Yamaha RAPTOR 350 Owner's Manual
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Yamaha RAPTOR 350 Owner's Manual

Yamaha RAPTOR 350 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM35RW
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-20-10
5YT-28199-14

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  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35RW WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-20-10 5YT-28199-14...
  • Page 2 EBU17091...
  • Page 3 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 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

    Clutch lever ..........4-5 EWB00010 WARNING Brake lever ..........4-5 Brake pedal ..........4-6 Indicates a potential hazard that could result in serious injury or death. Parking brake lever ........4-6 Shift pedal ...........4-7 Drive select lever ........4-8 Fuel tank cap ..........4-8 EBU17420 Fuel .............4-9 TABLE OF CONTENTS Fuel cock ..........4-10 Starter (choke) ..........4-12...
  • Page 7 Instruments, lights and switches ....5-9 WHAT TO DO..........7-28 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 driving in reverse ........
  • Page 8 Noise regulation ........11-3 Checking the wheel bearings ....8-34 Maintenance record ........11-4 Lubricating the swingarm pivots ....8-34 YAMAHA MOTOR CORPORATION, Lubricating the rear suspension relay arm U.S.A. ATV LIMITED WARRANTY ..11-5 and connecting arm pivoting points ..8-34 YAMAHA EXTENDED SERVICE Lubricating the upper and lower arm (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 17: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Headlights 1. Spark arrester 2. Front wheel 2. Seat 3. Fuel cock 3. Drive select lever 4. Rear wheel 4. Fuel tank cap 5. Shift pedal 5. Main switch 6. Brake pedal...

  • Page 18: Controls And Instruments

    EBU17712 Controls and instruments 1. Clutch lever 2. Parking brake lever 3. Brake lever 4. Throttle lever 5. Left handlebar switches NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 19: 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 20: 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 21: 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 22: 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) 3.

  • Page 23: Clutch Lever

    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 Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 2.0–4.0 mm (0.08–0.16 in).

  • Page 24: Brake Pedal

    1. Brake lever 1. Brake pedal EBU18432 EBU18510 Brake pedal Parking brake lever The brake pedal is located on the right side of the Use the parking brake before starting the engine or ATV. To apply the rear brake, push down on the parking the ATV, especially on a slope.

  • Page 25: 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 26: Drive Select Lever

    1. Shift pedal 1. Drive select lever EBU18571 EBU18720 Drive select lever Fuel tank cap The drive select lever is used for driving the ATV Remove the fuel tank cap by turning it counter- either forward or in reverse. See the “Operating the clockwise.

  • Page 27: Fuel

    1. Fuel tank filler tube 2. Fuel level 1. Fuel tank cap Recommended fuel: UNLEADED GASOLINE ONLY EBU18730 Fuel Fuel tank capacity: 9.0 L (2.38 US gal) (1.98 Imp.gal) Make sure that there is sufficient fuel in the tank. Fuel reserve amount: Fill the fuel tank to the bottom of the filler tube as 2.7 L (0.71 US gal) (0.59 Imp.gal) shown.

  • Page 28: Fuel Cock

    Your Yamaha engine has been designed to use HOW TO AVOID THE HAZARD regular unleaded gasoline with a pump octane Do not overfill the fuel tank. Be careful not to number [(R+M)/2] of 86 or higher, or a research oc- spill fuel, especially on the engine or ex- tane number of 91 or higher.
  • Page 29 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 30: Starter (Choke)

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

  • Page 31: Adjusting The Front Shock Absorber Assemblies

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat EBU18980 Insert the projections on the front of the seat into Adjusting the front shock absorber as- the seat holders and push down on the seat at the semblies rear.
  • Page 32 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): EWB00350 WARNING POTENTIAL HAZARD Improper shock absorber assembly adjust- ment.

  • Page 33: Adjusting The Rear Shock Absorber Assembly

    Adjust the spring preload as follows. NOTE: 1. Loosen the locknut. A special wrench can be obtained at a Yamaha 2. Turn the adjusting nut in direction (a) to in- dealer to make this adjustment. crease the spring preload and thereby harden...
  • Page 34 1. Special wrench 1. Distance A 3. Tighten the locknut to the specified torque. Spring preload setting: Minimum (hard): Tightening torque: Distance A = 218.5 mm (8.6 in) Locknut: Standard: 42 Nm (4.2 m·kgf, 30 ft·lbf) Distance A = 228.5 mm (9.0 in) Maximum (soft): ECB00080 Distance A = 233.5 mm (9.2 in)
  • Page 35 Do not deform or damage the cylinder in any way. Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha dealer for any service. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.

  • 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 • Check operation, and correct if necessary. Clutch • Lubricate cable if necessary. 8-28 • Check lever free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary.
  • Page 38 EWB00470 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Own- er’s Manual.

  • Page 39: Fuel

    EBU19530 Fuel Make sure that there is sufficient fuel in the tank. (See page 4-9.) EWB00500 WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun.

  • Page 40: Front And Rear Brakes

    If there is any leak- Check that there is no free play in the brake le- age, have a Yamaha dealer check the brake sys- ver. If there is free play, have a Yamaha dealer tem. check the brake system.

  • Page 41: Throttle Lever

    EBU19761 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary. EBU19770 Drive chain Check the condition of the drive chain and check the drive chain slack.

  • Page 42: 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 Co., Ltd. for this model. • Check and adjust tire pressures when Other tire combinations are not recom- the tires are cold.

  • Page 43: 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 22.0 kPa (3.2 psi) (0.220 kgf/cm²)

  • Page 44: Tire Wear Limit

    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 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Tire wear limit Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) EBU19840 Chassis fasteners Rear...

  • Page 45: 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 46 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: This model is equipped with an ignition circuit cut- off system.

  • Page 47: Starting A Warm Engine

    7. If the engine is started with the starter (choke) EBU20330 Operating the drive select lever and in position (1), the starter (choke) should be driving in reverse returned to position (2) to warm up the engine. ECB00170 If the engine is started with the starter (choke) CAUTION: in position (2), keep the starter (choke) in this Before shifting, stop the ATV, otherwise the...
  • Page 48 When in reverse, the reverse indicator light should be on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 5. Check behind you for people or obstacles, and then release the brake pedal.

  • Page 49: Shifting

    EBU20530 EBU20580 Shifting To start out and accelerate 1. Release the throttle lever, and then release This ATV has a 6-speed forward and 1-speed re- the parking brake. verse transmission. The transmission allows you ECB00200 to control the amount of power you have available CAUTION: at a given speed or for starting, accelerating, climb- Always close the throttle before shifting gears,...
  • Page 50 EWB00680 EWB00650 WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Opening the throttle abruptly or releasing Engaging a lower gear when the engine the clutch lever too quickly. speed is too high. WHAT CAN HAPPEN WHAT CAN HAPPEN The ATV could wheelie. This would increase The wheels could stop rotating and lose the chance of an accident, including over- traction.

  • Page 51: 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- cessive load on it for the first 20 hours.

  • Page 52: Parking On A Slope

    HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV transversely across the incline, apply the parking brake, stop the engine, shift into first gear, and then block the front and rear wheels with rocks or other objects.

  • Page 53: Accessories And Loading

    However, judgment as the stability and handling of an ATV it is not possible for Yamaha to test all non- can be changed. When adding accessories, keep Yamaha accessories, nor control over their qual-...
  • Page 54 Never exceed the weight limits shown. An over- Allow more braking distance. A heavier ATV loaded ATV can be unstable. takes longer to stop. Avoid making sharp turns unless at very slow MAXIMUM LOADING LIMIT speeds. ATV loading limit (total weight of rider, cargo, Avoid hills and rough terrain.
  • Page 55 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 6-11...

  • Page 56: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 57: Getting To Know Your Atv

    EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU21591 GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by expe- rienced operators only. Even if you are an experi- enced operator of all other all terrain ATVs or motorcycles, riding the ATV requires special skills acquired through practice.

  • Page 58: Ride With Care And Good Judgement

    Beginners should get training from a certified in- course offered by Yamaha. They should then structor. regularly practice the skills learned in the Become familiar with this ATV at slow speeds first, course and the operating techniques de- even if you are an experienced operator.
  • Page 59 WHAT CAN HAPPEN WHAT CAN HAPPEN Use by children of ATVs that are not recom- Greatly reduces your ability to balance and mended for their age can lead to severe inju- control this ATV. Could cause an accident, ry or death of the child. resulting in harm to you and/or your passen- HOW TO AVOID THE HAZARD ger.
  • Page 60 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 61 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. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.
  • Page 62 EWB00950 Do not operate at speeds too fast for your skills WARNING or the conditions. EWB00960 POTENTIAL HAZARD WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Operating this ATV at speeds too fast for Use of improper tires on this ATV, or opera- your skills or the conditions.
  • Page 63 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 100.0 kg (220 lb) EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN 1. Adjusting screw Could cause changes in ATV handling which Loading and accessories could lead to an accident.
  • Page 64 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 65 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 66: 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 67 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. Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles.
  • Page 68 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 69 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 70 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 71 EWB01240 EWB01070 WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Opening the throttle abruptly or releasing Engaging a lower gear when the engine the clutch lever too quickly. speed is too high. WHAT CAN HAPPEN WHAT CAN HAPPEN The ATV could wheelie. This would increase The wheels could stop rotating.

  • Page 72: 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 73: Climbing Uphill

    This procedure should be practiced at slow speed Try more difficult climbs only after you have devel- many times in a large off-road area with no obsta- oped your skill. In all cases avoid inclines with slip- cles. If an incorrect technique is used, your ATV pery or loose surfaces, or obstacles that might may continue to go straight.
  • Page 74 EWB01100 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 climb- ing hills as described in this Owner’s Manu- Always check the terrain carefully before you start up any hill.
  • Page 75 WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground.

  • Page 76: Riding Downhill

    EWB01251 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning. HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
  • Page 77 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. EWB01130 WARNING POTENTIAL HAZARD...

  • 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 7-24...

  • 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 ECB00240 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. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions.

  • Page 82: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN SLIDING AND SKIDDING Riding over rough terrain should be done with cau- Care should be used when riding on loose or slip- tion. Look out for obstacles which could cause pery surfaces since the ATV may slide. If unex- damage to the ATV or could lead to an upset or ac- pected and uncorrected, sliding could lead to an cident.

  • Page 83: What To Do If

    WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.
  • Page 84 If your ATV begins to tip while turning: If your ATV encounters shallow water: Lean more into the turn to regain balance. If nec- Ride slowly and carefully through slow moving essary, gradually let off the throttle and/or steer water, watching for obstacles. Be sure to let wa- to the outside of the turn.

  • Page 85: 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 86 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 87: 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 88 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 89: General Maintenance And Lubrication Chart

    EBU21862 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 90 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 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Engine oil filter ele- √ √ √ • Clean or replace if necessary. ment √ √ √ Engine oil strainer •...
  • Page 92 • Replace the brake hoses every four years and if cracked or damaged.

  • Page 93: 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 94 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 95: 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 a few minutes until the oil settles before checking.
  • Page 96 NOTE: 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. 7.
  • Page 97 5. Remove the oil filter element cover by remov- 9. Install the oil filter element cover by installing ing the bolts, and then remove the oil filter el- the bolts, and then tighten them to the speci- ement. fied torque. Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

  • Page 98: Cleaning The Air Filter Element

    EBU23730 Recommended oil: Cleaning the air filter element See page 10-1. The air filter element should be cleaned at the in- Oil quantity: tervals specified in the periodic maintenance and Without oil filter element replacement: lubrication chart. Clean the air filter element more 2.50 L (2.64 US qt) (2.20 Imp.qt) frequently if you are riding in unusually wet or dusty With oil filter element replacement:...
  • Page 99 2. Remove the air filter case cover by unhooking the holders. 1. Air filter element assembly 4. Remove the sponge material from the air filter 1. Air filter case cover element frame. 2. Air filter case holder 3. Pull the air filter element out of the air filter case.
  • Page 100 7. Check the sponge material and replace it if damaged. 1. Air filter element retaining plate 2. Air filter element frame 8. Apply Yamaha foam air filter oil or other qual- 3. Sponge material ity foam air filter oil to the sponge material. 4. Air filter element seat NOTE: 5.

  • Page 101: Cleaning The Spark Arrester

    EBU23862 NOTE: Cleaning the spark arrester The air filter element should be cleaned every 20– Be sure the exhaust pipe and muffler are cool be- 40 hours. It should be cleaned and lubricated more fore cleaning the spark arrester. often if the ATV is operated in extremely dusty ar- 1.

  • Page 102: Adjusting The Carburetor

    Improper cleaning of the spark arrester. most carburetor adjustments should be left to a Hot exhaust system. Yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment described in the following section, however, may be performed by the owner as part of routine main- tenance.

  • Page 103: Adjusting The Engine Idling Speed

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

  • Page 104: Adjusting The Throttle Cable Free Play

    (b). must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. 8-20...

  • Page 105: Checking The Front And Rear Brake Pads

    If a brake pad has worn to the point that the wear indicator groove is almost in contact with NOTE: the disc plate, have a Yamaha dealer replace the The wheels need to be removed to check the brake pads as a set.

  • Page 106: Checking The Brake Fluid Level

    Front brake 1. Wear indicator groove 1. Minimum level mark EBU24251 Rear brake Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary.

  • Page 107: Changing The Brake Fluid

    EBU24290 Changing the brake fluid When checking the fluid level, make sure that Have a Yamaha dealer change the brake fluid at the top of the brake fluid reservoir is level. the intervals specified in the NOTE after the peri- Use only the recommended quality brake fluid, odic maintenance and lubrication chart.

  • Page 108: Checking The Brake Pedal Position

    Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures 1. Brake lever free play should be performed by a Yamaha dealer. EWB02010 EBU24580 WARNING Checking the brake pedal position...

  • Page 109: Adjusting The Parking Brake Free Play

    Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 1. Brake pedal position EBU24700 Adjusting the parking brake free play...
  • Page 110 1. Release the parking brake by moving the If the cable length cannot be adjusted to specifica- parking brake lever to the right. tion, consult a Yamaha dealer. 2. Fully loosen the locknut and the adjusting bolt at the rear brake caliper.

  • Page 111: Brake Light Switches

    The brake light switch for the brake pedal can be Tightening torque: adjusted as follows, but the other brake light Locknut (rear brake caliper): switches should be adjusted by a Yamaha dealer. 16 Nm (1.6 m·kgf, 11 ft·lbf) NOTE: EWB02030...

  • Page 112: Adjusting The Clutch Lever Free Play

    EBU24820 2. To increase the clutch lever free play, turn the Adjusting the clutch lever free play adjusting bolt at the clutch lever in direction The clutch lever free play must be checked and, if (a), and to decrease it, turn the bolt in direction necessary, adjusted at the intervals specified in the (b).

  • Page 113: Drive Chain Slack

    NOTE: If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal clutch mechanism. EBU24841 Drive chain slack The drive chain slack should be checked before 1.
  • Page 114 1. Axle holding bolt (upper) 1. Locknut 2. Axle holding bolt (lower) 2. Drive chain slack adjusting bolt 3. Alignment marks 2. Loosen the locknut on each side of the swing- ECB00541 arm. To tighten the drive chain, turn the ad- CAUTION: justing bolts in direction (a).

  • Page 115: Lubricating The Drive Chain

    ECB00560 Tightening torques: CAUTION: Locknut: The drive chain must be lubricated after wash- 16 Nm (1.6 m·kgf, 12 ft·lbf) ing the ATV or riding in the rain. Axle holding bolt (upper): 120 Nm (12.0 m·kgf, 87 ft·lbf) 1. Clean the drive chain with kerosene and a Axle holding bolt (lower): small soft brush.

  • Page 116: Checking And Lubricating The Brake And Clutch Levers

    If a cable is damaged or does not move Recommended lubricant: smoothly, have a Yamaha dealer check or replace Lithium-soap-based grease (all-purpose grease) Recommended lubricant: Brake lever Engine oil EWB02120 WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN...

  • Page 117: Checking And Lubricating The Brake And Shift Pedals

    Clutch lever Brake pedal Shift pedal EBU24930 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 8-33...

  • Page 118: Checking The Wheel Bearings

    If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. EBU24990 Lubricating the swingarm pivots...

  • Page 119: Lubricating The Upper And Lower Arm Pivots

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

  • Page 120: Lubricating The Knuckle Shafts

    Right side EBU25100 Lubricating the steering shaft The steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Recommended lubricant: Lithium-soap-based grease EBU25212 Battery This model is equipped with a sealed-type (MF) battery, which does not require any maintenance.
  • Page 121 EWB02140 To charge the battery WARNING Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in POTENTIAL HAZARD mind that the battery tends to discharge more Failure to handle batteries or battery electro- quickly if the ATV is equipped with optional electri- lyte carefully.

  • Page 122: Replacing The Fuse

    If you do not have To prevent accidental short-circuiting, turn off access to a constant-voltage battery charg- the main switch when checking or replacing a er, have a Yamaha dealer charge your bat- fuse. tery. 8-38...

  • Page 123: 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. EBU25531 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 124 4. Install a new headlight bulb into the headlight unit by aligning the projection on the bulb with the groove in the headlight unit. 1. Headlight bulb holder 3. Remove the defective bulb from the headlight unit by pulling it out. 1.

  • Page 125: Adjusting A Headlight Beam

    ECB00690 pushing it inward, and turning it clockwise until CAUTION: it stops. It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the adjusting bolt in direction (a). To lower a headlight beam, turn the adjusting bolt in direction (b).

  • Page 126: Removing A Wheel

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

  • Page 127: Installing A Wheel

    4. Remove the wheel. systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose EBU25660 skilled technicians have the necessary tools, expe- Installing a wheel rience, and know-how to service the ATV properly.
  • Page 128 EWB02260 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 sys- tem.

  • Page 129: 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 130: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25890 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 131: 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 132 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 8-36.

  • Page 133: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 1780 mm (70.1 in) Electric starter Overall width: Lubrication system: 1095 mm (43.1 in) Wet sump Overall height: Engine oil: 1080 mm (42.5 in) Seat height: Type: 820 mm (32.3 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase: 1210 mm (47.6 in)
  • Page 134 With oil filter element replacement: Primary reduction ratio: 2.60 L (2.75 US qt) (2.29 Imp.qt) 76/24 (3.166) Air filter: Secondary reduction system: Chain drive Air filter element: Secondary reduction ratio: Wet element 38/13 (2.923) Fuel: Transmission type: Recommended fuel: Constant mesh 6-speed.forward, 1-speed.reverse Unleaded gasoline only Operation: Fuel tank capacity:...
  • Page 135 Front tire: Maximum: Front: Type: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Tubeless Rear: Size: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) AT21 x 7-10 Front wheel: Manufacturer/model: DUNLOP/KT851B Wheel type: Rear tire: Panel wheel Rim size: Type: 10x5.5AT Tubeless Rear wheel: Size: AT20 x 10-9 Wheel type:...
  • Page 136 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Neutral indicator light: Double wishbone 12 V, 1.7 W × 1 Spring/shock absorber type: Reverse indicator light: Coil spring/oil damper 12 V, 1.7 W × 1 Wheel travel: Fuse: 200 mm (7.9 in) Rear suspension: Fuse:...

  • Page 137: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 138 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 139: 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 140: 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 141: 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 142 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 143: 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 144 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 145 EBU26132 11-9...
  • Page 146 INDEX Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-9 Air filter element, cleaning ..........8-14 Engine break-in .............. 6-7 Engine, cold start ............6-1 Engine idling speed ............8-19 Battery ................8-36 Engine oil ............... 5-4 Brake and clutch levers, checking and lubricating ..
  • Page 147 Starter (choke) ............. 4-12 Start switch ..............4-3 Main switch ..............4-1 Steering shaft, lubricating ..........8-36 Maintenance and lubrication chart ......... 8-5 Storage ................9-2 Maintenance chart, emission control system ....8-3 Suspension, lubricating the upper and lower arm Maintenance record .............
  • Page 148 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.04-2.4×1 CR...

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