Page 99 of 140

8-20
8
7. Check the oil filler bolt gasket for damage, and
replace it if necessary.
8. Install the oil filler bolt and its gasket, and then
tighten the bolt to the specified torque.9. Check the final gear case for oil leakage. If oil
is leaking, check for the cause.
10. Install the final gear case guard by installing
the bolts and tightening them to the specified
torque.
EBU23686Cleaning the air filter element The air filter element should be cleaned at the in-
tervals specified in the periodic maintenance and
lubrication chart. Clean or, if necessary, replace
the air filter element more frequently if you are
riding in unusually wet or dusty areas.TIPThere is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-
ter case.
1. Final gear oil filler bolt
2. Gasket
3. Final gear oil
4. Correct oil levelRecommended final gear oil:
See page 10-1.
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
1
2
4
3
Tightening torque:
Final gear case guard bolt:
17 Nm (1.7 m·kgf, 12 ft·lbf)
U1P066E0.book Page 20 Thursday, August 5, 2010 4:15 PM
Page 109 of 140

8-30
8
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.EBU24281Changing the brake fluid Have a Yamaha dealer change the brake fluid at
the intervals specified in the TIP after the periodic
maintenance and lubrication chart. In addition,have the oil seals of the brake master cylinder 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.EBU24394Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have no
free play as shown. If there is free play, have a
Yamaha dealer check the brake system. Recommended brake fluid:
DOT 41. No brake lever free play
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Page 118 of 140

8-39
8
EBU30350Battery The battery is located behind the seat.
A poorly maintained battery will corrode and dis-
charge quickly. The electrolyte level, battery lead
connections and breather hose routing should be
checked before each ride and at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
WARNING
EWB02160Battery 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.KEEP OUT OF REACH OF CHILDREN.
To check the electrolyte level
1. Place the ATV on a level surface.
2. Remove the battery cover by pulling it upward.
3. Check the electrolyte level in the battery.1. Battery cover
U1P066E0.book Page 39 Thursday, August 5, 2010 4:15 PM
Page 132 of 140
10-1
10
EBU25960
SPECIFICATIONS
Dimensions:Overall length:
1916 mm (75.4 in)
Overall width:
1038 mm (40.9 in)
Overall height:
1118 mm (44.0 in)
Seat height:
772 mm (30.4 in)
Wheelbase:
1170 mm (46.1 in)
Ground clearance:
150 mm (5.9 in)
Minimum turning radius:
2900 mm (114 in)Weight:With oil and fuel:
216.0 kg (476 lb)Noise and vibration level:Noise level (77/311/EEC):
YFM25BA 77.5 dB(A)
Vibration on seat (EN1032, ISO5008):
YFM25BA Will not exceed 0.5 m/s²
Vibration on handlebar (EN1032, ISO5008):
YFM25BA Will not exceed 2.5 m/s²Engine:Engine type:
Air cooled 4-stroke, SOHCCylinder arrangement:
Forward-inclined single cylinder
Displacement:
229 cm³
Bore × stroke:
71.0 × 58.0 mm (2.80 × 2.28 in)
Compression ratio:
8.70 :1
Starting system:
Electric and recoil starter
Lubrication system:
Wet sump
Engine oil:Recommended brand:
YAMALUBE
U1P066E0.book Page 1 Thursday, August 5, 2010 4:15 PM
Page 138 of 140

INDEX
AAccessories and loading ................................................ 6-8
Air filter element, cleaning ............................................ 8-20BBattery ................................................................... 5-6, 8-39
Brake fluid, changing .................................................... 8-30
Brake fluid level, checking ............................................ 8-29
Brake lever free play, checking the front ...................... 8-30
Brake lever, front ............................................................ 4-4
Brake levers, checking and lubricating ......................... 8-36
Brake light switches ..................................................... 8-34
Brake pads and shoes, checking ................................. 8-28
Brake pedal and rear brake lever ................................... 4-5
Brake pedal, checking and lubricating ......................... 8-37
Brake pedal height and free play, and rear brake lever
free play, adjusting ..................................................... 8-31
Brakes .......................................................................... 8-28
Brakes, front and rear .................................................... 5-3CCables, checking and lubricating ................................. 8-35
Carburetor, adjusting .................................................... 8-25
Carrier, front ................................................................. 4-13
Carrier, rear .................................................................. 4-13
Chassis fasteners ........................................................... 5-6
Cleaning ......................................................................... 9-1
Clutch free play, adjusting ............................................ 8-35DDrive select lever ............................................................ 4-7Drive select lever and driving in reverse ........................ 6-3
Drive select lever safety system cable, adjusting ......... 8-28
EEngine break-in .............................................................. 6-6
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-26
Engine oil ....................................................................... 5-3
Engine oil and oil filter element .................................... 8-11
Engine, starting a warm ................................................. 6-3
Engine stop switch ......................................................... 4-2FFinal gear oil .......................................................... 5-3, 8-18
Fuel ......................................................................... 4-8, 5-3
Fuel cock ........................................................................ 4-9
Fuel tank cap .................................................................. 4-7
Fuse, replacing ............................................................. 8-42HHandlebar switches ........................................................ 4-2
Headlight beam, adjusting ............................................ 8-45
Headlight bulb, replacing .............................................. 8-43
Horn switch .................................................................... 4-3IIdentification numbers .................................................. 11-1
Indicator lights ................................................................ 4-2
Instruments, lights and switches .................................... 5-6LLabel locations ............................................................... 1-1
Light switch .................................................................... 4-3
U1P066E0.book Page 1 Thursday, August 5, 2010 4:15 PM