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Yamaha YFM25BX, Owner'S Manual

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Yamaha YFM25BX Owner'S Manual Download Page 152

Light switch  .................................................................... 4-3

M

Main switch  .................................................................... 4-1
Maintenance and lubrication chart  ................................. 8-5
Maintenance chart, emission control system  ................. 8-3
Maintenance record  ..................................................... 11-4
Model label  ................................................................... 11-2

N

Neutral indicator light  ..................................................... 4-2
Noise regulation  ........................................................... 11-3

O

Owner’s manual and tool kit  ........................................... 8-1

P

Parking ........................................................................... 6-7
Parking brake  ................................................................. 4-6
Parking on a slope  ......................................................... 6-8
Part locations  ................................................................. 3-1
Pre-operation check list .................................................. 5-1

R

Recoil starter  .................................................................. 4-8
Reverse indicator light .................................................... 4-2
Riding your ATV  ............................................................. 7-1

S

Safety information  .......................................................... 1-1
Seat .............................................................................. 4-12
Shifting ........................................................................... 6-5
Shift pedal  ...................................................................... 4-7
Shock absorber assembly, adjusting the rear  .............. 4-15
Spark arrester, cleaning  ............................................... 8-21
Spark plug, checking ...................................................... 8-8
Specifications ............................................................... 10-1
Speed limiter  .................................................................. 4-4

Starter (choke)  ............................................................. 4-12
Start switch ..................................................................... 4-3
Steering shaft, lubricating ............................................. 8-35
Storage ........................................................................... 9-2
Storage compartment ................................................... 4-13
Swingarm pivots, lubricating  ........................................ 8-35

T

Tail/brake light bulb, replacing  ..................................... 8-43
Throttle cable free play, adjusting  ................................ 8-24
Throttle lever  ........................................................... 4-3, 5-4
Tire pressure, measuring  ............................................... 5-6
Tires ............................................................................... 5-5
Tire wear limit ................................................................. 5-7
Troubleshooting ........................................................... 8-46
Troubleshooting chart  .................................................. 8-47

V

Valve clearance ............................................................ 8-24
Vehicle identification number  ....................................... 11-1

W

Warranty, extended ...................................................... 11-7
Warranty, limited  .......................................................... 11-5
Wheel hub bearings, checking  ..................................... 8-35
Wheel, installing  ........................................................... 8-44
Wheel, removing  .......................................................... 8-44

U1P013E0.book  Page 2  Tuesday, May 8, 2007  3:45 PM

Summary of Contents for YFM25BX

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

Page 2: ...EBU17091 U1P013E0 book Page 1 Tuesday May 8 2007 3 45 PM ...

Page 3: ... 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 TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INS...

Page 4: ...o change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage to the ATV A NOTE provides key information to make procedures easier o...

Page 5: ...and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17401 AFFIX DEALER LABEL HERE YFM25BX OWNER S MANUAL 2007 by Yamaha Motor Corporation U S A 1st edition April 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expr...

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

Page 7: ...LL 7 21 SLIDING AND SKIDDING 7 31 WHAT TO DO IF 7 33 WHAT TO DO 7 33 PERIODIC MAINTENANCE AND MINOR REPAIR 8 1 Owner s manual and tool kit 8 1 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Checking the spark plug 8 8 Engine oil and oil filter element 8 10 Final gear oil 8 15 Cleaning the air filter element 8 18 Cleaning the spark arres...

Page 8: ...ng the swingarm pivots 8 35 Lubricating the steering shaft 8 35 Battery 8 36 Replacing the fuse 8 39 Replacing a headlight bulb 8 40 Adjusting a headlight beam 8 42 Replacing the tail brake light bulb 8 43 Removing a wheel 8 44 Installing a wheel 8 44 Troubleshooting 8 46 Troubleshooting chart 8 47 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise regulation 11 3 Main...

Page 9: ...struc tor Contact an authorized ATV dealer or call 1 Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Never operate a...

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

Page 11: ... of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire p...

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

Page 13: ...ust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad equate ventilation U1P013E0 book Page 5 Tuesday May 8 2007 3 45 PM ...

Page 14: ...2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U1P013E0 book Page 1 Tuesday May 8 2007 3 45 PM ...

Page 15: ... 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 U1P013E0 book Page 2 Tuesday May 8 2007 3 45 PM ...

Page 16: ...2 U1P013E0 book Page 3 Tuesday May 8 2007 3 45 PM ...

Page 17: ...2 U1P013E0 book Page 4 Tuesday May 8 2007 3 45 PM ...

Page 18: ... Fuses 5 Battery 6 Tail brake light 7 Rear shock absorber assembly spring preload adjusting ring 1 Spark arrester 2 Storage compartment and tool kit 3 Air filter case 4 Engine oil filler cap 5 Front brake fluid reservoir 6 Brake pedal 7 Clutch adjusting screw U1P013E0 book Page 1 Tuesday May 8 2007 3 45 PM ...

Page 19: ...struments 1 Rear brake lever 2 Handlebar switches 3 Parking brake lock plate 4 Starter choke 5 Drive select lever 6 Main switch 7 Fuel tank cap 8 Throttle lever 9 Front brake lever U1P013E0 book Page 2 Tuesday May 8 2007 3 45 PM ...

Page 20: ...n switch The positions of the main switch are as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U1P013E0 book Page 1 Tuesday May 8 2007 3 45 PM ...

Page 21: ...ansmis EBU18061 Handlebar switches EBU18080 Engine stop switch Set this switch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The 1 Reverse indicator light R 2 Neutral indicator light N 1 Light switch OFF 2 Engine stop switch 3 Start switch U1P013E0 book Page 2 Tuesday M...

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

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

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

Page 25: ...ne or parking the ATV especially on a slope Apply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake 1 Brake pedal 1 Parking brake lock plate U1P013E0 book Page 6 Tuesday May 8 2007 3 45 PM ...

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

Page 27: ...ll the rope all the way out WARNING EWB02361 1 Drive select lever 1 Recoil starter POTENTIAL HAZARD Starting the engine in gear or starting the engine without applying the parking brake WHAT CAN HAPPEN The ATV could start to move unexpectedly which could cause an accident HOW TO AVOID THE HAZARD U1P013E0 book Page 8 Tuesday May 8 2007 3 45 PM ...

Page 28: ...cient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap 1 Fuel tank filler tube 2 Fuel level Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 12 0 L 3 17 US gal 2 64 Imp gal Fuel reserve amount 1 6 L 0 42 US gal 0 35 Imp gal U1P013E0 book Page 9 Tuesday May 8 2007 3 45 PM ...

Page 29: ...con tent does not exceed 10 Gasohol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ATV performance problems EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations WHAT CAN HAPPEN Fuel can spill which can cause a...

Page 30: ...s position when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark positioned over OFF 1 Arrow mark positioned over ON U1P013E0 book Page 11 Tuesday May 8 2007 3 45 PM ...

Page 31: ... possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Move the starter choke in direction b to turn off the starter choke See the Starting a cold engine section on page 6 1 for proper operation EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear 1 Arrow mark positioned over RES 1 Starter choke U1P013E0 book Page 12 Tuesday...

Page 32: ...torage compartment The storage compartment is located under the seat See page 4 12 When storing any documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage compartment 1 Seat 2 Seat lock lever 1 Projection 2 Seat holder U1P013E0 book Page 13 Tuesday May 8 2007 3 45 PM ...

Page 33: ...e compartment NOTE There is a check hose at the bottom of the storage EBU18960 Front carrier Do not exceed the load limit of 30 0 kg 66 lb for the front carrier Do not exceed the maximum load of 165 0 kg 364 lb for the ATV EBU18970 Rear carrier Do not exceed the load limit of 45 0 kg 99 lb for 1 Storage compartment 1 Storage compartment check hose U1P013E0 book Page 14 Tuesday May 8 2007 3 45 PM ...

Page 34: ...g ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 U1P013E0 book Page 15 Tuesday May 8 2007 3 45 PM ...

Page 35: ...4 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death U1P013E0 book Page 16 Tuesday May 8 2007 3 45 PM ...

Page 36: ...ine which service should be performed by a Yamaha dealer POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedu...

Page 37: ... necessary Check lever and pedal free play and adjust if necessary 5 3 8 25 8 28 Throttle lever Make sure that operation is smooth Lubricate cable and lever hous ing if necessary Check cable free play and adjust if necessary 5 4 8 24 Control cables Make sure that operation is smooth Lubricate if necessary 8 33 Wheels and tires Check wheel condition and replace if damaged Check tire condition and t...

Page 38: ...ove smoothly and there should be a firm feeling when the brake is applied If not have a Yamaha dealer check them Brake fluid level front brake Check the brake fluid level Add fluid if necessary See page 8 26 POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could s...

Page 39: ...ck the brake pads and shoes for wear See page 8 25 WARNING EWB00540 EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID TH...

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

Page 41: ...specifications Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 17 0 kPa 2 5 psi 0 170 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm Rear 250 kPa 36 psi 2 5 kgf cm Higher pre...

Page 42: ...d switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 20 0 kPa 2 9 psi 0 200 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 17 0 kPa 2 5 psi 0 170 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 23 0 kPa 3 3 psi 0 230 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm 1 Tire wear limit U1P013E0 book Page 7 Tuesday May...

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

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

Page 45: ... return the starter choke to position 3 before riding NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter choke is not required when the engine is warm Instead start the engine with the throttle slightly open EBU20310 Operating ...

Page 46: ...select lever to the rear until it completely stops NOTE When in reverse the reverse indicator light should be on If the indicator light does not come on have a Yamaha dealer check the electrical circuit 5 Check behind you for people or obstacles 1 Forward F 2 Reverse R 3 Drive select lever 1 Forward F 2 Reverse R 3 Drive select lever U1P013E0 book Page 4 Tuesday May 8 2007 3 45 PM ...

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

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

Page 49: ...correct operating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided 0 160 km 0 100 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary 160 320 km 100 200 mi or 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine through the gears freely but do not use full throttle at any tim...

Page 50: ... incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the ATV transversely across the incline shift into first gear stop the engine apply the parking brake and then block the front and rear wheels with rocks or other objects Do not park the ATV at all on h...

Page 51: ...ty Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with ac cessories The ...

Page 52: ... 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 sharp turns unless at very slow speeds Avoid hills and rough terrain Ch...

Page 53: ...rgo improperly WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing U1P013E0 book Page 11 Tuesday May 8 2007 3 45 PM ...

Page 54: ...7 EBU21131 RIDING YOUR ATV U1P013E0 book Page 1 Tuesday May 8 2007 3 45 PM ...

Page 55: ...quires special skills acquired through practice over a period of time Take the time to learn the ba sic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable ac tivity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin t...

Page 56: ... for children under 16 years of age WARNING EWB00901 POTENTIAL HAZARD Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training c...

Page 57: ... that are not recom mended for their age can lead to severe inju ry or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc U1P013E0 book Page 4 Tuesday May 8 2007 3 45 PM ...

Page 58: ... HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as need ed during operation It is not for carrying passengers U1P013E0 book Page 5 Tuesday May 8 2007 3 45 PM ...

Page 59: ...g without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeve...

Page 60: ...e influence of alcohol or drugs WARNING EWB00930 POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV U1P013E0 book Page 7 Tuesday May 8 2007 3 45 PM ...

Page 61: ... each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and mainte nance procedures and schedules described in the Owner s Manual WHAT CAN HAPPEN Use of improper tires on this ATV or opera tion of this ATV with improper or uneven tire pressure may cause loss of control in creasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size an...

Page 62: ...d See page 4 4 Loading and accessories Use extra caution when riding the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Re duce your speed when adding additional loads POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in a...

Page 63: ...railer hitch point 147 N 33 lbf 15 kgf POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own...

Page 64: ...uce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a foot board your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation POTENTIAL HAZARD Attempting wh...

Page 65: ...ich in some situations could HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nents designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer U1P013E0 book Page 12 Tuesday May ...

Page 66: ...tem WHAT CAN HAPPEN Dry grass or brush or other combustible ma terial accumulated around the engine area could catch fire Someone touching the exhaust system dur ing or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exha...

Page 67: ...veways parking lots and streets POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways U1P013E0 book Page 14 Tuesday May 8 2007 3 45 PM ...

Page 68: ...r terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV POTENTIAL HAZARD Failure to use extra care when operating on excessively rou...

Page 69: ...ip pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be in jured U1P013E0 book Page 16 Tuesday May 8 2007 3 45 PM ...

Page 70: ...gine idling lift the shift pedal to the 1st gear position and then release the parking brake Apply the throttle slowly and smoothly The centrif ugal clutch will engage and you will start to accel erate Once the ATV has attained adequate speed release the throttle and lift the shift pedal to the 2nd gear position Release the shift pedal and apply the throttle smoothly Use this same procedure as you...

Page 71: ...to lose traction reducing con trol and increasing the possibility of an accident WARNING EWB01070 POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before s...

Page 72: ... desired direction As you do so put your weight on the footboard to the out side of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV coul...

Page 73: ...ter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping ov...

Page 74: ...TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climb ing hills as described in this Owner s Manu al Always check the ter...

Page 75: ...7 U1P013E0 book Page 22 Tuesday May 8 2007 3 45 PM ...

Page 76: ...y crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turn ing on any hill Avoid crossing the side of a steep hill if pos sible When crossing the side o...

Page 77: ...OID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply the rear brake as well and then lock the parking brake Di...

Page 78: ...angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear WARNING EWB01130 POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner s Man ual Note ...

Page 79: ...7 U1P013E0 book Page 26 Tuesday May 8 2007 3 45 PM ...

Page 80: ...your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING EWB01141 POTENTIAL HAZARD Improperly crossing hills or turning on hills HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique ...

Page 81: ...7 U1P013E0 book Page 28 Tuesday May 8 2007 3 45 PM ...

Page 82: ...1150 Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in w...

Page 83: ...ng the check hose at the bottom of the air filter case the drive se lect lever box check hose and the storage compartment check hose Wash the ATV in fresh water if it has been operated in salt water or muddy conditions 1 Air filter case check hose U1P013E0 book Page 30 Tuesday May 8 2007 3 45 PM ...

Page 84: ...lide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help 1 Storage compartment check hose WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area ...

Page 85: ... side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide U1P013E0 book Page 32 Tuesday May 8 2007 3 45 PM ...

Page 86: ...tter control See page 7 19 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 19 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See page...

Page 87: ...gain balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 21 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 br...

Page 88: ...r DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01820 EBU21720 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and always carry it on the bottom of the seat as shown Put the owner s tool kit and low pres sure tire gauge under the seat POTENTIAL HAZARD Servicing an engine whi...

Page 89: ...erating this ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nen...

Page 90: ... should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if ...

Page 91: ...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 U1P013E0 book Page 4 Tuesday May 8 2007 3 45 PM ...

Page 92: ... 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 4 Rear brake Check operation and correct if necessary Check brake lever and pedal free play and adjust if necessary Replace brake shoes Whenever worn to the limit 5 Brake hoses Check for cracks or other damage and replace if necessary Re...

Page 93: ...system Check operation and repair or replace if damaged Check toe in and adjust if necessary 14 Axle boots Check for cracks or other damage and replace if necessary 15 Engine oil Change Check ATV for oil leakage and correct if neces sary 16 Engine oil filter ele ment Clean or replace if necessary 17 Engine oil strainer Clean 18 Final gear oil Change Check ATV for oil leakage and correct if neces N...

Page 94: ... 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 24 Battery Check electrolyte level and specific gravity and correct if necessary Make sure that the breather hose is properly rout ed NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first m...

Page 95: ...y spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit 1 Spark plug cap U1P013E0 boo...

Page 96: ...ug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spark plug wrench Specified spark plug NGK DR7EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in U1P013E0 book Page 9 Tuesday May 8 2007 3 4...

Page 97: ...be checked before each ride In addition the oil must be changed and the oil filter element cleaned at the intervals speci fied in the periodic maintenance and lubrication 2 Check the engine oil level on a cold engine NOTE 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 readi...

Page 98: ... cap To change the engine oil with or without oil fil ter element cleaning 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil CAUTION ECB00310 When removing the engine oil drain bolt the co...

Page 99: ...rd 7 Move the drive select lever safety system ca ble away from the oil filter element cover 8 Remove the oil filter element cover by remov ing the bolts and then the oil filter element 1 Footboard 2 Bolt 1 Brake pedal free play adjusting nut U1P013E0 book Page 12 Tuesday May 8 2007 3 45 PM ...

Page 100: ... and replace it if necessary 11 Install the oil filter element and the O ring NOTE Make sure that the O ring is properly seated 12 Install the oil filter element cover by installing the bolts and then tighten them to the speci fied torque 1 Oil filter element cover 2 Adjusting nut 3 Bolt 4 Drive select lever safety system cable 1 Oil filter element 2 O ring U1P013E0 book Page 13 Tuesday May 8 2007...

Page 101: ... engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 15 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaki...

Page 102: ...n the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oil level must be checked on a cold engine 2 Remove the final gear oil filler bolt and then check the oil level in the final gear case NOTE The oil level should be at the brim of the filler hole 1 Footboard bolt A 2 Footboard bolt B Tightening torques Footboard ...

Page 103: ... gear case guard by remov ing the bolts 2 Place the ATV on a level surface 3 Place an oil pan under the final gear case to collect the used oil 4 Remove the final gear oil filler bolt and the fi nal gear oil drain bolt to drain the oil from the final gear case 1 Final gear oil 2 Correct oil level 3 Final gear oil filler bolt Tightening torque Final gear oil filler bolt 1 Final gear case guard 2 Bo...

Page 104: ...le as shown CAUTION ECB00420 Be sure no foreign material enters the final gear case 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil 2 Correct oil level 3 Final gear oil filler bolt Recommended final gear oil See page 10 1 U1P013E0 book Page 17 Tuesday May 8 2007 3 45 PM ...

Page 105: ...filter element more frequently if you are riding in unusually wet or dusty areas NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air fil ter case 1 Remove the seat See page 4 12 2 Remove the air filter case cover by unhooking the holders Tightening torque Final gear oil filler bolt 23 Nm 2 3 ...

Page 106: ...ent assembly out of the air filter case 4 Remove the sponge material from the air filter element 1 Air filter case cover 2 Air filter case cover holder 1 Air filter element assembly U1P013E0 book Page 19 Tuesday May 8 2007 3 45 PM ...

Page 107: ...rial when squeezing it Do not apply oil to the sponge material 7 Check the sponge material and replace it if damaged 8 Tap the air filter element lightly to remove 1 Air filter element 2 Sponge material POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can U1P013E0 book Page 20 Tuesday May 8 2007 3 45 PM ...

Page 108: ...ring the engine CAUTION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the air filter element will affect carburetor jetting with subsequent poor performance a...

Page 109: ... POTENTIAL HAZARD Improperly purging the exhaust system Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When purging the exhaust system Always let the exhaust system cool prior to touching exhaust components Always wear eye protection and make sure no one is behind ...

Page 110: ...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 NOTE The engine is warm when it quickly responds to the throttle 2 Attach the tachometer to the spark plug lead 3 Check the engine idling speed and if neces s...

Page 111: ...the throttle cable free play and if nec essary adjust it as follows NOTE The engine idling speed must be checked and ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn 3 Tighten the locknut EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise T...

Page 112: ...es must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart EBU24171 Front brake pads Check each front brake pad for damage and mea sure the lining thickness If a brake pad is dam aged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set NOTE The wheels need to be removed to check the brake pads See...

Page 113: ... brake fluid is above brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor bra...

Page 114: ...ha dealer check the cause EBU24280 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the peri odic maintenance and lubrication chart In addi tion have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are EBU24380 Checking the front brake lever fr...

Page 115: ...edal should be positioned 43 0 53 0 mm 1 69 2 09 in above the top of the footboard bracket If the position is incorrect adjust it as follows WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy...

Page 116: ...shown If the free play is incorrect adjust it as follows 2 Turn the brake pedal free play adjusting nut on the brake rod at the rear wheel hub in direc tion a to increase the free play and in direc tion b to decrease it Adjusting the brake lever free play The brake lever free play should measure 5 0 7 0 mm 0 20 0 28 in as shown If the free play is in correct adjust it as follows 1 Brake pedal free...

Page 117: ...a sures 0 1 mm 0 0 04 in between the lever and the pin 3 Turn the brake lever free play adjusting bolt at the brake lever in direction a to increase the free play and in direction b to decrease it 1 Brake lever free play 2 Locknut 3 Brake lever free play adjusting bolt 1 Brake lever free play adjusting nut 2 Brake camshaft lever 3 Pin 4 Gap A U1P013E0 book Page 30 Tuesday May 8 2007 3 45 PM ...

Page 118: ...amage If any damage is found have them re placed by a Yamaha dealer EBU24760 Brake light switches The operation of the brake light switches must be 1 Locknut 2 Brake lever free play adjusting bolt WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure th...

Page 119: ... adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direc tion a To make the brake light come on lat er turn the adjusting nut in direction b 3 Install the footboard EBU24803 Adjusting the clutch free play The clutch free play must be adjusted periodically Adjust the free play as follows 1 Remove the footboard See Engine oi...

Page 120: ...ocknut 5 Install the footboard EBU24890 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWB02120 1 Locknut 2 Clutch adjusting screw Tightening torque Locknut Re...

Page 121: ...ver WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cables can also be come frayed or kinked which could restrict the operation of controls and lead to an acci dent or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Recommended lubricants Front brake lever Silicone grease Rear brake lever Lithium soap based grease all purpose U1P013E0 ...

Page 122: ...el hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU24992 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the in tervals specified in the periodic maintenance and lubrication chart EBU25090 Lubricating the steering shaft The steering shaft must be lubricated at the inter vals specified in the periodic maintenance and lu bricat...

Page 123: ...ead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica tion chart To check the electrolyte level 3 Check the electrolyte level in the battery 1 Grease nipple 1 Battery cover U1P013E0 book Page 36 Tuesday May 8 2007 3 45 PM ...

Page 124: ...ould be poisoned You could be se verely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gas es HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or veg...

Page 125: ...over by pulling it upward 2 Disconnect the negative battery lead 3 Remove the battery bracket by removing the bolts 4 Disconnect the positive battery lead 5 Remove the battery fully charge it and then place it in a cool dry place CAUTION ECB00600 Do not leave or store the battery on its side 6 If the battery will be stored for more than two 1 Battery 2 Battery bracket 3 Bolt 4 Positive battery lea...

Page 126: ...ery lead 5 Make sure that the breather hose is properly routed in good condition and not obstructed CAUTION ECB00610 If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery the frame could suf fer structural and external damages 6 Install the battery cover EBU25232 Replacing the fuse 1 Fuse U1P013E0 book Page 39 Tuesday May 8 2007 ...

Page 127: ...te 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25470 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off Specified fuse 20 0 A POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to...

Page 128: ... the bulb hold er by pushing it in 1 Headlight bulb holder cover POTENTIAL HAZARD A headlight bulb is hot when it is on and im mediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it U1P013E0 book Page 41 Tuesday May 8 2007 3 45 PM ...

Page 129: ...hol or thinner CAUTION ECB00670 Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 8 Adjust the headlight beam if necessary EBU25550 Adjusting a headlight beam CAUTION ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the adjusting screw in direction a To lower a headlight beam turn the adjusting ...

Page 130: ...eplace it as follows 1 Remove the bulb holder together with the bulb by turning it counterclockwise 2 Remove the defective bulb by pushing it in and turning it counterclockwise 1 Headlight beam adjusting screw 1 Tail brake light bulb holder U1P013E0 book Page 43 Tuesday May 8 2007 3 45 PM ...

Page 131: ...Removing a wheel 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel EBU25700 Installing a wheel 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward 1 Tail brake light bulb holder 2 Tail brake light bulb 1 Wheel nut U1P013E0 book Page 44 Tuesday May 8 2007 3 45 PM ...

Page 132: ...tapered side to wards the wheel 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U1P013E0 book Page 45 Tuesday May 8 2007 3 45 PM ...

Page 133: ... to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02260 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame ...

Page 134: ...Have a Yamaha dealer check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The battery is good Dry Wet O...

Page 135: ... ECB00710 Excessive water pressure may cause water ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places 5 Rinse the ATV off immediately with clean wa ter and dry all surfa...

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

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

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

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

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

Page 141: ... Coil spring oil damper Wheel travel 135 mm 5 3 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model CB14A A2 Voltage capacity 12 V 14 0 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage x quantity Headlight Reverse indicator light 12 V 1 7 W 1 Fuse Fuse 20 0 A U1P013E0 book Page 4 Tuesday May 8 2007 3 45 PM ...

Page 142: ... ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number is stamped into 1 Key identifi...

Page 143: ...TV EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need 1 Vehicle identification number 1 Model label U1P013E0 book Page 2 Tuesday May 8 2007 3 45 PM ...

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

Page 145: ...the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 U1P0...

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

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

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

Page 149: ...y expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 U1P013E0 book Page 8 Tuesday May 8 2007 3 45 ...

Page 150: ...11 EBU26132 U1P013E0 book Page 9 Tuesday May 8 2007 3 45 PM ...

Page 151: ...ng 8 28 Brakes front and rear 5 3 C Cables checking and lubricating 8 33 Carburetor adjusting 8 22 Carrier front 4 14 Carrier rear 4 14 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 25 E Engine break in 6 7 Engine cold start 6 1 Engine idling speed 8 23 Engine oil 5 3 Engine oil and oil filter element 8 10 Engine starting a warm 6 3 Engine stop sw...

Page 152: ... Safety information 1 1 Seat 4 12 Shifting 6 5 Starter choke 4 12 Start switch 4 3 Steering shaft lubricating 8 35 Storage 9 2 Storage compartment 4 13 Swingarm pivots lubricating 8 35 T Tail brake light bulb replacing 8 43 Throttle cable free play adjusting 8 24 Throttle lever 4 3 5 4 Tire pressure measuring 5 6 Tires 5 5 Tire wear limit 5 7 Troubleshooting 8 46 Troubleshooting chart 8 47 V Valve...

Page 153: ...U1P013E0 book Page 3 Tuesday May 8 2007 3 45 PM ...

Page 154: ...ct handling and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PU...

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