Page 16 of 450
EBU00015
1-CONTENTS
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 ............... 3-7
Model label ........................................... 3-9
CONTROL FUNCTIONS ........................ 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-3
Speedometer unit ................................. 4-9
Fuel gauge ......................................... 4-15
Handlebar switches ............................ 4-17
Throttle lever ...................................... 4-35
Speed limiter ...................................... 4-37
Front brake lever ................................ 4-39
Brake pedal and rear brake lever ....... 4-41
Drive select lever ................................ 4-43
Recoil starter ...................................... 4-43
1234
Fuel tank cap ..................................... 4-45
Fuel cock............................................ 4-47
Starter (choke) .................................. 4-49
Seat.................................................... 4-51
Storage compartment ........................ 4-53
Front carrier ....................................... 4-55
Rear carrier ........................................ 4-55
Front and rear shock absorber
adjustment ....................................... 4-57
Auxiliary DC jack ................................ 4-61
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Final gear oil ...................................... 5-15
Differential gear oil ............................. 5-17
Coolant............................................... 5-19
Throttle lever ...................................... 5-21
Fittings and fasteners......................... 5-21
Lights ................................................. 5-23
Switches............................................. 5-23
Tires ................................................... 5-25
How to measure tire pressure ............ 5-29
5
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Adjusting the rear brake lever and
brake pedal .................................... 8-105
Adjusting the rear brake light
switch ............................................. 8-109
Cable inspection and lubrication ...... 8-111
Lubricating the brake levers and
brake pedal .................................... 8-113
Rear knuckle upper and lower
pivot lubrication .............................. 8-115
Wheel removal ................................. 8-115
Wheel installation ............................. 8-117
Battery .............................................. 8-119
Battery maintenance ........................ 8-123
Fuse replacement............................. 8-125
Replacing a headlight bulb ............... 8-129
Headlight beam adjustment.............. 8-133
Tail/brake light bulb replacement ..... 8-133
Troubleshooting................................ 8-137
Troubleshooting chart....................... 8-139
CLEANING AND STORAGE .................. 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
910
CONVERSION TABLE .......................... 11-1
11
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3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber
assembly spring preload
adjusting ring
2. Storage compartment
and tool kit
3. Spark plug
4. Rear brake fluid reservoir
5. Front shock absorber
assembly spring preload
adjusting ring
6. Brake pedal
7. V-belt case
8. Radiator cap
9. Fuel cock
10. Air filter case
11. Fuses
12. Tail/brake light
13. Engine oil dipstick
14. Oil filter cartridge15. Coolant reservoir
16. V-belt cooling duct check
hose
17. Rear brake lever
18. Left handlebar switches
19. Starter (choke)
20. Horn switch
21. Drive select lever
22. Speedometer unit
23. Main switch
24. Fuel tank cap
25. Auxiliary DC jack
26. Right handlebar switch
27. Throttle lever
28. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
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5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-93, 8-97–8-103
Rear brakeCheck operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-95–8-101,
8-105–8-107
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-33–8-43
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.5-19–5-21,
8-57–8-67
Final gear oil and
differential gear oilCheck for leakage.5-15–5-17,
8-43–8-55
ThrottleCheck for proper throttle cable operation and free play. 5-21, 8-91
Wheels and tiresCheck tire pressure, wear and damage.5-25–5-31,
8-115–8-117
Fittings and fastenersCheck all fittings and fasteners. 5-21
Lights and switchesCheck for proper operation.5-23, 8-109,
8-129–8-133
Axle bootsCheck for damage. 8-67
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5-23
EBU01003
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU11700
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper op-
eration.
U1D960.book Page 23 Wednesday, June 23, 2004 3:59 PM
Page 166 of 450
6-5 a. Starter (choke)
1. Fully open
2. Half open
3. Closed
a. Starter (enrichisseur)
1. Complètement ouvert
2. Mi-ouvert
3. Fermé
a. Starter (choke)
1. Abre completamente
2. Semiabierto
3. Cerrado
NOTE:_
When the drive select lever is in the neutral or
park position, if either indicator light does not
come on, ask a Yamaha dealer to inspect the
respective electric circuit.
The engine can be started in any gear if the
rear brake lever is applied. However, it is rec-
ommended to shift into neutral or park before
starting the engine.
_5. Use the starter (choke) in reference to the fig-
ure:
Position
1: Cold engine start-
ambient temperature below 5°C.
Position
2: Cold engine start-
ambient temperature at 0°C–30°C
and warming up position.
Position
3: Cold engine start-
ambient temperature above 25°C
and warm engine start position.
6. Completely close the throttle lever and start
the engine by pushing the start switch.
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Page 174 of 450
6-13 1. Drive select lever
a. L (Low)
b. H (High)
c. N (Neutral)
d. R (Reverse)
e. P (Park)
1. Levier de présélection
a. L (Rapport inférieur)
b. H (Rapport supérieur)
c. N (Point mort)
d. R (Marche arrière)
e. P (Stationnement)
1. Palanca de selección de marcha
a. L (Baja)
b. H (Alta)
c. N (Punto muerto)
d. R (Marcha atrás)
e. P (Estacionamiento)
Shifting: Neutral to Reverse and Reverse to
ParkNOTE:_ The drive select lever cannot be shifted into or
from reverse or park without applying the rear
brake. _1. Bring the ATV to a complete stop and return
the throttle lever to the closed position.
2. Apply the brake pedal.
3. Shift from neutral to reverse or from reverse
to park and vice versa by moving the drive
select lever along the shift guide.NOTE:_
When in reverse, the reverse indicator light
should be on. If the light does not come on,
ask a Yamaha dealer to inspect the electrical
circuit.
Due to the synchronizing mechanism in the
engine, the light may not come on until the
ATV starts moving.
_
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8-9
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.NOTE:
Recommended brake fluid: DOT 4
Brake fluid replacement:
When disassembling the master cylinders or caliper cylinders, replace the brake fluid. Normally
check the brake fluid level and add fluid as required.
On the inner parts of the master cylinders and caliper cylinders, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
Front and rear axle boots*Check operation.
Replace if damaged.Stabilizer bushes*
Check for cracks or damage.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U1D960.book Page 9 Wednesday, June 23, 2004 3:59 PM
