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Yamaha WOLVERINE 350 YFM25XX Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM35XX
3D5-F8199-62

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Summary of Contents for Yamaha WOLVERINE 350 YFM25XX

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM35XX 3D5-F8199-62...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2007.07-0.3×1 CR (E,F,S)
  • Page 3 OWNER’S MANUAL YFM35XX 3D5-F8199-62-E0...
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or...
  • Page 7 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Starter (choke) ..........4-10 Seat ............4-11 LOCATION OF THE WARNING AND Storage compartment .......4-12 SPECIFICATION LABELS ......2-1 Adjusting the front shock absorber assemblies ..........4-13 DESCRIPTION ..........3-1 Adjusting the rear shock absorber Left view ............
  • Page 9 Operating the drive select lever and Periodic maintenance chart for the driving in reverse ........6-3 emission control system ......8-3 Engine break-in .......... 6-4 General maintenance and lubrication Parking ............6-5 chart ............8-5 Parking on a slope ........6-5 Removing and installing the panel ....8-8 Accessories and loading ......
  • Page 10 Axle boots ..........8-31 Brake light switches ......... 8-31 Checking and lubricating the cables ..8-32 Checking and lubricating the front and rear brake levers ........8-32 Checking and lubricating the brake pedal ............8-33 Checking the wheel hub bearings .... 8-33 Lubricating the steering shaft ....

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION EBU17534 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 12 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 13 hill. If you stall or roll backwards, follow the spe- Always be sure there are no obstacles or people cial procedure for braking described in this man- behind you when you operate in reverse. When ual. Dismount on the uphill side or to a side if it is safe to proceed in reverse, go slowly.
  • Page 14 When transporting the ATV in another vehi- EWB00070 WARNING cle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel Always operate your ATV in an area with ade- may leak out of the carburetor or fuel tank. quate ventilation.

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.

  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly spring preload adjusting 1. Spark arrester ring 2. Tail/brake light 2. Fuel cock 3. Spark plug 3. Air filter case 4. Front shock absorber assembly spring preload adjusting 4.

  • Page 19: Controls And Instruments

    EBU17712 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Drive select lever 5. Main switch 6. Fuel tank cap 7. Front brake lever 8. Throttle lever NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 20: Instrument And Control Functions

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

  • Page 21: Indicator Lights And Warning Light

    If the warning light stays on, allow the engine to 1. Reverse indicator light “R” cool. If the warning light stays on when the engine 2. Neutral indicator light “N” is cool, have a Yamaha dealer check the electrical 3. Oil temperature warning light “ ” circuit.

  • Page 22: Handlebar Switches

    EBU18061 EBU18100 Handlebar switches Start switch “ ” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18151 Light switch “ /OFF” Set this switch to “ ”...

  • Page 23: Throttle Lever

    Correct the problem be- the throttle lever. fore riding the ATV or consult a Yamaha dealer. EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 24: Front Brake Lever

    EBU18391 Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip. 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in) 3.

  • Page 25: Parking Brake

    EBU18460 Parking brake Use the parking brake before starting the engine or parking the ATV, 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. 1.

  • Page 26: Drive Select Lever

    Always be sure you have released the park- ing brake before you begin to ride. The brake could overheat if you ride the ATV without re- leasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely.

  • Page 27: Fuel

    1. Fuel tank cap 1. Fuel level 2. Fuel tank filler tube EBU18752 Fuel Recommended fuel: Make sure that there is sufficient fuel in the tank. UNLEADED GASOLINE ONLY Fill the fuel tank to the bottom of the filler tube as For Europe: Regular unleaded gasoline only shown.

  • Page 28: Fuel Cock

    EBU18820 NOTE: Fuel cock If knocking or pinging occurs, use a different brand The fuel cock supplies fuel from the tank to the car- of gasoline or higher octane grade. buretor while also filtering it. The fuel cock lever positions are explained as fol- ECB00070 lows and shown in the illustrations.

  • Page 29: Starter (Choke)

    1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.

  • Page 30: Seat

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Seat 1. Starter (choke) “ ” EBU26981 Seat To remove the seat Push the seat lock lever backward and pull up the seat at the rear.

  • Page 31: Storage Compartment

    To install the seat When storing any documents in the storage com- Fit the slot in the seat onto the projection on the partment, be sure to wrap them in a plastic bag so front cowling, insert the projections on the front of that they will not get wet.

  • Page 32: Adjusting The Front Shock Absorber Assemblies

    1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha 1. Storage compartment drain plug dealer to make this adjustment. EBU18990 Adjusting the front shock absorber as-...

  • Page 33: Adjusting The Rear Shock Absorber Assembly

    EWB00400 WARNING Always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. EBU19020 Adjusting the rear shock absorber as- sembly 1.
  • Page 34 1. Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: Maximum (hard): 4-15...

  • Page 35: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 36 ITEM ROUTINE PAGE • Check operation, and correct if necessary. Rear brake • Lubricate cables if necessary. 5-3, 8-25, 8-28 • Check lever and pedal free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary.

  • Page 37: Fuel

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

  • Page 38: Throttle Lever

    EBU19811 Tires the brake system. If there is any leakage, the brake EWB00591 system should be checked by a Yamaha dealer. WARNING Use of improper tires on this ATV, or operation Brake operation of this ATV with improper or uneven tire pres-...

  • Page 39: Measuring The Tire Pressure

    The tires should be set to the recommended Higher pressures and fast inflation may pressure: cause a tire to burst. Inflate the tires very Recommended tire pressure: slowly and carefully. Front: 25.0 kPa (3.6 psi) (0.250 kgf/cm²) EBU19820 Measuring the tire pressure Rear: 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Use the low-pressure tire gauge.

  • Page 40: Tire Wear Limit

    Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 1.

  • Page 41: Operation

    4. Shift the drive select lever into the neutral po- accident or injury. If there is a control or func- sition. The neutral indicator light should come tion you do not understand, ask your Yamaha on. If the indicator light does not come on, dealer.
  • Page 42 5. Use the starter (choke) in reference to the fig- 6. Completely close the throttle lever and start ure: the engine by pushing the start switch. Position (1): NOTE: Cold engine start with ambient temperature If the engine fails to start, release the start switch, below 5 °C (40 °F).

  • Page 43: Starting A Warm Engine

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

  • Page 44: Engine Break-In

    If the indicator light does not come on, resulting in serious injury. When you shift into have a Yamaha dealer check the electrical circuit. reverse, make sure there are no people or ob- stacles behind you. When it is safe to proceed, go slowly.

  • Page 45: Parking

    Do not park the ATV at all on hills that are so engine break-in period, immediately have a steep you could not walk up them easily. Yamaha dealer check the ATV. 1. Bring the ATV to a stop by applying the brakes in the forward position.

  • Page 46: Accessories And Loading

    3. With the rear brake lever and pedal applied, it is not possible for Yamaha to test all non- apply the parking brake, and then slowly re- Yamaha accessories, nor control over their qual- lease the brake pedal. ity or suitability. Choose a genuine Yamaha ac- cessory, or one that is equivalent in design and quality.
  • Page 47 judgment as the stability and handling of an ATV Ride more slowly than you would without a load. can be changed. When adding accessories, keep The more weight you carry, the slower you the following points in mind: should go. Never exceed the weight limits shown.

  • Page 48: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 49: Getting To Know Your Atv

    EBU26970 Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum performance until GETTING TO KNOW YOUR ATV you are totally familiar with the ATV’s handling and This ATV is intended for recreational use by expe- performance characteristics.
  • Page 50 Not recommended for children under 16 years This ATV is designed to carry operator and car- of age. go only – passengers prohibited. EWB01390 EWB01400 WARNING WARNING A child under 16 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 90 cc.
  • Page 51 Apparel 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 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet...
  • Page 52 EWB01410 WARNING Never operate this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 53 in the Owner’s Manual. Failure to inspect the Speed limiter ATV before operating or failure to properly For riders less experienced with this model, the maintain the ATV increases the possibility of throttle lever housing is equipped with a speed lim- an accident or equipment damage.
  • Page 54 Loading and accessories Always follow the instructions in your Own- As originally equipped, this ATV is not designed to er’s Manual for carrying cargo or pulling a carry cargo or tow a trailer. If you choose to add ac- trailer. cessories so that you can carry cargo or tow a trail- er, you must use common sense and good During operation...
  • Page 55 All parts and you or cause an accident. accessories added to this ATV should be gen- uine Yamaha or equivalent components de- Avoid wheelies and jumping. You may lose control signed for use on this ATV and should be of the ATV or overturn.

  • Page 56: Be Careful Where You Ride

    Do not park the ATV during or after operation EWB01510 WARNING in a place where others might be likely to touch it. Always avoid paved surfaces, including side- Do not operate, idle, or park the ATV in dry walks, driveways, parking lots and streets. grass, dry ground cover, or combustible ma- ATVs are designed for use on unpaved surfac- terials.
  • Page 57 While riding on unpaved public streets or roads Know the terrain where you ride. Ride cautiously in may be legal in your area, such operation can in- unfamiliar areas. Stay alert for holes, rocks, or crease the risk of collision with other vehicles. roots in the terrain, and other hidden hazards Watch carefully for other vehicles.
  • Page 58 EWB01540 When riding in an area where you might not easily WARNING be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket Do not operate on excessively rough, slippery as a trailer hitch. or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.

  • Page 59: Turning Your Atv

    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.
  • Page 60 EWB01570 WARNING Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions. As you approach a curve, slow down and begin to turn the handlebars in the desired direction.

  • Page 61: Climbing Uphill

    Improper riding procedures such as abrupt throttle EWB01580 WARNING changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the Never operate the ATV on hills too steep for the turn may cause the ATV to tip. If the ATV begins to ATV or for your abilities.
  • Page 62 Never go over the top of any hill at high EWB01600 WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never attempt to turn the ATV around on any of the hill. hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground.
  • Page 63 EWB01741 WARNING Maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Apply the parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill. Never apply the rear brake while rolling backwards.

  • Page 64: Riding Downhill

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

  • Page 65: Crossing A Slope

    the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path.

  • Page 66: Crossing Through Shallow Water

    EWB01640 WARNING Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the lin- ings.
  • Page 67 Test your brakes after leaving the water. Do not plug to drain any water that may have accumu- continue to ride your ATV without verifying that you lated. Wash the ATV in fresh water if it has been have regained proper braking ability. operated in salt water or muddy conditions.
  • Page 68 1. V-belt cooling duct check hose (left front side of ATV) 1. Storage compartment drain plug 1. Drive select lever box check hose 1. V-belt case drain plug 7-21...

  • Page 69: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times.

  • Page 70: What To Do If

    On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control. WHAT TO DO IF... This section is designed to be a reference guide only.
  • Page 71 If your ATV can’t make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE –...

  • Page 72: Periodic Maintenance And Minor Repair

    EBU28781 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21670 otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with Safety is an obligation of the owner. Periodic in- maintenance work. spection, adjustment and lubrication will keep your...
  • Page 73 NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING Never modify this ATV through improper in-...

  • Page 74: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 75 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 76: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
  • Page 77 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for wear, cracks or other damage, and re- √ √ √ √ V-belt place if necessary. •...
  • Page 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Drive select lever • Check operation and adjust or replace if neces- √ √ √ safety system cable sary.

  • Page 79: Removing And Installing The Panel

    EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 1. Panel A 2.
  • Page 80 Do not kit. attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 81: Engine Oil And Oil Filter Cartridge

    3. Install the spark plug with the spark plug Specified spark plug: wrench, and then tighten it to the specified NGK/DR8EA torque. To install the spark plug Tightening torque: 1. Measure the spark plug gap with a wire thick- Spark plug: ness gauge and, if necessary, adjust the gap 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) to specification.
  • Page 82 2. Check the engine oil level on a cold engine. NOTE: If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading.
  • Page 83 To change the engine oil (with or without oil fil- 5. Remove the oil filter cartridge with an oil filter ter cartridge replacement) wrench. 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 84 NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 6. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure that the O-ring is properly seated. 1. Torque wrench...

  • Page 85: Final Gear Oil

    Be sure to wipe off spilled oil on any parts after the age before each ride. If any leakage is found, have engine and exhaust system have cooled down. a Yamaha dealer check and repair the ATV. In ad- ECB00300 dition, the final gear oil level must be checked and...
  • Page 86 To change the final gear oil NOTE: 1. Remove the final gear case guard by remov- The oil level should be at the brim of the filler hole. ing the bolts. 1. Final gear oil 1. Final gear case guard 2.
  • Page 87 1. Final gear oil drain bolt 1. Final gear oil 2. Final gear oil filler bolt 5. Install the drain bolt, and then tighten it to the 3. Correct oil level specified torque. Recommended final gear oil: Tightening torque: See page 10-1. Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) ECB00420...

  • Page 88: Cleaning The Air Filter Element

    Tightening torque: NOTE: Final gear oil filler bolt: There is a check hose at the bottom of the air filter 23 Nm (2.3 m·kgf, 17 ft·lbf) case. If dust or water collects in this hose, empty the hose and clean the air filter element and air fil- 8.
  • Page 89 1. Air filter case cover holder 1. Air filter element 2. Air filter case cover 4. Pull off the lock plate, and then remove the 3. Pull the air filter element out of the air filter sponge material from the air filter element case.
  • Page 90 ECB00440 CAUTION: Do not twist the sponge material when squeez- ing it. 1. Air filter element frame 2. Sponge material 3. Air filter element lock plate 5. Wash the sponge material gently but thor- oughly in solvent. 7. Check the sponge material and replace it if EWB01940 damaged.

  • Page 91: Cleaning The Spark Arrester

    10. Insert the air filter element into the air filter will affect carburetor jetting with subsequent case, and then install the air filter case cover poor performance and possible engine over- by hooking the holders onto the air filter case. heating.

  • Page 92: V-Belt Cooling Duct Check Hose

    3. Tap the tailpipe lightly, and then use a wire EWB02340 WARNING brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside Do not start the engine when cleaning the of the tailpipe housing. spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire.

  • Page 93: V-Belt Case Drain Plug

    If water drains from the V-belt case after removing most carburetor adjustments should be left to a the plug, have a Yamaha dealer check the ATV as Yamaha dealer, who has the necessary profes- the water may affect other engine parts.
  • Page 94 Engine idling speed: tle stop screw in direction (a), and to decrease 1450–1550 r/min it, turn the screw in direction (b). NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 8-23...

  • Page 95: Adjusting The Throttle Cable Free Play

    The valve clearance changes with use, resulting in bolt in direction (b). improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. 8-24...

  • Page 96: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm which allows you to check the brake shoe wear (0.04 in), have a Yamaha dealer replace the brake without having to disassemble the brake. To check pads as a set.

  • Page 97: Checking The Brake Fluid Level

    1. Wear limit line 1. Minimum level mark 2. Wear indicator Observe these precautions: When checking the fluid level, make sure that EBU24251 Checking the brake fluid level the top of the brake fluid reservoir is level. Insufficient brake fluid may allow air to enter the Use only the recommended quality brake fluid, brake system, possibly causing it to become inef- otherwise the rubber seals may deteriorate,...

  • Page 98: Changing The Brake Fluid

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

  • Page 99: Adjusting The Brake Pedal And Rear Brake Lever Free Play And Checking The Brake Pedal Position

    Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24513 Adjusting the brake pedal and rear brake lever free play and checking the...
  • Page 100 1. Brake pedal free play adjusting nut 1. Brake lever free play 2. Brake lever free play adjusting nut 2. Locknut 3. Brake lever free play adjusting bolt Adjusting the brake lever free play 1. Loosen the locknut at the brake lever and fully The brake lever free play should measure 3.0–5.0 turn in the brake lever free play adjusting bolt.
  • Page 101 Make sure the brake pedal does not move. Checking the brake pedal position The top of the brake pedal should be positioned 72.0–82.0 mm (2.83–3.23 in) above the footboard bracket. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 8-30...

  • Page 102: Axle Boots

    Operating with improperly serviced or adjust- adjusted as follows, but the other brake light ed brakes could cause loss of braking ability, switches should be adjusted by a Yamaha dealer. which could lead to an accident. 1. Remove panel A. (See page 8-8.)

  • Page 103: Checking And Lubricating The Cables

    If a cable is damaged or does not move light switch in place. To make the brake light smoothly, have a Yamaha dealer check or replace come on earlier, turn the adjusting nut in direc- tion (a). To make the brake light come on lat- Recommended lubricant: er, turn the adjusting nut in direction (b).

  • Page 104: Checking And Lubricating The Brake Pedal

    Recommended lubricants: NOTE: Front brake lever: To access the brake pedal pivot, remove panel A. Silicone grease (See page 8-8.) Rear brake lever: Lithium-soap-based grease (all-purpose Recommended lubricant: grease) Lithium-soap-based grease (all-purpose grease) EBU28831 Checking and lubricating the brake EBU24962 pedal Checking the wheel hub bearings The operation of the brake pedal should be...

  • Page 105: Lubricating The Steering Shaft

    EWB02160 WARNING have a Yamaha dealer check the wheel hub bear- ings. Battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can EBU25100 cause severe burns. Avoid contact with skin, Lubricating the steering shaft eyes or clothing.
  • Page 106 To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat- tery. 8-35...

  • Page 107: Replacing A Fuse

    EBU25324 Replacing a fuse 1. Headlight fuse 2. Ignition fuse 1. Main fuse 3. Signaling system fuse 2. Spare main fuse 4. Spare fuse 3. Fuse box The main fuse and the fuse box are located under the seat. (See page 4-11.) If a fuse is blown, replace it as follows.

  • Page 108: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 8-37...
  • Page 109 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. 3. Remove the defective bulb from the headlight ECB00650 CAUTION: unit by pulling it out. EWB02220 Do not touch the glass part of the headlight WARNING bulb to keep it free from oil, otherwise the A headlight bulb is hot when it is on and imme- transparency of the glass, the luminosity of the...

  • Page 110: Adjusting A Headlight Beam

    If the tail/brake light bulb burns out, replace it as 7. Adjust the headlight beam if necessary. follows. 1. Remove the lens by removing the screws. EBU25560 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 8-39...

  • Page 111: Removing A Wheel

    3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. ECB00700 CAUTION: Do not overtighten the screws, otherwise the lens may break. EBU25650 Removing a wheel 1.

  • Page 112: Installing A Wheel

    4. Remove the wheel. EBU25700 Installing a wheel 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.

  • Page 113: Troubleshooting

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

  • Page 114: Troubleshooting Chart

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

  • Page 115: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25880 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 116: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the brakes after washing. Apply the brakes several 2.
  • Page 117 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-34.

  • Page 118: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 1978 mm (77.9 in) Electric starter Overall width: Lubrication system: 1063 mm (41.9 in) Wet sump Overall height: Engine oil: 1095 mm (43.1 in) Seat height: Type: 840 mm (33.1 in) SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 Wheelbase: or SAE20W40 or SAE20W50...
  • Page 119 Engine oil quantity: Clutch: Without oil filter cartridge replacement: Clutch type: 2.20 L (2.33 US qt) (1.94 Imp.qt) Wet, centrifugal automatic With oil filter cartridge replacement: Transmission: 2.30 L (2.43 US qt) (2.02 Imp.qt) Primary reduction system: Final gear oil: V-belt Type: Secondary reduction system:...
  • Page 120 Manufacturer/model: Front wheel: MAXXIS/M937 Wheel type: Rear tire: Panel wheel Type: Rim size: Tubeless 12 x 6.0AT Size: Rear wheel: AT23 x 10-12 Wheel type: Manufacturer/model: Panel wheel MAXXIS/M938 Rim size: Loading: 12 x 7.5AT Maximum loading limit: Front brake: 100.0 kg (220 lb) Type: (Total weight of rider, cargo, accessories, and tongue)
  • Page 121 Rear suspension: Fuses: Type: Main fuse: Swingarm (monocross) 20.0 A Spring/shock absorber type: Headlight fuse: Coil spring/oil damper 15.0 A Wheel travel: Signaling system fuse: 180 mm (7.1 in) 10.0 A Electrical system: Ignition fuse: 15.0 A Ignition system: DC. CDI Charging system: AC magneto Battery:...

  • Page 122: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 123 EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 124 INDEX Accessories and loading ..........6-6 Engine break-in .............. 6-4 Air filter element, cleaning ..........8-17 Engine, cold start ............6-1 Axle boots ..............8-31 Engine idling speed ............8-22 Engine oil ............... 5-3 Engine oil and oil filter cartridge ........8-10 Battery ................
  • Page 125 Storage ................9-2 Storage compartment ..........4-12 Main switch ..............4-1 Maintenance and lubrication chart ......... 8-5 Maintenance chart, emission control system ....8-3 Tail/brake light bulb, replacing ........8-39 Model label ..............11-2 Throttle cable free play, adjusting ........ 8-24 Throttle lever ............
  • Page 126 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2007.07-0.3×1 CR...

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