Page 77 of 124
8-6
8
EBU23070NOTE:The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.Replace the brake hoses every four years and if cracked or damaged.29*Throttle lever hous-
ing and cableCheck operation and correct if necessary.
Check throttle cable free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.√√√√√
30*Exhaust systemCheck for leakage and replace gasket(s) if neces-
sary.
Check for looseness and tighten all screw clamps
and joints if necessary.√√√
31 Spark arresterClean.√√√
32*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
33*Lights and switchesCheck operation and correct if necessary.
Adjust headlight beams.√√√√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300U3D560E0.book Page 6 Tuesday, December 27, 2005 12:13 PM
Page 79 of 124
8-8
8 plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown, with the
spark plug wrench included in the owner’s tool
kit.To check the spark plug
1. Check that the porcelain insulator around the
center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).
NOTE:If the spark plug shows a distinctly different color,
the engine could be defective. Do not attempt to di-
agnose such problems yourself. Instead, have aYamaha dealer check the ATV.
2. Check the spark plug for electrode erosion
and excessive carbon or other deposits, and
replace it if necessary.
1. Spark plug cap
1. Spark plug wrench
U3D560E0.book Page 8 Tuesday, December 27, 2005 12:13 PM
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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
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8-29
84. Tighten the locknut at the brake lever.
NOTE:When adjusting the rear brake lever free play:Be sure not to step on the brake pedal.Make sure the brake pedal does not move.
WARNING
EWB02080Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:
Make sure the brakes operate smoothly and
that the free play is correct.Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These proceduresshould be performed by a Yamaha dealer.EBU24751Brake light switches The operation of the brake light switches must be
checked and, if necessary, adjusted at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
The brake light switch for the brake pedal can be
adjusted as follows, but the other brake light
switches should be adjusted by a Yamaha dealer.
1. Remove panel A. (See page 8-7.)NOTE:The brake light switch is properly adjusted when
the brake light comes on just before braking takeseffect.
2. Turn the adjusting nut while holding the brake
light switch in place. To make the brake light
come on earlier, turn the adjusting nut in direc-
tion (a). To make the brake light come on lat-
er, turn the adjusting nut in direction (b).
1. Locknut
2. Brake lever free play adjusting boltU3D560E0.book Page 29 Tuesday, December 27, 2005 12:13 PM
Page 101 of 124
8-30
8 3. Install the panel.
EBU24900Checking and lubricating the cables The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
WARNING
EWB02130Inspect cables frequently and replace if dam-
aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could re-
strict the operation of controls and lead to anaccident or injury.EBU24911Checking and lubricating the front and
rear brake levers The operation of the front and rear brake levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary.
1. Brake light switch
2. Brake light switch adjusting nutRecommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease (all-purpose
grease)
U3D560E0.book Page 30 Tuesday, December 27, 2005 12:13 PM
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8-34
8 access to a constant-voltage battery charg-
er, have a Yamaha dealer charge your bat-
tery.EBU25322Replacing a fuse
The main fuse and the fuse box are located under
the seat. (See page 4-11.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off all electrical
circuits.CAUTION:ECB00640To prevent accidental short-circuiting, turn off
the main switch when checking or replacing afuse.
1. Main fuse
2. Spare main fuse
3. Fuse box
1. Headlight fuse
2. Ignition fuse
3. Signaling system fuse
4. Spare fuse
U3D560E0.book Page 34 Tuesday, December 27, 2005 12:13 PM
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8-35
82. Remove the blown fuse, and then install a
new fuse of the specified amperage.
WARNING
EWB02171Always use a fuse of the specified rating, and
never use a substitute object in place of the
proper fuse. An improper fuse or a substitute
object can cause damage to the electrical sys-tem, which could lead to a fire.
3. Turn the key to “ON” and turn on the electrical
circuits to check if the devices operate.
4. If the fuse immediately blows again, have a
Yamaha dealer check the electrical system.
EBU25540Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
1. Remove the headlight bulb holder cover at the
rear of the headlight by pulling it off.
2. Remove the headlight bulb holder by pushing
it inward and turning it counterclockwise. Specified fuses:
Main fuse:
20.0 A
Headlight fuse:
15.0 A
Ignition fuse:
15.0 A
Signaling system fuse:
10.0 A1. Headlight bulb holder cover
U3D560E0.book Page 35 Tuesday, December 27, 2005 12:13 PM
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8-36
8 3. Remove the defective bulb from the headlight
unit by pulling it out.
WARNING
EWB02220A headlight bulb is hot when it is on and imme-
diately after it is turned off. Wait for the bulb to
cool before touching or removing it. You can
be burned or a fire could start if the bulb touch-es something flammable.
4. Install a new headlight bulb into the headlight
unit by aligning the projection on the bulb with
the groove in the headlight unit.
CAUTION:ECB00650Do not touch the glass part of the headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the luminosity of the
bulb, and the bulb life will be adversely affect-
ed. Thoroughly clean off any dirt and finger-
prints on the headlight bulb using a clothmoistened with alcohol or thinner.
5. Install the headlight bulb holder by aligning the
projections with the holes in the headlight unit,
pushing it inward, and turning it clockwise until
it stops.
1. Headlight bulb holder
1. Do not touch the glass part of the bulb.
U3D560E0.book Page 36 Tuesday, December 27, 2005 12:13 PM
