Yamaha YFM35RX Owner's Manual
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Yamaha YFM35RX Owner's Manual

Yamaha YFM35RX Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM35RX
5YT-28199-64

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Summary of Contents for Yamaha YFM35RX

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM35RX 5YT-28199-64...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2007.04-0.3×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 OWNER’S MANUAL YFM35RX 5YT-28199-64-E0...
  • Page 5 INTRODUCTION EBU17320 Congratulations on your purchase of the Yamaha YFM35RX. This ATV represents the result of many years of 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 6 EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 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: 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...
  • Page 7 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! 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.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Fuel .............4-8 Fuel cock ............4-9 LOCATION OF THE WARNING AND Starter (choke) ..........4-11 SPECIFICATION LABELS ......2-1 Seat ............4-11 Adjusting the front shock DESCRIPTION ..........3-1 absorber assemblies .......4-12 Left view ............3-1 Adjusting the rear shock Right view............
  • Page 9 Starting a warm engine ......6-3 PERIODIC MAINTENANCE AND Operating the drive select lever and MINOR REPAIR ..........8-1 driving in reverse ........6-3 Owner’s manual and tool kit .......8-1 Shifting ............6-4 Periodic maintenance chart Engine break-in .......... 6-6 for the emission control system ....8-3 Parking ............
  • Page 10 Checking and lubricating the brake and SPECIFICATIONS ........10-1 clutch levers ........... 8-33 Checking and lubricating the brake and CONSUMER INFORMATION.......11-1 shift pedals ..........8-33 Identification numbers .......11-1 Checking the wheel hub bearings .... 8-34 Lubricating the swingarm pivots ....8-34 Lubricating the rear suspension relay arm and connecting arm pivoting points ..

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION EBU17462 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 12 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 13 speed when climbing a hill. If you stall or roll Always be sure there are no obstacles or people backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 14 nition such as the pilot lights of water heat- EWB00070 WARNING ers and clothes dryers. Gasoline can catch fire and you could be burned. Always operate your ATV in an area with ade- When transporting the ATV in another vehi- quate ventilation.

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 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. For Europe and Oceania...
  • Page 17 Impostare a pneumatici freddi. Bei kalten Reifen. Wanneer de banden koud zijn. Ajuste con los Regular com pneus 5FK-2151H-00 neumáticos en frío. frios. Pneus à froid. Ställ in med kalla däck. 5NF-21696-M0 YAMAHA MOTOR CO., LTD. SHIZUOKA JAPAN YAMAHA 4GB-2155A-00...
  • Page 18 For Europe...
  • Page 19 For Oceania...
  • Page 20 For Oceania WARNING UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 5FE-21697-01...

  • Page 21: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly spring preload adjusting 1. Spark arrester ring 2. Fuse 2. Fuel cock 3. Rear shock absorber assembly spring preload adjusting 3. Throttle stop screw 4. Air filter case 4.

  • Page 22: Controls And Instruments

    EBU17712 Controls and instruments 1. Clutch lever 2. Parking brake lever 3. Front brake fluid reservoir 4. Brake lever 5. Throttle lever 6. Main switch 7. Handlebar switches NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 23: Instrument And Control Functions

    EBU17731 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

  • Page 24: Indicator Lights

    EBU17791 EBU18061 Indicator lights Handlebar switches 1. Reverse indicator light “R” 1. Light switch “ /OFF” 2. Neutral indicator light “N” 2. Engine stop switch “ ” 3. Start switch “ ” EBU17830 Reverse indicator light “ ” EBU18080 Engine stop switch “ ”...

  • Page 25: Throttle Lever

    EBU18100 EBU18280 Start switch “ ” Throttle lever Push this switch to crank the engine with the start- Once the engine is running, movement of the throt- tle lever will increase the engine speed. ECB00050 Regulate the speed of the ATV by varying the CAUTION: throttle position.

  • Page 26: Speed Limiter

    If the throttle does not work smoothly, check for the cause. Correct the problem be- fore riding the ATV or consult a Yamaha dealer. EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 27: Clutch Lever

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

  • Page 28: Parking Brake Lever

    1. Brake pedal 1. Parking brake lever (locked position) 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).

  • Page 29: 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 30: Fuel Tank Cap

    1. Drive select lever 1. Fuel tank cap EBU18720 EBU18752 Fuel tank cap Fuel Remove the fuel tank cap by turning it counter- Make sure that there is sufficient fuel in the tank. clockwise. Fill the fuel tank to the bottom of the filler tube as shown.

  • Page 31: Fuel Cock

    ECB00070 CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. EWB00310 WARNING Do not overfill the fuel tank. Fuel expands 1.
  • Page 32 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “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 33: 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 pointing to “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 34: Adjusting The Front Shock Absorber Assemblies

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat EBU18990 Insert the projections on the front of the seat into Adjusting the front shock absorber as- the seat holders and push down on the seat at the semblies rear.
  • Page 35 1. Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: Maximum (hard): 4-13...

  • Page 36: Adjusting The Rear Shock Absorber Assembly

    Adjust the spring preload as follows. NOTE: 1. Loosen the locknut. A special wrench can be obtained at a Yamaha 2. Turn the adjusting nut in direction (a) to in- dealer to make this adjustment. crease the spring preload and thereby harden...
  • Page 37 1. Special wrench 1. Distance A 3. Tighten the locknut to the specified torque. Spring preload setting: Minimum (hard): Tightening torque: Distance A = 218.5 mm (8.6 in) Locknut: Standard: 42 Nm (4.2 m·kgf, 30 ft·lbf) Distance A = 228.5 mm (9.0 in) Maximum (soft): ECB00080 Distance A = 233.5 mm (9.2 in)
  • Page 38 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. 4-16...

  • Page 39: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 40 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 recommended brake fluid to specified level if necessary.

  • Page 41: Fuel

    Brake lever and brake pedal (See page 4-8.) Check that there is no free play in the brake le- EWB00520 ver. If there is free play, have a Yamaha dealer WARNING check the brake system. Do not overfill the fuel tank. Fuel expands Check for correct brake pedal height.

  • Page 42: Throttle Lever

    Apply the open smoothly and spring back to the idle position brakes firmly for one minute. If there is any leak- when released. Have a Yamaha dealer correct if age, have a Yamaha dealer check the brake sys- necessary. tem. EBU19770...

  • Page 43: Measuring The Tire Pressure

    Front: • Tire pressure below the minimum speci- Manufacturer/model: fied could cause the tire to dislodge from DUNLOP/KT851B the rim under severe riding conditions. Size: Minimum tire pressure: AT21 x 7-10 Front: Type: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Tubeless Rear: Rear: 22.0 kPa (3.2 psi) (0.220 kgf/cm²)

  • Page 44: Tire Wear Limit

    Recommended pressure: NOTE: Front The low-pressure tire gauge is included as stan- 25.0 kPa (3.6 psi) (0.250 kgf/cm²) dard equipment. Make two measurements of the Rear tire pressure and use the second reading. Dust or 25.0 kPa (3.6 psi) (0.250 kgf/cm²) dirt in the gauge could cause the first reading to be Minimum: incorrect.

  • Page 45: Chassis Fasteners

    1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.

  • Page 46: Operation

    If there is a control or func- indicator light should come on. If the indicator tion you do not understand, ask your Yamaha light does not come on, have a Yamaha deal- dealer. er check the electrical circuit.
  • Page 47 5. Use the starter (choke) in reference to the fig- 6. Completely close the throttle lever and start ure: the engine by pushing the start switch. Position (1): NOTE: Cold engine start with ambient temperature If the engine fails to start, release the start switch, below 5 °C (40 °F).

  • Page 48: Starting A Warm Engine

    NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm.

  • Page 49: Shifting

    If the indicator light does not come on, have When it stops, it will be in first gear. Raise the pedal a Yamaha dealer check the electrical circuit. slightly to reach the neutral position. 5. Check behind you for people or obstacles, and then release the brake pedal.
  • Page 50 ECB00200 EBU20650 To decelerate CAUTION: When slowing down or stopping, release the throt- Always close the throttle before shifting gears, tle and apply the brakes smoothly and evenly. As otherwise damage to the engine and drive train you slow down, shift to a lower gear. Be sure that may result.

  • Page 51: Engine Break-In

    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 52: Parking On A Slope

    Do not 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.

  • Page 53: Accessories And Loading

    However, judgment as the stability and handling of an ATV it is not possible for Yamaha to test all non- can be changed. When adding accessories, keep Yamaha accessories, nor control over their qual-...
  • Page 54 Never exceed the weight limits shown. An over- Allow more braking distance. A heavier ATV loaded ATV can be unstable. takes longer to stop. Avoid making sharp turns unless at very slow MAXIMUM LOADING LIMIT speeds. ATV loading limit (total weight of rider, cargo, Avoid hills and rough terrain.

  • Page 55: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 56: Getting To Know Your Atv

    EBU21611 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 GETTING TO KNOW YOUR ATV you are totally familiar with the ATV’s handling and This ATV is intended for recreational use by expe- performance characteristics.
  • Page 57 Not recommended for children under 16 years This ATV is designed to carry operator only – of age. passengers prohibited. EWB01390 EWB01400 WARNING WARNING A child under 16 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 90 cc.
  • Page 58 Apparel EWB01410 WARNING Always wear an approved motorcycle helmet that fits properly. Never operate this ATV without wearing an ap- You should also wear: proved motorcycle helmet, eye protection and eye protection (goggles or face shield) protective clothing. Operating without an ap- gloves proved motorcycle helmet increases your boots...
  • Page 59 in the Owner’s Manual. Failure to inspect the ATV before operating or failure to properly maintain the ATV increases the possibility of an accident or equipment damage. EWB01440 WARNING 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.
  • Page 60 Speed limiter Loading and accessories For riders less experienced with this model, the As originally equipped, this ATV is not designed to throttle lever housing is equipped with a speed lim- carry cargo or tow a trailer. If you choose to add ac- iter.
  • Page 61 Always follow the instructions in your Own- EWB01470 WARNING er’s Manual for carrying cargo or pulling a trailer. Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation. Removing even one hand or During operation foot can reduce your ability to control the ATV Always keep your feet on the footboards during op-...
  • Page 62 ATV should be gen- Do not operate, idle, or park the ATV in dry uine Yamaha or equivalent components de- grass, dry ground cover, or combustible ma- signed for use on this ATV and should be terials.

  • Page 63: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE This ATV is designed for use on unpaved surfaces only. Riding on paved surfaces can cause loss of control. EWB01510 WARNING While riding on unpaved public streets or roads Always avoid paved surfaces, including side- may be legal in your area, such operation can in- walks, driveways, parking lots and streets.
  • Page 64 EWB01520 EWB01530 WARNING WARNING Never operate this ATV on any paved street, Go slowly and be extra careful when operating paved road or motorway. You can collide with on unfamiliar terrain. Always be alert to chang- another vehicle. In many areas, it is illegal to ing terrain conditions when operating the ATV.
  • Page 65 when operating on excessively rough, slippery or loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. EWB01550 WARNING 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.
  • Page 66 haust pipe will be hot when riding and afterwards; do not allow skin or clothing to 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.

  • Page 67: Turning Your Atv

    EWB01720 TURNING YOUR ATV WARNING To achieve maximum traction on unpaved surfac- es, the two rear wheels are mounted solidly on one Always open the throttle gradually and release axle and turn together at the same speed. There- the clutch lever slowly. Otherwise, the ATV could wheelie which would increase the fore, unless the wheel on the inside of the turn is al- chance of an accident.

  • Page 68: Climbing Uphill

    Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip.
  • Page 69 EWB01580 Never go over the top of any hill at high WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never operate the ATV on hills too steep for the of the hill. ATV or for your abilities.
  • Page 70 EWB01600 WARNING Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.

  • Page 71: Riding Downhill

    EWB01731 WARNING Use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock the parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill.

  • Page 72: Crossing A Slope

    Whenever possible, ride your ATV straight down- hill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear. EWB01620 WARNING Always follow proper procedures for going...

  • Page 73: Crossing Through Shallow Water

    As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill.
  • Page 74 EWB01640 WARNING Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the lin- ings.

  • Page 75: Riding Over Rough Terrain

    1. Air filter case check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- ECB00240 tion. Look out for obstacles which could cause CAUTION: damage to the ATV or could lead to an upset or ac- After riding your ATV in water, be sure to drain cident.

  • Page 76: Sliding And Skidding

    you go over obstacles, always follow proper If the rear wheels of your ATV start to slide side- procedures as described in the Owner’s Manu- ways, control can usually be regained (if there is room to do so) by steering in the direction of the slide.

  • Page 77: What To Do If

    EWB01661 If your ATV starts to slide sideways: WARNING Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not Learn to safely control skidding or sliding by recommended until you have corrected the practicing at low speeds and on level, smooth terrain.
  • Page 78 BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-19.) 7-24...

  • Page 79: Periodic Maintenance And Minor Repair

    EBU28781 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21670 otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with Safety is an obligation of the owner. Periodic in- maintenance work. spection, adjustment and lubrication will keep your...
  • Page 80 NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING Never modify this ATV through improper in-...

  • Page 81: 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 82 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 83: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) √...
  • Page 84 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 for excessive play, and re- √ √ √ Swingarm pivots place bearings if necessary. •...
  • Page 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Engine oil filter ele- √ √ √ • Clean or replace if necessary. ment √ √ √ Engine oil strainer •...
  • Page 86 • Replace the brake hoses every four years and if cracked or damaged.

  • Page 87: Checking The Spark Plug

    NOTE: 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 88 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DR8EA To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

  • Page 89: Engine Oil And Oil Filter Element

    3. Remove the engine oil filler cap, and then NOTE: wipe the dipstick off with a clean rag. If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
  • Page 90 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level. 6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. To change the engine oil (with or without oil fil- ter element cleaning) 1.
  • Page 91 5. Remove the oil filter element cover by remov- 9. Install the oil filter element cover by installing ing the bolts, and then remove the oil filter el- the bolts, and then tighten them to the speci- ement. fied torque. Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

  • Page 92: Cleaning The Air Filter Element

    12. Start the engine, and then let it idle for several Recommended oil: minutes while checking it for oil leakage. If oil See page 10-1. is leaking, immediately turn the engine off and Oil quantity: check for the cause. Without oil filter element replacement: 13.
  • Page 93 1. Air filter case check hose 1. Air filter case cover 2. Air filter case holder 1. Remove the seat. (See page 4-11.) 3. Pull the air filter element out of the air filter 2. Remove the air filter case cover by unhooking case.
  • Page 94 1. Air filter element assembly 1. Air filter element retaining plate 2. Air filter element frame 4. Remove the sponge material from the air filter 3. Sponge material element frame. 4. Air filter element seat 5. Wash the sponge material gently but thor- oughly in solvent.
  • Page 95 ECB00440 10. Apply all-purpose grease to the air filter ele- CAUTION: ment seat. 11. Insert the air filter element into the air filter Do not twist the sponge material when squeez- case, and then install the air filter case cover ing it.

  • Page 96: Cleaning The Spark Arrester

    will affect carburetor jetting with subsequent 3. Tap the tailpipe lightly, and then use a wire poor performance and possible engine over- brush to remove any carbon deposits from the heating. spark arrester portion of the tailpipe and inside of the tailpipe housing. EBU27701 Cleaning the spark arrester Select a well-ventilated area free of combustible...

  • Page 97: Adjusting The Carburetor

    Therefore, most carburetor adjustments should be left to a Tightening torque: Yamaha dealer, who has the necessary profes- Purging bolt: sional knowledge and experience. The adjustment 27 Nm (2.7 m·kgf, 19 ft·lbf) 8-19...

  • Page 98: Adjusting The Engine Idling Speed

    NOTE: NOTE: If the specified idling speed cannot be obtained as The engine is warm when it quickly responds to the described above, have a Yamaha dealer make the throttle. adjustment. 2. Attach the tachometer to the spark plug lead.

  • Page 99: Adjusting The Throttle Cable Free Play

    (b). must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. 8-21...

  • Page 100: Checking The Front And Rear Brake Pads

    Yamaha dealer replace the brake pads as a set. a Yamaha dealer replace the brake pads as a set. 1. Wear indicator groove 1.

  • Page 101: Checking The Brake Fluid Level

    EBU24251 Rear brake Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary.

  • Page 102: Changing The Brake Fluid

    Brake fluid may deteriorate painted surfaces or free play of zero mm (zero in) as shown. If the free plastic parts. Always clean up spilled fluid imme- play is incorrect, have a Yamaha dealer check the diately. brake system. As the brake pads wear, it is normal for the brake fluid level to gradually go down.

  • Page 103: Checking The Brake Pedal Position

    Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be 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.

  • Page 104: Adjusting The Parking Brake Free Play

    NOTE: 1. Locknut If the cable length cannot be adjusted to specifica- 2. Adjusting bolt tion, consult a Yamaha dealer. 3. Cable length “A” 5. Tighten the locknut on the brake cable. 1. Release the parking brake by moving the 6.

  • Page 105: Brake Light Switches

    The brake light switch for the brake pedal can be Tightening torque: adjusted as follows, but the other brake light Locknut (rear brake caliper): switches should be adjusted by a Yamaha dealer. 16 Nm (1.6 m·kgf, 11 ft·lbf) NOTE: EWB02090...

  • Page 106: Adjusting The Clutch Lever Free Play

    1. Brake light switch 1. Locknut 2. Brake light switch adjusting nut 2. Clutch lever free play adjusting bolt 3. Clutch lever free play EBU24820 Adjusting the clutch lever free play 1. Loosen the locknut at the clutch lever. 2. To increase the clutch lever free play, turn the The clutch lever free play must be checked and, if adjusting bolt at the clutch lever in direction necessary, adjusted at the intervals specified in the...

  • Page 107: Drive Chain Slack

    8. Tighten the locknut at the crankcase and the 25.0–35.0 mm (0.98–1.38 in) 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. 8-29...
  • Page 108 1. Drive chain slack 1. Axle holding bolt (upper) 2. Axle holding bolt (lower) 3. If the drive chain slack is incorrect, adjust it as 2. Loosen the locknut on each side of the swing- follows. arm. To tighten the drive chain, turn the ad- To adjust the drive chain slack justing bolts in direction (a).

  • Page 109: Lubricating The Drive Chain

    mark on both drive chain pullers with the alignment 3. Tighten the locknuts and the axle holding bolts mark on either side of the swingarm for proper to the specified torques. wheel alignment. Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) Axle holding bolt (upper): 120 Nm (12.0 m·kgf, 85 ft·lbf) Axle holding bolt (lower):...

  • Page 110: Checking And Lubricating The Cables

    ECB00560 essary. If a cable is damaged or does not move CAUTION: smoothly, have a Yamaha dealer check or replace 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 Recommended lubricant: small soft brush.

  • Page 111: Checking And Lubricating The Brake And Clutch Levers

    EBU24921 Clutch lever 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. Recommended lubricants: Brake lever: Silicone grease Clutch lever: Lithium-soap-based grease (all-purpose grease)

  • Page 112: Checking The Wheel Hub Bearings

    If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- ings. EBU24992 Lubricating the swingarm pivots...
  • Page 113 Recommended lubricant: Lithium-soap-based grease 1. Grease nipple 1. Grease nipple 1. Grease nipple 8-35...

  • Page 114: Lubricating The Upper And Lower Arm Pivots

    EBU25030 Right side Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun. Recommended lubricant: Lithium-soap-based grease Left side 1.

  • Page 115: Battery

    Check and, if necessary, tighten the battery lead connections. To charge the battery ECB00620 Have a Yamaha dealer charge the battery as soon CAUTION: as possible if it seems to have discharged. Keep in Never attempt to remove the battery cell seals, mind that the battery tends to discharge more as this would permanently damage the battery.

  • Page 116: Replacing The Fuse

    2. Make sure to properly connect the battery access to a constant-voltage battery charg- leads to the battery terminals. er, have a Yamaha dealer charge your bat- tery. EBU25242 Replacing the fuse 1. Positive battery terminal 2. Negative battery terminal...

  • Page 117: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25541 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 118 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. 3. Remove the defective bulb from the headlight ECB00650 CAUTION: unit by pulling it out. EWB02220 Do not touch the glass part of the headlight WARNING bulb to keep it free from oil, otherwise the A headlight bulb is hot when it is on and imme- transparency of the glass, the luminosity of the...

  • Page 119: Adjusting A Headlight Beam

    If the tail/brake light bulb burns out, replace it as 7. Adjust the headlight beam if necessary. follows. 1. Remove the lens by removing the screws. EBU25560 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 8-41...

  • Page 120: Removing A Wheel

    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. ECB00700 CAUTION: Do not overtighten the screws, otherwise the lens may break. EBU25650 Removing a wheel 1.

  • Page 121: Installing A Wheel

    4. Remove the wheel. quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- EBU25660 rience, and know-how to service the ATV properly. Installing a wheel Use only genuine Yamaha replacement parts. Im- 1.

  • Page 122: 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 123: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25900 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 124: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the brakes after washing. Apply the brakes several 2.
  • Page 125 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-37.

  • Page 126: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 1780 mm (70.1 in) Electric starter Overall width: Lubrication system: 1095 mm (43.1 in) Wet sump Overall height: Engine oil: 1080 mm (42.5 in) Seat height: Type: 820 mm (32.3 in) SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 Wheelbase: or SAE20W40 or SAE20W50...
  • Page 127 Engine oil quantity: Transmission: Without oil filter element replacement: Primary reduction system: 2.50 L (2.64 US qt) (2.20 Imp.qt) Spur gear With oil filter element replacement: Primary reduction ratio: 2.60 L (2.75 US qt) (2.29 Imp.qt) 76/24 (3.166) Air filter: Secondary reduction system: Air filter element: Chain drive...
  • Page 128 Caster angle: Rear: 6.0 ° 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Trail: Maximum: 26.0 mm (1.02 in) Front: Front tire: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Rear: Type: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Tubeless Front wheel: Size: AT21 x 7-10 Wheel type: Manufacturer/model: Panel wheel...
  • Page 129 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Neutral indicator light: Double wishbone 12 V, 1.7 W × 1 Spring/shock absorber type: Reverse indicator light: Coil spring/oil damper 12 V, 1.7 W × 1 Wheel travel: Fuse: 200 mm (7.9 in) Rear suspension: Fuse:...

  • Page 130: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 131 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 from a Yamaha deal- 11-2...
  • Page 132 INDEX Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-8 Air filter element, cleaning ..........8-14 Engine break-in .............. 6-6 Engine, cold start ............6-1 Engine idling speed ............8-20 Battery ................8-37 Engine oil ............... 5-3 Brake and clutch levers, checking and lubricating ..
  • Page 133 Steering shaft, lubricating ..........8-36 Storage ................9-2 Main switch ..............4-1 Suspension, lubricating the upper and Maintenance and lubrication chart ......... 8-5 lower arm pivots ............8-36 Maintenance chart, emission control system ....8-3 Suspension relay arm and connecting Model label ..............
  • Page 134 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2007.04-0.3×1 CR...

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