Yamaha YFM25BA, YFM250A User Manual

READ THIS MANUAL CAREFULLY! It contains important safety information.

LIRE ATTENTIVEMENT CE MANUEL!

Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE!

Contiene indicaciones importantes acerca de la seguridad.

OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO

YFM25BA

YFM250A

1P0-F8199-66

YAMAHA MOTOR CO., LTD.

PRINTED IN USA

2010.08-0.3×1 CR (E,F,S)

READ THIS MANUAL CAREFULLY! It contains important safety information.

OWNER’S MANUAL

YFM25BA

YFM250A

1P0-F8199-66-E0

EBU17114

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.

EC Declaration of Conformity

conforming to Directive 2006/42/EC

We,YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product

YFM250 (YFM25B)

(5Y4AG01W0A0518901–)

(Make, model)

to which this declaration applies, conforms to the essential health and safety requirements of Directive 2006/42/EC

(If applicable)

and to the other relevant Directives of EEC

2004/108/EC

(Title and/or number and date of issue of the other Directives of EEC)

(If applicable)

To effect correct application of the essential health and safety requirements stated in the Directives of EEC, the following-standards and/or technical specifications were consulted:

ANSI/SVIA 1-2007

(Title and/or number and date of issue of standards and/or specifications)

Manufacturer

YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA 1000 GA Highway 34 East, Newnan, Georgia 30265-1320, U.S.A.

Authorized Representative

YAMAHA MOTOR EUROPE N.V.

Koolhovenlaan 101, 1119 NC Schiphol-Rijk, The Netherlands

Signature

Shinya Shimada

General Manager

RV Engineering Division

MC Operations

YAMAHA MOTOR CO., LTD.

Date of Issue

9 March, 2010

EBU17170

INTRODUCTION

EBU17292

Congratulations on your purchase of the Yamaha YFM25BA/YFM250A. 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. 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 completely before operating your ATV. Make sure you understand all instructions.

●Pay close attention to the warning and notice labels on the ATV.

●This ATV should not be ridden by anyone under 16 years of age.

EBU17330

IMPORTANT MANUAL INFORMATION

EBU17342

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:

				This is the safety alert symbol. It is used to alert you to potential per-
				sonal injury hazards. Obey all safety messages that follow this sym-
				bol to avoid possible injury or death.
				A WARNING indicates a hazardous situation which, if not avoided,
	WARNING
				could result in death or serious injury.
				A NOTICE indicates special precautions that must be taken to avoid
	NOTICE
				damage to the vehicle or other property.

TIP	A TIP provides key information to make procedures easier or clearer.

* Product and specifications are subject to change without notice.

EBU17350

IMPORTANT NOTICE

EBU17372

This ATV is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

Please check your local riding laws and regulations before operating this ATV.

EBU17410

YFM25BA/YFM250A

OWNER’S MANUAL ©2010 by Yamaha Motor Co., Ltd.

1st edition, July 2010 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

is expressly prohibited. Printed in U.S.A.

EBU17420

TABLE OF CONTENTS

LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................	1-1
SAFETY INFORMATION ..............................	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 lights ............................................	4-2
Handlebar switches ....................................	4-2
Throttle lever ..............................................	4-3
Speed limiter ..............................................	4-4
Front brake lever ........................................	4-4
Brake pedal and rear brake lever ...............	4-5
Parking brake .............................................	4-6
Shift pedal ..................................................	4-6
Drive select lever ........................................	4-7
Recoil starter ..............................................	4-7
Fuel tank cap ..............................................	4-7

Fuel .............................................................	4-8
Fuel cock ....................................................	4-9
Starter (choke) ..........................................	4-11
Seat ..........................................................	4-11
Storage compartment ...............................	4-12
Front carrier ..............................................	4-13
Rear carrier ...............................................	4-13
Adjusting the rear shock absorber
assembly .................................................	4-14
PRE-OPERATION CHECKS ..........................	5-1
Fuel .............................................................	5-3
Engine oil ....................................................	5-3
Final gear oil ...............................................	5-3
Front and rear brakes .................................	5-3
Throttle lever ...............................................	5-4
Tires ............................................................	5-4
Chassis fasteners .......................................	5-6
Instruments, lights and switches .................	5-6
Battery ........................................................	5-6
OPERATION...................................................	6-1
Starting a cold engine .................................	6-1
Starting a warm engine ...............................	6-3

Operating the drive select lever and
driving in reverse ......................................	6-3
Shifting .......................................................	6-4
Engine break-in ..........................................	6-6
Parking .......................................................	6-7
Parking on a slope .....................................	6-7
Accessories and loading ............................	6-8
RIDING YOUR ATV ......................................	7-1
GETTING TO KNOW YOUR ATV...............	7-2
RIDE WITH CARE AND GOOD
JUDGMENT ..............................................	7-2
BE CAREFUL WHERE YOU RIDE.............	7-9
TURNING YOUR ATV ..............................	7-12
CLIMBING UPHILL ...................................	7-14
RIDING DOWNHILL..................................	7-16
CROSSING A SLOPE...............................	7-17
CROSSING THROUGH SHALLOW
WATER ...................................................	7-18
RIDING OVER ROUGH TERRAIN ...........	7-20
SLIDING AND SKIDDING.........................	7-21
WHAT TO DO IF... ....................................	7-22
WHAT TO DO... ........................................	7-22
PERIODIC MAINTENANCE AND
ADJUSTMENT ...............................................	8-1
Owner’s manual and tool kit .......................	8-2

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
Final gear oil .............................................	8-18
Cleaning the air filter element ...................	8-20
Cleaning the spark arrester ......................	8-24
Adjusting the carburetor ............................	8-25
Adjusting the engine idling speed .............	8-26
Adjusting the throttle lever free play .........	8-27
Valve clearance ........................................	8-27
Adjusting the drive select lever safety
system cable ...........................................	8-28
Brakes .......................................................	8-28
Checking the front brake pads and rear
brake shoes ............................................	8-28
Checking the brake fluid level ...................	8-29
Changing the brake fluid ...........................	8-30
Checking the front brake lever free play ...	8-30
Adjusting the brake pedal height and
free play, and the rear brake lever free
play .........................................................	8-31
Brake light switches ..................................	8-34
Adjusting the clutch free play ....................	8-35
Checking and lubricating the cables .........	8-35

Checking and lubricating the front and
rear brake levers ....................................	8-36
Checking the shift pedal ...........................	8-37
Checking and lubricating the brake
pedal ......................................................	8-37
Checking the wheel hub bearings ............	8-37
Lubricating the swingarm pivots ...............	8-38
Lubricating the steering shaft ...................	8-38
Battery ......................................................	8-39
Replacing the fuse ...................................	8-42
Replacing a headlight bulb .......................	8-43
Adjusting a headlight beam ......................	8-45
Replacing the tail/brake light bulb ............	8-45
Removing a wheel ....................................	8-46
Installing a wheel ......................................	8-46
Troubleshooting .......................................	8-48
Troubleshooting chart ..............................	8-49
CLEANING AND STORAGE..........................	9-1
Cleaning .....................................................	9-1
Storage .......................................................	9-2
SPECIFICATIONS ......................................	10-1
CONSUMER INFORMATION ......................	11-1
Identification numbers ..............................	11-1

EBU29680

LOCATION OF THE WARNING AND SPECIFICATION LABELS

1

EBU30290

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.

For Europe

1-1

1		3
1	<
		30 kg
(		66 lbs)
		1P0-F817R-00

2

1P0-F816P-20

20.0 kPa	25.0 kPa
0.20 kgf/cm²	0.25 kgf/cm²
2.9 psi	3.6 psi
	4XE-F816M-M0

4

< 45 kg ( 99 lbs)

1P0-F817R-10

5

< 3230 N < 330 kgf < 727 lbf < 147 N < 15 kgf < 33 lbf

1P0-F817S-00

1-2

6

7

1

1P0-F816L-20

8

		9
		2010	YFM250
			12.2 kW
		YAMAHA MOTOR CO., LTD.
	1P0-F816R-00		216 kg

2500 SHINGAI, IWATA, JAPAN	1P0-F155A-30

1-3

Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model.

1

Read the Owner’s manual.

ALWAYS use an approved helmet and protective gear.

NEVER permit children under age 6 to operate this ATV.

Operation of this ATV by children under the age of 6 increases the risk of severe injury or death.

Adult supervision required for children under age 16.

NEVER permit children under age 10 to operate this ATV.

Operation of this ATV by children under the age of 10 increases the risk of severe injury or death.

Adult supervision required for children under age 16.

NEVER permit children under age 12 to operate this ATV.

Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.

Adult supervision required for children under age 16.

NEVER operate this ATV if you are under age 16.

Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.

NEVER use on paved roads.

NEVER carry passengers.

1-4

NEVER use with drugs or alcohol.

NEVER store fuel or flammable liquids.

This unit contains high-pressure nitrogen gas.

Mishandling can cause an explosion. Do not incinerate, puncture or open.

Use unleaded gasoline only.

Measure the tire pressure when the tires are cold.

		Adjust the tire pressure.
		Improper tire pressure can cause loss of
						1
		control.
		Loss of control can result in severe injury or
**.* kPa	**.* kPa	death.
*.** kgf/cm² *.** kgf/cm²
*.* psi	*.* psi
		Turning the ATV in	4WD-LOCK
		(“DIFF.LOCK”) takes more effort.
		Operate at a slow speed and allow extra
		time and distance for maneuvers to avoid
		loss of control.
		This pictogram shows the loading limits
		and/or maximum load capacity for this ATV.
		Follow all load limits and other loading
		guidelines in this manual.
		Load may include the driver, passenger,
		human protective gear, accessories, goods,
		luggage, and all other load related items.
		Make sure you do not exceed the load limits.
		Overloading can cause loss of control.
		Loss of control can result in severe injury or
		death.

1-5

This pictogram shows trailer Hitch Tow

weight limit. (Combined weight of the trailer

1

and all cargo in the trailer.)

Overloading can cause loss of control.

Loss of control can result in severe injury or

death.

This pictogram shows trailer Hitch Tongue

weight limit. (Weight on the trailer tongue.)

Overloading can cause loss of control.

Loss of control can result in severe injury or

death.

1

2 3

1

Year of construction

2

Model Name

****

******

YAMAHA MOTOR CO., LTD.

*** kW

3

Max. Power

*** kg

2500 SHINGAI, IWATA, JAPAN

4

Mass In Running Order

4

1-6

For Oceania

1

1-7

1

3

1

30 kg (66 lbs)

4XE-F4877-20

2

	4
20 kPa, (2.9 psi)
25 kPa, (3.6 psi)
		45 kg (99 lbs)
17 kPa, (2.5 psi)
22 kPa, (3.2 psi)
			4XE-F4897-20

5
165 kg, (364 lbs)
3230 N	( 3 3 0 k g f )

4XE-F816M-20	727
			( 15 k g f )
			4XE-F151K-00

1-8

6

7

1

UNDER

16

1-9

EBU17431

SAFETY INFORMATION

2 EBU17463

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.

●Always follow the age recommendation:

– A child under 16 years old should never operate 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 paved streets.

●Never operate an ATV on any paved street, paved road or motorway.

●Watch carefully for other vehicles when operating on unpaved public streets or roads. Make sure you know your country’s laws and regulations before you ride on unpaved public streets or roads.

●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.

●Never attempt wheelies, jumps, or other stunts.

2-1

●Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

●Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.

●Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

●Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on 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 2 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

2-2

speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up-

2hill. 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 be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly.

●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 brak-

ing.

EWB00071

WARNING

Avoid Carbon Monoxide Poisoning

All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death.

Carbon Monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust. Deadly levels of carbon monoxide can collect rapidly

2-3

and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas. If you experi-

ence any symptoms of carbon monoxide 2 poisoning, leave the area immediately, get

fresh air, and SEEK MEDICAL TREATMENT.

●Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels.

●Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports.

●Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors.

EWB02591

WARNING

When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.

2-4

EBU17680

	DESCRIPTION
EBU17690	EBU17700
Left view	Right view
	1	2	3	4

3

	9		8 7 6 5
1.	Headlights	1.	Spark arrester
2.	Fuel cock	2.	Storage compartment and tool kit
3.	Recoil starter	3.	Air filter case
4.	Fuses	4.	Engine oil filler cap
5.	Battery	5.	Brake pedal
6.	Tail/brake light	6.	Clutch adjusting screw
7.	Rear shock absorber assembly spring preload adjusting	7.	Oil filter element
	ring	8.	Rear brake light switch

8.Engine oil drain bolt

9.Shift pedal

3-1

EBU17712									TIP
Controls and instruments
									The ATV you have purchased may differ slightly
2	3	4	5	6	7	8	9	10	from the figures shown in this manual.

3

1				11

1.Drive select lever

2.Rear brake lever

3.Handlebar switches

4.Parking brake lock plate

5.Horn switch

6.Starter (choke)

7.Main switch

8.Brake fluid reservoir

9.Throttle lever

10.Front brake lever 11.Fuel tank cap

3-2

EBU17733

INSTRUMENT AND CONTROL FUNCTIONS

EBU17760

Main switch

The positions of the main switch are as follows:	OFF	ON

			ON	1
			All electrical systems are supplied with power. The
	4
			headlights and taillight come on when the light
			switch is on, and the engine can be started. The
			key cannot be removed.
			OFF
			All electrical systems are off. The key can be re-	1. Main switch
			moved.

4-1

EBU17793

Indicator lights

1.Neutral indicator light “N”

2.Reverse indicator light “R”

EBU17860

Neutral indicator light “”

This indicator light comes on when the transmission is in the neutral position.

EBU17830

Reverse indicator light “”

This indicator light comes on when the transmission is in the reverse position.

EBU18061

Handlebar switches

4

1.	Light switch “	/	/OFF”
2.	Engine stop switch “		/	”

3.Start switch “ ”

4.Horn switch “ ”

EBU18080

Engine stop switch “ / ”

Set this switch to “ ” 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 “ ”.

4-2

EBU18101

Start switch “ ”

Push this switch to crank the engine with the starter. See the starting instructions on page 6-1 prior to starting the engine.

		EBU18152
		Light switch “	/	/OFF”
	4	Set this switch to “		” to turn on the low beams
		and the taillight. Set the switch to “			” to turn on

the high beams and the taillight. Set the switch to “OFF” to turn off all the lights.

ECB00041

NOTICE

Do not use the headlights with the engine turned off for an extended period of time, otherwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. See page 8-39 for battery charging information.

EBU18170

Horn switch “ ”

Press the switch to sound the horn.

EBU18282

Throttle lever

Once the engine is running, pushing 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 throttle lever is released.

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.

4-3

EBU18323

Speed limiter

Your ATV is equipped 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). Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be damaged. Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). (See page 8-27.) WARNING! Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, resulting in an accident. [EWB00241]

4

1.Locknut

2.Adjusting screw

3.No more than 12 mm (0.47 in)

3.Tighten the locknut.

EBU18391

Front brake lever

The front brake lever is located on the right handlebar. To apply the front brake, pull the brake lever toward the handlebar grip.

4-4

4

1. Front brake lever

1. Brake pedal

EBU18442

Brake pedal and rear brake lever

The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.

1. Rear brake lever

4-5