READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35BAV WARNING LIT-11626-19-66 This ATV should not be ridden by anyone under 16 years of age.
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EE.book Page 1 Thursday, March 31, 2005 9:16 AM EBU00941 INTRODUCTION 1- Congratulations on your purchase of the Yamaha YFM35BA. 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 Thursday, March 31, 2005 9:16 AM EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
E_Info.fm Page 2 Friday, August 5, 2005 3:56 PM EBU15000 IMPORTANT NOTICE 1- 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 5 PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-2 Fuel ................................................. 5-4 Engine oil ........................................ 5-6 Final gear oil.................................... 5-6 Throttle lever ................................... 5-6 Fittings and fasteners...................... 5-7 Lights............................................... 5-7 Switches...................................
EE.book Page 3 Thursday, March 31, 2005 9:16 AM 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 Panel removal and installation ........ 8-6 Engine oil and oil filter cartridge ...... 8-7 Final gear oil .................................. 8-13 Spark plug inspection....................
EE.book Page 4 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 2 1 WARNING 7 8 Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident.
EE.book Page 3 Thursday, March 31, 2005 9:16 AM 3 5 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 : 80kg (176 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual.
EE.book Page 4 Thursday, March 31, 2005 9:16 AM 6 7 8 MAXIMUM .
EE.book Page 1 Thursday, March 31, 2005 9:16 AM EBU13401 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 Thursday, March 31, 2005 9:16 AM ● ● ● ● ● ● ● ● ● ● 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 a 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 Thursday, March 31, 2005 9:16 AM ● ● ● ● ● 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. 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 Thursday, March 31, 2005 9:16 AM ● ● ● ● ● ● ● 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.
EE.book Page 5 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1- 1. Rear shock absorber assembly spring preload adjusting ring 2. Spark arrester 3. Storage box and tool kit 4. Spark plug 5. Front shock absorber assembly spring preload adjusting ring 6. Brake pedal 7. V-belt case 8. Fuel cock 9. Air filter case 10. Fuses 11. Tail/brake light 12. V-belt cooling duct check hose 13. Oil filter cartridge 14. Engine oil dipstick 15. Rear brake lever 16.
EE.book Page 2 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 (front left side) NOTE: The vehicle identification number is used to identify your machine. 1.
EE.book Page 1 Thursday, March 31, 2005 9:16 AM EBU00039 CONTROL FUNCTIONS 1- 1 WARNING 2 Indicates a potential hazard that could result in serious injury or death. 3 4 EBU09420 5 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position. 6 1.
EE.book Page 2 Thursday, March 31, 2005 9:16 AM EBU08020 EBU09720 Indicator and warning lights Neutral indicator light “N” This indicator light comes on when the drive select lever is in the “N” position. EBU12500 Reverse indicator light “R” This indicator light comes on when the drive select lever is in the “R” position. 1. Neutral indicator light “N” 2. Reverse indicator light “R” 3.
EE.book Page 3 Thursday, March 31, 2005 9:16 AM EBU11400 Oil temperature warning light “ ” When the oil temperature reaches a specified level, this light comes on to warn that the engine oil temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes. CAUTION: _ ● ● The engine may overheat if the ATV is overloaded. If this happens, reduce the load to specification.
EE.book Page 4 Thursday, March 31, 2005 9:16 AM EBU00733 Oil temperature warning light checking method ACB-10E Turn the main switch to “ON” and the engine stop switch to “ ”. Oil temperature warning light does not come on. Oil temperature warning light comes on. Push start switch with the transmission in neutral. Check engine oil temperature. Oil temperature warning light comes on momentarily. Oil temperature warning light does not come on. Oil temperature is low. Oil temperature is high.
EE.book Page 5 Thursday, March 31, 2005 9:16 AM EBU00053 Handlebar switches CAUTION: _ Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. _ EBU12050 Engine stop switch “ / ” Make sure that the engine stop switch is set to “ ” before starting the engine.
EE.book Page 6 Thursday, March 31, 2005 9:16 AM EBU00607 EBU00062 Start switch “ ” The starter motor cranks the engine when this switch is pushed. 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.
EE.book Page 7 Thursday, March 31, 2005 9:16 AM Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. WARNING POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine.
EE.book Page 8 Thursday, March 31, 2005 9:16 AM EBU01159 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 9 Thursday, March 31, 2005 9:16 AM EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Brake pedal 1. Front brake lever EBU00732 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.
EE.book Page 10 Thursday, March 31, 2005 9:16 AM 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 11 Thursday, March 31, 2005 9:16 AM EBU01106 EBU01107 Drive select lever The drive select lever is used to shift your machine into the forward, neutral and reverse positions. (Refer to page 6-4 for the drive select lever operation.) 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. 1. Drive select lever 1.
EE.book Page 12 Thursday, March 31, 2005 9:16 AM EBU00092 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. WARNING POTENTIAL HAZARD Starting the engine without shifting into the neutral position. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Shift the drive select lever into the neutral position and apply the parking brake before starting the engine. 1.
EE.book Page 13 Thursday, March 31, 2005 9:16 AM 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 14 Thursday, March 31, 2005 9:16 AM EBU00095 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 pages 6-1–6-3.) RES Position 1. Arrow mark pointing to “RES” 1.
EE.book Page 15 Thursday, March 31, 2005 9:16 AM EBU05670 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) 4-15 2.
EE.book Page 16 Thursday, March 31, 2005 9:16 AM EBU14580 Storage box NOTE: There is a check hose at the bottom of the storage box. If any water collects in this hose, remove the hose, empty it, and then install it. _ Maximum load limit: 2.0 kg (4.4 lb) CAUTION: _ _ To protect from damage, do not put metal products, like tools or sharply edged products directly in the storage box. If they must be stored, wrap them in appropriate cushion material. _ 1. Storage box check hose 1.
EE.book Page 17 Thursday, March 31, 2005 9:16 AM EBU00582 Front carrier Maximum load limit: 40 kg (88 lb) EBU00583 Rear carrier Maximum load limit: 80 kg (176 lb) 1. Spring preload adjusting ring 2. Position indicator EBU01104 Front shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a.
EE.book Page 18 Thursday, March 31, 2005 9:16 AM EBU01103 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b. 1. Special wrench WARNING POTENTIAL HAZARD Improper shock absorber adjustment.
EE.book Page 19 Thursday, March 31, 2005 9:16 AM NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. _ _ Standard position: 2 1 - Minimum (soft) 5 - Maximum (hard) 1. Special wrench EBU00112 WARNING 4-19 Indicates a potential hazard that could result in serious injury or death.
EE.book Page 1 Thursday, March 31, 2005 9:16 AM 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. 5-2–5-3, 8-28–8-31 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 Thursday, March 31, 2005 9:16 AM EBU12521 Front and rear brakes Brake levers and brake pedal ● Check for correct free play in the front brake lever. If the free play is incorrect, have a Yamaha dealer adjust it. ● Check for correct free play in the rear brake lever and brake pedal. If the free play is incorrect, adjust it. (See pages 8-32–8-34.) ● Check operation of the levers and pedal. They should move smoothly and there should be a firm feeling when the brake is applied.
EE.book Page 3 Thursday, March 31, 2005 9:16 AM 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. WARNING POTENTIAL HAZARD Riding with improperly operating brakes.
EE.book Page 4 Thursday, March 31, 2005 9:16 AM 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 5 Thursday, March 31, 2005 9:16 AM 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 level WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury.
EE.book Page 6 Thursday, March 31, 2005 9:16 AM EBU10842 EBU00493 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-7– 8-12.) Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-13– 8-15 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 7 Thursday, March 31, 2005 9:16 AM EBU11620 EBU00157 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. Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure.
EE.book Page 8 Thursday, March 31, 2005 9:16 AM 2. The tires should be set to the recommended pressure: ● Recommended tire pressure Front 25 kPa (0.25 kgf/cm2, 3.6 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 22 kPa (0.22 kgf/cm2, 3.
EE.book Page 9 Thursday, March 31, 2005 9:16 AM 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: ACE-02EACE-02E Recommended pressure Minimum Maximum Front 25 kPa (0.25 kgf/cm2, 3.
EE.book Page 10 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM EBU00161 EBU14591 OPERATION Starting a cold engine 1- 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 Thursday, March 31, 2005 9:16 AM Position 3: Cold engine startambient temperature above 25 °C (80 °F) and warm engine start position. NOTE: ● When the drive select lever is in the neutral position, the neutral indicator light should come on. If it does not come on, ask a Yamaha dealer to inspect the electric circuit. ● 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM EBU14600 Drive select lever operation and reverse driving CAUTION: _ Before shifting, stop the machine and return the throttle lever to its closed position. Otherwise, the transmission may be damaged. _ Shifting: forward 1. Bring the machine to a complete stop and return the throttle lever to the closed position. 2. Shift the gear from neutral to forward and vice versa by moving the drive select lever along the shift guide. 1. Drive select lever 3.
EE.book Page 5 Thursday, March 31, 2005 9:16 AM Shifting: reverse 1. Bring the machine to a complete stop and return the throttle lever to the closed position. 2. Apply the brake pedal. 3. Shift the gear from neutral to reverse and vice versa by moving the drive select lever along the shift guide. 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. Drive select lever 4.
EE.book Page 6 Thursday, March 31, 2005 9:16 AM WARNING POTENTIAL HAZARD Improper operation in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.
EE.book Page 7 Thursday, March 31, 2005 9:16 AM EBU02101 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances.
EE.book Page 8 Thursday, March 31, 2005 9:16 AM EBU15690 10–20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time. Parking When parking, stop the engine and shift into the forward position. Turn the fuel cock to “OFF” and apply the parking brake. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally.
EE.book Page 9 Thursday, March 31, 2005 9:16 AM EBU13750 Parking on a slope 1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake lever and pedal applied, apply the parking brake, and then 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM EBU12461 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 Thursday, March 31, 2005 9:16 AM ● ● ● ● Ride more slowly than you would without a load. The more weight you carry, the slower you should go. 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. Added weight affects the stability and handling of the ATV. WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly.
EE.book Page 13 Thursday, March 31, 2005 9:16 AM EBU14640 WARNING _ Indicates a potential hazard that could result in serious injury or death.
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EE.book Page 3 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 the top speed and turning it out increases the top speed.
EE.book Page 11 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system.
EE.book Page 16 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM With the engine idling, return the starter (choke) to the closed position and shift the drive select lever into the forward position. Then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground resulting in a loss of directional control.
EE.book Page 22 Thursday, March 31, 2005 9:16 AM 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 23 Thursday, March 31, 2005 9:16 AM 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 24 Thursday, March 31, 2005 9:16 AM 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 25 Thursday, March 31, 2005 9:16 AM An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. WARNING 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 26 Thursday, March 31, 2005 9:16 AM 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. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
EE.book Page 27 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM If you begin rolling backwards: Keep weight uphill. Never apply the rear brake while rolling backwards. Apply the front brake. When fully stopped, apply the rear brake as well, and then lock the parking brake. 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 Thursday, March 31, 2005 9:16 AM 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. 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. Improper braking may also cause a loss of traction.
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EE.book Page 32 Thursday, March 31, 2005 9:16 AM 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. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills.
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EE.book Page 34 Thursday, March 31, 2005 9:16 AM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) 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 Thursday, March 31, 2005 9:16 AM 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 V-belt cooling duct check hose, the drive select lever box check hose and the storage box check hose.
EE.book Page 36 Thursday, March 31, 2005 9:16 AM 1. V-belt cooling duct check hose (left front side of ATV) 1. Storage box check hose 1. Drive select lever box check hose 1.
EE.book Page 37 Thursday, March 31, 2005 9:16 AM 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. WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision.
EE.book Page 38 Thursday, March 31, 2005 9:16 AM 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. If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.
EE.book Page 39 Thursday, March 31, 2005 9:16 AM 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. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
EE.book Page 40 Thursday, March 31, 2005 9:16 AM WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. ● WHAT TO DO ... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-22–7-23.
EE.book Page 41 Thursday, March 31, 2005 9:16 AM ● ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32– 7-33.
EE.book Page 1 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 3 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM EBU15720 General maintenance and lubrication chart ITEM Air filter element Engine oil Engine oil filter cartridge Final gear oil Front brake* Rear brake Select lever safety system cable* V-belt* Wheels* Wheel bearing* Front and rear suspension* Steering system* Drive shaft universal joint* Fittings and fasteners* Lights and switches* Whichever month comes first km (mi) hours ROUTINE • • • • • • • • • • • • • • • • • • • • • • • • • • • Clean.
EE.book Page 5 Thursday, March 31, 2005 9:16 AM NOTE: ● Recommended brake fluid: DOT 4 ● Brake fluid replacement: • When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and add fluid as required. • On the inner parts of the master cylinder and caliper, replace the oil seals every two years. • Replace the brake hoses every four years, or if cracked or damaged. WARNING _ Indicates a potential hazard that could result in serious injury or death.
EE.book Page 6 Thursday, March 31, 2005 9:16 AM EBU08070 EBU01147 Panel removal and installation The panel illustrated needs to be removed to perform some of the maintenance described in this chapter. Refer to this section each time the panel has to be removed or installed. Panel A To remove Remove the bolt, and then take the panel off. To install Place the panel in the original position and install the bolt. CAUTION: _ When installing the panel, be sure not to pinch the cables or wires. _ 1.
EE.book Page 7 Thursday, March 31, 2005 9:16 AM EBU14540 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. 4. Remove the engine oil filler cap and wipe off the dipstick with a clean rag. To check the engine oil level 1. Place the ATV on a level surface. 2.
EE.book Page 8 Thursday, March 31, 2005 9:16 AM 7. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. 5. Insert the dipstick in the oil filler hole (without screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the minimum and maximum level marks. _ _ 1. Maximum level mark 2. Minimum level mark 6.
EE.book Page 9 Thursday, March 31, 2005 9:16 AM To change the engine oil (with or without oil filter cartridge replacement) 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap. 3. Remove the engine oil drain bolt to drain the oil from the crankcase. NOTE: Skip steps 4–6 if the oil filter cartridge is not being replaced. _ _ 4.
EE.book Page 10 Thursday, March 31, 2005 9:16 AM 1. O-ring 1. Oil filter wrench NOTE: An oil filter wrench is available at a nearby Yamaha dealer. _ _ 5. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure the O-ring is seated properly.
EE.book Page 11 Thursday, March 31, 2005 9:16 AM 6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 7. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 8. Add the specified amount of recommended engine oil, and then install the engine oil filler cap and tighten it. Recommended engine oil: See page 10-2.
EE.book Page 12 Thursday, March 31, 2005 9:16 AM 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. _ 9. Start the engine and warm it up for several minutes.
EE.book Page 13 Thursday, March 31, 2005 9:16 AM 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. 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. CAUTION: _ Be sure no foreign material enters the final gear case. NOTE: The oil level should be at the brim of the filler hole. _ _ 4.
EE.book Page 14 Thursday, March 31, 2005 9:16 AM Replacing the final gear oil 1. Remove the final gear case cover by removing the bolts. 4. Remove the oil filler bolt and the drain bolt to drain the oil. 1. Final gear oil drain bolt 1. Final gear case cover 5. Install the drain bolt, and then tighten it to the specified torque. 2. Bolt (× 2) 2. Place the ATV on a level surface. 3. Place a container under the final gear case to collect the used oil.
EE.book Page 15 Thursday, March 31, 2005 9:16 AM 8. Check for oil leakage. If oil leakage is found, check for the cause. 9. Install the final gear case cover bolts, and then tighten them to the specified torque. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.23 L (0.20 Imp qt, 0.24 US qt) Tightening torque: Final gear case cover bolt: 16 Nm (1.6 m·kgf, 12 ft·lbf) CAUTION: _ Be sure no foreign material enters the final gear case. _ 7.
EE.book Page 16 Thursday, March 31, 2005 9:16 AM 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 wrench 1. Spark plug cap 8-16 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.
EE.book Page 17 Thursday, March 31, 2005 9:16 AM Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. Specified spark plug: DR8EA (NGK) a. Spark plug gap 2.
EE.book Page 18 Thursday, March 31, 2005 9:16 AM 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. Have the spark plug tightened to the specified torque as soon as possible. _ _ 4. Install the spark plug cap.
EE.book Page 19 Thursday, March 31, 2005 9:16 AM EBU15140 Air filter element cleaning 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. Fastener (× 4) 2. Air filter case cover 3. Remove the air filter element assembly. 1. Air filter case check hose 1. Remove the seat. (See page 4-15 for seat removal and installation procedures.) 2.
EE.book Page 20 Thursday, March 31, 2005 9:16 AM 1. Air filter element frame 3. Lock plate 1. Air filter element assembly 4. Pull off the lock plate, and then remove the air filter element from its frame. 2. Air filter element 5. Wash the element gently but thoroughly in solvent.
EE.book Page 21 Thursday, March 31, 2005 9:16 AM 8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element. WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. 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 air filter element. NOTE: The air filter element should be wet but not dripping. _ _ 9.
EE.book Page 22 Thursday, March 31, 2005 9:16 AM EBU06411 V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it. NOTE: The air filter element should be cleaned every 20–40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet to the filter case for obstructions.
EE.book Page 23 Thursday, March 31, 2005 9:16 AM EBU08741 EBU01066 V-belt case drain plug After riding in water deep enough to allow it to enter the V-belt case, remove this plug to drain the water from the case. Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler.
EE.book Page 24 Thursday, March 31, 2005 9:16 AM WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the exhaust system. 1. Spark arrester 4.
EE.book Page 25 Thursday, March 31, 2005 9:16 AM EBU00296 EBU13020 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. Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. _ _ 1.
EE.book Page 26 Thursday, March 31, 2005 9:16 AM EBU03050 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. 1. Throttle stop screw EBU00303 Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise.
EE.book Page 27 Thursday, March 31, 2005 9:16 AM EBU00307 Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3–5 mm (0.12–0.20 in). 3. Tighten the locknut. a. Throttle lever free play 1. Locknut 2.
EE.book Page 28 Thursday, March 31, 2005 9:16 AM EBU13090 EBU00313 Front brake pad check Check the brake pads for damage and wear. If a brake pad thickness is less than 1 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 29 Thursday, March 31, 2005 9:16 AM 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 30 Thursday, March 31, 2005 9:16 AM EBU11860 ● ● Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. ● Replace the oil seals every two years. ● Replace the brake hoses every four years. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
EE.book Page 31 Thursday, March 31, 2005 9:16 AM 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. 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.
EE.book Page 32 Thursday, March 31, 2005 9:16 AM EBU01239 Rear brake pedal and lever adjustment Brake pedal free play adjustment 1. Fully loosen the adjusting nut on the brake lever cable at the rear wheel. 2. Turn the adjusting nut on the brake pedal cable until the free play is 20–30 mm (0.79–1.18 in). a. Brake pedal free play 1. Adjusting nut (brake pedal cable) 2.
EE.book Page 33 Thursday, March 31, 2005 9:16 AM Brake lever free play adjustment 1. Loosen the locknut and fully turn in the adjusting bolt at the brake lever. 1. Locknut 2. Turn in the adjusting nut on brake cable to provide a gap of 0–1 mm (0–0.04 in) between the brake camshaft lever and the pin. 2. Adjusting bolt 1. Adjusting nut (brake lever cable) a.
EE.book Page 34 Thursday, March 31, 2005 9:16 AM 3. Turn the adjusting bolt at the brake lever until the free play at the brake lever pivot is 3–5 mm (0.12–0.20 in). 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.
EE.book Page 35 Thursday, March 31, 2005 9:16 AM EBU12590 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 panel A. (See page 8-6 for panel removal and installation procedures.) 2. Turn the adjusting nut while holding the rear brake light switch in place.
EE.book Page 36 Thursday, March 31, 2005 9:16 AM EBU00356 Cable inspection and lubrication WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables. Lubricate the inner cables and the cable ends.
EE.book Page 37 Thursday, March 31, 2005 9:16 AM EBU12600 Lubricating the brake levers and brake pedal Lubricate the pivoting parts. NOTE: To access the brake pedal pivot, remove panel A. (See page 8-6 for panel removal and installation procedures.
EE.book Page 38 Thursday, March 31, 2005 9:16 AM EBU01112 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. 1.
EE.book Page 39 Thursday, March 31, 2005 9:16 AM EBU11211 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. 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.
EE.book Page 40 Thursday, March 31, 2005 9:16 AM EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water.
EE.book Page 41 Thursday, March 31, 2005 9:16 AM EBU00385 EBU08762* Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. Fuse replacement 1. The main fuse and the fuse box are located under the seat. 2. If a fuse is blown, turn off the main switch and the switch of the circuit in question. Then, install a new fuse of the specified amperage. Turn on the main switch.
EE.book Page 42 Thursday, March 31, 2005 9:16 AM 1. Main fuse 3. Fuse box 2. Spare main fuse 1. 2. 3. 4.
EE.book Page 43 Thursday, March 31, 2005 9:16 AM 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. 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. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse.
EE.book Page 44 Thursday, March 31, 2005 9:16 AM 2. Disconnect the headlight coupler by lifting the tab as shown and pulling out the coupler. 1. Headlight bulb holder assembly NOTE: The headlight bulb cannot be removed from the headlight bulb holder. To replace the headlight bulb, replace the headlight bulb holder assembly. _ 1. Headlight coupler 3. Remove the headlight bulb holder assembly by turning it counterclockwise.
E-8.fm Page 45 Monday, April 4, 2005 10:29 AM 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. Do not touch the glass part of the bulb.
EE.book Page 46 Thursday, March 31, 2005 9:16 AM EBU01089 Headlight beam adjustment 5. Connect the headlight coupler. 6. Install the headlight bulb holder cover at the rear of the headlight. 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.
EE.book Page 47 Thursday, March 31, 2005 9:16 AM EBU01105 EBU00412 Tail/brake light bulb replacement If the tail/brake light bulb burns out, have a Yamaha dealer replace it. 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.
EE.book Page 48 Thursday, March 31, 2005 9:16 AM WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.
EE.book Page 49 Thursday, March 31, 2005 9:16 AM EBU04400 Troubleshooting chart Turn the fuel cock lever to “ON”. There is fuel. Turn the fuel cock lever to “OFF”. Remove the fuel hose from the fuel cock. Some fuel. Turn the fuel cock lever to “RES”. Restart the engine. No fuel. Supply fuel. 1. Fuel Check if there is fuel in the fuel tank. 2. Compression Use the electric starter to see if there is compression. 3. Ignition There is compression. Compression normal. No compression.
EE.book Page 1 Thursday, March 31, 2005 9:16 AM EBU00419 CLEANING AND STORAGE CAUTION: 1- 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM 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 Thursday, March 31, 2005 9:16 AM EBU00428 SPECIFICATIONS 1- 1 2 Model YFM35BA 3 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system 1,984 mm (78.1 in) 1,085 mm (42.7 in) 1,120 mm (44.1 in) 827 mm (32.6 in) 1,233 mm (48.5 in) 245 mm (9.65 in) 3,000 mm (118.
EE.book Page 2 Thursday, March 31, 2005 9:16 AM Model YFM35BA Engine oil: Type 0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20˚ Recommended engine oil classification: -10˚ 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 Thursday, March 31, 2005 9:16 AM Model YFM35BA Final gear case oil: Type Quantity Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type/quantity Manufacturer Spark plug: Type/manufacturer Spark plug gap Clutch type: SAE80 API GL-4 Hypoid gear oil 0.23 L (0.20 Imp qt, 0.24 US qt) Wet element UNLEADED GASOLINE ONLY 13.5 L (2.97 lmp gal, 3.57 US gal) 3.3 L (0.73 lmp gal, 0.87 US gal) BSR33 / 1 MIKUNI DR8EA / NGK 0.6–0.7 mm (0.02–0.
EE.book Page 4 Thursday, March 31, 2005 9:16 AM Model Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Forward gear Reverse gear Chassis: Frame type Caster angle Trail Tire: Type Size Brake: Front brake Rear brake YFM35BA V-belt Shaft drive 41/21 × 24/18 × 33/9 (9.545) V-belt automatic Left hand operation 35/20 (1.750) 26/15 (1.733) Steel tube frame 4° 21 mm (0.
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EE.book Page 1 Thursday, March 31, 2005 9:16 AM 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.
E-13.fm Page 1 Friday, August 5, 2005 3:56 PM EBU00432 YAMAHA MOTOR CORPORATION, U.S.A.
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EE.book Page 1 Thursday, March 31, 2005 9:16 AM EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.
EE.book Page 2 Thursday, March 31, 2005 9:16 AM 1 2 3 4 5 6 7 8 9 10 11 12 13 EBU00436 14 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.
