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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 ............... 3-5
Model label ........................................... 3-7
CONTROL FUNCTIONS ......................... 4-1
Main switch........................................... 4-1
Indicator lights ...................................... 4-3
Handlebar switches .............................. 4-5
Start switch .......................................... 4-7
Throttle lever ........................................ 4-9
Speed limiter ...................................... 4-11
Clutch lever ........................................ 4-13
Brake lever ......................................... 4-13
Brake pedal ........................................ 4-15
Parking brake lever ............................ 4-17
Shift pedal .......................................... 4-21
1234
Drive select lever ............................... 4-21
Fuel tank cap ..................................... 4-23
Fuel cock............................................ 4-23
Starter (choke) .................................. 4-27
Seat.................................................... 4-29
Front shock absorber adjustment ...... 4-31
Rear shock absorber adjustment ....... 4-33
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Chain.................................................. 5-13
Throttle lever ...................................... 5-15
Fittings and fasteners......................... 5-15
Lights ................................................. 5-15
Switches............................................. 5-15
Tires ................................................... 5-17
How to measure tire pressure ............ 5-21
Tire wear limit..................................... 5-23
5
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OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Warming up...........................................6-9
Drive select lever operation and
reverse driving ..................................6-11
Shifting ................................................6-15
To start out and accelerate .................6-17
To decelerate ......................................6-21
Engine break-in ...................................6-23
Parking ................................................6-27
Parking on a slope ..............................6-27
Accessories and loading .....................6-31
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 ...................7-27
Turning your ATV ................................7-41
Climbing uphill.....................................7-47
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
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Engine oil and oil filter element........... 8-17
Spark plug inspection ......................... 8-29
Air filter element cleaning ................... 8-33
Carburetor adjustment ........................ 8-41
Idle speed adjustment ........................ 8-43
Throttle lever adjustment .................... 8-45
Valve clearance adjustment ............... 8-45
Front brake pad inspection ................. 8-47
Rear brake pad inspection.................. 8-47
Brake fluid level check ........................ 8-49
Brake fluid replacement ...................... 8-53
Front brake lever free play.................. 8-55
Brake pedal height adjustment ........... 8-57
Parking brake adjustment ................... 8-59
Adjusting the rear brake light switch ... 8-65
Clutch lever free play adjustment ....... 8-67
Drive chain slack check ...................... 8-69
Drive chain slack adjustment .............. 8-71
Lubricating the drive chain.................. 8-73
Cable inspection and lubrication......... 8-75
Brake and shift pedal/brake and
clutch lever lubrication ...................... 8-75
8
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Front upper and lower arm pivot
lubrication ......................................... 8-79
Rear arm pivot lubrication .................. 8-81
Wheel removal ................................... 8-85
Wheel installation ............................... 8-87
Battery ................................................ 8-89
Battery maintenance .......................... 8-93
Fuse replacement............................... 8-95
Replacing a headlight bulb ................. 8-97
Headlight beam adjustment.............. 8-103
Tail/brake light bulb replacement ..... 8-105
Troubleshooting................................ 8-107
Troubleshooting chart....................... 8-109
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................. 10-1
CONVERSION TABLE .......................... 11-1
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3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Seat
2. Drive select lever
3. Fuel tank cap
4. Main switch
5. Brake pedal
6. Headlights
7. Front wheel
8. Fuel cock9. Rear wheel
10. Shift pedal
11. Clutch lever
12. Parking brake lever
13. Brake lever
14. Throttle lever
15. Handlebar switchesNOTE: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
BrakesCheck operation, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-47–8-57
ClutchCheck operation, condition and lever free play. 8-67
Parking brakeCheck operation, condition and cable length. 8-59–8-63
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-17–8-27
Drive chainCheck chain slack and condition.
Adjust if necessary.5-13, 8-69–8-73
ThrottleCheck for proper throttle cable operation and free play. 5-15, 8-45
Wheels and tiresCheck tire pressure, wear and damage.5-17–5-23,
8-85–8-87
Fittings and fastenersCheck all fittings and fasteners. 5-15
Lights and switchesCheck for proper operation.5-15, 8-65,
8-97–8-105
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5-15
EBU01083
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha
dealer repair as necessary for proper operation.
EBU01162
Fittings and fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.
EBU01003
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU01170
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper op-
eration.
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6-11 1. Drive select lever
2. Knob
3. For forward drive
4. For reverse drive
1. Levier de présélection
2. Bouton
3. Conduite en marche avant
4. Conduite en marche arrière
1. Palanca de selección de gama
2. Botón
3. Para marcha adelante
4. Para marcha atrás
EBU01171
Drive select lever operation and reverse driv-
ingCAUTION:_ Before shifting, stop the machine and return
the throttle lever to its closed position, other-
wise the transmission may be damaged. _NOTE:_ When shifting into reverse, the clutch must be dis-
engaged. _1. Bring the machine to a complete stop and re-
turn the throttle lever to the closed position.
2. Pull in the clutch lever to disengage the
clutch.
3. Apply the brake pedal.
4. While pulling the knob, move the drive select
lever toward the rear until it completely stops.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 machine. _
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6-29
1. Bring the machine to a stop by applying the
front brake.
2. With the front and rear brake applied, pull the
clutch lever, shift into the neutral position,
and then apply the parking brake.
3. Stop the engine by setting the engine stop
switch to “”.
4. With the front and rear brakes applied, pull
the clutch lever, shift into 1st gear, and then
slowly release the clutch lever, brake lever
and brake pedal.NOTE:_ Make sure that the neutral indicator light goes off. _5. Turn the key to “OFF”.
U5YT61.book Page 29 Wednesday, April 7, 2004 3:59 PM