5-1
1
2
3
45
6
7
8
9
10
11
EBU19200
PRE-OPERATION CHECKS
EBU19222
Pre-operation check list
Before operating this ATV, be sure to check the items listed in the following table.
WARNING
EWB00480
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 the Owner’s
Manual. Failure to inspect increases the possibility of an accident or equipment damage.
NOTE:
The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic
maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
ITEM ROUTINE PAGE
Fuel
Check fuel level in fuel tank, and add recommended fuel if neces-
sary.
Check fuel line for leakage. Correct if necessary.4-7, 5-3
Engine oil
Check oil level in engine, and add recommended oil to specified
level if necessary.
Check ATV for oil leakage. Correct if necessary.5-3, 8-10
Front brake
Check operation. If soft or spongy, have Yamaha dealer bleed
hydraulic system.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-3, 8-22, 8-23, 8-26
5-3
1
2
3
45
6
7
8
9
10
11
EBU19540
Fuel
Make sure that there is sufficient fuel in the tank.
(See page 4-7.)
WARNING
EWB00520
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 en-
gine 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.
EBU19560
Engine oil
Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-10.)
EBU19710
Front and rear brakes
Brake lever and brake pedal
Check that there is no free play in the brake le-
ver. If there is free play, have a Yamaha dealer
check the brake system.
Check for correct brake pedal height. (See
page 8-26.) If the pedal height is incorrect, have
a Yamaha dealer adjust it.
Check the operation of the lever and pedal. They
should move smoothly and there should be a
firm feeling when the brakes are applied. If not,
have a Yamaha dealer check the brake system.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See page 8-23.)
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or brake fluid reservoirs. Apply the
brakes firmly for one minute. If there is any leak-
age, have a Yamaha dealer check the brake sys-Recommended brake fluid:
DOT 4
8-13
1
2
3
4
5
6
78
9
10
11
8. Install the oil filter element and O-ring.
NOTE:
Make sure that the O-ring is properly seated.
9. Install the oil filter element cover by installing
the bolts, and then tighten them to the speci-
fied torque.10. Install the engine oil drain bolt and tighten it to
the specified torque.CAUTION:
ECB00320
Before installing the engine oil drain bolt, be
sure to install the O-ring, compression spring
and oil strainer.
11. Add the specified amount of the recommend-
ed engine oil, and then install and tighten the
engine oil filler cap.
NOTE:
Be sure to wipe off spilled oil on any parts after the
1. Oil filter element
2. O-ring
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
2
2
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
Recommended oil:
See page 10-1.
Oil quantity:
Without oil filter element replacement:
1.25 L (1.32 US qt) (1.10 Imp.qt)
With oil filter element replacement:
1.35 L (1.43 US qt) (1.19 Imp.qt)
8-25
1
2
3
4
5
6
78
9
10
11
3. Refill with brake fluid.
4. Install the brake fluid reservoir cap.
5. Install the brake fluid reservoir cap cover by
installing the bolt.
Observe these precautions:
When checking the fluid level, make sure that
the top of the brake fluid reservoir is level.
Use only the recommended quality brake fluid,
otherwise the rubber seals may deteriorate,
causing leakage and poor braking performance.
Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor braking performance.
Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and may
result in vapor lock.
Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid imme-
diately.
As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.
EBU24290
Changing the brake fluid
Have a Yamaha dealer change the brake fluid at
the intervals specified in the NOTE after the peri-
odic maintenance and lubrication chart. In addi-
tion, have the oil seals of the master cylinders and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.
1. Brake fluid reservoir cap
Recommended brake fluid:
DOT 4
1
8-33
1
2
3
4
5
6
78
9
10
11
the drive chain with steam cleaners, high-pres-
sure washers or inappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a
special O-ring chain lubricant.
CAUTION:
ECB00580
Do not use engine oil or any other lubricants
for the drive chain, as they may contain sub-
stances that could damage the O-rings.
EBU24900
Checking and lubricating the cables
The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
WARNING
EWB02130
Inspect cables frequently and replace if dam-aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could re-
strict the operation of controls and lead to an
accident or injury.
EBU24921
Checking and lubricating the brake and
clutch levers
The operation of the brake and clutch levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary.
Recommended lubricant:
Engine oil
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease (all-purpose
grease)
8-36
1
2
3
4
5
6
78
9
10
11
Right side
EBU25100
Lubricating the steering shaft
The steering shaft must be lubricated at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU25222
Battery
This model is equipped with a sealed-type (MF)battery, which does not require any maintenance.
There is no need to check the electrolyte or to add
distilled water. Check and, if necessary, tighten the
battery lead connections.CAUTION:
ECB00620
Never attempt to remove the battery cell seals,
as this would permanently damage the battery.WARNING
EWB02160
Battery electrolyte is poisonous and danger-
ous, as it contains sulfuric acid, which can
cause severe burns. Avoid contact with skin,
eyes or clothing. Always shield your eyes
when working near batteries.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg
or vegetable oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of ig-
nition away. Ventilate when charging or using
in an enclosed space.
1. Upper grease nipple
2. Lower grease nipple
Recommended lubricant:
Lithium-soap-based grease
1
2
10-1
1
2
3
4
5
6
7
8
910
11
EBU25960
SPECIFICATIONS
EBU2597A
Dimensions:
Overall length:
1625 mm (64.0 in)
Overall width:
1070 mm (42.1 in)
Overall height:
1040 mm (40.9 in)
Seat height:
730 mm (28.7 in)
Wheelbase:
1110 mm (43.7 in)
Ground clearance:
100 mm (3.9 in)
Minimum turning radius:
2900 mm (114 in)
Weight:
With oil and fuel:
150.0 kg (331 lb)
Engine:
Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
249.0 cm
3
Bore
×
stroke:
74.0
×
58.0 mm (2.91
×
2.28 in)
Compression ratio:
9.50 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:
Type:
SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SG type or higher, JASO standard MA
-20˚-10˚0˚
10˚20˚30˚40˚50˚C
10W/30
15W/4020W/4020W/50
10W/40
5W/30
10-2
1
2
3
4
5
6
7
8
910
11
Engine oil quantity:
Without oil filter element replacement:
1.25 L (1.32 US qt) (1.10 Imp.qt)
With oil filter element replacement:
1.35 L (1.43 US qt) (1.19 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Regular unleaded gasoline only (EUR)
Unleaded gasoline only (AUS)(NZL)
Fuel tank capacity:
9.0 L (2.38 US gal) (1.98 Imp.gal)
Fuel reserve amount:
1.0 L (0.26 US gal) (0.22 Imp.gal)
Carburetor:
Manufacturer:
MIKUNI
Type x quantity:
BSR29 x 1
Spark plug (s):
Manufacturer/model:
NGK/DR7EA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc
Operation:
Left hand operation
Transmission:
Primary reduction system:
Spur gear
Primary reduction ratio:
76/22 (3.455)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
38/14 (2.714)
Transmission type:
Constant mesh 5-speed
Operation:
Left foot operation
Gear ratio:
1st:
37/13 (2.846)
2nd:
33/18 (1.833)
3rd:
29/21 (1.381)
4th:
27/24 (1.125)
5th:
28/29 (0.966)
Chassis:
Frame type:
Steel tube frame
Caster angle:
6.0 °
Trail:
23.0 mm (0.91 in)