Page 89 of 124
8-18
8 5. Wash the sponge material gently but thor-
oughly in solvent.
WARNING
EWB01940Always use parts cleaning solvent to clean the
sponge material. Never use low-flash-point
solvents or gasoline to clean the sponge mate-
rial because the engine could catch fire or ex-plode.
6. Squeeze the excess solvent out of the sponge
material and let it dry.
CAUTION:ECB00440Do not twist the sponge material when squeez-ing it.
7. Check the sponge material and replace it if
damaged.
8. Apply a quality foam air filter oil to the sponge
material.NOTE:The sponge material should be wet but not drip-ping.
9. Pull the sponge material over the air filter ele-
ment frame, and then install the lock plate.
10. Insert the air filter element into the air filter
case, and then install the air filter case cover
by hooking the holders onto the air filter case.
11. Install the seat.NOTE:The air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the ATV is operated in extremely dusty ar-
eas. Each time the air filter element maintenance
is performed, check the air inlet of the air filter case
for obstructions. Check the air filter case rubber
joint to the carburetor fittings and the rubber joint
1. Air filter element frame
2. Sponge material
3. Air filter element lock plateU3D560E0.book Page 18 Tuesday, December 27, 2005 12:13 PM
Page 90 of 124
8-19
8manifold fittings for an air-tight seal. Tighten all fit-
tings securely to avoid the possibility of unfiltered
air entering the engine.CAUTION:ECB00460Make sure that the air filter element is prop-
erly seated in the air filter case.Never operate the engine with the air filter el-
ement removed. This will allow unfiltered air
to enter the engine, causing rapid engine
wear and possible engine damage. Addition-
ally, operation without the air filter element
will affect carburetor jetting with subsequent
poor performance and possible engine over-heating.EBU27010Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be-
fore cleaning the spark arrester.
1. Remove the tailpipe cover by removing the
bolts.
2. Remove the tailpipe by pulling it out of the
muffler.3. Tap the tailpipe lightly, and then use a wire
brush to remove any carbon deposits from the
spark arrester portion of the tailpipe and inside
of the tailpipe housing.
1. Bolt
2. Tailpipe cover
U3D560E0.book Page 19 Tuesday, December 27, 2005 12:13 PM
Page 91 of 124
8-20
8 4. Insert the tailpipe into the muffler and align the
bolt holes.
5. Install the tailpipe cover by installing the bolts.
WARNING
EWB02340Do not start the engine when cleaning the
spark arrester, otherwise it could cause injury
to the eyes, burns, carbon monoxide poison-
ing, possibly leading to death, and start a fire.
Always let the exhaust system cool prior totouching exhaust components.
EBU23920V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct
check hose, remove the hose and clean it.EBU23930V-belt case drain plug After riding in water deep enough to allow it to en-
ter the V-belt case, remove this plug to drain the
water from the case.NOTE:If water drains from the V-belt case after removing
the plug, have a Yamaha dealer check the ATV asthe water may affect other engine parts.
1. Tailpipe
2. Spark arrester
1. V-belt cooling duct check hose (left front side of ATV)
U3D560E0.book Page 20 Tuesday, December 27, 2005 12:13 PM
Page 92 of 124
8-21
8
EBU23940Adjusting the carburetor The carburetor should be checked and, if neces-
sary, adjusted at the intervals specified in the peri-
odic maintenance and lubrication chart. The
carburetor is an important part of the engine and
requires very sophisticated adjustment. Therefore,
most carburetor adjustments should be left to a
Yamaha dealer, who has the necessary profes-
sional knowledge and experience. The adjustment
described in the following section, however, may
be performed by the owner as part of routine main-
tenance.
CAUTION:ECB00480The carburetor has been set and extensively
tested at the Yamaha factory. Changing these
settings without sufficient technical knowl-
edge may result in poor performance of ordamage to the engine.EBU24000Adjusting the engine idling speed The engine idling speed must be checked and, if
necessary, adjusted as follows at the intervals
specified in the periodic maintenance and lubrica-
tion chart.NOTE:A diagnostic tachometer is needed to make thisadjustment.
1. Start the engine and warm it up.NOTE:The engine is warm when it quickly responds to thethrottle.
2. Attach the tachometer to the spark plug lead.
3. Check the engine idling speed and, if neces-
sary, adjust it to specification by turning the
throttle stop screw at the carburetor. To in-
1. V-belt case drain plugU3D560E0.book Page 21 Tuesday, December 27, 2005 12:13 PM
Page 93 of 124
8-22
8 crease the engine idling speed, turn the throt-
tle stop screw in direction (a), and to decrease
it, turn the screw in direction (b).
NOTE:If the specified idling speed cannot be obtained as
described above, have a Yamaha dealer make theadjustment.
EBU24041Adjusting the throttle cable free play The throttle cable free play should be checked
and, if necessary, adjusted at the intervals speci-
fied in the periodic maintenance and lubrication
chart.
The throttle cable free play should measure 3.0–
5.0 mm (0.12–0.20 in) as shown. Periodically
check the throttle cable free play and, if necessary,
adjust it as follows.NOTE:The engine idling speed must be checked, and ad-
justed if necessary, before adjusting the throttle ca-ble free play.
1. Loosen the locknut.
2. To increase the throttle cable free play, turn
the adjusting bolt in direction (a). To decrease
the throttle cable free play, turn the adjusting
bolt in direction (b).
1. Throttle stop screwEngine idling speed:
1450–1550 r/min
U3D560E0.book Page 22 Tuesday, December 27, 2005 12:13 PM
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8-23
83. Tighten the locknut.
EBU24060Valve clearance The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24070Adjusting the drive select lever safety
system cable The drive select lever safety system cable stretch-
es with use, which can result in improper function.
Therefore, the safety system cable should be
checked and adjusted at the intervals specified in
the periodic maintenance and lubrication chart.EBU24120Checking the front brake pads and rear
brake shoes The front brake pads and the rear brake shoes
must be checked for wear at the intervals specified
in the periodic maintenance and lubrication chart.EBU24171Front brake pads
Check each front brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-
aged or if the lining thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer replace the brake
pads as a set.
1. Locknut
2. Throttle cable free play adjusting bolt
3. Throttle cable free playU3D560E0.book Page 23 Tuesday, December 27, 2005 12:13 PM
Page 95 of 124
8-24
8
NOTE:The wheels need to be removed to check thebrake pads. (See page 8-38.)EBU24180Rear brake shoes
The rear brake is provided with a wear indicator,
which allows you to check the brake shoe wear
without having to disassemble the brake. To check
the brake shoe wear, check the position of the
wear indicator while applying the brake. If a brake
shoe has worn to the point that the wear indicator
reaches the wear limit line or mark, have a
Yamaha dealer replace the brake shoes as a set.
EBU24251Checking the brake fluid level Insufficient brake fluid may allow air to enter the
brake system, possibly causing it to become inef-
fective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish if neces-
sary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
1. Lining thickness
1. Wear limit line
2. Wear indicator
U3D560E0.book Page 24 Tuesday, December 27, 2005 12:13 PM
Page 96 of 124
8-25
8Observe these precautions:
When checking the fluid level, make sure that
the top of the brake fluid reservoir is level.Use only the recommended quality brake fluid,
otherwise the rubber seals may deteriorate,
causing leakage and poor braking performance.Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor braking performance.
Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and may
result in vapor lock.Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid imme-
diately.As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.EBU24280Changing the brake fluid Have a Yamaha dealer change the brake fluid at
the intervals specified in the NOTE after the peri-
odic maintenance and lubrication chart. In addi-
tion, have the oil seals of the brake master cylinder
and calipers as well as the brake hoses replaced at
the intervals listed below or whenever they are
damaged or leaking.Oil seals: Replace every two years.Brake hoses: Replace every four years.
1. Minimum level markRecommended brake fluid:
DOT 4
U3D560E0.book Page 25 Tuesday, December 27, 2005 12:13 PM
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