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Yamaha YFM35RW, Owner'S Manual

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Yamaha YFM35RW Owner'S Manual Download Page 108

8-30

8

EBU24880

Lubricating the drive chain 

The drive chain must be cleaned and lubricated at
the intervals specified in the periodic maintenance
and lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or wet areas.
Service the drive chain as follows.

CAUTION:

ECB00560

The drive chain must be lubricated after wash-
ing the ATV or riding in the rain.

1. Clean the drive chain with kerosene and a

small soft brush.

CAUTION:

ECB00570

To prevent damaging the O-rings, do not clean
the drive chain with steam cleaners, high-pres-
sure washers or inappropriate solvents.

2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a

special O-ring chain lubricant.

CAUTION:

ECB00580

Do not use engine oil or any other lubricants
for the drive chain, as they may contain sub-
stances that could damage the O-rings.

EBU24900

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-

Tightening torques:

Locknut:

16 Nm (1.6 m·kgf, 11 ft·lbf)

Axle holding nut (upper):

120 Nm (12.0 m·kgf, 85 ft·lbf)

Axle holding nut (lower):

73 Nm (7.3 m·kgf, 53 ft·lbf)

1. O-ring

U10P60E0.book  Page 30  Thursday, June 15, 2006  4:19 PM

Summary of Contents for YFM35RW

Page 1: ...YFM35RW 10P 28199 60 OWNER S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO ...

Page 2: ...PRINTED IN JAPAN 2006 06 0 7 1 CR E F S PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO YAMAHA MOTOR CO LTD ...

Page 3: ...OWNER S MANUAL YFM35RW 10P 28199 60 E0 U10P60E0 book Page 1 Thursday June 15 2006 4 19 PM ...

Page 4: ...U10P60E0 book Page 2 Thursday June 15 2006 4 19 PM ...

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

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

Page 7: ...face paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM35RW OWNER S MANUAL 2006 by Yamaha Motor Co Ltd 1st edition June 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U10P60E0 book Page 1 Thursday June 15 2006 4 19 P...

Page 8: ...dal 4 7 Parking brake lever 4 7 Shift pedal 4 8 Drive select lever 4 9 Fuel tank cap 4 9 Fuel 4 10 Fuel cock 4 11 Starter choke 4 12 Steering lock 4 13 Seat 4 14 Adjusting the front shock absorber assemblies 4 14 Adjusting the rear shock absorber assembly 4 16 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Drive chain 5 4 ...

Page 9: ... Periodic maintenance and lubrication chart 8 3 Checking the spark plug 8 8 Engine oil and oil filter element 8 10 Cleaning the air filter element 8 13 Cleaning the spark arrester 8 16 Adjusting the carburetor 8 17 Adjusting the engine idling speed 8 17 Adjusting the throttle cable free play 8 19 Valve clearance 8 19 Checking the front and rear brake pads 8 20 Checking the brake fluid level 8 21 C...

Page 10: ...Battery 8 35 Replacing a fuse 8 37 Headlight bulb 8 38 Headlight beam 8 38 Replacing the tail brake light bulb 8 38 Replacing a turn signal light bulb 8 38 Replacing the license plate light bulb 8 39 Auxiliary light bulb 8 40 Removing a wheel 8 40 Installing a wheel 8 41 Troubleshooting 8 42 Troubleshooting chart 8 43 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER I...

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

Page 12: ... 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 terr...

Page 13: ... Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always 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 pre...

Page 14: ...us If you should swal low some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are pois...

Page 15: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U10P60E0 book Page 1 Thursday June 15 2006 4 19 PM ...

Page 16: ... These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer U10P60E0 book Page 2 Thursday June 15 2006 4 19 PM ...

Page 17: ...2 3 2 U10P60E0 book Page 3 Thursday June 15 2006 4 19 PM ...

Page 18: ...0 Left view EBU17700 Right view 1 Headlight 2 Front wheel 3 Fuel cock 4 Rear wheel 5 Shift pedal 1 Spark arrester 2 Seat 3 Drive select lever 4 Fuel tank cap 5 Main switch 6 Brake pedal U10P60E0 book Page 1 Thursday June 15 2006 4 19 PM ...

Page 19: ...purchased may differ slightly from the figures shown in this manual 1 Clutch lever 2 Parking brake lever 3 Speedometer unit 4 Brake lever 5 Throttle lever 6 Engine stop switch 7 Starter choke 8 Handlebar switches U10P60E0 book Page 2 Thursday June 15 2006 4 19 PM ...

Page 20: ...systems are supplied with power The auxiliary light taillight and license plate light come on and the engine can be started The key cannot be removed NOTE The headlight comes on when the light switch is set to or OFF All electrical systems are off The key can be re moved 1 Main switch U10P60E0 book Page 1 Thursday June 15 2006 4 19 PM ...

Page 21: ...ght comes on when the transmis sion is in the neutral position EBU27980 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on EBU28050 Speedometer The speedometer shows the riding speed This speedometer is equipped with an odometer The odometer shows the total distance traveled 1 High beam indicator light 2 Turn signal indicator light 3 Reverse ...

Page 22: ...ne 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 EBU18100 Start switch Push this switch to crank the engine with the start er 1 Light switch 2 Hazard switch 3 Turn signal switch 4 Horn switch 5 Start switch 1 Engine stop switch U10P60E0 book Page 3 Thursday June 15 2006 4 19 PM ...

Page 23: ...witch in after it has returned to the center po sition EBU18170 Horn switch Press the switch to sound the horn EBU28000 Hazard switch With the key in the ON position turn this switch to to turn on the hazard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergen cy or to warn other drivers when your vehicle is stopped where it might be a traffic haz...

Page 24: ...t the problem be fore riding the ATV or consult a Yamaha dealer EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum 1 Loosen the locknut 2 To increase the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To ...

Page 25: ... lever The clutch lever is located on the left handlebar and the ignition circuit cut off system is incorporat ed in the clutch lever holder To disengage the clutch pull the clutch lever toward the handlebar grip To engage the clutch release the clutch lever The clutch lever should be pulled rapidly and re leased slowly for smooth clutch operation See page 6 1 for a description of the ignition cir...

Page 26: ...ront brakes For full braking performance apply both the brake lever and the brake pedal si multaneously EBU18520 Parking brake lever Use the parking brake before starting the engine or parking the ATV especially 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 lever 1 Brake pedal U10P6...

Page 27: ...rheat if you ride the ATV without re leasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely EBU18530 Shift pedal This ATV is equipped with a constant mesh 6 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 1 Parking brake lever loc...

Page 28: ... or in reverse See the Operating the drive select lever and driving in reverse section on page 6 3 for the drive select lever operation EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise 1 Shift pedal 1 Drive select lever U10P60E0 book Page 9 Thursday June 15 2006 4 19 PM ...

Page 29: ...erent brand of gasoline or higher octane grade 1 Fuel tank cap 1 Fuel tank filler tube 2 Fuel level Recommended fuel UNLEADED GASOLINE ONLY For Europe Regular unleaded gasoline only with a research octane number of 91 or high er Fuel tank capacity 9 0 L 2 38 US gal 1 98 Imp gal Fuel reserve amount 2 7 L 0 71 US gal 0 59 Imp gal U10P60E0 book Page 10 Thursday June 15 2006 4 19 PM ...

Page 30: ...haust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations...

Page 31: ...rn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke 1 Arrow mark pointing to ON 1 Arrow mark ...

Page 32: ...urn the handlebar all the way to either side 2 Open the steering lock cap and then insert the steering lock key 3 Turn the key 1 8 turn counterclockwise push it in and then turn the key 1 8 turn clockwise 4 Check that the steering is locked remove the key and then close the steering lock cap 1 Starter choke 1 Steering lock cap 2 Steering lock U10P60E0 book Page 13 Thursday June 15 2006 4 19 PM ...

Page 33: ... the seat at the rear To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely fitted EBU18990 Adjusting the front shock absorber as semblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows 1 Seat lock lever 1 ...

Page 34: ... 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 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 3 Maximum hard 5 U10P60E0 book Page 15 Thursday June 15 2006 4 19 PM ...

Page 35: ...ng nut in direction a to in crease the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment The spring preload setting is determined by measuring distance A shown in the illustration The shorter distance A is the higher the spring preload...

Page 36: ...s tighten the locknut against the adjust ing nut and then tighten it to the specified torque 1 Special wrench Spring preload setting Minimum hard Distance A 218 5 mm 8 6 in Standard Distance A 228 5 mm 9 0 in Maximum soft Distance A 233 5 mm 9 2 in 1 Distance A Tightening torque Locknut 42 Nm 4 2 m kgf 30 ft lbf 1 U10P60E0 book Page 17 Thursday June 15 2006 4 19 PM ...

Page 37: ...esult in poor handling which could cause an accident Do not tamper with or attempt to open the cylinder assembly Do not subject the shock absorber assembly to an open flame or other high heat Do not deform or damage the cylinder in any way Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly to a Yamaha deal er for any service U10P60E0 book Page...

Page 38: ...ded oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 10 Front brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check brake pads for wear and replace if necessary Check brake fluid level in reservoir and add recommended brake fluid to specified level if necessary Check hydraulic system for leakage Correct if necessary 5 3 8 ...

Page 39: ...ake sure that operation is smooth Lubricate if necessary 8 30 Drive chain Check chain slack and adjust if necessary Check chain condition Lubricate if necessary 5 4 8 27 8 30 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 5 5 5 6 Brake and shift pedals Make sure that operation is sm...

Page 40: ...ne oil Make sure that the engine oil is at the specified lev el Add oil as necessary See page 8 10 EBU19710 Front and rear brakes Brake lever and brake pedal Check that there is no free play in the brake le ver If there is free play have a Yamaha dealer check the brake system Check for correct brake pedal height See page 8 23 If the pedal height is incorrect have a Yamaha dealer adjust it Check th...

Page 41: ...rected by the adjust ment procedures provided in this manual have a Yamaha dealer check for the cause EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19770 Drive chain Check the condition of the drive chain and check the drive chain slack Lubricate and adjust the ...

Page 42: ...ressure Front 22 0 kPa 3 2 psi 0 220 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 pressures and fast inflation may cause a tire to burst Inflate the tires very slowly and carefully EBU19820 Measuring the tire pressure Use the low pres...

Page 43: ...re groove decreases to 3 mm 0 12 in 1 Low pressure tire gauge Recommended pressure Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm U10P60E0 book Page 6 Thursday June 15 2006 4 19 PM ...

Page 44: ... 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 1 Tire wear limit U10P60E0 book Page 7 Thursday June 15 2006 4 19 PM ...

Page 45: ...ad to an acci dent or collision CAUTION ECB00150 See the Engine break in section on page 6 6 prior to operating the engine for the first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator light does not come on have a Yamaha deal er check...

Page 46: ...gine start with ambient temperature above 25 C 80 F Ambient temp starter choke position 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE If the engine fails to start release the start switch then push it again Pause a few seconds before the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more th...

Page 47: ...esponds 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 EBU20340 Operating the drive select lever and driving in reverse CAUTION ECB00170 Before shifting stop the...

Page 48: ...hen release the brake pedal 6 Open the throttle lever gradually and release the clutch lever slowly Continue to watch to the rear while backing WARNING EWB00720 Improper operation in reverse could make you hit an obstacle or even a person behind you resulting in serious injury When you shift into reverse make sure there are no people or ob stacles behind you When it is safe to proceed go slowly EB...

Page 49: ...ift into first gear 4 Open the throttle gradually and at the same time release the clutch lever slowly WARNING EWB02401 Stones or mud may come off the rear tires and be thrown backwards when starting or acceler ating Use caution when starting out or acceler ating when others are behind the ATV 5 Once the ATV has attained adequate speed release the throttle and at the same time quickly pull in the ...

Page 50: ...e the wheels stop rotating and lose traction This could cause loss of control an accident and injury It could also cause engine or drive train damage CAUTION ECB00180 Even with the transmission in the neutral po sition do not 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 Inadequ...

Page 51: ...m 0 100 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 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 time 320 km 200 mi or 20 hours and beyond The ATV can now be operated normally CAUTION EC...

Page 52: ...ot park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the ATV to a stop by applying the front brake 2 With the front and rear brake applied pull the clutch lever shift into the neutral position re lease the clutch lever and then apply the parking brake 3 Stop the engine by setting the engine stop switch to 4 With the front and rear brakes applied pull the clut...

Page 53: ...o control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which 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 ATV may handle differently than it does without accessories EBU20940 Loading As originally equipped t...

Page 54: ...d 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 Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING EWB00820 Never exceed the stated load capacity for this ATV Ove...

Page 55: ...7 1 7 EBU21141 RIDING YOUR ATV U10P60E0 book Page 1 Thursday June 15 2006 4 19 PM ...

Page 56: ...on and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics WARNING...

Page 57: ...f the child This ATV is designed to carry operator only passengers prohibited WARNING EWB01400 Never carry a passenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or your pas...

Page 58: ...creases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and in creases your chances of a severe injury in the event of an accident Operating without protec tive clothing increases your chances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s performance ca...

Page 59: ...r equipment damage WARNING EWB01440 Always use the size and type tires specified in the Owner s Manual for this ATV on page 5 4 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 5 Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pres sure may cause loss of control increasing your risk of an accident Do not operate at speeds to...

Page 60: ... carry cargo or tow a trailer If you choose to add ac cessories so that you can carry cargo or tow a trail er you must use common sense and good judgment 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 WARNING EWB01460 Never exceed the stated load capacity for this...

Page 61: ...your ATV during operation Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident Avoid wheelies and jumping You may lose control of the ATV or overturn WARNING EWB01480 Never...

Page 62: ...ons consult an au thorized ATV dealer Exhaust system The exhaust system on the ATV is very hot during and following operation To prevent burns avoid touching the exhaust system Park the ATV in a place where pedestrians or children are not likely to touch it Also avoid parking in or around dry grass brush or other combustible materials to pre vent causing a fire hazard WARNING EWB01500 Do not touch...

Page 63: ...surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision 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 ri...

Page 64: ...es rocks or roots in the terrain and other hidden hazards which may cause the ATV to upset WARNING EWB01530 Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to chang ing terrain conditions when operating the ATV WARNING EWB01540 Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the A...

Page 65: ...esert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING EWB01550 Always mount a caution flag on the ATV to make you more visible when operating in areas where you might not be seen by other vehicles Watch carefully for other vehicles Do not ride in areas posted no trespassing Do not ride on private property without getting per mission U10P60E0 book...

Page 66: ... come in contact with these components With the engine idling pull the clutch lever to dis engage the clutch and shift into 1st gear and then release the parking brake Open the throttle grad ually and at the same time release the clutch le ver slowly Once the ATV has attained adequate speed release the throttle lever and at the same time quickly pull in the clutch lever and shift into 2nd gear Ope...

Page 67: ...paved surfac es the two rear wheels are mounted solidly on one axle and turn together at the same speed There fore unless the wheel on the inside of the turn is al lowed to slip or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed WARNING EWB01570 Al...

Page 68: ... 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 over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid ATV over t...

Page 69: ...ures for climb ing hills as described in this Owner s Manu al Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle...

Page 70: ...eight to the uphill side of the ATV If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose control If you are unable to continue up the hill dismount the ATV on the up hill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply th...

Page 71: ...aight uphill Turn the ATV around and re mount following the procedure described in the Owner s Manual RIDING DOWNHILL 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 Improper braking may cause a...

Page 72: ...the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have l...

Page 73: ...mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV CROSSING THROUGH SH...

Page 74: ...ater If necessary apply them several times to let friction dry out the lin ings If the ATV is operated through deep or fast flowing water the tires may float causing loss of traction and loss of control which could lead to an accident Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability U10P60E0 book Page 20 Thurs...

Page 75: ...be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult WARNING EWB01650 Before operating in a new area check for ob stacles Never attempt to ride over large obsta cles such as large rocks ...

Page 76: ...he rear wheels of your ATV start to slide 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 With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers sinc...

Page 77: ...de 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 7 22 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip bac...

Page 78: ...ENT turn signals horn headlight etc FOR PROP ER OPERATION when you come out of the wa ter Do not continue to ride your ATV until you have regained adequate braking ability See page 7 19 U10P60E0 book Page 24 Thursday June 15 2006 4 19 PM ...

Page 79: ...ON AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar wi...

Page 80: ...nce required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for use on this ATV and should be install...

Page 81: ...R MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1200 750 2400 1500 2400 1500 4800 3000 hours 20 75 150 150 300 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 necessary 4 Air filter element Clean and replace if nece...

Page 82: ...ressure and balance and correct if necessary 12 Wheel bearings Check for looseness or damage and replace if necessary 13 Swingarm pivots Check operation and for excessive play and re place bearings if necessary Lubricate with lithium soap based grease 14 Upper and lower arm pivots Lubricate with lithium soap based grease 15 Drive chain Check chain slack and adjust if necessary Check rear wheel ali...

Page 83: ... system Check operation and repair or replace if damaged Check toe in and adjust if necessary 22 Carburetor Check starter choke operation and correct if nec essary Check engine idling speed and adjust if neces sary 23 Crankcase breather system Check breather hose for cracks or other damage and replace if necessary 24 Engine oil Change Check ATV for oil leakage and correct if neces sary 25 Engine o...

Page 84: ...ate throttle lever housing and cable 29 Exhaust system Check for leakage and replace gasket s if neces sary Check for looseness and tighten all screw clamps and joints if necessary 30 Spark arrester Clean 31 Front and rear brake switches Check operation and correct if necessary 32 Lights and switches Check operation and correct if necessary Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB IN...

Page 85: ...the brake master cylinders and calipers and change the brake fluid Every two years replace the piston seals and O ring of the brake equalizer Replace the brake hoses every four years and if cracked or damaged U10P60E0 book Page 7 Thursday June 15 2006 4 19 PM ...

Page 86: ...rk 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 NOTE If the spark plug shows a distinctly different color the engine could be operating im...

Page 87: ...to 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 DR8EA 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 U10P60E0 book ...

Page 88: ... the engine oil level 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 Wait a few minutes until the oil settles before checking 4 Remove the engine oil filler cap and then wipe the dipstick off with a clean rag 5 Insert the dipstick into the filler hole without screwing it in and then remove it again to check the oil level NOTE The engine...

Page 89: ...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 CAUTION ECB00310 When removing the engine oil drain bolt the compression spring oil strainer and O ring will fall out Take care not to lose these parts NOTE Skip steps 5 9 if the oil filter element is not being cleaned 1 Engine oil drain bolt 2 ...

Page 90: ...0 Install the oil strainer compression spring O ring and engine oil drain bolt Tighten the en gine oil drain bolt to the specified torque CAUTION ECB00320 Before installing the engine oil drain bolt be sure to install the O ring compression spring and oil strainer 11 Add the specified amount of the recommend ed engine oil and then install and tighten the engine oil filler cap 1 Oil filter element ...

Page 91: ...eck the oil lev el and correct it if necessary EBU23740 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air 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 ...

Page 92: ...ders 3 Pull the air filter element out of the air filter case 4 Remove the sponge material from the air filter element frame 1 Air filter case cover 2 Air filter case holder 1 Air filter element assembly 1 Unlock U10P60E0 book Page 14 Thursday June 15 2006 4 19 PM ...

Page 93: ...erial should be wet but not drip ping 9 Pull the sponge material over the air filter ele ment frame 10 Apply all purpose grease to the air filter ele ment seat 11 Insert the air filter element into the air filter case and then install the air filter case cover by hooking the holders onto the air filter case 12 Install the seat NOTE The air filter element should be cleaned every 20 40 hours It shou...

Page 94: ... 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 and possible engine over heating EBU27490 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the bolt 2 Remove the tailpipe by pulling it out ...

Page 95: ...ne 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 CAUTION ECB00480 The carburetor has been set and extensively tested at the Yamaha factory Changing th...

Page 96: ...nd if neces sary adjust it to specification by turning the throttle stop screw at the carburetor To in crease the engine idling speed turn the throt tle stop screw in direction a and to decrease it turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment 1 Throttle stop screw Engine idling speed 1450 1550 r min ...

Page 97: ... adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle cable free play turn the adjusting bolt in direction b 3 Tighten the locknut EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring th...

Page 98: ... the wear indicator groove is almost in contact with the disc plate have a Yamaha dealer replace the brake pads as a set NOTE The wheels need to be removed to check the brake pads See page 8 40 EBU24200 Rear brake pads Each brake pad is provided with a wear indicator groove which allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the we...

Page 99: ...luid 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 Minimum level mark 1 Minimum level mark U10P60E0 book Page 21 Thursday June 15 2006 4 19 PM ...

Page 100: ...evel to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24290 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 master cylinders and calipers as well as the brake hoses replaced at the in...

Page 101: ...e performed by a Yamaha dealer EBU24591 Checking the brake pedal position The brake pedal position must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The top of the brake pedal should be positioned 50 2 mm 1 98 in above the top of the frame as shown If the brake pedal is not positioned as spec ified have a Yamaha dealer adjust it ...

Page 102: ...e checked and if necessary adjusted at the intervals specified in the periodic maintenance 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 cabl...

Page 103: ... performance This could increase the chance of a collision or accident After adjusting the parking brake free play block the rear of the ATV off the ground and spin the rear wheels Check to make sure there is no brake drag If brake drag is noticed perform the adjustment again EBU24740 Brake light switches The operation of the brake light switches must be checked and if necessary adjusted at the in...

Page 104: ... EBU24820 Adjusting the clutch lever 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 Loosen the locknut at the clutch lever 1 Brake light switch 2 Brake light swit...

Page 105: ...cknut at the crankcase and the clutch lever NOTE If the specified free play cannot be obtained as de scribed above or if the clutch does not operate cor rectly have a Yamaha dealer check the internal clutch mechanism EBU28142 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the ATV on a level surface NOTE Wh...

Page 106: ...a To loosen the drive chain turn the adjusting bolts in direction b and push the wheels forward Turn each adjusting bolt exactly the same amount to maintain correct axle alignment NOTE There are alignment marks on both drive chain pullers and an alignment mark on each side of the swingarm Make sure to align the same alignment 1 Drive chain slack 1 Axle holding nut upper 2 Axle holding nut lower U1...

Page 107: ...or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten the locknuts and the axle holding nuts to the specified torques NOTE Make sure that the curved edge of the speed sen sor bracket touches the rear wheel hub when tight ening the axle holding nuts 1 Locknut 2 Drive chain slack adjusting bolt 3 Alignment marks 1 Speed sensor bracket 2 Rear whee...

Page 108: ...th steam cleaners high pres sure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECB00580 Do not use engine oil or any other lubricants for the drive chain as they may contain sub stances that could damage the O rings EBU24900 Checking and lubricating the cables The operation and the condition of all ...

Page 109: ...or kinked which could re strict the operation of controls and lead to an accident or injury EBU24920 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 Clutch lever Recommended lubricant Engine oil Recommended lubricant Lithium soap based grease all p...

Page 110: ...arings 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 bearings EBU24992 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the in tervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithi...

Page 111: ... pivoting points must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart Lubricate the pivoting points using a grease gun Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease 1 Grease nipple 1 Grease nipple U10P60E0 book Page 33 Thursday June 15 2006 4 19 PM ...

Page 112: ...icated at the intervals specified in the periodic mainte nance and lubrication chart Lubricate the pivoting points using a grease gun Left side 1 Grease nipple Recommended lubricant Lithium soap based grease 1 Upper grease nipple 2 Lower grease nipple U10P60E0 book Page 34 Thursday June 15 2006 4 19 PM ...

Page 113: ...ttery 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 eg...

Page 114: ...it and then place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and ful ly charge it if necessary To install the battery NOTE Be sure the battery is fully charged 1 Place the battery in its compartment 2 Make sure to properly connect the battery leads to the battery terminals CAUTION ECB00630 Always keep the battery charged Storing a...

Page 115: ...wn fuse and then install a new fuse of the specified amperage WARNING EWB02171 Always use a fuse of the specified rating and never use a substitute object in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical sys tem which could lead to a fire 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse imme...

Page 116: ...ove the lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counterclockwise 3 Insert a new bulb into the socket push it in and then turn it clockwise until it stops 4 Install the lens by installing the screws CAUTION ECB00700 Do not overtighten the screws otherwise the lens may break EBU28030 Replacing a turn signal light bulb 1 Remove the turn signal light len...

Page 117: ...lling the screw CAUTION ECB00870 Do not overtighten the screw otherwise the lens may break EBU28181 Replacing the license plate light bulb If the license plate light bulb burns out replace it as follows 1 Remove the license plate light body by remov ing the screw 2 Remove the socket together with the bulb 1 Screw 1 Screw 2 License plate light body U10P60E0 book Page 39 Thursday June 15 2006 4 19 P...

Page 118: ...by installing the screw CAUTION ECB00880 Do not overtighten the screw as the license plate light body may break EBU28020 Auxiliary light bulb If the auxiliary light bulb burns out have a Yamaha dealer replace it EBU25650 Removing a wheel 1 Loosen the wheel nuts 1 License plate light bulb socket 1 License plate light bulb U10P60E0 book Page 40 Thursday June 15 2006 4 19 PM ...

Page 119: ...nd the nuts NOTE When installing the wheel make sure its arrow mark points toward the rotating direction of the wheel 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques 1 Nut 1 Arrow mark Tightening torques Front wheel nut 45 Nm 4 5 m kgf 32 ft lbf Rear wheel nut 45 Nm 4 5 m kgf 32 ft lbf U10P60E0 book Page 41 Thursday June 15 2006 4 19 PM ...

Page 120: ...ny repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or...

Page 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: ...CAUTION ECB00710 Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type ...

Page 123: ...ause rust To prevent corrosion avoid damp cellars stables because of the presence of ammo nia and areas where strong chemicals are stored Long term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from bu...

Page 124: ...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 prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a c...

Page 125: ...ine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 349 0 cm Bore stroke 83 0 64 5 mm 3 27 2 54 in Compression ratio 9 20 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Recommended engine oil grade API service SG type or higher JASO standard MA 20 10 ...

Page 126: ...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 24 3 166 Secondary reduction system Chain drive Secondary reduction ratio 38 13 2 923 Transmission type Constant mesh 6 speed forward 1 speed reverse Operation Left foot operation Gear ratio 1st 36 16 20 27 29 18 2 68...

Page 127: ...i 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm Front wheel Wheel type Panel wheel Rim size 10 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 9 x 8 5AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DO...

Page 128: ... YTZ10S Voltage capacity 12 V 8 6 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 35 0 35 0 W 1 Tail brake light 12 V 5 0 21 0 W 1 Front turn signal light 12 V 10 0 W Rear turn signal light 12 V 10 0 W Auxiliary light 12 V 5 0 W License plate light 12 V 5 0 W Neutral indicator light 12 V 1 7 W 1 High beam indicator light LED Turn signal indicator light LED Revers...

Page 129: ...BER MODEL LABEL INFORMATION EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame NOTE The vehicle identification number is used to identify your ATV EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts fr...

Page 130: ...11 2 11 1 Model label U10P60E0 book Page 2 Thursday June 15 2006 4 19 PM ...

Page 131: ...is fasteners 5 7 Cleaning 9 1 Clutch lever 4 6 Clutch lever free play adjusting 8 26 D Drive chain 5 4 Drive chain lubricating 8 30 Drive chain slack 8 27 Drive select lever 4 9 Drive select lever and driving in reverse 6 3 E Engine break in 6 6 Engine cold start 6 1 Engine idling speed 8 17 Engine oil 5 3 Engine oil and oil filter element 8 10 Engine starting a warm 6 3 Engine stop switch 4 3 F F...

Page 132: ... 8 8 Specifications 10 1 Speed limiter 4 5 Speedometer 4 2 Starter choke 4 12 Start switch 4 3 Steering lock 4 13 Steering shaft lubricating 8 35 Storage 9 2 Suspension lubricating the upper and lower arm pivots 8 34 Suspension relay arm and connecting arm pivoting points lubricating the rear 8 33 Swingarm pivots lubricating 8 32 T Tail brake light bulb replacing 8 38 Throttle cable free play adju...

Page 133: ...U10P60E0 book Page 3 Thursday June 15 2006 4 19 PM ...

Page 134: ...YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006 06 0 7 1 CR E U10P60E0 book Page 1 Thursday June 15 2006 4 19 PM ...

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