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Yamaha YFM250R-W Owner's Manual
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Yamaha YFM250R-W Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM250R-W
33B-F8199-71

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Summary of Contents for Yamaha YFM250R-W

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM250R-W 33B-F8199-71...
  • Page 2 EBU28980 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 3 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 4 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 5 This ATV is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations before operating this ATV. EBUM0010 YFM250R-W OWNER’S MANUAL ©2011 by MBK INDUSTRIE 1st edition, July 2011...

  • Page 6: Table Of Contents

    EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel .............4-9 SPECIFICATION LABELS ......1-1 Fuel cock ..........4-10 Starter (choke) ..........4-12 SAFETY INFORMATION ......2-1 Steering lock ..........4-13 Seat ............4-13 DESCRIPTION ..........3-1 Adjusting the front shock absorber Left view ............3-1 assemblies ..........4-14 Right view............
  • Page 7 Engine break-in .......... 6-4 General maintenance and lubrication Parking ............6-5 chart ............8-5 Parking on a slope ........6-6 Checking the spark plug ......8-9 Accessories and loading ......6-6 Engine oil and oil filter element ....8-11 Cleaning the air filter element ....8-14 RIDING YOUR ATV ........
  • Page 8 Checking the wheel hub bearings .... 8-34 Lubricating the swingarm pivots ....8-34 Lubricating the upper and lower arm pivots ............8-34 Lubricating the steering shaft ....8-35 Battery ............8-36 Replacing a fuse ........8-38 Headlight bulb .......... 8-39 Headlight beam ........

  • Page 9: Location Of The Warning And Specification Labels

    Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.
  • Page 10 4D3-2816L-20 43P-2816R-01 43P-2816P-00...
  • Page 11 27.5 kPa 27.5 kPa 0.275 kgf/cm² 0.275 kgf/cm² 4.0 psi 4.0 psi 4AA-22259-40 4D3-2816M-M0 2011 YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 8AC-2817L-00...
  • Page 12 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
  • Page 13 NEVER use with drugs or alcohol. Adjust the tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids.
  • Page 14 Overloading can cause loss of control. Loss of control can result in severe injury or death. Model Name ****** Max. Power *** kW *** kg Mass In Running Order **** 1 Year of construction YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN...

  • Page 15: Safety Information

    EBU17431 SAFETY INFORMATION EBU17594 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 16 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 17 speed when climbing a hill. If you stall or roll Always use the size and type of tires specified in backwards, follow the special procedure for this manual. braking described in this manual. Dismount on Always maintain proper tire pressure as de- the uphill side or to a side if pointed straight up- scribed in this manual.
  • Page 18 closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT. Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels.

  • Page 19: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 2 3 4 1. Headlight 1. Spark arrester 2. Fuel cock 2. Seat 3. Starter (choke) 3. Fuel tank cap 4. Throttle stop screw 4. Steering lock 5. Fuse 5. Oil filter element 6.

  • Page 20: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Clutch lever 2. Handlebar switches 3. Speedometer unit 4. Parking brake lever 5. Main switch 6. Engine stop switch 7. Throttle lever 8.

  • Page 21: Instrument And Control Functions

    EBU17733 INSTRUMENT AND CONTROL FUNCTIONS EBU30700 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The meter lighting, auxiliary light and taillight come on, and the engine can be started. The key cannot be removed.

  • Page 22: Indicator Lights

    EBU17793 EBU27980 High beam indicator light “ ” Indicator lights This indicator light comes on when the high beam of the headlight is switched on. EBU28051 Speedometer This speedometer is equipped with an odometer. The odometer shows the total distance traveled. 1.

  • Page 23: Handlebar Switches

    EBU18061 Handlebar switches 1. Engine stop switch “ ” EBU18080 1. Light switch “ / ” Engine stop switch “ ” 2. Start switch “ ” Set this switch to “ ” before starting the engine. 3. Horn switch “ ”...

  • Page 24: Throttle Lever

    EBU28063 EBU28001 Light switch “ / ” Hazard switch “ ” Set the switch to “ ” to turn on the high beam. With the key in the “ON” position, use this switch to Set this switch to “ ” to turn on the low beam. turn on the hazard lights (simultaneous flashing of Set the switch to “...

  • Page 25: Speed Limiter

    crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b). Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be dam- aged.

  • Page 26: Clutch Lever

    3. Tighten the locknut. EBU18411 Brake lever EBU18382 The brake lever is located at the right handlebar Clutch lever grip. To apply the front brake, pull the brake lever The clutch lever is located on the left handlebar toward the handlebar grip. and the ignition circuit cut-off system is incorporat- ed in the clutch lever holder.

  • Page 27: Parking Brake Lever

    When pressing down on the brake pedal, the brak- ing force is applied to the rear brake and a portion of the front brakes. For full braking performance, apply both the brake lever and the brake pedal si- multaneously. 1. Parking brake lever (locked position) 1.

  • Page 28: Shift Pedal

    EWB00220 WARNING Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. Always be sure you have released the park- ing brake before you begin to ride.

  • Page 29: Fuel

    of sparks, open flames, or other sources of ig- nition such as the pilot lights of water heaters and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole.

  • Page 30: Fuel Cock

    Fuel reserve amount: 1.0 L (0.26 US gal, 0.22 Imp.gal) Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane 3. Wipe up any spilled fuel immediately.
  • Page 31 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 32: 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. 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 33: Steering Lock

    EBU28010 To unlock the steering Steering lock 1. Open the steering lock cap, and then insert the key. 2. Turn the key 1/8 turn counterclockwise to re- lease the lock. 3. Remove the key, and then close the steering lock cap. EBU18891 Seat To remove the seat...

  • Page 34: Adjusting The Front Shock Absorber Assemblies

    To install the seat EWB00400 WARNING Insert the projections on the front of the seat into the seat holders and push down on the seat at the Always adjust the shock absorber assemblies rear. Make sure that the seat is securely fitted. on the left and right side to the same setting.

  • Page 35: Adjusting The Rear Shock Absorber Assembly

    3. Position indicator thereby harden the suspension, and in direc- tion (b) to decrease the spring preload and thereby soften the suspension. A special wrench can be obtained at a Yamaha dealer to make this adjustment. Spring preload setting: Minimum (soft):...
  • Page 36 2. Spring preload adjusting nut 3. Distance A Tightening torque: Locknut: 42 Nm (4.2 m·kgf, 30 ft·lbf) A special wrench can be obtained at a Yamaha dealer to make this adjustment. EWB00450 The spring preload setting is determined by WARNING measuring distance A, shown in the illustration.
  • Page 37 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. 4-17...

  • Page 38: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 39 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Rear brake 5-3, 8-22, 8-23, 8-25 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.

  • Page 40: Fuel

    Check that there is no free play in the brake le- do not provide proper braking performance, check ver. If there is free play, have a Yamaha dealer the brake pads for wear. (See page 8-22.) check the brake system.

  • Page 41: Drive Chain

    EBU19770 Recommended tire pressure: Drive chain Front Check the condition of the drive chain and check 27.5 kPa (0.275 kgf/cm², 4.0 psi) the drive chain slack. Lubricate and adjust the Rear drive chain as necessary. (See page 8-29.) 27.5 kPa (0.275 kgf/cm², 4.0 psi) Minimum tire pressure: EBU28083 Tires...
  • Page 42 1. Low-pressure tire gauge 1. Tire wear limit Tire wear limit Tire information When the tire groove decreases to 3 mm (0.12 in) This ATV is equipped with tubeless tires with due to wear, replace the tire. valves. EWB02551 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent.

  • Page 43: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are MAXXIS/C9207 working properly. Correct if necessary. Size: AT21 x 7-10 Type: Tubeless Rear: Manufacturer/model: MAXXIS/M976 Size: AT20 x 10-9 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling,...

  • Page 44: Operation

    If the indicator Read the Owner’s Manual carefully before riding light does not come on, have a Yamaha deal- the ATV. If there is a control or function you do not er check the electrical circuit.

  • Page 45: Starting A Warm Engine

    Ambient temp./starter (choke) position 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine. If the engine is started with the starter (choke) in position (2), keep the starter (choke) in this position to warm up the engine.

  • Page 46: Shifting

    EBU20522 EBU28112 To start out and accelerate Shifting 1. Release the throttle lever, and then release This ATV has a 5-speed forward transmission. The the parking brake. transmission allows you to control the amount of ECB00200 power you have available at a given speed or for NOTICE starting, accelerating, climbing hills, etc.

  • Page 47: Engine Break-In

    5. Once the ATV has attained adequate speed, traction. This could cause loss of control, an release the throttle, and at the same time, accident and injury. It could also cause engine quickly pull in the clutch lever. or drive train damage. 6.

  • Page 48: Parking

    There is never a more important period in the life of engine break-in period, immediately have a your engine than the first 320 km (200 mi) or 20 Yamaha dealer check the ATV. hours of riding. For this reason, you should read the following material carefully.

  • Page 49: Parking On A Slope

    4. Turn the fuel cock to “OFF”. nection to Yamaha manufacture parts and acces- sories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies pro- duce. Therefore, Yamaha can neither endorse nor...
  • Page 50 Do not mount an accessory where it could inter- Yamaha or modifications not specifically recom- fere with your ability to control the ATV. Exam- mended by Yamaha, even if sold and installed by ples include (but are not limited to) a heavy or a Yamaha dealer.
  • Page 51 er, you must use common sense and good practice not to exceed 2nd gear whenever you judgment as the stability and handling of an ATV are carrying heavier loads or when towing a trail- can be changed. When adding accessories, keep the following points in mind: Allow more braking distance.

  • Page 52: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 53: Getting To Know Your Atv

    EBU28125 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is intended for recreational use by expe- WARNING rienced operators only. This section, Riding your Do not operate this ATV or allow anyone else ATV, provides general ATV riding instructions for to operate it without proper instruction.
  • Page 54 Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
  • Page 55 proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. [EWB01411] Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision.
  • Page 56 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 57 opening, even when the throttle lever is pushed to Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see “MAXIMUM LOADING the maximum engine power available and de- LIMIT” below or vehicle labeling). creases the maximum speed of the ATV.
  • Page 58 All parts and accessories added to this ATV should be genuine Yamaha or equivalent components de- signed for use on this ATV and should be installed and used according to instructions. If you have...
  • Page 59 questions, consult an authorized ATV dealer. other hot parts. Check under the vehicle after op- WARNING! Operating this ATV with improper erating in areas where combustible materials may modifications may cause changes in handling have collected. Do not idle or park the vehicle in which in some situations could lead to an acci- long dry grass or other dry ground cover.

  • Page 60: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE Watch carefully for other vehicles. Make sure you This ATV is designed for use on unpaved surfaces know your country’s laws and regulations before only. WARNING! Paved surfaces may seriously you ride on unpaved public streets or roads. Do not affect handling and control of the ATV, and ride on any paved public street, road or motorway.
  • Page 61 have enough time to react to hidden rocks, loose terrain could cause loss of traction or bumps, or holes. Go slowly and be extra care- ATV control, which could result in an accident, ful when operating on unfamiliar terrain. Al- including an overturn.
  • Page 62 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.

  • Page 63: Turning Your Atv

    trol. NOTICE: Do not shift gears without To achieve maximum traction on unpaved surfac- [EWB02631] releasing the throttle. Damage to the engine or es, the two rear wheels turn together at the same drive train may occur. speed. Therefore, unless the wheel on the inside [ECB01071] Use this same procedure as you move into the of the turn is allowed to slip or lose some traction,...

  • Page 64: Climbing Uphill

    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.
  • Page 65 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 or person could be on the other side of the hill.
  • Page 66 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footrests and leaning forward over the handlebars. Whenever possible, ride straight up hills.

  • Page 67: Riding Downhill

    If you start to roll backwards, DO NOT apply the brake pedal, and apply the front brake gradually. The ATV could easily tip over backwards. When fully stopped, apply the brake pedal as well, and then lock the parking brake. Dismount the ATV im- mediately on the uphill side or to a side if pointed straight uphill.
  • Page 68 Never operate the ATV on hills too steep for Whenever possible, ride your ATV straight down- the ATV or for your abilities. The ATV can hill. Avoid sharp angles which could allow the ATV overturn more easily on extremely steep hills to tip or roll over.

  • Page 69: Crossing A Slope

    CROSSING A SLOPE As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the EWB01632 WARNING steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to slopes, be sure not to make sharp turns either up...

  • Page 70: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER EWB01641 WARNING Operating this vehicle through deep or fast- flowing water can lead to loss of control or an overturn. To reduce your risk of drowning or other injuries, use care when crossing through water. Never operate this ATV water deeper than the depth specified in your Owner’s Man- ual, as tires may float, increasing the risk of an overturn.

  • Page 71: Riding Over Rough Terrain

    1. Air filter case check hose RIDING OVER ROUGH TERRAIN EWB01651 WARNING After riding your ATV in water, be sure to drain the Riding improperly over obstacles could cause trapped water by removing the check hose at the loss of control or a collision. Before operating bottom of the air filter case.

  • Page 72: Sliding And Skidding

    cident. Be sure to keep your feet firmly mounted on the footrests at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01662 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 73: What To Do If

    WHAT TO DO... If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footrest to the outside of the turn. Position your weight over the front wheels for better control.
  • Page 74 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 75: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 76: Owner's Manual And Tool Kit

    Always carry the owner’s man- If you do not have the tools or experience required ual along with the low-pressure tire gauge and the for a particular job, have a Yamaha dealer perform owner’s tool kit under the seat. it for you.

  • Page 77: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 79: General Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 80 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years √...
  • Page 81 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Make sure that all nuts, bolts, and screws are √ √ √ √ √ 14 * Chassis fasteners properly tightened.
  • Page 82 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. √ √ √ √ √ Lights and switches • Adjust headlight beam. EBU23071 Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle.

  • Page 83: Checking The Spark Plug

    (the ideal color when the ATV is ridden normally). If the spark plug shows a distinctly different color, 1. Spark plug cap the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV.
  • Page 84 2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.

  • Page 85: Engine Oil And Oil Filter Element

    EBU28957 Engine oil and oil filter element The engine oil should be between the minimum The engine oil level should be checked before and maximum level marks. each ride. In addition, the oil must be changed and the oil filter element must be replaced at the inter- vals specified in the periodic maintenance and lu- brication chart.
  • Page 86 6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. Skip steps 5–7 if the oil filter element is not being replaced. To change the engine oil (with or without oil fil- ter element replacement) 5.
  • Page 87 8. Install the engine oil drain bolt and its new gasket, and then tighten the bolt to the speci- fied torque. Tightening torque: Engine oil drain bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) 9. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap.

  • Page 88: Cleaning The Air Filter Element

    ECB00300 NOTICE There is a check hose at the bottom of the air filter In order to prevent clutch slippage (since the case. If dust or water collects in this hose, empty engine oil also lubricates the clutch), do not the hose and clean the air filter element and air fil- mix any chemical additives.
  • Page 89 1. Air filter case cover 1. Air filter element 2. Air filter case cover holder 2. Washer 3. Wing bolt 4. Loosen the wing bolt. 5. Remove the air filter element together with the 6. Remove the wing bolt and washer from the air wing bolt and washer.
  • Page 90 2. Air filter element frame damaged. 8. Wash the sponge material gently but thor- 11. Apply Yamaha foam air filter oil or other qual- oughly in solvent. WARNING! Always use ity foam air filter oil to the sponge material. parts cleaning solvent to clean the sponge material.
  • Page 91 1. Air filter element seat 1. Washer 14. Install the washer onto the air filter element 15. Insert the air filter element into the air filter frame, and then insert the wing bolt into the case, and then tighten the wing bolt. NOTICE: hole in the air filter element frame.

  • Page 92: Cleaning The Spark Arrester

    17. Install the seat. The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar- eas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions.
  • Page 93 1. Tailpipe 1. Gasket 2. Spark arrester 2. Tailpipe 3. Tailpipe bolt 4. Check the gasket for damage, and replace it if 6. Install the bolts and tighten them to the speci- necessary. fied torque. 5. Make sure the gasket is properly positioned, then insert the tailpipe into the muffler and Tightening torque: align the bolt holes.

  • Page 94: Adjusting The Carburetor

    Therefore, 1. Start the engine and warm it up. most carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- The engine is warm when it quickly responds to the sional knowledge and experience. The adjustment throttle.

  • Page 95: Adjusting The Throttle Lever Free Play

    (a). To decrease the throttle lever free 1600–1700 r/min play, turn the adjusting bolt in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EBU24047 Adjusting the throttle lever free play...

  • Page 96: Valve Clearance

    If a brake pad has worn to the point that must be adjusted by a Yamaha dealer at the inter- the wear indicator groove has almost disappeared, vals specified in the periodic maintenance and lu- have a Yamaha dealer replace the brake pads as brication chart.

  • Page 97: Checking The Brake Fluid Level

    To check the brake pad wear, check the wear indica- tor grooves. If a brake pad has worn to the point that a wear indicator groove almost appears, have a Yamaha dealer replace the brake pads as a set. 8-23...
  • Page 98 Front brake Specified brake fluid: DOT 4 EWB02720 WARNING Improper maintenance can result in loss of braking ability. Observe these precautions: Insufficient brake fluid may allow air to enter the brake system, reducing braking perfor- mance. Clean the filler cap before removing. Use only DOT 4 brake fluid from a sealed contain- 1.

  • Page 99: Changing The Brake Fluid

    If the brake fluid level goes down suddenly, have a Yamaha dealer check the cause before fur- ther riding. EBU24291 Changing the brake fluid...

  • Page 100: Adjusting The Parking Brake Free Play

    The top of the brake pedal should be positioned 40.0 mm (1.57 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. 1. Cable length “A” 2. Locknut 3.

  • Page 101: Brake Light Switches

    ATV off the ground and spin the rear wheels. If the cable length cannot be adjusted to specifica- Check to make sure there is no brake drag. If tion, consult a Yamaha dealer. brake drag is noticed, perform the adjustment 6. Tighten the locknut on the brake cable.

  • Page 102: Adjusting The Clutch Lever Free Play

    10.0 mm (0.20–0.39 in) as shown. If the free play should be adjusted by a Yamaha dealer. is incorrect, adjust it as follows. Turn the rear brake light switch adjusting nut while holding the brake light switch in place.

  • Page 103: Drive Chain Slack

    5. Slide the rubber cover back to its original po- sition. 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. EBUM0201 Drive chain slack The drive chain slack should be checked before 1.
  • Page 104 1. Rear wheel axle pinch bolt 2. Rod 3. Drive chain tensioner 4. Hole A rod can be obtained at a Yamaha dealer to make this adjustment. Tightening torque: Rear axle pinch bolt: 4. Shift the transmission into neutral.

  • Page 105: Lubricating The Drive Chain

    Tightening torque: Speed sensor bracket bolt: This specified clearance is necessary for the 13 Nm (1.3 m·kgf, 9.4 ft·lbf) speedometer to indicate an accurate reading. EBU24882 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.

  • Page 106: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Yamaha Chain and Cable Lube or engine oil EWB02581 WARNING Inspect cables frequently and replace if dam- aged. Corrosion can result when the cable sheaths become damaged, and cables can 1.

  • Page 107: Checking And Lubricating The Brake And Clutch Levers

    Brake lever Checking the shift pedal The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle. EBU28871 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.

  • Page 108: Checking The Wheel Hub Bearings

    Recommended lubricant: Lubricating the swingarm pivots Lithium-soap-based grease The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the pe- EBU24963 riodic maintenance and lubrication chart. Checking the wheel hub bearings The front and rear wheel hub bearings must be...

  • Page 109: Lubricating The Steering Shaft

    1. Upper grease nipple 2. Lower grease nipple EBU25092 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Upper grease nipple 2. Lower grease nipple For parts equipped with a grease nipple, use a grease gun.

  • Page 110: Battery

    EBU2522E KEEP OUT OF REACH OF CHILDREN. Battery ECB00620 The battery is located under the seat. (See page NOTICE 4-13.) Never attempt to remove the battery cell seals, This model is equipped with a VRLA (Valve Regu- as this would permanently damage the battery. lated Lead Acid) battery.
  • Page 111 3. Disconnect the negative battery lead first, To charge the battery then the positive battery lead by removing Have a Yamaha dealer charge the battery as soon their bolt. NOTICE: When removing the bat- as possible if it seems to have discharged. Keep in...

  • Page 112: Replacing A Fuse

    To install the battery 3. Install the battery holding plate by installing the bolts, and then hook the band to secure the owner’s tool kit. Be sure the battery is fully charged. 4. Install the seat. (See page 4-13.) 1. Place the battery in its compartment. EBU30710 2.

  • Page 113: Headlight Bulb

    EBU28160 the main switch when checking or replacing a Headlight bulb fuse. If the headlight bulb burns out, have a Yamaha dealer replace it. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. WARNING! Always use a fuse of the spec-...

  • Page 114: Headlight Beam

    EBU28170 Headlight beam If a headlight beam adjustment is necessary, have a Yamaha dealer perform it. EBU25601 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Remove the lens by removing the screws.

  • Page 115: Auxiliary Light Bulb

    1. Wheel nut 4. Install the lens by installing the screw. NOTICE: Do not overtighten the screw, otherwise the lens may break. [ECB00871] EBU28020 Auxiliary light bulb If the auxiliary light bulb burns out, have a Yamaha dealer replace it. 8-41...

  • Page 116: Installing A Wheel

    Rear 1. Arrow mark 1. Wheel nut 3. Lower the ATV to the ground. 3. Elevate the ATV and place a suitable stand 4. Tighten the wheel nuts to the specified under the frame. torques. 4. Remove the nuts from the wheel. 5.

  • Page 117: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 118: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 119: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU28191 speeds to let friction dry out the linings. Cleaning NOTICE: Excessive water pressure [EWB02311] Frequent, thorough cleaning of your ATV will not may cause water seepage and deteriora- only enhance its appearance but will improve its tion of wheel bearings, brakes, transmis- general performance and extend the useful life of sion seals and electrical devices.

  • Page 120: Storage

    abrasives which may mar the paint or protec- 4. Fill up the fuel tank and add fuel stabilizer (if tive finish. When finished cleaning, start the available) to prevent the fuel from deteriorat- engine and let it idle for several minutes. ing.
  • Page 121 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.

  • Page 122: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Compression ratio: 9.50 : 1 Overall length: Starting system: 1650 mm (65.0 in) Electric starter Overall width: Lubrication system: 1080 mm (42.5 in) Wet sump Overall height: Engine oil: 1100 mm (43.3 in) Seat height: Recommended brand: 730 mm (28.7 in) YAMALUBE Wheelbase:...
  • Page 123 Engine oil quantity: Primary reduction ratio: Without oil filter element replacement: 76/22 (3.455) 1.25 L (1.32 US qt, 1.10 Imp.qt) Secondary reduction system: With oil filter element replacement: Chain drive 1.35 L (1.43 US qt, 1.19 Imp.qt) Secondary reduction ratio: Air filter: 38/14 (2.714) Transmission type:...
  • Page 124 Size: Rear wheel: AT21 x 7-10 Wheel type: Manufacturer/model: Panel wheel MAXXIS/C9207 Rim size: Rear tire: 9 x 8.5AT Type: Front brake: Tubeless Type: Size: Disc brake AT20 x 10-9 Operation: Manufacturer/model: Right hand operation MAXXIS/M976 Specified brake fluid: Loading: DOT 4 Maximum loading limit: Rear brake:...
  • Page 125 Wheel travel: Turn signal indicator light: 200 mm (7.9 in) Electrical system: Fuses: Ignition system: Main fuse: DC CDI 15.0 A Charging system: Accessory fuse: AC magneto 7.5 A Battery: Model: YTZ7S Voltage, capacity: 12 V, 6.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage ×...

  • Page 126: Consumer Information

    Record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 127 1. Model label 11-2...
  • Page 128 INDEX Drive chain slack ............8-29 Accessories and loading ..........6-6 Air filter element, cleaning ..........8-14 Engine break-in .............. 6-4 Auxiliary light bulb ............8-41 Engine, cold start ............6-1 Engine idling speed ............8-20 Engine oil ............... 5-3 Battery ................
  • Page 129 Steering lock ..............4-13 Steering shaft, lubricating ..........8-35 Main switch ..............4-1 Storage ................9-2 Maintenance and lubrication chart ......... 8-5 Suspension, lubricating the upper and lower arm Maintenance chart, emission control system ....8-3 pivots ................. 8-34 Model label ..............11-1 Swingarm pivots, lubricating ........
  • Page 130 PRINTED IN FRANCE 2011.09 (E)

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