2014

ASSEMBLY MANUAL

YF35GTE
YFM350TE

B14-F8107-E0
EBA00002

FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha
vehicle prior to delivery to the customer. Since some external parts of the vehicle have been re-
moved at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is re-
quired. It should be noted that the assembled vehicle should be thoroughly cleaned, checked, and
adjusted prior to delivery to the customer.
EBA00004

IMPORTANT
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 au-
thorized 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.
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 per-
sonal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided,

WARNING
could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

NOTICE
damage to the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer.

EBA00001

YF35GTE/YFM350TE
ASSEMBLY MANUAL
©2013 by Yamaha Motor Co., Ltd.
First edition, October 2013
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EBA01001

SYMBOLS USED IN THE ASSEMBLY MANUAL

In order to simplify descriptions in this assembly manual, the following symbols are used:
SYMBOL DEFINITION SYMBOL DEFINITION

Coat with lithium-soap-based

Filling fluid
grease.

Tighten to 10 Nm.
Lubricant 10 (10 Nm = 1.0 m·kgf, 7.2 ft·lbf)

Special tool FWD Towards the front of the vehicle

Tightening torque Clearance required

UP Install so that the arrow mark faces

Wear limit, clearance
upward.

Engine speed Apply motor oil.

Electrical data Made of rubber or plastics

A: Ref. No. (indicating the order of operations)

B: Part name
C: Quantity of parts per vehicle
D: Place where parts are held
(1): Refer to “PARTS LOCATION”.
V: Stored in plastic bag
C: Stored in carton box
S: Fixed inside the steel frame and/or con-
tained in the Styrofoam tray (upper or
d D d lower)
: Temporarily installed or secured
Example:
(1)-V
(1) signifies the location of the parts and V
D d
d
signifies that the part is stored in a plastic
bag.
E: Size or material of parts
d/D: Diameter of part
: Length of part
e.g., 5 (0.20) = 5 mm (0.20 in)
EBA00006

PREPARATION
To assemble the vehicle correctly, supplies (e.g. oils, greases, and shop rags) and sufficient work-
ing space are required.
Workshop
The workshop where the vehicle is assembled should be clean, spacious, and have a level floor.
Self-protection
Protect your eyes with suitable safety glasses or goggles when using compressed air, when grind-
ing or when doing any operation which may cause particles to fly off.
Protect hands and feet by wearing safety gloves and shoes.
EBA00007

SYMBOLS USED ON TRANSPORT PACKAGE COVER

Contents of the transport package
Insert the forklift arms from this
are fragile, therefore it must be
side.
handled with care.

Indicates correct upright position of Insertion of the forklift arms from

the transport package. this side can cause damage.

Transport package must be kept

away from rain.

Arrow mark “1”

Lift arm insertion positions
If the forklift arms cannot be inserted under the
transport package in alignment with the two
arrow mark, adjust the arms so that they are
positioned evenly in relation to these marks
while taking care not to damage the package
contents.

LIFT HERE

1 1
EBA00008
5. Remove the strap “8”.
UNPACKING
1. Remove the plastic locking ties “1”.

1
6. Remove the clip “9”, and then remove the
vehicle from the pin “10”.
2. Remove the frame cover “2”.

2
10

3. Remove the top frame “3”, side frames “4”,

and corner uprights “5”.
5 4

4
5

4. Remove the nuts “6”, and then pull out the

bottom frame bars “7”.

1
EBA00009

PARTS LOCATION
NOTICE
99 Do not use a cutter, scissors, or other sharp object to open the carton boxes; otherwise,
the included parts could be damaged.
99 Wear suitable protective gear such as gloves when handling and opening the carton boxes.

1 6

6
2,3,4 5

1. Engine skid plate

2. Bubble wrap pack 1
3. Bubble wrap pack 2
4. Supplied with the vehicle
5. Front wheels
6. Rear wheels

2
EBA00010
(3) Bubble wrap pack 2
(1) Engine skid plate

1 2 3
1

1. Wheel caps (front)

1. Engine skid plate
2. Wheel caps (rear)
3. Fuel tank cap with hose
(2) Bubble wrap pack 1
(4) Supplied with the vehicle
1 2
1 2

3 4 3 4

1. Flange bolts (front shock absorbers)

[d = 10 (0.39), = 48 (1.89)]
1. Owner’s tool kit
2. Self-locking nuts (front shock absorbers)
2. Band
[d = 10 (0.39)]
3. Low-pressure air gauge
3. Nuts (front and rear wheels)
4. Owner’s manual
[d = 10 (0.39)]
5. Safety handbook (for CAN)
4. Flange bolts (engine skid plate)
[d = 6 (0.24), = 12 (0.47)]

3
(5) Front wheels

1. Front wheels

(6) Rear wheels

1. Rear wheels

4
EBA00012

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

WARNING
This model is equipped with low pressure tires. Refer to “ADJUSTMENTS AND PREDELIV-
ERY SERVICE”.

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

4 1

3 2

1 5,6,7,8

2 9 3

5
EBA00028 EBA00034

1. FRONT SHOCK ABSORBERS 3. REAR WHEELS

3 2
FW C
A D
45 2
B 1 D
3

A A 1
4
5 55
45
B B

1 Front shock absorber 2 1 Wheel cap 2 (3)-V

2 Flange bolt 2 d = 10 (0.39), = 48 (1.89) 2 Rear wheel 2 (6)-S
3 Self-locking nut 2 d = 10 (0.39) 3 Nut 8 (2)-V d = 10 (0.39)
4 Flange bolt 2 (2)-V d = 10 (0.39), = 48 (1.89)
5 Self-locking nut 2 (2)-V d = 10 (0.39)
A: Install the wheel caps onto the wheel rims.
B: Install the wheels so that the air valves are
A: Install the flange bolts from rear to front. facing out.
B: Tighten the nuts to specification. C: The arrow mark on the tire must point to-
Nut ward the rotating direction of the wheel.
45 Nm (4.5 m·kgf, 33 ft·lbf) D: Tighten the nuts to specification.
Nut
EBA00033 55 Nm (5.5 m·kgf, 40 ft·lbf)
2. FRONT WHEELS
WARNING
1 C Install the nuts with the tapered side facing
A
the wheel.
2

EBA00013

4. HANDLEBAR
D
FW
3 D
B D 55

1 Wheel cap 2 (3)-V

2 Front wheel 2 (5)-S
3 Nut 8 (2)-V d = 10 (0.39)
4
FWD A,F
A: Install the wheel caps onto the wheel rims.
B: Install the wheels so that the air valves are 5
facing out. H
1
C: The arrow mark on the tire must point to- 23
ward the rotating direction of the wheel. B,E
3
2
D: Tighten the nuts to specification.
C 21.9˚
Nut G
55 Nm (5.5 m·kgf, 40 ft·lbf)

WARNING
Install the nuts with the tapered side facing
the wheel.

6
 1 Handlebar 1 1 Battery 1
2 Handlebar holder 2 2 Battery bracket 1
3 Flange bolt 4 d = 8 (0.31), = 30 (1.18) 3 Flange bolt 2 d = 6 (0.24), = 20 (0.79)
4 Handlebar cover 1 4 Bolt 2 d = 6 (0.24), = 12 (0.47)
5 Fuel tank cap with hose 1 (3)-V
A: Before installing the battery, charge the bat-
A: Remove the handlebar cover from the han- tery.
dlebar without disconnecting the main TIP
switch coupler, and then move the cover
Refer to “ADJUSTMENTS AND PREDELIV-
away from the handlebar.
ERY SERVICE”.
NOTICE
99 Make sure that the handlebar cover re- B: Tighten the bolts to specification.
mains supported. Bolt
99 Be careful not to pull the main switch 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
lead.
C: First, connect the positive lead (red color
B: Loosen the flange bolts. lead) to the positive terminal.
C: Adjust the position of the handlebar so that D: Connect the negative lead (black color
it is 21.9° from the vertical line shown in the lead) to the negative terminal.
illustration. TIP
D: Make sure that each handlebar holder is in- Refer to “CABLE ROUTING”.
stalled with its punch mark facing forward.
E: Tighten the bolts to specification.
EBA00048
NOTICE
6. OWNER’S TOOL KIT
First tighten the bolts on the front side, and
A
then tighten the bolts on the rear side. 2 3

1
Bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
F: Install the handlebar cover onto the handle-
bar.
G: Remove the dummy cap from the fuel tank,
and then install the fuel tank cap.
H: Pass the fuel tank breather hose through
1 Owner’s tool kit 1 (4)-
the hole in the handlebar cover.
2 Low-pressure air gauge 1 (4)-
TIP 3 Band 1 (4)-
Refer to “CABLE ROUTING”.
A: Secure the air gauge and the owner’s tool
kit to the rear fender with the band.
EBA00047

5. BATTERY EBA00049

7. OWNER’S MANUAL
B 4 4 C
7 D B
3 7
2 A
3
1
A 1

7
 1 Owner’s manual 1 (4)-

A: Place the owner’s manual in the holder on

the bottom of the seat. Advise the customer
of the following when delivering the vehicle.
TIP
The owner’s manual should always be put in
the plastic bag and placed in the holder on the
bottom of the seat.

EBA00050

8. SEAT

1 A

1 Seat 1

A: Insert the lobes on the seat front into the

receptacles on the frame, then push down
the seat at the end.
EBA00039

9. ENGINE SKID PLATE

A 1
7

1 Engine skid plate 1 (1)-S

2 Flange bolt 8 (2)-V d = 6 (0.24), = 12 (0.47)

A: Tighten the bolts to specification.

Bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)

8
EBA00100

CABLE ROUTING
WARNING
Proper cable and lead routing is essential to assure safe vehicle operation.

1 2 3 4

8 7 C B A 6

4 6 3 2

7
5 1
8

1. Rear brake lever light switch lead A. Fasten the front brake light switch lead to the
2. Starter cable handlebar with the plastic bands.
3. Rear brake lever cable B. Fasten the starter cable, handlebar switch
4. Front brake hose lead, horn switch lead (for Europe and Oce-
5. Front brake light switch lead ania) and rear brake lever light switch lead to
6. Throttle cable the handlebar with the plastic band.
7. Horn switch lead (for Europe and Oceania) C. Fasten the handlebar switch lead, horn switch
8. Handlebar switch lead lead (for Europe and Oceania) and rear brake
9. Main switch lead lever light switch lead to the handlebar with
the plastic band.

9
 A

A
1

2, B

1. Plastic band A. 7–17 mm (0.28–0.67 in)

2. Fuel tank breather hose B. Pass the fuel tank breather hose through the
hole in the handlebar cover.

10
 A

1. Battery A. Fasten the negative battery lead with the hold-

2. Negative battery lead ers.
3. Positive battery lead

11
EBA00101

ADJUSTMENTS AND PREDELIVERY SERVICE

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

P N F, I M C, F, G A E

L B D B I

O Q H, K N P

B I J, M B L

12
EBA00102
A. CHECKING AND CHARGING THE
BATTERY
TIP
The battery used in this vehicle is a VRLA
(Valve Regulated Lead Acid) battery, it has
been pre-filled with electrolyte at the factory so
there is no need to add fluid at any time.
1. Check:
Using a digital voltmeter, the state of a dis-
charged VRLA (Valve Regulated Lead Acid)
battery can be checked by measuring open-
circuit voltage (the voltage measured with
the positive and negative terminals being
disconnected).
Open-circuit
Charging time
voltage
12.8 V or Charging is not
higher necessary
WARNING
99 Do not attempt boost charging under
any circumstances.
99 Battery electrolyte is poisonous and
dangerous, causing severe burns, etc. It
contains sulfuric acid. Avoid contact
with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physi-
cian immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention. Bat-
teries produce explosive gases. Keep
sparks, flame, cigarettes, etc., away. Ven-
tilate when charging or using in en-
closed space. Always shield eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHIL-
DREN.
NOTICE
99 If the voltage is lower than 12.8 V, the
battery must be charged. If this is not
done, the life of the battery will be short-
ened drastically. Since the procedure for
charging the battery is not explained in
the assembly manual, refer to the ser-
vice manual for more details.
13
99 Never remove the strip of caps, nor add
any water or electrolyte.
EBA00105
B. CHECKING THE TIRE PRESSURE
WARNING
This model is equipped with low-pressure
tires. Pay attention to the following points:
Recommended tire pressure:
Front: 25 kPa (0.25 kgf/cm2, 3.6 psi)
Rear: 25 kPa (0.25 kgf/cm2, 3.6 psi)
Maximum vehicle load: 210 kg (463 lb)
Tire size: Front AT25 × 8-12
Rear AT25 × 10-12
1. Excessive tire pressure [over 250 kPa
(2.5 kgf/cm2, 36 psi)] may cause tires to
burst. Inflate tires very slowly. Fast infla-
tion could cause tire to burst.
2. Too low a pressure [Front: 22 kPa (0.22
kgf/cm 2 , 3.2 psi), Rear: 22 kPa (0.22
kgf/cm2, 3.2 psi)] will cause the tire to
dislodge from the rim.
3. Put the same pressure in both rear tires.
Uneven tire pressure will severely affect
the handling.
4. Set tire pressure cold.
1. Check:
99 Tire pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Use an appropriate low-pressure tire gauge.
Set tire pressures to the following specifica-
tions:
Reference tire pressure
Front: 25 kPa (0.25 kgf/cm2, 3.6 psi)
Rear: 25 kPa (0.25 kgf/cm2, 3.6 psi)
Minimum tire pressure
Front: 22 kPa (0.22 kgf/cm2, 3.2 psi)
Rear: 22 kPa (0.22 kgf/cm2, 3.2 psi)
NOTICE
Never use a tire pressure below minimum
specification. The tire could separate from
the wheel under severe operating condi-
tions.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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 into a container.
1
WARNING b
FUEL IS HIGHLY FLAMMABLE:
99 Always turn off the engine when drain- a
ing fuel.
99 Take care not to spill any fuel on the en-
gine or exhaust pipe(s)/muffler(s) when Recommended brand
YAMALUBE
draining fuel.
Type
99 Never drain fuel while smoking or in the SAE 5W-30, 10W-30, 10W-40,
vicinity of an open flame. 15W-40, 20W-40 or 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
Engine oil quantity
Without oil filter cartridge replace-
ment
2.2 L (2.33 US qt, 1.94 Imp.qt)

0 10 30 50 70 90 110 130 ˚F

SAE 5W-30
SAE 10W-30
3. Tighten the drain screw securely. SAE 10W-40
SAE 15W-40
EBA00107

D. CHECKING THE ENGINE OIL LEVEL SAE 20W-40

1. Place the vehicle on a level surface. SAE 20W-50

2. Check the engine oil level on a cold engine.

–20 –10 0 10 20 30 40 50 ˚C
TIP
If the engine was started before checking the NOTICE
oil level, be sure to warm up the engine suffi- 99 Engine oil also lubricates the clutch, and
ciently, and then wait at least 10 minutes until the wrong oil types or additives could
the oil settles for an accurate reading. cause clutch slippage. Therefore, do not
add any chemical additives or use en-
3. Check: gine oils with a grade of CD or higher
99 Engine oil level and do not use oils labeled “ENERGY
The engine oil level should be between the CONSERVING II” or higher.
minimum level mark “a” and maximum level 99 Do not allow foreign material to enter
mark “b”. the crankcase.
Below the minimum level mark → Add the
recommended engine oil to the proper level. 4. Start the engine, warm it up for several min-
TIP utes, and then turn it off.
Do not screw the dipstick “1” in when checking 5. Check the engine oil level again.
the oil level. TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled.

14
EBA00115

E. CHECKING THE FINAL GEAR OIL LEVEL

1. Place the vehicle on a level surface.
2. Remove: 1
99 Final gear oil filler bolt “1”
3. Check:
99 Final gear oil level
The final gear oil level should be up to the
brim “2” of the filler hole.
Below the brim → Add the recommended
final gear oil to the proper level.
b. Measure the starter plunger stroke distance
Recommended oil “a” of the starter lever “3” fully from the
SAE 80 API GL-4 Hypoid gear oil closed position to the fully open position. If
Oil quantity (periodic oil change) the distance is out of specification, adjust it
0.23 L (0.24 US qt, 0.20 Imp.qt) as described below.
NOTICE Starter plunger stroke distance
15 mm (0.59 in)
Take care not to allow foreign material to
enter the final gear case.
A
1 a
B
2 2

4. Install:
99 Final gear oil filler bolt
Final gear oil filler bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)

EBA00120

F. ADJUSTING THE STARTER CABLE

1. Remove: A. Fully closed position
99 Seat B. Fully open position
99 Fuel tank side panel (left) c. Slide back the rubber cover “4”.
2. Adjust: d. Loosen the locknut “5”.
99 Starter cable e. Turn the adjusting bolt “6” in or out until the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ correct distance is obtained.
a. Disconnect the starter cable “1” from the
carburetor. Turning in Distance increased.
TIP
Do not remove the starter plunger “2” from the Turning out Distance decreased.
starter cable.

15
 4 6 5

f. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

g. Slide the rubber cover to its original posi-
tion. EBA00122

h. Connect the starter cable to the carburetor. H. ADJUSTING THE THROTTLE LEVER
FREE PLAY
WARNING
NOTICE
After adjusting the starter cable, turn the
handlebar to right and left, and make sure Before adjusting the throttle lever free play,
that the engine idling speed does not in- make sure that the adjuster and locknut on
crease. the carburetor side are fully tightened. If
not, the throttle does not operate properly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install: TIP
99 Fuel tank side panel (left) Engine idling speed should be adjusted prop-
99 Seat erly before adjusting the throttle lever free play.
EBA00121
1. Check:
G. ADJUSTING THE ENGINE IDLING SPEED
99 Throttle lever free play “a”
TIP Out of specification → Adjust.
A diagnostic tachometer is needed to make
Throttle lever free play
this adjustment.
3–5 mm (0.12–0.20 in)
1. Start the engine and let it warm up for sev-
eral minutes.
2. Check:
99 Engine idling speed
Out of specification → Adjust.
Engine idling speed
1450–1550 r/min
3. Adjust: a
99 Engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Adjust:
a. Turn the throttle stop screw “1” in direction 99 Throttle lever free play
“a” or “b” until the specified idling speed is ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
obtained.
a. Slide back the rubber cover “1”.
b. Loosen the locknut “2”.
Direction “a” Idling speed increases.
c. Turn the adjusting bolt “3” in direction “b” or
“c” until the correct free play is obtained.
Direction “b” Idling speed decreases.

16
 b
Direction “b” Free play is increased.

Direction “c” Free play is decreased.

1 2
c

b 2. Adjust:
99 Rear brake pedal free play
99 Rear brake lever free play
3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

TIP
d. Tighten the locknut.
Before adjusting the free play, pump the brake
e. Slide the rubber cover to its original posi-
pedal 2 to 3 times.
tion.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Fully loosen the brake lever free play ad-
WARNING justing nut “1”.
b. Turn the brake pedal free play adjusting nut
After adjusting the throttle lever free play,
“2” until the brake pedal free play is within
turn the handlebar to the right and to the
the specified limits.
left to ensure that this does not cause the
engine idling speed to change.

EBA00126

I. ADJUSTING THE REAR BRAKE 2

1. Check:
99 Brake pedal free play “a” 1
99 Rear brake lever free play “b”
Out of specification → Adjust.
Brake pedal free play
20–30 mm (0.79–1.18 in) c. Loosen the locknut “3”.
Rear brake lever free play d. Fully screw in the brake lever free play ad-
3–5 mm (0.12–0.20 in) justing bolt “4”.
3 4

e. Turn the brake lever free play adjusting nut

until the gap “c” is within the specified limits.
Gap
0–1 mm (0–0.04 in)

17
 a 1

c b

f. Check that the brake pedal free play is ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

within the specified limits. If not, perform the
above steps again. EBA00131

g. Turn the brake lever free play adjusting bolt K. CHECKING THE BRAKE FLUID LEVEL
until the rear brake lever free play is within 1. Place the vehicle on a level surface.
the specified limits. TIP
h. Tighten the locknut. When checking the brake fluid level, make
WARNING sure that the top of the brake fluid reservoir
top is horizontal.
After this adjustment is performed, lift the
front and rear wheels off the ground by
2. Check:
placing a block under the engine, and spin 99 Brake fluid level
the rear wheels to ensure there is no brake
Below the minimum level mark “1” → Add
drag. If any brake drag is noticed, perform
the specified brake fluid to the proper level.
the above steps again.
Specified brake fluid
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ DOT 4

EBA00129

J. ADJUSTING THE REAR BRAKE LIGHT

SWITCH
TIP
99 The rear brake light switch is operated by
movement of the brake pedal.
99 The rear brake light switch is properly ad-
justed when the brake light comes on just
before the braking effect starts.

1. Check: WARNING
99 Rear brake light operation timing
99 Use only the designated brake fluid.
Incorrect → Adjust.
2. Adjust: Other brake fluids may cause the rubber
99 Rear brake light operation timing seals to deteriorate, causing leakage
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
and poor brake performance.
99 Refill with the same type of brake fluid
a. Hold the main body “1” of the rear brake that is already in the system. Mixing brake
light switch so that it does not rotate and fluids may result in a harmful chemical re-
turn the rear brake light switch adjusting nut action, leading to poor brake performance.
“2” in direction “a” or “b” until the rear brake 99 When refilling, be careful that water
light comes on at the proper time. does not enter the brake master cylin-
Brake light comes on der. Water will significantly lower the
Direction “a” boiling point of the brake fluid and could
sooner.
cause vapor lock.
Brake light comes on
Direction “b”
later.

18
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
EBA00132
L. BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
Bleed the hydraulic brake system when-
ever:
99 the system is disassembled,
99 a brake hose or brake pipe was loos-
ened or removed,
99 the brake fluid is very low,
99 the brake operation is faulty.
A loss of braking performance may occur if
the brake system is not properly bled.
1. Bleed:
99 Hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Add the specified brake fluid to the proper
level.
b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic hose “1” tightly to
the bleed screw “2”.
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever
to travel towards its limit.
h. Tighten the bleed screw when the lever limit
has been reached, then release the lever.
i. Repeat steps (e) to (h) until all the air bub-
bles have disappeared from the fluid.
j. Tighten the bleed screw to specification.
Front brake caliper bleed screw
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
19
TIP
If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours. Re-
peat the bleeding procedure when the tiny
bubbles in the system have disappeared.
k. Add brake fluid to the proper level.
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBA00133
M. ADJUSTING THE DRIVE SELECT LEVER
CONTROL CABLE AND SHIFT ROD
WARNING
Before moving the drive select lever, bring
the vehicle to a complete stop and return
the throttle lever to its closed position. Oth-
erwise the transmission may be damaged.
1. Adjust:
99 Brake pedal free play
2. Adjust:
99 Drive select lever control cable
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Drive select lever control cable:
a. Make sure the drive select lever is in NEU-
TRAL.
b. Adjust the control cable so there is zero
free play in the cable. When the adjustment
is correct, slack in the return spring “1” will
be taken up.
TIP
In some cases it will be necessary to further
adjust the cable with the locknuts “2” arrange-
ment that holds the cable to its mount.
2
1
c. When the brake begins to work “a” = 20–30
mm (0.79–1.18 in), verify that the drive se-
lect lever can be shifted to REVERSE from
NEUTRAL, to NEUTRAL from REVERSE.
d. Before the brake begins to work “a” = 0–20
mm (0–0.79 in), verify that the drive select
lever cannot be shifted to REVERSE from
d. Tighten the locknuts to specification.
Locknut
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBA00135

NEUTRAL, to NEUTRAL from REVERSE. N. ADJUSTING THE FRONT SHOCK

ABSORBERS
WARNING
Always adjust both front shock absorber
spring preload to the same setting. Uneven
adjustment can result in poor handling and
loss of stability.

1. Adjust:
99 Spring preload
Turn the adjusting ring “1” in direction “a” or
e. Check that the locknuts “2” are tightened “b”.
correctly.
f. If the operation of the drive select lever is Spring preload is
incorrect, adjust the drive select lever con- Direction “a” increased (suspension
trol cable “3” with the adjusting bolt “4”. is harder).
Spring preload is
3
Direction “b” decreased (suspension
4 is softer).
2
Standard position
2
Minimum (Soft) position
1
Maximum (Hard) position
5

Drive select lever shift rod:

a. Make sure the drive select lever is in NEU-
TRAL. 1
b. Loosen both locknuts “5”.
c. Adjust the shift rod length for smooth and
correct shifting. a
b

5
EBA00136

O. ADJUSTING THE REAR SHOCK

ABSORBER
NOTICE
Never attempt to turn the adjusting ring be-
yond the maximum or minimum settings.

20
1. Adjust: Q. LUBRICATING THE AIR FILTER
99 Spring preload ELEMENT
Turn the adjusting ring “1” in direction “a” or 1. Remove:
“b”. 99 Seat
2. Remove:
Spring preload is 99 Air filter case cover “1”
Direction “a” increased (suspension
is harder).
Spring preload is
Direction “b” decreased (suspension
is softer).

Standard position
2
Minimum (Soft) position
1
Maximum (Hard) position
5 3. Remove:
99 Air filter element “2”
NOTICE
The engine should never be run without
the air filter; excessive piston and/or cylin-
1 der wear may result.

a b

EBA00138

P. ADJUSTING THE HEADLIGHT BEAMS

1. Adjust:
99 Headlight beam (vertically)
Turn the adjusting screw “1” direction “a” or
“b”.
4. Apply:
Headlight beam is 99 Yamaha foam air filter oil
Direction “a”
raised. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Headlight beam is low- a. Squeeze the initial oil out of the element.
Direction “b”
ered.
NOTICE
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.
TIP
The element should be wet but not dripping.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

21
5. Install:
99 Air filter element
99 Air filter case cover
TIP
Insert the air filter element into the air filter
case, and then install the air filter case cover
by hooking the holders onto the cover.

6. Install:
99 Seat

22
EBA00200

APPENDICES
SERVICE DATA
Engine idling speed 1450–1550 r/min
Spark plug
Type/Manufacturer DR8EA/NGK
Gap 0.6–0.7 mm (0.024–0.028 in)
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 13.5 L (3.57 US gal, 2.97 Imp.gal)
Valve clearance (cold)
IN 0.06–0.10 mm (0.0024–0.0039 in)
EX 0.16–0.20 mm (0.0063–0.0079 in)

EBA00210

STANDARD EQUIPMENT
1. Owner’s manual 1 pc.
2. Safety handbook (for CAN) 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)

23
EBA00230

TIGHTENING TORQUES
Tightening torque
Item Thread size
Nm m·kgf ft·lbf
Engine:
Spark plug M12 18 1.8 13
Engine oil drain bolt M12 23 2.3 17
Chassis:
Engine bracket (front-upper) and frame M8 33 3.3 24
Engine bracket (front-lower) and frame M8 33 3.3 24
Engine bracket (front-upper) and engine M10 42 4.2 30
Engine bracket (front-lower) and engine M10 42 4.2 30
Engine and frame (rear-upper) M10 56 5.6 41
Engine and frame (rear-lower) M10 56 5.6 41
Frame and bearing retainer (steering stem holder bear-
M42 40 4.0 29
ing)
Drive select lever assembly and frame M8 23 2.3 17
Swingarm M12 82 8.2 59
Rear shock absorber and frame M12 82 8.2 59
Final gear case and swingarm M10 63 6.3 46
Final gear case and rear axle housing M10 63 6.3 46
Swingarm and rear axle housing M10 63 6.3 46
Front arm and frame M10 45 4.5 33
Front shock absorber and frame M10 45 4.5 33
Front shock absorber and upper front arm M10 45 4.5 33
Steering stem, pitman arm and frame M14 190 19 137
Steering stem holder and frame M8 23 2.3 17
Steering stem and handlebar holder M8 23 2.3 17
Pitman arm and tie-rod end M12 30 3.0 22
Tie-rod and locknut M12 40 4.0 29
Steering knuckle and upper front arm M12 30 3.0 22
Steering knuckle and lower front arm M12 30 3.0 22
Steering knuckle and tie-rod M12 30 3.0 22
Fuel tank and fuel cock M6 4.0 0.40 2.9
Fuel tank M6 10 1.0 7.2
Front wheel and wheel hub M10 55 5.5 40
Front axle and wheel hub M16 150 15 108
Steering knuckle and brake caliper M8 30 3.0 22
Front brake disc and wheel hub M8 30 3.0 22
Rear wheel and rear wheel hub M10 55 5.5 40
Rear axle and nut M16 150 15 108
Brake drum cover and brake shoe plate M6 7 0.7 5.1
Front brake hose and steering knuckle M6 7 0.7 5.1

24
 Tightening torque
Item Thread size
Nm m·kgf ft·lbf
Front brake hose and upper front arm M6 7 0.7 5.1
Front brake hose and frame M6 7 0.7 5.1
Front brake pipe nut M10 19 1.9 14
Front brake hose union bolt M10 27 2.7 20
Front brake caliper bleed screw M8 5 0.5 3.6
Master cylinder and handlebar M6 7 0.7 5.1
Footrest bracket and frame M8 16 1.6 12
Front bumper and frame M8 34 3.4 25
Front carrier and frame M8 34 3.4 25
Front carrier and front bumper M8 34 3.4 25
Rear carrier and frame M8 34 3.4 25
Engine skid plate M6 7 0.7 5.1
Final gear oil filler bolt M14 23 2.3 17
Final gear oil drain bolt M14 23 2.3 17
Bearing retainer (drive pinion gear) M65 100 10 72
Final gear case and bearing housing M10 40 4.0 29
M8 23 2.3 17
Battery holding bracket M6 7 0.7 5.1
Footrest board and footrest bracket M6 7 0.7 5.1
Trailer hitch bracket M10 32 3.2 23
Front brake pad holding bolt M8 17 1.7 12
Front brake caliper retaining bolt M8 17 1.7 12
Rear brake light switch bracket M8 23 2.3 17
Rear brake lever holder bracket M6 7 0.7 5.1
Brake camshaft lever M6 9 0.9 6.5
Oil hose protector M6 7 0.7 5.1

25
 YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
 ATV Pre-Delivery Inspection
ATV Pre-Delivery Certificate
Inspection Certificate

This vehicle
Thismust be delivered
vehicle to each customer,
must be delivered completely
to each customer, built and ready
completely to use.
built and ready A to
complete pre-delivery
use. A complete inspectioninspection
pre-delivery has to behas to be
Unit Information
Unit Information
carried out by theout
carried dealer,
by theprior to delivery.
dealer, prior to The pre-delivery
delivery. inspectioninspection
The pre-delivery sheet shall be signed
sheet bysigned
shall be the dealer and
by the the customer
dealer and
and the customer and
one copyone
shallcopy
be handed
shall betohanded
the customer.
to the customer. Model Model Frame NoF.r(aVmIN
e)No. (VIN) Engine NE
o.ngine No.
Check that the unit
Check thathas
thebeen assembled
unit has in accordance
been assembled with the relevant
in accordance with theYamaha
relevant Assembly Manual byManual
Yamaha Assembly a suitably
by atrained mechanic.
suitably trained mechanic.
The following points should
The following points beshould
re-checked at the time
be re-checked at of
thefinal
timepre-delivery inspection:
of final pre-delivery inspection:
Dealer Information
Dealer Information
Set-Up Set-Up
Assembly Assembly
 FRONTANDFRONTREAR AND WHEELS – Torque –toTorque
REAR WHEELS specification  CONTROLS
to specification  CONTROLS
– Check for properfor
– Check operation and cableand
proper operation routing
cable routing
 WHEEL ALIGNMENT
WHEEL ALIGNMENT – Check and adjust
– Check as adjust
and required  KEYS
as required – Check
KEYS all locks for
– Check all proper operation
locks for proper operation Dealer Name:
Dealer Name: Dealer No.:
Dealer No.:
 FRONTANDFRONTREAR AND AXLE
REAR COTTER
AXLE COTTER PINS – Check  ALL NUTS
PINS – Check  ALL AND
NUTSBOLTSAND– BOLTS
Check tightness
– Check tightness
 WIRING
 CONNECTORS
WIRING CONNECTORS – Check for color code
– Check andcode and Check
for color theCheck
torquethe
of torque
the following:
of the following:
proper connection
proper connection  Enginemounting bolts and/or
Engine mounting nuts
bolts and/or nuts Address: Address: Dealer Phone:
Dealer Phone:
 HANDLEBAR
 HANDLEBAR
HOLDERS – Torque –toTorque
HOLDERS specifications
to specifications  Steering
 head
Steering head
 INSTALL
 INSTALL
FRONT SHOCKFRONT ABSORBERS
SHOCK ABSORBERS  Rear swing
 Rear armswing
pivotarm
shaftpivot shaft
 BRAKES
 BRAKES
– Install per assembly
– Install manual manual
per assembly  Axles andAxles
wheels
and wheels
 INSTRUMENTS
 INSTRUMENTS
– Install instruments and routeand
– Install instruments the route  Engine,
cablesthe cables transmission and gear and
Engine, transmission casegear
drain bolts
case drain bolts
as shownasonshown
cable routing
on cablediagrams; tighten cable
routing diagrams; at nuts 
nutscable
tighten at Brake caliper
Brakebolts
caliper bolts
both endsboth ends Customer’s Check List
Customer’s Check List
Set-Up by:
Set-Up by:  Above checklist completed
Above checklist and explained
completed and explained Yamaha guarantees the build quality
Yamaha guarantees the buildof quality
your vehicle.
of your vehicle.
 Unit visually
 Unitinspected
visually inspected The serviceThemanager certifies your
service manager vehicle
certifies yourhas beenhas been
vehicle
Date: Date:  All warning
 Alllabels
warning reviewed
labels reviewed thoroughly checked and
thoroughly adequately
checked prepared.prepared.
and adequately
 All controls
 Allexplained and adjusted
controls explained and adjusted By signing Bybelow,
signing below,
Pre-Delivery ServiceService
Pre-Delivery  Instructional
 Instructional
material received
material received I certify that I have
I certify been
that informed
I have of the vehicle’s
been informed of the vehicle’s
 Improper
 Improper
riding risks explained
riding risks explained recommended use, maintenance,
recommended and warranty
use, maintenance, conditionsconditions
and warranty
 TIRES– TIRES
Adjust pressure accordingaccording
– Adjust pressure to specifictoassembly
specific assembly  ENGINE/TRANSMISSION
 ENGINE/TRANSMISSION OIL – Check OIL level
– Check level  Need  for Need
protective apparel discussed
for protective (helmet, eye
apparel discussed (helmet, eye applicableapplicable
to my vehicle.
to my vehicle.
manual: front
manual: front rear rear  Engine Engine protection, etc.)
protection, etc.) I have visually
I haveinspected the unit and
visually inspected the found no found
unit and defects
no defects
 MECHANICAL
 MECHANICAL BRAKESBRAKES – Check and adjust
– Check freeplay
and adjustand freeplay and  Transfer
 gear (if equipped)
Transfer gear (if equipped)  Warranty
 Warranty
conditionsconditions
fully explained
fully explained
operationoperation  Final gear
 Final
oil gear oil  Warranty
 Warranty
registration information
registration confirmedconfirmed
information
Customer’s Signature:
Customer’s Signature:
 Parking brake
Parking (if equipped)
brake (if equipped) Adjust if necessary  Differential
– Adjust if– necessary  Differential
gear oil (maygearrequire
oil (maydraining
requiretodraining
check level)
to check level)  Tool kitreceived
Tool kit received
 HYDRAULIC
 HYDRAULIC
DISC BRAKES DISC BRAKES(front and/or rear)
(front – Check
and/or rear) – Check CLUTCH  CLUTCH
– Check and adjust
– Check freeplay
and adjust(if equipped)
freeplay (if equipped)  
Maintenance/care schedule
Maintenance/care explained
schedule explained
master cylinder
master cylinder  SERVICE SERVICE
BULLETINS – Applicable
BULLETINS bulletins checked
– Applicable bulletins and
checked and  Maintenance
 Maintenance
and off-season storage needs
and off-season discussed
storage needs discussed
fluid level;fluid
addlevel;
brakeadd fluid if necessary;
brake check thatcheck
fluid if necessary; therethat
is thereservice
is performed
service performed  Enginebreak-in
Engine procedure explainedexplained
break-in procedure Date: Date:
no contamination of the discs;
no contamination check
of the andcheck
discs; adjust freeplay:
and  CLEAN
adjust freeplay: –CLEAN
Prepare– for delivery.
Prepare for delivery.  Key 
received
Key received
check operation
check operation
I HAVE PERFORMED
I HAVE PERFORMED THE PRE-DELIVERY
THE PRE-DELIVERY
 Frame number
Frameand location
number andhas beenhas
location verified
been verified
 FUEL  TANK
FUEL – Fill tank–with
TANK specified
Fill tank fuel
with specified fuel
ADJUSTMENTS
ADJUSTMENTSAS SPECIFIED
AS IN THE ASSEMBLY
SPECIFIED IN THE ASSEMBLY
 Personnel
 Personnel
 COOLING  COOLING SYSTEM FLUID LEVEL (if equipped) – Check
SYSTEM FLUID LEVEL (if equipped) – Check  Questions
 Questions
answeredanswered
by dealership personnelpersonnel
by dealership
MANUAL,MANUAL,
SERVICESERVICE SPECIFICATIONS,
SPECIFICATIONS,AND ANYAND ANY
coolant level;
coolant addlevel;
coolant addif coolant
necessary if necessary  Owner’s  manual
Owner’sreceived
manual and reviewed
received with
and reviewed with
 CABURETOR
 CABURETOR – Adjust starter
– Adjust lever freeplay
starter lever(if equipped)
freeplay TECHNICAL
(if equipped) BULLETINS
TECHNICAL APPLYING
BULLETINS TO THIS TO
APPLYING MODEL.
THIS MODEL. dealership personnelpersonnel
dealership
 IDLE SPEED IDLE–SPEED Check: – Check:rpm rpm
 FUEL  INJECTION
FUEL INJECTION – Check and/or – Check adjust
and/or idleadjust
speed idle speedPre-Delivery by:
Pre-Delivery by:
accordingaccording
to specifictoassembly manual: manual:rpm
specific assembly rpm
(if equipped)
(if equipped)
 THROTTLE THROTTLE
OPERATION – Check throttle
OPERATION – Checklever freeplay,
throttle lever freeplay, Date: Date:
cable routing,
cableand throttle
routing, andoperation in all steering
throttle operation in all steering
positions positions
(adjust if (adjust
necessary) if necessary)  Test Ride
 Test– Check
Ride for properfor
– Check assembly, control operation,
proper assembly, control operation,
 FOAMAIR FOAMFILTER AIR–FILTER
Service–with Yamaha
Service with foam
Yamaha air filter
foam air filter and overall
andoperation as specified
overall operation for the unit.
as specified for the unit.
oil or equivalent
oil or equivalent  After Test
 After
RideTest
– Check
Ride for fuel, oil,
– Check forbrake fluid,
fuel, oil, andfluid, and
brake
 ELECTRICAL
 ELECTRICALCOMPONENTS COMPONENTS – Check proper– Check operation
proper operation coolant leaks
coolant leaks
(if equipped)
(if equipped)  VehicleisVehicle
in working
is inorder
working order
 BatteryBreather Tube – Install
Battery Breather Tubeand routeand
– Install properly;
route properly;
Test RideTest
by:Ride by:
check for check
restrictions
for restrictions
 VRLA(Valve Regulated
VRLA(Valve Lead
Regulated Acid) Battery
Lead Acid) – Check
Battery – Check
voltage; voltage;
Date: Date:
 Chargeaccording to the Assembly
Charge according Manual if Manual
to the Assembly necessary if necessary
    
Headlight –
HeadlightHi – Low Hi Adjust
Low beam
Adjust beam
 Taillight  Taillight Service Manager’s
Service Manager’sSignature: Signature:
 Stoplight  front lever
 Stoplight  front lever  rear
rear lever or pedal
lever or pedal
 Indicator  Indicator
lights lights
 Instrument Instrument
lights lights Date: Date:
 Enginestop Engineswitchstop switch Service Manager certifies that
Service Manager the checks
certifies that thelisted above
checks have
listed above have
 DRIVECHAINDRIVE– CHAIN Check/adjust (as necessary)
– Check/adjust (as necessary) been performed in accordance
been performed with the recommendations
in accordance of
with the recommendations of
 V-BELT –V-BELT
Check for properfor
– Check shifting
properand operation
shifting of the
and operation of Yamaha.
the Yamaha.
primary and secondary
primary sheaves. sheaves.
and secondary (as necessary)(as necessary)

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