Yamaha YFM250RZ Owner'S Manual Download | Manualshive

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EBU17170

INTRODUCTION

EBU17322

Congratulations on your purchase of the Yamaha YFM25RZ/YFM250RZ. This ATV represents the result of
many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing ma-
chines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and
reliability that have made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this ATV.

This manual includes 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 instructions.

●

Pay close attention to the warning and notice labels on the ATV.

●

This ATV should not be ridden by anyone under 16 years of age.

●

This ATV is a high-performance ATV for off-road use only, for sport-type recreational and competitive use
by experienced operators.

U1BT60E0.book Page 1 Wednesday, April 15, 2009 1:13 PM

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Summary of Contents for YFM250RZ

Page 1: ...L PROPIETARIO 1BT 28199 60 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 2009 04 0 3 1 CR E F S PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO YAMAHA MOTOR CO LTD DIC183 ...

Page 3: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL YFM25RZ YFM250RZ 1BT 28199 60 E0 U1BT60E0 book Page 1 Wednesday April 15 2009 1 13 PM ...

Page 4: ...ectives of EEC If applicable YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Shinya Shimada Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 98 37 EC 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following stan...

Page 5: ...portant 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 instr...

Page 6: ...afety 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 inform...

Page 7: ... or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM25RZ YFM250RZ OWNER S MANUAL 2009 by Yamaha Motor Co Ltd 1st edition April 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1BT60E0 book Page 1 Wednesday April 15 2009 1 13 PM ...

Page 8: ...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 OPERATION...

Page 9: ...element 8 13 Cleaning the spark arrester 8 17 Adjusting the carburetor 8 19 Adjusting the engine idling speed 8 20 Adjusting the throttle cable free play 8 21 Valve clearance 8 21 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 position 8 25 Adjusting the...

Page 10: ... 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 U1BT60E0 book Page 3 Wednesday April 15 2009 1 13 PM ...

Page 11: ...els 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 2 1 4 3 7 5 8 6 U1BT60E0 book Page 1 Wednesday April 15 2009 1 13 PM ...

Page 12: ...1 2 1 4D3 2816L 20 43P 2816R 00 43P 2816P 00 1 2 3 U1BT60E0 book Page 2 Wednesday April 15 2009 1 13 PM ...

Page 13: ...f cm 4 0 psi 4D3 2816M M0 MODEL YFM250R MAX POWER 14 0 kW MASS IN RUNNING ORDER 150 kg 4D3 2156A 00 5PG 2817L 10 YEAROFCONSTRUCTION 2009 YAMAHAMOTORCO LTD 2500SHINGAI IWATA JAPAN 4AA 22259 40 4 6 7 8 5 U1BT60E0 book Page 3 Wednesday April 15 2009 1 13 PM ...

Page 14: ...hildren under age 10 to operate this ATV Operation of this ATV by children under the age of 10 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 12 to operate this ATV 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 ...

Page 15: ...h Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control 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 ot...

Page 16: ... Overloading can cause loss of control Loss of control can result in severe injury or death This pictogram shows trailer Hitch Tongue weight limit Weight on the trailer tongue Overloading can cause loss of control Loss of control can result in severe injury or death U1BT60E0 book Page 6 Wednesday April 15 2009 1 13 PM ...

Page 17: ...1 7 1 For Oceania 2 1 4 3 5 U1BT60E0 book Page 7 Wednesday April 15 2009 1 13 PM ...

Page 18: ...oper 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: ...ow minimum 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 4 5 U1BT60E0 book Page 9 Wednesday April 15 2009 1 13 PM ...

Page 20: ...ild 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 la...

Page 21: ...described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terra...

Page 22: ...topping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribed in this manual Never modify an ATV through improper installa tion or use of accessories Never exceed the stated load capacity for an ATV Cargo should be proper...

Page 23: ...apidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors WARNING EWB02591 When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fue...

Page 24: ... 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 U1BT60E0 book Page 1 Wednesday April 15 2009 1 13 PM ...

Page 25: ...rchased 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 U1BT60E0 book Page 2 Wednesday April 15 2009 1 13 PM ...

Page 26: ...ollows 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 U1BT60E0 book Page 1 Wednesday April 15 2009 1 13 PM ...

Page 27: ...ch 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 U1BT60E0 book Page 2 Wednesday April 15 2009 1 13 PM ...

Page 28: ...at the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 35 for battery charging information EBU18281 Throttle lever Once the engine is running movement of the throt tle lever will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the en...

Page 29: ...djusted 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 30: ...o 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 U1BT60E0 book Page 5 Wednesday April 15 2009 1 13 PM ...

Page 31: ...cially 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 U1BT60E0 book Page 6 Wednesday April 15 2009 1 13 PM ...

Page 32: ...ou 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 f...

Page 33: ...uel while 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...

Page 34: ...your clothes NOTICE ECB00070 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system If knocking or pinging occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce maintenance costs EBU18820 Fuel cock The fuel cock supplies fuel from th...

Page 35: ...tion 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 U1BT60E0 book Page 10 Wednesday April 15 2009 1 13 PM ...

Page 36: ...her 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 EBU18891 Seat To remove the seat Insert your hand between the rear of the seat and the rear fender pull the seat lock lever upward a...

Page 37: ...sorber 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 U1BT60E0 book Page 12 Wednesday Apri...

Page 38: ...to suit the rid er s weight and the riding conditions NOTICE ECB00090 Never turn an 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 decrease the spring preload and thereby soften the sus...

Page 39: ... 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 Distanc...

Page 40: ...sorber 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 U1BT60E0 book Page 15 Wednesday April 15 2009 1 13 PM ...

Page 41: ... 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 10 Front brake Check operation If so...

Page 42: ...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 43: ... 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 spee...

Page 44: ...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 45: ...ubeless 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 U1BT60E0 book Page 5 Wednesday April 15 2009 1 13 PM ...

Page 46: ... 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 DUNLOP KT201 Size AT20 x 7 10 Type Tubeless Rear Manufacturer model DUNLOP KT205A Size AT19 x 10 9 Type Tubeless U1BT60E0 book Pa...

Page 47: ... 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 rec...

Page 48: ...r 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 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 normally to the throttle with the starter choke turned off...

Page 49: ...ore shifting gears otherwise damage to the engine and drive train may result 2 Pull the clutch lever to disengage the clutch 3 Shift into first gear 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 chance of an accident includ ing an ...

Page 50: ... 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 51: ...le at any 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 EBU20721 Parking When parking the ATV stop the engine shift into first gear apply the parking brake and then turn the fuel cock to OFF EBU20862 Parking on a slope WARNING EWB00850...

Page 52: ...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 53: ...ts 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 att...

Page 54: ...e 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 making...

Page 55: ...7 1 7 EBU21141 RIDING YOUR ATV U1BT60E0 book Page 1 Wednesday April 15 2009 1 13 PM ...

Page 56: ...ual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 4 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 increased...

Page 57: ...B01390 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 Ne...

Page 58: ... 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 wit...

Page 59: ...ch 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 ri...

Page 60: ...trol 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 cargo y...

Page 61: ...cident 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 A...

Page 62: ...h 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 oth...

Page 63: ...n 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 unfamiliar...

Page 64: ...G 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 anot...

Page 65: ...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 O...

Page 66: ...ng 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 resist ...

Page 67: ...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 ri...

Page 68: ...d 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 U1BT60E0 book Page 14 Wednesday April 15 20...

Page 69: ...er 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 sh...

Page 70: ... 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 as ...

Page 71: ...ll 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 Im...

Page 72: ...equires 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 loose...

Page 73: ...ing 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 your...

Page 74: ...1651 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 caus...

Page 75: ...lowly 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 I...

Page 76: ... 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 77: ...ou 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 See...

Page 78: ...rforming 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 1 for more information about carbon monoxide The intervals given in the periodic mainten...

Page 79: ...nor 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 Owner s tool kit 3 Owner s manual 4 Manual cover 1 2 3 4 4 3 U1BT60E0 book Page 2 Wednesday April 15 2009 1 13 PM ...

Page 80: ...e 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 if...

Page 81: ...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 U1BT60E0 book Page 4 Wednesday April 15 2009 1 13 PM ...

Page 82: ... ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 4 Rear brake Check operation and correct if necessary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years 6 Parking brake Check operation and adjust ...

Page 83: ...sis fasteners Make sure that all nuts bolts and screws are properly tightened 15 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 16 Steering shaft Lubricate with lithium soap based grease 17 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 18 Engine oil Change Check ATV for oil l...

Page 84: ...acked or damaged 20 Moving parts and cables Lubricate 21 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 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 ITEM ...

Page 85: ... 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 impro...

Page 86: ...o specification 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK DR7EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in 1 Spark plug gap Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf U1BT60E0 book P...

Page 87: ... check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes 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...

Page 88: ...thout oil fil ter element replacement 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase TIP Skip steps 5 8 if the oil filter element is not being replaced 5 Remove the o...

Page 89: ...s are properly seated 8 Install the oil filter element cover by installing the bolts and then tighten them to the speci fied torque 1 Oil filter element cover 2 Bolt 1 2 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 U1BT60E0 book Page 12 Wednesday April 15 2009 1 13 PM ...

Page 90: ...ase 11 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 12 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary EBU23706 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the peri...

Page 91: ...er case 1 Place the ATV on a level surface 2 Remove the seat See page 4 11 3 Remove the air filter case cover by unhooking the holders 4 Loosen the wing bolt 5 Remove the air filter element together with the wing bolt and washer 1 Air filter case check hose 1 1 Air filter case cover 2 Air filter case cover holder 1 2 U1BT60E0 book Page 14 Wednesday April 15 2009 1 13 PM ...

Page 92: ...n the sponge material Never use low flash point sol vents or gasoline to clean the sponge ma terial because the engine could catch fire or explode EWB01941 9 Squeeze the excess solvent out of the sponge material and let it dry NOTICE Do not twist the sponge material when squeezing it ECB00441 1 Wing bolt 2 Air filter element 3 Washer 1 2 3 1 Sponge material 2 Air filter element frame 1 2 U1BT60E0 ...

Page 93: ...ull the sponge material over the air filter ele ment frame 13 Apply all purpose grease to the air filter ele ment seat 14 Install the washer onto the air filter element frame and then insert the wing bolt into the hole in the air filter element frame NOTICE Be sure to install the washer with the bent edge facing outward as shown ECB00452 1 Air filter element seat 1 U1BT60E0 book Page 16 Wednesday ...

Page 94: ...g the holders onto the air filter case 17 Install the seat TIP The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the carburetor fitting...

Page 95: ...ush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Make sure the gasket is properly positioned then insert the tailpipe into the muffler and align the bolt holes 1 Bolt 2 Tailpipe 2 1 1 1 Tailpipe 2 Spark arrester 2 1 U1BT60E0 book Page 18 Wednesday April 15 2009 1 13 PM ...

Page 96: ...t The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment described in the following section however may be performed by the owner as part of routine main tenance NOTICE ECB00480 The carburetor has been set and exte...

Page 97: ... the throttle 2 Attach the tachometer to the spark plug lead 3 Check the engine idling speed and if neces sary adjust it to specification by turning the throttle stop screw at the carburetor To in crease the engine idling speed turn the throt tle stop screw in direction a and to decrease it turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a...

Page 98: ...ck 2 Loosen the locknut 3 To increase the throttle cable free play turn the throttle cable free play adjusting bolt in di rection a To decrease the throttle cable free play turn the adjusting bolt in direction b 4 Tighten the locknut 5 Slide the rubber cover to its original position EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine n...

Page 99: ... pad wear without having to disassemble the brake To check the brake pad wear check the wear indica tor groove If a brake pad has worn to the point that the wear indicator groove has almost disappeared have a Yamaha dealer replace the brake pads as a set TIP The wheels need to be removed to check the brake pads See page 8 41 EBU28800 Rear brake pads Each brake pad is provided with two wear indicat...

Page 100: ... is above the minimum level mark and replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Front brake Rear brake 1 Wear indicator groove 1 1 Minimum level mark 1 Minimum level mark 1 1 U1BT60E0 book Page 23 Wednesday April 15 2009 1 13 PM ...

Page 101: ...fluid reservoir cap cover by in stalling the bolt 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 1 Bolt 2 Brake fluid reservoir cap cover 1 2 1 Brake fluid reservoir cap Recommended brake fluid DOT...

Page 102: ... intervals specified in the TIP after the periodic maintenance 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 fr...

Page 103: ...and lubrication 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 Loosen the locknut on the brake cable 4 Turn the adjusting nut on the brake cable in di rection a to increase the cable length ...

Page 104: ...rmance 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 EBU24740 Brake light switches The operation of the brake light switches must be checked and if necessary adjusted at the inter va...

Page 105: ...er free play The clutch lever free play must be checked and if 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 1 Brake light switch 2 Brake light switch a...

Page 106: ...ck 1 Place the ATV on a level surface TIP When checking and adjusting the drive chain slack there should be no weight on the ATV and all tires must be touching the ground 2 Move the ATV back and forth to locate the tightest portion of the drive 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 ...

Page 107: ...her 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 108: ...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 EBU24901 Checking and lubricating the cables The operation and the condition...

Page 109: ...egin 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 Recommended lubricant...

Page 110: ...he 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 EBU24994 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the in tervals specified in the periodic mai...

Page 111: ... lubricated at the intervals specified in the periodic mainte nance and lubrication chart Lubricate the pivoting points using a grease gun Left side Recommended lubricant Lithium soap based grease 1 Upper grease nipple 2 Lower grease nipple 2 1 U1BT60E0 book Page 34 Wednesday April 15 2009 1 13 PM ...

Page 112: ...ry cell seals as this would permanently damage the battery WARNING EWB02160 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg o...

Page 113: ...nd then remove the battery 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 le...

Page 114: ... ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 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...

Page 115: ...as follows 1 Remove the seat See page 4 11 2 Unhook the band securing the owner s tool kit and then remove the battery holding plate by removing the bolts 1 Battery holding plate 2 Bolt 2 1 1 Battery holding plate 2 Bolt 1 Fuse 2 Spare fuse 2 1 1 2 U1BT60E0 book Page 38 Wednesday April 15 2009 1 13 PM ...

Page 116: ...ectrical system which could lead to a fire EWB02172 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 5 Install the battery holding plate by installing the bolts and then hook the band to secure the owner s tool kit 6 Install the seat EBU25443 Replacing a headlight bulb If ...

Page 117: ...eadlight 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 U1BT60E0 book Page 40 Wednesday April 15...

Page 118: ... 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 nuts 1 Do not to...

Page 119: ...wheel 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 Nut 1 Nut 1 1 1 Arrow mark U1BT60E0 book Page 42 Wednesday April 15 2009 1 13 PM ...

Page 120: ...ke 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 cau...

Page 121: ...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 122: ... 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 dete...

Page 123: ...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 sparking...

Page 124: ...m 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 U1BT60E0 book Page 3 Wednesday April 15 2009 1 13 PM ...

Page 125: ...on level Noise level 77 311 EEC YFM25RZ 81 0 dB A Vibration on seat EN1032 ISO5008 YFM25RZ Will not exceed 0 5 m s Vibration on handlebar EN1032 ISO5008 YFM25RZ Will not exceed 2 5 m s Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 249 cm Bore stroke 74 0 58 0 mm 2 91 2 28 in Compression ratio 9 50 1 Starting system Electric starter L...

Page 126: ... 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 reduction ...

Page 127: ...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 size 9 ...

Page 128: ...nsion Type Swingarm Spring shock absorber type Coil spring gas oil damper Wheel travel 200 mm 7 9 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model YTZ7S Voltage capacity 12 V 6 0 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage quantity Headlight 12 V 30 30 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 U1BT6...

Page 129: ...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 EBU26041 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key ide...

Page 130: ...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 1 Vehicle identification number 2 Year of manufacture 0 0 8 2008 9 2009 A 2010 B 2011 I O Q U Z not used 1 2 U1BT60E0 book Page 2 Wednesday April 15 2009 1 13 PM ...

Page 131: ...11 3 11 1 Model label 1 U1BT60E0 book Page 3 Wednesday April 15 2009 1 13 PM ...

Page 132: ... 8 19 Chassis fasteners 5 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 10 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...

Page 133: ... absorber assembly adjusting the rear 4 13 Spark arrester cleaning 8 17 Spark plug checking 8 8 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 33 T Tail brake light bulb replacing 8 41 Throttle cable free play adjusting 8 21 Throttle lever ...

Page 134: ...YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009 04 0 3 1 CR E U1BT60E0 book Page 1 Wednesday April 15 2009 1 13 PM ...

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