READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM25BV WARNING LIT-11626-19-40 This ATV should not be ridden by anyone under 16 years of age.
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EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU00941 INTRODUCTION 1- Congratulations on your purchase of the Yamaha YFM25BV. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting 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.
EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU00801 IMPORTANT MANUAL INFORMATION 1- FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
EE.book Page 2 Friday, May 27, 2005 2:09 PM EBU15000 IMPORTANT NOTICE 2- This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV.
EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1 2 SAFETY INFORMATION.................. 2-1 3 DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2 Key identification number................ 3-2 Vehicle identification number .......... 3-3 Model label ................................
EE.book Page 2 Friday, May 27, 2005 2:09 PM 5 6 PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-3 Fuel ................................................. 5-5 Engine oil ........................................ 5-7 Final gear oil.................................... 5-7 Throttle lever ................................... 5-7 Fittings and fasteners...................... 5-8 Lights............................................... 5-8 Switches....................................
EE.book Page 3 Friday, May 27, 2005 2:09 PM 8 PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1 Owner’s manual and tool kit............ 8-1 Periodic maintenance chart for the emission control system.......... 8-3 General maintenance and lubrication chart ............................. 8-4 Engine oil and oil filter element ....... 8-6 Final gear oil .................................. 8-12 Spark plug inspection.................... 8-15 Air filter element cleaning..............
EE.book Page 4 Friday, May 27, 2005 2:09 PM 9 CLEANING AND STORAGE............ 9-1 A. Cleaning...................................... 9-1 B. Storage ....................................... 9-3 10 SPECIFICATIONS.......................... 10-1 11 NOISE REGULATION.................... 11-1 12 MAINTENANCE RECORD ............ 12-1 13 ATV LIMITED WARRANTY............ 13-1 14 YAMAHA EXTENDED SERVICE (Y.E.S.) ...........................................
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EE.book Page 2 Friday, May 27, 2005 2:09 PM 2 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 1 2 3 Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 4 5 6 1 7 WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident.
EE.book Page 3 Friday, May 27, 2005 2:09 PM 5 3 6 4 WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum rear cargo limit of : 45kg (99 lbs) NEVER sit on the carrier. Refer to instructions in the Owner’s Manual.
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EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU13351 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.
EE.book Page 2 Friday, May 27, 2005 2:09 PM ● ● ● ● ● ● ● ● ● ● Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions.
EE.book Page 3 Friday, May 27, 2005 2:09 PM ● ● ● ● ● Always follow proper procedures for climbing hills as described in this manual. 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. 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.
EE.book Page 4 Friday, May 27, 2005 2:09 PM ● ● ● ● ● ● ● Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability.
EE.book Page 5 Friday, May 27, 2005 2:09 PM WARNING When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately.
EE.book Page 6 Friday, May 27, 2005 2:09 PM WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.
EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1- 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Spark arrester Storage compartment Air filter case Engine oil dipstick Front brake fluid reservoir Brake pedal Clutch adjusting bolt Engine oil filter element Rear brake light switch Headlight Fuel cock Recoil starter Fuses Battery 15. Tail/brake light 16. Rear shock absorber spring preload adjusting ring 17. Engine oil drain bolt 18. Shift pedal 19.
EE.book Page 2 Friday, May 27, 2005 2:09 PM EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: Key identification number The key identification number is stamped on the key as shown in the following illustration.
EE.book Page 3 Friday, May 27, 2005 2:09 PM EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 1.
EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU00039 CONTROL FUNCTIONS 1 WARNING 2 Indicates a potential hazard that could result in serious injury or death. 3 4 EBU00942 5 Main switch Functions of the respective switch positions are as follows: 6 7 8 ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. 9 10 11 12 OFF: All electrical circuits are switched off. The key can be removed in this position.
EE.book Page 2 Friday, May 27, 2005 2:09 PM EBU00043 EBU00053 Indicator lights Handlebar switches 1. Reverse indicator light “R” 2. Neutral indicator light “N” 1. Light switch “OFF/ / 2. Engine stop switch “ / 3. Start switch “ ” ” ” EBU12500 EBU12050 Reverse indicator light “R” This indicator light comes on when the drive select lever is in the “R” position. Engine stop switch “ / ” Make sure that the engine stop switch is set to “ ” before starting the engine.
EE.book Page 3 Friday, May 27, 2005 2:09 PM EBU12040 EBU06070 Light switch “OFF/ / ” Set the switch to “ ” to turn on the low beam and the taillight. Set the switch to “ ” to turn on the high beam and the taillight. Set the switch to “OFF” to turn off all the lights. Start switch “ ” The starter motor cranks the engine when this switch is pushed. CAUTION: _ See starting instructions prior to starting the engine. (See page 6-1 for details.
EE.book Page 4 Friday, May 27, 2005 2:09 PM EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly.
EE.book Page 5 Friday, May 27, 2005 2:09 PM EBU11590 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result.
EE.book Page 6 Friday, May 27, 2005 2:09 PM EBU00070 EBU00732 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. Push down on the pedal or pull the lever toward the handlebar to apply the rear brake. 1. Front brake lever 1.
EE.book Page 7 Friday, May 27, 2005 2:09 PM 1.
EE.book Page 8 Friday, May 27, 2005 2:09 PM EBU00074 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine.
EE.book Page 9 Friday, May 27, 2005 2:09 PM EBU00083 EBU00085 Shift pedal This machine is equipped with a constantmesh 5-speed transmission. The shift pedal is located on the left side of the engine. Neutral is at the bottom position. Drive select lever The drive select lever is used for driving the machine either forward or in reverse. Refer to page 6-4 for drive select lever operation. 1. Drive select lever 1. Shift pedal N.
EE.book Page 10 Friday, May 27, 2005 2:09 PM EBU00590 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out. WARNING POTENTIAL HAZARD Starting the engine in gear and/or starting the engine without setting the parking brake. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident.
EE.book Page 11 Friday, May 27, 2005 2:09 PM EBU00092 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1.
EE.book Page 12 Friday, May 27, 2005 2:09 PM EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve.
EE.book Page 13 Friday, May 27, 2005 2:09 PM EBU00950 Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “Starting a cold engine” for proper operation. (See page 6-1.) 1.
EE.book Page 14 Friday, May 27, 2005 2:09 PM EBU00567 Seat To remove the seat, pull the seat lock lever upward and pull up 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. 1. Seat 2. Seat lock lever 1. Projection (× 2) 4-14 2.
EE.book Page 15 Friday, May 27, 2005 2:09 PM EBU10620 Storage compartment The storage compartment is located under the seat. (See page 4-14 for seat removal and installation procedures.) When storing any documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartment. NOTE: There is a check hose at the bottom of the storage compartment.
EE.book Page 16 Friday, May 27, 2005 2:09 PM EBU00582 Front carrier Maximum load limit: 30 kg (66 lb) EBU00583 Rear carrier Maximum load limit: 45 kg (99 lb) 1. Spring preload adjusting ring EBU01103 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions.
EE.book Page 17 Friday, May 27, 2005 2:09 PM 1. Special wrench Standard position: 2 1 - Minimum (soft) 5 - Maximum (hard) EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death.
EE.book Page 1 Friday, May 27, 2005 2:09 PM PRE-OPERATION CHECKS 1- Before using this machine, check the following points: ITEM ROUTINE PAGE Front brake • Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. Rear brake • Check operation, condition and free play. • Adjust if necessary. Fuel • Check fuel level. • Fill with fuel if necessary. Engine oil • Check oil level. • Fill with oil if necessary.
EE.book Page 2 Friday, May 27, 2005 2:09 PM WARNING 1 POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
EE.book Page 3 Friday, May 27, 2005 2:09 PM EBU12521 Brake fluid leakage (front brake) Check to see if any brake fluid is leaking out of the hose, joint or brake fluid reservoir of the front brake. Apply the brake firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be inspected by a Yamaha dealer. Front and rear brakes Brake levers and brake pedal ● Check for correct free play in the front brake lever.
EE.book Page 4 Friday, May 27, 2005 2:09 PM WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have a Yamaha dealer check for the cause.
EE.book Page 5 Friday, May 27, 2005 2:09 PM EBU01085 Fuel Make sure there is sufficient gasoline in the tank. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.
EE.book Page 6 Friday, May 27, 2005 2:09 PM Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. 1. Fuel tank filler tube WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury.
EE.book Page 7 Friday, May 27, 2005 2:09 PM EBU10842 EBU00493 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See page 8-6.) Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-12– 8-14 for details.) CAUTION: _ ● ● Recommended oil: SAE 80 API GL-4 Hypoid gear oil In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
EE.book Page 8 Friday, May 27, 2005 2:09 PM EBU11620 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. EBU10030 Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation. EBU11700 Switches Check the operation of all switches.
EE.book Page 9 Friday, May 27, 2005 2:09 PM EBU00157 Tires 2. The tires should be set to the recommended pressure: ● Recommended tire pressure Front 20 kPa (0.20 kgf/cm2, 2.9 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) ● Check and adjust tire pressures when the tires are cold. ● Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 17 kPa (0.17 kgf/cm2, 2.
EE.book Page 10 Friday, May 27, 2005 2:09 PM 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst.
EE.book Page 11 Friday, May 27, 2005 2:09 PM EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure with tires cold. Set tire pressures to the following specifications: 1.
EE.book Page 12 Friday, May 27, 2005 2:09 PM EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a.
EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU00161 EBU07490 OPERATION Starting a cold engine WARNING WARNING POTENTIAL HAZARD Freezing control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding. Indicates a potential hazard that could result in serious injury or death.
EE.book Page 2 Friday, May 27, 2005 2:09 PM Position 3: Cold engine startambient temperature above 25°C (80°F) and warm engine start position. NOTE: ● When the transmission is in neutral, the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. ● The engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral before starting the engine. _ 1 2 3 4 5 6 _ 7 5.
EE.book Page 3 Friday, May 27, 2005 2:09 PM NOTE: ● If the engine fails to start, release the start switch, then push the start switch 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 than 10 seconds on each attempt. ● If the battery is discharged, pull the recoil starter to start the engine. CAUTION: _ _ See the “Engine break-in” section prior to operating the engine for the first time.
EE.book Page 4 Friday, May 27, 2005 2:09 PM EBU15450 Drive select lever operation and reverse driving CAUTION: _ Before shifting, you must stop the ATV and return the throttle lever to its closed position, otherwise the transmission may be damaged. _ NOTE: When shifting into reverse, the transmission must be in first gear. _ 1. Drive select lever NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the ATV. _ _ 1.
EE.book Page 5 Friday, May 27, 2005 2:09 PM EBU02000 Shifting This model has a 5-speed forward transmission with centrifugal automatic clutch. The transmission allows you to control the amount of power you have available at a given speed or for starting accelerating, climbing, etc. To shift into neutral, return the throttle lever to its original position and repeatedly depress the shift pedal until it stops. WARNING POTENTIAL HAZARD Improperly operating in reverse.
EE.book Page 6 Friday, May 27, 2005 2:09 PM 4. Once the machine has attained adequate speed, release the throttle lever. 5. Shift into second gear and release the shift pedal. 6. Open the throttle gradually. 7. Follow the same procedure when shifting to the next higher gear. CAUTION: _ Do not coast for long periods with the engine off, and do not tow the machine a long distance. Even with gears in neutral, the transmission is only properly lubricated when the engine is running.
EE.book Page 7 Friday, May 27, 2005 2:09 PM EBU00207 EBU02092 To decelerate: When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident.
EE.book Page 8 Friday, May 27, 2005 2:09 PM EBU02111 Parking When parking, stop the engine and shift into first gear. Turn the fuel cock to “OFF” and apply the parking brake. If any abnormality is noticed during this period, consult a Yamaha dealer. 0–10 hours: Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to time. Do not operate it at one set throttle position.
EE.book Page 9 Friday, May 27, 2005 2:09 PM EBU12960 Parking on a slope 1. Bring the ATV to a stop by applying the brakes in low gear. 2. Stop the engine. 3. With the rear brake lever and pedal applied, apply the parking brake and slowly release the brake pedal. WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines.
EE.book Page 10 Friday, May 27, 2005 2:09 PM EBU00221 Accessories and loading ● EBU00222 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market.
EE.book Page 11 Friday, May 27, 2005 2:09 PM EBU15510 Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable.
EE.book Page 12 Friday, May 27, 2005 2:09 PM ● ● ● ● Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully.
EE.book Page 13 Friday, May 27, 2005 2:09 PM EBU15540 WARNING _ Indicates a potential hazard that could result in serious injury or death.
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EE.book Page 3 Friday, May 27, 2005 2:09 PM WARNING _ Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time.
EE.book Page 4 Friday, May 27, 2005 2:09 PM RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Get training if you are inexperienced.
EE.book Page 5 Friday, May 27, 2005 2:09 PM Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc.
EE.book Page 6 Friday, May 27, 2005 2:09 PM This ATV is designed to carry operator and cargo only - passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
EE.book Page 7 Friday, May 27, 2005 2:09 PM Apparel Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
EE.book Page 8 Friday, May 27, 2005 2:09 PM Do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
EE.book Page 9 Friday, May 27, 2005 2:09 PM Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident.
EE.book Page 10 Friday, May 27, 2005 2:09 PM Speed limiter For riders less experienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning the adjusting screw in limits the maximum engine power available and decreases the maximum speed of the ATV. Turning the adjusting screw in decreases top speed and turning it out increases top speed.
EE.book Page 11 Friday, May 27, 2005 2:09 PM Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads. WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
EE.book Page 12 Friday, May 27, 2005 2:09 PM During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN 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.
EE.book Page 13 Friday, May 27, 2005 2:09 PM Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
EE.book Page 14 Friday, May 27, 2005 2:09 PM Modifications WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
EE.book Page 15 Friday, May 27, 2005 2:09 PM 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. WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire. Someone touching the exhaust system during or after operation could be burned.
EE.book Page 16 Friday, May 27, 2005 2:09 PM BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
EE.book Page 17 Friday, May 27, 2005 2:09 PM Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
EE.book Page 18 Friday, May 27, 2005 2:09 PM Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.
EE.book Page 19 Friday, May 27, 2005 2:09 PM WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
EE.book Page 20 Friday, May 27, 2005 2:09 PM When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”.
EE.book Page 21 Friday, May 27, 2005 2:09 PM With the engine idling, lift the shift pedal to the 1st gear position and then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. Once the ATV has attained adequate speed, release the throttle and lift the shift pedal to the 2nd gear position. Release the shift pedal and apply the throttle smoothly. Use this same procedure as you move into the higher gears.
EE.book Page 22 Friday, May 27, 2005 2:09 PM CAUTION: WARNING _ Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear.
EE.book Page 23 Friday, May 27, 2005 2:09 PM TURNING YOUR ATV To achieve maximum traction while riding offroad, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist 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.
EE.book Page 24 Friday, May 27, 2005 2:09 PM 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 movements, 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.
EE.book Page 25 Friday, May 27, 2005 2:09 PM CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
EE.book Page 26 Friday, May 27, 2005 2:09 PM WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
EE.book Page 27 Friday, May 27, 2005 2:09 PM If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
EE.book Page 28 Friday, May 27, 2005 2:09 PM 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 uphill side. Physically turn the ATV around and then descend the hill. WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill.
EE.book Page 29 Friday, May 27, 2005 2:09 PM Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s Manual.
EE.book Page 30 Friday, May 27, 2005 2:09 PM RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces.
EE.
EE.book Page 32 Friday, May 27, 2005 2:09 PM 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 learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path.
EE.book Page 33 Friday, May 27, 2005 2:09 PM When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
EE.book Page 34 Friday, May 27, 2005 2:09 PM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
EE.book Page 35 Friday, May 27, 2005 2:09 PM Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the drive select lever box check hose, and the storage compartment check hose. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. _ 1.
EE.book Page 36 Friday, May 27, 2005 2:09 PM RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. 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 result. 1. Drive select lever box check hose 1.
EE.book Page 37 Friday, May 27, 2005 2:09 PM SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision.
EE.book Page 38 Friday, May 27, 2005 2:09 PM With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost.
EE.book Page 39 Friday, May 27, 2005 2:09 PM WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.
EE.book Page 40 Friday, May 27, 2005 2:09 PM ● ● If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See pages 7-37–7-38.) 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.
EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Have a Yamaha dealer perform service if you are not familiar with machine service. 1- Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.
EE.book Page 2 Friday, May 27, 2005 2:09 PM The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the Owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
EE.book Page 3 Friday, May 27, 2005 2:09 PM EBU15731 Periodic maintenance chart for the emission control system NOTE: _ ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. How- ever, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
EE.book Page 4 Friday, May 27, 2005 2:09 PM EBU15720 General maintenance and lubrication chart INITIAL ITEM Whichever month comes first km (mi) ROUTINE hours Air filter element • Clean. • Replace if necessary. Engine oil • Replace (Warm engine before draining). Engine oil filter element • Clean. Engine oil strainer • Clean. Final gear oil • Check oil level/oil leakage. • Replace. Front brake* • Check operation/fluid leakage/see NOTE page 8-5. • Correct if necessary.
EE.book Page 5 Friday, May 27, 2005 2:09 PM INITIAL ITEM Whichever month comes first km (mi) ROUTINE hours Steering shaft* • Lubricate every 6 months with lithium-soap-based grease (allpurpose grease). Fittings and fasteners* • Check all chassis fittings and fasteners. • Correct if necessary. Battery* • Check specific gravity. • Check that the breather hose is routed correctly. • Correct if necessary. Lights and switches* • Check operation. • Adjust headlight beams.
EE.book Page 6 Friday, May 27, 2005 2:09 PM EBU11005 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes, and then turn it off. 3. Wait at least ten minutes until the oil level settles before checking. 4.
EE.book Page 7 Friday, May 27, 2005 2:09 PM To change the engine oil (with or without oil filter element cleaning) 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes, and then turn it off. 3. Place a container under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase. 1. Engine oil drain bolt 3. Compression spring CAUTION: 2. O-ring 4.
EE.book Page 8 Friday, May 27, 2005 2:09 PM 5. Remove the footboard by removing the bolts. 1. Footboard 6. Fully loosen the brake pedal free play adjusting nut, push the brake pedal downward, and then remove the oil filter element cover bolts. 2. Bolt (× 8) 1.
EE.book Page 9 Friday, May 27, 2005 2:09 PM 7. Remove the oil filter element cover and oil filter element. NOTE: To remove or install the oil filter element cover and oil filter element, move the select lever safety system cable away from the cover. _ _ CAUTION: _ Do not loosen the adjusting nuts shown when removing the oil filter element cover or oil filter element. 1. Oil filter element cover 2. Adjusting nut (× 3) 1. Engine oil filter element 2.
EE.book Page 10 Friday, May 27, 2005 2:09 PM 8. Clean the oil strainer and oil filter element with solvent. 9. Check the O-ring for damage and replace it if necessary. CAUTION: _ Before installing the engine oil drain bolt, be sure to install the O-ring, compression spring and oil strainer. NOTE: Make sure the O-ring is seated properly. _ _ Tightening torque: Engine oil drain bolt: 43 Nm (4.3 m·kgf, 31 ft·lbf) _ 10. Install the oil filter element. 11.
EE.book Page 11 Friday, May 27, 2005 2:09 PM CAUTION: _ ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase. 1. Bolt A (× 6) 2. Bolt B (× 2) Tightening torque: Footboard bolt A: 3.8 Nm (0.38 m·kgf, 2.
EE.book Page 12 Friday, May 27, 2005 2:09 PM EBU11453 Final gear oil Checking the final gear oil 1. Place the ATV on a level surface. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. NOTE: The oil level should be at the brim of the filler hole. _ _ 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 1. Final gear oil 3.
EE.book Page 13 Friday, May 27, 2005 2:09 PM Replacing the final gear oil 1. Remove the final gear case cover by removing the bolts. 1. Final gear case cover 2. Place the ATV on a level surface. 3. Place a container under the final gear case to collect the used oil. 4. Remove the oil filler bolt and the drain bolt to drain the oil. 2. Bolt (× 2) 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil drain bolt: 23 Nm (2.
EE.book Page 14 Friday, May 27, 2005 2:09 PM 9. Install the final gear case cover bolts, and then tighten them to the specified torque. 6. Add the recommended final gear oil to the brim of the filler hole. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.25 L (0.22 Imp qt, 0.26 US qt) Tightening torque: Final gear case cover bolt: 17 Nm (1.7 m·kgf, 12 ft·lbf) CAUTION: _ Be sure no foreign material enters the final gear case. _ 7.
EE.book Page 15 Friday, May 27, 2005 2:09 PM EBU14550 Spark plug inspection Removal 1. Remove the spark plug cap. 2. Use the spark plug wrench in the owner’s tool kit to remove the spark plug as shown. 1. Spark plug cap 1.
EE.book Page 16 Friday, May 27, 2005 2:09 PM Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator around the center electrode is a medium-to-light tan color for an ATV that is being ridden normally.
EE.book Page 17 Friday, May 27, 2005 2:09 PM 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 and tighten it to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight.
EE.book Page 18 Friday, May 27, 2005 2:09 PM EBU13010 Air filter element cleaning 1. Remove the seat. (See page 4-14 for seat removal and installation procedures.) 2. Remove the air filter case cover by unhooking the holders. NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. _ _ 1. Air filter case cover 1. Air filter case check hose 8-18 2.
EE.book Page 19 Friday, May 27, 2005 2:09 PM 3. Pull the air filter element out. 4. Remove the foam cover from the air filter element. 1. Air filter element 1. Air filter element 8-19 2.
EE.book Page 20 Friday, May 27, 2005 2:09 PM 5. Tap the element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown. If the air filter element is damaged, replace it. WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the foam cover. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the foam cover. 7.
EE.book Page 21 Friday, May 27, 2005 2:09 PM 10. Install the air filter element. 11. Install the air filter case cover by fastening the holders. 12. Install the seat. CAUTION: _ Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating.
EE.book Page 22 Friday, May 27, 2005 2:09 PM EBU13621 Spark arrester cleaning Select a well-ventilated area free of combustible materials and make sure the exhaust pipe and muffler are cool. 1. Remove the purging bolt. 3. Stop the engine and allow the exhaust pipe to cool. 4. Install the purging bolt and tighten it. 1. Purging bolt 2. Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel.
EE.book Page 23 Friday, May 27, 2005 2:09 PM EBU00296 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine. WARNING POTENTIAL HAZARD Improperly purging the exhaust system. Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes.
EE.book Page 24 Friday, May 27, 2005 2:09 PM EBU13020 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. _ _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw.
EE.book Page 25 Friday, May 27, 2005 2:09 PM EBU00307 EBU03050 Throttle lever adjustment Select lever safety system cable adjustment The select lever safety system cable stretches with use, resulting in improper function. To prevent this, the cable must be adjusted regularly. This adjustment, however, should be left to a Yamaha dealer. NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2.
EE.book Page 26 Friday, May 27, 2005 2:09 PM EBU13090 EBU00313 Front brake pad check Check the brake pads for damage and wear. If a brake pad thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the pads as a set. Rear brake shoe inspection A wear indicator is provided on the rear brake. This indicator allows checking of brake shoe wear without disassembling the brake. Apply the rear brake and check the position of the indicator.
EE.book Page 27 Friday, May 27, 2005 2:09 PM EBU13040 Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. 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.
EE.book Page 28 Friday, May 27, 2005 2:09 PM EBU11870 ● Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer check the brake system. Have a Yamaha dealer check the cause if the brake fluid level goes down. EBU11860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel.
EE.book Page 29 Friday, May 27, 2005 2:09 PM WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: sure the brakes operate ● Make smoothly and that the free play is correct. ● Make sure the brakes do not drag. ● Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge.
EE.book Page 30 Friday, May 27, 2005 2:09 PM EBU15432 Adjusting the brake pedal free play 1. Fully loosen the brake cable adjusting nut. Adjusting the brake pedal and rear brake lever Adjusting the brake pedal height 1. Remove the footboard. (See page 8-8.) 2. Loosen the adjusting bolt locknuts. 3. Turn the adjusting bolt so that the top of the brake pedal is positioned 43–53 mm (1.69–2.09 in) above the top of the footboard bracket. 1. Adjusting nut (brake cable) 1. Locknut (× 2) a.
EE.book Page 31 Friday, May 27, 2005 2:09 PM Adjusting the rear brake lever free play 1. Loosen the locknut and fully turn in the adjusting bolt at the brake lever. 2. Turn the adjusting nut on the brake rod until the free play is 20.0–30.0 mm (0.79– 1.18 in). a. Rear brake pedal free play 1. Locknut 8-31 2.
EE.book Page 32 Friday, May 27, 2005 2:09 PM 2. Turn in the adjusting nut on the brake cable to provide a gap of 0–1 mm (0– 0.04 in) between the lever and the pin. 1. Adjusting nut (brake cable) 3. Pin 3. Turn the adjusting bolt until the free play at the brake lever pivot is 5.0–7.0 mm (0.20–0.28 in). 2. Lever a. Gap 1. Locknut 2. Adjusting bolt a. Rear brake lever free play 4. Tighten the locknut. 5. Install the footboard.
EE.book Page 33 Friday, May 27, 2005 2:09 PM WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.
EE.book Page 34 Friday, May 27, 2005 2:09 PM EBU15420 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and rear brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Remove the footboard. (See page 8-8.) 2. Turn the adjusting nut while holding the rear brake light switch in place.
EE.book Page 35 Friday, May 27, 2005 2:09 PM EBU15470 Clutch adjustment 1. Remove the footboard. (See page 8-8.) 2. Loosen the locknut. 3. Slowly turn the adjusting bolt counterclockwise until resistance is felt. Then, turn it 1/8 turn clockwise. NOTE: Turn the adjusting bolt counterclockwise to decrease the clutch free play and turn it clockwise to increase the free play. _ _ 5. Install the footboard. EBU00356 Cable inspection and lubrication WARNING 1.
EE.book Page 36 Friday, May 27, 2005 2:09 PM EBU00717 Brake lever and brake pedal lubrication Lubricate the pivoting parts. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them.
EE.book Page 37 Friday, May 27, 2005 2:09 PM EBU14060 Steering shaft lubrication Lubricate the pivot point with a grease gun. Recommended lubricant: Lithium-soap-based grease (all purpose grease) 1.
EE.book Page 38 Friday, May 27, 2005 2:09 PM EBU01112 EBU11211 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Wheel installation 1. Install the wheel and the nuts. NOTE: ● The arrow mark on the tire must point toward the rotating direction of the wheel. ● Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. _ _ 1.
EE.book Page 39 Friday, May 27, 2005 2:09 PM 1. Tapered nut 2. Lower the ATV so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear: 55 Nm (5.
EE.book Page 40 Friday, May 27, 2005 2:09 PM EBU00378 Battery Check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low. CAUTION: Do not leave or store the battery on its side. When inspecting the battery, be sure the breather hose is routed correctly. If it touches the frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cosmetic damage to the machine can occur. 1. Battery 8-40 2.
EE.book Page 41 Friday, May 27, 2005 2:09 PM WARNING EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space. POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases.
EE.book Page 42 Friday, May 27, 2005 2:09 PM EBU15401 Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly. The battery fluid should be checked at least once a month. 1. Remove the battery cover by pulling it upward. 2. The electrolyte level should be between the minimum and maximum level marks. Use only distilled water if refilling is necessary. CAUTION: _ Normal tap water contains minerals which are harmful to a battery.
EE.book Page 43 Friday, May 27, 2005 2:09 PM 3. Disconnect the negative (-) lead. 4. Disconnect the positive (+) lead. 5. Remove the battery bracket bolts, bracket and battery. 6. When the ATV is not to be used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reusing. 7. If the battery is to be stored for a longer period than the above, check the specific gravity at least once a month and recharge the battery when it is too low. 8.
EE.book Page 44 Friday, May 27, 2005 2:09 PM EBU00390 Fuse replacement 1. The fuse case is located under the seat. 2. If the fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches. If the fuse immediately blows again, consult a Yamaha dealer. WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire.
EE.book Page 45 Friday, May 27, 2005 2:09 PM EBU15951 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the bulb holder cover at the rear of the headlight by pulling it off. 2. Disconnect the headlight coupler by lifting the tab as shown and pulling out the coupler. 1. Headlight coupler 3. Remove the headlight bulb holder assembly by turning it counterclockwise. 1.
EE.book Page 46 Friday, May 27, 2005 2:09 PM WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. 1. Headlight bulb holder assembly NOTE: The headlight bulb cannot be removed from the headlight bulb holder.
EE.book Page 47 Friday, May 27, 2005 2:09 PM 5. Connect the headlight coupler. 6. Install the headlight bulb holder cover at the rear of the headlight. 1. Do not touch the glass part of the bulb. CAUTION: _ Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.
EE.book Page 48 Friday, May 27, 2005 2:09 PM EBU01089 EBU08610 Headlight beam adjustment Tail/brake light bulb replacement 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. CAUTION: _ It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. 1. Bulb holder 2.
EE.book Page 49 Friday, May 27, 2005 2:09 PM 1. Bulb holder 2. Bulb 3. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 4. Install the bulb holder (together with the bulb) by turning it clockwise.
EE.book Page 50 Friday, May 27, 2005 2:09 PM EBU00412 Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer.
EE.book Page 51 Friday, May 27, 2005 2:09 PM EBU00440 Troubleshooting chart There is fuel. Turn the fuel cock lever to “OFF”. Remove the fuel hose. Some fuel. Turn the fuel cock to “RES”. Restart engine. No fuel. Supply fuel. 1. Fuel Check if there is fuel in the fuel tank. 2. Compression Use electric starter to see if there is compression. 3. Ignition Turn the fuel cock lever to “ON”. No fuel. Fuel cock clogged. Clean fuel cock. There is compression. Compression normal. No compression.
EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU00419 CLEANING AND STORAGE CAUTION: Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A.
EE.book Page 2 Friday, May 27, 2005 2:09 PM 6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. WARNING POTENTIAL HAZARD Operation with wet brakes after washing.
EE.book Page 3 Friday, May 27, 2005 2:09 PM EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product. 2.
EE.book Page 4 Friday, May 27, 2005 2:09 PM 7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0°C (30°F) or more than 30°C (90°F)). NOTE: Make any necessary repairs before storing the machine.
EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU00428 SPECIFICATIONS 1- MODEL YFM25BV Dimension: Overall length Overall width Overall height Seat height Wheel base Minimum ground clearance Minimum turning radius 1,916 mm ( 75.4 in) 1,038 mm ( 40.9 in) 1,118 mm ( 44.0 in) 772 mm ( 30.4 in) 1,170 mm ( 46.1 in) 150 mm ( 5.91 in) 2,900 mm (114.2 in) Basic weight: With oil and full fuel tank 216.
EE.book Page 2 Friday, May 27, 2005 2:09 PM MODEL YFM25BV 1 Engine oil: Type 0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F YAMALUBE 4 (20W40) or SAE 20W40 5 SAE 5W30 Recommended engine oil classification: -10˚ 3 4 YAMALUBE 4 (10W30) or SAE 10W30 -20˚ 2 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
EE.book Page 3 Friday, May 27, 2005 2:09 PM MODEL YFM25BV Final gear case oil: Type Quantity: Periodic oil change SAE 80 API GL-4 Hypoid gear oil 0.25 L (0.22 Imp qt, 0.26 US qt) Air filter: Dry element Fuel: Type Tank capacity Reserve amount UNLEADED GASOLINE ONLY 12.0 L (2.64 Imp gal, 3.17 US gal) 1.6 L (0.35 Imp gal, 0.42 US gal) Carburetor: Type × quantity Manufacturer BSR33 × 1 MIKUNI Spark plug: Type/manufacturer Gap DR7EA/NGK 0.6–0.7 mm (0.024–0.
EE.book Page 4 Friday, May 27, 2005 2:09 PM MODEL YFM25BV Gear ratio: 1st 2nd 3rd 4th 5th Reverse 34/12 (2.833) 34/19 (1.789) 29/22 (1.318) 26/25 (1.040) 23/28 (0.821) 73/22 × 34/12 × 19/18 (9.924) Chassis: Frame type Caster angle Trail Steel tube frame 4.0° 20.0 mm (0.79 in) Tire: Type Size: Front Size: Rear Tubeless AT22 × 7.00-10 AT22 × 10.
EE.book Page 5 Friday, May 27, 2005 2:09 PM MODEL YFM25BV Wheel travel: Front Rear 125.0 mm (4.92 in) 135.0 mm (5.31 in) Electrical: Ignition system Generator system Battery type/voltage, capacity DC CDI AC magneto CB14A-A2/12V 14.0 Ah Headlight type: Halogen bulb Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator light: Neutral Reverse 12 V 30 W/30.0 W × 2 12 V 5.0 W/21.0 W × 1 12 V 1.7 W × 1 12 V 1.7 W × 1 Fuse: 20.
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EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU15740 1- MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU26310 YAMAHA MOTOR CORPORATION, U.S.A.
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EE.book Page 1 Friday, May 27, 2005 2:09 PM EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.
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EE.book Page 3 Friday, May 27, 2005 2:09 PM EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death.
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EBU00438 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.
