Yamaha BIGBEAR 250 Owner'S Manual Download | Manualshive

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8

8. Check the final gear case for oil leakage. If oil

is leaking, check for the cause.

9. Install the final gear case guard by installing

the bolts and tightening them to the specified
torque.

EBU23670

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.

NOTE:

There is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-
ter case.

1. Remove the seat. (See page 4-12.)
2. Remove the air filter case cover by unhooking

the holders.

Tightening torque:

Final gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

Tightening torque:

Final gear case guard bolt:

17 Nm (1.7 m·kgf, 12 ft·lbf)

1. Air filter case check hose

U1P012E0.book Page 19 Thursday, April 20, 2006 2:31 PM

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Summary of Contents for BIGBEAR 250

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL ...

Page 2: ...EBU17091 U1P012E0 book Page 1 Thursday April 20 2006 2 31 PM ...

Page 3: ...bout special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTR...

Page 4: ...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 5: ...d spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17401 AFFIX DEALER LABEL HERE YFM25BW OWNER S MANUAL 2006 by Yamaha Motor Corporation U S A 1st edition March 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expres...

Page 6: ...UNCTIONS 4 1 Main switch 4 1 Front brake lever 4 5 Brake pedal and rear brake lever 4 5 Parking brake 4 6 Shift pedal 4 7 Drive select lever 4 7 Recoil starter 4 8 Fuel tank cap 4 9 Fuel 4 9 Fuel cock 4 10 Starter choke 4 12 Seat 4 12 Storage compartment 4 13 Front carrier 4 14 Rear carrier 4 14 Adjusting the rear shock absorber assembly 4 15 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 F...

Page 7: ... 7 20 SLIDING AND SKIDDING 7 30 WHAT TO DO IF 7 32 WHAT TO DO 7 32 PERIODIC MAINTENANCE AND MINOR REPAIR 8 1 Owner s manual and tool kit 8 1 Periodic maintenance 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 Final gear oil 8 16 Cleaning the air filter element 8 19 Cleaning the spark arreste...

Page 8: ...ricating the swingarm pivots 8 37 Lubricating the knuckle shafts 8 37 Lubricating the steering shaft 8 37 Battery 8 37 Replacing the fuse 8 41 Replacing a headlight bulb 8 42 Adjusting a headlight beam 8 44 Replacing the tail brake light bulb 8 44 Removing a wheel 8 45 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise ...

Page 9: ...ruc tor Contact an authorized ATV dealer or call 1 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 streets Never operate an ...

Page 10: ...Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for brakin...

Page 11: ...f skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have 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 pre...

Page 12: ...open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the ATV in another vehi cle be sure it is kept upright and that the fuel cock is in the OFF position Other wise fuel may leak out of the carburetor or fuel tank HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some gas oline in...

Page 13: ...t fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad equate ventilation U1P012E0 book Page 5 Thursday April 20 2006 2 31 PM ...

Page 14: ...2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U1P012E0 book Page 1 Thursday April 20 2006 2 31 PM ...

Page 15: ...hese 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 U1P012E0 book Page 2 Thursday April 20 2006 2 31 PM ...

Page 16: ...2 U1P012E0 book Page 3 Thursday April 20 2006 2 31 PM ...

Page 17: ...2 U1P012E0 book Page 4 Thursday April 20 2006 2 31 PM ...

Page 18: ...uses 5 Battery 6 Tail brake light 7 Rear shock absorber assembly spring preload adjusting ring 1 Spark arrester 2 Storage compartment and tool kit 3 Air filter case 4 Engine oil filler cap 5 Front brake fluid reservoir 6 Brake pedal 7 Clutch adjusting screw U1P012E0 book Page 1 Thursday April 20 2006 2 31 PM ...

Page 19: ...nstruments 1 Rear brake lever 2 Left handlebar switches 3 Parking brake 4 Starter choke 5 Drive select lever 6 Main switch 7 Fuel tank cap 8 Throttle lever 9 Front brake lever U1P012E0 book Page 2 Thursday April 20 2006 2 31 PM ...

Page 20: ...switch The positions of the main switch are 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 U1P012E0 book Page 1 Thursday April 20 2006 2 31 PM ...

Page 21: ...smis EBU18060 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 1 Reverse indicator light R 2 Neutral indicator light N 1 Light switch OFF 2 Engine stop switch 3 Start switch U1P012E0 book Page 2 Thursday Ap...

Page 22: ...for an extended period of time oth erwise the battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU18270 Throttle lever Once the engine is running movement of the throt tle lever will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loade...

Page 23: ...D Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate mak ing it difficult to speed up or slow down when you need to This could cause an acci dent HOW TO AVOID THE HAZARD Check the operation of the throttle lever be fore you start the engine If it does not work smoothly check for the cause Correct the problem before riding the ATV Consult a Yamaha dealer if you can t find...

Page 24: ...e push down on the brake pedal or pull the brake lever toward the handlebar grip POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Im proper throttle operation could result You could lose control have an accident or be in jured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sur...

Page 25: ... or parking the ATV especially on a slope Apply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake 1 Brake pedal 1 Parking brake lock plate U1P012E0 book Page 6 Thursday April 20 2006 2 31 PM ...

Page 26: ...tart moving unexpectedly if the parking brake is not applied before start ing the engine This could cause loss of con trol or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting ...

Page 27: ... the rope all the way out WARNING EWB02361 1 Drive select lever 1 Recoil starter POTENTIAL HAZARD Starting the engine in gear or starting the engine without applying the parking brake WHAT CAN HAPPEN The ATV could start to move unexpectedly which could cause an accident HOW TO AVOID THE HAZARD U1P012E0 book Page 8 Thursday April 20 2006 2 31 PM ...

Page 28: ...ent fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap 1 Fuel tank filler tube 2 Fuel level Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 12 0 L 3 17 US gal 2 64 Imp gal Fuel reserve amount 1 6 L 0 42 US gal 0 35 Imp gal U1P012E0 book Page 9 Thursday April 20 2006 2 31 PM ...

Page 29: ...n tent does not exceed 10 Gasohol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ATV performance problems 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 illustrations WHAT CAN HAPPEN Fuel can spill which can cause a f...

Page 30: ...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 1 Arrow mark positioned over ON U1P012E0 book Page 11 Thursday April 20 2006 2 31 PM ...

Page 31: ...ossible and be sure to turn the fuel cock lever back to ON EBU18850 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 the rear 1 Arrow mark positioned over RES 1 Starter choke U1P012E0 book Page 12 Thursday ...

Page 32: ...rage compartment The storage compartment is located under the seat See page 4 12 When storing any documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage compartment 1 Seat 2 Seat lock lever 1 Projection 2 Seat holder U1P012E0 book Page 13 Thursday April 20 2006 2 31 PM ...

Page 33: ...compartment NOTE There is a check hose at the bottom of the storage EBU18960 Front carrier Do not exceed the load limit of 30 0 kg 66 lb for the front carrier Do not exceed the maximum load of 165 0 kg 364 lb for the ATV EBU18970 Rear carrier Do not exceed the load limit of 45 0 kg 99 lb for 1 Storage compartment 1 Storage compartment check hose U1P012E0 book Page 14 Thursday April 20 2006 2 31 PM...

Page 34: ...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 NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 U1P012E0 book Page 15 Thursday April 20 2006 2 31 P...

Page 35: ...4 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death U1P012E0 book Page 16 Thursday April 20 2006 2 31 PM ...

Page 36: ...ces sary Check fuel line for leakage Correct if necessary 4 9 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 Final gear oil Check ATV for oil leakage Correct if necessary 5 3 8 16 Front brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check brake pads for wea...

Page 37: ... smooth Lubricate pedal pivoting point if necessary 8 36 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 35 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 7 Instruments lights and switches Check operation and correct if necessary 5 7 Battery Check electrolyte level Fill with distilled water if necessary 8 37 POTENT...

Page 38: ...e smoothly and there should be a firm feeling when the brake is applied If not have a Yamaha dealer check them Brake fluid level front brake Check the brake fluid level Add fluid if necessary See page 8 27 POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spi...

Page 39: ... the brake pads and shoes for wear See page 8 26 WARNING EWB00540 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 POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE ...

Page 40: ...e been approved by Yamaha Motor Manufacturing Corpora tion of America for this model Other tire combinations are not recommended Front Manufacturer model MAXXIS M905 Size AT22 x 7 00 10 Rear Manufacturer model MAXXIS M906 Size AT22 x 10 00 10 Type Tubeless The tires should be set to the recommend ed pressure Recommended tire pressure Front 20 0 kPa 2 9 psi 0 200 kgf cm Rear 25 0 kPa 3 6 psi 0 250 ...

Page 41: ...ecifications Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 17 0 kPa 2 5 psi 0 170 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 press...

Page 42: ...switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 20 0 kPa 2 9 psi 0 200 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 17 0 kPa 2 5 psi 0 170 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 23 0 kPa 3 3 psi 0 230 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm 1 Tire wear limit U1P012E0 book Page 7 Thursday Apri...

Page 43: ...amiliar with all controls WHAT CAN HAPPEN Loss of control which could cause an acci dent or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer POTENTIAL HAZARD Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AV...

Page 44: ...e starter choke in reference to the fig ure Position 1 Cold engine start with ambient temperature below 5 C 40 F Position 2 Cold engine start with ambient temperature between 0 C 30 F and 30 C 90 F Position 3 Cold engine start with ambient temperature Ambient temp starter choke position 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE If the engine fails ...

Page 45: ...eturn the starter choke to position 3 before riding NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off 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 EBU20310 Operating th...

Page 46: ...lect lever to the rear until it completely stops NOTE When in reverse the reverse indicator light should be on If the indicator light does not come on have a Yamaha dealer check the electrical circuit 5 Check behind you for people or obstacles 1 Forward F 2 Reverse R 3 Drive select lever 1 Forward F 2 Reverse R 3 Drive select lever U1P012E0 book Page 4 Thursday April 20 2006 2 31 PM ...

Page 47: ...it stops EBU20600 To start out and accelerate 1 Release the throttle lever CAUTION ECB00200 Always close the throttle before shifting gears otherwise damage to the engine and drive train may result POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or even a person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse mak...

Page 48: ...ngine is running Inade quate lubrication may damage the POTENTIAL HAZARD Opening the throttle before releasing the shift pedal WHAT CAN HAPPEN The ATV could wheelie This would increase the chance of an accident including over turn HOW TO AVOID THE HAZARD Release the shift pedal before opening the throttle Open the throttle gradually POTENTIAL HAZARD Engaging a lower gear when the engine speed is t...

Page 49: ...hat might result in engine overheating must be avoided 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine through the gears freely but do not use full throttle at any time CAUTION ECB00220 If any engine trouble should occur during the engin...

Page 50: ... designed for your ATV Your Yamaha dealer has a variety of gen POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the ATV transversely across the incline shift into first gear stop the engine apply the parking ...

Page 51: ... ATV may handle differently than it does without accessories EBU21090 Loading Cargo or a trailer can change the stability and han dling of an ATV You must use common sense and good judgment Do not exceed the maximum tongue weight You can measure tongue weight with a bath room scale Put the tongue of the loaded trailer on the scale with the tongue at hitch height Ad just the load in the trailer if ...

Page 52: ...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 EWB00750 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death POTENTIAL HAZARD Overloading this ATV or...

Page 53: ...7 EBU21131 RIDING YOUR ATV U1P012E0 book Page 1 Thursday April 20 2006 2 31 PM ...

Page 54: ...o familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you ular attention to the safety information on pages 1 1 1 5 Please also read all caution 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 ...

Page 55: ...should then regularly practice the skills learned in the course and the operating techniques de scribed in this Owner s Manual For more in formation about the training course contact an authorized ATV dealer or call 1 800 887 2887 POTENTIAL HAZARD Failure to follow the age recommendations WHAT CAN HAPPEN Use by children of ATVs that are not recom mended for their age can lead to severe inju ry or ...

Page 56: ...APPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as need ed during operation It is not for carrying passengers U1P012E0 book Page 4 Thursday April 20 2006 2 31 PM ...

Page 57: ...without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved ...

Page 58: ...influence of alcohol or drugs WARNING EWB00930 POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV U1P012E0 book Page 6 Thursday April 20 2006 2 31 PM ...

Page 59: ...ach time you use it to make sure the ATV is in safe operating condition Always follow the inspection and mainte nance procedures and schedules described in the Owner s Manual WHAT CAN HAPPEN Use of improper tires on this ATV or opera tion of this ATV with improper or uneven tire pressure may cause loss of control in creasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and ...

Page 60: ...See page 4 4 Loading and accessories 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 POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an ...

Page 61: ...ailer hitch point 147 N 33 lbf 15 kgf POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own ...

Page 62: ...e 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 foot board your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation POTENTIAL HAZARD Attempting whee...

Page 63: ...h in some situations could HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nents designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer U1P012E0 book Page 11 Thursday April...

Page 64: ...m WHAT CAN HAPPEN Dry grass or brush or other combustible ma terial accumulated around the engine area could catch fire Someone touching the exhaust system dur ing or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaus...

Page 65: ...ways parking lots and streets POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways U1P012E0 book Page 13 Thursday April 20 2006 2 31 PM ...

Page 66: ...terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV POTENTIAL HAZARD Failure to use extra care when operating on excessively rough...

Page 67: ... pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be in jured U1P012E0 book Page 15 Thursday April 20 2006 2 31 PM ...

Page 68: ...ne idling lift the shift pedal to the 1st gear position and then release the parking brake Apply the throttle slowly and smoothly The centrif ugal clutch will engage and you will start to accel erate Once the ATV has attained adequate speed release the throttle and lift the shift pedal to the 2nd gear position Release the shift pedal and apply the throttle smoothly Use this same procedure as you m...

Page 69: ... lose traction reducing con trol and increasing the possibility of an accident WARNING EWB01070 POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shi...

Page 70: ...esired direction As you do so put your weight on the footboard to the out side of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could ...

Page 71: ...r curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over...

Page 72: ... AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climb ing hills as described in this Owner s Manu al Always check the terra...

Page 73: ...7 U1P012E0 book Page 21 Thursday April 20 2006 2 31 PM ...

Page 74: ...crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turn ing on any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of ...

Page 75: ...D THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped If you begin rolling backwards Keep weight uphill 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 Dism...

Page 76: ...gles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear WARNING EWB01130 POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner s Man ual Note a ...

Page 77: ...7 U1P012E0 book Page 25 Thursday April 20 2006 2 31 PM ...

Page 78: ...ur ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING EWB01141 POTENTIAL HAZARD Improperly crossing hills or turning on hills HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as...

Page 79: ...7 U1P012E0 book Page 27 Thursday April 20 2006 2 31 PM ...

Page 80: ...50 Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in wat...

Page 81: ... the check hose at the bottom of the air filter case the drive se lect lever box check hose and the storage compartment check hose Wash the ATV in fresh water if it has been operated in salt water or muddy conditions 1 Air filter case check hose U1P012E0 book Page 29 Thursday April 20 2006 2 31 PM ...

Page 82: ...de If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help 1 Storage compartment check hose WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area ch...

Page 83: ...ide 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 U1P012E0 book Page 31 Thursday April 20 2006 2 31 PM ...

Page 84: ...er control See page 7 18 If your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off the throttle and or steer to the outside of the turn See page 7 18 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See page 7...

Page 85: ...in balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 20 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate brak...

Page 86: ...DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01820 EBU21720 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and always carry it on the bottom of the seat as shown Put the owner s tool kit and low pres sure tire gauge under the seat POTENTIAL HAZARD Servicing an engine while...

Page 87: ...ating this ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nents...

Page 88: ...hould be performed 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 ne...

Page 89: ... 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 U1P012E0 book Page 4 Thursday April 20 2006 2 31 PM ...

Page 90: ...rake 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 4 Rear brake Check operation and correct if necessary Check brake lever and pedal free play and adjust if necessary Replace brake shoes Whenever worn to the limit 5 Brake hoses Check for cracks or other damage and replace if necessary Repl...

Page 91: ...ssary 13 Knuckle shafts Lubricate with lithium soap based grease 14 Steering shaft Lubricate with lithium soap based grease 15 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 16 Engine oil Change Check ATV for oil leakage and correct if neces sary 17 Engine oil filter ele ment Clean or replace if necessary 18 Engine oil strainer Clean NO ITEM C...

Page 92: ...te 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 25 Battery Check electrolyte level and specific gravity and correct if necessary Make sure that the breather hose is properly rout ed NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first...

Page 93: ...8 Replace the brake hoses every four years and if cracked or damaged U1P012E0 book Page 8 Thursday April 20 2006 2 31 PM ...

Page 94: ...spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition 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 1 Spark plug cap U1P012E0 book ...

Page 95: ... shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spark plug wrench Specified spark plug NGK DR7EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in U1P012E0 book Page 10 Thursday April 20 2006 ...

Page 96: ... checked before each ride In addition the oil must be changed and the oil filter element cleaned at the intervals speci fied in the periodic maintenance and lubrication 2 Start the engine warm it up for several min utes and then turn it off 3 Wait at least ten minutes until the oil settles before checking 4 Remove the engine oil filler cap and then wipe the dipstick off with a clean rag 5 Insert t...

Page 97: ...ith or without oil fil ter element cleaning 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase CAUTION ECB00310 When removing the engine oil drain bolt the compression sp...

Page 98: ...ust ing nut and push the brake pedal downward 7 Remove the oil filter element cover by remov ing the bolts and then the oil filter element 1 Footboard 2 Bolt 1 Brake pedal free play adjusting nut U1P012E0 book Page 13 Thursday April 20 2006 2 31 PM ...

Page 99: ...when 9 Check the O rings for damage and replace it if necessary 10 Install the oil filter element and the O ring NOTE Make sure that the O ring is properly seated 11 Install the oil filter element cover by installing the bolts and then tighten them to the speci fied torque 1 Oil filter element cover 2 Adjusting nut 3 Bolt 1 Oil filter element 2 O ring U1P012E0 book Page 14 Thursday April 20 2006 2...

Page 100: ...with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 14 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 15 Turn the engine off and the...

Page 101: ...the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oil level must be checked on a cold engine 2 Remove the final gear oil filler bolt and then check the oil level in the final gear case NOTE The oil level should be at the brim of the filler hole 1 Footboard bolt A 2 Footboard bolt B Tightening torques Footboard bo...

Page 102: ...ear case guard by remov ing the bolts 2 Place the ATV on a level surface 3 Place an oil pan under the final gear case to collect the used oil 4 Remove the final gear oil filler bolt and the fi nal gear oil drain bolt to drain the oil from the final gear case 1 Final gear oil 2 Correct oil level 3 Final gear oil filler bolt Tightening torque Final gear oil filler bolt 1 Final gear case cover 2 Bolt...

Page 103: ... as shown CAUTION ECB00420 Be sure no foreign material enters the final gear case 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil 2 Correct oil level 3 Final gear oil filler bolt Recommended final gear oil See page 10 1 U1P012E0 book Page 18 Thursday April 20 2006 2 31 PM ...

Page 104: ...lter element more frequently if you are riding in unusually wet or dusty areas NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air fil ter case 1 Remove the seat See page 4 12 2 Remove the air filter case cover by unhooking the holders Tightening torque Final gear oil filler bolt 23 Nm 2 3 m ...

Page 105: ...er element out of the air filter case 4 Remove the sponge material from the air filter element frame 1 Air filter case cover 2 Air filter case holder 1 Air filter element U1P012E0 book Page 20 Thursday April 20 2006 2 31 PM ...

Page 106: ...sponge material and replace it if damaged 8 Tap the air filter element frame lightly to re move most of the dust and dirt Blow out the remaining dirt with compressed air as shown If the air filter element frame is damaged re place it 1 Air filter element 2 Sponge material POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solven...

Page 107: ...e for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint mani fold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air en tering the engine CAUTION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case will affect carburetor jetting with subsequent poor performan...

Page 108: ...er as part of routine main tenance CAUTION ECB00480 The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24000 POTENTIAL HAZARD Improperly purging the exhaust system Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause ca...

Page 109: ...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 NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment 1 Throttle stop screw Engine idling speed 1400 1500 r min U1P...

Page 110: ... ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle cable free play turn the adjusting bolt in direction b 3 Tighten the locknut EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To ...

Page 111: ... must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart EBU24171 Front brake pads Check each front brake pad for damage and mea sure the lining thickness If a brake pad is dam aged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set NOTE The wheels need to be removed to check the brake pads See p...

Page 112: ...rake fluid is above 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 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 braki...

Page 113: ... a Yamaha dealer check the cause EBU24280 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the peri odic maintenance and lubrication chart In addi tion have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are EBU24380 Checking the front brake l...

Page 114: ...the brake pedal position The top of the brake pedal should be positioned 43 0 53 0 mm 1 69 2 09 in above the top of the footboard bracket If the position is incorrect adjust it as follows POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes ...

Page 115: ...ake pedal free play The brake pedal free play should measure 20 0 30 0 mm 0 79 1 18 in as shown If the free play is incorrect adjust it as follows 1 Fully loosen the brake lever free play adjust ing nut on the brake cable at the rear wheel hub 2 Turn the brake pedal free play adjusting nut on the brake rod at the rear wheel hub in direc tion a to increase the free play and in direc 1 Locknut 2 Bra...

Page 116: ...and fully turn in the brake lever free play adjusting bolt 2 Turn the brake lever free play adjusting nut at the brake camshaft lever so that gap A mea sures 0 1 mm 0 0 04 in between the lever and the pin 1 Brake lever free play adjusting nut 2 Brake pedal free play adjusting nut 1 Brake lever free play 2 Locknut 3 Brake lever free play adjusting bolt U1P012E0 book Page 31 Thursday April 20 2006 2...

Page 117: ... locknut at the brake lever 5 Install the footboard NOTE When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move 1 Brake lever free play adjusting nut 2 Brake camshaft lever 3 Pin 4 Gap A 1 Locknut 2 Brake lever free play adjusting bolt U1P012E0 book Page 32 Thursday April 20 2006 2 31 PM ...

Page 118: ...e light switch in place To make the brake light come on earlier turn the adjusting nut in direc tion a To make the brake light come on lat er turn the adjusting nut in direction b POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate ...

Page 119: ...sting screw in direction a decreases clutch free play and turning it in direc tion b increases clutch free play 4 Tighten the locknut to the specified torque NOTE When tightening the locknut hold the clutch ad justing screw with a screwdriver so that it does not turn together with the locknut 5 Install the footboard EBU24890 Checking and lubricating the cables The operation and the condition of al...

Page 120: ... POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cables can also be come frayed or kinked which could restrict the operation of controls and lead to an acci dent or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Recommended lubricant Lithium soap based grease all purpose grease U1P012E0 book Pag...

Page 121: ...earings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EBU24980 Lubricating the drive shaft universal joint Recommended lubricant Lithium soap based grease all purpose grease U1P012E0 book Page 36 Thursday...

Page 122: ...nd lu brication chart Lubricate the knuckle shafts using a grease gun EBU25100 Lubricating the steering shaft The steering shaft must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart EBU25190 Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease 1 Grease nipple Reco...

Page 123: ...y cover by pulling it upward 3 Check the electrolyte level in the battery NOTE The electrolyte should be between the minimum and maximum level marks 4 If the electrolyte is at or below the minimum level mark add distilled water to raise it to the maximum level mark ECB00590 1 Battery cover 1 Battery 2 Maximum level mark 3 Minimum level mark U1P012E0 book Page 38 Thursday April 20 2006 2 31 PM ...

Page 124: ...ilure to handle batteries or battery electro lyte carefully WHAT CAN HAPPEN You could be poisoned You could be se verely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gas es HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink...

Page 125: ...ll the battery NOTE Be sure the battery is fully charged 1 Install the battery 2 Connect the positive lead 3 Install the battery bracket by installing the bolts 4 Connect the negative lead 5 Make sure that the breather hose is properly routed in good condition and not obstructed 1 Battery 2 Battery bracket 3 Bolt 4 Positive lead 5 Negative lead U1P012E0 book Page 40 Thursday April 20 2006 2 31 PM ...

Page 126: ...ircuits CAUTION ECB00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING EWB02151 1 Fuse Specified fuse 20 0 A POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOI...

Page 127: ...electrical system EBU26892 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the bulb holder cover at the rear of the headlight by pulling it off 3 Remove the headlight bulb holder assembly by turning it counterclockwise 1 Headlight bulb holder cover 1 Headlight coupler U1P012E0 book Page 42 Thursday April 20 2006 2 31 PM ...

Page 128: ... 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 POTENTIAL HAZARD A headlight bulb is hot when it is on and im mediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something f...

Page 129: ... a Yamaha dealer make this adjustment To raise a headlight beam turn the adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25610 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Headlight beam adjusting screw U1P012E0 boo...

Page 130: ...der push it in and then turn it clockwise until it stops 4 Install the bulb holder together with the bulb by turning it clockwise EBU25650 Removing a wheel 1 Loosen the wheel nuts 1 Tail brake light bulb holder 1 Tail brake light bulb holder 2 Tail brake light bulb U1P012E0 book Page 45 Thursday April 20 2006 2 31 PM ...

Page 131: ...wheel EBU25700 Installing a wheel 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side to wards the wheel 1 Wheel nut 1 Arrow mark U1P012E0 book Page 46 Thursday April 20 2006 2 31 PM ...

Page 132: ... systems yourself 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 EWB02260 1 Tapered...

Page 133: ...HE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces U1P012E0 book Page 48 Thursday April 20 2006 2 31 PM ...

Page 134: ...ve a Yamaha dealer 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 The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The battery is good Dry Wet Ope...

Page 135: ...CB00710 Excessive water pressure may cause water ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places 5 Rinse the ATV off immediately with clean wa ter and dry all surface...

Page 136: ...ain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping abil ity increasing the chance of an ...

Page 137: ... the spark plug cap 6 Lubricate all control cables and the pivoting points of all levers and pedals 7 Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to sively c...

Page 138: ...With oil and fuel 216 0 kg 476 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Compression ratio 8 70 1 Starting system Electric and recoil starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or S...

Page 139: ...uretor Manufacturer MIKUNI Type x quantity BSR33 x 1 Spark plug s Manufacturer model NGK DR7EA Spark plug gap Transmission Primary reduction system Spur gear Primary reduction ratio 73 22 3 318 Secondary reduction system Shaft drive Secondary reduction ratio 19 18 46 11 4 414 Transmission type Constant mesh 5 speed forward 1 speed reverse Operation Left foot operation Gear ratio 1st 34 12 2 833 2n...

Page 140: ...r pressure measured on cold tires Recommended Front 20 0 kPa 2 9 psi 0 200 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Maximum Front 23 0 kPa 3 3 psi 0 230 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm Front wheel Wheel type Panel wheel Rim size 10 x 6 0 AT Rear wheel Wheel type Panel wheel Rim size 10 x 8 0 AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear ...

Page 141: ...oil spring oil damper Wheel travel 135 mm 5 3 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model CB14A A2 Voltage capacity 12 V 14 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight Reverse indicator light 12 V 1 7 W 1 Fuse Fuse 20 0 A U1P012E0 book Page 4 Thursday April 20 2006 2 31 PM ...

Page 142: ...ef 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 1 Key identifica...

Page 143: ... EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need 1 Vehicle identification number 1 Model label U1P012E0 book Page 2 Thursday April 20 2006 2 31 PM ...

Page 144: ...e of noise control prior to its sale or delivery to the ul timate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muff...

Page 145: ...e maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 U1P012...

Page 146: ...quent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also warra...

Page 147: ...set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha ATV dealer within the con...

Page 148: ... pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging ...

Page 149: ...expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 U1P012E0 book Page 8 Thursday April 20 2006 2 3...

Page 150: ...11 EBU26132 U1P012E0 book Page 9 Thursday April 20 2006 2 31 PM ...

Page 151: ...and rear 5 3 C Cables checking and lubricating 8 34 Carburetor adjusting 8 23 Carrier front 4 14 Carrier rear 4 14 Chassis fasteners 5 7 Drive select lever safety system cable adjusting 8 26 Drive shaft universal joint lubricating 8 36 E Engine break in 6 7 Engine cold start 6 1 Engine idling speed 8 23 Engine oil 5 3 Engine oil and oil filter element 8 11 Engine starting a warm 6 3 Engine stop sw...

Page 152: ... 1 S Safety information 1 1 Specifications 10 1 Speed limiter 4 4 Starter choke 4 12 Start switch 4 3 Steering shaft lubricating 8 37 Storage 9 2 Storage compartment 4 13 Swingarm pivots lubricating 8 37 T Tail brake light bulb replacing 8 44 Throttle cable free play adjusting 8 25 Throttle lever 4 3 5 4 Tire pressure measuring 5 6 Tires 5 5 Tire wear limit 5 7 Troubleshooting 8 47 Troubleshooting...

Page 153: ...ct handling and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PU...

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