Yamaha YFM35XY Owner's Manual

3D5-F8199-13LIT-11626-22-44This ATV should not be ridden by anyone under 16 years of age.WARNINGYFM35XYOWNER’S MANUALREAD THIS MANUAL CAREFULLY!It con

1-21● Always inspect your ATV each time you use it tomake sure it is in safe operating condition. Al-ways follow the inspection and maintenanceprocedu

8-1984. Pull the air filter element out of the air filtercase.5. Pull off the air filter element lock plate, andthen remove the sponge material from t

8-2086. Wash the sponge material gently but thor-oughly in solvent.WARNINGEWB019007. Squeeze the excess solvent out of the spongematerial and let it d

8-218TIPThe sponge material should be wet but not drip-ping.10. Pull the sponge material over the air filter ele-ment frame, and then install the lock

8-2283. Tap the tailpipe lightly, and then use a wirebrush to remove any carbon deposits from thespark arrester portion of the tailpipe and insideof t

8-238WARNINGEWB01910EBU23920V-belt cooling duct check hose If dust or water collects in the V-belt cooling ductcheck hose, remove the hose and clean i

8-248EBU23940Adjusting the carburetor The carburetor should be checked and, if neces-sary, adjusted at the intervals specified in the peri-odic mainte

8-258crease the engine idling speed, turn the throt-tle stop screw in direction (a), and to decreaseit, turn the screw in direction (b).TIPIf the spec

8-2684. Tighten the locknut.5. Slide the rubber cover to its original position.EBU24060Valve clearance The valve clearance changes with use, resulting

8-278TIPThe wheels need to be removed to check thebrake pads. (See page 8-43.)EBU24180Rear brake shoesThe rear brake is provided with a wear indicator

8-288Observe these precautions:● When checking the fluid level, make sure thatthe top of the brake fluid reservoir is level.● Use only the recommended

1-31hill. If you stall or roll backwards, follow the spe-cial procedure for braking described in this man-ual. Dismount on the uphill side or to a sid

8-298EBU24382Checking the front brake lever free play The brake lever free play must be checked at theintervals specified in the periodic maintenance

8-308● Before adjusting the brake lever and brake pedalfree play, check the rear brake shoes for wear.Adjusting the brake pedal free playThe brake ped

8-3181. Loosen the locknut at the brake lever and fullyturn in the brake lever free play adjusting bolt.2. Turn the brake lever free play adjusting nu

8-3284. Tighten the locknut at the brake lever.TIPWhen adjusting the rear brake lever free play:● Be sure not to step on the brake pedal.● Make sure t

8-338WARNINGEWB02020EBU24230Axle boots The axle boots must be checked for damage at theintervals specified in the periodic maintenance andlubrication

8-3483. Install the panel.EBU24890Checking and lubricating the cables The operation and the condition of all control ca-bles should be checked before

8-358EBU28832Checking and lubricating the brake pedal The operation of the brake pedal should bechecked before each ride, and the pedal pivotshould be

8-368EBU29171Battery This model is equipped with a VRLA (Valve Regu-lated Lead Acid) battery. There is no need to checkthe electrolyte or to add disti

8-3784. Pull the battery out of its compartment.To charge the batteryHave a Yamaha dealer charge the battery as soonas possible if it seems to have di

8-3883. Install the battery holding plate by installingthe bolts.4. Install the seat. (See page 4-12.)NOTICEECB00940Always keep the battery charged. S

1-41WARNINGEWB00021WARNINGEWB00030POTENTIAL HAZARDImproper handling of gasoline.WHAT CAN HAPPENGasoline can catch fire and you could beburned.HOW TO A

8-398The main fuse and the fuse box are located underthe seat. (See page 4-12.)If a fuse is blown, replace it as follows.1. Turn the key to “OFF” and

8-4084. If the fuse immediately blows again, have aYamaha dealer check the electrical system.EBU25531Replacing a headlight bulb If a headlight bulb bu

8-4184. Install a new headlight bulb into the headlightunit by aligning the projection on the bulb withthe groove in the headlight unit.NOTICEECB00650

8-428EBU25560Adjusting a headlight beam NOTICEECB00690It is advisable to have a Yamaha dealer makethis adjustment.To raise a headlight beam, turn the

8-4383. Insert a new bulb into the socket, push it in,and then turn it clockwise until it stops.4. Install the lens by installing the screws.NOTICEECB

8-448● Tapered nuts are used for both the front and rearwheels. Install the nuts with their tapered side to-wards the wheel.3. Lower the ATV to the gr

8-458EBU25710Troubleshooting Although Yamaha ATVs receive a thorough in-spection before shipment from the factory, troublemay occur during operation.

8-468EBU25751Troubleshooting chart Check the fuel level inthe fuel tank.1. FuelThere is enough fuel.There is no fuel.Check the compression.Supply fuel

9-19EBU25860CLEANING AND STORAGEEBU25870Cleaning Frequent, thorough cleaning of your ATV will notonly enhance its appearance but will improve itsgener

9-29EBU25932Storage Short-termAlways store your ATV in a cool, dry place and, ifnecessary, protect it against dust with a porouscover.NOTICEECB00720●

1-51WHAT CAN HAPPENExhaust fumes are poisonous and maycause loss of consciousness and deathwithin a short time.HOW TO AVOID THE HAZARDAlways operate y

9-39c. Install the spark plug cap onto the sparkplug, and then place the spark plug on thecylinder head so that the electrodes aregrounded. (This will

10-110EBU25960SPECIFICATIONS Dimensions:Overall length:1978 mm (77.9 in)Overall width:1063 mm (41.9 in)Overall height:1095 mm (43.1 in)Seat height:840

10-210Engine oil quantity:Without oil filter cartridge replacement:2.20 L (2.33 US qt, 1.94 Imp.qt)With oil filter cartridge replacement:2.30 L (2.43

10-310Manufacturer/model:MAXXIS/M937Rear tire:Type:TubelessSize:AT23 x 10-12Manufacturer/model:MAXXIS/M938Loading:Maximum loading limit:100.0 kg (220

10-410Electrical system:Ignition system:DC. CDICharging system:AC magnetoBattery:Model:YTX14AHVoltage, capacity:12 V, 12.0 AhHeadlight:Bulb type:Krypt

11-111EBU25981CONSUMER INFORMATIONEBU26011Identification numbers Record the key identification number, vehicle iden-tification number and model label

11-211TIPThe vehicle identification number is used to identifyyour ATV.EBU26050Model label The model label is affixed at the location in the il-lustra

11-311EBU26060Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:Federal law prohibits the following acts or the causing thereof: (1) The

11-411EBU26080Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main-tenance do

11-511EBU26501YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased fr

2-12EBU17660LOCATION OF THE WARNING AND SPECIFICATION LABELS U3D513E0.book Page 1 Monday, May 19, 2008 3:19 PM

11-611WARRANTY QUESTIONS AND ANSWERSQ. What costs are my responsibility during the warranty period?A. The customer’s responsibility includes all costs

11-711EBU26122YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S

11-811We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-b

11-911EBU26132U3D513E0.book Page 9 Monday, May 19, 2008 3:19 PM

INDEXAAccessories and loading ...6-6Air filter element, cleaning ...

MMain switch ... 4-1Maintenance and lubrication chart ...

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PRINTED IN USA2008.05-0.4×1 CR(E)YAMAHA MOTOR CO., LTD.EBU26151LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.(For replacement m

2-22EBU17670Read and understand all of the labels on your ATV. These labels contain important information for safe andproper operation.Never remove an

2-32U3D513E0.book Page 3 Monday, May 19, 2008 3:19 PM

3-13EBU17680DESCRIPTION EBU17690Left viewEBU17700Right view1. Front shock absorber assembly spring preload adjusting ring2. Fuel cock3. Air filter cas

3-23EBU17712Controls and instrumentsTIPThe ATV you have purchased may differ slightlyfrom the figures shown in this manual.1. Rear brake lever2. Handl

4-14EBU17722INSTRUMENT AND CONTROL FUNCTIONSWARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.EBU17760Main switc

EBU17092Read this manual carefully before operating this vehicle. This manual should stay with this ve-hicle if it is sold.U3D513E0.book Page 1 Mond

4-24EBU17813Indicator lights and warning light EBU17830Reverse indicator light “” This indicator light comes on when the transmis-sion is in the rever

4-34EBU18061Handlebar switches EBU18080Engine stop switch “ / ” Set this switch to “” before starting the engine.The engine stop switch controls the i

4-44EBU18270Throttle lever Once the engine is running, movement of the throt-tle lever will increase the engine speed.Regulate the speed of the ATV by

4-54crease the maximum engine power availableand the maximum speed of the ATV, turn theadjusting screw in direction (b).3. Tighten the locknut.WARNING

4-64EBU18442Brake pedal and rear brake lever The brake pedal is located on the right side of theATV and the rear brake lever is located on the lefthan

4-74EBU18450Parking brake Use the parking brake before starting the engine orparking the ATV, especially on a slope. Apply therear brake lever and pus

4-84EBU18720Fuel tank cap Remove the fuel tank cap by turning it counter-clockwise.EBU18730Fuel Make sure that there is sufficient fuel in the tank.Fi

4-94NOTICEECB00070Use only unleaded gasoline. The use of leadedgasoline will cause severe damage to internalengine parts, such as the valves and pisto

4-104WARNINGEWB00270EBU18820Fuel cock The fuel cock supplies fuel from the tank to the car-buretor while also filtering it.The fuel cock lever positio

4-114ONWith the fuel cock lever in this position, fuel flowsto the carburetor. Turn the fuel cock lever to thisposition when starting the engine and r

EBU17170INTRODUCTIONEBU17301Congratulations on your purchase of the Yamaha YFM35XY. This ATV represents the result of many yearsof Yamaha experience i

4-124Move the starter (choke) in direction (b) to turn offthe starter (choke).See the “Starting a cold engine” section on page6-1 for proper operation

4-134To install the seatFit the slot in the seat onto the projection on thefront cowling, insert the projections on the front ofthe seat into the seat

4-144● Do not exceed the maximum load of 100.0 kg(220 lb) for the ATV.TIPDrain plugs are fitted at the bottom of the storagecompartment. If any water

4-154WARNINGEWB00350EBU19021Adjusting the rear shock absorber as-sembly The spring preload can be adjusted to suit the rid-er’s weight and the riding

4-164TIPA special wrench can be obtained at a Yamahadealer to make this adjustment.WARNINGEWB00010Indicates a potential hazard that could result inser

5-15EBU19200PRE-OPERATION CHECKSEBU19213Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table.W

5-25Engine oil• Check oil level in engine, and add recommended oil to specified lev-el if necessary.• Check ATV for oil leakage. Correct if necessary.

5-35EBU19530Fuel Make sure that there is sufficient fuel in the tank.(See page 4-8.)WARNINGEWB00500EBU19560Engine oil Make sure that the engine oil is

5-45EBU27660Front and rear brakes Brake levers and brake pedal● Check that there is no free play in the front brakelever. If there is free play, have

5-55EBU19761Throttle lever Check the operation of the throttle lever. It mustopen smoothly and spring back to the idle positionwhen released. Have a Y

EBU17330IMPORTANT MANUAL INFORMATIONEBU17342FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN-JURY OR DEATH.Particularl

5-65EBU19802Tires WARNINGEWB00552POTENTIAL HAZARDOperating this ATV with improper tires, orwith improper or uneven tire pressure.WHAT CAN HAPPENUse of

5-75EBU19821Measuring the tire pressure Use the low-pressure tire gauge.TIPThe low-pressure tire gauge is included as stan-dard equipment. Make two me

5-85EBU19830Tire wear limit Replace the tire when the tire groove decreases to3 mm (0.12 in).EBU19840Chassis fasteners Make sure that all nuts, bolts

6-16EBU19870OPERATIONWARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.EBU19890WARNINGEWB00610EBU26940Starting a

6-264. Shift the drive select lever into the neutral po-sition. The neutral indicator light should comeon. If the indicator light does not come on,hav

6-367. If the engine is started with the starter (choke)in position (1), the starter (choke) should bereturned to position (2) to warm up the engine.I

6-463. Open the throttle lever gradually.Shifting: Reverse1. Bring the ATV to a complete stop.2. Apply the brake pedal.3. Shift from neutral to revers

6-56WARNINGEWB00670EBU20682Engine break-in TIP● For ATVs equipped with an odometer or an hourmeter, follow the figures given in km (mi) or thefigures

6-66EBU20700Parking When parking the ATV, stop the engine, shift thedrive select lever into the forward position, applythe parking brake, and then tur

6-76● Choose only accessories designed for yourATV. Your Yamaha dealer has a variety of gen-uine Yamaha accessories. Other accessoriesmay also be avai

EBU17350IMPORTANT NOTICEEBU17360Welcome to the Yamaha world of motor sports!This ATV is designed and manufactured for OFF-ROAD use only. It is illegal

6-86● Tie down cargo securely to the carriers. Makesure cargo in the trailer cannot move around. Ashifting load can cause an accident.● Make sure the

7-17EBU21131RIDING YOUR ATV U3D513E0.book Page 1 Monday, May 19, 2008 3:19 PM

7-27WARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.EBU26962GETTING TO KNOW YOUR ATVThis ATV is intended for r

7-37Riding your ATV requires skills acquiredthrough practice over a period of time.Take the time to learn the basic techniques wellbefore attempting m

7-47This ATV is designed to carry operator and car-go only – passengers prohibited.WARNINGEWB00910POTENTIAL HAZARDCarrying a passenger on this ATV.WHA

7-57ApparelWARNINGEWB00920POTENTIAL HAZARDOperating this ATV without wearing an ap-proved motorcycle helmet, eye protectionand protective clothing.WHA

7-67Do not operate after consuming alcohol ordrugs.The operator’s performance capability is reducedby the influence of alcohol or drugs.WARNINGEWB0093

7-77WARNINGEWB00950WARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.Do not operate at speeds too fast for your

7-87Speed limiterFor riders less experienced with this model, thethrottle lever housing is equipped with a speed lim-iter. The speed limiter keeps the

7-97During operationAlways keep your feet on the footboards during op-eration, otherwise they may contact the rearwheels.HOW TO AVOID THE HAZARDNever

WARNINGEWB00010Indicates a potential hazard that could resultin serious injury or death.EBU17420TABLE OF CONTENTSSAFETY INFORMATION ...

7-107WARNINGEWB00980Avoid wheelies and jumping. You may lose controlof the ATV or overturn.WARNINGEWB00990POTENTIAL HAZARDRemoving hands from handleba

7-117ModificationsWARNINGEWB01000POTENTIAL HAZARDOperating this ATV with improper modifica-tions.WHAT CAN HAPPENImproper installation of accessories o

7-127Exhaust systemThe exhaust system on the ATV is very hot duringand following operation. To prevent burns, avoidtouching the exhaust system. Park t

7-137Do not ride on any public road, street, or highway.Riding on public roads can result in collisions withother vehicles.WARNINGEWB01030HOW TO AVOID

7-147Know the terrain where you ride. Ride cautiously inunfamiliar areas. Stay alert for holes, rocks, orroots in the terrain, and other hidden hazard

7-157When riding in an area where you might not easilybe seen, such as desert terrain, mount a cautionflag on the ATV. DO NOT use the flag pole bracke

7-167Do not ride in areas posted “no trespassing”.Do not ride on private property without getting per-mission.Select a large, flat area off-road to be

7-177used to allow the ATV to make turns quickly andeasily. It is essential that this skill be learned first atlow speed.WARNINGEWB01080As you approac

7-187Improper riding procedures such as abrupt throttlechanges, excessive braking, incorrect body move-ments, or too much speed for the sharpness of t

7-197HOW TO AVOID THE HAZARDAlways follow proper procedures for climb-ing hills as described in this Owner’s Manu-al.Always check the terrain carefull

OPERATION ... 6-1Starting a cold engine ... 6-1Starting a warm engine ..

7-207If you are climbing a hill and you find that you havenot properly judged your ability to make it to thetop, you should turn the ATV around while

7-217If you start to roll backwards, DO NOT apply therear brake to stop or try to put the ATV in gear. TheATV could easily tip over backwards. Instead

7-227RIDING DOWNHILLWhen riding your ATV downhill, shift your weightas far to the rear and uphill side of the ATV as pos-sible. Move back on the seat

7-237U3D513E0.book Page 23 Monday, May 19, 2008 3:19 PM

7-247CROSSING A SLOPETraversing a sloping surface on your ATV requiresyou to properly position your weight to maintainproper balance. Be sure that you

7-257U3D513E0.book Page 25 Monday, May 19, 2008 3:19 PM

7-267CROSSING THROUGH SHALLOW WATERThe ATV can be used to cross slow moving, shal-low water of up to a maximum of 35 cm (14 in) indepth. Before enteri

7-277NOTICEECB00730After riding your ATV in water, be sure to drainthe trapped water by removing the check hoseat the bottom of the air filter case, t

7-287RIDING OVER ROUGH TERRAINRiding over rough terrain should be done with cau-tion. Look out for obstacles which could causedamage to the ATV or cou

7-297SLIDING AND SKIDDINGCare should be used when riding on loose or slip-pery surfaces since the ATV may slide. If unex-pected and uncorrected, slidi

Adjusting the brake pedal and rear brake lever free play and checking the brake pedal position ... 8-29Axle boo

7-307With practice, over a period of time, skill at con-trolled sliding can be developed. The terrainshould be chosen carefully before attempting such

7-317● If your ATV begins to tip while turning:Lean more into the turn to regain balance. If nec-essary, gradually let off the throttle and/or steerto

8-18EBU21648PERIODIC MAINTENANCE AND MINOR REPAIREBU21660Safety is an obligation of the owner. Periodic in-spection, adjustment and lubrication will k

8-28The service information included in this manualand the tools provided in the owner’s tool kit are in-tended to assist you in the performance of pr

8-38EBU21742Periodic maintenance chart for the emission control system TIP● For ATVs not equipped with an odometer or an hour meter, follow the month

8-486 * Exhaust system• Check for leakage and replace gasket(s) if neces-sary.• Check for looseness and tighten all screw clamps and joints if necessa

8-58EBU21864General maintenance and lubrication chart NO. ITEMCHECK OR MAINTENANCE JOBINITIAL EVERYWhichev-er comes firstmonth136612km (mi)320 (200)13

8-689 * V-belt• Check for wear, cracks or other damage, and re-place if necessary.√ √√√10 * Chassis fasteners• Make sure that all nuts, bolts, and scr

8-78EBU28390TIP● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.● Hydraulic brake service• Regularly che

8-88WARNINGEWB00010Indicates a potential hazard that could result inserious injury or death.EBU23080Removing and installing the panel The panel shown

1-11EBU17430SAFETY INFORMATIONEBU17513AN ATV IS NOT A TOY AND CAN BE HAZARD-OUS TO OPERATE.An ATV handles differently from other vehicles, in-cluding

8-98EBU23211Checking the spark plug The spark plug is an important engine component,which is easy to check. Since heat and depositswill cause any spar

8-1082. Check the spark plug for electrode erosionand excessive carbon or other deposits, andreplace it if necessary.To install the spark plug1. Measu

8-118TIPIf a torque wrench is not available when installinga spark plug, a good estimate of the correct torqueis 1/4–1/2 turn past finger tight. Howev

8-128TIPThe engine oil should be between the minimumand maximum level marks.5. If the engine oil is at or below the minimumlevel mark, add sufficient

8-1384. Remove the oil filter cartridge with an oil filterwrench.TIPAn oil filter wrench is available at a nearby Yamahadealer.5. Apply a thin coat of

8-1487. Install the engine oil drain bolt, and then tight-en it to the specified torque.8. Refill with the specified amount of the recom-mended engine

8-1589. Start the engine, and then let it idle for severalminutes while checking it for oil leakage. If oilis leaking, immediately turn the engine off

8-1683. If the oil is below the brim of the filler hole, addsufficient oil of the recommended type to raiseit to the correct level.4. Install the oil

8-1785. Install the drain bolt, and then tighten it to thespecified torque.6. Refill with the recommended final gear oil tothe brim of the filler hole

8-1888. Check the final gear case for oil leakage. If oilis leaking, check for the cause.9. Install the final gear case guard by installingthe bolts a