Page 13 of 350

LOCATION OF THE WARNING AND
SPECIFICATION LABELS .......................1-1
SAFETY INFORMATION .........................2-1
DESCRIPTION AND MACHINE
IDENTIFICATION.....................................3-1
Identification number records ...............3-3
Key identification number .....................3-5
Vehicle identification number ...............3-5
Model label ...........................................3-7
CONTROL FUNCTIONS..........................4-1
Main switch ...........................................4-1
Indicator lights ......................................4-3Handlebar switches ..............................4-5
Throttle lever ........................................4-9
Speed limiter ......................................4-11
Front brake lever ................................4-13
Rear brake lever .................................4-13
Parking brake .....................................4-15
Drive select lever ................................4-17
Fuel tank cap ......................................4-17
Fuel cock ............................................4-19
Starter (choke) ....................................4-21
Seat ....................................................4-23
PRE-OPERATION CHECKS ...................5-1
Front and rear brakes ...........................5-5
Fuel ......................................................5-7
EBU00015
CONTENTS
1
2
3
45
5VJ-9-61-01 3/14/03 11:48 PM Page 12
Page 14 of 350

Engine and transmission oil ...............5-11
Chain ..................................................5-15
Throttle lever ......................................5-15
Fittings and fasteners .........................5-17
Lights ..................................................5-17
Switches .............................................5-17
Battery ................................................5-17
Tires ...................................................5-19
How to measure tire pressure ............5-23
Tire wear limit .....................................5-25
OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine ......................6-11
Warming up ........................................6-11
Drive select lever operation and reverse
driving ...............................................6-13
Engine break-in ..................................6-19Parking ...............................................6-23
Parking on a slope ..............................6-25
Accessories and loading ....................6-27
Riding Your ATV ......................................7-1
Getting to know your ATV.....................7-3
Ride with care and good
judgement ...........................................7-5
Be careful where you ride ...................7-29
Turning your ATV ...............................7-41
Climbing uphill ....................................7-45
Riding downhill ...................................7-57
Crossing a slope .................................7-61
Crossing through shallow water .........7-65
Riding over rough terrain ....................7-69
Sliding and skidding ...........................7-71
What to do if .......................................7-75
What to do ..........................................7-75
6
7
5VJ-9-61-01 3/14/03 11:48 PM Page 13
Page 15 of 350

PERIODIC MAINTENANCE AND
ADJUSTMENT .........................................8-1
Owner’s manual and tool kit .................8-3
Periodic maintenance/Lubrication ........8-7
Engine oil ............................................8-13
Transmission oil .................................8-21
Spark plug inspection .........................8-27
Engine and V-belt compartment
air filter element cleaning .................8-31
Idle speed adjustment ........................8-41
Valve clearance adjustment ...............8-43
Throttle lever adjustment ....................8-43
Front and rear brake shoe
inspection .........................................8-45
Front brake lever free play
adjustment ........................................8-47
Rear brake adjustment .......................8-55
Drive chain slack check ......................8-57
Drive chain slack adjustment ..............8-59Lubricating and drive chain ................8-63
Draining the V-belt compartment ........8-65
Cable inspection and lubrication ........8-67
Brake lever lubrication ........................8-69
Knuckle shaft, lower arms and
steering shaft lubrication ..................8-69
Wheel removal ...................................8-71
Wheel installation ...............................8-71
Battery ................................................8-73
Replenishing the battery fluid .............8-77
Fuse replacement ...............................8-81
Replacing the headlight bulb ..............8-83
Tail/brake light bulb replacement .......8-87
Headlight beam adjustment ................8-89
Troubleshooting ..................................8-91
Troubleshooting chart .........................8-958
5VJ-9-61-01 3/14/03 11:48 PM Page 14
Page 45 of 350
2-15
8Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed
and securely attached. Reduce speed and fol-
low instructions in this manual for carrying
cargo. Allow greater distance for braking.
w
8Always turn off the engine when refueling.
8Do not refuel right after the engine has
been running and is still very hot.
8Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or while in the
vicinity of sparks, open flames, or other
sources of ignition such as the pilot lights
of water heaters and clothes dryers.
Gasoline can catch fire and you could be
burned.
5VJ-9-61-02 3/14/03 11:49 PM Page 16
Page 49 of 350
3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION
1. Seat 11. Rear brake lever
2. Drive select lever 12. Parking brake
3. Headlight 13. Reverse indicator light
4. Front cover 14. Neutral indicator light
5. Front wheel 15. Front brake lever
6. Starter (choke) 16. Throttle lever
7. Fuel cock 17. Main switch
8. Rear wheel 18. Fuel tank cap
9. Tail/brake light 19. Handlebar switches
10. Footboard
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
wqer
!5!2!1
!3
!4
!6
!9!8!7
!0
i uyto
5VJ-9-61-03 3/14/03 11:49 PM Page 2
Page 57 of 350
4-1
EBU00040
CONTROL FUNCTIONS
EBU00041
Main switch
Functions of the respective switch positions are
as follows:
ON:
Engine can be started only at this position and
the headlight and taillight come on when the
light switch is on.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
OFF ON
5VJ-9-61-04 3/17/03 4:47 PM Page 2
Page 59 of 350
4-3
EBU00043
Indicator lights
EBU00044
Reverse indicator light “REVERSE”
This indicator light comes on when the transmis-
sion is in reverse.
EBU00045
Neutral indicator light “NEUTRAL”
This indicator light comes on when the transmis-
sion is in neutral.
wqe
1. Main switch
2. Reverse indicator light “REVERSE”
3. Neutral indicator light “NEUTRAL”
1. Contacteur à clé
2. Témoin de marche arrière “REVERSE”
3. Témoin de point mort “NEUTRAL”
1. Interruptor principal
2. Luz de control de marcha atrás “REVERSE”
3. Luz de control de punto muerto “NEUTRAL”
5VJ-9-61-04 3/17/03 4:47 PM Page 4
Page 61 of 350
4-5
EBU00053
Handlebar switches
EBU11580
Engine stop switch “ENG. STOP”
Make sure that the engine stop switch is in the
“RUN” position before starting the engine. The
engine stop switch controls ignition and can be
used at all times to stop the engine, especially in
an emergency. The engine will not start or run
when the engine stop switch is turned to “OFF”.
EBU00056
Start switch “START”
The starter motor cranks the engine when this
switch is pushed.
cC
See starting instructions prior to starting
engine (see page 6-3 for details).
w
q
e
1. Engine stop switch “ENG. STOP”
2. Light switch “LIGHTS”
3. Start switch “START”
1. Coupe-circuit du moteur “ENG. STOP”
2. Contacteur d’éclairage “LIGHTS”
3. Contacteur de démarreur “START”
1. Interruptor de paro del motor “ENG. STOP”
2. Interruptor de luces “LIGHTS”
3. Interruptor de arranque “START”
5VJ-9-61-04 3/17/03 4:47 PM Page 6