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Yamaha WOLVERINE 350 YFM25XX, Owner'S Manual, Page: 100 / 126

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Yamaha WOLVERINE 350 YFM25XX Owner'S Manual Download Page 100

8-29

8

Adjusting the brake lever free play

The brake lever free play should measure 3.0–5.0
mm (0.12–0.20 in) as shown. If the free play is in-
correct, adjust it as follows.

1. Loosen the locknut at the brake lever and fully

turn in the brake lever free play adjusting bolt.

2. Turn the brake lever free play adjusting nut on

the brake cable at the rear wheel hub so that
gap “A” measures 0–1 mm (0–0.04 in).

1. Brake pedal free play adjusting nut
2. Brake lever free play adjusting nut

1. Brake lever free play
2. Locknut

3. Brake lever free play adjusting bolt

U3D562E0.book  Page 29  Wednesday, June 6, 2007  12:58 PM

Summary of Contents for WOLVERINE 350 YFM25XX

Page 1: ...YFM35XX OWNER S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO 3D5 F8199 62 DIC183 ...

Page 2: ...PRINTED IN USA 2007 07 0 3 1 CR E F S YAMAHA MOTOR CO LTD DIC183 ...

Page 3: ...OWNER S MANUAL YFM35XX 3D5 F8199 62 E0 U3D562E0 book Page 1 Wednesday June 6 2007 12 58 PM ...

Page 4: ...U3D562E0 book Page 2 Wednesday June 6 2007 12 58 PM ...

Page 5: ...mation It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDER STAND ALL INSTRUCTIONS PAY CLOSE A...

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

Page 7: ...face paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17410 YFM35XX OWNER S MANUAL 2007 by Yamaha Motor Co Ltd 1st edition May 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A U3D562E0 book Page 1 Wednesday June 6 2007 12 58 P...

Page 8: ... 4 6 Drive select lever 4 7 Fuel tank cap 4 7 Fuel 4 8 Fuel cock 4 9 Starter choke 4 10 Seat 4 11 Storage compartment 4 12 Adjusting the front shock absorber assemblies 4 13 Adjusting the rear shock absorber assembly 4 14 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Tires 5 4 Measuring the tire pressur...

Page 9: ...eral maintenance and lubrication chart 8 5 Removing and installing the panel 8 8 Checking the spark plug 8 8 Engine oil and oil filter cartridge 8 10 Final gear oil 8 14 Cleaning the air filter element 8 17 Cleaning the spark arrester 8 20 V belt cooling duct check hose 8 21 V belt case drain plug 8 22 Adjusting the carburetor 8 22 Adjusting the engine idling speed 8 22 Adjusting the throttle cabl...

Page 10: ...ing the steering shaft 8 34 Battery 8 34 Replacing a fuse 8 36 Replacing a headlight bulb 8 37 Adjusting a headlight beam 8 39 Replacing the tail brake light bulb 8 39 Removing a wheel 8 40 Installing a wheel 8 41 Troubleshooting 8 42 Troubleshooting chart 8 43 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 U3D562E0 book ...

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

Page 12: ...mbing 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 Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully ...

Page 13: ... Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribed in this manual Never modify an ATV thro...

Page 14: ...gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are poisonous and may cause loss of consciousness and death within ...

Page 15: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U3D562E0 book Page 1 Wednesday June 6 2007 12 58 PM ...

Page 16: ... These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer U3D562E0 book Page 2 Wednesday June 6 2007 12 58 PM ...

Page 17: ...2 3 2 U3D562E0 book Page 3 Wednesday June 6 2007 12 58 PM ...

Page 18: ...and tool kit 6 Seat lock lever 7 Rear shock absorber assembly spring preload adjusting ring 8 Engine oil filler cap 9 Oil filter cartridge 10 V belt cooling duct check hose 1 Spark arrester 2 Tail brake light 3 Spark plug 4 Front shock absorber assembly spring preload adjusting ring 5 Rear brake light switch 6 Brake pedal 7 V belt case U3D562E0 book Page 1 Wednesday June 6 2007 12 58 PM ...

Page 19: ...purchased may differ slightly from the figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Starter choke 4 Drive select lever 5 Main switch 6 Fuel tank cap 7 Front brake lever 8 Throttle lever U3D562E0 book Page 2 Wednesday June 6 2007 12 58 PM ...

Page 20: ... 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 U3D562E0 book Page 1 Wednesday June 6 2007 12 58 PM ...

Page 21: ...set to and then pushing the start switch If the warning light does not come on while the start switch is being pushed then go off after the start switch is released have a Yamaha dealer check the electrical circuit If the warning light stays on allow the engine to cool If the warning light stays on when the engine is cool have a Yamaha dealer check the electrical circuit CAUTION ECB00010 The engin...

Page 22: ...ting instructions on page 6 1 prior to starting the engine EBU18151 Light switch OFF Set this switch to to turn on the low beams and the taillight Set the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights CAUTION ECB00040 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to t...

Page 23: ... slow down when you need to This could cause an accident Check the op eration of the throttle lever before you start the engine If the throttle does not work smoothly check for the cause Correct the problem be fore riding the ATV or consult a Yamaha dealer EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even whe...

Page 24: ...3 0 5 0 mm 0 12 0 20 in See page 8 24 EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull the brake lever toward the handlebar grip EBU18442 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 To apply the rear brake push down on the brake ped...

Page 25: ...the parking brake Squeeze the rear brake lever to release the parking brake WARNING EWB00220 Always set the parking brake before starting the engine The ATV could start moving un expectedly if the parking brake is not ap plied This could cause loss of control or a collision 1 Brake pedal 1 Rear brake lever 1 Parking brake lock plate U3D562E0 book Page 6 Wednesday June 6 2007 12 58 PM ...

Page 26: ...ld also wear out the brakes prematurely EBU18581 Drive select lever The drive select lever is used to shift your ATV into the forward neutral and reverse positions See the Operating the drive select lever and driving in re verse section on page 6 3 for the drive select lever operation EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise 1 Drive select lever U3D562E0 book...

Page 27: ...1 Fuel tank cap 1 Fuel level 2 Fuel tank filler tube Recommended fuel UNLEADED GASOLINE ONLY For Europe Regular unleaded gasoline only with a research octane number of 91 or high er Fuel tank capacity 14 5 L 3 83 US gal 3 19 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal U3D562E0 book Page 8 Wednesday June 6 2007 12 58 PM ...

Page 28: ...to spill fuel especially on the engine or exhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explaine...

Page 29: ...e fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke 1 Arrow mark positioned over ON 1 Arrow mark p...

Page 30: ...choke See the Starting a cold engine section on page 6 1 for proper operation EBU26981 Seat To remove the seat Push the seat lock lever backward and pull up the seat at the rear 1 Starter choke 1 Seat 1 Seat lock lever U3D562E0 book Page 11 Wednesday June 6 2007 12 58 PM ...

Page 31: ... 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 CAUTION ECB00130 Do not store metal or sharply edged objects like tools in the storage compartment If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartment Do not exce...

Page 32: ...g preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Storage com...

Page 33: ...s sembly The spring preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum ha...

Page 34: ...obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 U3D562E0 book Page 15 Wednesday June 6 2007 12 58 PM ...

Page 35: ...ine which service should be performed by a Yamaha dealer ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 8 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 10 Final gear oil Check ATV for oil leakage Cor...

Page 36: ... and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 5 5 5 6 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 33 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 32 Axle boots Check for cracks or damage and replace if necessary 8 31 Chas...

Page 37: ...s at the specified level Add oil as necessary See page 8 14 EBU27670 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front brake lever If there is free play have a Yamaha dealer check the brake system Check for correct free play in the rear brake lever and brake pedal If the free play is incorrect ad just it See page 8 28 Check operation of the levers and...

Page 38: ...cedures provided in this manual have a Yamaha dealer check for the cause EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19811 Tires WARNING EWB00591 Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pres sure may cause loss o...

Page 39: ... 3 2 psi 0 220 kgf cm Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm Rear 250 kPa 36 psi 2 5 kgf cm Higher pressures and fast inflation may cause a tire to burst Inflate the tires very slowly and carefully EBU19820 Measuring the tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is inclu...

Page 40: ...prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm ...

Page 41: ...h could lead to an acci dent or collision CAUTION ECB00150 See the Engine break in section on page 6 4 prior to operating the engine for the first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to 4 Shift the drive select lever into the neutral po sition The neutral indicator light should come on If the indicator light does not come ...

Page 42: ...nking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt 7 If the engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine CAUTION ECB001...

Page 43: ...lever and driving in reverse CAUTION ECB00170 Before shifting stop the ATV otherwise the transmission may be damaged Shifting Forward 1 Bring the ATV to a complete stop 2 Shift from neutral to forward and vice versa by moving the drive select lever along the shift guide NOTE Make sure that the drive select lever is completely shifted into position 3 Open the throttle lever gradually Shifting Rever...

Page 44: ...o reverse make sure there are no people or ob stacles behind you When it is safe to proceed go slowly EBU20682 Engine break in NOTE For ATVs equipped with an odometer or an hour meter follow the figures given in km mi or the figures given in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine...

Page 45: ...a Yamaha dealer check the ATV EBU20700 Parking When parking the ATV stop the engine shift the drive select lever into the forward position apply the parking brake and then turn the fuel cock to OFF EBU20760 Parking on a slope WARNING EWB00830 Avoid parking on hills or other inclines Park ing on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident ...

Page 46: ... design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering diffic...

Page 47: ...you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING EWB00820 Never exceed the stated load capacity for ...

Page 48: ...7 1 7 EBU21141 RIDING YOUR ATV U3D562E0 book Page 1 Wednesday June 6 2007 12 58 PM ...

Page 49: ...on and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics WARNING...

Page 50: ...child This ATV is designed to carry operator and car go only passengers prohibited WARNING EWB01400 Never carry a passenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or you...

Page 51: ...e helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet U3D562E0 book Page 4 Wednesday June 6 2007 12 58 PM ...

Page 52: ...hances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s performance capability is reduced by the influence of alcohol or drugs WARNING EWB01420 Never consume alcohol or drugs before or while driving this ATV Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding for proper care of the ATV and to ensur...

Page 53: ...RNING EWB01450 Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at speeds too fast for your skills or the conditions in creases your chances of losing control of the ATV which can result in an accident Speed limiter For riders less experienced with this model the throttle lever housing is equipped with a speed lim iter ...

Page 54: ...should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards during op eration otherwise they may contact the rear wheels WARNING EWB01470 Always keep both hands on...

Page 55: ... be gen uine Yamaha or equivalent components de signed for use on this ATV and should be installed and used according to instructions Improper installation of accessories or modifi cation of this ATV may cause changes in han dling which in some situations could lead to an accident If you have questions consult an au thorized ATV dealer Exhaust system The exhaust system on the ATV is very hot durin...

Page 56: ...E This ATV is designed for use on unpaved surfaces only Riding on paved surfaces can cause loss of control WARNING EWB01510 Always avoid paved surfaces including side walks driveways parking lots and streets ATVs are designed for use on unpaved surfac es only Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control U3D562E0 book Page 9 Wednesda...

Page 57: ...ever operate this ATV on any paved street paved road or motorway You can collide with another vehicle In many areas it is illegal to operate ATVs on public streets roads and highways Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards which may cause the ATV to upset WARNING EWB01530 Go slowly and be extra ...

Page 58: ...accident including an overturn When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING EWB01550 Always mount a caution flag on the ATV to make you more visible when operating in areas where you might not be seen by other vehicles Watch carefully for other vehicles Do not ride in are...

Page 59: ...n release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds un til you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the throt tle and...

Page 60: ...This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly This procedure should be practiced at slow speed many times in a large unpaved area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slipper...

Page 61: ...kill In all cases avoid inclines with slip pery or loose surfaces or obstacles that might cause you to lose control WARNING EWB01580 Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Practice on small er hills before attempting large hills It is important when climbing a hill to...

Page 62: ...oom to do so and go down the hill WARNING EWB01600 Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hi...

Page 63: ...ad ap ply the front brake gradually or dismount the ATV immediately on the uphill side WARNING EWB01741 Maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Apply 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 stopp...

Page 64: ... hill Avoid sharp angles 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 EWB01620 Always follow proper procedures for going down hills as described in this Owner s Manu al Note a special technique is required when braking as you go down a hill Always check the terrain carefully before ...

Page 65: ... 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 EWB01631 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...

Page 66: ...and care fully WARNING EWB01640 Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the lin ings If the ATV is operated through deep or fast flowing water the tires may float causing loss...

Page 67: ...by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hose and the storage compartment drain plugs Also remove the V belt case drain plug to drain any water that may have accumu lated Wash the ATV in fresh water if it has been operated in salt water or muddy conditions 1 Air filter case check hose U3D562E0 book Page 20 W...

Page 68: ... 7 1 V belt cooling duct check hose left front side of ATV 1 Drive select lever box check hose 1 Storage compartment drain plug 1 V belt case drain plug U3D562E0 book Page 21 Wednesday June 6 2007 12 58 PM ...

Page 69: ...obstacles always follow proper procedures as described in the Owner s Manu al SLIDING AND SKIDDING Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes hel...

Page 70: ... section is designed to be a reference guide only Be sure to read each section on riding tech niques completely WHAT TO DO If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See page 7 12 If your ATV...

Page 71: ...oned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 14 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter drain...

Page 72: ...IDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with maintenan...

Page 73: ...nce required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for use on this ATV and should be install...

Page 74: ...re special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust i...

Page 75: ...ss 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 U3D562E0 book Page 4 Wednesday June 6 2007 12 58 PM ...

Page 76: ... pads Whenever worn to the limit 3 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 4 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years 5 Wheels Check runout and for damage and replace if nec essary 6 Tires Check tread depth and for damage and re...

Page 77: ...t if necessary 14 Engine mount Check for cracks or other damage and replace if necessary 15 Axle boots Check for cracks or other damage and replace if necessary 16 Engine oil Change Check ATV for oil leakage and correct if neces sary 17 Engine oil filter car tridge Replace 18 Engine oil strainer Clean 19 Final gear oil Change Check ATV for oil leakage and correct if neces sary 20 Moving parts and ...

Page 78: ...stem cable Check operation and adjust or replace if neces sary 22 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 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...

Page 79: ...move the bolt and then take the panel off To install the panel Place the panel in the original position and install the bolt CAUTION ECB00380 When installing the panel be sure not to pinch the cables or wires EBU23211 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark 1 Panel A 1...

Page 80: ...k plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally NOTE If the spark plug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 2 Check the spark plug for electrode erosio...

Page 81: ...is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap EBU23313 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the intervals spec ified in the periodic maintenance and lubrication cha...

Page 82: ...the dipstick into the filler hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level 6 Insert the dipstick into the oil filler hole and then tighten the engine oil filler ...

Page 83: ...an 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 NOTE Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil drain bolt 1 Oil filter cartridge 1 Oil filter wrench U3D562E0 book Page 12 Wednesday June 6 2007 1...

Page 84: ... and then tighten it to the specified torque with a torque wrench 8 Install the engine oil drain bolt and then tight en it to the specified torque 9 Add the specified amount of the recommend ed engine oil and then install and tighten the engine oil filler cap 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 23 Nm 2 3 ...

Page 85: ...t least ten minutes and then check the oil level and correct it if necessary EBU23381 Final gear oil The final gear case must be checked for oil leak age before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In ad dition the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication cha...

Page 86: ... Remove the final gear 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 Final gear oil filler bolt 3 Correct oil level Tightening torque Final gear oil filler bolt 23 Nm 2 3 m...

Page 87: ... no foreign material enters the final gear case 7 Install the oil filler bolt and then tighten it to the specified torque 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 Final gear oil filler bolt 3 Correct oil level Recommended final gear oil See page 10 1 U3D562E0 book Page 16 Wednesday June 6 2007 12 58 PM ...

Page 88: ...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 11 2 Remove the air filter case cover by unhooking the holders Tightening torque Final gear oil filler bolt 23 Nm 2 3 ...

Page 89: ... the air filter case 4 Pull off the lock plate and then remove the sponge material from the air filter element frame 1 Air filter case cover holder 2 Air filter case cover 1 Air filter element U3D562E0 book Page 18 Wednesday June 6 2007 12 58 PM ...

Page 90: ...ut of the sponge material and let it dry CAUTION ECB00440 Do not twist the sponge material when squeez ing it 7 Check the sponge material and replace it if damaged 8 Apply a quality foam air filter oil to the sponge material NOTE The sponge material should be wet but not drip ping 9 Pull the sponge material over the air filter ele ment frame and then install the lock plate 1 Air filter element fra...

Page 91: ...t tings securely to avoid the possibility of unfiltered air entering the engine CAUTION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the air filter element w...

Page 92: ...t the engine when cleaning the spark arrester otherwise it could cause injury to the eyes burns carbon monoxide poison ing possibly leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components EBU23920 V belt cooling duct check hose If dust or water collects in the V belt cooling duct check hose remove the hose and clean it 1 Tailpipe 2 Spark arrester T...

Page 93: ...ated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment described in the following section however may be performed by the owner as part of routine main tenance CAUTION ECB00480 The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficien...

Page 94: ...d 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 1450 1550 r min U...

Page 95: ... adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle cable free play turn the adjusting bolt in direction b 3 Tighten the locknut EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring th...

Page 96: ...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 page 8 40 EBU24180 Rear brake shoes The rear brake is provided with a wear indicator which allows you to check the brake shoe wear witho...

Page 97: ...eck 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 braking performance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical r...

Page 98: ...brication 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 damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EBU24390 Checking the front brake lever free play The brake lever free play must be checked at the intervals specified in the periodi...

Page 99: ...dic maintenance and lu brication chart NOTE Always perform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting the brake lever and brake pedal free play check the rear brake shoes for wear Adjusting the brake 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 follow...

Page 100: ...rake lever and fully turn in the brake lever free play adjusting bolt 2 Turn the brake lever free play adjusting nut on the brake cable at the rear wheel hub so that gap A measures 0 1 mm 0 0 04 in 1 Brake pedal free play adjusting nut 2 Brake lever free play adjusting nut 1 Brake lever free play 2 Locknut 3 Brake lever free play adjusting bolt U3D562E0 book Page 29 Wednesday June 6 2007 12 58 PM ...

Page 101: ...lay Be sure not to step on the brake pedal Make sure the brake pedal does not move Checking the brake pedal position The top of the brake pedal should be positioned 72 0 82 0 mm 2 83 3 23 in above the footboard bracket If the brake pedal position is incorrect have a Yamaha dealer adjust it 1 Brake lever free play adjusting nut 2 Gap A 1 Locknut 2 Brake lever free play adjusting bolt U3D562E0 book ...

Page 102: ... lubrication chart Check the axle boots for tears or damage If any damage is found have them re placed by a Yamaha dealer EBU24751 Brake light switches The operation of the brake light switches must be checked and if necessary adjusted at the inter vals specified in the periodic maintenance and lu brication chart The brake light switch for the brake pedal can be adjusted as follows but the other b...

Page 103: ...maged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWB02130 Inspect cables frequently and replace if dam aged Corrosion can result when the cable sheaths become damaged and cables can also become frayed or kinked which could re strict the operation of controls and lead to an accident or injury EBU28710 Checking and lubricating the front and rear brake levers The opera...

Page 104: ...page 8 8 EBU24962 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play Recommended lubricants Front brake lever Silicone grease Rear brake lever Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease all purpose grease U3D562E0 book Pa...

Page 105: ...sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explos...

Page 106: ...compartment 2 Make sure to properly connect the battery leads to the battery terminals CAUTION ECB00630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a spe cial constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a constant voltage...

Page 107: ...lows 1 Turn the key to OFF and turn off all electrical circuits CAUTION ECB00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 1 Main fuse 2 Spare main fuse 3 Fuse box 1 Headlight fuse 2 Ignition fuse 3 Signaling system fuse 4 Spare fuse U3D562E0 book Page 36 Wednesday June 6 2007 12 58 PM ...

Page 108: ...s to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25541 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the headlight bulb holder cover at the rear of the headlight by pulling it off 2 Remove the headlight bulb holder by pushing it inward and turning it counterclockwise Specified fuses...

Page 109: ...in the headlight unit CAUTION ECB00650 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affect ed Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth moistened with alcohol or thinner 5 Install the headlight bulb holder by aligning the pro...

Page 110: ... a headlight beam CAUTION ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the adjusting bolt in direction a To lower a headlight beam turn the adjusting bolt in direction b EBU25600 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the lens by removing the screws 1 Headlight beam adjusting ...

Page 111: ... stops 4 Install the lens by installing the screws CAUTION ECB00700 Do not overtighten the screws otherwise the lens may break EBU25650 Removing a wheel 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 1 Screw 1 Tail brake light bulb 1 Wheel nut U3D562E0 book Page 40 Wednesday June 6 2007 12 58 PM ...

Page 112: ...pered nuts are used for both the front and rear wheels Install the nuts with their tapered side to wards the wheel 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U3D562E0 book Page 41 Wednesday June 6 2007 12 58 PM ...

Page 113: ...ny repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or...

Page 114: ... and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the battery lead...

Page 115: ...rioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places ...

Page 116: ...d areas where strong chemicals are stored Long term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabiliz...

Page 117: ...if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it on...

Page 118: ...ne type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 348 0 cm Bore stroke 83 0 64 5 mm 3 27 2 54 in Compression ratio 9 20 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Recommended engine oil grade API service SG type or higher JASO standard MA 20 10 0...

Page 119: ...L 1 19 US gal 0 99 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BSR33 x 1 Spark plug s Manufacturer model NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Shaft drive Secondary reduction ratio 41 21 24 18 33 9 9 545 Transmission type V belt automatic Operation Left hand ...

Page 120: ...i 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm Front wheel Wheel type Panel wheel Rim size 12 x 6 0AT Rear wheel Wheel type Panel wheel Rim size 12 x 7 5AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Drum brake Operation Left hand and right foot operation Fr...

Page 121: ...tage capacity 12 V 12 0 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage x quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Oil temperature warning light 12 V 1 7 W 1 Fuses Main fuse 20 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A U3D562E0 book Page 4 Wednesday J...

Page 122: ...erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key ide...

Page 123: ...he model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number 1 Model label U3D562E0 book Page 2 Wednesday June 6 2007 12 58 PM ...

Page 124: ...32 Carburetor adjusting 8 22 Chassis fasteners 5 6 Cleaning 9 1 D Drive select lever 4 7 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 25 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 22 Engine oil 5 3 Engine oil and oil filter cartridge 8 10 Engine starting a warm 6 3 Engine stop switch 4 3 F Final gear oil 5 3 8 14 Fuel 4 8 5...

Page 125: ... absorber assembly adjusting the rear 4 14 Spark arrester cleaning 8 20 Spark plug checking 8 8 Specifications 10 1 Speed limiter 4 4 Starter choke 4 10 Start switch 4 3 Steering shaft lubricating 8 34 Storage 9 2 Storage compartment 4 12 T Tail brake light bulb replacing 8 39 Throttle cable free play adjusting 8 24 Throttle lever 4 4 5 4 Tire pressure measuring 5 5 Tires 5 4 Tire wear limit 5 6 T...

Page 126: ...YAMAHA MOTOR CO LTD PRINTED IN USA 2007 07 0 3 1 CR E U3D562E0 book Page 1 Wednesday June 6 2007 12 58 PM ...

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