YFM250RX

ASSEMBLY MANUAL

LIT-11666-21-22 4D3-28107-10
EBA00002

FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha vehi-
cle prior to delivery to the customer. Since some external parts of the vehicle have been removed at
the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It
should be noted that the assembled vehicle should be thoroughly cleaned, checked, and adjusted
prior to delivery to the customer.

EBA00003

NOTICE
The service specifications given in this assembly manual are based on the model as manufactured.
Modifications and significant changes in specifications and/or procedures will be forwarded to autho-
rized Yamaha dealers.
The procedures below are described in the order that the procedures are carried out correctly and
completely. Failure to do so can result in poor performance and possible harm to the vehicle and/or
rider.

CONCERNING CRATE DAMAGE:

Follow the instructions in the Dealer Warranty Handbook, Procedure Section.

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 or death to

the vehicle operator, a bystander, or a person checking or repairing the vehicle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EBA00001

YFM250RX
ASSEMBLY MANUAL
©2007 by Yamaha Motor Corporation,
U.S.A. First Edition, June 2007
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11666-21-22
 EBA01001

(1) (2) SYMBOLS USED IN THE

ASSEMBLY MANUAL
In order to simplify descriptions in this
assembly manual, the following symbols
are used:
(1): Filling fluid
(3) (4) (2): Lubricant
(3): Special tool
(4): Tightening torque
(5): Wear limit, clearance
(6): Engine speed
(7): Electrical data
(8): Coat with lithium-soap-based grease.
(5) (6) (9): Tighten to 10 Nm.
(10 Nm = 1.0 m•kg, 7.4 ft•lb)
(10): Towards the front of the vehicle
(11): Clearance required
(12): Install so that the arrow mark faces
upward.
(13): Apply motor oil.
(7) (8) (14): Made of rubber or plastics
(15):
A: Ref. No. (indicating the order of
operations.)
B: Part name
C: Quantity of parts per vehicle
D: Place where parts are held
(9) (10)
(1): Refer to “PARTS LOCA-
TION”.
V: Stored in Vinyl bag
C: Stored in carton box
S Fixed inside the steel frame
and/or contained in the Sty-
(11) (12) rofoam tray (upper or lower)
: Temporarily installed or
secured
Example:
(1)-V
(1) signifies the location of the
parts and V signifies that the part
(13) (14) is stored in a plastic bag.
E: Size or material of parts
d/D: Diameter of part
: Length of part
e.g., 5 = 5 mm (0.2 in)

(15)
 EBA00006

PREPARATION
To assemble the vehicle correctly, supplies
(e.g. oils, greases, and shop rags) and suf-
ficient working space are required.
Workshop
The workshop where the vehicle is assem-
bled should be clean, spacious, and have
a level floor.
Self-protection
Protect your eyes with suitable safety
glasses or goggles when using com-
pressed air, when grinding or when doing
any operation which may cause particles
to fly off.
Protect hands and feet by wearing safety
gloves and shoes.

EBA00007
(1) (2) SYMBOLS USED ON
TRANSPORT PACKAGE
COVER
(1) Contents of the transport package are
fragile, therefore the package must be
handled with care.
(3) (4) (2) Indicates correct upright position of the
transport package.
(3) Transport package must be kept away
from rain.
(4) Do not step anywhere on the transport
package.
(5) Up to 9 of the transport packages can
(5) (6)
be piled up.
(6) Only stack this unit with transport
packages of the same size.
(7) Made of high-density polyethylene.
(8) Yellow labels
Lift arm insertion positions
(7) If the forklift arms cannot be inserted
under the transport package in align-
ment with the two yellow labels, adjust
the arms so that they are positioned
evenly in relation to these marks while
taking care not to damage the package
contents.
EBA00008

UNPACKING
1. Open the zipper (1), and then remove
the plastic cover.

2. Remove the bolts (2), bolts (3), bracket

(4) and washers (steering stem).

Keep bolts (3) for installation.

3. Remove the packing frames (5). (Lift up

and then move to the side.)

Remove the bolts while holding the frame.

4. Remove the bolt (6) and nut (7) (right

footrest).

5. Remove the bolt (8) and nut (9) (left

footrest).

–1–
EBA00009

PARTS LOCATION
(1) Bubble wrap pack 1
(2) Bubble wrap pack 2
(3) Carton box 1
(4) Carton box 2
(5) Rear wheels
(6) Front wheels

(A) Left view

(B) Right view

–2–
EBA00010

(1) Bubble wrap pack 1

1. Clutch and parking brake lever assem-
bly
2. Vinyl bag
3. Bracket (clutch and parking brake lever
assembly)
4. Bolts (clutch and parking brake lever
assembly)
[d = 5 (0.20), = 16 (0.63)]

(2) Bubble wrap pack 2

1. Front brake master cylinder
2. Vinyl bag
3. Bracket (front brake master cylinder)
4. Flange bolts (front brake master cylin-
der)
[d = 6 (0.24), = 22 (0.87)]
5. Flange bolts (front shock absorbers)
[d = 10 (0.39), = 48 (1.89)]

(3) Carton box 1

1. Handlebar protector
2. Front bumper
3. Battery cover

–3–
(4) Carton box 2
1. Left foot protector
2. Right foot protector
3. Front brake disc guards
4. Vinyl bag
5. Engine skid plate
6. Vinyl bag
7. Swingarm end cover
8. Rear carrier bar
9. Owner’s manual
10.Safety hand book
11.Tag warning
12.Tag NER (Normalized Emissions Rat-
ing)
13.Vinyl bag
14.Owner's tool kit
15.Fuel tank breather hose
16.Rear fender stays
17.Swingarm end cover plate
18.Vinyl bag
19.Plastic bands (handlebar)
20.Low-pressure air gauge
21.Vinyl bag
22.Flange nuts (front and rear wheels)
[d = 10 (0.39)]
23.Flange bolts (swingarm end cover)
[d = 6 (0.24), = 14 (0.55)]
24.Flange bolts (left and right foot protec-
tors)
[d = 8 (0.31), = 16 (0.63)]
25.Flange bolts (left and right foot protec-
tors)
[d = 8 (0.31), = 25 (0.98)]
26.Flange nuts (left and right foot protec-
tors)
[d = 8 (0.31)]
27.Washers (left and right foot protectors)
[d = 8 (0.31), D = 20 (0.79)]
28.Flange bolts (engine skid plate)
[d = 6 (0.24), = 16 (0.79)]
29.Flange bolts (front bumper)
[d = 8 (0.31), = 12 (0.47)]
30.Flange bolts (rear carrier bar)
[d = 8 (0.31), = 14 (0.55)]
31.Hexagon socket bolts (rear fender
stays)
[d = 6 (0.24), = 16 (0.63)]
32.Flange nuts (rear fender stays)
[d = 6 (0.24)]
33.Flange bolts (battery cover)
[d = 6 (0.24), = 16 (0.63)]
34.Nuts (front shock absorbers)
[d = 10 (0.39)]
35.Washers (front shock absorbers)
[d = 11 (0.43), D = 22 (0.87)]
36.Plug (frame rear end)

–4–
(5) Rear wheels
1. Rear wheels

(6) Front wheels

1. Front wheels

–5–
EBA00012

SETUP PROCEDURES
• After opening the crate, place the ATV on a suitable rack and follow the setup procedures.
• Before starting the setup, supply the specified tire pressure to the four wheels.

This model is equipped with low pressure tires. Refer to “ADJUSTMENTS AND PREDELIVERY SERVICE”.

Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.

–6–
 EBA00028

1. FRONT SHOCK
ABSORBERS
A: Install the flange bolts from
front to rear.
B: Tighten the nuts to specifica-
tion.

Nut
48 Nm
(4.8 m•kg, 35 ft•lb)

1 Front shock absorber 2

2 Flange bolt 4 d = 10 (0.39), = 48 (1.89)
3 Washer 2 d = 10 (0.39), D = 22 (0.87)
4 Self-locking nut 4 d = 10 (0.39)

EBA00033

2. FRONT WHEELS
A: Install the wheels so that the
air valves are facing out.
B: The arrow mark on the tire
must point toward the rotating
direction of the wheel.
C: Tighten the nuts to specifica-
tion.

Nut
45 Nm
(4.5 m•kg, 33 ft•lb)

1 Front brake disc guard 2 (4)-C

2 Front wheel 2 (6)-S
3 Flange nut 8 (4)-V d = 10 (0.39)

EBA00034

3. REAR WHEELS
A: Install the wheels so that the
air valves are facing out.
B: The arrow mark on the tire
must point toward the rotating
direction of the wheel.
C: Tighten the nuts to specifica-
tion.

Nut
45 Nm
(4.5 m•kg, 33 ft•lb)

1 Rear wheel 2 (5)-S

2 Flange nut 8 (4)-V d = 10 (0.39)

–7–
 EBA00013

4. HANDLEBAR
A: Install the handlebar from the
horizontal line shown in the
illustration.
B: Install each handlebar holder
with its punch mark facing for-
ward.

First tighten the bolts on the

front side, and then tighten the
bolts on the rear side.

1 Handlebar 1 C: Tighten the bolts to specifica-

2 Handlebar holder 2 tion.
3 Flange bolt 4 d = 8 (0.31), = 30 (1.18)
Bolt
20 Nm
(2.0 m•kg, 15 ft•lb)

EBA00015 C: Check the brake lever for

5. FRONT BRAKE smooth action.
MASTER CYLINDER
A: Fit the master cylinder projec-
Proper hose routing is essen-
tion into the collar indent.
tial to assure safe vehicle oper-
B: Tighten the bolts to specifica-
ation. Refer to “CABLE
tion.
ROUTING”.
Bolt
7 Nm
(0.7 m•kg, 5.2 ft•lb)

• Make sure that the “UP” mark

1 Front brake master cylinder 1 (2)-S on the bracket is pointed
2 Bracket 1 (2)-V upwards.
3 Flange bolt 2 (2)-V d = 6 (0.24), = 22 (0.87) • Install the brake lever at 10
degrees angle as shown.
• First tighten the bolt on the
upper side of the master cylin-
der bracket, and then tighten
the bolt on the lower side.

6. CLUTCH AND PARKING

BRAKE LEVER Proper cable routing is essen-
ASSEMBLY tial to assure safe vehicle oper-
A: Install the clutch and parking ation. Refer to “CABLE
brake lever assembly as ROUTING”.
shown.
(a) 53 ~ 54 mm (2.09 ~ 2.13 in)
B: Tighten the bolts to specifica-
tion.

Bolt
4 Nm
(0.4 m•kg, 3.0 ft•lb)
1 Clutch and parking brake lever 1 (1)-S
assembly
2 Bracket 1 (1)-V Install the clutch lever at 10
3 Bolt 2 (1)-V d = 5 (0.20), = 16 (0.63) degrees angle as shown.

C: Check the clutch lever for

smooth operation.

–8–
 7. CABLE TIES
(HANDLEBAR)
A: Fasten the handlebar switch
lead and clutch switch lead at
the bends in the handlebar
with two plastic bands.
B: Fasten the front brake light
switch lead at the bend in the
handlebar with a plastic band.

Refer to “CABLE ROUTING”.

1 Plastic band 3 (4)-V

8. HANDLEBAR
PROTECTOR
A: Pass the fuel tank breather
hose through the hole on the
handlebar cover.

1 Handlebar protector 1 (3)-C

2 Fuel tank breather hose 1 (4)-V

EBA00032

9. SWINGARM END
COVER
A: Tighten the bolts to specifica-
tion.

Bolt
9 Nm
(0.9 m•kg, 6.6 ft•lb)

1 Swingarm end cover 1 (4)-C

2 Plate 1 (4)-V
3 Flange bolt 4 (4)-V d = 6 (0.24), = 14 (0.55)

–9–
 EBA00037

10. LEFT FOOT

PROTECTOR
A: Tighten the bolt to specifica-
tion.

Bolt
17 Nm
(1.7 m•kg, 13 ft•lb)

B: Tighten the nut to specifica-

tion.

Nut
1 Left foot protector 1 (4)-C 17 Nm
2 Flange bolt 1 (4)-V d = 8 (0.31), = 16 (0.63)
(1.7 m•kg, 13 ft•lb)
3 Flange bolt 2 (4)-V d = 8 (0.31), = 25 (0.98)
4 Flange nut 2 (4)-V d = 8 (0.31)
5 Washer 3 (4)-V d = 8 (0.31), D = 20 (0.79)

EBA00037

11. RIGHT FOOT

PROTECTOR
A: Tighten the bolt to specifica-
tion.

Bolt
17 Nm
(1.7 m•kg, 13 ft•lb)

B: Tighten the nut to specifica-

tion.

Nut
1 Right foot protector 1 (4)-C 17 Nm
2 Flange bolt 1 (4)-V d = 8 (0.31), = 16 (0.63)
(1.7 m•kg, 13 ft•lb)
3 Flange bolt 2 (4)-V d = 8 (0.31), = 25 (0.98)
4 Flange nut 2 (4)-V d = 8 (0.31)
5 Washer 3 (4)-V d = 8 (0.31), D = 20 (0.79)

EBA00039

12. ENGINE SKID PLATE

A: Tighten the bolts to specifica-
tion.

Bolt
7 Nm
(0.7 m•kg, 5.2 ft•lb)

1 Engine skid plate 1 (4)-C

2 Flange bolt 4 (4)-V d = 6 (0.24), = 16 (0.79)

–10–
 13. FRONT BUMPER
A: Tighten the bolts to specifica-
tion.
a

Bolt
31 Nm
(3.1 m•kg, 23 ft•lb)

1 Front bumper 1 (3)-C

2 Flange bolt 4 (4)-V d = 8 (0.31), = 12 (0.47)

14. REAR CARRIER BAR

A: Tighten the bolt to specifica-
tion.

Bolt
34 Nm
(3.4 m•kg, 25 ft•lb)

Fasten the rear fender stays with

the rear carrier bar.

B: Tighten the nut to specifica-

tion.
1 Rear carrier bar 1 (4)-C
2 Rear fender stay 2 (4)-V
Nut
3 Flange bolt 4 (4)-V d = 8 (0.31), = 14 (0.55)
7 Nm
(0.7 m•kg, 5.2 ft•lb)
4 Hexagon socket bolt 2 (4)-V d = 6 (0.24), = 16 (0.63)
5 Flange nut 2 (4)-V d = 6 (0.24)

EBA00047

15. BATTERY
A: Before installing the battery,
charge the battery.

Refer to “ADJUSTMENTS AND

PREDELIVERY SERVICE”.

B: Tighten the bolts to specifica-

tion.

Bolt
7 Nm
(0.7 m•kg, 5.2 ft•lb)
1 Battery 1
2 Battery cover 1 (3)-C
C: First, connect the positive
lead (red color lead) to the
3 Flange bolt 2 (4)-V d = 6 (0.24), = 16 (0.63)
positive terminal.
4 Bolt 2 d = 5 (0.20), = 9 (0.35)
D: Connect the negative lead
(black color lead) to the nega-
tive terminal.

–11–
 EBA00048

16. OWNER’S TOOL KIT

A: Put the low-pressure air
gauge and the owner’s tool kit
in the storage compartment
shown.

1 Owner’s tool kit 1 (4)-V

2 Low-pressure air gauge 1 (4)-V

EBA00049

17. OWNER’S MANUAL

A:

Put this owner’s manual in the

vinyl bag and place it in the stor-
age compartment shown.

1 Owner’s manual 1 (4)-C

EBA00050

18. SEAT
A: Insert the lobes on the seat
front into the receptacles on
the fuel tank and frame, then
push down the seat at the
end.

1 Seat 1

–12–
EBA00100

CABLE ROUTING

Proper cable and lead routing is essential to assure safe vehi-

cle operation.

(1) Front brake hose

(2) Front brake light switch lead
(3) Throttle cable
(4) Plastic band
(5) Clutch cable
(6) Parking brake cable
(7) Clutch switch lead
(8) Handlebar switch lead
(A) Clamp the front brake light switch lead.
(B) Set on the bended parts of the handle.
(C) Route the front brake hose and throttle cable through the guide
of the handlebar protector.
(D) Route the throttle cable under the front brake hose.
(E) Route the clutch cable and parking brake cable through the
guide of the handlebar protector.
(F) Route the clutch cable in front of the parking brake cable.
(G) Clamp the clutch switch lead and handlebar switch lead.

–13–
(1) CDI unit (H) Insert each relay all the way into the rib on the air filter side.
(2) Band (I) Insert the starter relay all the way into the rib on the air filter
(3) Battery side.
(4) Starter relay lead
(5) Starter relay
(6) Taillight lead
(7) Battery negative lead
(8) AC magneto coupler
(9) Starter motor lead
(10) Headlight relay
(11) Neutral relay
(12) Damper
(13) CDI unit lead
(14) Relay lead
(A) Route the starter relay lead under the starter motor lead.
(B) Clamp the taillight lead.
(C) Do not clamp.
(D) When clamping the wire harness, make sure that the insulator
lock is behind the clamp.
(E) After connecting the battery negative lead, push the sag in the
box.
(F) After connecting the taillight lead and each electric part, the
length between the air filter and AC magneto coupler should be
185 mm (7.28 in) on straight line.
(G) There is no particular order in placing each lead.

–14–
EBA00101

ADJUSTMENTS AND PREDELIVERY

SERVICE
Perform the predelivery service in the order indicated by the letters.
Always follow the order as shown.

–15–
EBA00102 Internal: Drink large quantities of
A. CHECKING AND CHARGING water or milk. Follow with milk of
THE BATTERY magnesia, beaten egg, or vegetable
1. Check: oil. Call a physician immediately.
Using a digital voltmeter, the state of a Eyes: Flush with water for 15 min-
discharged MF battery can be checked utes and get prompt medical atten-
by measuring the open-circuit voltage tion. Batteries produce explosive
(the voltage measured with the positive gases. Keep sparks, flames, ciga-
and negative terminals being discon- rettes, etc., away. Ventilate when
nected). charging or using in an enclosed
space. Always shield eyes when
Open-circuit working near batteries.
Charging time
voltage KEEP OUT OF THE REACH OF
12.8 V or CHILDREN.
Charging is not necessary
higher

• If the voltage is lower than 12.8 V,

• Do not attempt boost charging the battery must be charged. If this
under any circumstances. is not done, the life of the battery
• Battery electrolyte is poisonous and will be shortened drastically. Since
dangerous, causing severe burns, the procedure for charging the bat-
etc. It contains sulfuric acid. Avoid tery is not explained in the assem-
contact with skin, eyes or clothing. bly manual, refer to the service
Antidote: manual for more details.
External: Flush with water. • Never remove the strip of caps, nor
add any water or electrolyte.

EBA00105

B. CHECKING THE TIRE a. Use an appropriate low-pressure tire

PRESSURE gauge. Set tire pressures to the follow-
ing specifications:

This model is equipped with low pres- Reference tire pressure

sure tires. Pay attention to the following Front
points: 27.5 kPa (0.275 kg/cm2, 4.0 psi)
Recommended tire pressure: Rear
Front: 27.5 kPa (0.275 kg/cm2, 4.0 psi) 27.5 kPa (0.275 kg/cm2, 4.0 psi)
Rear: 27.5 kPa (0.275 kg/cm2, 4.0 psi) Minimum tire pressure
Maximum vehicle load: 100 kg (220 lb) Front
Tire size: Front AT20 × 7-10 24.5 kPa (0.245 kg/cm2, 3.5 psi)
Rear AT19 × 10-9 Rear
1. Excessive tire pressure [over 250 24.5 kPa (0.245 kg/cm2, 3.5 psi)
kPa (2.5 kg/cm2, 36 psi)] may cause
the tires to burst. Inflate tires very
slowly. Fast inflation can cause the Never use a tire pressure below mini-
tires to burst. mum specification. The tire could sepa-
2. Too low a pressure [Front: 24.5 kPa rate from the wheel under severe
(0.245 kg/cm2, 3.5 psi), Rear: 24.5 operating conditions.
kPa (0.245 kg/cm2, 3.5 psi)] will
cause the tire to dislodge from the
rim.
3. Put the same pressure in both rear
tires.
Uneven tire pressure will severally
affect the handling.
4. Set the tire pressures when the tires
are cold.

1. Check:
• tire pressure

–16–
EBA00106

C. DRAINING THE FUEL

1. Put a rag under the carburetor drain
hose so fuel does not contact the
crankcase.
2. Loosen the drain screw (1) and drain
the standing fuel.

FUEL IS HIGHLY FLAMMABLE:

• Always turn off the engine when
draining fuel.
• Take care not to spill any fuel on the
engine or exhaust pipe/muffler
when draining fuel.
• Never drain fuel while smoking or in
the vicinity of an open flame.

3. Tighten the drain screw securely.

EBA00109

D. CHECKING THE ENGINE OIL Recommended engine oil

LEVEL At 0 °C (32 °F) or higher
Yamalube 4 (20W40) or
1. Place the vehicle on a level surface.
SAE20W40
2. Start the engine, warm it up until the
API service, SG type or
engine oil has reached a normal tem-
higher, JASO standard MA
perature of 40 °C (104 °F), let it con-
At –10 °C (14 °F) or higher
tinue to idle for ten seconds, and then
Yamalube 4 (10W30) or
turn the engine off.
SAE10W30
API service, SG type or
To achieve the proper engine oil tempera-
higher, JASO standard MA
ture for an accurate oil level reading, the
At 0 °C (32 °F) or lower
engine must have first completely cooled
Yamalube 4-CW (5W30) or
down, and then warmed up again for sev-
SAE5W30
eral minutes to normal operating tempera-
API service, SG type or
ture.
higher, JASO standard MA
3. Check: Oil quantity (periodic oil change)
• engine oil level Engine
The engine oil level should be between 1.25 L (1.10 Imp qt, 1.32 US qt)
the minimum level mark (a) and maxi-
mum level mark (b).
Below the minimum level mark → Add Do not allow foreign material to enter
the recommended engine oil to the the crankcase.
proper level.
4. Start the engine, warm it up for several
minutes, and then turn it off.
• Before checking the engine oil level,
5. Check the engine oil level again.
wait a few minutes until the oil has set-
tled.
• Do not screw the dipstick (1) in when Before checking the engine oil level, wait a
checking the oil level. few minutes until the oil has settled.

–17–
EBA00121

E. ADJUSTING THE ENGINE a. Turn the throttle stop screw (1) in direc-
IDLING SPEED tion (a) or (b) until the specified idling
1. Start the engine and let it warm up for speed is obtained.
several minutes. Direction (a) Idling speed is increased.
2. Check:
Direction (b) Idling speed is decreased.
• engine idling speed
Out of specification → Adjust.

Engine idling speed

1,500 ~ 1,600 r/min

3. Adjust:
• engine idling speed

EBA00122 c. Tighten the locknut (1).

F. ADJUSTING THE THROTTLE
LEVER FREE PLAY If the free play cannot be adjusted here,
adjust it at the throttle lever side of the
cable.
Before adjusting the throttle lever free
play, make sure that the adjuster and d. Slide back the adjuster cover.
locknut on the carburetor side are fully e. Loosen the locknut (3).
tightened. If not, the throttle does not f. Turn the adjusting bolt (4) in direction
operate properly. (d) or (e) until the correct free play is
obtained.
Engine idling speed should be adjusted Direction (d) Free play is increased.
properly before adjusting the throttle lever Direction (e) Free play is decreased.
free play.
g. Tighten the locknut.
1. Check: h. Slide the adjuster cover to its original
• throttle lever free play (a) position.
Out of specification → Adjust.

Throttle lever free play

After adjusting the free play, turn the
2 ~ 4 mm (0.08 ~ 0.16 in)
handlebar to right and left and make
2. Adjust: sure that the engine idling speed does
• throttle lever free play not increase.

a. Loosen the locknut (1) on the carbure-

tor side.
b. Turn the adjuster (2) in direction (b) or
(c) until the correct free play is
obtained.

Direction (b) Free play is increased.

Direction (c) Free play is decreased.

–18–
EBA00123

G. ADJUSTING THE CLUTCH

CABLE
1. Check:
• clutch lever free play (a)
Out of specification → Adjust.

Clutch lever free play

(at the clutch lever end)
5 ~ 10 mm (0.20 ~ 0.39 in)

2. Adjust:
• clutch lever free play

a. Loosen the locknut (1).

b. Turn the adjusting nut (2) in direction
(b) or (c) until the specified clutch cable
free play is obtained.

Clutch cable free play is

Direction (b)
increased.
Clutch cable free play is
Direction (c)
decreased.

EBA00128 c. Tighten the locknut (1).

H. ADJUSTING THE REAR BRAKE
1. Check:
• brake pedal height (a) After this adjustment is performed, lift
Out of specification → Adjust. the front and rear wheels off the ground
by placing a block under the engine,
Brake pedal height and spin the rear wheels to ensure
40.0 mm (1.57 in) there is no brake drag. If any brake drag
is noticed, perform the above steps
2. Adjust:
again.
• rear brake pedal height

a. Loosen the locknut (1).

b. Turn the adjusting bolt (2) until the
brake pedal height is within the speci-
fied limits.

EBA00129

I. ADJUSTING THE REAR BRAKE a. Hold the main body (1) of the rear
LIGHT SWITCH brake light switch so that it does not
rotate and turn the adjusting nut (2) in
direction (a) or (b) until the rear brake
• The rear brake light switch is operated
light comes on at the proper time.
by movement of the brake pedal.
• The rear brake light switch is properly Brake light comes on
adjusted when the brake light comes Direction (a)
sooner.
on just before the braking effect starts.
Brake light comes on
Direction (b)
1. Check: later.
• rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
• rear brake light operation timing

–19–
EBA00130 d. Tighten the locknut (1).
J. ADJUSTING THE PARKING e. Slide the rubber cover to its original
BRAKE position.
1. Check:
• parking brake cable end length (a)
After this adjustment is performed, lift
Out of specification → Adjust.
the rear wheels off the ground by plac-
Parking brake cable end length ing a block under the engine, and spin
64 ~ 68 mm (2.52 ~ 2.68 in) the rear wheels to ensure there is no
brake drag. If any brake drag is noticed
2. Adjust: perform the above steps again.
• parking brake cable end length

a. Slide back the rubber cover.

b. Loosen the locknut (1).
c. Turn the adjusting nut (2) in direction
(b) or (c) until the specified brake cable
end length is obtained.

Direction (b) End length is increased.

Direction (c) End length is decreased.

EBA00131

K. CHECKING THE BRAKE FLUID

• Use only the designated brake fluid.
LEVEL
Other brake fluids may cause the
1. Place the vehicle on a level surface.
rubber seals to deteriorate, causing
leakage and poor brake perfor-
When checking the brake fluid level, make
mance.
sure that the top of the brake fluid reser-
• Refill with the same type of brake
voir top is horizontal.
fluid that is already in the system.
2. Check: Mixing brake fluids may result in a
• brake fluid level harmful chemical reaction, leading
Below the minimum level mark (1) → to poor brake performance.
Add the recommended brake fluid to • When refilling, be careful that water
the proper level. does not enter the master cylinder
and/or reservoir. Water will signifi-
Recommended brake fluid cantly lower the boiling point of the
DOT 4 brake fluid and could cause vapor
lock.
(A) Front brake
(B) Rear brake
Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any split brake fluid
immediately.

–20–
EBA00132 f. Pull the lever in or push down on the
L. BLEEDING THE HYDRAULIC pedal and hold it.
BRAKE SYSTEM g. Loosen the bleed screw and allow the
lever or pedal to travel towards its limit.
h. Tighten the bleed screw when the lever
Bleed the hydraulic brake system or pedal limit has been reached, then
whenever: release the lever or pedal.
• the system was disassembled, i. Repeat steps (e) to (h) until all the air
• a brake hose or brake pipe was bubbles have disappeared from the
loosened or removed, fluid.
• the brake fluid is very low, j. Tighten the bleed screw to specifica-
• the brake operation is faulty. tion.
A loss of braking performance may
occur if the brake system is not prop- Bleed screw
erly bled. 6 Nm (0.6 m•kg, 4.3 ft•lb)

(A) Front brake

(B) Rear brake If bleeding is difficult, it may be necessary
1. Bleed: to let the brake fluid settle for a few hours.
• hydraulic brake system Repeat the bleeding procedure when the
tiny bubbles in the system have disap-
a. Add the recommended brake fluid to peared.
the proper level.
b. Install the diaphragm. Be careful not to k. Add brake fluid to the proper level.
spill any fluid or allow the reservoir to
overflow. After bleeding the hydraulic brake sys-
c. Connect a clear plastic hose (1) tightly tem, check the brake operation.
to the bleed screw (2).
d. Place the other end of the hose into a
container.
e. Slowly apply the brake lever or pedal
several times.

EBA00134 b. Insert an appropriate shaft (c) in the

M. ADJUSTING THE DRIVE CHAIN hole (d) of the rear axle hub.
SLACK c. Shift the transmission into the neutral
position.
Measure the drive chain slack halfway d. To loosen the drive chain, push the
between the drive axle and the rear axle. ATV forward, and to tighten the drive
chain, pull the ATV backward.
1. Check:
• drive chain slack (a)
Out of specification → Adjust. Excessive chain slack will overload the
engine and other vital parts. Keep the
Drive chain slack slack within the specified limits.
45 ~ 55 mm (1.77 ~ 2.17 in)
e. Tighten the rear axle pinch bolts in the
proper sequence as shown.
Make sure that the vehicle is positioned
upright without an operator on it when Rear axle pinch bolt
checking the chain slack. 21 Nm (2.1 m•kg, 15 ft•lb)

2. Adjust:
• drive chain slack The chain should be cleaned and lubri-
cated after every use of the vehicle.

The drive chain slack is adjusted by the

rotation of the rear axle hub (b).

a. Loosen the rear axle pinch bolts.

–21–
EBA00135 2. Adjust:
N. ADJUSTING THE FRONT • spring preload
SHOCK ABSORBERS
a. Turn the adjusting ring (1) in direction
(a) or (b).
Always adjust the spring preload, of b. Align the desired position on the
both front shock absorbers to the same adjusting ring with the stopper (2).
setting. Uneven adjustment can result
in poor handling and loss of stability. Spring preload is
Direction (a) increased (suspension is
harder).
When checking the spring preload, place a
Spring preload is
suitable stand under the frame to keep the
Direction (b) decreased (suspension is
front wheels raised. No weight must be on
softer).
the front wheels.

1. Check:
• spring preload

Spring preload
Minimum position
1
Standard position
2
Maximum position
5

EBA00137

O. ADJUSTING THE REAR SHOCK Spring preload is

ABSORBER Direction (b) increased (suspension is
harder).
When checking the spring preload, place a Spring preload is
suitable stand under the frame to keep the Direction (c) decreased (suspension is
rear wheels raised. No weight must be on softer).
the rear wheels.
c. Tighten the locknut to specification.
1. Check: Locknut
• spring preload 42 Nm (4.2 m•kg, 31 ft•lb)
Spring length (a)
Standard length
230 mm (9.06 in) Never attempt to turn the adjusting nut
Minimum length (Hard) beyond the maximum or minimum set-
222 mm (8.74 in) ting.
Maximum length (Soft)
234 mm (9.21 in)
Always tighten the locknut against the
2. Adjust: adjusting nut, then torque it to specifica-
• spring preload tion.

a. Loosen the locknut (1).

b. Turn the adjusting nut (2) in direction
(b) or (c) until the correct adjustment is
obtained.

EBA00138

P. ADJUSTING THE HEADLIGHT Direction (a) Headlight beam is raised.

BEAMS Headlight beam is low-
Direction (b)
1. Adjust: ered.
• headlight beam (vertically)
Turn the adjusting bolt (1) in direction
(a) or (b).

–22–
Q. LUBRICATING THE AIR FILTER
ELEMENT
1. Remove:
• seat
2. Remove:
• air filter case cover (1)
3. Remove:
• air filter element (2)

The engine should never be run without

the air filter; excessive piston and/or
cylinder wear may result.

4. Apply:
• Yamaha foam air filter oil

a. Squeeze the initial oil out of the ele-

ment.

Do not twist or wring out the element.

This could damage the foam material.

b. Apply Yamaha foam air filter oil or

other quality foam air filter oil.
c. Squeeze out the excess oil.

The element should be wet but not drip-

ping.

5. Install:
• air filter element
• air filter case cover

Insert the air filter element assembly into

the air filter case and then install the air fil-
ter case cover by hooking the holders onto
the air filter case.

6. Install:
• seat

–23–
EBA00200

APPENDICES
SERVICE DATA

Engine idling speed: 1,500 ~ 1,600 r/min

Spark plug:
Type/Manufacturer DR7EA/NGK
Gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Fuel:
Recommended fuel Unleaded gasoline only
Fuel tank capacity 9.0 L (1.97 Imp gal, 2.37 US gal)
Valve clearance (cold):
IN 0.05 ~ 0.10 mm (0.0020 ~ 0.0039 in)
EX 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in)
EBA00210

STANDARD EQUIPMENT

1. Owner’s manual 1 pc.

2. Safety hand book 1 pc.
3. Owner’s tool kit 1 pc.
4. Low-pressure air gauge 1 pc.
EBA00220

OWNER’S TOOL KIT

1. Owner’s tool bag 1 pc.

2. Spark plug wrench 1 pc.
3. Screwdriver grip 1 pc.
4. Screwdriver bit 1 pc.
(Phillips head and slotted head)
5. Pliers 1 pc.
6. Wrench (10-12) 1 pc.
7. Wrench (14-17) 1 pc.
8. Hexagon wrench (6) 1 pc.

–24–
EBS01005

TIGHTENING TORQUES
ENGINE

Part Thread Tightening torque

Part to be tightened Q’ty
name size Nm m•kg ft•lb
Cylinder head (upper) Bolt M8 4 24 2.4 18
See NOTE *1
Cylinder head Bolt M8 2 20 2.0 15
Camshaft lock plate Bolt M6 2 8 0.8 5.9
Cylinder head side cover (1 and 2) Bolt M55 2 18 1.8 13
Cylinder head side cover 3 Bolt M6 2 10 1.0 7.4
Cylinder head breather plate Bolt M6 2 10 1.0 7.4
Spark plug — M12 1 18 1.8 13
Cylinder head stud bolt Stud bolt M8 2 15 1.5 11
Oil gallery bolt Bolt M6 1 7 0.7 5.2
Carburetor joint Bolt M6 2 10 1.0 7.4
Plate, 2 Bolt M6 2 12 1.2 8.9
Cylinder Bolt M6 2 10 1.0 7.4
Left crankcase cover Bolt M6 9 10 1.0 7.4
Pickup coil rotor Bolt M10 1 60 6.0 44
Balancer weight gear Nut M12 1 55 5.5 41
Valve clearance adjusting locknut Nut M6 2 14 1.4 10
Camshaft sprocket Bolt M10 1 60 6.0 44
Timing chain tensioner Bolt M6 2 10 1.0 7.4
Timing chain tensioner cap bolt Bolt M6 1 8 0.8 5.9
Timing chain guide (intake side) Bolt M6 2 8 0.8 5.9
Oil filter element cover Bolt M6 3 10 1.0 7.4
Oil delivery pipe Union M10 1 20 2.0 15
bolt
Oil delivery pipe and cylinder Union M8 1 17 1.7 13
bolt
Oil pump assembly Screw M8 3 6 0.6 4.4
Carburetor joint clamp screw (front) Screw M4 2 4 0.4 3.0
Carburetor joint clamp screw (rear) Screw M4 1 4 0.4 3.0
Exhaust pipe nut Nut M8 2 18 1.8 13
Muffler joint Bolt M8 1 20 2.0 15
Muffler Bolt M8 2 34 3.4 25
Left crankcase cover Bolt M5 1 7 0.7 5.2
Right crankcase cover Bolt M6 13 10 1.0 7.4
Crankcase Bolt M6 12 10 1.0 7.4
Oil drain bolt Bolt M12 1 20 2.0 15
Ground lead, clutch cable holder Bolt M6 1 10 1.0 7.4
Neutral switch lead clamp Bolt M6 1 10 1.0 7.4
Starter idle gear cover Bolt M6 3 10 1.0 7.4
Starter clutch Bolt M8 3 30 3.0 22
Primary drive gear nut Nut M16 1 80 8.0 59

–25–
 Part Thread Tightening torque
Part to be tightened Q’ty
name size Nm m•kg ft•lb
Clutch boss nut Nut M16 1 75 7.5 55
Clutch spring Screw M6 5 8 0.8 5.9
Push lever adjusting screw locknut Nut M6 1 8 0.8 5.9
Push lever shaft Bolt M8 1 12 1.2 8.9
Chain case cover Bolt M10 2 10 1.0 7.4
Drive sprocket nut Nut M18 1 110 11.0 81
Stopper lever Bolt M6 1 10 1.0 7.4
Shift pedal Bolt M6 1 10 1.0 7.4
Neutral switch — M10 1 20 2.0 15
Starter motor Bolt M6 2 10 1.0 7.4
Stator coil Bolt M6 3 10 1.0 7.4
Pickup coil Bolt M6 2 10 1.0 7.4

NOTE:
*1: Apply oil to the bearing surface of (upper) cylinder head bolt.
Further, apply molybdenum disulfide grease to thread part.

–26–
EBS01006

CHASSIS

Thread Tightening torque

Part to be tightened
size Nm m•kg ft•lb
Engine upper stay and frame M8 33 3.3 24
Engine upper stay and engine M10 66 6.6 49
Engine lower stay and engine M10 40 4.0 30
Engine and frame M10 66 6.6 49
Engine lower stay and frame M8 33 3.3 24
Swingarm pivot shaft and frame M14 100 10 74
Rear shock absorber and frame M12 55 5.5 41
Rear shock absorber locknut M20 42 4.2 31
Rear axle pinch bolt M8 21 2.1 15
Front shock absorber and frame M10 48 4.8 35
Front shock absorber and lower front arm M10 48 4.8 35
Upper front arm and frame M10 45 4.5 33
Lower front arm and frame M10 45 4.5 33
Steering stem and frame M10 35 3.5 26
Steering stem bushing and frame M8 23 2.3 17
Steering stem and handlebar holder M8 20 2.0 15
Tie-rod end and locknut M10 15 1.5 11
Steering knuckle and front wheel hub M14 70 7.0 52
Steering knuckle and front arm (upper and lower) M10 25 2.5 18
Steering knuckle and tie-rod ball joint M10 25 2.5 18
Pitman arm and tie-rod ball joint M10 25 2.5 18
Fuel tank and fuel cock M6 4 0.4 3.0
Fuel tank and frame M6 7 0.7 5.2
Front wheel and front wheel hub M10 45 4.5 33
Steering knuckle and front brake caliper bracket M8 28 2.8 21
Front brake disc and front wheel hub M8 28 2.8 21
Rear axle and rear wheel hub M14 120 12 89
Rear brake caliper and brake caliper bracket M8 34 3.4 25
Rear wheel and rear wheel hub M10 45 4.5 33
Driven sprocket and sprocket bracket M10 55 5.5 41
Front brake pipe nut M10 19 1.9 14
Front brake master cylinder and handlebar M6 7 0.7 5.2
Parking brake lever and clutch lever M6 7 0.7 5.2

–27–
 Thread Tightening torque
Part to be tightened
size Nm m•kg ft•lb
Front brake master cylinder and brake lever M6 6 0.6 4.4
Front brake master cylinder and brake hose M10 27 2.7 20
Brake hose joint and frame M6 10 1.0 7.4
Bleed screw M8 6 0.6 4.4
Front brake pad retaining bolt M10 17 1.7 13
Front brake caliper and brake hose M10 27 2.7 20
Rear brake caliper retaining bolt M8 22 2.2 16
Parking brake case and caliper M8 27 2.7 20
Rear axle ring nut M33 140 14 103
Rear axle ring nut set bolt M6 7 0.7 5.2
Rear brake pad retaining bolt M8 17 1.7 13
Rear brake caliper and brake hose M10 31 3.1 23
Rear brake master cylinder and frame M8 20 2.0 15
Rear brake master cylinder and brake hose M10 31 3.1 23
Parking brake adjusting bolt and locknut M8 15 1.5 11
Rear brake disc and brake disc bracket M8 28 2.8 21
Rear brake fluid reservoir, cover and bracket M6 7 0.7 5.2
Front bumper and frame M8 31 3.1 23
Front fender stay and frame M6 7 0.7 5.2
Side cover and frame M6 7 0.7 5.2
Rear fender and frame M6 7 0.7 5.2
Rear fender and air filter case and frame M6 7 0.7 5.2
Front fender stay and front fender M6 7 0.7 5.2
Rear carrier bar and frame M8 31 3.1 23
Footrest and frame M10 73 7.3 54
Foot protector stay foot protector M6 7 0.7 5.2
Foot protector stay foot protector M5 6 0.6 4.4
Foot protector stay and frame M8 17 1.7 13
Foot protector stay and footrest M8 17 1.7 13
Battery cover and air filter case and frame M6 7 0.7 5.2
Air filter case and frame M6 7 0.7 5.2
Headlight and frame M6 7 0.7 5.2
Tail/brake light bracket and air filter case M6 4 0.4 3.0
Drive chain guide roller and frame M8 23 2.3 17
Engine skid plate and frame M6 7 0.7 5.2

–28–
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN

PRINTED IN U.S.A.