Yamaha YFM35XY 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
YFM35XY
3D5-F8199-63
YAMAHA MOTOR CO., LTD.
PRINTED IN USA
2008.05-0.3×1 CR
(E,F,S)
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM35XY
3D5-F8199-63-E0
EBU29190
Read this manual carefully before operating this vehicle. This manual should stay with this ve-
hicle if it is sold.
EC Declaration of Conformity
conforming to Directive 98/37/
We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,
declare in sole responsibility, that the product
YFM350AS (5Y4AH14W080502401~)
to which this declaration applies, conforms to the essential health
and safety requirements of Directive 98
(
)
If applicable
and to the other relevant Directives of EEC
(
/
or number and date of issue of the other Directives of EEC
Title and
(
)
If applicable
To effect correct
stated in the Directives of EEC, the
specifications were consulted:
(
/
or number and date of issue of standards and/or specifications
Title and
Manufacturer
YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA
Newnan, Georgia 30265-1320, U.S.A.
Authorized Representative
YAMAHA MOTOR EUROPE N.V.
Koolhovenlaan 101, 1119NC Schiphol-Rijk, The Netherlands
(
Make, model
89/336/EEC or 2004/108/EC
application
of the
EN292 ANSI/SVIA 1-2007
Signature
General Manager
RV Engineering Division
RV Company
Date of Issue
EC
)
/37/
EC,
)
essential
health
following-standards and/or
and safety requirements
Shinya Shimada
26 March, 2008
technical
)
EBU17170
INTRODUCTION
EBU17321
Congratulations on your purchase of the Yamaha YFM35XY. 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 NOTICE 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
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 personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
WARNING
NOTICE
TIP
A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
* Product and specifications are subject to change without notice.
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IMPORTANT NOTICE
EBU17370
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
YFM35XY
OWNER’S MANUAL
©2008 by Yamaha Motor Co., Ltd.
1st edition, April 2008
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 chart for
the emission control system .....................8-3
General maintenance and lubrication
chart ..........................................................8-5
Removing and installing the panel ..............8-8
Checking the spark plug .............................8-8
Engine oil and oil filter cartridge ................8-10
Final gear oil .............................................8-14
Cleaning the air filter element ...................8-17
Cleaning the spark arrester ......................8-21
V-belt cooling duct check hose .................8-22
V-belt case drain plug ...............................8-22
Adjusting the carburetor ............................8-23
Adjusting the engine idling speed .............8-23
Adjusting the throttle cable free play .........8-24
Valve clearance ........................................8-25
Adjusting the drive select lever safety
system cable ...........................................8-25
Checking the front brake pads and rear
brake shoes ............................................8-25
Checking the brake fluid level ...................8-26
Changing the brake fluid ...........................8-27
Checking the front brake lever free play ...8-28
Adjusting the brake pedal and rear brake
lever free play and checking the brake
pedal position ..........................................8-28
Axle boots .................................................8-32
Brake light switches ................................. 8-32
Checking and lubricating the cables ........ 8-32
Checking and lubricating the front and
rear brake levers .................................... 8-33
Checking and lubricating the brake
pedal ...................................................... 8-33
Checking the wheel hub bearings ............ 8-34
Lubricating the steering shaft ................... 8-34
Battery ...................................................... 8-34
Replacing a fuse ...................................... 8-37
Replacing a headlight bulb ....................... 8-38
Adjusting a headlight beam ...................... 8-40
Replacing the tail/brake light bulb ............ 8-40
Removing a wheel .................................... 8-41
Installing a wheel ...................................... 8-42
Troubleshooting ....................................... 8-43
Troubleshooting chart .............................. 8-44
CLEANING AND STORAGE.......................... 9-1
Cleaning ..................................................... 9-1
Storage ....................................................... 9-2
SPECIFICATIONS ...................................... 10-1
CONSUMER INFORMATION ...................... 11-1
Identification numbers .............................. 11-1
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SAFETY INFORMATION
EBU17534
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.
1
● 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 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 filler cap
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. Rear brake light switch
6. Brake pedal
7. V-belt case
EBU17712
Controls and instruments
1. Rear brake lever
2. Handlebar switches
3. Starter (choke)
4. Drive select lever
5. Main switch
6. Fuel tank cap
7. Front brake lever
8. Throttle lever
TIP
The ATV you have purchased may differ slightly
from the figures shown in this manual.
3
3-2
EBU17732
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
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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.
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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
NOTICE
● 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
EBU18061
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
NOTICE
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
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.
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 8-24.)
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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
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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
EBU18752
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
TIP
If knocking or pinging occurs, use a different brand
of gasoline or higher octane grade.
ECB00070
NOTICE
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
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