Yamaha YFM35RX, Owner'S Manual

Page 1: ...YFM35RX OWNER S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO 5YT 28199 64 DIC183 ...

Page 2: ...PRINTED IN JAPAN 2007 04 0 3 1 CR E F S PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO YAMAHA MOTOR CO LTD DIC183 ...

Page 3: ...OWNER S MANUAL YFM35RX 5YT 28199 64 E0 U5YT64E0 book Page 1 Monday April 9 2007 1 03 PM ...

Page 4: ...U5YT64E0 book Page 2 Monday April 9 2007 1 03 PM ...

Page 5: ...rmation 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 COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDER STAND ALL INSTRUCTIONS PAY CLOSE ...

Page 6: ... change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage to the ATV A NOTE provides key information to make procedures easier or...

Page 7: ...face paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM35RX OWNER S MANUAL 2007 by Yamaha Motor Co Ltd 1st edition March 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5YT64E0 book Page 1 Monday April 9 2007 1 03 PM...

Page 8: ...rake lever 4 6 Shift pedal 4 7 Drive select lever 4 7 Fuel tank cap 4 8 Fuel 4 8 Fuel cock 4 9 Starter choke 4 11 Seat 4 11 Adjusting the front shock absorber assemblies 4 12 Adjusting the rear shock absorber assembly 4 14 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Drive chain 5 4 Tires 5 4 Measuring the tire pressure ...

Page 9: ...chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Checking the spark plug 8 9 Engine oil and oil filter element 8 11 Cleaning the air filter element 8 14 Cleaning the spark arrester 8 18 Adjusting the carburetor 8 19 Adjusting the engine idling speed 8 20 Adjusting the throttle cable free play 8 21 Valve clearance 8 21 Checking the front and rear brake pads 8 ...

Page 10: ...g the upper and lower arm pivots 8 36 Lubricating the steering shaft 8 36 Battery 8 37 Replacing the fuse 8 38 Replacing a headlight bulb 8 39 Adjusting a headlight beam 8 41 Replacing the tail brake light bulb 8 41 Removing a wheel 8 42 Installing a wheel 8 43 Troubleshooting 8 43 Troubleshooting chart 8 44 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION...

Page 11: ...child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Watch carefully for other vehicles when operat ing on unpaved public streets or roads Make sure you know your country s ...

Page 12: ...s 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 ter...

Page 13: ...l 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 be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire pr...

Page 14: ...ous If you should swal low some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are poi...

Page 15: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5YT64E0 book Page 1 Monday April 9 2007 1 03 PM ...

Page 16: ...ls contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer For Europe and Oceania 1 U5YT64E0 book Page 2 Monday April 9 2007 1 03 PM ...

Page 17: ...D E F I NL P S Set with tires cold Pneus à froid Bei kalten Reifen Ajuste con los neumáticos en frío Impostare a pneumatici freddi Ställ in med kalla däck Wanneer de banden koud zijn Regular com pneus frios YAMAHA MOTOR CO LTD SHIZUOKA JAPAN YAMAHA 4GB 2155A 00 U5YT64E0 book Page 3 Monday April 9 2007 1 03 PM ...

Page 18: ...2 4 2 For Europe U5YT64E0 book Page 4 Monday April 9 2007 1 03 PM ...

Page 19: ...2 5 2 For Oceania U5YT64E0 book Page 5 Monday April 9 2007 1 03 PM ...

Page 20: ... UNDER WARNING 5FE 21697 01 NEVER operate this ATV if you are under age 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death U5YT64E0 book Page 6 Monday April 9 2007 1 03 PM ...

Page 21: ...ew 4 Air filter case 5 Battery 6 Owner s tool kit 7 Oil filter element 8 Shift pedal 1 Spark arrester 2 Fuse 3 Rear shock absorber assembly spring preload adjusting nut 4 Drive select lever 5 Fuel tank cap 6 Spark plug 7 Engine oil filler cap 8 Brake pedal 9 Rear brake light switch 10 Rear brake fluid reservoir U5YT64E0 book Page 1 Monday April 9 2007 1 03 PM ...

Page 22: ...u have purchased may differ slightly from the figures shown in this manual 1 Clutch lever 2 Parking brake lever 3 Front brake fluid reservoir 4 Brake lever 5 Throttle lever 6 Main switch 7 Handlebar switches U5YT64E0 book Page 2 Monday April 9 2007 1 03 PM ...

Page 23: ...e as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U5YT64E0 book Page 1 Monday April 9 2007 1 03 PM ...

Page 24: ...8061 Handlebar switches EBU18080 Engine stop switch Set this switch to 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 1 Reverse indicator light R 2 Neutral indicator light N 1 Light switch OFF 2 Engine stop switch ...

Page 25: ...rly If this should happen remove the battery and recharge it EBU18280 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 return to an idle any time the hand is removed from the throttle lever Before st...

Page 26: ... 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 3 Tighten the locknut WARNING EWB00240 Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation You could lose control have an accident or be injured Do not turn the adjust...

Page 27: ...should be pulled rapidly and re leased slowly for smooth clutch operation See page 6 1 for a description of the ignition circuit cut off system 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 EBU18432 Brake pedal The brake pedal is located on the right side of the ATV To apply the rear brake push do...

Page 28: ...specially 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 1 Brake pedal 1 Parking brake lever locked position 1 Parking brake lever unlocked position U5YT64E0 book Page 6 Monday April 9 2007 1 03 PM ...

Page 29: ...ing performance which could cause an accident You could also wear out the brakes prematurely EBU18530 Shift pedal This ATV is equipped with a constant mesh 6 speed transmission The shift pedal is located on the left side of the engine and is used in combina tion with the clutch when shifting EBU18571 Drive select lever The drive select lever is used for driving the ATV either forward or in reverse...

Page 30: ...k cap by turning it counter clockwise EBU18752 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 Drive select lever 1 Fuel tank cap U5YT64E0 book Page 8 Monday April 9 2007 1 03 PM ...

Page 31: ...xhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustration...

Page 32: ...to this position when the engine is not running 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 1 Arrow mark pointing to OFF 1 Arrow mark pointing to ON U5YT64E0 book Page 10 Monday April 9 2007 1 03 PM ...

Page 33: ...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 EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at ...

Page 34: ...ber as semblies 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 Seat lock lever 1 Projection 2 Seat holder U5YT64E0 book Page 12 Mo...

Page 35: ... obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 3 Maximum hard 5 U5YT64E0 book Page 13 Monday April 9 2007 1 03 PM ...

Page 36: ...ing nut in direction a to in crease the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment The spring preload setting is determined by measuring distance A shown in the illustration The shorter distance A is the higher the spring preloa...

Page 37: ...ys tighten the locknut against the adjust ing nut and then tighten it to the specified torque 1 Special wrench Spring preload setting Minimum hard Distance A 218 5 mm 8 6 in Standard Distance A 228 5 mm 9 0 in Maximum soft Distance A 233 5 mm 9 2 in 1 Distance A Tightening torque Locknut 42 Nm 4 2 m kgf 30 ft lbf 1 U5YT64E0 book Page 15 Monday April 9 2007 1 03 PM ...

Page 38: ...result in poor handling which could cause an accident Do not tamper with or attempt to open the cylinder assembly Do not subject the shock absorber assembly to an open flame or other high heat Do not deform or damage the cylinder in any way Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly to a Yamaha deal er for any service U5YT64E0 book Pag...

Page 39: ...ntenance charts on page 8 3 to determine which service should be performed by a Yamaha dealer ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 8 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 11 Front b...

Page 40: ...trol cables Make sure that operation is smooth Lubricate if necessary 8 32 Drive chain Check chain slack and adjust if necessary Check chain condition Lubricate if necessary 5 4 8 29 8 31 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 5 5 5 6 Brake and shift pedals Make sure that op...

Page 41: ...ine oil Make sure that the engine oil is at the specified lev el Add oil as necessary See page 8 11 EBU19710 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 25 If the pedal height is incorrect have a Yamaha dealer adjust it Check t...

Page 42: ...nnot be corrected by the adjust ment procedures provided 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 necessary EBU19770 Drive chain Check the condition of the drive chain and check the drive chain slack Lubricate and ...

Page 43: ...re pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 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 cm Rear 250 kPa 36 psi 2 5 kgf cm Higher pressures and fast i...

Page 44: ...t the tire pressures to the following specifications EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm 0 12 in 1 Low pressure tire gauge Recommended pressure Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1...

Page 45: ...t 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 1 Tire wear limit U5YT64E0 book Page 7 Monday April 9 2007 1 03 PM ...

Page 46: ...ead to an acci dent or collision CAUTION ECB00150 See the Engine break in section on page 6 6 prior to operating the engine for the first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator light does not come on have a Yamaha deal er chec...

Page 47: ...ranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt 7 If the 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 CAUTION ECB0...

Page 48: ...Bring the ATV to a complete stop 2 Pull in the clutch lever to disengage the clutch 3 Apply the brake pedal 4 While pulling the drive select lever handle up ward move the drive select lever forward until it completely stops 5 Release the brake pedal 6 Open the throttle lever gradually and release the clutch lever slowly Shifting Forward to Reverse 1 Bring the ATV to a complete stop 2 Pull in the c...

Page 49: ... are no people or ob stacles behind you When it is safe to proceed go slowly EBU20530 Shifting This ATV has a 6 speed forward and 1 speed re verse transmission The transmission allows you to control the amount of power you have available at a given speed or for starting accelerating climb ing hills etc To shift into neutral return the throttle lever to the closed position apply the clutch and then...

Page 50: ...he chance of an accident including an overturn EBU20650 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 possibil...

Page 51: ...n 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 a...

Page 52: ...the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the ATV to a stop by applying the front brake 2 With the front and rear brake applied pull the clutch lever shift into the neutral position re lease the clutch lever and then apply the parking brake 3 Stop the engine by setting the engine stop switch to 4 With the front and rear brakes applied pull the clutch lever...

Page 53: ...e 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 limits your ability to move around on the seat or one that limits your view Use extra caution...

Page 54: ...o 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 WARNING EWB00820 Never exceed the s...

Page 55: ...7 1 7 EBU21141 RIDING YOUR ATV U5YT64E0 book Page 1 Monday April 9 2007 1 03 PM ...

Page 56: ...ion and warning labels on your ATV 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 WARNIN...

Page 57: ...of the child This ATV is designed to carry operator only passengers prohibited WARNING EWB01400 Never carry a passenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or your pa...

Page 58: ...ncreases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and in creases your chances of a severe injury in the event of an accident Operating without protec tive clothing increases your chances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s performance c...

Page 59: ...or equipment damage WARNING EWB01440 Always use the size and type tires specified in the Owner s Manual for this ATV on page 5 4 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 5 Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pres sure may cause loss of control increasing your risk of an accident Do not operate at speeds t...

Page 60: ...o 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 WARNING EWB01460 Never exceed the stated load capacity for thi...

Page 61: ... your ATV during operation 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 con tact with the rear wheels which could injure you or cause an accident Avoid wheelies and jumping You may lose control of the ATV or overturn WARNING EWB01480 Neve...

Page 62: ...ions consult an au thorized 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 in a place where pedestrians or children are not likely to touch it Also avoid parking in or around dry grass brush or other combustible materials to pre vent causing a fire hazard WARNING EWB01500 Do not touc...

Page 63: ... surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles Watch carefully for other vehicles Make sure you know your country s laws and regulations before you ride on unpaved public streets or roads Do not r...

Page 64: ...les rocks or roots in the terrain and other hidden hazards which may cause the ATV to upset WARNING EWB01530 Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to chang ing terrain conditions when operating the ATV WARNING EWB01540 Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ...

Page 65: ...desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING EWB01550 Always mount a caution flag on the ATV to make you more visible when operating in areas where you might not be seen by other vehicles Watch carefully for other vehicles Do not ride in areas posted no trespassing Do not ride on private property without getting per mission U5YT64E0 boo...

Page 66: ...o 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 Op...

Page 67: ...npaved surfac es 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 WARNING EWB01570 A...

Page 68: ...n 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 ...

Page 69: ...dures for climb ing hills as described in this Owner s Manu al 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 vehicl...

Page 70: ...weight to the uphill side of the ATV 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 t...

Page 71: ...aight uphill Turn the ATV around and re mount following the procedure described in the Owner s Manual RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Choose a low gear which will allow the en gine compression to do most of the braking for you Improper braking may cause a...

Page 72: ... 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 ATV to lean sharply to one side Go straight down the hill where possi ble 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 ...

Page 73: ... 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 scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV CROSSING THROUGH S...

Page 74: ...water If necessary apply them several times to let friction dry out the lin ings If the ATV is operated through deep or fast flowing water the tires may float causing loss of traction and loss of control which could lead to an accident Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability U5YT64E0 book Page 20 Mond...

Page 75: ... be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident 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 WARNING EWB01650 Before operating in a new area check for ob stacles Never attempt to ride over large obsta cles such as large rocks...

Page 76: ...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 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 sin...

Page 77: ...ide 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 the slide See page 7 22 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 ba...

Page 78: ...7 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 19 U5YT64E0 book Page 24 Monday April 9 2007 1 03 PM ...

Page 79: ...ION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar w...

Page 80: ...ence required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for use on this ATV and should be instal...

Page 81: ...uire special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust...

Page 82: ...ness and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U5YT64E0 book Page 4 Monday April 9 2007 1 03 PM ...

Page 83: ...f necessary Replace brake pads Whenever worn to the limit 4 Rear brake Check operation and correct if necessary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years 6 Parking brake Check operation and adjust if necessary 7 Wheels Check runout a...

Page 84: ...orber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 16 Rear suspension re lay arm and con necting arm pivoting points Check operation and correct if necessary Lubricate with lithium soap based grease 17 Steering shaft Lubricate with lithium soap based grease 18 Steering system Check operation and repair or replace if damaged Check toe in and ad...

Page 85: ...iner Clean 22 Moving parts and cables Lubricate 23 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 24 Front and rear brake switches Check operation and correct if necessary 25 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK ...

Page 86: ...8 8 8 Replace the brake hoses every four years and if cracked or damaged U5YT64E0 book Page 8 Monday April 9 2007 1 03 PM ...

Page 87: ...ark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit 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 If the spark plug shows a distinctly different color the engine could be operating i...

Page 88: ... to specification 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in 1 Spark plug gap Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf U5YT64E0 book...

Page 89: ...ion chart 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 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 4 Insert t...

Page 90: ...m 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 CAUTION ECB00310 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 t...

Page 91: ...10 Install the oil strainer compression spring O ring and engine oil drain bolt Tighten the en gine oil drain bolt to the specified torque CAUTION ECB00320 Before installing the engine oil drain bolt be sure to install the O ring compression spring and oil strainer 11 Add the specified amount of the recommend ed engine oil and then install and tighten the engine oil filler cap 1 Oil filter element...

Page 92: ... engine off and check for the cause 13 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary EBU23741 Cleaning the air filter element The air filter element should be cleaned at the in 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 NOT...

Page 93: ...Remove the air filter case cover by unhooking the holders 3 Pull the air filter element out of the air filter case 1 Air filter case check hose 1 Air filter case cover 2 Air filter case holder U5YT64E0 book Page 15 Monday April 9 2007 1 03 PM ...

Page 94: ... material Never use low flash point solvents or gasoline to clean the sponge mate rial because the engine could catch fire or ex plode 6 Squeeze the excess solvent out of the sponge material and let it dry 1 Air filter element assembly 1 Unlock 1 Air filter element retaining plate 2 Air filter element frame 3 Sponge material 4 Air filter element seat U5YT64E0 book Page 16 Monday April 9 2007 1 03 ...

Page 95: ... 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 possibility of...

Page 96: ...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 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the bolt and tighten it to the specified torque 6 Remove the purging bolt 1 Bolt 1 Tailpipe 2 Spark arrester Tightening torque ...

Page 97: ...the exhaust system cool prior to touching exhaust components Always wear eye protection and make sure no one is behind the ATV Make sure there are no combustible materi als in the area EBU23940 Adjusting the carburetor The carburetor should be checked and if neces sary adjusted at the intervals specified in the peri odic maintenance and lubrication chart The carburetor is an important part of the ...

Page 98: ...rica tion chart NOTE 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 Check the engine idling speed and if neces sary adjust it to specification by turning the throttle stop screw at the carburetor To in crease the engine idling speed turn the...

Page 99: ...e 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 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 from occurring t...

Page 100: ...to the point that a wear indicator groove almost appears have a Yamaha dealer replace the brake pads as a set NOTE The wheels need to be removed to check the brake pads See page 8 42 EBU28800 Rear brake pads Each brake pad is provided with two 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...

Page 101: ... the brake pads for wear and the brake system for leakage Front brake Rear brake 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 Refill with the same type of brake fluid Mixing fluids may result in ...

Page 102: ...e 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 EBU24390 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 ...

Page 103: ...0 2 mm 1 98 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 WARNING EWB02110 Operating with improperly serviced or adjust ed brakes could cause loss of braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that the brake pedal position is correct Make sure the brakes do not ...

Page 104: ... the adjusting bolt at the rear brake caliper 3 Loosen the locknut on the brake cable 4 Turn the adjusting nut on the brake cable in di rection a to increase the cable length and in direction b to decrease it NOTE 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...

Page 105: ...ight switches The operation of the brake light switches must be checked and if necessary adjusted at the inter 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 The brake light switch is properly adjusted when the brake light comes on j...

Page 106: ...ver free play turn the adjusting bolt at the clutch lever in direction a and to decrease it turn the bolt in direction b 3 Tighten the locknut at the clutch lever If the specified free play cannot be obtained proceed with the following steps 4 Loosen the locknut at the clutch lever 5 Fully turn the adjusting bolt at the clutch lever in direction a to loosen the clutch cable 6 Loosen the locknut at...

Page 107: ...24842 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the ATV on a level surface NOTE When checking and adjusting the drive chain slack there should be no weight on the ATV and all tires must be touching the ground 2 Move the ATV back and forth to locate the tightest portion of the drive chain and then meas...

Page 108: ... a To loosen the drive chain turn the adjusting bolts in direction b and push the wheels forward Turn each adjusting bolt exactly the same amount to maintain correct axle alignment NOTE There are alignment marks on both drive chain pullers and an alignment mark on each side of the swingarm Make sure to align the same alignment 1 Drive chain slack 1 Axle holding bolt upper 2 Axle holding bolt lower...

Page 109: ...d the axle holding bolts to the specified torques 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 out especially when riding in dusty or wet areas Service the drive chain as follows 1 Locknut 2 Drive chain slack adjusting bolt 3 Alignment marks Tightening ...

Page 110: ...in as they may contain sub stances that could damage the O rings EBU24900 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWB02130 Inspect cables frequently and...

Page 111: ...ng 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 lever Silicone grease Clutch lever Lithium soap based grease all purpose grease Recommended lubricants Brake pedal Silicone grease Shift pedal Lithium soap based grease all purpose grease U5Y...

Page 112: ...cating the swingarm pivots The swingarm pivots must be lubricated at the in tervals specified in the periodic maintenance and lubrication chart EBU25001 Lubricating the rear suspension relay arm and connecting arm pivoting points The rear suspension relay arm and connecting arm pivoting points must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart Lubrica...

Page 113: ...8 35 8 Recommended lubricant Lithium soap based grease 1 Grease nipple 1 Grease nipple 1 Grease nipple U5YT64E0 book Page 35 Monday April 9 2007 1 03 PM ...

Page 114: ...a grease gun Left side Right side 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 1 Upper grease nipple 2 Lower grease nipple 1 Upper grease nipple 2 Lower grease nipple Recommended lubricant Lithium soap based grease U5YT64E0 book Page 36 Mon...

Page 115: ...an immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN 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 th...

Page 116: ...ired 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 EBU25242 Replacing the fuse The fuse holder is located under the seat See page 4 11 If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits 1 Positive battery terminal 2 Negative ba...

Page 117: ...electrical sys tem which could lead to a fire 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25541 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the headlight bulb holder cover at the rear of the headlight by pulling it off 2 ...

Page 118: ... in the headlight unit CAUTION ECB00650 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise 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 5 Install the headlight bulb holder by aligning the pr...

Page 119: ...ng a headlight beam CAUTION ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the adjusting bolt in direction a To lower a headlight beam turn the adjusting bolt in direction b EBU25600 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the lens by removing the screws 1 Headlight beam adjustin...

Page 120: ...it stops 4 Install the lens by installing the screws CAUTION ECB00700 Do not overtighten the screws otherwise the lens may break EBU25650 Removing a wheel 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 1 Screw 1 Tail brake light bulb 1 Wheel nut U5YT64E0 book Page 42 Monday April 9 2007 1 03 PM ...

Page 121: ...ver should your ATV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly 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 WARNING EWB02280 Do not smoke when checking the ...

Page 122: ...g and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the battery lea...

Page 123: ...bearings brakes transmission seals and electrical de vices Many expensive repair bills have result 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...

Page 124: ...nd 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 OFF 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 stabili...

Page 125: ... 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 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it o...

Page 126: ...gine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 349 0 cm Bore stroke 83 0 64 5 mm 3 27 2 54 in Compression ratio 9 20 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Recommended engine oil grade API service SG type or higher JASO standard MA 20 10...

Page 127: ...er model NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet multiple disc Operation Left hand operation Transmission Primary reduction system Spur gear Primary reduction ratio 76 24 3 166 Secondary reduction system Chain drive Secondary reduction ratio 38 13 2 923 Transmission type Constant mesh 6 speed forward 1 speed reverse Operation Left foot operation Gear ratio 1st 36 ...

Page 128: ...5 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 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 Recomm...

Page 129: ...amper Wheel travel 210 mm 8 3 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage x quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Fuse Fuse 15 0 A U5YT64E0 book Page 4 Monday A...

Page 130: ...f erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION 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 EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key i...

Page 131: ...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 1 Vehicle identification number 1 Model label U5YT64E0 book Page 2 Monday April 9 2007 1 03 PM ...

Page 132: ...5 7 Cleaning 9 1 Clutch lever 4 5 Clutch lever free play adjusting 8 28 D Drive chain 5 4 Drive chain lubricating 8 31 Drive chain slack 8 29 Drive select lever 4 7 Drive select lever and driving in reverse 6 3 E Engine break in 6 6 Engine cold start 6 1 Engine idling speed 8 20 Engine oil 5 3 Engine oil and oil filter element 8 11 Engine starting a warm 6 3 Engine stop switch 4 2 F Fuel 4 8 5 3 F...

Page 133: ...4 14 Spark arrester cleaning 8 18 Spark plug checking 8 9 Specifications 10 1 Speed limiter 4 4 Starter choke 4 11 Start switch 4 3 Steering shaft lubricating 8 36 Storage 9 2 Suspension lubricating the upper and lower arm pivots 8 36 Suspension relay arm and connecting arm pivoting points lubricating the rear 8 34 Swingarm pivots lubricating 8 34 T Tail brake light bulb replacing 8 41 Throttle ca...

Page 134: ...YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2007 04 0 3 1 CR E U5YT64E0 book Page 1 Monday April 9 2007 1 03 PM ...