Yamaha BIGBEAR 250 Owner's Manual
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Yamaha BIGBEAR 250 Owner's Manual

Yamaha BIGBEAR 250 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM25BW
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-20-16
1P0-F8199-12

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  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM25BW WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-20-16 1P0-F8199-12...
  • Page 2 EBU17091...
  • Page 3 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.
  • Page 4 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 5 EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! 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.

  • Page 6: Table Of Contents

    Front brake lever .........4-5 EWB00010 WARNING Brake pedal and rear brake lever ....4-5 Parking brake ..........4-6 Indicates a potential hazard that could result in serious injury or death. Shift pedal ...........4-7 Drive select lever ........4-7 Recoil starter ..........4-8 Fuel tank cap ..........4-9 EBU17420 Fuel .............4-9 TABLE OF CONTENTS...
  • Page 7 Chassis fasteners ........5-7 SLIDING AND SKIDDING ......7-30 Instruments, lights and switches ....5-7 WHAT TO DO IF........7-32 Battery ............5-7 WHAT TO DO..........7-32 OPERATION ..........6-1 PERIODIC MAINTENANCE AND MINOR Starting a cold engine ........ 6-1 REPAIR ............8-1 Starting a warm engine ......6-3 Owner’s manual and tool kit .......8-1 Operating the drive select lever and Periodic maintenance chart for the...
  • Page 8 Checking and lubricating the Noise regulation ........11-3 brake pedal ..........8-36 Maintenance record ........11-4 Checking the wheel bearings ....8-36 YAMAHA MOTOR CORPORATION, Lubricating the drive shaft universal U.S.A. ATV LIMITED WARRANTY ..11-5 joint ............8-36 YAMAHA EXTENDED SERVICE Lubricating the swingarm pivots ....8-37 (Y.E.S.) ...........11-7...

  • Page 9: Safety Information

    EBU17430 SAFETY INFORMATION EBU17442 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 10 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 11 speed when climbing a hill. If you stall or roll Always be sure there are no obstacles or people backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 12 EWB00021 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- POTENTIAL HAZARD oline in your eyes, seek medical help Improper handling of gasoline. immediately. If gasoline spills on your skin, WHAT CAN HAPPEN wash with soap and water.
  • Page 13 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 ad- equate ventilation.

  • Page 14: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 15 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. Headlights 1. Spark arrester 2. Fuel cock 2. Storage compartment and tool kit 3. Recoil starter 3. Air filter case 4. Fuses 4. Engine oil filler cap 5. Battery 5. Front brake fluid reservoir 6.

  • Page 19: Controls And Instruments

    EBU17712 Controls and instruments 1. Rear brake lever 2. Left handlebar switches 3. Parking brake 4. Starter (choke) 5. Drive select lever 6. Main switch 7. Fuel tank cap 8. Throttle lever 9. Front brake lever NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 20: Instrument And Control Functions

    EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17760 Main switch The positions of the main switch are as follows: 1. Main switch 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.

  • Page 21: Indicator Lights

    EBU17790 EBU18060 Indicator lights Handlebar switches 1. Reverse indicator light “R” 1. Light switch “ /OFF” 2. Neutral indicator light “N” 2. Engine stop switch “ ” 3. Start switch “ ” EBU17830 Reverse indicator light “ ” EBU18080 Engine stop switch “ ”...

  • Page 22: Throttle Lever

    EBU18100 EBU18270 Start switch “ ” Throttle lever Push this switch to crank the engine with the start- Once the engine is running, movement of the throt- tle lever will increase the engine speed. ECB00050 Regulate the speed of the ATV by varying the CAUTION: throttle position.

  • Page 23: Speed Limiter

    If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a 1. Locknut Yamaha dealer if you can’t find or solve the 2. Adjusting screw problem yourself. 3. No more than 12 mm (0.47 in) EBU18311 3.

  • Page 24: Front Brake Lever

    EWB00190 WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result. You could lose control, have an accident or be in- jured. HOW TO AVOID THE HAZARD 1.

  • Page 25: Parking Brake

    EBU18450 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: Shift Pedal

    EWB00170 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 start- ing the engine. This could cause loss of con- trol or a collision. The brake could overheat if you ride the ATV without releasing the parking brake.

  • Page 27: Recoil Starter

    1. Drive select lever 1. Recoil starter EWB02361 EBU27371 WARNING Recoil starter Firmly grasp the handle and pull slightly until en- POTENTIAL HAZARD gagement can be felt. Then pull forcefully, being Starting the engine in gear or starting the careful not to pull the rope all the way out. engine without applying the parking brake.

  • Page 28: Fuel Tank Cap

    EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Fuel tank filler tube 2. Fuel level Recommended fuel: 1. Fuel tank cap UNLEADED GASOLINE ONLY Fuel tank capacity: EBU18730 12.0 L (3.17 US gal) (2.64 Imp.gal) Fuel Fuel reserve amount: Make sure that there is sufficient fuel in the tank.

  • Page 29: Fuel Cock

    HOW TO AVOID THE HAZARD Your Yamaha engine has been designed to use Do not overfill the fuel tank. Be careful not to regular unleaded gasoline with a pump octane...
  • Page 30 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 31: Starter (Choke)

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 32: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18920 Storage compartment Insert the projections on the front of the seat into the seat holders and push down on the seat at the The storage compartment is located under the rear.

  • Page 33: Front Carrier

    ECB00130 CAUTION: Do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartment. 1. Storage compartment check hose EBU18960 Front carrier Do not exceed the load limit of 30.0 kg (66 lb) for the front carrier.

  • Page 34: Adjusting The Rear Shock Absorber Assembly

    EBU19020 NOTE: Adjusting the rear shock absorber as- A special wrench can be obtained at a Yamaha sembly dealer to make this adjustment. The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Adjust the spring preload as follows.
  • Page 35 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4-16...

  • Page 36: Pre-Operation Checks

    Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 37 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary. 5-4, 8-25 • Check cable free play, and adjust if necessary. Control cables • Make sure that operation is smooth. Lubricate if necessary. 8-34 •...

  • Page 38: Fuel

    WHAT CAN HAPPEN Check that there is no free play in the front brake Fuel can spill, which can cause a fire and se- lever. If there is free play, have a Yamaha dealer vere injury. check the brake system.

  • Page 39: Throttle Lever

    If there is any leakage, the brake vided in this manual, have a Yamaha dealer system should be checked by a Yamaha dealer. check for the cause.

  • Page 40: Tires

    HOW TO AVOID THE HAZARD Rear: The tires listed below have been approved 25.0 kPa (3.6 psi) (0.250 kgf/cm²) by Yamaha Motor Manufacturing Corpora- • Check and adjust tire pressures when tion of America for this model. Other tire the tires are cold.

  • Page 41: Specifications

    Tire pressure below the minimum speci- NOTE: fied could cause the tire to dislodge from The low-pressure tire gauge is included as stan- the rim under severe riding conditions. dard equipment. Make two measurements of the Minimum tire pressure: tire pressure and use the second reading. Dust or Front: dirt in the gauge could cause the first reading to be 17.0 kPa (2.5 psi) (0.170 kgf/cm²)

  • Page 42: Tire Wear Limit

    Recommended pressure: Front 20.0 kPa (2.9 psi) (0.200 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 17.0 kPa (2.5 psi) (0.170 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Tire wear limit Front 23.0 kPa (3.3 psi) (0.230 kgf/cm²) EBU19840 Chassis fasteners Rear...

  • Page 43: Operation

    Read the Owner’s Manual carefully. If there is prior to operating the engine for the first time. a control or function you do not understand, ask your Yamaha dealer. 1. Set the parking brake. 2. Turn the fuel cock to “ON”.
  • Page 44 4. Shift the transmission into neutral. The neutral Ambient temp./starter (choke) position indicator light should come on. If the indicator light does not come on, have a Yamaha deal- er check the electrical circuit. NOTE: The engine can be started under the following con- ditions: The transmission is in neutral.

  • Page 45: Starting A Warm Engine

    If the battery is discharged, pull the recoil starter EBU20291 Starting a warm engine to start the engine. Follow the same procedure as for starting a cold 7. If the engine is started with the starter (choke) engine, with the exception that the starter (choke) in position (1), the starter (choke) should be is not required when the engine is warm.
  • Page 46 NOTE: be on. If the indicator light does not come on, have To shift into reverse, the transmission must be in a Yamaha dealer check the electrical circuit. first gear. 5. Check behind you for people or obstacles, 1. Bring the ATV to a complete stop.

  • Page 47: Shifting

    EWB00660 WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or even a person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no people or obstacles behind you. When it is safe to proceed, go slowly.
  • Page 48 5. Shift into second gear and release the shift EWB00650 WARNING pedal. 6. Open the throttle gradually. POTENTIAL HAZARD 7. Follow the same procedure when shifting to Engaging a lower gear when the engine the next higher gear. speed is too high. EWB00690 WHAT CAN HAPPEN WARNING...

  • Page 49: Engine Break-In

    20 hours of riding. For engine break-in period, immediately have a this reason, you should read the following material Yamaha dealer check the ATV. carefully. Since the engine is brand new, do not put an ex- EBU20721 cessive load on it for the first 20 hours.

  • Page 50: Parking On A Slope

    Yamaha accessories. Other accessories plied, apply the parking brake and slowly re- may also be available on the market. However, lease the brake pedal. it is not possible for Yamaha to test all non- Yamaha accessories, nor control over their qual-...
  • Page 51 Choose a genuine Yamaha ac- MAXIMUM LOADING LIMIT cessory, or one that is equivalent in design and ATV loading limit (total weight of rider, cargo, quality. accessories, and tongue): Accessories should be rigidly and securely 165.0 kg (364 lb) mounted.
  • Page 52 Load cargo on the carriers as close to the center EWB00750 WARNING of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, POTENTIAL HAZARD and center it. Overloading this ATV or carrying or towing Tie down cargo securely to the carriers.

  • Page 53: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 54: Getting To Know Your Atv

    EWB00010 ular attention to the safety information on pages WARNING 1-1–1-5. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. RIDE WITH CARE AND GOOD JUDGEMENT EBU21321 Get training if you are inexperienced.
  • Page 55 Yamaha. They should then ry or death of the child. regularly practice the skills learned in the HOW TO AVOID THE HAZARD course and the operating techniques de- A child under 16 should never operate an scribed in this Owner’s Manual.
  • Page 56 This ATV is designed to carry operator and car- go only – passengers prohibited. EWB00910 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 passen- ger.
  • Page 57 Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet EWB00920 WARNING that fits properly. You should also wear: POTENTIAL HAZARD eye protection (goggles or face shield) Operating this ATV without wearing an ap- gloves proved motorcycle helmet, eye protection boots and protective clothing.
  • Page 58 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. by the influence of alcohol or drugs. EWB00930 WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs.
  • Page 59 Pre-operation checks WHAT CAN HAPPEN Always perform the pre-operation checks listed on Use of improper tires on this ATV, or opera- page 5-1 before riding for proper care of the ATV tion of this ATV with improper or uneven tire and to ensure safety.
  • Page 60 EWB00010 the maximum engine power available and de- WARNING creases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and Indicates a potential hazard that could result in turning it out increases top speed. (See page 4-4.) serious injury or death.
  • Page 61 HOW TO AVOID THE HAZARD MAXIMUM LOADING LIMIT Never exceed the stated load capacity for ATV loading limit (total weight of cargo, rider, this ATV. accessories, and tongue): Cargo should be properly distributed and se- 165.0 kg (364 lb) curely attached. Front carrier: Reduce speed when carrying cargo or pull- 30.0 kg (66 lb)
  • Page 62 During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op- Removing even one hand or foot can reduce eration, otherwise they may contact the rear your ability to control the ATV or could wheels. cause you to lose your balance and fall off of the ATV.
  • Page 63 Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo- nents designed for use on this ATV and should be installed and used according to instructions.

  • Page 64: Be Careful Where You Ride

    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. EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system.
  • Page 65 HOW TO AVOID THE HAZARD EWB01030 WARNING Always avoid paved surfaces, including sidewalks, driveways, parking lots and POTENTIAL HAZARD streets. 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.
  • Page 66 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. EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 67 HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. EWB01060 WARNING POTENTIAL HAZARD...
  • Page 68 Do not ride in areas posted “no trespassing”. the shift pedal. Remember that the engine and ex- Do not ride on private property without getting per- haust pipe will be hot when riding and afterwards; mission. do not allow skin or clothing to come in contact with these components.
  • Page 69 When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an accident.

  • Page 70: Turning Your Atv

    TURNING YOUR ATV As you approach a curve, slow down and begin to To achieve maximum traction while riding off-road, turn the handlebars in the desired direction. As you the two rear wheels are mounted solidly on one do so, put your weight on the footboard to the out- axle and turn together at the same speed.
  • Page 71 may continue to go straight. If the ATV doesn’t turn, come to a stop and then practice the proce- dure again. If the riding surface is slippery or loose, it may help to position more of your weight over the front wheels by moving forward on the seat.

  • Page 72: Climbing Uphill

    CLIMBING UPHILL EWB01100 WARNING Use proper riding techniques to avoid ATV over- turns on hills. Be sure that you can maneuver your POTENTIAL HAZARD ATV well on flat ground before attempting any in- Climbing hills improperly. cline and then practice riding first on gentle slopes. WHAT CAN HAPPEN Try more difficult climbs only after you have devel- Could cause loss of control or cause the...
  • Page 73 7-21...
  • Page 74 If you are climbing a hill and you find that you have When crossing the side of a hill: not properly judged your ability to make it to the Always follow proper procedures as de- top, you should turn the ATV around while you still scribed in the Owner’s Manual.
  • Page 75 If you start to roll backwards, DO NOT apply the If you begin rolling backwards: rear brake to stop or try to put the ATV in gear. The Keep weight uphill. ATV could easily tip over backwards. Instead, ap- Never apply the rear brake while rolling ply the front brake gradually, or dismount the ATV backwards.

  • Page 76: Riding Downhill

    RIDING DOWNHILL HOW TO AVOID THE HAZARD When riding your ATV downhill, shift your weight Always follow proper procedures for going as far to the rear and uphill side of the ATV as pos- down hills as described in this Owner’s Man- sible.
  • Page 77 7-25...

  • Page 78: Crossing A Slope

    CROSSING A SLOPE HOW TO AVOID THE HAZARD Traversing a sloping surface on your ATV requires Never attempt to turn the ATV around on any you to properly position your weight to maintain hill until you have mastered the turning tech- proper balance.
  • Page 79 7-27...

  • Page 80: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
  • Page 81 1. Air filter case check hose ECB00290 CAUTION: After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the drive se- lect lever box check hose, and the storage compartment check hose.

  • Page 82: Riding Over Rough Terrain

    WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.
  • Page 83 If the rear wheels of your ATV start to slide side- ways, 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. 7-31...

  • Page 84: What To Do If

    With practice, over a period of time, skill at con- WHAT TO DO IF... trolled sliding can be developed. The terrain This section is designed to be a reference guide should be chosen carefully before attempting such only. Be sure to read each section on riding tech- maneuvers, since both stability and control are re- niques completely.
  • Page 85 THE REAR BRAKE – the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See page 7-20.) If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance.

  • Page 86: Periodic Maintenance And Minor Repair

    Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.
  • Page 87 Yamaha ATV dealer. additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

  • Page 88: 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 89 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 90: General Maintenance And Lubrication Chart

    EBU21863 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 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and for excessive play, and re- √ √ √ Swingarm pivots place bearings if necessary. •...
  • Page 92 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 93 • Replace the brake hoses every four years and if cracked or damaged.

  • Page 94: Checking The Spark Plug

    EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23211 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- 1.
  • Page 95 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 1. Spark plug gap 2. Check the spark plug for electrode erosion 2.

  • Page 96: Engine Oil And Oil Filter Element

    3. Install the spark plug with the spark plug 2. Start the engine, warm it up for several min- wrench, and then tighten it to the specified utes, and then turn it off. torque. 3. Wait at least ten minutes until the oil settles before checking.

  • Page 97: To Change The Engine Oil

    NOTE: Be sure to wait at least ten minutes until the oil settles before checking. The engine oil should be between the minimum and maximum level marks. 6. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level.
  • Page 98 1. Footboard 1. Brake pedal free play adjusting nut 2. Bolt 7. Remove the oil filter element cover by remov- 6. Fully loosen the brake pedal free play adjust- ing the bolts, and then the oil filter element. ing nut, and push the brake pedal downward. 8-13...
  • Page 99 1. Oil filter element cover 1. Oil filter element 2. Adjusting nut 2. O-ring 3. Bolt 9. Check the O-rings for damage and replace it if necessary. NOTE: 10. Install the oil filter element and the O-ring. To remove or install the oil filter element cover and oil filter element, move the drive select lever safety NOTE: system cable away from the cover.
  • Page 100 12. Install the oil strainer, compression spring, O- ECB00300 CAUTION: ring and engine oil drain bolt, and then tighten the engine oil drain bolt to the specified In order to prevent clutch slippage (since the torque. engine oil also lubricates the clutch), do not ECB00320 mix any chemical additives.

  • Page 101: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 102 To change the final gear oil 1. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil 2. Correct oil level 3. Final gear oil filler bolt 1. Final gear case cover 3. If the oil is below the brim of the filler hole, add 2.
  • Page 103 1. Final gear oil drain bolt 1. Final gear oil 2. Correct oil level 5. Install the drain bolt, and then tighten it to the 3. Final gear oil filler bolt 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 104: 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 105 1. Air filter case cover 1. Air filter element 2. Air filter case holder 4. Remove the sponge material from the air filter 3. Pull the air filter element out of the air filter element frame. case. 8-20...
  • Page 106 6. Squeeze the excess water or solvent out of the sponge material and let it dry. ECB00470 CAUTION: Do not twist the sponge material when squeezing it. Do not apply oil to the sponge material. 7. Check the sponge material and replace it if damaged.

  • Page 107: Cleaning The Spark Arrester

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

  • Page 108: Adjusting The Carburetor

    Therefore, Improperly purging the exhaust system. most carburetor adjustments should be left to a Hot exhaust system. Yamaha dealer, who has the necessary profes- WHAT CAN HAPPEN sional knowledge and experience. The adjustment Could injure the eyes.
  • Page 109 Engine idling speed: tle stop screw in direction (a), and to decrease 1400–1500 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. 8-24...

  • Page 110: 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. 8-25...

  • Page 111: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm The rear brake is provided with a wear indicator, (0.04 in), have a Yamaha dealer replace the brake which allows you to check the brake shoe wear pads as a set.

  • Page 112: Checking The Brake Fluid Level

    Yamaha dealer replace the brake shoes as a set. pads for wear and the brake system for leakage. 1. Wear indicator 1.

  • Page 113: Changing The Brake Fluid

    Water will signifi- free play of zero mm (zero in) as shown. If the free cantly lower the boiling point of the fluid and may play is incorrect, have a Yamaha dealer check the result in vapor lock. brake system.

  • Page 114: Adjusting The Brake Pedal Position, Free Play And The Rear Brake Lever Free Play

    Replacement of brake components requires professional knowledge. These procedures Adjusting the brake pedal position should be performed by a Yamaha dealer. The top of the brake pedal should be positioned 43.0–53.0 mm (1.69–2.09 in) above the top of the footboard bracket. If the position is incorrect, adjust it as follows.
  • Page 115 Adjusting the brake pedal free play The brake pedal free play should measure 20.0– 30.0 mm (0.79–1.18 in) as shown. If the free play is incorrect, adjust it as follows. 1. Locknut 2. Brake pedal position adjusting bolt 3. Brake pedal position 1.
  • Page 116 1. Brake lever free play adjusting nut 1. Brake lever free play 2. Brake pedal 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 5.0–7.0 turn in the brake lever free play adjusting bolt.
  • Page 117 1. Brake lever free play adjusting nut 1. Locknut 2. Brake camshaft lever 2. Brake lever free play adjusting bolt 3. Pin 4. Tighten the locknut at the brake lever. 4. Gap “A” 5. Install the footboard. 3. Turn the brake lever free play adjusting bolt at NOTE: the brake lever in direction (a) to increase the When adjusting the rear brake lever free play:...

  • Page 118: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light 1. Brake light switch switches should be adjusted by a Yamaha dealer. 2. Brake light switch adjusting nut 8-33...

  • Page 119: Adjusting The Clutch Free Play

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace 1. Locknut 2. Clutch adjusting screw...

  • Page 120: Checking And Lubricating The Front And Rear Brake Levers

    Recommended lubricant: Recommended lubricant: Engine oil Lithium-soap-based grease (all-purpose grease) EWB02120 WARNING Front brake lever POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged, and cables can also be- come frayed or kinked, which could restrict the operation of controls and lead to an acci- dent or injury.

  • Page 121: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel bearings. Recommended lubricant: EBU24980 Lubricating the drive shaft universal...

  • Page 122: Lubricating The Swingarm Pivots

    Recommended lubricant: Lithium-soap-based grease EBU24992 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the in- tervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 1. Grease nipple EBU25070 EBU25100 Lubricating the knuckle shafts Lubricating the steering shaft The knuckle shafts must be lubricated at the inter- The steering shaft must be lubricated at the inter-...
  • Page 123 checked before each ride and at the intervals specified in the periodic maintenance and lubrica- tion chart. To check the electrolyte level 1. Place the ATV on a level surface. 2. Remove the battery cover by pulling it upward. 1. Battery 2.
  • Page 124 EWB02140 5. Check and, if necessary, tighten the battery WARNING lead connections and correct the breather hose routing. POTENTIAL HAZARD 6. Install the battery cover. Failure to handle batteries or battery electro- lyte carefully. To store the battery WHAT CAN HAPPEN If the ATV will not be used for more than one You could be poisoned.
  • Page 125 To install the battery NOTE: Be sure the battery is fully charged. 1. Install the battery. 2. Connect the positive lead. 3. Install the battery bracket by installing the bolts. 4. Connect the negative lead. 5. Make sure that the breather hose is properly routed, in good condition, and not obstructed.

  • Page 126: Replacing The Fuse

    ECB00610 1. Turn the key to “OFF” and turn off all electrical CAUTION: circuits. If the breather hose is positioned in such a way ECB00640 CAUTION: that the frame is exposed to electrolyte or gas expelled from the battery, the frame could suf- To prevent accidental short-circuiting, turn off fer structural and external damages.

  • Page 127: 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. EBU26892 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 128 NOTE: The headlight bulb cannot be removed from the headlight bulb holder. To replace the headlight bulb, replace the headlight bulb holder assembly. EWB02180 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and im- mediately after it is turned off. WHAT CAN HAPPEN 1.

  • Page 129: Adjusting A Headlight Beam

    7. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make 1. Headlight beam adjusting screw this adjustment. EBU25610 Replacing the tail/brake light bulb To raise a headlight beam, turn the adjusting screw in direction (a).

  • Page 130: Removing A Wheel

    1. Tail/brake light bulb holder 1. Tail/brake light bulb holder 2. Tail/brake light bulb 2. Remove the defective bulb by pushing it in 3. Insert a new bulb into the bulb holder, push it and turning it counterclockwise. in, and then turn it clockwise until it stops. 4.

  • Page 131: Installing A Wheel

    Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Wheel nut 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 1.

  • Page 132: Troubleshooting

    The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- 1. Tapered nut rience, and know-how to service the ATV properly.
  • Page 133 HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys- tem. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces. 8-48...

  • Page 134: 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 135: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25870 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 136: Storage

    EWB02300 To prevent corrosion, avoid damp cellars, WARNING stables (because of the presence of ammo- nia) and areas where strong chemicals are POTENTIAL HAZARD stored. Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping abil- Long-term ity, increasing the chance of an accident.
  • Page 137 b. Pour a teaspoonful of engine oil into the sively cold or warm place [less than 0 °C (30 spark plug bore. °F) or more than 30 °C (90 °F)]. For more in- c. Install the spark plug cap onto the spark formation on storing the battery, see page plug, and then place the spark plug on the 8-37.

  • Page 138: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 8.70 :1 Overall length: Starting system: 1916 mm (75.4 in) Electric and recoil starter Overall width: Lubrication system: 1038 mm (40.9 in) Wet sump Overall height: Engine oil: 1118 mm (44.0 in) Seat height: Type: 772 mm (30.4 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase:...
  • Page 139 With oil filter element removal: Transmission: 1.60 L (1.69 US qt) (1.41 Imp.qt) Primary reduction system: Final gear oil: Spur gear Type: Primary reduction ratio: SAE80 API GL-4 Hypoid gear oil 73/22 (3.318) Quantity: Secondary reduction system: 0.25 L (0.26 US qt) (0.22 Imp.qt) Shaft drive Air filter: Secondary reduction ratio:...
  • Page 140 Trail: Maximum: 20.0 mm (0.79 in) Front: Front tire: 23.0 kPa (3.3 psi) (0.230 kgf/cm²) Rear: Type: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Tubeless Front wheel: Size: AT22 x 7.00-10 Wheel type: Manufacturer/model: Panel wheel MAXXIS/M905 Rim size: Rear tire: 10 x 6.0 AT Rear wheel: Type:...
  • Page 141 Spring/shock absorber type: Reverse indicator light: 12 V, 1.7 W × 1 Coil spring/oil damper Wheel travel: Fuse: 125 mm (5.0 in) Fuse: Rear suspension: 20.0 A Type: Swingarm (monocross) Spring/shock absorber type: Coil spring/oil damper Wheel travel: 135 mm (5.3 in) Electrical system: Ignition system: DC.

  • Page 142: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 143 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 144: Noise Regulation

    EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ul- timate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 145: Maintenance Record

    EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 146: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 147 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 148: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”...
  • Page 149 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 150 EBU26132 11-9...
  • Page 151 INDEX Drive select lever safety system cable, adjusting ..8-26 Drive shaft universal joint, lubricating ......8-36 Accessories and loading ..........6-8 Air filter element, cleaning ..........8-19 Engine break-in .............. 6-7 Engine, cold start ............6-1 Battery ..............5-7, 8-37 Engine idling speed .............
  • Page 152 Specifications ............... 10-1 Speed limiter ..............4-4 Label locations ............... 2-1 Starter (choke) ............. 4-12 Light switch ..............4-3 Start switch ..............4-3 Steering shaft, lubricating ..........8-37 Main switch ..............4-1 Storage ................9-2 Maintenance and lubrication chart ......... 8-5 Storage compartment ...........
  • Page 153 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN USA 2006.05-1.0×1 CR...

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