Yamaha YFM35XV User Manual

OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO

YFM35XV

3D5-F8199-60

YAMAHA MOTOR CO., LTD.

PRINTED IN USA

2006.01-0.7×2 CR

(E,F,S)

OWNER’S MANUAL

YFM35XV

3D5-F8199-60-E0

EBU17170

INTRODUCTION

EBU17320

Congratulations on your purchase of the Yamaha YFM35XV. 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 proce-

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 COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDER-

STAND ALL INSTRUCTIONS.

● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.

● 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 REC-

REATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.

EBU17330

IMPORTANT MANUAL INFORMATION

EBU17341

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

WARNING

or death to the ATV operator, a bystander, or a person inspecting or
repairing the ATV.

CAUTION:

NOTE:

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 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

YFM35XV

OWNER ’S MANUAL

©2005 by Yamaha Motor Co., Ltd.

1st edition, December 2005

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

SAFETY INFORMATION .............................. 1-1

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 lights and warning light ................ 4-2

Handlebar switches .................................... 4-3

Throttle lever .............................................. 4-4

Speed limiter .............................................. 4-4

Front brake lever ........................................ 4-5

Brake pedal and rear brake lever ............... 4-5

Parking brake ............................................. 4-6

Drive select lever ........................................ 4-7

Fuel tank cap .............................................. 4-7

Fuel ............................................................ 4-8

Fuel cock .................................................... 4-9

Starter (choke) ...........................................4-10

Seat ..........................................................4-11

Storage compartment ...............................4-12

Adjusting the front shock absorber

assemblies ..............................................4-13

Adjusting the rear shock absorber

assembly .................................................4-14

PRE-OPERATION CHECKS ..........................5-1

Pre-operation check list ..............................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

Measuring the tire pressure ........................5-5

Tire wear limit .............................................5-6

Chassis fasteners .......................................5-6

Instruments, lights and switches .................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

Engine break-in .......................................... 6-4

Parking ....................................................... 6-5

Parking on a slope ..................................... 6-5

Accessories and loading ............................ 6-6

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............. 7-9

TURNING YOUR ATV .............................. 7-12

CLIMBING UPHILL ................................... 7-14

RIDING DOWNHILL.................................. 7-17

CROSSING A SLOPE............................... 7-18

CROSSING THROUGH SHALLOW

WATER ................................................... 7-19

RIDING OVER ROUGH TERRAIN ........... 7-22

SLIDING AND SKIDDING ......................... 7-22

WHAT TO DO IF... .................................... 7-23

WHAT TO DO... ........................................ 7-23

PERIODIC MAINTENANCE AND MINOR

REPAIR .......................................................... 8-1

Owner’s manual and tool kit ....................... 8-1

Periodic maintenance and lubrication

chart ..........................................................8-3

Removing and installing the panel ..............8-7

Checking the spark plug .............................8-7

Engine oil and oil filter cartridge ..................8-9

Final gear oil .............................................8-13

Cleaning the air filter element ...................8-16

Cleaning the spark arrester ......................8-19

V-belt cooling duct check hose .................8-20

V-belt case drain plug ...............................8-20

Adjusting the carburetor ............................8-21

Adjusting the engine idling speed .............8-21

Adjusting the throttle cable free play .........8-22

Valve clearance ........................................8-23

Adjusting the drive select lever safety

system cable ...........................................8-23

Checking the front brake pads and rear

brake shoes ............................................8-23

Checking the brake fluid level ...................8-24

Changing the brake fluid ...........................8-25

Checking the front brake lever free

play .........................................................8-26

Adjusting the brake pedal and rear brake

lever free play .........................................8-26

Brake light switches ..................................8-29

Checking and lubricating the cables .........8-30

Checking and lubricating the front and

rear brake levers .................................... 8-30

Checking and lubricating the brake

pedal ...................................................... 8-31

Checking the wheel bearings ................... 8-31

Lubricating the drive shaft universal

joint ......................................................... 8-31

Lubricating the knuckle pivots .................. 8-32

Lubricating the knuckle shafts .................. 8-32

Lubricating the steering shaft ................... 8-32

Battery ...................................................... 8-32

Replacing a fuse ...................................... 8-34

Replacing a headlight bulb ....................... 8-35

Adjusting a headlight beam ...................... 8-37

Replacing the tail/brake light bulb ............ 8-37

Removing a wheel .................................... 8-38

Installing a wheel ...................................... 8-39

Troubleshooting ....................................... 8-40

Troubleshooting chart .............................. 8-41

CLEANING AND STORAGE.......................... 9-1

Cleaning ..................................................... 9-1

Storage ....................................................... 9-2

SPECIFICATIONS .......................................10-1

CONSUMER INFORMATION.......................11-1

Identification numbers ...............................11-1

EBU17430

SAFETY INFORMATION

EBU17533

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 fol-

low 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.

1

● 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 operat-

ing 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 ap-

proved 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.

1-1

● Always inspect your ATV each time you use it to

make sure it is in safe operating condition. Al-

1

ways 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 op-

erating 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
throttle suddenly. 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, maintain a steady speed when climbing a

1-2

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 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 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 de-

scribed in this manual.

● Never modify an ATV through improper installa-

tion 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. Al­low greater distance for braking.

EWB00061

WARNING

● Always turn off the engine when refueling.

● Do not refuel right after the engine has been

running and is still very hot.

● Do not spill gasoline on the engine or ex-

haust pipe/muffler when refueling. Never re­fuel while smoking, or in the vicinity of
sparks, open flames, or other sources of ig­nition such as the pilot lights of water heat­ers and clothes dryers. Gasoline can catch
fire and you could be burned.

1

1-3

● When transporting the ATV in another vehi-

cle, be sure it is kept upright and that the fuel

1

cock is in the “OFF” position. Otherwise, fuel
may leak out of the carburetor or fuel tank.

● Gasoline is poisonous. If you should swal-

low 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.

EWB00070

WARNING

Always operate your ATV in an area with ade­quate ventilation. Never start or run the engine
in a closed area. Exhaust fumes are poisonous
and may cause loss of consciousness and
death within a short time.

1-4

EBU17660

LOCATION OF THE WARNING AND SPECIFICATION LABELS

2

2-1

EBU17670

Read and understand all of the labels on your ATV. These labels contain important information for safe and
proper operation.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace-

2

ment label from your Yamaha dealer.

2-2

2-323-1

EBU17680

DESCRIPTION

EBU17690

Left view

3

1. Front shock absorber assembly spring preload adjusting
ring

2. Fuel cock

3. Air filter case

4. Fuses

5. Storage compartment and tool kit

6. Seat lock lever

7. Rear shock absorber assembly spring preload adjusting
ring

8. Engine oil dipstick

9. Oil filter cartridge

10.V-belt cooling duct check hose

EBU17700

Right view

1. Spark arrester

2. Tail/brake light

3. Spark plug

4. Front shock absorber assembly spring preload adjusting
ring

5. Brake pedal

6. V-belt case

EBU17712

Controls and instruments

1. Rear brake lever

2. Left handlebar switches

3. Starter (choke)

4. Drive select lever

5. Main switch

6. Fuel tank cap

7. Front brake lever

8. Throttle lever

NOTE:

The ATV you have purchased may differ slightly
from the figures shown in this manual.

3

3-2

EBU17730

INSTRUMENT AND CONTROL FUNCTIONS

EBU17760

Main switch

The positions of the main switch are as follows:

ON

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 re­moved.

1. Main switch

4-1

EBU17811

Indicator lights and warning light

1. Reverse indicator light “R”

2. Neutral indicator light “N”

3. Oil temperature warning light “”

EBU17830

Reverse indicator light “”

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

EBU17860

Neutral indicator light “”

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

EBU26931

Oil temperature warning light “”

This warning light comes on when the engine over­heats. When this occurs, stop the engine as soon
as it is safe to do so, and allow it to cool.
The electrical circuit of the warning light can be
checked by turning the key to “ON”, with the engine
stop switch set to “”, and then pushing the start
switch.
If the warning light does not come on while the start
switch is being pushed, then go off after the start
switch is released, have a Yamaha dealer check
the electrical circuit.
If the warning light stays on, allow the engine to
cool. If the warning light stays on when the engine
is cool, have a Yamaha dealer check the electrical
circuit.

ECB00010

CAUTION:

● The engine may overheat if the ATV is over-

loaded. In this case, reduce the load to spec­ification.

● Start the engine after making sure that the

warning light is out. Continuous use while
the warning light is on may cause damage to
the engine.

4

4-2

EBU18060

Handlebar switches

4

1. Light switch “ / /OFF”

2. Engine stop switch “ / ”

3. Start 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 “”.

EBU18100

Start switch “”

Push this switch to crank the engine with the start­er.

ECB00050

CAUTION:

See the starting instructions on page 6-1 prior
to starting the engine.

EBU18151

Light switch “ //OFF”

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.

ECB00040

CAUTION:

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.

4-3

EBU18280

Throttle lever

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.

EWB00250

WARNING

Malfunction of the throttle could make it diffi­cult to speed up or slow down when you need
to. This could cause an accident. Check the op­eration of the throttle lever before you start the
engine. If the throttle does not work smoothly,
check for the cause. Correct the problem be­fore riding the ATV or consult a Yamaha dealer.

EBU18321

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).

4

4-4

4

1. Locknut

2. Adjusting screw

3. No more than 12 mm (0.47 in)

3. Tighten the locknut.

EWB00240

WARNING

Improper adjustment of the speed limiter and
throttle could cause throttle cable damage or
improper throttle operation. You could lose
control, have an accident or be injured. 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 8-22.)

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.

1. Front brake lever

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.

4-5

1. Brake pedal

1. Rear brake lever

EBU18460

Parking brake

Use the parking brake before starting the engine or
parking the ATV, especially on a slope. Apply the
rear brake lever and push down the lock plate to
apply the parking brake. Squeeze the rear brake
lever to release the parking brake.

4

1. Parking brake lock plate

EWB00220

WARNING

● Always set the parking brake before starting

the engine. The ATV could start moving un­expectedly if the parking brake is not ap­plied. This could cause loss of control or a
collision.

4-6

● Always be sure you have released the park-

ing brake before you begin to ride. 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.

4

EBU18581

Drive select lever

The drive select lever is used to shift your ATV into
the forward, neutral and reverse positions. See the
“Operating the drive select lever and driving in re­verse” section on page 6-3 for the drive select lever
operation.

1. Drive select lever

EBU18720

Fuel tank cap

Remove the fuel tank cap by turning it counter­clockwise.

4-7

1. Fuel tank cap 1. Fuel level

EBU18750

Fuel

Make sure that there is sufficient fuel in the tank.
Fill the fuel tank to the bottom of the filler tube as
shown.

2. Fuel tank filler tube

Recommended fuel:

UNLEADED GASOLINE ONLY
For Europe: Regular unleaded gasoline only
with a research octane number of 91 or high­er

Fuel tank capacity:

14.5 L (3.83 US gal) (3.19 Imp.gal)

Fuel reserve amount:

4.5 L (1.19 US gal) (0.99 Imp.gal)

4-8

4

NOTE:

If knocking or pinging occurs, use a different brand
of gasoline or higher octane grade.

ECB00070

CAUTION:

Use only unleaded gasoline. The use of leaded
gasoline will cause severe damage to internal

4

engine parts, such as the valves and piston
rings, as well as to the exhaust system.

EWB00310

WARNING

● Do not overfill the fuel tank. 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.

● Be careful not to spill fuel, especially on the

engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.

● Do not refuel right after the engine has been

running and is still very hot.

● Be sure the fuel tank cap is closed securely.

EBU18820

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

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.

4-9

ON

1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES”

RES

4

With the fuel cock lever in this position, fuel flows
to the carburetor. Turn the fuel cock lever to this
position when starting the engine and riding.

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”!

EBU18850

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
the starter (choke).

4-10

Move the starter (choke) in direction (b) to turn off
the starter (choke).
See the “Starting a cold engine” section on page
6-1 for proper operation.

4

1. Starter (choke) “”

EBU26981

Seat

To remove the seat

Push the seat lock lever backward and pull up the
seat at the rear.

1. Seat

1. Seat lock lever

4-11