cable length A should measure 64 68 mm 2 52 2 60 in Adjust the parking brake free pla
90. t higher gear 6 4 EWBO00680 A WARNING POTENTIAL HAZARD Opening the throttle abruptly or releasing the clutch lever too quickly WHAT CAN HAPPEN The ATV could wheelie This would increase the chance of an accident including over turn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually EBU20640 To decelerate 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 EWBO00650 POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating and lose trac tion This could cause loss of control an ac cident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear ECB00180 CAUTION Even with the transmission in the neutral po sition do not coast for long periods of time with the engine off and do not tow the ATV for long distances The transmission is prop erly lubricated only when the engine is run ning Inadequate lubrication may damage the transmission Always use the clutch when changing gea
91. te Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical at tention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flames cigarettes or other sources of ignition Ventilate when charging or using in a closed space 8 39 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 To store the battery 1 If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and ful ly charge it if necessary To install the battery NOTE Be sure the battery is fully charged 1 Place the battery in its compartment 2 Make sure to properly connect the battery leads to the battery terminals ECB00630 CAUTION Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type
92. teep hill if pos sible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV 7 21 OK If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose control If you are unable to continue up the hill dismount the ATV on the up hill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply the rear brake to stop or try to put the ATV in gear The ATV could easily tip over backwards Instead ap ply the front brake gradually or dismount the ATV immediately on the uphill side EWBO01251 A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped If you begin rolling backwards Keep weight uphill When riding your ATV downhill shift your weight Never apply the rear brake while rolling as far to the rear and uphill side of the ATV as pos backwards Apply the front brake sible Mov
93. ter 6 8 of the ATV as possible Put cargo at the rear of the front carrier at the front of the rear carrier and center it Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail er Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV EWB00750 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 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 EWBO00010 Indicates a potential hazard that could result in serious injury or death 6 9 EBU21131 RIDING YOUR ATV 7 1 EWBO00010 A WARNING Indicates a poten
94. the slide See page 7 28 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 19 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 If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 19 If your ATV encounters shallow water 7 30 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 See page 7 25 EWBO00010 WARNING Indicates a potential hazard that could result in serious injury or death EBU21647 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21660 Safety is an obligation of the owner Periodic in spection adjustment and lubrication will keep your ATV in the safest and best operating condition possible The most important points of inspectio
95. the battery cover by installing the bat fuse tery cover bracket bolts 6 Place the owner s tool kit and the low pres sure tire gauge onto the battery cover and then hook the band 7 Install the seat 2 Remove the blown fuse and then install a new fuse of the specified amperage 8 41 EBU25430 F Replacing a headlight bulb rt If a headlight bulb burns out replace it as follows 1 Remove the headlight unit by removing the a 1 bolts A F lt gt G LS yy y ws X TIETY AA aN 5 Q ne AG J 1 Headlight bulb holder cover 2 Headlight coupler 7 4 Remove the headlight bulb holder by pushing it in and turning it counterclockwise and then 8 1 Headlight assembly remove the defective bulb 2 Bolt 2 Disconnect the headlight coupler 3 Remove the headlight bulb holder cover 8 42 N i a LAIT z JA axi ML 2 iI 1 Headlight bulb holder EWB02180 A 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 HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it 5 Place a new headlight bulb into position 8 43 1 Do not touch the glass part of the bulb ECB00650 CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherw
96. tial hazard that could result in serious injury or death EBU21591 GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by expe rienced operators only Even if you are an experi enced operator of all other all terrain ATVs or motorcycles riding the ATV requires special skills acquired through practice Take your time to fully learn techniques before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable ac tivity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 1 1 1 5 Please also read all caution and warning labels on your ATV 7 2 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics EWB01280 Not recommended for children under 16 years A WARNING of age POTENTIAL HAZARD E000 Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an a
97. ting the parking brake free play 8 28 Brake light switches ccceeeeseeeeeeeeeeees 8 30 Adjusting the clutch lever free play 8 31 Drive chain slack suicesinccanctesccectantecceneticersdne 8 32 Lubricating the drive chain c08 8 33 Checking and lubricating the cables 8 34 Checking and lubricating the brake and clutch levers 10 cccecceseceesececseeeneeeeneneenens 8 35 Checking and lubricating the brake and shift pedals css sacs cesactesssccnianedacesencesedeceadext 8 36 Checking the wheel hub bearings 8 36 Lubricating the swingarm pivots 8 36 Lubricating the upper and lower arm 6 0 a ene ene R 8 37 Lubricating the steering shaft 8 38 BAO e E 8 38 Replacing the fuse cccccseeeeeeeeeeeeees 8 40 Replacing a headlight bulb 00 8 42 Adjusting a headlight beam 0006 8 44 Replacing the tail brake light bulb 8 44 Removing a wheel cccceeeeeseeeeeeeeeeeees 8 44 Installing a wheel sssssssssssseneserssereernnnn 8 45 Troubleshooting cccocesicecsccninctensondenateceis 8 45 Troubleshooting chart c ccccceeeeeees 8 47 CLEANING AND STORAGE 9 1 EEEE E EE A TT 9 1 Storage ccnsssceesdcenecodsanesactepsanepetetaacctaniessanencs 9 2 SPECIFICATIONS sciuisricrGtsnerernnesweavestecinaca sa 10 1 CONSUMER INFORMATION 0008 11 1 Identification numbers
98. tle abruptly or releasing the clutch lever too quickly WHAT CAN HAPPEN The ATV could wheelie This would increase the chance of an accident including over turn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually EWB01070 A WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train dam age HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear ECB00230 CAUTION Do not shift gears without releasing the throt tle Damage to the engine or drive train may oc cur TURNING YOUR ATV To achieve maximum traction while riding off road the two rear wheels are mounted solidly on one axle and turn together at the same speed There fore unless the wheel on the inside of the turn is al lowed to slip or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed 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 c
99. ustment again EBU24740 Brake light switches The operation of the brake light switches must be checked and if necessary adjusted at the inter 8 30 vals specified in the periodic maintenance and lu brication chart 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 NOTE gt The brake light switch is properly adjusted when the brake light comes on just before braking takes effect Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjust ing nut in direction b 1 Brake light switch 2 Brake light switch adjusting nut EBU24810 Adjusting the clutch lever free play The clutch lever free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The clutch lever free play should measure 5 0 10 0 mm 0 20 0 39 in as shown If the free play is incorrect adjust it as follows 8 31 1 Clutch lever free play 2 Clutch lever free play adjusting bolt 3 Locknut 1 Loosen the locknut at the clutch lever 2 Toincrease the clutch lever free play turn the adjusting bolt in direction a and to decrease it turn the bolt in direction b 3 Tighten the locknut NOTE gt If the specifi
100. ways perform the pre operation checks listed on page 5 1 before riding for proper care of the ATV and to ensure safety aubea HOW TO AVOID THE HAZARD WARNING Always use the size and type tires specified POTENTIAL HAZARD in the Owner s Manual for this ATV on page Failure to inspect the ATV before operating 5 7 Failure to properly maintain the ATV Always maintain proper tire pressure as de WHAT CAN HAPPEN scribed in the Owner s Manual on page 5 8 Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use Indicates a potential hazard that could result in it to make sure the ATV is in safe operating serious injury or death condition Always follow the inspection and mainte Do not operate at speeds too fast for your nance procedures and schedules described skills or the conditions in the Owner s Manual Ba WARNING EWB00010 EWB00950 POTENTIAL HAZARD Operating this ATV at speeds too fast for POTENTIAL HAZARD your skills or the conditions Operating this ATV with improper tires or WHAT CAN HAPPEN with improper or uneven tire pressure Increases your chances of losing control of WHAT CAN HAPPEN the ATV which can result in an accident Use of improper tires on this ATV or opera HOW TO AVOID THE HAZARD tion of this ATV with improper or uneven tire Always go at a speed that is proper for the pressure may cause loss of control increas terrain
101. ways store your ATV in a cool dry place and if necessary protect it against dust with a porous cover ECB00720 CAUTION Storing the ATV in a poorly ventilated room or covering it with a tarp while it is still wet will allow water and humidity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammo 9 2 nia and areas where strong chemicals are stored Long term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Turn the fuel cock lever to OFP 3 Drain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing Specified amount 7 5 ml of stabilizer to each liter of fuel or 1 oz of stabilizer to each gallon of fuel 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat th
102. ximum level mark 4 Minimum level mark NOTE gt 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 6 Insert the dipstick into the oil filler hole and then tighten the engine oil filler cap To change the engine oil with or without oil filter element cleaning 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 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase F SAA x TSK Ra E D ae 1 Engine oil drain bolt ECB00310 CAUTION When removing the engine oil drain bolt the compression spring oil strainer and O ring will fall out Take care not to lose these parts NOTE Skip steps 5 9 if the oil filter element is not being cleaned 5 Remove the oil filter element cover by remov ing the bolts and then remove the oil filter el ement 1 Oil filter element cover 2 Bolt 8 13 6 Clean the oil filter element with solvent 7 Check the O rings for damage and replace it if necessary 1 Oil filter element 2 O ring 8 NOTE Make sure that the O ring is properly seated 9 Install the oil filter element and O ring Install the oil
103. y as follows 1 Adjusting bolt 2 Cable length A 3 Locknut a 2 e w Release the parking brake by moving the parking brake lever to the right Fully loosen the locknut and the adjusting bolt at the rear brake caliper Loosen the locknut on the brake cable Turn the adjusting nut on the brake cable in di rection a to increase the cable length and in direction b to decrease it 8 29 1 Locknut 2 Adjusting nut NOTE gt If the cable length cannot be adjusted to specifica tion consult a Yamaha dealer 5 Tighten the locknut on the brake cable 6 Turn in the adjusting bolt at the rear brake cal iper until it feels tight then turn it out 1 8 turn and tighten its locknut to the specified torque ECB00520 CAUTION When tightening the locknut hold the adjust ing bolt with a wrench so that it does not turn together with the locknut Tightening torque Locknut rear brake caliper 16 Nm 1 6 m kof 11 6 ft lbf EWB02030 A WARNING POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN The brakes could malfunction causing re duced braking performance This could in crease the chance of a collision or accident HOW TO AVOID THE HAZARD After adjusting the parking brake free play block the rear of the ATV off the ground and spin the rear wheels Check to make sure there is no brake drag If brake drag is no ticed perform the adj
104. y information dacs csansicdassaserteddwarsinedersdansantiannuatadenieens 1 1 E E E E cee E ee 4 12 SA aea E 6 3 SM pedalen 4 7 Shock absorber assemblies adjusting the front 4 13 Spark arrester cleaning cceceeeeceeeeeeeeeeeeeeeeeeeeaeaees 8 19 Spark plug CHECKIN Gisarsascadsnsetceanceatahucscterstseicanzesacemienetes 8 9 SPECINCANOMS ossein aa rannis 10 1 Speed MMM ceiien inete anan EE 4 4 Starter choke snssnnsnsssserrsresrrrrrerssrnrrrrerrnrrrerssnnnne 4 11 Sta SWIG eion A geddieas 4 3 Steering shaft WOMCANNG sc sc onsccaccciecnasavaaenvartarncannnedseans 8 38 LON AG e A A EE E EE EE T 9 2 Suspension lubricating the upper and lower arm DIVO IO ceea ea E EEE 8 37 Swingarm pivots lubricating ccccsseeeseeeeeeeeeeeeeeees 8 36 T Tail brake light bulb replacing sssssssessessenennreseseeen 8 44 Throttle cable free play adjusting c ccssceeeesees 8 22 Throttle lever setwodiventasisdahagnastswsy cnndunnadanaesnaapsoeteeeces 4 3 5 5 Tire pressure measuring cceceeeeeeeeeeceeeeeeeeeeeeeeeeees 5 8 cok eee N EEEN EESE AEA AE eee eee 5 7 Tire wear Miil escuresina ERR 5 9 TroubIesShOOLING se cetntcecssetattadsncnossaententactenveuensotenieadieae 8 45 Troubleshooting chart seta secds sees etemectncsatcesateredeadtnnceonced 8 47 V Valve CICALANCE ccccceseceecssseeeeeeeeeeesseseeeeseeeeeensaseeees 8 22 Vehicle identification NUMbeT 0ccceeee
105. y or loose surfaces Shift your weight to the uphill side of the ATV 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 Drive slowly and care fully 7 25 EWB01150 WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have re duced stopping ability Test your brakes af ter leaving water If necessary apply them Test your brakes after leaving the water Do not several times to let friction dry out the lin continue to ride your ATV without verifying that you Ings have regained proper braking ability 7 26 ECB00240 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 Wash the ATV in fresh water if it has been operated in salt water or muddy conditions 7 27 O we 1 Air filter case check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau tion Lo

Yamaha YFM25RX Offroad Vehicle User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents