Yamaha YFM25RY, Owner'S Manual

Page 1: ... PROPRIÉTAIRE OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad ...

Page 2: ...PRINTED IN JAPAN 2008 03 0 8x2 E F S YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO ...

Page 3: ...This A READ THIS MANUAL CAREFULLY It contains important safety information 4D3 28199 62 E0 YFM25RY OWNER S MANUAL ...

Page 4: ...EEC If applicable If applicable To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted EN292 ANSI SVIA 1 2007 Title and or number and date of issue of standards and or specifications General Manager RV Engineering Division RV Company Signature Date of Issue Shinya Shimada 2...

Page 5: ...des 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 COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDER STAND AL...

Page 6: ...ithout notice This is the safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other propert...

Page 7: ...is ATV on any paved surface paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM25RY OWNER S MANUAL 2008 by Yamaha Motor Co Ltd 1st edition February 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 8: ...ake lever 4 5 Shift pedal 4 6 Fuel tank cap 4 7 Fuel 4 7 Fuel cock 4 8 Starter choke 4 10 Seat 4 10 Adjusting the front shock absorber assemblies 4 11 Adjusting the rear shock absorber assembly 4 12 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 5 5 Tire wear limit 5 6 ...

Page 9: ...eaning the spark arrester 8 18 Adjusting the carburetor 8 19 Adjusting the engine idling speed 8 20 Adjusting the throttle cable free play 8 20 Valve clearance 8 21 Checking the front and rear brake pads 8 22 Checking the brake fluid level 8 23 Changing the brake fluid 8 25 Checking the front brake lever free play 8 26 Checking the brake pedal position 8 26 Adjusting the parking brake free play 8 ...

Page 10: ...light beam 8 42 Replacing the tail brake light bulb 8 42 Removing a wheel 8 42 Installing a wheel 8 43 Troubleshooting 8 44 Troubleshooting chart 8 45 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 ...

Page 11: ...han 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 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 ...

Page 12: ...e 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 chang...

Page 13: ... 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 im...

Page 14: ...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 poisonous and may cause loss of consciousness a...

Page 15: ...2 1 1 2 3 4 5 6 7 8 9 10 11 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 3 2 5 4 6 1 7 ...

Page 16: ...erstand all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer ...

Page 17: ... handboken 5FK 21568 00 WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate 9 without proper training or instruction 9 at speeds too fast for your skills or the conditions 9 on public roads a collision can occur with another vehicle 9 with a pas...

Page 18: ...f 16 increases your chance of severe injuryor death NEVER operate this ATV if you are under age 16 4D3 2816L 00 For Europe For Oceania 3 3 3B4 2151H 10 WARNING NEVER NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 3B4 2151H 00 4 For Europe For Oceania 4 ...

Page 19: ...s For Europe For Oceania 5 For Europe 7 6 WARNING q Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death OPERATING TIRE PRESSURE Set with tires cold LOADING 0 Never set tire pressure below minimum It could cause the tire to dislodge from the rim 0 Maximum Vehicle Load 100kg 220lbs Includes weight of operator cargo and accessories 4D3 ...

Page 20: ...TION EBU17690 Left view EBU17700 Right view 1 Headlights 2 Fuel cock 3 Starter choke 4 Throttle stop screw 5 Fuse 6 Tail brake light 7 Shift pedal 7 1 2 3 4 5 6 1 Spark arrester 2 Seat 3 Fuel tank cap 4 Oil filter element 5 Brake pedal 4 1 2 3 5 ...

Page 21: ...7712 Controls and instruments TIP The ATV you have purchased may differ slightly from the figures shown in this manual 1 Clutch lever 2 Handlebar switches 3 Parking brake lever 4 Main switch 5 Throttle lever 6 Brake lever 1 2 3 4 5 6 ...

Page 22: ...lectrical 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 EBU17781 Indicator light EBU17860 Neutral indicator light This indicator light comes on when the transmis sion is in the neutral position 1 Main switch OFF ON 1 1 Neutral indicator light N 1 ...

Page 23: ...ng instructions on page 6 1 prior to starting the engine EBU18151 Light switch OFF Set this switch to to turn on the low beams and the taillight Set the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00040 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to the ...

Page 24: ... slow down when you need to This could cause an accident Check the op eration of the throttle lever before you start the engine If the throttle does not work smoothly check for the cause Correct the problem be fore riding the ATV or consult a Yamaha dealer EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even whe...

Page 25: ...ree play is adjusted to 2 0 4 0 mm 0 08 0 16 in See page 8 20 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 f...

Page 26: ...e brake pedal is located on the right side of the ATV To apply the rear brake push down on the brake pedal EBU18520 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 1 Brake lever 1 1 Brake pedal ...

Page 27: ...ou begin to ride The brake could overheat if you ride the ATV without re leasing the parking brake You could lose braking 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 5 speed transmission The shift pedal is located on the left side of the engine and is used in combina tion with the clutch whe...

Page 28: ...720 Fuel tank cap Remove the fuel tank 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 Shift pedal 1 1 Fuel tank cap 1 ...

Page 29: ...m the en gine or the sun Be careful not to spill fuel especially on the engine or exhaust 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 1 ...

Page 30: ... in this position fuel will not flow Always turn the fuel cock lever 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 positioned over OFF OFF 1 1 Arrow mark positioned over ON ON 1 ...

Page 31: ... 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 EBU18890 Seat To remove the seat Insert your hand between the rear of the seat and the rear fe...

Page 32: ...0 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 Seat lock lever 1 1 Projection 2 Se...

Page 33: ...ing the rear shock absorber assembly The spring preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows 1 Loosen the locknut 2 Turn the adjusting 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 1 Spring preload adjustin...

Page 34: ...adjusting nut distance A is changed by 1 0 mm 0 04 in NOTICE ECB00090 Never turn an adjusting mechanism beyond the minimum and maximum settings 3 Tighten the locknut to the specified torque NOTICE ECB00080 Always tighten the locknut against the adjust ing nut and then tighten it to the specified torque 1 Locknut 2 Adjusting nut 3 Distance A 2 1 b 3 a Spring preload setting Minimum hard Distance A ...

Page 35: ...b sorber cylinder damage could also 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 ...

Page 36: ...aha dealer Refer to the periodic maintenance 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 7 5 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Co...

Page 37: ...0 Control cables Make sure that operation is smooth Lubricate if necessary 8 33 Drive chain Check chain slack and adjust if necessary Check chain condition Lubricate if necessary 5 4 8 30 8 32 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 Shift pedal Make sure that operatio...

Page 38: ...as necessary See page 8 10 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 26 If the pedal height is incorrect have a Yamaha dealer adjust it Check the operation of the lever and pedal They should move smoothly and there s...

Page 39: ...tle 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 adjust the drive chain as necessary See page 8 30 EBU19792 Tires WARNING EWB00602 Use of improper tires on this ATV or operatio...

Page 40: ...m tire pressure Front 24 5 kPa 0 245 kgf cm2 3 6 psi Rear 24 5 kPa 0 245 kgf cm2 3 6 psi Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures and fast inflation may cause a tire to burst Inflate the tires very slowly and carefully EBU19821 Measuring the tire pressure Use ...

Page 41: ...cifications 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 27 5 kPa 0 275 kgf cm2 4 0 psi Rear 27 5 kPa 0 275 kgf cm2 4 0 psi Minimum Front 24 5 kPa 0 245 kgf cm2 3 6 psi Rear 24 5 kPa 0 245 kgf cm2 3 6 psi 1 Tire wear limit ...

Page 42: ... 11 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 ...

Page 43: ...ontrol the ATV which could lead to an acci dent or collision NOTICE ECB00150 See the Engine break in section on page 6 5 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...

Page 44: ...e 25 C 80 F Ambient temp starter choke position 6 Completely close the throttle lever and start the engine by pushing the start switch TIP 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 1 Fully open 2 Half...

Page 45: ...ds normally to the throttle with the starter choke turned off EBU20291 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 EBU20520 Shifting This ATV has a 5 speed forward transmission The transmission allows you to control the amount...

Page 46: ...hrottle abruptly or releasing the clutch lever too quickly could make the ATV wheelie which would increase the 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 ...

Page 47: ...efully 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 ...

Page 48: ...g brake and then block the front and rear wheels with rocks or other objects Do not park 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 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 EBU20910 Accessories and loading EBU...

Page 49: ... 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 EBU20940 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 ...

Page 50: ...e 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 stated load capacity for this ATV Overloading this ATV or carrying or tow ing cargo improperly could cause changes in ATV handling which could lea...

Page 51: ...7 1 1 2 3 4 5 6 7 8 9 10 11 EBU21141 RIDING YOUR ATV ...

Page 52: ...s 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 WARNING EWB01380 Never oper...

Page 53: ...ssenger 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 passenger Apparel Always wear an approved motorcycle helmet that fits properly You should also wear eye protection...

Page 54: ...n 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 capability is reduced by the influence of alcohol or drugs WARNING EWB01420 Never consume alcohol or drugs before or while driving t...

Page 55: ...his ATV with improper or uneven tire pres sure may cause loss of control increasing your risk of an accident Do not operate at speeds too fast for your skills or the conditions WARNING EWB01450 Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at speeds too fast for your skills or the conditions in creases your chances o...

Page 56: ...speed when adding additional loads WARNING EWB01460 Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footb...

Page 57: ...emove 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 Never attempt stunts such as wheelies or jumps Don t try to show off Modifications WARNING EWB01490 Never modify this ATV through improper in stallation or use of accessories Al...

Page 58: ...avoid parking in or around dry grass brush or other combustible materials to pre vent causing a fire hazard WARNING EWB01500 Do not touch the hot exhaust system Do not park the ATV during or after operation in a place where others might be likely to touch it Do not operate idle or park the ATV in dry grass dry ground cover or combustible ma terials BE CAREFUL WHERE YOU RIDE This ATV is designed fo...

Page 59: ... ride on unpaved public streets or roads Do not ride on any paved public street road or motorway WARNING EWB01520 Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle In many areas it is illegal to operate ATVs on public streets roads and highways Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or root...

Page 60: ...e terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ...

Page 61: ... 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 paved surfaces the ATV is designed for use on unpaved surfaces 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...

Page 62: ...NG EWB01720 Always open the throttle gradually and release the clutch lever slowly Otherwise the ATV could wheelie which would increase the chance of an accident NOTICE ECB00230 Do not shift gears without releasing the throt tle Damage to the engine or drive train may oc cur When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a low...

Page 63: ...nd 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 This procedure should be practiced at slow speed many times in a large unpaved area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV d...

Page 64: ...ery or loose surfaces or obstacles that might cause you to lose control WARNING EWB01580 Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Practice on small er hills before attempting large hills It is important when climbing a hill to make sure that your weight is transferred f...

Page 65: ...ound 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 scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill sid...

Page 66: ...ose 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 Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and re mou...

Page 67: ...ote a special technique is required when braking as you go down a hill Always 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 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...

Page 68: ... 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 SHALLOW WATER The ATV can be used to cross slow m...

Page 69: ...eep 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 NOTICE ECB00240 After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filte...

Page 70: ...large obsta cles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manu al 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 condi...

Page 71: ...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 If 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 ...

Page 72: ... 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 17 If your ATV encounters shallow water Ride slowly and carefully through slow moving water wa...

Page 73: ...RAPHICAL LOCATION 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 ...

Page 74: ...you do not have the tools or experience 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 u...

Page 75: ...rmed by a Yamaha dealer as they require 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 Valv...

Page 76: ...ket s if neces sary Check for looseness 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 ...

Page 77: ... ATV for fluid leakage and correct if 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 ...

Page 78: ...s bolts and screws are properly tightened 15 Shock absorber assemblies Check operation and correct if necessary Check for oil leakage and replace if necessary 16 Steering shaft Lubricate with lithium soap based grease 17 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 18 Engine mount Check for cracks or other damage and replace if necessary 19 ...

Page 79: ...st if neces sary Lubricate throttle lever housing and cable 23 Front and rear brake switches Check operation and correct if necessary 24 Lights and switches Check operation and correct if necessary Adjust headlight beams 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 ...

Page 80: ...in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level 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 cracked or damaged ...

Page 81: ...ion of the engine To remove the spark 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 TIP If the spark plug shows a distinctly different colo...

Page 82: ...e specified torque TIP 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 EBU28953 Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must ...

Page 83: ...ler cap and then wipe the dipstick off with a clean rag 4 Insert the dipstick into the filler hole without screwing it in and then remove it again to check the oil level TIP 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 ...

Page 84: ... the used oil 3 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase TIP Skip steps 4 7 if the oil filter element is not being replaced 4 Remove the oil filter element cover by remov ing the bolts and then remove the oil filter el ement 5 Check the O rings for damage and replace them if necessary 1 Engine oil drain bolt 1 1 Oil filter elem...

Page 85: ...ler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down NOTICE ECB00300 In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils 1 Oil filter element 2 O ring Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 2 Tightening torque Engine oil ...

Page 86: ...urn the engine off wait at least ten minutes and then check the oil level and correct it if necessary EBU23703 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 TIP There is a check hose at the bottom of ...

Page 87: ...unhooking the holders 4 Loosen the wing bolt 5 Remove the air filter element together with the wing bolt and washer 6 Remove the wing bolt and washer from the air filter element 7 Remove the sponge material from the air filter element frame 1 Air filter case cover 2 Air filter case cover holder 1 2 1 Wing bolt 2 Air filter element 1 2 ...

Page 88: ... engine could catch fire or ex plode 9 Squeeze the excess solvent out of the sponge material and let it dry NOTICE ECB00440 Do not twist the sponge material when squeez ing it 10 Check the sponge material and replace it if damaged 11 Apply a quality foam air filter oil to the sponge material TIP The sponge material should be wet but not drip ping 12 Pull the sponge material over the air filter ele...

Page 89: ...remely 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 unfiltered air entering the engine NOTICE ECB00460 Make sure that the air fi...

Page 90: ...he 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 4 Make sure the gasket is properly positioned then insert the tailpipe into the muffler and align the bolt holes 1 Bolt 2 Tailpipe 2 1 1 1 Tailpipe 2 Spark arrester 2 1 ...

Page 91: ... odic maintenance and lubrication chart The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore 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 be performed by the owner as part of routine main tenance NOTICE ECB0048...

Page 92: ...ad 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 throt tle stop screw in direction a and to decrease it turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EBU24044 Adjusting the ...

Page 93: ...e throttle cable free play turn the throttle cable free play adjusting bolt in di rection 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 the valve clearance must be adjusted by a Yamaha deale...

Page 94: ...ica tor groove If a brake pad has worn to the point that the wear indicator groove has almost disappeared have a Yamaha dealer replace the brake pads as a set TIP The wheels need to be removed to check the brake pads See page 8 42 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 t...

Page 95: ...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 Front brake 1 Wear indicator 1 1 Minimum level mark 1 ...

Page 96: ...rake If the rear brake fluid level is low replenish as fol lows 1 Remove the brake fluid reservoir cap cover by removing the bolt 2 Remove the brake fluid reservoir cap 1 Minimum level mark 1 1 Bolt 2 Brake fluid reservoir cap cover 1 2 ...

Page 97: ...ll signifi cantly lower the boiling point of the fluid and may result in vapor lock Brake 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 EBU24291 Changing the brake fluid Have ...

Page 98: ...e brakes operate smoothly and that there is no free play 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 EBU24591 Checking the brake pedal position The brake pedal position must be checked and if necessary adjusted a...

Page 99: ...bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24710 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 68 in Adjust ...

Page 100: ... out 1 8 turn and tighten its locknut to the specified torque NOTICE ECB00520 When tightening the locknut hold the adjust ing bolt with a wrench so that it does not turn together with the locknut WARNING EWB02090 Operating with improperly serviced or adjust ed brakes could cause the brakes to malfunc tion resulting in reduced braking performance This could increase the chance of a collision or acc...

Page 101: ...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 EBU24810 Adjusting the clutch lever free play The clutch lever free play must be checked and if necessary adjusted at the intervals specifie...

Page 102: ...tch mechanism EBU26863 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 TIP 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 cha...

Page 103: ... 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 TIP A rod can be obtained at a Yamaha dealer to make this adjustment 4 Shift the transmission into neutral 5 To tighten the drive chain push the ATV back ward To loosen the drive chain push the ATV forward 1 Drive chain slack 1 1 Rear wheel axle pinch bolt 2 Rod 3 Drive chain tensioner...

Page 104: ...pecified torque in the order shown 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 NOTICE ECB00560 The drive chain must be lubricated after wash ing the ATV or riding in th...

Page 105: ... 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 replace if dam aged Corrosion can result when the cable sheaths become damaged and cables can also become frayed or kinked which could re strict the operation of controls an...

Page 106: ...rake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary 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...

Page 107: ...rt EBU25032 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 Left side Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease 1 Upper grease nipple 2 Lower grease nipple 2 1 ...

Page 108: ...y damage the battery WARNING EWB02160 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immed...

Page 109: ...y if the ATV is equipped with optional electri cal accessories To store the battery 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 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary To install the battery TIP Be sure the battery is fully charged 1 Place ...

Page 110: ...ll damage the battery If you do not have access to a constant voltage battery charger have a Yamaha dealer charge your battery EBU28924 Replacing the fuse The fuse holder is located beside the battery and can be accessed as follows 1 Remove the seat See page 4 10 2 Unhook the band securing the owner s tool kit and then remove the battery holding plate by removing the bolts 1 Negative battery lead ...

Page 111: ... An improper fuse or a substitute object can cause damage to the 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 5 Install the battery cover by installing the bat tery cover bracket bolts 6 Place the owner s tool kit onto the ...

Page 112: ...t coupler 3 Remove the headlight bulb holder cover 4 Remove the headlight bulb holder by pushing it in and turning it counterclockwise and then remove the defective bulb 1 Headlight assembly 2 Bolt 1 2 1 Headlight bulb holder cover 2 Headlight coupler 1 2 ...

Page 113: ...OTICE 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 6 Install the headlight bulb holder by pushing it in and turning it clockwise 7...

Page 114: ...amaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25580 Replacing the tail brake light bulb If the tail brake light bulb burns out have a Yamaha dealer replace it EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts Front 1 Headlight ...

Page 115: ...ce the ATV on a level surface 2 Install the wheel and the nuts TIP When installing a front wheel make sure its arrow mark points toward the rotating direction of the wheel Front 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Nut 1 Arrow mark Tightening torques Front wheel nut 45 Nm 4 5 m kgf 32 5 ft lbf Rear wheel nut 45 Nm 4 5 m kgf 32 5 ft lbf ...

Page 116: ...lf However should your ATV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly 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 checki...

Page 117: ...r check the ATV Remove the spark plug 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 b...

Page 118: ...seepage and deterioration of wheel 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 ...

Page 119: ...erm 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 stabilizer if available to prevent the fuel from deterio...

Page 120: ...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 once a month Do not store the battery in an exces...

Page 121: ...oise and vibration level Noise level 77 311 EEC 81 0 dB A EUR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s2 EUR Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s2 EUR Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 249 0 cm3 Bore stroke 74 0 58 0 mm 2 91 2 28 in Compression ratio 9 50 1 Starting system Electric ...

Page 122: ...y 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 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 Transmission Primary reduction system Spur gear Primary reduction ratio 76 22 3 455 Secondary reduction system ...

Page 123: ...9 Manufacturer model DUNLOP KT205A Loading Maximum loading limit 100 0 kg 220 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 27 5 kPa 0 275 kgf cm2 4 0 psi Rear 27 5 kPa 0 275 kgf cm2 4 0 psi Minimum Front 24 5 kPa 0 245 kgf cm2 3 6 psi Rear 24 5 kPa 0 245 kgf cm2 3 6 psi Front wheel Wheel type Panel wheel Rim size 10 x 5 5AT Rear w...

Page 124: ...eel 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 Bulb voltage wattage quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 Neutral indicator li...

Page 125: ...arts from a Yamaha dealer or for ref 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 EBU26040 Vehicle identification number The vehicle identification numbe...

Page 126: ...ation 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 1 Vehicle identification number 1 1 Vehicle identification number 2 Year of manufacture ...

Page 127: ...11 3 1 2 3 4 5 6 7 8 9 10 11 1 Model label 1 ...

Page 128: ... lubricating 8 33 Carburetor adjusting 8 19 Chassis fasteners 5 7 Cleaning 9 1 Clutch lever 4 4 Clutch lever free play adjusting 8 29 D Drive chain 5 4 Drive chain lubricating 8 32 Drive chain slack 8 30 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 20 Engine oil 5 3 Engine oil and oil filter element 8 10 Engine starting a warm 6 3 Engine stop switch 4 2 F Fuel 4 7 5 3 Fuel coc...

Page 129: ...lies adjusting the front 4 11 Shock absorber assembly adjusting the rear 4 12 Spark arrester cleaning 8 18 Spark plug checking 8 9 Specifications 10 1 Speed limiter 4 3 Starter choke 4 10 Start switch 4 2 Steering shaft lubricating 8 36 Storage 9 2 Suspension lubricating the upper and lower arm pivots 8 35 Swingarm pivots lubricating 8 35 T Tail brake light bulb replacing 8 42 Throttle cable free ...

Page 130: ...PRINTED IN JAPAN 2008 03 0 8x2 E YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER ...