Yamaha YFM250 Owner'S Manual Download | Manualshive

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exposed to the noise. Also the permissible expo-
sure level can vary from country. This information,
however, will enable the user of the machine to
make a better evaluation of the hazard and risk.

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Summary of Contents for YFM250

Page 1: ...L PROPIETARIO 1BT 28199 63 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad DIC183 ...

Page 2: ...PRINTED IN JAPAN 2012 03 0 3 1 CR E F S DIC183 PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO ...

Page 3: ...CAREFULLY It contains important safety information WARNING OWNER S MANUAL YFM25RD YFM250RD This ATV should not be ridden by anyone under 16 years of age 1BT 28199 63 E0 U1BT63E0 book Page 1 Friday March 9 2012 11 22 AM ...

Page 4: ... or number and date of issue of the other Directives of EEC If applicable YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Eiji Kato Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Direc...

Page 5: ...important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manual completely before operating your ATV Make sure you understand all ins...

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

Page 7: ... or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM25RD YFM250RD OWNER S MANUAL 2012 by Yamaha Motor Co Ltd 1st edition February 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1BT63E0 book Page 1 Friday March 9 2012 11 22 AM ...

Page 8: ...l 4 5 Parking brake lever 4 6 Shift pedal 4 7 Fuel tank cap 4 7 Fuel 4 8 Fuel cock 4 9 Starter choke 4 11 Seat 4 11 Adjusting the front shock absorber assemblies 4 12 Adjusting the rear shock absorber assembly 4 13 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Front and rear brakes 5 3 Throttle lever 5 3 Drive chain 5 4 Tires 5 4 Chassis fasteners 5 6 Instruments lights and switches 5 6 OPERATI...

Page 9: ...r element 8 14 Cleaning the spark arrester 8 18 Adjusting the carburetor 8 20 Adjusting the engine idling speed 8 20 Adjusting the throttle lever free play 8 21 Valve clearance 8 22 Brakes 8 22 Checking the front and rear brake pads 8 22 Checking the brake fluid level 8 23 Changing the brake fluid 8 25 Checking the front brake lever free play 8 25 Checking the brake pedal height 8 25 Adjusting the...

Page 10: ...b 8 39 Adjusting a headlight beam 8 41 Replacing the tail brake light bulb 8 41 Removing a wheel 8 41 Installing a wheel 8 42 Troubleshooting 8 43 Troubleshooting chart 8 44 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 U1BT63E0 book Page 3 Friday March 9 2012 11 22 AM ...

Page 11: ...abels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer For Europe 6 7 5 1 2 4 3 U1BT63E0 book Page 1 Friday March 9 2012 11 22 AM ...

Page 12: ...1 2 1 43P 2816P 00 43P 2816R 01 1PD 2811R 00 1 2 3 U1BT63E0 book Page 2 Friday March 9 2012 11 22 AM ...

Page 13: ...5 kPa 0 275 kgf cm 4 0 psi 27 5 kPa 0 275 kgf cm 4 0 psi 4D3 2156A 10 YFM250R 14 0 kW 150 kg 4AA 22259 40 8AC 2817L 00 YAMAHAMOTORCO LTD 2500SHINGAI IWATA JAPAN 2012 4 5 6 7 U1BT63E0 book Page 3 Friday March 9 2012 11 22 AM ...

Page 14: ... from 12 years old Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 16 Use from 16 years old Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER use on paved roads NEVER carry passengers NEVER use with drugs or alcohol NEVER store fuel or flammable...

Page 15: ...loss of control Adjust the tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all other load rel...

Page 16: ...1 6 1 kW kg 1 2 3 YAMAHAMOTORCO LTD 2500SHINGAI IWATA JAPAN 1 1 2 3 Model Name Max Power Mass In Running Order 1 Year of construction U1BT63E0 book Page 6 Friday March 9 2012 11 22 AM ...

Page 17: ...1 7 1 For Oceania 5 1 2 4 3 U1BT63E0 book Page 7 Friday March 9 2012 11 22 AM ...

Page 18: ...roper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns avoid paved surfaces pavement may seriously affect handling and...

Page 19: ...It could cause the tire to dislodge from the rim LOADING Maximum weight capacity 100 kg 220 lbs Includes weight of operator cargo and accessories Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death 4 0 psi 4 0 psi 3 6 psi 3 6 psi 4D3 2816M 00 4AA 22259 40 4 5 U1BT63E0 book Page 9 Friday March 9 2012 11 22 AM ...

Page 20: ...16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV This vehicle is intended for off road use only Do not operate on any paved surfaces such as sidewa...

Page 21: ...ver operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly or make sud...

Page 22: ...ng or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type of tires specified in this manual Always maintain proper tire pressure a...

Page 23: ...and ride gently back to camp or other known location where you can receive medical atten tion If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If your vehicle will not restart or is not in safe operating condition turn off the main switch and engine stop switch If the breakdown oc curs at twilight or nigh...

Page 24: ...nd others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guide lines in mind as well as those provided under Loading when mounting accessories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground ...

Page 25: ... areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do no...

Page 26: ...w 6 Rear shock absorber assembly spring preload adjusting nut 7 Owner s tool kit 8 Engine oil drain bolt 9 Shift pedal 3 4 5 6 7 2 1 9 8 1 Spark arrester 2 Fuse 3 Battery 4 Air filter case 5 Rear brake fluid reservoir 6 Fuel tank cap 7 Oil filter element 8 Engine oil filler cap 9 Brake pedal 10 Rear brake light switch 8 1 4 6 5 2 3 7 9 10 U1BT63E0 book Page 1 Friday March 9 2012 11 22 AM ...

Page 27: ...urchased may differ slightly from the figures shown in this manual 1 Clutch lever 2 Handlebar switches 3 Parking brake lever 4 Main switch 5 Front brake fluid reservoir 6 Throttle lever 7 Brake lever 1 2 3 4 6 7 5 U1BT63E0 book Page 2 Friday March 9 2012 11 22 AM ...

Page 28: ...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 OFF ON 1 U1BT63E0 book Page 1 Friday March 9 2012 11 22 AM ...

Page 29: ...itch Set this switch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to 1 Neutral indicator light N 1 1 Light switch OFF 2 Engine stop switch 3 Start switch 1 2 3 U1BT63E0 book Page 2 Friday March 9 2012 11 22 AM ...

Page 30: ... discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 35 EBU18282 Throttle lever Once the engine is running pushing the throttle le ver will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will r...

Page 31: ...adjusted to 2 0 4 0 mm 0 08 0 16 in See page 8 21 WARNING Improper ad justment of the speed limiter and throttle could cause throttle cable damage or im proper throttle operation You could lose control resulting in an accident EWB00241 3 Tighten the locknut EBU18382 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut off system is incorporat ed in the clutch...

Page 32: ... To apply the front brake pull the brake lever toward the handlebar grip EBU18432 Brake pedal The brake pedal is located on the right side of the ATV To apply the rear brake push down on the brake pedal 1 Clutch lever 1 Brake lever 1 U1BT63E0 book Page 5 Friday March 9 2012 11 22 AM ...

Page 33: ...pecially on a slope To apply the parking brake move the parking brake lever in direction a To release the parking brake move the parking brake lever in direction b 1 Brake pedal 1 1 Parking brake lever locked position 1 Parking brake lever unlocked position U1BT63E0 book Page 6 Friday March 9 2012 11 22 AM ...

Page 34: ...you ride the ATV without re leasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely EBU18530 Shift pedal This ATV is equipped with a constant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in combina tion with the clutch when shifting EBU18720 Fuel tank cap Remove the ...

Page 35: ...e smoking or while in the vicinity of sparks open flames or other sources of ig nition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reach es the bottom of the filler tube Because fuel expands when it heats up heat from the en gine or the sun can...

Page 36: ...eaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of 91 or higher 95 or higher for Europe If knocking or pinging occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce ...

Page 37: ...sition when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark positioned over OFF OFF 1 1 Arrow mark positioned over ON ON 1 U1BT63E0 book Page 10 Friday March 9 2012 11 22 AM ...

Page 38: ...a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke Move the starter choke in direction b to turn off the starter choke See the Starting a cold engine section on page 6 1 for proper operation EBU26731 Seat To remove the seat Insert your hand between the rear of the seat and the rear fender pull the seat lock lever and...

Page 39: ...bsorber as semblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions WARNING EWB00400 Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac cident 1 Seat lock lever 1 1 Projection 2 Seat holder 1 2 U1BT63E0 book Page 12 Friday March ...

Page 40: ...sorber as sembly The spring preload can be adjusted to suit the rid er s weight and the riding conditions NOTICE ECB01090 Never turn the adjusting mechanism beyond the minimum and maximum settings Adjust the spring preload as follows 1 Loosen the locknut 2 Turn the spring preload adjusting nut in direc tion a to increase the spring preload and thereby harden the suspension and in direc tion b to d...

Page 41: ...st the adjusting nut and then tighten it to the specified torque ECB00081 WARNING EWB00450 This shock absorber assembly contains highly pressurized nitrogen gas If the shock absorb er assembly is damaged it could explode causing injury or property damage Shock ab sorber cylinder damage could also result in poor handling which could cause an accident 1 Locknut 2 Spring preload adjusting nut 3 Dista...

Page 42: ...absorber assembly to an open flame or other high heat Do not deform or damage the cylinder in any way Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly to a Yamaha deal er for any service U1BT63E0 book Page 15 Friday March 9 2012 11 22 AM ...

Page 43: ... a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 8 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 11 Front brake Check operation If ...

Page 44: ...peration is smooth Lubricate if necessary 8 31 Drive chain Check chain slack and adjust if necessary Check chain condition Lubricate if necessary 5 4 8 29 8 31 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Shift pedal Make sure that operation is smooth Correct if necessary 8 33 Bra...

Page 45: ...ed If not have a Yamaha dealer check the brake system Brake fluid level Check the brake fluid level Add fluid if necessary See page 8 23 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If there is any leak age have a Yamaha dealer check the brake sys tem Brake operation Test the brakes at slow sp...

Page 46: ... of control or rollover Tire pressure below the minimum specified could also cause the tire to dislodge from the rim un der severe riding conditions EWB02541 Set tire pressures to the following specifications The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to...

Page 47: ... tubeless tires with valves WARNING EWB02551 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd 1 Low pressure tire gauge 1 Tire wear limit U1BT63E0 book Page 5 Friday March 9 2012 11 22 AM ...

Page 48: ...ns may not be appropriate EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary Front Manufacturer model DURO DI K102 Size AT20 x 7 10 Type Tubeless Rear Manufacturer model DURO DI K502A Size AT19 x 10 9 Type Tubeless U1BT63E0 book ...

Page 49: ...to 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator light does not come on have a Yamaha deal er check the electrical circuit TIP This model is equipped with an ignition circuit cut off system The engine can be started under the following conditions The transmission is in neutral The clutch is disengaged with the transmission in gear However it is r...

Page 50: ...ted 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 idles smoothly then return the starter choke to position 3 before riding TIP The engine is warm when it responds quickly to the throttle with the starter choke turned off NOTICE ECB00163 For maximum engine life never accelerate hard when the engine is col...

Page 51: ...e clutch 3 Shift into first gear and then release the brake NOTICE Always close the throttle before shifting gears otherwise damage to the engine and drive train may result ECB00201 4 Open the throttle gradually and at the same time release the clutch lever slowly WARNING Opening the throttle abruptly or releasing the clutch lever too quickly could make the ATV wheelie which would increase the cha...

Page 52: ...t coast for long periods of time with the engine off and do not tow the ATV for long distances The transmission is prop erly lubricated only when the engine is run ning Inadequate lubrication may damage the transmission Always use the clutch when changing gears The engine transmission and drive train are not designed to withstand the shock of forced shifting and can be damaged by shift ing without...

Page 53: ...y time 320 km 200 mi or 20 hours and beyond The ATV can now be operated normally NOTICE ECB00220 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the ATV EBU20722 Parking When parking the ATV shift into first gear stop the engine apply the parking brake and then turn the fuel cock to OFF EBU20865 Parking on a slope WARNING EWB00851 Avoid p...

Page 54: ...aler have been designed tested and approved by Yamaha for use on your ATV Many companies with no con nection to Yamaha manufacture parts and acces sories or offer other modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket companies pro duce Therefore Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modificati...

Page 55: ...its your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU20941 Loading WARNING EWB00820 Never exceed the stated load capacity for this ATV Overloading this ATV or carrying or tow ing cargo improperly could cause changes in ATV handling which could lead to an accident Cargo should be properly distributed and se curely at...

Page 56: ...ke sure the load does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail er Allow more braking distance A heavier ATV takes longer to stop Avoid makin...

Page 57: ...7 1 7 EBU21141 RIDING YOUR ATV U1BT63E0 book Page 1 Friday March 9 2012 11 22 AM ...

Page 58: ...nual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 6 Also read all warning and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01381 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increase...

Page 59: ...EWB01390 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WARNING ...

Page 60: ...G Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating wi...

Page 61: ...ach time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual WARNING Failure to inspect the ATV before operating it and to maintain it prop erly increases the possibility of an accident or equipment damage EWB01431 Speed limiter For r...

Page 62: ...r control or ability to see where you are going Reduce speed and allow more room to stop A heavier vehicle takes longer to stop Avoid hills and rough terrain Choose terrain carefully Use extreme caution when towing or carrying a load on inclines Turn gradually and go slowly As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add ac cessories to carry ca...

Page 63: ...ccident EWB02660 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off EWB01481 Modifications and accessories Never modify this ATV through improper installa tion or use of accessories or other modification All parts and accessories added to this ...

Page 64: ...uch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine parts become ex tremely hot during operation and remain hot after the engine has stopped To reduce the risk of fire during operation or after leaving the ATV do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to o...

Page 65: ...on with other vehicles Watch carefully for other vehicles Make sure you know your country s laws and regulations before you ride on unpaved public streets or roads Do not ride on any paved public street road or motorway WARNING Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle EWB01521 Know the terrain where you ride Ride cautiously in unfamilia...

Page 66: ...ING Failure to use extra care when op erating on excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn EWB01541 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 You could collide with an...

Page 67: ... not to accidentally move the shift pedal With the engine idling pull the clutch lever to disengage the clutch and shift into 1st gear and then release the parking brake Open the throttle gradually and at the same time re lease the clutch lever slowly Once the ATV has at tained adequate speed release the throttle lever and at the same time quickly pull in the clutch le ver and shift into 2nd gear ...

Page 68: ...ning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions ATV could go out of control causing a collision or overturn To achieve maximum traction on unpaved surfac es the two rear wheels turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resis...

Page 69: ...o tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL WARNING EWB01591 Climbing hills improperly can cause overturns or loss of control Use proper ...

Page 70: ...ld be on the other side of the hill 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 pos sible When crossing the side of a hill shift your weight to the uphill side of the ATV U1BT63E0 book Page 14 Friday March 9 2012 ...

Page 71: ...ver possible ride straight up hills Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side there could be another person an obstacle or a sharp drop off Use common sense and remember that some hills are too steep for you to climb or de scend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you s...

Page 72: ...ng the procedure described in the Owner s Manual WARNING Stalling rolling backwards or improperly dismounting while climbing a hill could result in ATV overturning If you cannot control the ATV dismount immediately on the uphill side EWB01802 RIDING DOWNHILL WARNING EWB01131 Going down a hill improperly could cause overturns or loss of control Always follow proper procedures for going down hills a...

Page 73: ...ill When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Choose a low gear which will allow the en gine compression to do most of the braking for you Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces I...

Page 74: ...requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loos...

Page 75: ...oving shal low water of up to a maximum of 35 cm 14 in in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and care fully Test your brakes after leaving the water If neces sary apply them several times to let friction dry out the linings Do not continue to ride yo...

Page 76: ...01651 Riding improperly over obstacles could cause loss of control or a collision Before operating in a new area check for obstacles Never at tempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with cau tion Look out for obstacles which could cau...

Page 77: ...slowly and be very cautious in order to re duce the chance of skidding or sliding out of control 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 help ...

Page 78: ...f the turn Position your weight over the front wheels for better control See page 7 12 If your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off the throttle and or steer to the outside of the turn See page 7 12 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is...

Page 79: ... you discover that the ATV is going to tip over dismount on the uphill side See page 7 18 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability S...

Page 80: ...rn off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 6 for more information about carbon monoxide WARNING EWB02690 B...

Page 81: ...l and the tools provided in the owner s tool kit are in tended to assist you in the performance of preven tive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Low pressure tire gauge 2 Ow...

Page 82: ...ire special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust ...

Page 83: ...ess 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 U1BT63E0 book Page 4 Friday March 9 2012 11 22 AM ...

Page 84: ...s 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 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Clutch Check operation and adjust if necessary 3 Front brake Check operation and correct if necessary Check fluid level and ATV f...

Page 85: ...ary 10 Swingarm pivots Check operation and for excessive play and re place bearings if necessary Lubricate with lithium soap based grease 11 Upper and lower arm pivots Lubricate with lithium soap based grease 12 Drive chain Check chain slack and adjust if necessary Check rear wheel alignment and correct if neces sary Clean and lubricate 13 Drive chain roller Check for wear and replace if necessary...

Page 86: ...il leakage and correct if neces sary 19 Engine oil filter ele ment Replace 20 Moving parts and cables Lubricate 21 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 22 Front and rear brake switches Check operation and correct if necessary 23 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ...

Page 87: ...t full throttle Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U1BT63E0 book Page 8 Friday March 9 2012 11 22 AM ...

Page 88: ...k plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally TIP If the spark plug shows a distinctly different color the engine could be operating impr...

Page 89: ... plug threads 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque TIP If a torque wrench is not available when installing the spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 3 Install the spark plug cap Specified spark plug NGK DR7EA ...

Page 90: ...tes until the oil set tles for an accurate reading 3 Remove the engine oil filler cap and then wipe the engine oil dipstick off with a clean rag 4 Insert the dipstick into the filler hole without screwing it in and then remove it again to check the oil level TIP The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark add suffic...

Page 91: ... oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 5 7 if the oil filter element is not being replaced 5 Remove the oil filter element cover by remov ing the bolts and then remove the oil filter el ement and the O rings 1 Engine oil drain bolt 2 Gasket 1 2 ...

Page 92: ...ded engine oil and then install and tight en the engine oil filler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down 1 Oil filter element 2 O ring Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 2 Tightening torque Engine oil drain bolt 20 Nm 2 0 m kgf 14 ft lbf Recommended oil See page 10 1 Oil quantity Without...

Page 93: ... off wait at least ten minutes and then check the oil level and correct it if necessary EBU23707 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean or if necessary replace the air filter element more frequently if you are riding in unusually wet or dusty areas TIP There is a check hose at the ...

Page 94: ...nd washer 6 Remove the wing bolt and washer from the air filter element 7 Remove the sponge material from the air filter element frame 1 Air filter case cover 2 Air filter case cover holder 1 2 1 Air filter element 2 Washer 3 Wing bolt 3 1 2 U1BT63E0 book Page 15 Friday March 9 2012 11 22 AM ...

Page 95: ...material and let it dry NOTICE Do not twist the sponge material when squeezing it ECB00441 10 Check the sponge material and replace it if damaged 11 Apply Yamaha foam air filter oil or other qual ity foam air filter oil to the sponge material TIP The sponge material should be wet but not drip ping 12 Pull the sponge material over the air filter ele ment frame 13 Apply all purpose grease to the air...

Page 96: ...er element is properly seated in the air filter case Never operate the engine with the air filter ele ment removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addi tionally operation without the air filter ele ment will affect carburetor jetting with subsequent poor performance and possi ble engine overheating ECB00461 16 Install the air ...

Page 97: ...ittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine EBU28903 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the tailpipe bolts 2 Remove the tailpipe by pulling it out of the muffler and then remove the gasket 3 Tap the tailpipe lightly and then use a wire ...

Page 98: ...ll the bolts and tighten them to the speci fied torque WARNING EWB02340 Do not start the engine when cleaning the spark arrester otherwise it could cause injury to the eyes burns carbon monoxide poison 1 Tailpipe 2 Spark arrester 2 1 1 Gasket 2 Tailpipe 3 Tailpipe bolt Tightening torque Tailpipe bolt 11 Nm 1 1 m kgf 8 0 ft lbf 1 2 3 3 U1BT63E0 book Page 19 Friday March 9 2012 11 22 AM ...

Page 99: ...et and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart TIP A diagnostic tachometer is n...

Page 100: ...08 0 16 in as shown Periodically check the throttle lever free play and if necessary adjust it as follows TIP The engine idling speed must be checked and ad justed if necessary before adjusting the throttle le ver free play 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle lever free play turn the throttle lever free play adjusting bolt in di rection a To decrease the t...

Page 101: ...akes could lead to a loss in braking ability and an accident EBU24130 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EBUM0190 Front brake pads Each brake pad is provided with a wear indicator groove which allows you to check the brake pad wear without having to disassemble t...

Page 102: ...he wear indica tor grooves If a brake pad has worn to the point that a wear indicator groove almost appears have a Yamaha dealer replace the brake pads as a set EBU29841 Checking the brake fluid level Before riding check that the brake fluid is above the minimum level mark Check the brake fluid lev el with the top of the reservoir level Replenish the brake fluid if necessary 1 Wear indicator groov...

Page 103: ... er Use only the specified brake fluid otherwise the rubber seals may deteriorate causing leakage Refill with the same type of brake fluid Add ing a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock 1 Minimum l...

Page 104: ...nce and lubrication chart In addition have the oil seals of the master cylinders and cali pers as well as the brake hoses replaced at the in tervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EBU24394 Checking the front brake lever free play The brake lever free play must be checked at the intervals specified in the p...

Page 105: ... chart Cable length A should measure 64 68 mm 2 52 2 68 in Adjust the parking brake free play as follows 1 Release the parking brake by moving the parking brake lever to the right 2 Fully loosen the locknut and the adjusting bolt at the rear brake caliper 3 Slide the rubber cover back at the brake ca ble 4 Loosen the locknut 5 Turn the parking brake free play adjusting nut in direction a to increa...

Page 106: ...rviced or adjust ed brakes could cause the brakes to malfunc tion resulting in reduced braking performance This could increase the chance of a collision or accident After adjusting the parking brake free play block the rear of the ATV off the ground and spin the rear wheels Check to make sure there is no brake drag If brake drag is noticed perform the adjustment again EBU24743 Brake light switches...

Page 107: ...necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The clutch lever free play should measure 5 0 10 0 mm 0 20 0 39 in as shown If the free play is incorrect adjust it as follows 1 Slide the rubber cover back 2 Loosen the locknut at the clutch lever 3 To increase the clutch lever free play turn the clutch lever free play adjusting bolt in direction a and...

Page 108: ...the drive chain slack there should be no weight on the ATV and all tires must be touching the ground 2 Move the ATV back and forth to locate the tightest portion of the drive chain and then measure the drive chain slack as shown 3 If the drive chain slack is incorrect adjust it as follows To adjust the drive chain slack 1 Place the ATV on a level surface 2 Loosen the rear wheel axle pinch bolts 3 ...

Page 109: ...ther vital parts of the ATV and can lead to drive chain slippage or breakage To pre vent this from occurring keep the drive chain slack within the specified limits ECB00542 6 Pull the rod out and then tighten the rear axle pinch bolts to the specified torque in the order shown 1 Rear wheel axle pinch bolt 2 Rod 3 Drive chain tensioner 4 Hole 2 1 1 3 4 Tightening torque Rear axle pinch bolt 21 Nm 2...

Page 110: ...h NOTICE To prevent dam aging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents ECB00571 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings ECB00581 EBU24...

Page 111: ...thly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an acci dent or collision EBU24922 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lubricated if necessary Brake lever Reco...

Page 112: ...uld be checked before each ride and the pedal pivot should be lubricated if necessary EBU24963 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings Recommended lubricant ...

Page 113: ... and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte nance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun Left side Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease 1 Upper grease nipple 2 Lower grease nipple 2 1 U1BT63E0 book Page 34 Friday March ...

Page 114: ...NG EWB02160 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with wat...

Page 115: ...ttery holding plate by removing the bolts 3 Disconnect the negative battery lead first then the positive battery lead by removing their bolt NOTICE When removing the bat tery the main switch must be off and the negative lead must be disconnected be fore the positive lead ECB01001 4 Pull the battery out of its compartment 1 Battery holding plate 2 Bolt 2 1 1 Negative battery lead black 2 Positive b...

Page 116: ... it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00940 Always keep the battery charged Storing a dis charged battery can cause permanent battery damage To install the battery TIP Be sure the battery is fully charged 1 Place the battery in its compartment 2 Connect the positive ...

Page 117: ...then remove the battery holding plate by removing the bolts If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits NOTICE ECB00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Always use a fuse of the spec ified ra...

Page 118: ...electrical system 5 Install the battery holding plate by installing the bolts and then hook the band to secure the owner s tool kit 6 Install the seat EBU25444 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the headlight unit by removing the bolt and pulling the headlight unit outward as shown 2 Disconnect the headlight coupler 3 Remove the headlight bulb h...

Page 119: ... headlight bulb to keep it free from oil oth erwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the head light bulb using a cloth moistened with al cohol or thinner ECB00651 1 Headlight bulb holder cover 2 Headlight coupler 1 2 1 Headlight bulb holder 1 U1BT63E0 book Page 40 Friday March 9 2...

Page 120: ...is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting bolt in direction a To lower a headlight beam turn the adjusting bolt in direction b EBU25580 Replacing the tail brake light bulb If the tail brake light bulb burns out have a Yamaha dealer replace it EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel n...

Page 121: ... 5 Remove the wheel EBU27481 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP When installing the wheel make sure its arrow mark points toward the rotating direction of the wheel 1 Wheel nut 1 Wheel nut 1 1 1 Arrow mark U1BT63E0 book Page 42 Friday March 9 2012 11 22 AM ...

Page 122: ...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 explode c...

Page 123: ... 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 connectio...

Page 124: ...gs EWB02311 NOTICE Excessive water pressure may cause water seepage and deteriora tion of wheel bearings brakes transmis sion seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applica tions such as those available in coin oper ated car washers ECB00711 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild de...

Page 125: ...f available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparki...

Page 126: ...rom entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery see page 8 35 TIP Make any necessary repairs before storing the ATV U1BT63E0 book Page 3 Friday March 9 2012 11 22 AM ...

Page 127: ...11 EEC YFM25RD 81 0 dB A 3500 r min A weighted sound power level YFM25RD 93 0 dB A 3500 r min Vibration on seat EN1032 ISO5008 YFM25RD Will not exceed 0 5 m s Vibration on handlebar EN1032 ISO5008 YFM25RD Will not exceed 2 5 m s Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder Displacement 249 cm Bore stroke 74 0 58 0 mm 2 91 2 28 in Compression ratio 9 50 1 Startin...

Page 128: ...38 US gal 1 98 Imp gal Fuel reserve amount 1 0 L 0 26 US gal 0 22 Imp gal Carburetor Type quantity BSR29 x 1 Spark plug s Manufacturer model NGK DR7EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet multiple disc Operation Left hand operation Transmission Primary reduction system Spur gear Primary reduction ratio 76 22 3 455 Secondary reduction system Chain drive Secondary reductio...

Page 129: ...02A Loading Maximum loading limit 100 0 kg 220 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 27 5 kPa 0 275 kgf cm 4 0 psi Rear 27 5 kPa 0 275 kgf cm 4 0 psi Minimum Front 24 5 kPa 0 245 kgf cm 3 6 psi Rear 24 5 kPa 0 245 kgf cm 3 6 psi Front wheel Wheel type Panel wheel Rim size 10 x 5 5AT Rear wheel Wheel type Panel wheel Rim siz...

Page 130: ...ltage wattage 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 Fuse Fuse 15 0 A EBU30401 For Europe only The figures quoted are emission levels and are not necessarily safe working levels Whilst there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are...

Page 131: ...oise Also the permissible expo sure level can vary from country This information however will enable the user of the machine to make a better evaluation of the hazard and risk U1BT63E0 book Page 5 Friday March 9 2012 11 22 AM ...

Page 132: ...BER MODEL LABEL INFORMATION EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to identify your ATV EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts fro...

Page 133: ...11 2 11 1 Model label 1 U1BT63E0 book Page 2 Friday March 9 2012 11 22 AM ...

Page 134: ... 6 Cleaning 9 1 Clutch lever 4 4 Clutch lever free play adjusting 8 28 D Drive chain 5 4 Drive chain lubricating 8 31 Drive chain slack 8 29 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 20 Engine oil 5 3 Engine oil and oil filter element 8 11 Engine starting a warm 6 2 Engine stop switch 4 2 F Fuel 4 8 5 3 Fuel cock 4 9 Fuel tank cap 4 7 Fuse replacing 8 38 H Handlebar switche...

Page 135: ...13 Spark arrester cleaning 8 18 Spark plug checking 8 9 Specifications 10 1 Speed limiter 4 4 Starter choke 4 11 Start switch 4 3 Steering shaft lubricating 8 35 Storage 9 2 Suspension lubricating the upper and lower arm pivots 8 34 Swingarm pivots lubricating 8 34 T Tail brake light bulb replacing 8 41 Throttle lever 4 3 5 3 Throttle lever free play adjusting 8 21 Tires 5 4 Troubleshooting 8 43 T...

Page 136: ...ET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS PRIN...

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