Yamaha YFM250XR Bear Tracker 2003 Owner's Manual PDF
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Summary of Content for Yamaha YFM250XR Bear Tracker 2003 Owner's Manual PDF
4XE-F8199-15LIT-11626-16-14
READ THIS MANUAL CAREFULLY! It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.WARNING
YFM250XR
OWNERS MANUAL
PRINTED IN USA 2002.05-2.01 CR
(E)
PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD.
EBU00438
LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558)
WARNING
ALWAYS: use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. avoid paved surfaces-pavement may seriously affect handling and control.
Improper ATV use can result in SEVERE INJURY or DEATH.
NEVER operate: without proper training or instruction. at speeds too fast for your skills or the conditions. on public roads-a collision can occur with another vehicle. with a passenger-passengers affect balance and steering and increase risk of losing control.
ALWAYS USE AN APPROVED HELMET AND
PROTECTIVE GEAR
NEVER USE ON PUBLIC
ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
B EE R
B EE R
EBU00776
EBU00941
1-INTRODUCTION
Congratulations on your purchase of the Yamaha YFM250X. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of crafts- manship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND
COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE
TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION.
THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.
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EBU00801
ON
ANUAL CAN RESULT IN
following notations:
ION! BECOME ALERT!
could result in severe bystander or a person
that must be taken to
e procedures easier or
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1-IMPORTANT MANUAL INFORMATI
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS M SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the
The Safety Alert Symbol means ATTENT YOUR SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions injury or death to the machine operator, a inspecting or repairing the machine.
CAUTION: A CAUTION indicates special precautions avoid damage to the machine.
NOTE: A NOTE provides key information to mak clearer.
nly. It is illegal and unsafe to
and spark arrester laws and
g this machine.
YFM250XR ERS MANUAL aha Motor Corporation,
U.S.A. ition, March 2002 erved. Any reprinting or
unauthorized use without the written permission of
Yamaha Motor Corporation, U.S.A. is expressly prohibited.
Printed in U.S.A. P/N LIT-11626-16-14
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AFFIX DEAL
LABEL HER
EBU00011
This machine is designed operate this machine on an This machine complies wi regulations in effect at the Please check your local rid
EBU00531
ER
E
IMPORTANT NOTICE
and manufactured for OFF-ROAD use o y public street, road or highway.
th all applicable OFF-ROAD noise level time of manufacture. ing laws and regulations before operatin
OWN 2002 by Yam
1st Ed All rights res
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Key identification Vehicle identifica Model label ........
NCTIONS...................4-1 ......................................4-1 ts..................................4-2 witches .........................4-2 r ....................................4-4 r ....................................4-5 ever..............................4-6 edal and lever .............4-6 e...................................4-8 ......................................4-9 lever .............................4-9 r..................................4-10 p .................................4-11 ....................................4-12 e) ...............................4-13
....................................4-14
....................................4-15 ...................................4-16 ....................................4-16 bsorber ...................................4-16
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number................ 3-2 tion number .......... 3-3 .............................. 3-3
Front carrier Rear carrier Rear shock a adjustment
WARNING Indicates a potential hazard that could result in serious injury or death.
CONTENTS
LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1
SAFETY INFORMATION.................. 2-1
DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2
1
2
3
CONTROL FU Main switch Indicator ligh Handlebar s Throttle leve Speed limite Front brake l Rear brake p Parking brak Shift pedal .. Drive select Recoil starte Fuel tank ca Fuel cock.... Starter (chok Seat............ Storage box
4
k-in ...............................6-7 .......................................6-8 a slope...........................6-9 and loading ...............6-10
R ATV..........................7-1 now your atv..................7-3 re and good ......................................7-4 here you ride..............7-16 r atv.............................7-23 hill ...............................7-25 hill ..............................7-30
slope............................7-32 rough shallow water ....7-34 rough terrain...............7-36 skidding.......................7-37 if...................................7-39 .....................................7-39
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PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-3 Fuel ................................................. 5-5 Engine oil ........................................ 5-7 Final gear oil.................................... 5-8 Throttle lever ................................... 5-8 Fittings and Fasteners .................... 5-8 Lights............................................... 5-8 Switches.......................................... 5-8 Battery............................................. 5-8 Tires ................................................ 5-9 How to measure tire pressure....... 5-11 Tire wear limit................................ 5-12
OPERATION..................................... 6-1 Starting a cold engine ..................... 6-1 Starting a warm engine................... 6-3 Warming up..................................... 6-3 Drive select lever operation and reverse driving............................... 6-4
Shifting ............................................ 6-5 To start out and accelerate: ............ 6-6 To decelerate: ................................. 6-7
Engine brea Parking...... Parking on Accessories
RIDING YOU Getting to k Ride with ca judgement
Be careful w Turning you Climbing up Riding down Crossing a Crossing th Riding over Sliding and What to do What to do
5
6
7
tion and ....................................8-24 nd brake pedal
....................................8-25 ft lubrication ...............8-26 val...............................8-27 lation...........................8-27 ....................................8-29 the battery fluid ........8-31 ment ..........................8-32 headlight bulb ............8-33 am adjustment...........8-34 ht bulb t .................................8-35
er cleaning..................8-37 ting .............................8-38 ting chart ....................8-39
ND STORAGE ............9-1 ......................................9-1 ......................................9-3
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PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1 Owners manual and tool kit............ 8-1 Periodic maintenance/ lubrication ...................................... 8-3
Engine oil......................................... 8-5 Final gear oil .................................... 8-9 Spark plug inspection.................... 8-11 Air filter cleaning............................ 8-12 Carburetor adjustment................... 8-15 Idle speed adjustment ................... 8-15 Valve clearance adjustment.......... 8-16 Throttle lever adjustment............... 8-16 Front brake pad inspection............ 8-17 Rear brake shoe inspection .......... 8-17 Brake fluid level inspection............ 8-18 Brake fluid replacement................. 8-19 Front brake adjustment ................. 8-19 Rear brake adjustment.................. 8-21 Adjusting the rear brake light switch........................................... 8-23
Clutch adjustment.......................... 8-24
Cable inspec lubrication.
Brake lever a lubrication.
Steering sha Wheel remo Wheel instal Battery........ Replenishing Fuse replace Replacing a Headlight be Tail/brake lig replacemen
Spark arrest Troubleshoo Troubleshoo
CLEANING A A. Cleaning B. Storage ..
8
9
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SPECIFICATIONS.......................... 10-1
NOISE REGULATION.................... 11-1
MAINTENANCE RECORD ............ 12-1
ATV LIMITED WARRANTY............ 13-1
YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................... 14-1
10
11
12
13
14
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D
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1-1
1-LOCATION OF THE WARNING AN SPECIFICATION LABELS
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1-2
Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
Overloading this ATV or carrying cargo improperly can change handling. stability and braking performance and can lead to an accident. Never exceed the maximum front cargo limit of : 30kg (66 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual.
4XE-F4877-30
WARNING 1
2
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1-3
Overloading this ATV or carrying cargo improperly can change handling. stability and braking performance and can lead to an accident. Never exceed the maximum rear cargo limit of : 45kg (99 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual.
4XE-F4897-30
WARNING
3
4
5
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1-4
6 7
8
9
EBU00924
An ATV handles differently er can occur quickly, even bstacles, if you fail to take
tructions: rocedures described. Training Course. Begin- thorized ATV dealer or call
ne size greater than 90cc. pervision, and never allow bilities to operate it safely.
idewalks, driveways, park-
a dirt or gravel one.
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2-1
1-SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. from other vehicles including motorcycles and cars. A collision or rollov during routine maneuvers such as turning and riding on hills or over o proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these ins Read this manual and all labels carefully and follow the operating p Never operate an ATV without proper training or instruction. Take a
ners should receive training from a certified instructor. Contact an au 1-800-887-2887 to find out about the training courses nearest you.
Always follow the age recommendation: - A child under 16 years old should never operate an ATV with engi
Never allow a child under age 16 to operate an ATV without adult su continued use of an ATV by a child if he or she does not have the a
Never carry passenger on an ATV. Always avoid operating an ATV on any paved surfaces, including s
ing lots and streets. Never operate an ATV on any public street, road or highway, even
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lmet that fits properly. You boots, long-sleeved shirt or
. lways go at a speed that is xperience.
afe operating condition. Al- ules described in this man-
otboards of the ATV during
r terrain. Always be alert to
you have learned and prac- s be especially cautious on
nual. Practice turning at low xcessive speed. bilities. Practice on smaller
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2-2
Never operate an ATV without wearing an approved motorcycle he should also wear eye protection (goggles or face shield), gloves, jacket, and long pants.
Never consume alcohol or drugs before or while operating this ATV Never operate at speeds too fast for your skills or the conditions. A
proper for the terrain, visibility and operating conditions, and your e Never attempt wheelies, jumps, or other stunts. Always inspect your ATV each time you use it to make sure it is in s
ways follow the inspection and maintenance procedures and sched ual.
Always keep both hands on the handlebars and both feet on the fo operation.
Always go slowly and be extra careful when operating on unfamilia changing terrain conditions when operating the ATV.
Never operate on excessively rough, slippery or loose terrain until ticed the skills necessary to control the ATV on such terrain. Alway these kinds of terrain.
Always follow proper procedures for turning as described in this ma speeds before attempting to turn at faster speeds. Do not turn at e
Never operate the ATV on hills too steep for the ATV or for your a hills before attempting larger hills.
his manual. Check the ter- cessively slippery or loose nly or make sudden gear
ng on hills as described in ill. Shift your weight back-
an angle that would cause ere possible. described in this manual. ight to the uphill side of the ave mastered the turning
g the side of a steep hill if
mbing a hill. To avoid stall- hill. If you stall or roll back- manual. Dismount on the and remount, following the
or fallen trees. Always fol- in this manual.
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2-3
Always follow proper procedures for climbing hills as described in t rain carefully before you start up any hill. Never climb hills with ex surfaces. Shift your weight forward. Never open the throttle sudde changes. Never go over the top of a hill at high speed.
Always follow proper procedures for going down hills and for braki this manual. Check the terrain carefully before you start down any h ward. Never go down a hill at high speed. Avoid going down a hill at the vehicle to lean sharply to one side. Go straight down the hill wh
Always follow proper procedures for crossing the side of a hill as Avoid hills with excessively slippery or loose surfaces. Shift your we ATV. Never attempt to turn the ATV around on any hill until you h technique described in this manual on level ground. Avoid crossin possible.
Always use proper procedures if you stall or roll backwards when cli ing, use proper gear and maintain a steady speed when climbing a wards, follow the special procedure for braking described in this uphill side or to a side if pointed straight uphill. Turn the ATV around procedure described in this manual.
Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks low proper procedures when operating over obstacles as described
skidding or sliding by prac- pery surfaces, such as ice, idding or sliding out of con-
n that recommended in this bility. Test your brakes after dry out the linings. en you operate in reverse.
sories. be properly distributed and anual for carrying cargo or
mer Products Safety Com- 1-800-852-5344.
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2-4
Always be careful when skidding or sliding. Learn to safely control ticing at low speeds and on level, smooth terrain. On extremely slip go slowly and be very cautious in order to reduce the chance of sk trol.
Never operate an ATV in fast flowing water or in water deeper tha manual. Remember that wet brakes may have reduced stopping a leaving water. If necessary, apply them several times to let friction
Always be sure there are no obstacles or people behind you wh When it is safe to proceed in reverse, go slowly.
Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual. Never modify an ATV through improper installation or use of acces Never exceed the stated load capacity for an ATV. Cargo should
securely attached. Reduce speed and follow instructions in this m pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consu mission at 1-800-638-2772, or the ATV Distributors Safety Hotline at
ng the ATV in another it is kept upright and k is in the OFF posi- fuel may leak out of the l tank. PEN onous and can cause
THE HAZARD allow some gasoline or gasoline vapor, or get n your eyes, see your ely. on your skin, wash with . If gasoline spills on ange your clothes.
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2-5
WARNING
POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refuel- ing. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refu- el while smoking, or while in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of wa- ter heaters and clothes dryers.
When transporti vehicle, be sure that the fuel coc tion. Otherwise, carburetor or fue WHAT CAN HAP Gasoline is pois injuries. HOW TO AVOID If you should sw inhale a lot of some gasoline i doctor immediat If gasoline spills soap and water your clothing, ch
WARNING
ZARD ning the engine in a
PEN are poisonous and may nsciousness and death
me. THE HAZARD your ATV in an area with tion.
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2-6
POTENTIAL HA Starting or run closed area. WHAT CAN HAP Exhaust fumes cause loss of co within a short ti HOW TO AVOID Always operate adequate ventila
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ICATION
7. Rear brake light switch
12. Recoil starter 13. Tail/brake light 14. Rear wheel 15. Shift pedal 16. Drive select lever 17. Rear brake lever 18. Parking brake 19. Main switch 20. Front brake lever 21. Throttle lever 22. Handlebar switches
ve purchased may differ slightly the figures of this manual.
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1-DESCRIPTION A
3-1
8. Front wheel 9. Headlight
10. Fuel cock 11. Starter (choke)
NOTE: The machine you ha from those shown in
ND MACHINE ID
1. Spark a 2. Rear ca 3. Seat 4. Fuel tan 5. Front ca 6. Brake p
ENTIF
rrester rrier
k cap rrier edal
1
2
3
4
5
6
7
8
9
10
11
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14
number tion number is stamped on in the following illustration. be used for ordering a new
ber
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3-2
EBU00600
Identification number records Record the key identification number, vehicle identification number and model label infor- mation in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER:
ACA-02E
2. VEHICLE IDENTIFICATION NUMBER: ACA-02E
3. MODEL LABEL INFORMATION: ACA-01E
EBU00035
Key identification The key identifica the key as shown This number can key.
1. Key identification num
EBU00036 EBU00787
ffixed to the location in the the information on this la- vided. This information will er spare parts from your
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3-3
Vehicle identification number The vehicle identification number is stamped into the frame.
1. Vehicle identification number
NOTE: The vehicle identification number is used to identify your machine.
Model label The model label is a illustration. Record bel in the space pro be needed to ord Yamaha dealer.
1. Model label
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3
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6
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4-1
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CONTROL FUNCTIONS
WARNING Indicates a potential hazard that could result in serious injury or death.
EBU00942
Main switch Functions of the respective switch positions are as follows:
ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on.
OFF: All electrical circuits are switched off. The key can be removed in this position.
EBU00043 EBU00053
es
G.STOP
h ENG. STOP engine stop switch is in the engine stop switch controls used at all times to stop the in an emergency. The en- run when the engine stop FF.
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4-2
Indicator lights
1. Reverse indicator light R 2. Neutral indicator light N
EBU00602
Reverse indicator light R This indicator light comes on when the trans- mission is in reverse.
EBU00603
Neutral indicator light N This indicator light comes on when the trans- mission is in neutral.
Handlebar switch
1. Light switch LIGHTS 2. Engine stop switch EN 3. Start switch START
EBU00054
Engine stop switc Make sure that the RUN position. The ignition and can be engine, especially gine will not start or switch is turned to O
HTS the LO position to switch nd the tail/brake light. the HI position to switch and the tail/brake light. the OFF position to switch nd the tail/brake light.
eadlights with the engine ore than thirty minutes. discharge to the point motor will not operate should happen, remove charge it.
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4-3
EBU00056
Start switch START The starter motor cranks the engine when this switch is pushed.
CAUTION: _
See starting instructions prior to starting engine (see page 6-1 for details). _
NOTE: _
If the starter switch is pushed with the main switch ON and the engine stop switch OFF, the starter motor will be activated but the engine will not start. To start the engine, be sure to position the engine stop switch at RUN. _
EBU01076
Light switch LIG Turn the switch to on the low beam a Turn the switch to on the high beam Turn the switch to off the headlights a
CAUTION: _
Do not use the h turned off for m The battery may that the starter properly. If this the battery and re _
EBU00062
WARNING
ARD rottle. PEN ld be hard to operate, lt to speed up or slow need to. This could t.
THE HAZARD tion of the throttle lever he engine. If it does not check for the cause.
blem before riding the Yamaha dealer if you e the problem yourself.
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4-4
Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the le- ver is released.
1. Throttle lever
POTENTIAL HAZ Malfunction of th WHAT CAN HAP The throttle cou making it difficu down when you cause an acciden HOW TO AVOID Check the opera before you start t work smoothly, Correct the pro ATV. Consult a cant find or solv
WARNING
ZARD ment of the speed limit-
PEN ble could be damaged. e operation could result. control, have an acci- d.
THE HAZARD speed adjuster out more 7 in). Always make sure r free play is adjusted to .20 in). See page 8-16.
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4-5
EBU00066
Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the ad- juster limits the maximum engine power avail- able and decreases the maximum speed of the ATV.
1. Locknut 2. Adjuster a. 12 mm (0.47 in)
POTENTIAL HA Improper adjust er and throttle. WHAT CAN HAP The throttle ca Improper throttl You could lose dent or be injure HOW TO AVOID Do not turn the than 12 mm (0.4 the throttle leve 35 mm (0.120
EBU00070 EBU00073
and lever located on the right side of e brake lever is located on ush down on the pedal or
rd the handlebar to apply
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4-6
Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to ap- ply the front brake.
1. Front brake lever
Rear brake pedal The brake pedal is the machine and th the left handlebar. P pull the lever towa the rear brake.
1. Rear brake pedal
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4-7
1. Rear brake lever
EBU00074
WARNING
ARD the parking brake. PEN tart moving unexpect- g brake is not applied
the engine. This could ntrol or a collision. overheat if you ride the eleasing the parking d lose braking perfor- uld cause an accident. wear out the brakes
THE HAZARD parking brake before
ne. you have released the fore you begin to ride.
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4-8
Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to re- lease the parking brake.
1. Lock plate
POTENTIAL HAZ Improper use of WHAT CAN HAP The ATV could s edly if the parkin before starting cause loss of co The brake could ATV without r brake. You coul mance which co You could also prematurely. HOW TO AVOID Always set the starting the engi Always be sure parking brake be
ver is used for driving the ward or in reverse. Refer to select lever operation.
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4-9
EBU00083
Shift pedal This machine is equipped with a constant- mesh 5-speed transmission. The shift pedal is located on the left side of the engine. Neutral is at the bottom position.
1. Shift pedal N. Neutral position
EBU00085
Drive select lever The drive select le machine either for page 6-4 for drive
1. Drive select lever
EBU00590
WARNING
ARD ne in gear and/or start- ithout setting the park-
PEN tart to move unexpect-
d cause an accident. THE HAZARD sion in neutral and set
e before starting the en-
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4-10
Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out.
1. Recoil starter
POTENTIAL HAZ Starting the engi ing the engine w ing brake. WHAT CAN HAP The ATV could s edly, which coul HOW TO AVOID Put the transmis the parking brak gine.
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4-11
EBU00092
Fuel tank cap Remove the fuel tank cap by turning it coun- terclockwise.
1. Fuel tank cap
EBU00093
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4-12
Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions.
OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running.
ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.
RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY. After refuelling, return the fuel cock lever to the ON position.
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4-13
EBU00094
Starter (choke) Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to Starting a cold engine for proper op- eration. (See page 6-1.)
1. Fully-open 2. Half open 3. Closed A. Starter (choke)
EBU00567
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4-14
Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear.
1. Seat lock lever
amage, do not put metal ls or sharply edged prod- the storage box. If they wrap them in appropriate .
imit: 2 kg (4.4 lb)
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4-15
To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear.
NOTE: Make sure that the seat is securely fitted.
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Storage box
CAUTION: To protect from d products, like too ucts directly in must be stored, cushion material _
Maximum load l
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g ring
can be obtained at a ake this adjustment.
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4-16
Front carrier
EBU00583
Rear carrier
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Rear shock absorber adjustment The spring preload can be adjusted to suit the riders weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the ad- justing ring in direction a. To decrease the spring preload, turn the ad- justing ring in direction b.
1. Spring preload adjustin
NOTE: _
A special wrench Yamaha dealer to m _
Maximum load limit: 30 kg (66 lb)
Maximum load limit: 45 kg (99 lb)
E-4.fm Page 17 Monday, April 22, 2002 5:07 PM
4-17
1. Special wrench
EBU00112
WARNING Indicates a potential hazard that could result in serious injury or death.
Standard position: B A - Minimum (soft) E - Maximum (hard)
PAGE
e. 5-3, 8-178-20
5-3, 8-178-23
5-55-6
5-7, 8-58-8
5-8, 8-98-10
5-8, 8-16
5-95-12, 8-278-28
5-8
5-8, 8-338-36
5-8, 8-298-31
U4XE15.book Page 1 Monday, April 8, 2002 2:19 PM
5-1
1-PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE
Front brake Check operation, free play, fluid level and fluid leakag Fill with DOT 4 brake fluid if necessary.
Rear brake Check operation, condition and free play. Adjust if necessary.
Fuel Check fuel level. Fill with fuel if necessary.
Engine oil Check oil level. Fill with oil if necessary.
Final gear oil Check for leakage.
Throttle Check for proper throttle cable operation.
Wheels and tires Check tire pressure, wear and damage.
Fittings and Fasteners Check all fittings and fasteners.
Lights Check for proper operation.
Battery Check fluid level. Fill with distilled water if necessary.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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5-2
WARNING
POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op- erating condition. Always follow the inspection and main- tenance procedures and schedules de- scribed in the Owners Manual.
EBU01008
(front brake) brake fluid is leaking out of rake fluid reservoir of the
the brake firmly for one er moves slowly inward, ak in the brake system. If e, the brake system should amaha dealer.
slow speed after starting ey are working properly. If rovide proper braking per- the brakes for wear. (See
U4XE15.book Page 3 Monday, April 8, 2002 2:19 PM
5-3
Front and rear brakes Brake levers and brake pedal Check for correct free play in the brake levers and brake pedal. If the free play is incorrect, adjust it. (See pages 8-198-23.) Check operation of the levers and pedal. They should move smoothly and there should be a firm feeling when the brake is applied. If not, have a Yamaha dealer inspect it.
Brake fluid level (front brake) Check the brake fluid level. Add fluid if neces- sary. (See pages 8-188-19.)
Brake fluid leakage Check to see if any the hose, joint or b front brake. Apply minute. If the lev there may be a le there is any leakag be inspected by a Y
Brake operation Test the brakes at out to make sure th the brakes do not p formance, inspect page 8-17.)Recommended brake fluid: DOT 4
U4XE15.book Page 4 Monday, April 8, 2002 2:19 PM
5-4
WARNING
POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the ad- justment procedures provided in this manual, have a Yamaha dealer check for the cause.
EBU01085
ine has been designed to ed gasoline with a pump +M]/2) of 86 or higher, or umber of 91 or higher. If g occurs, use a different r premium unleaded fuel. ive you longer spark plug intenance cost.
U4XE15.book Page 5 Monday, April 8, 2002 2:19 PM
5-5
Fuel Make sure there is sufficient gasoline in the tank.
CAUTION: _
Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. _
Your Yamaha eng use regular unlead octane number ([R research octane n knocking or pingin brand of gasoline o Unleaded fuel will g life and reduced ma
Recommended fuel: UNLEADED GASOLINE ONLY
Fuel tank capacity: Total:
12 L (2.64 Imp gal, 3.17 US gal) Reserve:
16 L (0.35 Imp gal, 0.42 US gal)
WARNING
ZARD hen refueling. PEN
which can cause a fire y. hen it heats up. If the
filled, fuel could spill out the engine or the sun. THE HAZARD he fuel tank. Be careful especially on the engine Wipe up any spilled fuel sure the fuel tank cap is . ght after the engine has d is still very hot.
U4XE15.book Page 6 Monday, April 8, 2002 2:19 PM
5-6
Gasohol There are two types of gasohol; gasohol con- taining ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gaso- hol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems.
1. Filler tube 2. Fuel level
POTENTIAL HA Improper care w WHAT CAN HAP Fuel can spill, and severe injur Fuel expands w fuel tank is over due to heat from HOW TO AVOID Do not overfill t not to spill fuel, or exhaust pipe. immediately. Be closed securely Do not refuel ri been running an
EBU01084
revent clutch slippage gine oil also lubricates o not mix any chemical not use oils with a diesel of CD or oils of a high- n specified. In addition, oils labeled ENERGY II or higher. t no foreign material en- case.
nge: p qt, 1.6 US qt) placement: p qt, 1.7 US qt)
p qt, 1.9 US qt)
U4XE15.book Page 7 Monday, April 8, 2002 2:19 PM
5-7
Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See page 8-5.)
CAUTION: _
In order to p (since the en the clutch), d additives. Do specification er quality tha do not use CONSERVING
Make sure tha ters the crank
_
Recommended oil:
Recommended engine oil classification: API Service SE, SF, SG type or higher
100 30 50 70 90 110
SAE 5W30
20 10 0
10 20 30 40
YAMALUBE 4 (20W40) or SAE20W40
YAMALUBE 4 (10W30) or SAE10W30
130F
50C
Oil quantity: Periodic oil cha
1.5 L (1.3 Im With oil filter re
1.6 L (1.4 Im Total amount:
1.8 L (1.6 Im
eners tightness of chassis fittings re a ride. Take the machine r or refer to the Service Man- ning torque.
hts and tail/brake light to e in working condition. Re- for proper operation.
n of all switches. Repair as er operation.
nd fill if necessary. Use only efilling is necessary. (See
U4XE15.book Page 8 Monday, April 8, 2002 2:19 PM
5-8
EBU00493
Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-9 8-10 for details.)
If desired, an SAE 80W90 hypoid gear oil may be used for all conditions.
NOTE: GL-4 is a quality and additive rating, GL-5 or GL-6 rated hypoid gear oils may also be used. _
EBU01083
Throttle lever Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation.
EBU00152
Fittings and Fast Always check the and fasteners befo to a Yamaha deale ual for correct tighte
EBU00991
Lights Check the headlig make sure they ar pair as necessary
EBU01082
Switches Check the operatio necessary for prop
EBU00499
Battery Check fluid level a distilled water if r pages 8-298-31.)
Recommended oil: SAE 80 API GL-4 Hypoid gear oil
EBU00157
ould be set to the rec- ressure:
d tire pressure 0.20 kgf/cm2, 2.9 psi) 0.25 kgf/cm2, 3.6 psi) ust tire pressures when ld. must be equal on both
e below the minimum uld cause the tire to
m the rim under severe tions. g are minimums: (0.17 kgf/cm2, 2.5 psi) (0.22 kgf/cm2, 3.2 psi)
U4XE15.book Page 9 Monday, April 8, 2002 2:19 PM
5-9
Tires
WARNING
POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or op- eration of this ATV with improper or un- even tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD 1. The tires listed below have been ap-
proved by Yamaha Motor Co., Ltd. for this model. Other tire combina- tions are not recommended.
ACE-01EACE-01E
Manufacturer Size Type
Front DUNLOP AT22 710 KT 701
CHENG SHIN AT22 710 M 905
Rear DUNLOP AT22 1010 KT 705
CHENG SHIN AT22 1010 M 906
2. The tires sh ommended p
Recommende Front 20 kPa ( Rear 25 kPa (
Check and adj the tires are co
Tire pressures sides.
3. Tire pressur specified co dislodge fro riding condi The followin Front 17 kPa Rear 22 kPa
U4XE15.book Page 10 Monday, April 8, 2002 2:19 PM
5-10
4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst.
EBU00159
e
U4XE15.book Page 11 Monday, April 8, 2002 2:19 PM
5-11
How to measure tire pressure Use the low-pressure tire gauge.
NOTE: The low-pressure tire gauge is included as standard equipment. Make two measure- ments of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.
Set pressure with tires cold. Set tire pressures to the following specifica- tions: ACE-02EACE-02E
1. Low-pressure tire gaug
Recommended pressure
Minimum Maximum
Front 20 kPa
(0.20 kgf/cm2, 2.9 psi)
17 kPa (0.17 kgf/cm2,
2.5 psi)
23 kPa (0.23 kgf/cm2,
3.3 psi)
Rear 25 kPa
(0.25 kgf/cm2, 3.6 psi)
22 kPa (0.22 kgf/cm2,
3.2 psi)
28 kPa (0.28 kgf/cm2,
4.0 psi)
U4XE15.book Page 12 Monday, April 8, 2002 2:19 PM
5-12
EBU00160
Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire.
a. 3 mm (0.12 in)
EBU00161 EBU00500
gine
brake. ock to ON. switch to ON and the en- h to RUN. ission into neutral.
WARNING
ARD cables in cold weather. PEN able to control the ATV, to an accident or colli-
THE HAZARD cold weather, always control cables work
you begin riding.
U4XE15.book Page 1 Monday, April 8, 2002 2:19 PM
6-1
OPERATION
WARNING Indicates a potential hazard that could result in serious injury or death.
Starting a cold en
1. Set the parking 2. Turn the fuel c 3. Turn the main
gine stop switc 4. Shift the transm
WARNING
POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owners Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.
POTENTIAL HAZ Freezing control WHAT CAN HAP You could be un which could lead sion. HOW TO AVOID When riding in make sure all smoothly before
1
2
3
4
5
6
7
8
9
10
11
12
13
14
engine start-ambient tem- ure above 25C (80F) and engine start position.
2. Half open a. Starter (choke)
lose the throttle lever and ine by pushing the start
U4XE15.book Page 2 Monday, April 8, 2002 2:19 PM
6-2
NOTE: _
When the transmission is in neutral, the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it.
The engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral be- fore starting the engine.
_
5. Use the starter (choke) in reference to the figure:
Position 1: Cold engine start- ambient temperature below 5C (40F).
Position 2: Cold engine start- ambient temperature at 0C (30F)30C (90F) and warm- ing up position.
Position 3: Cold perat warm
1. Fully open 3. Closed
6. Completely c start the eng switch.
reak-in section prior to for the first time.
ngine ine, refer to the Starting a ion. The starter (choke) d. The throttle should be
ngine life, always warm up tarting off. Never acceler- engine! To see whether or rm, check if it responds to
ly with the starter (choke)
U4XE15.book Page 3 Monday, April 8, 2002 2:19 PM
6-3
NOTE: _
If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery en- ergy. Do not crank the engine more than 10 seconds on each attempt.
If the battery is discharged, pull the recoil starter to start the engine.
_
7. If the engine is started with the starter (choke) in position 1, the starter (choke) should be returned to position 2 to warm up the engine. If the engine is started with the starter (choke) in position 2, keep the starter (choke) in this position to warm up the engine.
8. Continue warming up the engine until it idles smoothly and return the starter (choke) to position 3 before riding.
CAUTION: _
See the Engine b operating engine _
EBU00180
Starting a warm e To start a warm eng cold engine sect should not be use opened slightly.
EBU00182
Warming up To get maximum e the engine before s ate hard with a cold not the engine is wa the throttle normal turned off.
2. Lock release button b. Reverse
the reverse indicator light e light does not come on, ler to inspect the machine.
you for people or obsta- ase the rear brake pedal. ttle lever gradually and con- to the rear while backing.
U4XE15.book Page 4 Monday, April 8, 2002 2:19 PM
6-4
EBU00185
Drive select lever operation and reverse driving
CAUTION: Before shifting, stop the machine and re- turn the throttle lever to its closed posi- tion. Otherwise the transmission may be damaged.
NOTE: When shifting into reverse, the transmission must be in first gear.
1. Bring the machine to a complete stop and return the throttle lever to the closed position.
2. Apply the rear brake pedal. 3. Shift the transmission into first gear. 4. While pulling the lock release button,
move the drive select lever toward the rear until it completely stops.
1. Drive select lever a. Forward
NOTE: When in reverse, should be on. If th ask a Yamaha dea
5. Check behind cles, then rele
6. Open the thro tinue to watch
EBU00201
speed forward and 1-speed n with centrifugal automatic ssion allows you to control er you have available at a tarting accelerating, climb- neutral, return the throttle osition and repeatedly de-
l until it stops.
N. Neutral position
U4XE15.book Page 5 Monday, April 8, 2002 2:19 PM
6-5
Shifting This model has a 5- reverse transmissio clutch. The transmi the amount of pow given speed or for s ing, etc. To shift into lever to its original p press the shift peda
1. Shift pedal
WARNING
POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person be- hind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.
hine has attained adequate e the throttle lever. ond gear and release the
ttle gradually. e procedure when shifting
her gear.
WARNING
ZARD rottle before releasing
PEN uld wheelie. This would ance of an accident, in- .
THE HAZARD ft pedal before opening n the throttle gradually.
U4XE15.book Page 6 Monday, April 8, 2002 2:19 PM
6-6
CAUTION: Do not coast for long periods with the en- gine off, and do not tow the machine a long distance. Even with gears in neutral, the transmission is only properly lubricat- ed when the engine is running. Inadequate lubrication may damage the transmission.
EBU00205
To start out and accelerate: 1. Release the throttle lever.
CAUTION: Always close the throttle while shifting gears. Otherwise, damage to the engine and drive train may result.
2. Shift into first gear and release the shift pedal.
3. Open the throttle gradually.
4. Once the mac speed, releas
5. Shift into sec shift pedal.
6. Open the thro 7. Follow the sam
to the next hig
POTENTIAL HA Opening the th the shift pedal. WHAT CAN HAP The machine co increase the ch cluding overturn HOW TO AVOID Release the shi the throttle. Ope
EBU00207 EBU00209
ore important period in the e than the period between
ask that you carefully read ial. Because the engine is ust not put an excessive t several hours of running. hours, the various parts in d polish themselves to the earances. rolonged full throttle oper- n which might result in ex- ating must be avoided.
ary (23 seconds maxi- peration under load does . Each full throttle acceler- uld be followed with a sub-
for the engine by cruising engine can rid itself of the
of heat.
U4XE15.book Page 7 Monday, April 8, 2002 2:19 PM
6-7
To decelerate: When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improp- er use of the brakes or shifting can cause the tires to lose traction, reducing control and in- creasing the possibility of an accident.
Engine break-in There is never a m life of your machin zero and 20 hours. For this reason, we the following mater brand new, you m load on it for the firs During the first 20 the engine wear an correct operating cl During this period, p ation or any conditio cessive engine he However, moment mum) full throttle o not harm the engine ation sequence sho stantial rest period at lower r/min so the temporary build up
WARNING
POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear.
p the engine and shift into el cock to OFF and apply
U4XE15.book Page 8 Monday, April 8, 2002 2:19 PM
6-8
If any abnormality is noticed during this peri- od, consult a Yamaha dealer. 1. 010 hours:
Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of opera- tion. Vary the speed of the machine from time to time. Do not operate it at one set throttle position.
2. 1020 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throt- tle at any time.
3. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally.
EBU00211
Parking When parking, sto neutral. Turn the fu the parking brake.
1. Lock plate
EBU00219
hine to a stop by applying w gear.
e. brake lever and pedal ap- parking brake and slowly r brake pedal.
U4XE15.book Page 9 Monday, April 8, 2002 2:19 PM
6-9
Parking on a slope 1. Bring the mac the brakes in lo
2. Stop the engin 3. With the rear
plied, apply the release the rea
WARNING
POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, in- creasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, put the machine in low gear, apply the parking brake, and block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily.
uld be rigidly and securely cessory which can shift po- ff while you are riding could y to control the ATV. n accessory where it could ur ability to control the ATV. e (but are not limited to) a
object attached to the han- ould make steering difficult, at limits your ability to move eat, or one that limits your
n when riding an ATV with ATV may handle differently
out accessories.
U4XE15.book Page 10 Monday, April 8, 2002 2:19 PM
6-10
EBU00221
Accessories and loading
EBU00222
Accessories Accessories can affect the handling and con- trol of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. Choose only accessories designed for your
ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other ac- cessories may also be available on the market. However, it is not possible for Yamaha to test all non-Yamaha accesso- ries, nor have any control over the quality or suitability of them. Choose a genuine Yamaha accessory, or one that is equiva- lent in design and quality.
Accessories sho mounted. An ac sition or come o affect your abilit
Do not mount a interfere with yo Examples includ heavy or bulky dlebars which c an accessory th around on the s view.
Use extra cautio accessories. The than it does with
EBU00588
the maximum tongue measure tongue weight scale. Put the tongue of er on the scale with the eight. Adjust the load in the ry, to reduce the weight on
g cargo and towing a trail- ngue weight in the maxi-
d limit. he carrier as close to the icle as possible. Put cargo e rear carrier. Center the side. securely to the carriers. in the trailer cannot move g load can cause an acci-
ad does not interfere with bility to see where you are
U4XE15.book Page 11 Monday, April 8, 2002 2:19 PM
6-11
Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judg- ment when carrying cargo or towing a trailer. Keep the following points in mind: Never exceed the weight limits shown. An
overloaded ATV can be unstable.
Do not exceed weight. You can with a bathroom the loaded trail tongue at hitch h trailer, if necessa hitch.
If you are carryin er, include the to mum vehicle loa
Load cargo on t center of the veh at the front of th load from side to
Tie down cargo Make sure cargo around. A shiftin dent.
Make sure the lo controls or your a going.
MAXIMUM LOADING LIMIT Vehicle loading limit (total weight of car-
go, rider and accessories, and tongue weight): 165 kg (364 lb)
Front carrier: 30 kg (66 lb) Rear carrier: 45 kg (99 lb) Storage box: 2 kg (4.4 lb) Trailer hitch:
Pulling load (total weight of trailer and cargo): 330 kgf (727 lbf) Tongue weight (vertical weight on trailer hitch point): 15 kgf (33 lbf)
WARNING
ZARD ATV or carrying or tow- perly. PEN
hanges in vehicle han- ld lead to an accident. THE HAZARD he stated load capacity
be properly distributed ttached. Reduce speed argo or pulling a trailer. stance for braking.
U4XE15.book Page 12 Monday, April 8, 2002 2:19 PM
6-12
Ride more slowly than you would without a load. The more weight you carry, the slow- er you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trailer.
Allow more braking distance. A heavier ve- hicle takes longer to stop.
Avoid making sharp turns unless at very slow speeds.
Avoid hills and rough terrain. Choose ter- rain carefully. Added weight affects the sta- bility and handling of the ATV.
POTENTIAL HA Overloading this ing cargo impro WHAT CAN HAP Could cause c dling which cou HOW TO AVOID Never exceed t for this ATV. Cargo should and securely a when carrying c Allow greater di
6-13
otential hazard that could s injury or death.
U4XE15.book Page 13 Monday, April 8, 2002 2:19 PM
EBU00901
WARNING _
Indicates a p result in seriou
7
U4XE15.book Page 1 Monday, April 8, 2002 2:19 PM
1-Riding
Your
ATV
7-1
U4XE15.book Page 2 Monday, April 8, 2002 2:19 PM
7-2
WAR _
Indicates result in s
GETTING This ATV i be used f your ATV structions and techn however, riding. Rid acquired time. Take niques we maneuvers.
l completely and understand f the controls. Pay particular safety information on pages also read all caution and n your ATV.
U4XE15.book Page 3 Monday, April 8, 2002 2:19 PM
7-3
Riding your new ATV can be a very enjoyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely. Before you begin to ride, be sure you have read this
NING a potential hazard that could
erious injury or death.
TO KNOW YOUR ATV s mainly for utility use, but may also or recreation. This section, Riding , provides general ATV riding in- for recreational riding. The skills iques described in this section, are appropriate for all types of ing your ATV requires special skills through practice over a period of the time to learn the basic tech- ll before attempting more difficult
Owners Manua the operation o attention to the 2-12-6. Please warning labels o
requires skills acquired ver a period of time. arn the basic techniques
ting more difficult maneu-
THE HAZARD experienced operators the certified training
y Yamaha. They should actice the skills learned nd the operating tech- in this Owners Manu-
ation about the training n authorized ATV deal-
87-2887.
U4XE15.book Page 4 Monday, April 8, 2002 2:19 PM
7-4
RIDE WITH CARE AND GOOD JUDGEMENT
Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experi- enced operator. Do not attempt to operate at maximum performance until you are totally fa- miliar with the ATVs handling and perfor- mance characteristics.
Riding your ATV through practice o Take the time to le well before attemp vers.
WARNING
POTENTIAL HAZARD Operating this ATV without proper in- struction. WHAT CAN HAPPEN The risk of an accident is greatly in- creased if the operator does not know how to operate the ATV properly in dif- ferent situations and on different types of terrain.
HOW TO AVOID Beginning and in should complete course offered b then regularly pr in the course a niques described al. For more inform course, contact a er or call 1-800-8
U4XE15.book Page 5 Monday, April 8, 2002 2:19 PM
7-5
Not recommended for children under 16 years of age.
WARNING
POTENTIAL HAZARD Failure to follow the age recommenda- tions for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended for their age can lead to se- vere injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc.
U4XE15.book Page 6 Monday, April 8, 2002 2:19 PM
7-6
This ATV is designed to carry operator and cargo only passengers prohibited.
WARNING
POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
t protective clothing in- nces of severe injury in the nt. THE HAZARD n approved motorcycle properly. wear: n face shield)
et
U4XE15.book Page 7 Monday, April 8, 2002 2:19 PM
7-7
Apparel
WARNING
POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye pro- tection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci- dent. Operating with- out eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.
Operating withou creases your cha event of an accide HOW TO AVOID Always wear a helmet that fits You should also
eye protectio (goggles or
gloves boots long-sleeved shirt or jack long pants.
WARNING
ARD TV after consuming al-
PEN affect your judgment. to react more slowly. r balance and percep- t in an accident. THE HAZARD alcohol or drugs before his ATV.
U4XE15.book Page 8 Monday, April 8, 2002 2:19 PM
7-8
Do not operate after consuming alcohol or drugs. Operators performance capability is reduced by the influence of alcohol or drugs.
POTENTIAL HAZ Operating this A cohol or drugs. WHAT CAN HAP Could seriously Could cause you Could affect you tion. Could resul HOW TO AVOID Never consume or while driving t
WARNING
ZARD TV with improper tires,
er or uneven tire pres-
PEN tires on this ATV, or op- TV with improper or un- ure, may cause loss of ing your risk of an acci-
THE HAZARD size and type tires spec- ers Manual for this vehi- 5-10. proper tire pressure as e Owners Manual on
U4XE15.book Page 9 Monday, April 8, 2002 2:19 PM
7-9
Pre-operation checks Always perform the pre-operation checks list- ed on page 5-1 before riding for safety and proper care of the ATV.
WARNING
POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op- erating condition. Always follow the inspection and main- tenance procedures and schedules de- scribed in the Owners Manual.
POTENTIAL HA Operating this A or with improp sure. WHAT CAN HAP Use of improper eration of this A even tire press control, increas dent. HOW TO AVOID Always use the ified in the Own cle on pages 5-9 Always maintain described in th page 5-11.
nced with this model, this with a speed limiter in the g. The speed limiter limits
speed of the ATV. Turning ses top speed, and turning speed.
2. Adjuster
U4XE15.book Page 10 Monday, April 8, 2002 2:19 PM
7-10
WARNING _
Indicates a potential hazard that could result in serious injury or death.
Do not operate at speeds too fast for your skills or the conditions.
Speed limiter For riders inexperie model is equipped throttle lever housin the power and top the screw in decrea it out increases top
1. Locknut
WARNING
POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing con- trol of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating con- ditions, and your experience.
WARNING
ZARD ATV or carrying or tow- perly. PEN
hanges in vehicle han- ld lead to an accident. THE HAZARD he stated load capacity
be properly distributed ached. when carrying cargo or . Allow greater distance
he instructions in your l for carrying cargo or
U4XE15.book Page 11 Monday, April 8, 2002 2:19 PM
7-11
Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or car- go. The ATVs handling may be adversely af- fected. Reduce your speed when adding additional loads.
MAXIMUM LOADING LIMIT Vehicle loading limit (total weight of
cargo, rider and accessories, and tongue weight): 165 kg (364 lb)
Front carrier: 30 kg (66 lb) Rear carrier: 45 kg (99 lb) Storage box: 2 kg (4.4 lb) Trailer hitch:
Pulling load (total weight of trailer and cargo): 330 kgf (727 lbf) Tongue weight (vertical weight on trailer hitch point): 15 kgf (33 lbf)
POTENTIAL HA Overloading this ing cargo impro WHAT CAN HAP Could cause c dling which cou HOW TO AVOID Never exceed t for this ATV. Cargo should and securely att Reduce speed pulling a trailer for braking. Always follow t Owners Manua pulling a trailer.
WARNING
ARD s from handlebars or rds during operation.
PEN ne hand or foot can re- to control the ATV or to lose your balance
e ATV. If you remove a board, your foot or leg contact with the rear uld injure you or cause
THE HAZARD h hands on the handle- et on the footboards of operation.
U4XE15.book Page 12 Monday, April 8, 2002 2:19 PM
7-12
During operation Always keep your feet on the footboards dur- ing operation. Otherwise your feet may con- tact the rear wheels.
POTENTIAL HAZ Removing hand feet from footboa WHAT CAN HAP Removing even o duce your ability could cause you and fall off of th foot from a foot may come into wheels, which co an accident. HOW TO AVOID Always keep bot bars and both fe your ATV during
U4XE15.book Page 13 Monday, April 8, 2002 2:19 PM
7-13
Avoid wheelies and jumping. You may lose control of the ATV or overturn.
WARNING
POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, in- cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Dont try to show off.
U4XE15.book Page 14 Monday, April 8, 2002 2:19 PM
7-14
Modifications
WARNING
POTENTIAL HAZARD Operating this ATV with improper modi- fications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improp- er installation or use of accessories. All parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized ATV dealer.
U4XE15.book Page 15 Monday, April 8, 2002 2:19 PM
7-15
Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it.
WARNING
POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en- gine area could catch fire. Someone touching the exhaust system during or after operation could be burned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it.
U4XE15.book Page 16 Monday, April 8, 2002 2:19 PM
7-16
BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control.
WARNING
POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of con- trol. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.
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7-17
Do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles.
WARNING
POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and high- ways.
U4XE15.book Page 18 Monday, April 8, 2002 2:19 PM
7-18
Know the terrain where you ride. Ride cau- tiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the ter- rain, and other hidden hazards which may cause the ATV to upset.
WARNING
POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when op- erating on unfamiliar terrain. Always be alert to changing terrain con- ditions when operating the ATV.
U4XE15.book Page 19 Monday, April 8, 2002 2:19 PM
7-19
WARNING
POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an acci- dent, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills neces- sary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
s posted no trespassing. te property without getting
PEN a collision. You could
THE HAZARD caution flag on the ATV re visible. Watch care- hicles.
U4XE15.book Page 20 Monday, April 8, 2002 2:19 PM
7-20
When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch.
Do not ride in area Do not ride on priva permission.
WARNING
POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles.
WHAT CAN HAP You could be in be injured. HOW TO AVOID Always mount a to make you mo fully for other ve
ling, lift the shift pedal to the nd then release the parking rottle slowly and smoothly. tch will engage and you will e. Once the ATV has at- peed, release the throttle
dal to the 2nd gear position. edal and apply the throttle
s same procedure as you er gears. Be sure to coordi- he throttle and shift pedal ottle is applied too abruptly ot released during shifting,
l is not released before ap- the front wheels may lift off ing in a loss of directional her speeds until you are
r with the operation of your
U4XE15.book Page 21 Monday, April 8, 2002 2:19 PM
7-21
Select a large, flat area off-road to become fa- miliar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Al- ways avoid riding on paved surfaces: the ATV is designed for off-road use only, and han- dling maneuvers are more difficult to perform on pavement.
Set the parking brake and follow the instruc- tion on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. As you get on the ATV, be sure not to accidentally move the shift pedal. Remem- ber that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components.
With the engine id 1st gear position a brake. Apply the th The centrifugal clu start to accelerat tained adequate s and lift the shift pe Release the shift p smoothly. Use thi move into the high nate the use of t properly. If the thr or if the throttle is n or if the shift peda plying the throttle, the ground result control. Avoid hig thoroughly familia ATV.
WARNING
ARD r gear when the engine .
PEN ld stop rotating. This of control, an accident ld also cause engine or ge. THE HAZARD ngine has sufficiently ifting to a lower gear.
U4XE15.book Page 22 Monday, April 8, 2002 2:19 PM
7-22
CAUTION: _
Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. _
When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improp- er use of the brakes or shifting can cause the tires to lose traction, reducing control and in- creasing the possibility of an accident.
POTENTIAL HAZ Engaging a lowe speed is too high WHAT CAN HAP The wheels cou could cause loss and injury. It cou drive train dama HOW TO AVOID Make sure the e slowed before sh
curve, slow down and be- dlebars in the desired direc- o, put your weight on the utside of the turn (opposite tion) and lean your upper
Use the throttle to maintain ough the turn. This maneu- el on the inside of the turn g the ATV to make the turn
THE HAZARD proper procedures for cribed in this Owners
at low speeds before at- at faster speeds. Do not oo fast for your skills or
U4XE15.book Page 23 Monday, April 8, 2002 2:19 PM
7-23
TURNING YOUR ATV To achieve maximum traction while riding off- road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the in- side of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is es- sential that this skill be learned first at low speed.
As you approach a gin to turn the han tion. As you do s footboard to the o your desired direc body into the turn. an even speed thr ver will let the whe slip slightly, allowin properly.
WARNING
POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn.
HOW TO AVOID Always follow turning as des Manual. Practice turning tempting to turn turn at speeds t the conditions.
arned this technique you erform it at higher speeds
ocedures such as abrupt xcessive braking, incorrect or too much speed for the rn may cause the ATV to s to tip over to the outside turn, lean more to the in- necessary to gradually let nd steer to the outside of ping over. igher speeds until you are with the operation of your
U4XE15.book Page 24 Monday, April 8, 2002 2:19 PM
7-24
This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesnt turn, come to a stop and then practice the procedure again. If the riding sur- face is slippery or loose, it may help to posi- tion more of your weight over the front wheels by moving forward on the seat.
Once you have le should be able to p or in tighter curves.
Improper riding pr throttle changes, e body movements, sharpness of the tu tip. If the ATV begin while negotiating a side. It may also be off on the throttle a the turn to avoid tip Remember: Avoid h thoroughly familiar ATV.
en climbing a hill to make ht is transferred forward on be accomplished by lean- n steeper inclines, standing and leaning forward over
THE HAZARD e ATV on hills too steep r your abilities. ller hills before attempt-
U4XE15.book Page 25 Monday, April 8, 2002 2:19 PM
7-25
CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can ma- neuver your ATV well on flat ground before at- tempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose sur- faces, or obstacles that might cause you to lose control.
It is important wh sure that your weig the ATV. This can ing forward and, o on the footboards the handlebars.
WARNING
POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur- faces or small hills.
HOW TO AVOID Never operate th for the ATV or fo Practice on sma ing large hills.
harp drop, or another n could be on the other
U4XE15.book Page 26 Monday, April 8, 2002 2:19 PM
7-26
WARNING
POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Own- ers Manual. Always check the terrain carefully be- fore you start up any hill. Never climb hills with excessively slip- pery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards. Never go over the top of any hill at high speed.
An obstacle, a s vehicle or perso side of the hill.
the side of a hill: roper procedures as de- wners Manual. excessively slippery or
t to the uphill side of the
U4XE15.book Page 27 Monday, April 8, 2002 2:19 PM
7-27
If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.
WARNING
POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owners Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.
When crossing Always follow p scribed in the O Avoid hills with loose surfaces. Shift your weigh ATV.
WARNING
ARD ackwards or improper- hile climbing a hill.
PEN TV overturning. THE HAZARD r and maintain steady bing a hill. ward speed: phill. es.
ing brake, after you are
g backwards: phill. e rear brake while roll- . t brake. opped, apply the rear and then lock the park-
U4XE15.book Page 28 Monday, April 8, 2002 2:19 PM
7-28
If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dis- mount the ATV on the uphill side. Physically turn the ATV around and then descend the hill.
If you start to roll backwards, DO NOT use the rear brake to stop or try to put the ATV in gear. The ATV could easily tip over backwards. In- stead, dismount the ATV immediately on the uphill side.
POTENTIAL HAZ Stalling, rolling b ly dismounting w WHAT CAN HAP Could result in A HOW TO AVOID Use proper gea speed when clim If you lose all for
Keep weight u Apply the brak Lock the park stopped.
If you begin rollin Keep weight u Never apply th ing backwards Apply the fron When fully st brake as well, ing brake.
U4XE15.book Page 29 Monday, April 8, 2002 2:19 PM
7-29
Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the pro- cedure described in the Owners Manu- al.
WARNING
ARD ll improperly. PEN of control or cause the
THE HAZARD oper procedures for go- described in this Own- : a special technique is
raking as you go down
e terrain carefully be- wn any hill. t backward. hill at high speed. n a hill at an angle that vehicle to lean sharply straight down the hill
U4XE15.book Page 30 Monday, April 8, 2002 2:19 PM
7-30
RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and trac- tion may be adversely affected by these sur- faces. Improper braking may also cause a loss of traction.
Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could al- low the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear.
POTENTIAL HAZ Going down a hi WHAT CAN HAP Could cause loss ATV to overturn. HOW TO AVOID Always follow pr ing down hills as ers Manual. Note required when b a hill. Always check th fore you start do Shift your weigh Never go down a Avoid going dow would cause the to one side. Go where possible.
U4XE15.book Page 31 Monday, April 8, 2002 2:19 PM
7-31
egin to tip over, gradually ill direction if there are no ath. As you regain proper steer again in the direction
WARNING
ARD ing hills or turning on
PEN of control or cause the
THE HAZARD turn the ATV around
you have mastered the e as described in the
l on level ground. Be en turning on any hill. he side of a steep hill if
U4XE15.book Page 32 Monday, April 8, 2002 2:19 PM
7-32
CROSSING A SLOPE Traversing a sloping surface on your ATV re- quires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance.
As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the steering when riding on loose sur- faces by pointing the front wheels slightly up- hill. When riding on slopes be sure not to make sharp turns either up or down hill.
If your ATV does b steer in the downh obstacles in your p balance, gradually you wish to travel.
POTENTIAL HAZ Improperly cross hills. WHAT CAN HAP Could cause loss ATV to overturn. HOW TO AVOID Never attempt to on any hill until turning techniqu Owners Manua very careful wh Avoid crossing t possible.
U4XE15.book Page 33 Monday, April 8, 2002 2:19 PM
7-33
When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
et brakes may have re- bility. Test your brakes
ter. If necessary, apply es to let friction dry out
U4XE15.book Page 34 Monday, April 8, 2002 2:19 PM
7-34
CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the wa- ter, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or up- set the ATV. Drive slowly and carefully.
WARNING
POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that spec- ified in your Owners Manual.
Remember that w duced stopping a after leaving wa them several tim the linings.
ATV in water, be sure to d water by removing the e bottom of the air filter TV in fresh water if it has salt water or muddy con-
U4XE15.book Page 35 Monday, April 8, 2002 2:19 PM
7-35
Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability.
CAUTION: _
After riding your drain the trappe check hose at th case. Wash the A been operated in ditions. _
1. Check hose
WARNING
ARD ting over obstacles.
PEN s of control or a colli- e the ATV to overturn. THE HAZARD in a new area, check
ride over large obsta- ge rocks or fallen trees. r obstacles, always fol-
edures as described in ual.
U4XE15.book Page 36 Monday, April 8, 2002 2:19 PM
7-36
RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result.
POTENTIAL HAZ Improperly opera WHAT CAN HAP Could cause los sion. Could caus HOW TO AVOID Before operating for obstacles. Never attempt to cles, such as lar When you go ove low proper proc the Owners Man
of your ATV start to slide can usually be regained (if so) by steering in the direc- pplying the brakes or accel- ommended until you have .
U4XE15.book Page 37 Monday, April 8, 2002 2:19 PM
7-37
SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, position- ing your weight over the front wheels will sometimes help.
If the rear wheels sideways, control there is room to do tion of the slide. A erating is not rec corrected the slide
WARNING
ARD ng improperly. PEN ntrol of this ATV. You
traction unexpectedly, the ATV to overturn.
THE HAZARD ontrol skidding or slid- at low speeds and on rain. pery surfaces, such as
nd be very cautious in the chance of skidding control.
U4XE15.book Page 38 Monday, April 8, 2002 2:19 PM
7-38
With practice, over a period of time, skill at controlled sliding can be developed. The ter- rain should be chosen carefully before at- tempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost.
POTENTIAL HAZ Skidding or slidi WHAT CAN HAP You may lose co may also regain which may cause HOW TO AVOID Learn to safely c ing by practicing level, smooth ter On extremely slip ice, go slowly a order to reduce or sliding out of
ts to slide sideways: ction of the slide if you have ing the brakes or accelerat- mended until you have cor- (See pages 7-377-38.) t make it up a hill you are
round if you still have for- not, stop, dismount on the e ATV and physically turn d. If the ATV starts to slip NOT USE THE REAR TV may tip over on top of the ATV on the uphill side. 57-29.)
U4XE15.book Page 39 Monday, April 8, 2002 2:19 PM
7-39
WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely.
WHAT TO DO ... If your ATV doesnt turn when you want it
to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-237-24.)
If your ATV begins to tip while turning: Lean more into the turn to regain balance. If necessary, gradually let off the throttle and/ or steer to the outside of the turn. (See pages 7-237-24.)
If your ATV star Steer in the dire the room. Apply ing is not recom rected the slide.
If your ATV can trying to climb: Turn the ATV a ward speed. If uphill side of th the ATV aroun backwards DO BRAKE - the A you. Dismount (See pages 7-2
ntial hazard that could jury or death.
U4XE15.book Page 40 Monday, April 8, 2002 2:19 PM
7-40
If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to main- tain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you dis- cover that the ATV is going to tip over, dis- mount on the uphill side. (See pages 7-32 7-33.)
If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV un- til you have regained adequate braking ability. (See pages 7-347-35.)
WARNING _
Indicates a pote result in serious in
U4XE15.book Page 41 Monday, April 8, 2002 2:19 PM
EBU00515
nd tool kit nded to put this owners bag and always carry it un- wn. Put the owners tool kit tire gauge in the storage
ealer perform service if amiliar with machine
U4XE15.book Page 1 Monday, April 8, 2002 2:19 PM
8-1
1-PERIODIC MAINTENANCE AND ADJUSTMENT
Periodic inspection, adjustment and lubrica- tion will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, ad- justment and lubrication are explained on the following pages.
EBU00535
Owners manual a You are recomme manual in the vinyl der the seat as sho and low-pressure box.
1. Owners manual
WARNING
POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or can start fires. HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified.
Have a Yamaha d you are not f service.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
WARNING
ZARD TV with improper modi-
PEN lation of accessories or this vehicle may cause ling which in some situ- d to an accident. THE HAZARD is ATV through improp- r use of accessories. All sories added to this ve- e genuine Yamaha or ponents designed for and should be installed rding to instructions. If ions, consult an autho- TV dealer.
U4XE15.book Page 2 Monday, April 8, 2002 2:19 PM
8-2
1. Tool kit 2. Low-pressure tire gauge
The service information included in this man- ual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor re- pairs. The tools provided in the Owners tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts.
NOTE: _
If you do not have a torque wrench available during a service operation requiring one, take your machine to a Yamaha dealer to check the torque settings and adjust them as neces- sary. _
POTENTIAL HA Operating this A fications. WHAT CAN HAP Improper instal modification of changes in hand ations could lea HOW TO AVOID Never modify th er installation o parts and acces hicle should b equivalent com use on this ATV and used acco you have quest rized Yamaha A
EBU00261
INITIAL EVERY
3 months
6 months
6 months
1 year
Every 2040 hours ore often in wet or dusty areas)
U4XE15.book Page 3 Monday, April 8, 2002 2:19 PM
8-3
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINE 1 month
Valves* Check valve clearance. Adjust if necessary.
Spark plug Check condition. Adjust gap and clean. Replace if necessary.
Air filter Clean. Replace if necessary. (m
Carburetor* Check idle speed/starter operation. Adjust if necessary.
Cylinder head breather system*
Check breather hose for cracks or damage. Replace if necessary.
Exhaust system* Check for leakage. Retighten if necessary. Replace gasket if necessary.
Spark arrester Clean.
Fuel line* Check fuel hose for cracks or damage. Replace if necessary.
Engine oil Replace (Warm engine before draining).
Engine oil filter Clean.
Engine oil strainer Clean.
Final gear oil Check oil level/oil leakage. Replace.
Front brake* Check operation/fluid leakage/see NOTE page 8-4. Correct if necessary.
Rear brake* Check operation. Adjust if necessary.
Clutch* Check operation. Adjust if necessary.
Yamaha dealer
t.
oseness/damage
asteners.
is working proper
INE INITIAL EVERY
th 3
months 6
months 6
months 1
year
tential hazard that could injury or death.
U4XE15.book Page 4 Monday, April 8, 2002 2:19 PM
* It is recommended that these items be serviced by a ** Lithium-soap-based grease (all-purpose grease)
Wheels* Check balance/damage/runou Repair if necessary.
Wheel bearings* Check bearing assembly for lo Replace if damaged.
Front and rear suspension*
Check operation. Correct if necessary.
Steering system*
Check operation. Correct if damaged. Check toe-in. Adjust if necessary.
Steering shaft* Lubricate every 6 months.**
Fittings and Fasteners* Check all chassis fittings and f Correct if necessary.
Battery* Check specific gravity. Check that the breather hose Correct if necessary.
ITEM ROUT
NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1. When disassembling the master cylinder or
per, replace the brake fluid. Normally check brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and iper, replace the oil seals every two years.
3. Replace the brake hoses every four years, cracked or damaged.
8-4
cali- the
cal-
or if
WARNING Indicates a po result in serious
.
.
ly.
1 mon
EBU01100
eign material enters the
2. Dipstick 4. Minimum level mark
U4XE15.book Page 5 Monday, April 8, 2002 2:19 PM
8-5
Engine oil Engine oil level measurement 1. Place the machine on a level surface. 2. Warm up the engine for several minutes
and stop it. Wait at least ten minutes for the oil to drain back into the crankcase before checking the oil level.
NOTE: _
Be sure to wait at least ten minutes until the oil level settles before checking. _
3. Remove the engine oil filler cap and wipe the dipstick off with a clean rag. Insert the dipstick in the filler hole without screwing it in.
4. Remove the dipstick and check the oil level.
5. The oil level should be between the max- imum and minimum marks. If the level is low, add oil to raise it to the proper level.
6. Install the engine oil filler cap.
CAUTION: _
Make sure no for crankcase. _
1. Oil filler cap 3. Maximum level mark
2. O-ring 4. Oil strainer
U4XE15.book Page 6 Monday, April 8, 2002 2:19 PM
8-6
Engine oil replacement and oil filter ele- ment cleaning 1. Place the machine on a level surface. 2. Warm up the engine for several minutes
and stop it. 3. Place a container under the engine to
collect the used oil. 4. Remove the engine oil filler cap and then
the drain bolt to drain the oil.
CAUTION: _
When removing the drain bolt, the com- pression spring, oil strainer and O-ring will fall out. Take care not to lose these parts. _
1. Drain bolt 3. Compression spring
rainer and oil filter element
ring and replace it if dam-
lter element, O-ring and oil
il strainer, compression and drain bolt. rain bolt and the oil filter he specified torques.
he drain bolt, be sure to compression spring and
: ine):
kgf, 31 ftlbf) olt: kgf, 7.2 ftlbf)
U4XE15.book Page 7 Monday, April 8, 2002 2:19 PM
8-7
5. Remove the oil filter cover and oil filter el- ement.
1. Oil filter cover 2. Oil filter element 3. O-ring
6. Clean the oil st with solvent.
7. Inspect the O- aged.
8. Install the oil fi filter cover.
9. Install the o spring, O-ring
10. Tighten the d cover bolts to t
CAUTION: _
Before installing t install the O-ring, oil strainer. _
Tightening torque Drain bolt (eng
43 Nm (4.3 m Oil filter cover b
10 Nm (1.0 m
und, stop the engine im- eck for the cause.
U4XE15.book Page 8 Monday, April 8, 2002 2:19 PM
8-8
11. Fill the engine with oil and install the en- gine oil filler cap.
CAUTION: _
Be sure no foreign material enters the crankcase. _
12. Warm up the engine for several minutes at idle speed. Check for oil leakage while warming up.
CAUTION: _
If oil leakage is fo mediately and ch _
Recommended engine oil: See page 10-2.
Oil quantity: Periodic oil change:
1.5 L (1.3 Imp qt, 1.6 US qt) With oil filter element cleaning:
1.6 L (1.4 Imp qt, 1.7 US qt) Total amount:
1.8 L (1.6 Imp qt, 1.9 US qt)
EBU00825
orrect oil level 3. Oil filler bolt
cement al gear case cover.
U4XE15.book Page 9 Monday, April 8, 2002 2:19 PM
8-9
Final gear oil Final gear oil measurement 1. Place the machine on a level place. 2. Remove the oil filler bolt and check the oil
level. It should be up to the brim of the hole. If the level is low, add oil to raise it to the proper level.
CAUTION: _
Be sure no foreign material enters the final gear case. _
3. Install the oil filler bolt and tighten it to the specified torque.
1. Final gear oil 2. C
Final gear oil repla 1. Remove the fin
Tightening torque: Oil filler bolt:
23 Nm (2.3 mkgf, 17 ftlbf)
ear case with oil.
n material enters the final
er bolt and tighten to the ue.
leakage. If oil leakage is for the cause. l gear case cover.
oil: .
ange: Imp qt, 0.26 US qt)
Imp qt, 0.29 US qt)
e: l gear case): mkgf, 17 ftlbf)
U4XE15.book Page 10 Monday, April 8, 2002 2:19 PM
8-10
2. Place the machine on a level place. 3. Place a container under the final gear
case to collect the used oil. 4. Remove the oil filler bolt and the drain
bolt to drain the oil.
1. Drain bolt
5. Install the drain bolt and tighten it to the specified torque.
6. Fill the final g
CAUTION: _
Be sure no foreig gear case. _
7. Install the fill specified torq
8. Check for oil found, check
9. Install the fina
Tightening torque: Drain bolt (final gear case):
23 Nm (2.3 mkgf, 17 ftlbf)
Recommended See page 10-2
Oil quantity: Periodic oil ch
0.25 L (0.22 Total amount:
0.27 L (0.24
Tightening torqu Filler bolt (fina
23 Nm (2.3
EBU00870*
e spark plug, measure the a feeler gauge and adjust
.0240.028 in)
U4XE15.book Page 11 Monday, April 8, 2002 2:19 PM
8-11
Spark plug inspection The spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes ex- cessive, you should replace the spark plug with one of the proper type.
Before installing th electrode gap with to specification.
a. Spark plug gap
Standard spark plug: DR7EA (NGK)
Spark plug gap: 0.60.7 mm (0
eat. (Refer to page 4-14 for nd installation procedures.) ir filter case cover.
r
U4XE15.book Page 12 Monday, April 8, 2002 2:19 PM
8-12
When installing the spark plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tight- en to the specified torque.
EBU00851
Air filter cleaning
NOTE: _
There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. _
1. Check hose
1. Remove the s seat removal a
2. Remove the a
1. Air cleaner case cove
Tightening torque: Spark plug:
17.5 Nm (1.75 mkgf, 12.5 ftlbf)
nt lightly to remove most of irt. Blow out the remaining ressed air as shown. If the aged, replace it.
m cover gently but thor- r or solvent.
U4XE15.book Page 13 Monday, April 8, 2002 2:19 PM
8-13
3. Pull out the air filter element. 4. Separate the foam cover from the air filter
element.
1. Air filter element 2. Foam cover
5. Tap the eleme the dust and d dirt with comp element is dam
6. Wash the foa oughly in wate
ilter assembly and parts re- ess.
nt should be cleaned every ould be cleaned more often perated in extremely dusty filter element maintenance ck the air inlet to the filter ns. Check the air cleaner
carburetor and manifold fit- seal. Tighten all fittings se- possibility of unfiltered air
e.
e engine with the air filter . This will allow unfiltered ng rapid engine wear and amage. Additionally, op- e filter element will affect
g with subsequent poor possible engine over-
U4XE15.book Page 14 Monday, April 8, 2002 2:19 PM
8-14
7. Squeeze the excess water or solvent out of the foam cover and let it dry.
CAUTION: _
Do not twist the foam cover when squeezing it.
Do not add oil to the foam cover. _
8. Inspect the foam cover. If damaged, re- place it.
9. Install the foam cover onto the air filter el- ement.
10. Install the air f moved for acc
NOTE: _
The air filter eleme 2040 hours. It sh if the machine is o areas. Each time is performed, che case for obstructio rubber joint to the tings for an airtight curely to avoid the entering the engin _
CAUTION: _
Never operate th element removed air to enter, causi possible engine d eration without th carburetor jettin performance and heating. _
WARNING
POTENTIAL HAZARD Using low flash point solvents or gaso- line to clean the foam cover. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the foam cover.
EBU00296 EBU00301
ent
eter must be used for this
e and warm it up for a few roximately 1,000 to 2,000 nally rev the engine to
r/min. The engine is warm responds to the throttle. chometer and set the idle idling speed by adjusting
p screw. Turn the screw in gine speed, and out to de- speed.
ed: min
U4XE15.book Page 15 Monday, April 8, 2002 2:19 PM
8-15
Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and ex- perience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine.
CAUTION: The carburetor was set at the Yamaha fac- tory after many tests. If the settings are disturbed by someone without sufficient technical knowledge, poor engine perfor- mance and damage may result.
Idle speed adjustm
NOTE: A diagnostic tachom procedure.
1. Start the engin minutes at app r/min. Occasio 4,000 to 5,000 when it quickly
2. Connect the ta to the specified the throttle sto to increase en crease engine
Specified idle spe 1,4001,500 r/
ustment
idling speed before adjust- r free play.
cknut. ting bolt until the throttle le-
s 35 mm (0.120.20 in). cknut.
2. Adjusting bolt .120.20 in)
U4XE15.book Page 16 Monday, April 8, 2002 2:19 PM
8-16
1. Throttle stop screw
EBU00303
Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clear- ance must be adjusted regularly. This adjust- ment however, should be left to a professional Yamaha service technician.
EBU00307
Throttle lever adj
NOTE: Adjust the engine ing the throttle leve
1. Loosen the lo 2. Turn the adjus
ver free play i 3. Tighten the lo
1. Locknut a. Free play: 35 mm (0
EBU00312 EBU00313
nspection rovided on the rear brake. s checking of brake shoe
sembling the brake. Apply heck the position of the in- tor reaches the wear limit
dealer to replace shoes as
2. Wear limit
U4XE15.book Page 17 Monday, April 8, 2002 2:19 PM
8-17
Front brake pad inspection Inspect the brake pads for damage and wear. If the thickness is less than the specified val- ue, have a Yamaha dealer replace the pads.
1. Brake pad a. Wear limit: 1 mm (0.04 in)
NOTE: The wheels need to be removed to inspect the brake pads. See page 8-27 for removal proce- dures.
Rear brake shoe i A wear indicator is p This indicator allow wear without disas the rear brake and c dicator. If the indica line, ask a Yamaha a set.
1. Wear indicator
esignated quality brake flu- the rubber seals may dete- g leakage and poor brake
same type of brake fluid. may result in a harmful
tion and lead to poor brake t water does not enter the
er when refilling. Water will wer the boiling point of the
result in vapor lock. ay deteriorate painted sur- tic parts. Always clean up mediately. ha dealer check the cause id level goes down.
brake fluid: DOT 4
U4XE15.book Page 18 Monday, April 8, 2002 2:19 PM
8-18
EBU00755
Brake fluid level inspection Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the lower level and replenish when necessary.
1. Minimum level mark
Observe these precautions: 1. When checking the fluid level, make sure
the top of the master cylinder is level by turning the handlebars.
2. Use only the d id. Otherwise, riorate, causin performance.
3. Refill with the Mixing fluids chemical reac performance.
4. Be careful tha master cylind significantly lo fluid and may
5. Brake fluid m faces or plas spilled fluid im
6. Have a Yama if the brake flu
Recommended
EBU01118 EBU00623
tment er should have a free play n) at the lever end. If not, ler to adjust it.
ero in)
U4XE15.book Page 19 Monday, April 8, 2002 2:19 PM
8-19
Brake fluid replacement 1. Complete fluid replacement should be
done only by trained Yamaha service personnel.
2. Have a Yamaha dealer replace the fol- lowing components during periodic main- tenance or when they are damaged or leaking. Replace all rubber seals every two
years. Replace all hoses every four years.
Front brake adjus The front brake lev of zero mm (zero i ask a Yamaha dea
a. Free play: Zero mm (Z
U4XE15.book Page 20 Monday, April 8, 2002 2:19 PM
8-20
WARNING
POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: Make sure the brakes operate
smoothly and that the free play is cor- rect.
Make sure the brakes do not drag. Make sure the brakes are not spongy.
All air must be bled from the brake system.
Replacement of brake components re- quires professional knowledge. These procedures should be performed by a Yamaha dealer.
EBU01075
0.81.2 in)
cknut and fully turn in the n the handlebar.
2. Adjusting bolt
U4XE15.book Page 21 Monday, April 8, 2002 2:19 PM
8-21
Rear brake adjustment Brake pedal 1. Fully loosen the adjusting nut on the
brake cable.
1. Brake cable adjusting nut 2. Brake rod adjusting nut
2. Turn the adjusting nut on the brake rod until free play is 2030 mm (0.81.2 in).
a. Free play: 2030 mm (
Brake lever 1. Loosen the lo
adjusting bolt o
1. Locknut
usting bolt until free play m (0.20.3 in) at the lever
2. Adjusting bolt .20.3 in)
cknut.
U4XE15.book Page 22 Monday, April 8, 2002 2:19 PM
8-22
2. Turn the adjusting nut on the brake cable to provide a gap of 01 mm (00.04 in) between the cam shaft lever and pin.
1. Brake cable adjusting nut a. Gap: 01 mm (00.04 in)
3. Turn the adj reaches 57 m pivot.
1. Locknut a. Free play: 57 mm (0
4. Tighten the lo
EBU00834
brake light switch t switch, which is activated and brake levers, is prop- the brake light comes on takes effect. If necessary, ht switch as follows.
2. Adjusting nut
nut while holding the rear place. To make the brake r, turn the adjusting nut in
ke the brake light come on ting nut in direction b.
U4XE15.book Page 23 Monday, April 8, 2002 2:19 PM
8-23
Adjusting the rear The rear brake ligh by the brake pedal erly adjusted when just before braking adjust the brake lig
1. Rear brake light switch
Turn the adjusting brake light switch in light come on earlie direction a. To ma later, turn the adjus
WARNING
POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: Make sure the brakes operate
smoothly and that the free play is cor- rect.
Make sure the brakes do not drag. Replacement of brake components re- quires professional knowledge. These procedures should be performed by a Yamaha dealer.
g bolt counterclockwise to h free play and turn it clock- e free play.
and lubrication
WARNING
ZARD l cables. PEN result when the outer ntrol cables becomes
les can also become . Operation of controls ted, which could cause jury.
THE HAZARD requently. Replace dam-
U4XE15.book Page 24 Monday, April 8, 2002 2:19 PM
8-24
EBU00346
Clutch adjustment 1. Loosen the locknut. 2. Slowly turn the adjusting bolt counter-
clockwise until resistance is felt. Then, turn it 1/8 turn clockwise.
1. Locknut 2. Adjusting bolt
3. Tighten the locknut to specification.
NOTE: Turn the adjustin decrease the clutc wise to increase th
EBU00356
Cable inspection
Tightening torque: 15 Nm (1.5 mkgf, 11 ftlbf)
POTENTIAL HA Damaged contro WHAT CAN HAP Corrosion can covering of co damaged. Cab frayed or kinked could be restric an accident or in HOW TO AVOID Inspect cables f aged cables.
EBU00717
rake pedal lubrication ng parts.
bricant: ased grease ease)
U4XE15.book Page 25 Monday, April 8, 2002 2:19 PM
8-25
Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them.
Brake lever and b Lubricate the pivoti
Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil
Recommended lu Lithium-soap-b (all-purpose gr
rication points. Use a grease gun.
lubricant: base grease
U4XE15.book Page 26 Monday, April 8, 2002 2:19 PM
8-26
EBU00370
Steering shaft lub Lubricate the pivot
Recommended Lithium soap
EBU01112 EBU01121
el and the nuts.
are used for both the front ls. Install the nut with its ta- ards the wheel. k on the tire must point ting direction of the wheel.
U4XE15.book Page 27 Monday, April 8, 2002 2:19 PM
8-27
Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable
stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel.
Wheel installation 1. Install the whe
NOTE: _
Tapered nuts and rear whee pered side tow
The arrow mar toward the rota
_
1. Arrow mark
U4XE15.book Page 28 Monday, April 8, 2002 2:19 PM
8-28
1. Tapered nut
2. Lower the ATV so that the wheel is on the ground.
3. Tighten the wheel nuts to the specified torque.
Wheel nut torque: Front: 55 Nm (5.5 mkgf, 40 ftlbf) Rear: 55 Nm (5.5 mkgf, 40 ftlbf)
EBU00378
breather hose 3. Clamp ( 3)
U4XE15.book Page 29 Monday, April 8, 2002 2:19 PM
8-29
Battery Check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low.
CAUTION: Do not leave or store the battery on its side. When inspecting the battery, be sure the breather hose is routed correctly. If it touches the frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cosmet- ic damage to the machine can occur.
1. Battery 2. Battery
th water for 15 minutes medical attention. Keep rom sparks, flames, cig- sources of ignition. Ven- ging or using in a closed
U4XE15.book Page 30 Monday, April 8, 2002 2:19 PM
8-30
WARNING
POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or cloth- ing. Always shield eyes when working near batteries. Keep out of reach of chil- dren. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of wa- ter or milk. Follow with milk of magne- sia, beaten egg or vegetable oil. Get prompt medical attention.
EYES: Flush wi and get prompt batteries away f arettes or other tilate when char space.
EBU00542
contains minerals which battery. Therefore, refill water.
hine is not to be used for a r, remove the battery and
ol, dark place. Completely attery before reusing. s to be stored for a longer above, check the specific t once a month and re-
tery when it is too low. sure the connections are utting the battery back in Make sure the breather rly connected and is not structed.
U4XE15.book Page 31 Monday, April 8, 2002 2:19 PM
8-31
Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly. The battery fluid should be checked at least once a month. 1. The level should be between the upper
and lower level marks. Use only distilled water if refilling is necessary.
1. Maximum level mark 2. Minimum level mark
2. Disconnect the negative (-) lead. 3. Disconnect the positive (+) lead. 4. Remove the battery bracket bolts, brack-
et and battery.
CAUTION: _
Normal tap water are harmful to a only with distilled _
5. When the mac month or longe store it in a co recharge the b
6. If the battery i period than the gravity at leas charge the bat
7. Always make correct when p the machine. hose is prope damaged or ob
idental short-circuiting, switch when checking or
WARNING
ZARD er fuse. PEN e can cause damage to stem which could lead
THE HAZARD se of the specified rat- material in place of the
U4XE15.book Page 32 Monday, April 8, 2002 2:19 PM
8-32
EBU00390
Fuse replacement 1. The fuse case is located under the seat. 2. If the fuse is blown, turn off the main
switch and install a new fuse of the spec- ified amperage. Then turn on the switch- es. If the fuse immediately blows again, consult a Yamaha dealer.
1. Main fuse 2. Spare fuse
CAUTION: To prevent acc turn off the main replacing a fuse.
Specified fuse: 20 A
POTENTIAL HA Using an improp WHAT CAN HAP An improper fus the electrical sy to a fire. HOW TO AVOID Always use a fu ing. Never use a proper fuse.
EBU01072
holder counterclockwise to fective bulb.
U4XE15.book Page 33 Monday, April 8, 2002 2:19 PM
8-33
Replacing a headlight bulb If a headlight bulb burns out, replace the bulb as follows. 1. Remove the headlight cover.
1. Headlight cover
2. Remove the bulb holder cover.
1. Bulb holder cover ( 2)
3. Turn the bulb remove the de
1. Bulb holder
djustment
have a Yamaha dealer ent.
, turn the adjusting screw in
, turn the adjusting screw in
U4XE15.book Page 34 Monday, April 8, 2002 2:19 PM
8-34
4. Put a new bulb into position and secure it in place with the bulb holder.
5. Install the bulb holder cover and head- light cover.
6. Adjust the headlight beam if necessary.
EBU01089
Headlight beam a
CAUTION: _
It is advisable to make this adjustm _
To raise the beam direction a. To lower the beam direction b.
1. Adjusting screw ( 2)
WARNING
POTENTIAL HAZARD The headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flamma- ble. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it.
EBU00945
efective bulb from the bulb ing it inward and turning it ise.
U4XE15.book Page 35 Monday, April 8, 2002 2:19 PM
8-35
Tail/brake light bulb replacement 1. Open the storage box. (See page 4-15.) 2. Remove the nuts together with washers.
1. Storage box 2. Nut ( 2)
3. Remove the bulb holder (together with the bulb) by turning it counterclockwise.
1. Bulb holder
4. Remove the d holder by push counterclockw
U4XE15.book Page 36 Monday, April 8, 2002 2:19 PM
8-36
1. Bulb holder 2. Bulb
5. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise.
6. Install the bulb holder (together with the bulb).
7. Install the washers, and then install the nuts.
EBU00754
ing bolt and tighten it.
WARNING
ARD ng the exhaust system. em. PEN eyes. ns. bon monoxide poison- ding to death. . THE HAZARD e spark arrester: haust system cool pri- haust components. Al- protection, and make hind the vehicle. Never in an enclosed area.
are no combustible ma- .
U4XE15.book Page 37 Monday, April 8, 2002 2:19 PM
8-37
Spark arrester cleaning Select a well-ventilated area free of combusti- ble materials and make sure the exhaust pipe and muffler are cool. 1. Remove the purging bolt.
1. Purging bolt
2. Start the engine and rev it up approxi- mately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel.
3. Stop the engine and allow the exhaust pipe to cool.
4. Install the purg
POTENTIAL HAZ Improperly purgi Hot exhaust syst WHAT CAN HAP Could injure the Could cause bur Could cause car ing, possibly lea Could start a fire HOW TO AVOID When cleaning th Always let the ex or to touching ex ways wear eye sure no one is be run the engine Make sure there terials in the area
WARNING
ZARD el system while smok-
pen flame. PEN
or explode, causing se- operty damage. THE HAZARD when checking the fuel ure there are no open s in the area, including om water heaters or
U4XE15.book Page 38 Monday, April 8, 2002 2:19 PM
8-38
EBU00412
Troubleshooting Although Yamaha machines receive a rigid in- spection before shipment from the factory, trouble may occur during operation. Any prob- lem in the fuel, compression, or ignition sys- tems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer. The skilled technicians at a Yamaha dealer- ship have the tools, experience, and know- how to properly service your machine. Use only genuine Yamaha parts on your machine. Imitation parts may look like Yamaha parts, but they are often inferior. Consequently, they have a shorter service life and can lead to ex- pensive repair bills.
POTENTIAL HA Checking the fu ing or near an o WHAT CAN HAP Fuel can ignite vere injury or pr HOW TO AVOID Do not smoke system. Make s flames or spark pilot lights fr furnaces.
EBU00440
No fuel. Fuel cock clogged.
Clean fuel cock.
ood. Ignition system normal.
eak.
Adjust plug gap or replace plug.k.
aha dealer to
U4XE15.book Page 39 Monday, April 8, 2002 2:19 PM
8-39
Troubleshooting chart
1. Fuel
Check if there is fuel in the fuel tank.
There is fuel. Turn the fuel cock to OFF.
Remove the fuel pipe.
Some fuel. Turn the fuel cock to RES. Restart engine.
No fuel. Supply fuel.
2. Compression
Use electric starter to see if there is compression.
There is compression. Compression normal.
No compression. Ask a Yamaha dealer to inspect.
3. Ignition
Remove plug and check electrode.
Wet Wipe clean with dry cloth.
Dry Attach plug cap and ground to chassis.
Use the electric starter.
Spark g
Spark w
No spar
Ask a Yam inspect.
4. Battery
Use electric starter.
Engine turns over quickly. Battery good.
Engine turns over slowly.
Check fluid, recharge, check connections.
Check fuel flow.
U4XE15.book Page 40 Monday, April 8, 2002 2:19 PM
EBU00419
ressure may cause wa- deterioration of wheel transmission seals and . Many expensive repair ed from improper high nt applications such as
in coin-operated car
ority of the dirt has been sh all surfaces with warm , detergent-type soap. An
or bottle brush is handy for places. hine off immediately with
nd dry all surfaces with a n towel or soft absorbent
U4XE15.book Page 1 Monday, April 8, 2002 2:19 PM
9-1
CLEANING AND STORAGE
A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to
prevent water entry. A plastic bag and strong rubber band may be used.
b. Make sure the spark plug and all filler caps are properly installed.
2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply degreaser to the wheel axles.
3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job.
CAUTION: Excessive water p ter seepage and bearings, brakes, electrical devices bills have result pressure deterge those available washers.
4. Once the maj hosed off, wa water and mild old toothbrush hard-to-get-at
5. Rinse the mac clean water a chamois, clea cloth.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
WARNING
ZARD wet brakes after wash-
PEN have reduced stopping g the chance of an acci-
THE HAZARD after washing. Apply the times at slow speeds to ut the linings.
U4XE15.book Page 2 Monday, April 8, 2002 2:19 PM
9-2
6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.
7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes.
POTENTIAL HA Operation with ing. WHAT CAN HAP Wet brakes may ability, increasin dent. HOW TO AVOID Test the brakes brakes several let friction dry o
EBU00530
park plug, pour about one SAE 10W30 or 20W40 spark plug hole and rein- plug. Ground the spark
turn the engine over seve- t the cylinder wall with oil. ntrol cables. ame to raise all wheels off
ag over the exhaust pipe nt moisture from entering. humid or salt-air atmo- ll exposed metal surfaces of oil. Do not apply oil to ts or the seat cover.
U4XE15.book Page 3 Monday, April 8, 2002 2:19 PM
9-3
B. STORAGE Long term storage (60 days or more) of your machine will require some preventive proce- dures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add
the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equiva- lent product.
NOTE: _
Use of fuel stabilizer and conditioner elimi- nates the need to drain the fuel system. Con- sult a Yamaha dealer if the fuel system needs to be drained instead. _
2. Remove the s tablespoon of motor oil in the stall the spark plug wire and ral times to coa
3. Lubricate all co 4. Block up the fr
the ground. 5. Tie a plastic b
outlet to preve 6. If storing in a
sphere, coat a with a light film any rubber par
Specified amount: 1 oz of stabilizer to each gallon of fuel (or 7.5 cc of stabilizer to each liter of fuel)
U4XE15.book Page 4 Monday, April 8, 2002 2:19 PM
9-4
7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an ex- cessively warm or cold place (less than 0C (30F) or more than 30C (90F)).
NOTE: _
Make any necessary repairs before storing the machine. _
EBU00428
M250X
HC inclined
8 in)
oil starter
U4XE15.book Page 1 Monday, April 8, 2002 2:19 PM
10-1
SPECIFICATIONS
MODEL YF
Dimension: Overall length Overall width Overall height Seat height Wheel base Minimum ground clearance Minimum turning radius
1,940 mm (76.3 in) 1,005 mm (39.5 in) 1,118 mm (44.0 in)
780 mm (30.7 in) 1,170 mm (46.0 in)
150 mm ( 5.9 in) 2,900 mm ( 114 in)
Basic weight: With oil and full fuel tank 212 kg (467 lb)
Engine: Type Cylinder arrangement Displacement Bore Stroke Compression ration Starting system Lubrication system
Air cooled, 4-stroke, SO Single cylinder, forward 229.6 cm3 71 58 mm (2.79 2.2 8.7 : 1 Electric starter and rec Wet sump
1
2
3
4
5
6
7
8
9
10
11
12
13
14
US qt) US qt) US qt)
ypoid gear oil
.29 US qt)
NE ONLY .17 US gal) .42 US gal)
.028 in)
FM250X
U4XE15.book Page 2 Monday, April 8, 2002 2:19 PM
10-2
Engine oil: Type Quantity:
Periodic oil change With oil filter replacement Total amount
See page 5-7
1.5 L (1.3 Imp qt, 1.6 1.6 L (1.4 Imp qt, 1.7 1.8 L (1.6 Imp qt, 1.9
Final gear case oil: Type Quantity:
Total amount
SAE 80 API GL-4 H
0.27 L (0.23 Imp qt, 0
Air filter Dry type element
Fuel: Type Tank capacity Reserve amount
UNLEADED GASOLI 12 L (2.64 Imp gal, 3 1.6 L (0.35 Imp gal, 0
Carburetor: Type/quantity Manufacturer
BST34/1 MIKUNI
Spark plug: Type Manufacturer Gap
DR7EA NGK 0.60.7 mm (0.0240
MODEL Y
atic
d forward, 1-speed reverse
9.924)
M250X
U4XE15.book Page 3 Monday, April 8, 2002 2:19 PM
10-3
Clutch type Wet, centrifugal autom
Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation
Spur gear 73/22 (3.318) Shaft drive 19/18 46/11 (4.414) Constant mesh 5-spee Left foot operation
Gear ratio: 1st 2nd 3rd 4th 5th
Reverse
34/12 (2.833) 34/19 (1.789) 29/22 (1.318) 26/25 (1.040) 23/28 (0.821) 73/22 34/12 19/18 (
Chassis: Frame type Caster angle Trail
Steel tube 4 20 mm (0.78 in)
Tire: Type Size: Front Size: Rear
Tubeless AT22 7-10 AT22 10-10
MODEL YF
ot operation
)
r r
FM250X
U4XE15.book Page 4 Monday, April 8, 2002 2:19 PM
10-4
Brake: Front brake type Operation Rear brake type Operation
Dual disc brake Right hand operation Drum brake Left hand and right fo
Suspension: Front Rear
Strut Swingarm (monocross
Shock absorber: Front Rear
Coil spring, Oil dampe Coil spring, Oil dampe
Wheel travel: Front Rear
125 mm (4.9 in) 135 mm (5.3 in)
Electrical: Ignition system Generator system Battery type/voltage, capacity
DC C.D.I. AC magneto YB14A-A2/12V, 14AH
Headlight type Bulb
Bulb voltage, wattage quantity: Headlight Tail/brake light Indicator light:
Neutral Reverse
Specified fuse:
12V, 25/25W 2 12V, 5/21W 1
12V, 1.7W 1 12V, 1.7W 1 20A
MODEL Y
11-1
EBU00430
NOISE REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate 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.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW. These acts include tampering with the following systems; i.e., modification, removal, etc.
Exhaust system Muffler Exhaust pipe Silencer
Intake system Air cleaner case Air cleaner element Intake duct
U4XE15.book Page 1 Monday, April 8, 2002 2:19 PM
12-1
1
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3
4
5
6
7
8
9
10
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EBU00431
MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work is required. It is not acceptable proof of maintenance work. ACL-02E
MAINTENANCE INTERVAL
DATE OF SERVICE
MILEAGE SERVICING DEALER
NAME AND ADDRESS REMARKS
1 Month
3 Months
6 Months
12 Months
18 Months
24 Months
30 Months
36 Months
42 Months
48 Months
54 Months
60 Months
U4XE15.book Page 1 Monday, April 8, 2002 2:19 PM
EBU00432
U4XE15.book Page 1 Monday, April 8, 2002 2:19 PM
13-1
YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY
1
2
3
4
5
6
7
8
9
10
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14
U4XE15.book Page 2 Monday, April 8, 2002 2:19 PM
13-2
EBU00435
U4XE15.book Page 1 Monday, April 8, 2002 2:19 PM
14-1
YAMAHA EXTENDED SERVICE (Y.E.S.)
1
2
3
4
5
6
7
8
9
10
11
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14
U4XE15.book Page 2 Monday, April 8, 2002 2:19 PM
14-2
otential hazard that could s injury or death.
U4XE15.book Page 3 Monday, April 8, 2002 2:19 PM
EBU00436
WARNING Indicates a p result in seriou
U4XE15.book Page 4 Monday, April 8, 2002 2:19 PM
EBU00437
U4XE15.book Page 5 Monday, April 8, 2002 2:19 PM
EBU00776
4XE-F8199-15LIT-11626-16-14
READ THIS MANUAL CAREFULLY! It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.WARNING
YFM250XR
OWNERS MANUAL
PRINTED IN USA 2002.05-2.01 CR
(E)
PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD.
EBU00438
LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558)
WARNING
ALWAYS: use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. avoid paved surfaces-pavement may seriously affect handling and control.
Improper ATV use can result in SEVERE INJURY or DEATH.
NEVER operate: without proper training or instruction. at speeds too fast for your skills or the conditions. on public roads-a collision can occur with another vehicle. with a passenger-passengers affect balance and steering and increase risk of losing control.
ALWAYS USE AN APPROVED HELMET AND
PROTECTIVE GEAR
NEVER USE ON PUBLIC
ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
B EE R
B EE R
Card.fm Page 1 Monday, April 8, 2002 3:23 PM
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