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8-20
8
10. Install panel C.
11. Install the engine oil drain bolt, and then tight-
en it to the specified torque.12. Add the specified amount of the recommend-
ed engine oil, and then install and tighten the
engine oil filler cap.
CAUTION:ECB00300In order to prevent clutch slippage (since the
engine oil also lubricates the clutch), do not
mix any chemical additives. Do not use oils
with a diesel specification of “CD” or oils of
a higher quality than specified. In addition,
do not use oils labeled “ENERGY CONSERV-
ING II” or higher.Make sure that no foreign material enters thecrankcase.
1. Torque wrenchTightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torque:
Engine oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Recommended oil:
See page 10-1.
Oil quantity:
Without oil filter cartridge replacement:
2.30 L (2.43 US qt) (2.02 Imp.qt)
With oil filter cartridge replacement:
2.40 L (2.54 US qt) (2.11 Imp.qt)
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8-21
8 13. Start the engine, and then let it idle for several
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
14. Turn the engine off, and then check the oil lev-
el and correct it if necessary.
15. Install panel D.
EBU23381Final gear oil The final gear case must be checked for oil leak-
age before each ride. If any leakage is found, have
a Yamaha dealer check and repair the ATV. In ad-
dition, the final gear oil level must be checked and
the oil changed as follows at the intervals specified
in the periodic maintenance and lubrication chart.
To check the final gear oil level
1. Place the ATV on a level surface.NOTE:The final gear oil level must be checked on a coldengine.
2. Remove the final gear oil filler bolt, and then
check the oil level in the final gear case.
NOTE:The oil level should be at the brim of the filler hole.
3. If the oil is below the brim of the filler hole, add
sufficient oil of the recommended type to raise
it to the correct level.
4. Install the oil filler bolt, and then tighten it to the
specified torque.1. Final gear oil
2. Final gear oil filler bolt
3. Correct oil levelTightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
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8-25
8
The differential gear case capacity is greater
than the recommended oil quantity, therefore
the oil level cannot be accurately checked fromthe oil filler hole.CAUTION:ECB00410Be sure no foreign material enters the differen-tial gear case.
6. Install the oil filler bolt, and then tighten it to the
specified torque.
7. Check the differential gear case for oil leak-
age. If oil is leaking, check for the cause.
EBU23470Coolant The coolant level should be checked before each
ride. In addition, the coolant must be changed at
the intervals specified in the periodic maintenance
and lubrication chart.EBU23481To check the coolant level
1. Place the ATV on a level surface.NOTE:The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-ture.
2. Check the coolant level in the coolant reser-
voir.NOTE:The coolant should be between the minimum andmaximum level marks. Recommended differential gear oil:
See page 10-1.
Oil quantity:
0.35 L (0.37 US qt) (0.31 Imp.qt)
Tightening torque:
Differential gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
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8-27
8
If water has been used instead of coolant, re-
place it with coolant as soon as possible,
otherwise the engine may not be sufficiently
cooled and the cooling system will not be
protected against frost and corrosion.If water has been added to the coolant, have
a Yamaha dealer check the antifreeze con-
tent of the coolant as soon as possible, oth-
erwise the effectiveness of the coolant willbe reduced.
NOTE:If the engine overheats, see page 8-54 for furtherinstructions.EBU26440To change the coolant
WARNING
EWB01890Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always place a thick rag over the cap
when opening. Allow any remaining pressureto escape before completely removing the cap.
1. Place the ATV on a level surface.2. Remove panels C and D. (See page 8-8.)
3. Place a container under the engine, and then
remove the coolant drain bolt. (Use a trough
or a similar object as shown to prevent coolant
from spilling on the footrest.)
1. Coolant drain bolt
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8-29
8 10. Connect the coolant reservoir hose.
11. Pour the recommended coolant into the reser-
voir to the maximum level mark, and then in-
stall the reservoir cap.
12. Pour the recommended coolant into the radia-
tor until it is full.
CAUTION:ECB00400If coolant is not available, use distilled water
or soft tap water instead. Do not use hard wa-
ter or salt water since it is harmful to the en-
gine.
If water has been used instead of coolant, re-
place it with coolant as soon as possible,
otherwise the engine may not be sufficiently
cooled and the cooling system will not be
protected against frost and corrosion.If water has been added to the coolant, have
a Yamaha dealer check the antifreeze con-
tent of the coolant as soon as possible, oth-
erwise the effectiveness of the coolant willbe reduced.
13. Install the radiator cap, start the engine, let it
idle for several minutes, and then turn it off.
14. Remove the radiator cap to check the coolant
level in the radiator. If it is low, add sufficient
coolant until it reaches the top of the radiator,
and then install the radiator cap.
15. Start the engine, and then check for coolant
leakage.
NOTE:If any leakage is found, have a Yamaha dealercheck the cooling system.
16. Install the cowling.
17. Install the panels. Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol antifreeze con-
taining corrosion inhibitors for aluminum en-
gines
Coolant quantity:
Radiator capacity (including all routes):
1.32 L (1.40 US qt) (1.16 Imp.qt)
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
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8-31
8 4. Pull off the lock plate, and then remove the
sponge material from the air filter element
frame.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.
1. Air filter element
1. Air filter element frame
2. Sponge material
3. Air filter element lock plate
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8
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 jointmanifold 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.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.
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8
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.
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.
1. V-belt cooling duct check hose (left front side of ATV)
1. V-belt case drain plug
U3C260E0.book Page 33 Tuesday, August 2, 2005 9:52 AM
