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Yamaha BRUIN 250, Owner'S Manual, Page: 8 / 174

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Yamaha BRUIN 250 Owner'S Manual Download Page 8

PERIODIC MAINTENANCE AND 
ADJUSTMENT.................................. 8-1

Owner’s manual and tool kit............ 8-1
Periodic maintenance/

lubrication ...................................... 8-3

Engine oil and oil filter element ....... 8-6
Final gear oil .................................. 8-12
Spark plug inspection .................... 8-15
Air filter element cleaning .............. 8-18
Spark arrester cleaning ................. 8-22
Carburetor adjustment................... 8-23
Idle speed adjustment ................... 8-24
Valve clearance adjustment .......... 8-24
Throttle lever adjustment............... 8-25
Select lever safety system cable 

adjustment................................... 8-25

Front brake pad check .................. 8-26
Rear brake shoe inspection .......... 8-26
Brake fluid level check................... 8-27
Brake fluid replacement................. 8-28
Front brake lever free play ............ 8-28
Adjusting the brake pedal and 

rear brake lever ........................... 8-30

Adjusting the rear brake light 

switch ...........................................8-34

Clutch adjustment ..........................8-35
Cable inspection and 

lubrication.....................................8-35

Brake lever and brake pedal 

lubrication.....................................8-36

Steering shaft lubrication ...............8-37
Wheel removal ...............................8-38
Wheel installation...........................8-38
Battery............................................8-40
Replenishing the battery fluid ........8-42
Fuse replacement ..........................8-44
Replacing a headlight bulb ............8-45
Headlight beam adjustment...........8-48
Tail/brake light bulb 

replacement .................................8-48

Troubleshooting .............................8-50
Troubleshooting chart ....................8-51

CLEANING AND STORAGE ............9-1

A. Cleaning ......................................9-1
B. Storage ........................................9-3

8

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EE.book  Page 3  Wednesday, June 23, 2004  1:13 PM

Summary of Contents for BRUIN 250

Page 1: ......

Page 2: ......

Page 3: ...information It provides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures 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 COMPLETELY BEFORE OPERATING YOUR ATV...

Page 4: ...Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or cleare...

Page 5: ...all applicable OFF ROAD noise level and spark arrester laws and regu lations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU13340 YFM250BT OWNER S MANUAL 2004 by Yamaha Motor Corporation U S A 1st edition June 2004 All rights reserved Any reprinting or unauthorized use without the written permission of EE book Page 2 Wednesday ...

Page 6: ... identification number 3 2 Vehicle identification number 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator lights 4 2 Handlebar switches 4 2 Throttle lever 4 4 Speed limiter 4 5 Front brake lever 4 6 Brake pedal and rear brake lever 4 6 Parking brake 4 8 Shift pedal 4 9 Drive select lever 4 9 Recoil starter 4 10 Fuel tank cap 4 11 Fuel cock 4 12 Starter choke 4 13 Seat 4 14 Storage compart...

Page 7: ...ing a warm engine 6 3 Warming up 6 3 Engine break in 6 7 Parking 6 8 Parking on a slope 6 9 Accessories and loading 6 10 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 23 Climbing uphill 7 25 Riding downhill 7 30 Crossing a slope 7 32 Crossing through shallow water 7 34 Riding over rough terrain 7 36 Sliding ...

Page 8: ... Select lever safety system cable adjustment 8 25 Front brake pad check 8 26 Rear brake shoe inspection 8 26 Adjusting the rear brake light switch 8 34 Clutch adjustment 8 35 Cable inspection and lubrication 8 35 Brake lever and brake pedal lubrication 8 36 Steering shaft lubrication 8 37 Wheel removal 8 38 Wheel installation 8 38 Battery 8 40 Replenishing the battery fluid 8 42 Fuse replacement 8...

Page 9: ...SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 10 11 12 13 14 EE book Page 4 Wednesday June 23 2004 1 13 PM ...

Page 10: ...EBU00464 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS EE book Page 1 Wednesday June 23 2004 1 13 PM ...

Page 11: ... difficult to read or comes off a replacement label is available from your Yamaha dealer Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an accident Never exceed the maximum front cargo limit of 30kg 66 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 4XE F4877 30 WARNING 1 2 EE book Page 2 Wednesday Ju...

Page 12: ...ling stability and braking performance and can lead to an accident Never exceed the maximum rear cargo limit of 45kg 99 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 4XE F4897 30 WARNING 3 4 6 5 EE book Page 3 Wednesday June 23 2004 1 13 PM ...

Page 13: ...7 9 8 EE book Page 4 Wednesday June 23 2004 1 13 PM ...

Page 14: ...out proper training or instruction Take a Training Course Begin ners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc Never allow a child under age 16 to operate a...

Page 15: ...ou use it to make sure it is in safe operating condition Al ways follow the inspection and maintenance procedures and schedules described in this man ual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV ...

Page 16: ...n the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if...

Page 17: ...e 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 pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly...

Page 18: ...flames or other sources of ignition such as the pilot When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some g...

Page 19: ...in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation EE book Page 6 Wednesday June 23 2004 1 13 PM ...

Page 20: ... bolt 8 Engine oil filter element 9 Rear brake light switch 10 Headlight 11 Fuel cock 12 Recoil starter 15 Tail brake light 16 Rear shock absorber spring preload adjusting ring 17 Engine oil drain bolt 18 Shift pedal 19 Rear brake lever 20 Handlebar switches 21 Parking brake 22 Starter choke 23 Drive select lever 24 Main switch 25 Fuel tank cap EE book Page 1 Wednesday June 23 2004 1 13 PM ...

Page 21: ...ts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER ACA 02E 2 VEHICLE IDENTIFICATION NUMBER ACA 02E 3 MODEL LABEL INFORMATION ACA 01E EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number EE book Page 2 Wed...

Page 22: ...ehicle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label EE book Page 3 Wednesday June 23 2004 1 13 PM ...

Page 23: ...ious injury or death EBU00942 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key EE book Page 1 Wednesday June 23 2004 1 13 PM ...

Page 24: ...his indicator light comes on when the drive select lever is in the R position EBU00053 Handlebar switches 1 Light switch OFF 2 Engine stop switch 3 Start switch EBU12050 Engine stop switch Make sure that the engine stop switch is set to before starting the engine The engine EE book Page 2 Wednesday June 23 2004 1 13 PM ...

Page 25: ...hts with the engine turned off for more than thirty minutes 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 _ EBU06070 Start switch The starter motor cranks the engine when this switch is pushed CAUTION _ See starting instructions prior to starting the engine See page 6 1 for details _ EE book Page 3 W...

Page 26: ...t is operating smoothly Make sure it returns to the idle position as soon as the le ver is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine If it does n...

Page 27: ...o more than 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to ...

Page 28: ... brake 1 Front brake lever EBU00732 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar Push down on the pedal or pull the lever toward the handlebar to apply the rear brake 1 Rear brake pedal EE book Page 6 Wednesday June 23 2004 1 13 PM ...

Page 29: ...1 Rear brake lever EE book Page 7 Wednesday June 23 2004 1 13 PM ...

Page 30: ...use of the parking brake WHAT CAN HAPPEN The ATV could start moving unexpect edly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking perfor mance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID ...

Page 31: ...e left side of the engine Neutral is at the bottom position 1 Shift pedal N Neutral position EBU00085 Drive select lever The drive select lever is used for driving the machine either forward or in reverse Refer to page 6 4 for drive select lever operation 1 Drive select lever EE book Page 9 Wednesday June 23 2004 1 13 PM ...

Page 32: ...coil starter WARNING POTENTIAL HAZARD Starting the engine in gear and or start ing the engine without setting the park ing brake WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Put the transmission in neutral and set the parking brake before starting the en gine EE book Page 10 Wednesday June 23 2004 1 13 PM ...

Page 33: ...EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap EE book Page 11 Wednesday June 23 2004 1 13 PM ...

Page 34: ...this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to EE book Page 12 Wednesday June 23 2004 1 13 PM...

Page 35: ...el mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 EE book Page 13 Wednesday June 23 2004 1 13 PM ...

Page 36: ...t the rear 1 Seat 2 Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely fitted 1 Projection 2 2 Seat holder 2 EE book Page 14 Wednesday June 23 2004 1 13 PM ...

Page 37: ...mpartment be sure to wrap them in a plas tic bag so that they will not get wet When washing the ATV be careful not to let any wa ter enter the storage compartment NOTE _ There is a check hose at the bottom of the storage compartment If any water collects in this hose remove the hose empty it and then install it _ 1 Storage compartment EE book Page 15 Wednesday June 23 2004 1 13 PM ...

Page 38: ...s follows To increase the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring 2 Position indicator NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ Maximum load limit 30 kg 66 lb Maximum load limit 45 kg 99 lb EE book Page 16 Wednesday June 23 2004 1 13 PM ...

Page 39: ...1 Special wrench EBU00112 WARNING Indicates a potential hazard that could Standard position 2 1 Minimum soft 5 Maximum hard EE book Page 17 Wednesday June 23 2004 1 13 PM ...

Page 40: ...level Fill with fuel if necessary 5 5 5 6 Engine oil Check oil level Fill with oil if necessary 5 7 8 6 8 11 Final gear oil Check for leakage 5 7 8 12 8 14 Throttle Check for proper throttle cable operation 5 7 8 25 Wheels and tires Check tire pressure wear and damage 5 9 5 12 8 38 8 39 Fittings and fasteners Check all fittings and fasteners 5 8 Lights and switches Check for proper operation 5 8 8...

Page 41: ...CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op erating condition Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual EE book Page 2 Wednesday June 23 2004 1 13 PM ...

Page 42: ...ake Check the brake fluid level Add fluid if neces sary See pages 8 27 8 28 Brake fluid leakage front brake Check to see if any brake fluid is leaking out of the hose joint or brake fluid reservoir of the front brake Apply the brake firmly for one minute If the lever moves slowly inward there may be a leak in the brake system If there is any leakage the brake system should be inspected by a Yamaha...

Page 43: ...ead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected by the ad justment procedures provided in this manual have a Yamaha dealer check for the cause EE book Page 4 Wednesday June 23 2004 1 13 PM ...

Page 44: ...esigned to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 12 0 L 2 64 Imp gal 3 17 US gal Res...

Page 45: ...L HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure ...

Page 46: ...ure that no foreign material en ters the crankcase _ EBU00493 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 12 8 14 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used _ EBU01083 Throttle lever Check to see that the ...

Page 47: ...o the Service Manual for correct tightening torque EBU10030 Lights Check the headlights and tail brake light to make sure they are in working condition Re pair as necessary for proper operation EBU11700 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for proper operation EE book Page 8 Wednesday June 23 2004 1 13 PM ...

Page 48: ...re not recommended ACE 01EACE 01E Manufacturer Size Type Front MAXXIS AT22 7 00 10 M 905 Rear MAXXIS AT22 10 00 10 M 906 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 20 kPa 0 20 kgf cm2 2 9 psi Rear 25 kPa 0 25 kgf cm2 3 6 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimu...

Page 49: ...he tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst EE book Page 10 Wednesday June 23 2004 1 13 PM ...

Page 50: ...reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifica tions ACE 02EACE 02E 1 Low pressure tire gauge Recommended pressure Minimum Maximum Front 20 kPa 0 20 kgf cm2 2 9 psi 17 kPa 0 17 kgf cm2 2 5 psi 23 kPa 0 23 kgf cm2 3 3 psi 25 kPa 2 22 kPa 2 28 kPa 2 EE book Page 11 Wednesday June 23 2004 1 13 ...

Page 51: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit EE book Page 12 Wednesday June 23 2004 1 13 PM ...

Page 52: ...controls WHAT CAN HAPPEN Loss of control which could cause an accident 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 WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW TO AVOID THE...

Page 53: ...re starting the engine _ 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warm ing up position Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 6 Completely close...

Page 54: ...ne If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it CAUTION _ See the Engine break in section prior to operating the engine for the first time _ EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used Th...

Page 55: ...a complete stop and re turn the throttle lever to the closed posi tion 2 Apply the brake pedal 3 Shift the transmission into first gear 4 Move the drive select lever toward the 1 Drive select lever NOTE _ When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the ATV _ 5 Check behind you for people or obsta cles and then release the br...

Page 56: ...neutral return the throttle lever to its original position and repeatedly depress the shift pedal until it stops WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go sl...

Page 57: ...he engine and drive train may result 2 Shift into first gear and release the shift 4 Once the machine has attained adequate speed release the throttle lever 5 Shift into second gear and release the shift pedal 6 Open the throttle gradually 7 Follow the same procedure when shifting to the next higher gear WARNING POTENTIAL HAZARD Opening the throttle before releasing the shift pedal WHAT CAN HAPPEN...

Page 58: ...s brand new you must not put an excessive load on it for the first several hours of running During the first 20 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition which might result in ex cessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle...

Page 59: ... time Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at any time After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00211 Parking When parking stop the engine and shift into neutral Turn the fuel cock to OFF and apply the parking brake 1 Loc...

Page 60: ... hill or other incline WHAT CAN HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline put the ATV in low gear apply the parking brake and 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 ...

Page 61: ...e a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object at...

Page 62: ...rrying cargo and towing a trail er include the tongue weight in the maxi mum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can caus...

Page 63: ...id hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed ...

Page 64: ...EBU15540 WARNING _ Indicates a potential hazard that could result in serious injury or death EE book Page 13 Wednesday June 23 2004 1 13 PM ...

Page 65: ...7 1 Riding Your ATV EE book Page 1 Wednesday June 23 2004 1 13 PM ...

Page 66: ...types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure Owner s Manual completely and understand the operation of the controls Pay particular at tention to the safety in...

Page 67: ...f time Take the time to learn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills l...

Page 68: ...commenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc EE book Page 5 Wednesday June 23 2004 1 13 PM ...

Page 69: ...PEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers EE book Page 6 Wednesday June 23 2004 1 13 PM ...

Page 70: ... ac cident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event Operating without protective clothing increases 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 sl...

Page 71: ...ZARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV EE book Page 8 Wednesday June 23 2004 1 13 PM ...

Page 72: ...TV is in safe op erating condition Always follow the inspection and main WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use the size...

Page 73: ...hed to the maxi mum Turning the adjusting screw in limits the maximum engine power available and de creases the maximum speed of the ATV Turning the adjusting screw in decreases top speed and turning it out increases top speed WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV which c...

Page 74: ... trailer and cargo 330 kgf 727 lbf Tongue weight vertical weight on trailer hitch point 15 kgf 33 lbf WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securel...

Page 75: ... even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation ...

Page 76: ...NG POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off EE book Page 13 Wednesday June 23 2004 1 13 PM ...

Page 77: ... cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed EE book Page 14 Wednesday June 23 2004 1 13 PM ...

Page 78: ...ikely to touch it WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during 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 EE book Page 15 Wednesday June 23 2004 1 13...

Page 79: ...g this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets EE book Page 16 Wednesday June 23 2004 1 13 PM ...

Page 80: ...perating 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 high ways EE book Page 17 Wednesday June 23 2004 1 13 PM ...

Page 81: ...TV to upset WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op EE book Page 18 Wednesday June 23 2004 1 13 PM ...

Page 82: ... or vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain EE book Page 19 Wednesday June 23 2004 1 13 PM ...

Page 83: ...iler hitch Do not ride in areas posted no trespassing Do not ride on private property without getting permission WARNING WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles EE book Page 20 Wednesday June 23 2004 1 13 PM ...

Page 84: ...d afterwards do not allow With the engine idling lift the shift pedal to the 1st gear position and then release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate Once the ATV has at tained adequate speed release the throttle and lift the shift pedal to the 2nd gear position Release the shift pedal and apply the throttle smo...

Page 85: ...prop er use of the brakes or shifting can cause the tires to lose traction reducing control and in creasing the possibility of an accident WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make...

Page 86: ...on As you do so put your weight on the footboard to the outside 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 maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of contr...

Page 87: ...Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements 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 in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember ...

Page 88: ...ortant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small...

Page 89: ... as described in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV An obstacle a sharp drop or another vehicle or person could be on the other side of the hill EE book Page 26 Wednesday June 23 2004 1 13 PM...

Page 90: ...ls or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the 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 w...

Page 91: ...ATV in gear The ATV could easily tip over back wards Instead dismount the ATV immediate ly on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply...

Page 92: ...Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu al EE book Page 29 Wednesday June 23 2004 1 13 PM ...

Page 93: ...ction Whenever possible ride your ATV straight downhill Avoid sharp angles which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for go ing down hills as described in this O...

Page 94: ...EE book Page 31 Wednesday June 23 2004 1 13 PM ...

Page 95: ...ting the front wheels slightly up hill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN H...

Page 96: ... 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 EE book Page 33 Wednesday June 23 2004 1 13 PM ...

Page 97: ...ry or upset the ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to let...

Page 98: ...N _ After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case the drive select 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 con ditions _ EE book Page 35 Wednesday June 23 2004 1 13 PM ...

Page 99: ... with caution Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may result EE book Page 36 Wednesday June 23 2004 1 13 PM ...

Page 100: ... the front wheels will sometimes help WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper proce...

Page 101: ...ntil you have corrected the slide With practice over a period of time skill at controlled sliding can be developed The ter rain should be chosen carefully before at tempting such maneuvers since both stability and control are reduced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost EE book Page 38 Wednesday June 2...

Page 102: ...while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by p...

Page 103: ...pages 7 25 7 29 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned towards the uphill side of the ATV to main tain 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 dis cover that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow w...

Page 104: ...EBU14510 Owner s manual and tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it on the bottom of the seat as shown Put the own er s tool kit and low pressure tire gauge under the seat WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can ...

Page 105: ...o a Yamaha dealer to check the torque settings and adjust them as neces sary _ WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or u...

Page 106: ...EM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours more often in wet or dusty areas Carburetor Check starter choke Adjust...

Page 107: ...ust if necessary Clutch Check operation Adjust if necessary Wheels Check balance damage runout Repair if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Front and rear suspension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3...

Page 108: ...e oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged WARNING _ Indicates a potential hazard that could result in serious injury or death Battery Check specific gravity Check that the breather hose is working properly Correct if necessary Lights and switches Check operation Adjust headlight beams ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6...

Page 109: ...n minutes until the oil level settles before checking 4 Remove the engine oil filler cap and then wipe the dipstick off with a clean rag In sert the dipstick in the filler hole without screwing it in and then remove it again to check the oil level NOTE _ 5 If the engine oil is at or below the mini mum level mark add sufficient oil of the recommended type to raise it to the cor rect level CAUTION _...

Page 110: ... engine oil filler cap and then remove the engine oil drain bolt to drain the oil from the crankcase CAUTION _ When removing the engine oil drain bolt the compression spring oil strainer and O ring will fall out Take care not to lose these parts _ 1 Engine oil drain bolt 2 O ring 3 Compression spring 4 Engine oil strainer NOTE _ Skip steps 5 11 if the oil filter element is not being cleaned _ EE b...

Page 111: ...oard by removing the bolts 1 Footrest 2 Bolt 8 6 Loosen the brake pedal free play adjust ing nut and then remove the oil filter ele ment cover bolts 1 Adjusting nut brake rod EE book Page 8 Wednesday June 23 2004 1 13 PM ...

Page 112: ...element cover and oil filter element move the select lever safety system cable away from the cover _ CAUTION _ Do not loosen the adjusting nuts shown when removing the oil filter element cover or oil filter element _ 1 Oil filter element cover 2 Adjusting nut EE book Page 9 Wednesday June 23 2004 1 13 PM ...

Page 113: ...rain bolt and then tighten the engine oil drain bolt CAUTION _ Before installing the engine oil drain bolt be sure to install the O ring compression spring and oil strainer _ 13 Add the specified amount of the recom mended engine oil then install and tight en the engine oil filler cap Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf Tightening torque Engine oil drain bolt...

Page 114: ...material en ters 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 then check the oil level and correct it if necessary 1 Bolt A 6 2 Bolt B 2 17 Adjust the brake pedal free play See pages 8 30 8 31 Tightening torque Footboard bolt A 3 8 N...

Page 115: ... brim of the filler hole _ 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level CAUTION _ Be sure no foreign material enters the final gear case _ 4 Install the oil filler bolt and then tighten it to the specified torque 1 Final gear oil 2 Correct oil level 3 Final gear oil filler bolt EE book Page 12 Wednesday June 23 2004 1...

Page 116: ...t 2 2 Place the ATV on a level surface 3 Place a container under the final gear case to collect the used oil 4 Remove the oil filler bolt and the drain bolt to drain the oil 1 Final gear oil drain bolt 5 Install the drain bolt and then tighten it to the specified torque EE book Page 13 Wednesday June 23 2004 1 13 PM ...

Page 117: ... the specified torque 9 Install the final gear case cover bolts and then tighten them to the specified torque Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf Tightening torque Final gear case cover bolt 17 Nm 1 7 m kgf 12 ft lbf EE book Page 14 Wednesday June 23 2004 1 13 PM ...

Page 118: ...ug inspection Removal 1 Remove the spark plug cap 1 Spark plug cap 2 Use the spark plug wrench in the owner s tool kit to remove the spark plug as shown 1 Spark plug wrench EE book Page 15 Wednesday June 23 2004 1 13 PM ...

Page 119: ...Instead take the ATV to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes ex cessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Installation 1 Measure the electrode gap with a wire thickness gauge and if...

Page 120: ...fied torque NOTE _ If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible _ 4 Install the spark plug cap Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 5 ft lbf EE book Page 17 Wednesday June 23 2004 1 13 PM ...

Page 121: ...n this hose empty the hose and clean the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seat See page 4 14 for seat removal and installation proce dures 2 Remove the air filter case cover by un hooking the holders 1 Air filter case cover 2 Holder 3 EE book Page 18 Wednesday June 23 2004 1 13 PM ...

Page 122: ...3 Pull the air filter element out 4 Remove the foam cover from the air filter element 1 Air filter element 1 Air filter element 2 Foam cover EE book Page 19 Wednesday June 23 2004 1 13 PM ...

Page 123: ...excess water or solvent out of the foam cover and let it dry CAUTION _ Do not twist the foam cover when squeezing it Do not apply oil to the foam cover _ WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the foam cover WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the foam cover...

Page 124: ...ctions Check the air filter ele ment rubber joint to the carburetor and mani fold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfil tered air entering the engine _ CAUTION _ Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration with...

Page 125: ...sure the exhaust pipe and muffler are cool 1 Remove the purging bolt 1 Purging bolt 2 Start the engine and rev it up approxi mately twenty times while momentarily 3 Stop the engine and allow the exhaust pipe to cool 4 Install the purging bolt and tighten it EE book Page 22 Wednesday June 23 2004 1 13 PM ...

Page 126: ...e disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result WARNING POTENTIAL HAZARD Improperly purging the exhaust system Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let t...

Page 127: ...d and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction a to increase the engine speed and in direc tion b to decrease the engine speed 1 Throttle stop screw EBU00303 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clear ance must be...

Page 128: ... throttle le ver free play is 3 0 5 0 mm 0 12 0 20 in 3 Tighten the locknut EBU03050 Select lever safety system cable adjustment The select lever safety system cable stretch es with use resulting in improper function To prevent this the cable must be adjusted regu larly This adjustment however should be left to a Yamaha dealer EE book Page 25 Wednesday June 23 2004 1 13 PM ...

Page 129: ...ed to be removed to check the EBU00313 Rear brake shoe inspection A wear indicator is provided on the rear brake This indicator allows checking of brake shoe wear without disassembling the brake Apply the rear brake and check the position of the in dicator If the indicator reaches the wear limit line ask a Yamaha dealer to replace shoes as a set 1 Wear indicator 2 Wear limit line EE book Page 26 W...

Page 130: ...or leakage Observe these precautions When checking the brake fluid level make sure the top of the brake fluid reservoir is level Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per 1 Minimum level mark Refill with the same type of brake fluid Mix ing fluids may result in a harmful chemical reaction and lead to poor brake perfor...

Page 131: ...e the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years EBU11870 Front brake lever free play The front brake lever should have a free play of zero mm zero in at the lever end If not have a Yamaha dealer check the brake sys tem a Front brake lever free play EE book Page 28 Wednesday Jun...

Page 132: ... could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is cor rect Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re EE book Page 29 Wednesday June 23 2004 1 13 PM ...

Page 133: ... adjusting bolt locknuts 3 Turn the adjusting bolt so that the top of the brake pedal is positioned 43 53 mm 1 69 2 09 in above the top of the foot board bracket Adjusting the brake pedal free play 1 Fully loosen the brake cable adjusting nut 1 Adjusting nut brake cable 2 Adjusting nut brake rod E 8 fm Page 30 Friday June 25 2004 5 00 PM ...

Page 134: ...e play is 20 0 30 0 mm 0 79 1 18 in a Rear brake pedal free play Adjusting the rear brake lever free play 1 Loosen the locknut and fully turn in the adjusting bolt at the brake lever 1 Locknut 2 Adjusting bolt EE book Page 31 Wednesday June 23 2004 1 13 PM ...

Page 135: ...nd the pin 1 Adjusting nut brake cable 2 Lever 3 Pin a Gap 3 Turn the adjusting bolt until the free play at the brake lever pivot is 5 0 7 0 mm 0 20 0 28 in 1 Locknut 2 Adjusting bolt a Rear brake lever free play 4 Tighten the locknut 5 Install the footboard EE book Page 32 Wednesday June 23 2004 1 13 PM ...

Page 136: ...uld lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components re quires professional knowledge These procedures should be performed by a Yamaha dealer EE book Page 33 Wednesday June 23 2004 1 13 PM ...

Page 137: ...s sary adjust the brake light switch as follows 1 Remove the footboard See page 8 8 2 Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjust ing nut in direction b 1 Rear brake light switch 2 Adjusting nut 3 Install the footboard EE book Page 34 Wed...

Page 138: ...e adjusting bolt counterclockwise to decrease the clutch free play and turn it clock wise to increase the free play _ 5 Install the footboard EBU00356 Cable inspection and lubrication WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be re...

Page 139: ...amaha dealer to replace them EBU00717 Brake lever and brake pedal lubrication Lubricate the pivoting parts Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil Recommended lubricant Lithium soap based grease all purpose grease EE book Page 36 Wednesday June 23 2004 1 13 PM ...

Page 140: ...4060 Steering shaft lubrication Lubricate the pivot point with a grease gun 1 Grease nipple Recommended lubricant Lithium soap based grease all purpose grease EE book Page 37 Wednesday June 23 2004 1 13 PM ...

Page 141: ...wheel 4 Remove the wheel EBU11211 Wheel installation 1 Install the wheel and the nuts NOTE _ The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its ta pered side towards the wheel _ EE book Page 38 Wednesday June 23 2004 1 13 PM ...

Page 142: ...er the ATV so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf EE book Page 39 Wednesday June 23 2004 1 13 PM ...

Page 143: ...store the battery on its side When inspecting the battery be sure the breather hose is routed correctly If it touches the frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cosmet ic damage to the machine can occur 1 Battery 2 Battery breather hose 3 Clamp 5 EE book Page 40 Wednesday June 23 2004 1 13 PM ...

Page 144: ... HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flames cig arettes or other sources of ignition Ven tilate when charging or using in a closed spa...

Page 145: ...h 1 Remove the battery cover by pulling it up ward 1 Battery cover 2 The electrolyte level should be between the upper and lower level marks Use only distilled water if refilling is neces sary CAUTION _ Normal tap water contains minerals which are harmful to a battery Therefore refill only with distilled water _ EE book Page 42 Wednesday June 23 2004 1 13 PM ...

Page 146: ... Completely recharge the battery before reusing 7 If the battery is to be stored for a longer period than the above check the specific gravity at least once a month and re charge the battery when it is too low 8 Always make sure the connections are correct when putting the battery back in the ATV Make sure the breather hose is properly connected and is not damaged or obstructed EE book Page 43 Wed...

Page 147: ...dealer CAUTION To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse Specified fuse 20 0 A WARNING 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 AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse...

Page 148: ...replace it as fol lows 1 Remove the bulb holder cover at the rear of the headlight by pulling it off 1 Headlight bulb holder cover 2 Remove the headlight bulb holder by turning it counterclockwise 1 Headlight bulb holder EE book Page 45 Wednesday June 23 2004 1 13 PM ...

Page 149: ...ENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it EE book Page 46 Wednesday June 23 2004 1 13 PM ...

Page 150: ...free from oil otherwise the transparency of the glass the luminos ity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner _ 5 Install the headlight bulb holder by turn ing it clockwise 6 Install the headlight bulb holder cover at the rear of the headlight EE book Page 47 Wedne...

Page 151: ... direction a To lower the beam turn the adjusting screw in direction b EBU08610 Tail brake light bulb replacement 1 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Bulb holder 2 Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise EE book Page 48 Wednesday June 23 2004 1 13 PM ...

Page 152: ...r 2 Bulb 3 Install a new bulb in the bulb holder by pushing it inward and turning it clockwise 4 Install the bulb holder together with the bulb by turning it clockwise EE book Page 49 Wednesday June 23 2004 1 13 PM ...

Page 153: ...erience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se ve...

Page 154: ... There is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove spark plug and check electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark good Ignition system normal Spark weak Adjust plug gap or replace plug No spark Ask a Yamaha dealer to 4 Battery Use electric starter Engine turns over qu...

Page 155: ...axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 Once the m...

Page 156: ...ch may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out th...

Page 157: ...ark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If sto...

Page 158: ...ry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE _ Make any necessary repairs before storing the machine _ EE book Page 4 Wednesday June 23 2004 1 13 PM ...

Page 159: ...772 mm 30 4 in 1 170 mm 46 1 in 150 mm 5 91 in 2 900 mm 114 2 in Basic weight With oil and full fuel tank 216 0 kg 476 lb Engine Type Cylinder arrangement Displacement Bore Stroke Compression ration Starting system Lubrication system Air cooled 4 stroke SOHC Forward inclined single cylinder 229 6 cm3 71 0 58 0 mm 2 80 2 28 in 8 70 1 Electric and recoil starter Wet sump EE book Page 1 Wednesday Jun...

Page 160: ...30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher EE book Page 2 Wednesday June 23 2004 1 13 PM ...

Page 161: ...2 0 L 2 64 Imp gal 3 17 US gal 1 6 L 0 35 Imp gal 0 42 US gal Carburetor Type quantity Manufacturer BSR33 1 MIKUNI Spark plug Type manufacturer Gap DR7EA NGK 0 6 0 7 mm 0 024 0 028 in Clutch type Wet centrifugal automatic Transmission Primary reduction system Primary reduction ratio Secondary reduction system Spur gear 73 22 3 318 Shaft drive MODEL YFM250B E 10 fm Page 3 Wednesday June 23 2004 4 1...

Page 162: ...ype Caster angle Trail Steel tube frame 4 0 20 0 mm 0 79 in Tire Type Size Front Size Rear Tubeless AT22 7 00 10 AT22 10 00 10 Brake Front brake type Operation Rear brake type Operation Dual disc brake Right hand operation Drum brake Left hand and right foot operation Suspension MODEL YFM250B EE book Page 4 Wednesday June 23 2004 1 13 PM ...

Page 163: ...pe voltage capacity DC C D I A C magneto CB14A A2 12V 14 0 Ah Headlight type Incandescence Bulb voltage wattage quantity Headlight Tail brake light Indicator light Neutral Reverse 12 V 30 W 30 0 W 2 12 V 5 W 21 0 W 1 12 V 1 7 W 1 12 V 1 7 W 1 Fuse 20 0 A MODEL YFM250B EE book Page 5 Wednesday June 23 2004 1 13 PM ...

Page 164: ...ose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muf...

Page 165: ... re minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 06E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 200 750 75 6 2 400 1 500 150 12 4 800 3 000 300 18 7 200 4 500 450 24 9 600 6 000 600 30 12 000 7 500 750 36 14 400 9 000 900 42 16 800 10 500 1 050 48 19 200 12 000 1...

Page 166: ...EBU00432 1 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY EE book Page 1 Wednesday June 23 2004 1 13 PM ...

Page 167: ...1 2 3 4 5 6 7 8 9 10 11 12 13 EE book Page 2 Wednesday June 23 2004 1 13 PM ...

Page 168: ...EBU00435 1 YAMAHA EXTENDED SERVICE Y E S EE book Page 1 Wednesday June 23 2004 1 13 PM ...

Page 169: ...1 2 3 4 5 6 7 8 9 10 11 12 13 EE book Page 2 Wednesday June 23 2004 1 13 PM ...

Page 170: ...EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death EE book Page 3 Wednesday June 23 2004 1 13 PM ...

Page 171: ...EBU00437 EE book Page 5 Wednesday June 23 2004 1 13 PM ...

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