Yamaha RAPTOR 250 User Manual
WARNING
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM25RX
This A
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-21-22
4D3-28199-10
EBU17091
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INTRODUCTION
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Congratulations on your purchase of the Yamaha YFM25RX. This ATV represents the result of many years
of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the
purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have
made Yamaha a leader in these fields.
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 the ATV.
dures. 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 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16
YEARS OF AGE.
●
THIS ATV IS A HIGH-PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT-TYPE RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.
It also includes basic maintenance and inspection proce-
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WARNING
CAUTION:
NOTE:
IMPORTANT MANUAL INFORMATION
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FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury
or death to the ATV operator, a bystander, or a person inspecting or
repairing the ATV.
A CAUTION indicates special precautions that must be taken to avoid
damage to the ATV.
A NOTE provides key information to make procedures easier or clearer.
* Product and specifications are subject to change without notice.
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IMPORTANT NOTICE
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Welcome to the Yamaha world of motor sports!
This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV
on any public street, road or highway.
This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in
effect at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
EBU17381
AFFIX DEALER
LABEL HERE
YFM25RX
OWNER’S MANUAL
©2007 by Yamaha Motor Corporation, U.S.A.
1st edition, May 2007
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-21-22
EWB00010
WARNING
Indicates a potential hazard that could result in
serious injury or death.
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TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
Clutch lever ................................................ 4-5
Brake lever ................................................. 4-5
Brake pedal ................................................ 4-6
Parking brake lever .................................... 4-6
Shift pedal .................................................. 4-7
Fuel tank cap ............................................. 4-8
Fuel ............................................................ 4-8
Fuel cock ................................................. 4-10
Starter (choke) ......................................... 4-11
Seat ......................................................... 4-12
Adjusting the front shock absorber
assemblies ............................................. 4-13
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ..................................................... 3-1
Right view................................................... 3-1
Controls and instruments ........................... 3-2
INSTRUMENT AND CONTROL
FUNCTIONS ..................................................4-1
Main switch ............................................... 4-1
Indicator light ............................................. 4-2
Handlebar switches ................................... 4-2
Throttle lever ............................................. 4-3
Speed limiter ............................................. 4-4
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ............................. 5-1
Fuel ............................................................ 5-4
Engine oil ................................................... 5-4
Front and rear brakes ................................ 5-4
Throttle lever .............................................. 5-5
Drive chain ................................................. 5-5
Tires ........................................................... 5-7
Measuring the tire pressure ....................... 5-8
Tire wear limit ............................................ 5-9
Chassis fasteners ...................................... 5-9
Instruments, lights and switches ................ 5-9
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Shifting ...................................................... 6-3
Engine break-in ......................................... 6-5
Parking ...................................................... 6-6
Parking on a slope .................................... 6-6
Accessories and loading ........................... 6-7
RIDING YOUR ATV ......................................7-1
GETTING TO KNOW YOUR ATV.............. 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT........................................... 7-2
BE CAREFUL WHERE YOU RIDE.......... 7-12
TURNING YOUR ATV ............................. 7-17
CLIMBING UPHILL .................................. 7-19
RIDING DOWNHILL................................. 7-22
CROSSING A SLOPE.............................. 7-24
CROSSING THROUGH SHALLOW
WATER .................................................. 7-25
RIDING OVER ROUGH TERRAIN .......... 7-27
SLIDING AND SKIDDING........................ 7-28
WHAT TO DO IF... ................................... 7-29
WHAT TO DO... ....................................... 7-29
PERIODIC MAINTENANCE AND MINOR
REPAIR.......................................................... 8-1
Owner’s manual and tool kit ...................... 8-1
Periodic maintenance chart for the
emission control system .......................... 8-3
General maintenance and lubrication
chart ........................................................ 8-5
Checking the spark plug ............................ 8-9
Engine oil and oil filter element ................ 8-11
Cleaning the air filter element .................. 8-15
Cleaning the spark arrester ..................... 8-19
Adjusting the carburetor ........................... 8-20
Adjusting the engine idling speed ............ 8-21
Adjusting the throttle cable free play ........ 8-22
Valve clearance ....................................... 8-22
Checking the front and rear brake
pads ....................................................... 8-23
Checking the brake fluid level .................. 8-24
Changing the brake fluid .......................... 8-26
Checking the front brake lever free
play ........................................................ 8-27
Checking the brake pedal position ........... 8-27
Adjusting the parking brake free play ...... 8-28
Brake light switches ................................. 8-30
Adjusting the clutch lever free play .......... 8-31
Drive chain slack ...................................... 8-32
Lubricating the drive chain ....................... 8-33
Checking and lubricating the cables ........ 8-34
Checking and lubricating the brake and
clutch levers ........................................... 8-35
Checking and lubricating the brake and
shift pedals ............................................. 8-36
Checking the wheel hub bearings ............ 8-36
Lubricating the swingarm pivots .............. 8-36
Lubricating the upper and lower arm
pivots ..................................................... 8-37
Lubricating the steering shaft .................. 8-38
Battery ..................................................... 8-38
Replacing the fuse .................................. 8-40
Replacing a headlight bulb ...................... 8-42
Adjusting a headlight beam ..................... 8-44
Replacing the tail/brake light bulb ........... 8-44
Removing a wheel ................................... 8-44
Installing a wheel ..................................... 8-45
Troubleshooting ...................................... 8-45
Troubleshooting chart ............................. 8-47
CLEANING AND STORAGE.......................... 9-1
Cleaning .................................................... 9-1
Storage ...................................................... 9-2
SPECIFICATIONS ...................................... 10-1
CONSUMER INFORMATION ...................... 11-1
Identification numbers ............................. 11-1
Noise regulation ...................................... 11-3
Maintenance record ................................ 11-4
YAMAHA MOTOR CORPORATION,
U.S.A. ATV LIMITED WARRANTY ....... 11-5
YAMAHA EXTENDED SERVICE
(Y.E.S.) .................................................. 11-7
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SAFETY INFORMATION
SAFETY INFORMATION
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AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine
maneuvers such as turning and riding on hills or
over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:
●
Read this manual and all labels carefully and follow the operating procedures described.
●
Never operate an ATV without proper training or
instruction.
should receive training from a certified instructor. Contact an authorized ATV dealer or call 1800-887-2887 to find out about the training
courses nearest you.
●
Always follow the age recommendation:
– A child under 16 years old should never oper-
Take a Training Course.
Beginners
ate an ATV with engine size greater than 90 cc.
●
Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she
does not have the abilities to operate it safely.
●
Never carry a passenger on an ATV.
●
Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, parking lots and streets.
●
Never operate an ATV on any public street, road
or highway, even a dirt or gravel one.
●
Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face
shield), gloves, boots, a long-sleeved shirt or a
jacket, and long pants.
●
Never consume alcohol or drugs before or while
operating this ATV.
●
Never operate at speeds too fast for your skills
or the riding conditions. Always go at a speed
that is proper for the terrain, visibility, operating
conditions, and your experience.
1-1
1
2
3
4
5
6
7
8
9
10
11
10
11
●
Never attempt wheelies, jumps, or other stunts.
●
Always inspect your ATV each time you use it to
1
make sure it is in safe operating condition. Always follow the inspection and maintenance
2
procedures and schedules described in this
manual.
3
●
Always keep both hands on the handlebars and
both feet on the footpegs of the ATV during op-
4
eration.
●
Always go slowly and be extra careful when op-
5
erating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the
6
ATV.
●
Never operate on excessively rough, slippery or
7
loose terrain until you have learned and practiced the skills necessary to control the ATV on
8
such terrain. Always be especially cautious on
9
these kinds of terrain.
●
Always follow proper procedures for turning as
described in this manual. Practice turning at low
speeds before attempting to turn at faster
speeds and never turn at excessive speeds.
●
Never operate the ATV on hills too steep for the
ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
●
Always follow proper procedures for climbing
hills as described in this manual. Check the terrain carefully before you start up any hill. Never
climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the
throttle suddenly or make sudden gear changes.
Never go over the top of a hill at high speed.
●
Always follow proper procedures for going down
hills and for braking on hills as described in this
manual. Check the terrain carefully before you
start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going
down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight
down the hill where possible.
●
Always follow proper procedures for crossing
the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the
ATV. Never attempt to turn the ATV around on
any hill until you have mastered the turning technique described in this manual on level ground.
Avoid crossing the side of a steep hill if possible.
●
Always use proper procedures if you stall or roll
backwards when climbing a hill. To avoid stalling, use the proper gear and maintain a steady
speed when climbing a hill. If you stall or roll
1-2
backwards, follow the special procedure for
braking described in this manual. Dismount on
the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following
the 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 or fallen trees. Always follow
proper procedures when operating over obstacles as described in this manual.
●
Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
●
Never operate an ATV in fast flowing water or in
water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.
●
Always use the size and type of 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 accessories.
●
Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY,
call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s
Safety Hotline at 1-800-852-5344.
1
2
3
4
5
6
7
8
9
10
11
1-3
EWB00021
WARNING
1
POTENTIAL HAZARD
Improper handling of gasoline.
2
WHAT CAN HAPPEN
Gasoline can catch fire and you could be
3
burned.
HOW TO AVOID THE HAZARD
4
Always turn off the engine when refueling.
Do not refuel right after the engine has been
5
running and is still very hot.
Do not spill gasoline on the engine or ex-
6
haust pipe/muffler when refueling.
Never refuel while smoking, or in the vicinity
7
of sparks, open flames, or other sources of
8
ignition such as the pilot lights of water heaters and clothes dryers.
9
When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel
10
cock is in the “OFF” position. Otherwise, fuel
may leak out of the carburetor or fuel tank.
11
WHAT CAN HAPPEN
Gasoline is poisonous and can cause injuries.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help
immediately. If gasoline spills on your skin,
wash with soap and water. If gasoline spills
on your clothing, change your clothes.
EWB00030
WARNING
POTENTIAL HAZARD
Starting or running the engine in a closed area.
1-4
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death within a short time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with adequate ventilation.
1
2
3
4
5
6
7
8
9
10
11
1-5
1
2
3
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LOCATION OF THE WARNING AND SPECIFICATION LABELS
3
10
11
4
2
5
6
7
8
9
1
5
2-1
4
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Read and understand all of the labels on your ATV. These labels contain important information for safe and
proper operation.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer.
1
2
3
4
5
6
7
8
9
10
11
2-2
10
11
1
2
3
4
5
6
7
8
9
2-3
NEVERNEVER
1
2
3
4
5
6
7
8
9
10
11
2-4
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1
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Left view
2
3
4
5
6
7
8
1. Headlights
2. Fuel cock
9
3. Starter (choke)
4. Throttle stop screw
10
5. Fuse
6. Tail/brake light
11
7. Shift pedal
DESCRIPTION
123456
7
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Right view
123
4
5
1. Spark arrester
2. Seat
3. Fuel tank cap
4. Oil filter element
5. Brake pedal
3-1
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Controls and instruments
1 2 3 4 5 6
1
2
3
4
5
6
1. Clutch lever
2. Handlebar switches
3. Parking brake lever
4. Main switch
5. Throttle lever
6. Brake lever
NOTE:
The ATV you have purchased may differ slightly
from the figures shown in this manual.
7
8
9
10
11
3-2
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INSTRUMENT AND CONTROL FUNCTIONS
1
EWB00010
2
3
4
5
6
7
8
9
10
11
WARNING
Indicates a potential hazard that could result in
serious injury or death.
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Main switch
The positions of the main switch are as follows:
ON
All electrical systems are supplied with power, and
the engine can be started. The key cannot be removed.
OFF
All electrical systems are off. The key can be removed.
OFF ON
1
1. Main switch
4-1
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Indicator light
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Handlebar switches
1
1
1. Neutral indicator light “N”
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Neutral indicator light “”
This indicator light comes on when the transmission is in the neutral position.
1
2
3
1. Light switch “LIGHTS”
2. Engine stop switch “ENG. STOP”
3. Start switch “START”
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Engine stop switch “ENG. STOP”
Set this switch to “RUN” before starting the engine.
The engine stop switch controls the ignition and
stops the engine when it is running. Use this switch
to stop the engine in an emergency situation. The
engine will not start or run when this switch is set
to “OFF”.
4-2
2
3
4
5
6
7
8
9
10
11
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Start switch “START”
Push this switch to crank the engine with the start-
1
er.
ECB00050
2
CAUTION:
3
See the starting instructions on page 6-1 prior
to starting the engine.
4
EBU18120
5
Light switch “LIGHTS”
Set this switch to “LO” to turn on the low beams
6
and the taillight. Set the switch to “HI” to turn on the
high beams and the taillight. Set the switch to
7
“OFF” to turn off all the lights.
8
NOTE:
The headlights and the taillight can be turned on
9
only when the engine is running.
10
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Throttle lever
11
Once the engine is running, movement of the throttle lever will increase the engine speed.
Regulate the speed of the ATV by varying the
throttle position. Because the throttle is springloaded, the ATV will decelerate, and the engine will
return to an idle any time the hand is removed from
the throttle lever.
1. 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 lever is released.
EWB00200
WARNING
POTENTIAL HAZARD
Malfunction of throttle.
WHAT CAN HAPPEN
The throttle could be hard to operate, making
it difficult to speed up or slow down when
you need to. This could cause an accident.
4-3
HOW TO AVOID THE HAZARD
Check the operation of the throttle lever before you start the engine. If it does not work
smoothly, check for the cause. Correct the
problem before riding the ATV. Consult a
Yamaha dealer if you can’t find or solve the
problem yourself.
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Speed limiter
Your ATV was delivered with an adjustable speed
limiter. The speed limiter keeps the throttle from
fully opening, even when the throttle lever is
pushed to the maximum.
1. Loosen the locknut.
2. To increase the maximum engine power available and the maximum speed of the ATV, turn
the adjusting screw in direction (a). To decrease the maximum engine power available
and the maximum speed of the ATV, turn the
adjusting screw in direction (b).
3
1. Locknut
2. Adjusting screw
3. No more than 12 mm (0.47 in)
3. Tighten the locknut.
(a)
1
2
1
2
(b)
3
4
5
6
7
8
9
10
11
4-4
EWB00190
WARNING
1
POTENTIAL HAZARD
Improper adjustment of the speed limiter and
2
throttle.
WHAT CAN HAPPEN
3
The throttle cable could be damaged. Improper throttle operation could result. You
4
could lose control, have an accident or be injured.
5
HOW TO AVOID THE HAZARD
Do not turn the adjusting screw out more
6
than 12 mm (0.47 in). Always make sure the
throttle lever free play is adjusted to 2.0–4.0
7
mm (0.08–0.16 in). (See page 8-22.)
8
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Clutch lever
9
The clutch lever is located on the left handlebar
10
and the ignition circuit cut-off system is incorporated in the clutch lever holder. To disengage the
11
clutch, pull the clutch lever toward the handlebar
grip. To engage the clutch, release the clutch lever.
The clutch lever should be pulled rapidly and released slowly for smooth clutch operation. (See
page 6-1 for a description of the ignition circuit cut-
off system.)
1. Clutch lever
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Brake lever
The brake lever is located at the right handlebar
grip. To apply the front brake, pull the brake lever
toward the handlebar grip.
4-5
1
1
1. Brake lever
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Brake pedal
The brake pedal is located on the right side of the
ATV. To apply the rear brake, push down on the
brake pedal.
1
1. Brake pedal
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Parking brake lever
Use the parking brake before starting the engine or
parking the ATV, especially on a slope. To apply
the parking brake, move the parking brake lever in
direction (a). To release the parking brake, move
the parking brake lever in direction (b).
4-6
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
1. Parking brake lever (locked position)
7
8
9
10
11
1. Parking brake lever (unlocked position)
EWB00170
WARNING
POTENTIAL HAZARD
Improper use of the parking brake.
WHAT CAN HAPPEN
The ATV could start moving unexpectedly if
the parking brake is not applied before starting the engine. This could cause loss of control or a collision.
The brake could overheat if you ride the ATV
without releasing the parking brake. You
could lose braking performance which could
cause an accident. You could also wear out
the brakes prematurely.
HOW TO AVOID THE HAZARD
Always set the parking brake before starting
the engine.
Always be sure you have released the parking brake before you begin to ride.
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Shift pedal
This ATV is equipped with a constant-mesh 5speed transmission. The shift pedal is located on
the left side of the engine and is used in combination with the clutch when shifting.
4-7
1
2
3
1
1. Shift pedal
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Fuel tank cap
Remove the fuel tank cap by turning it counterclockwise.
1. Fuel tank cap
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Fuel
Make sure that there is sufficient fuel in the tank.
Fill the fuel tank to the bottom of the filler tube as
shown.
4-8
1
4
5
6
7
8
9
10
11
rings, as well as to the exhaust system.
1
2
3
4
5
6
1. Fuel level
2. Filler tube
7
Recommended fuel:
8
9
UNLEADED GASOLINE ONLY
Fuel tank capacity:
9.0 L (2.38 US gal) (1.98 Imp.gal)
10
Fuel reserve amount:
1.0 L (0.26 US gal) (0.22 Imp.gal)
11
ECB00070
CAUTION:
Use only unleaded gasoline. The use of leaded
gasoline will cause severe damage to internal
engine parts, such as the valves and piston
Your Yamaha engine has been designed to use
regular unleaded gasoline with a pump octane
number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking or pinging
occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol
containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing
methanol is not recommended by Yamaha because it can cause damage to the fuel system or
ATV performance problems.
EWB00270
WARNING
POTENTIAL HAZARD
Improper care when refueling.
4-9
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire and severe injury.
Fuel expands when it heats up. If the fuel
tank is overfilled, fuel could spill out due to
heat from the engine or the sun.
HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful not to
spill fuel, especially on the engine or exhaust
pipe. Wipe up any spilled fuel immediately.
Be sure the fuel tank cap is closed securely.
Do not refuel right after the engine has been
running and is still very hot.
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Fuel cock
The fuel cock supplies fuel from the tank to the carburetor while also filtering it.
The fuel cock lever positions are explained as follows and shown in the illustrations.
OFF
OFF
1. Arrow mark positioned over “OFF”
With the fuel cock lever in this position, fuel will not
flow. Always turn the fuel cock lever to this position
when the engine is not running.
1
2
3
4
5
6
7
8
9
10
11
4-10
ON
1
2
RES
3
4
5
ON
6
1. Arrow mark positioned over “ON”
7
With the fuel cock lever in this position, fuel flows
8
to the carburetor. Turn the fuel cock lever to this
position when starting the engine and riding.
9
10
11
RES
1. Arrow mark positioned over “RES”
This indicates reserve. With the fuel cock lever in
this position, the fuel reserve is made available.
Turn the fuel cock lever to this position if you run
out of fuel while riding. When this occurs, refuel as
soon as possible and be sure to turn the fuel cock
lever back to “ON”!
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Starter (choke)
Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).
Move the starter (choke) in direction (a) to turn on
4-11
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