Page 18 of 402

Adjusting the rear brake light switch... 8-87
Cable inspection and lubrication ........ 8-89
Lubricating the brake levers and
brake pedal ...................................... 8-91
Wheel removal ................................... 8-93
Wheel installation ............................... 8-95
Battery ................................................ 8-97
Battery maintenance ........................ 8-101
Fuse replacement............................. 8-103
Replacing a headlight bulb ............... 8-107
Headlight beam adjustment.............. 8-113
Tail/brake light bulb replacement ..... 8-113
Troubleshooting................................ 8-115
Troubleshooting chart....................... 8-117
CLEANING AND STORAGE .................. 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
91011U5UH62.book Page 3 Tuesday, April 5, 2005 6:57 PM
Page 42 of 402
2-5
Never attempt wheelies, jumps, or other stunts.
Always inspect your ATV each time you use it
to make sure it is in safe operating condition.
Always follow the inspection and maintenance
procedures and schedules described in this
manual.
Always keep both hands on the handlebars
and both feet on the footboards of the ATV dur-
ing operation.
Always go slowly and be extra careful when op-
erating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the
ATV.
Never operate on excessively rough, slippery
or loose terrain until you have learned and
practiced the skills necessary to control the
ATV on such terrain. Always be especially cau-
tious on these kinds of terrain.
U5UH62.book Page 5 Tuesday, April 5, 2005 6:57 PM
Page 56 of 402
3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber
assembly spring preload
adjusting ring
2. Storage box and tool kit
3. Spark plug
4. Front shock absorber
assembly spring preload
adjusting ring
5. Brake pedal
6. V-belt case
7. Fuel cock
8. Air filter case
9. Fuses
10. Tail/brake light
11. V-belt cooling duct check
hose12. Oil filter cartridge
13. Engine oil dipstick
14. Rear brake lever
15. Left handlebar switches
16. Starter (choke)
17. Horn switch
18. Drive select lever
19. Speedometer
20. Main switch
21. Fuel tank cap
22. On-Command four-wheel
drive switch
23. Throttle lever
24. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5UH62.book Page 1 Tuesday, April 5, 2005 6:57 PM
Page 68 of 402

4-3 1. Reverse indicator light “REVERSE”
2. Neutral indicator light “NEUTRAL”
3. Four-wheel-drive indicator light “”
4. Oil temperature warning light “”
1. Témoin de marche arrière “REVERSE”
2. Témoin de point mort “NEUTRAL”
3. Témoin 4x4 “”
4. Témoin d’avertissement de la température d’huile “”
1. Luz indicadora de marcha atrás “REVERSE”
2. Luz de control de punto muerto “NEUTRAL”
3. Luz de control del modo de tracción de cuatro ruedas “”
4. Luz de aviso de la temperatura del aceite “”
EBU08020
Indicator and warning lights
EBU14530
Reverse indicator light “REVERSE”
This indicator light comes on when the drive select
lever is in reverse.
EBU14630
Neutral indicator light “NEUTRAL”
This indicator light comes on when the drive select
lever is in neutral.
EBU00605
Four-wheel-drive indicator light “”
This indicator light comes on when the 2WD/4WD
switch is in the 4WD position.NOTE:_ Due to the synchronizing mechanism in the differ-
ential gear case, the light may not come on until
the ATV starts moving. _
U5UH62.book Page 3 Tuesday, April 5, 2005 6:57 PM
Page 70 of 402

4-5 1. Reverse indicator light “REVERSE”
2. Neutral indicator light “NEUTRAL”
3. Four-wheel-drive indicator light “”
4. Oil temperature warning light “”
1. Témoin de marche arrière “REVERSE”
2. Témoin de point mort “NEUTRAL”
3. Témoin 4x4 “”
4. Témoin d’avertissement de la température d’huile “”
1. Luz indicadora de marcha atrás “REVERSE”
2. Luz de control de punto muerto “NEUTRAL”
3. Luz de control del modo de tracción de cuatro ruedas “”
4. Luz de aviso de la temperatura del aceite “”
EBU11400
Oil temperature warning light “”
When the oil temperature reaches a specified lev-
el, this light comes on to warn that the engine oil
temperature is too hot. If the light comes on during
operation, stop the engine as soon as it is safe to
do so and allow the engine to cool down for about
10 minutes.CAUTION:_
The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.
Restart after making sure that the light is
out. Continuous use while the light is on
may cause damage to the engine.
_
U5UH62.book Page 5 Tuesday, April 5, 2005 6:57 PM
Page 82 of 402
4-17 1. On-Command four-wheel drive switch “2WD/4WD”
1. Contacteur de commande du mode de traction “2WD/4WD”
1. Interruptor del modo de tracción en las cuatro ruedas
“2WD/4WD”
EBU00611
On-Command four-wheel drive switch
“2WD/4WD”
To change from two-wheel drive (2WD) to four-
wheel drive (4WD), stop the ATV and set the
switch to the 4WD position.
To change from four-wheel drive (4WD) to two-
wheel drive (2WD), stop the ATV and set the
switch to the 2WD position.
WARNING
_ Always stop the ATV before changing from
2WD to 4WD or from 4WD to 2WD. The ATV
handles differently in 2WD than in 4WD in
some circumstances. Changing from 2WD to
4WD or vice-versa while moving may cause
the ATV to unexpectedly handle differently.
This could distract the operator and increase
the risk of losing control and an accident. _
E-4.fm Page 17 Thursday, April 7, 2005 9:10 AM
Page 112 of 402
5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-71–8-79
Rear brakeCheck operation, condition and free play.
Adjust if necessary.5-5–5-7,
8-71, 8-81–8-85
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-21–8-31
Final gear oil and
differential gear oilCheck for leakage.5-15–5-17,
8-31–8-43
ThrottleCheck for proper throttle cable operation and free play. 5-17, 8-69
Wheels and tiresCheck tire pressure, wear and damage.5-21–5-27,
8-93–8-95
Fittings and fastenersCheck all fittings and fasteners. 5-19
Lights and switchesCheck for proper operation. 5-19, 8-107–8-113
Axle bootsCheck for damage. 8-45
U5UH62.book Page 1 Tuesday, April 5, 2005 6:57 PM
Page 158 of 402
6-19
EBU13760
Parking on a slope
WARNING
_ Avoid parking on hills or other inclines. Park-
ing on a hill or other incline could cause the
ATV to roll out of control, increasing the
chance of an accident. If you must park on an
incline, place the machine transversely across
the incline, apply the parking brake, and block
the front and rear wheels with rocks or other
objects. Do not park the ATV at all on hills that
are so steep you could not walk up them easi-
ly. _1. Bring the machine to a stop by applying the
brakes.
2. Stop the engine.
3. With the rear brake lever and pedal applied,
apply the parking brake, and then slowly re-
lease the brake pedal.
U5UH62.book Page 19 Tuesday, April 5, 2005 6:57 PM