8-18
1
2
3
4
5
6
78
9
10
11
5. Wash the sponge material gently but thor-
oughly in solvent.
WARNING
EWB01940
Always 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:
ECB00440
Do 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 by
turning it.
1. Sponge material
2. Air filter element frame
3. Air filter element lock plate
1 22
1
3
8-33
1
2
3
4
5
6
78
9
10
11
Rear brake
Observe 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.
EBU24290
Changing 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 master cylinders and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.
EBU24390
Checking the front brake lever free play
The brake lever free play must be checked at the
1. Minimum level mark
Recommended brake fluid:
DOT 4
LOWER
1
8-41
1
2
3
4
5
6
78
9
10
11
CAUTION:
ECB00560
The drive chain must be lubricated after wash-
ing the ATV or riding in the rain.
1. Clean the drive chain with kerosene and a
small soft brush.
CAUTION:
ECB00570
To prevent damaging the O-rings, do not clean
the drive chain with steam cleaners, high-pres-
sure washers or inappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a
special O-ring chain lubricant.CAUTION:
ECB00580
Do not use engine oil or any other lubricants
for the drive chain, as they may contain sub-
stances that could damage the O-rings.
EBU24900
Checking 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
EWB02130
Inspect 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 an
accident or injury.
1. O-ring
Recommended lubricant:
Engine oil
9-3
1
2
3
4
5
6
7
89
10
11
with oil.)
e. Remove the spark plug caps from the
spark plugs, and then install the spark
plugs and the spark plug caps.
6. Lubricate all control cables and the pivoting
points of all levers and pedals.
7. Check and, if necessary, correct the tire air
pressure, and then block up the ATV so that
all of its wheels are off the ground. Alternative-
ly, turn the wheels a little every month in order
to prevent the tires from becoming degraded
in one spot.
8. Cover the muffler outlet with a plastic bag to
prevent moisture from entering it.
NOTE:
Make any necessary repairs before storing the
ATV.
INDEX
A
Accessories and loading ................................................ 6-6
Air filter element, cleaning ............................................ 8-16
B
Brake and clutch levers, checking and lubricating ....... 8-42
Brake and shift pedals, checking and lubricating ......... 8-42
Brake fluid, changing.................................................... 8-33
Brake fluid level, checking............................................ 8-32
Brake lever ..................................................................... 4-5
Brake lever free play, checking the front ...................... 8-33
Brake light switches ..................................................... 8-37
Brake pads, checking the front and rear ...................... 8-31
Brake pedal .................................................................... 4-5
Brake pedal position, checking .................................... 8-34
Brakes, front and rear .................................................... 5-4
C
Cables, checking and lubricating ................................. 8-41
Carburetor settings, changing ...................................... 8-21
Chassis fasteners........................................................... 5-8
Cleaning ......................................................................... 9-1
Clutch lever .................................................................... 4-4
Clutch lever free play, adjusting ................................... 8-37
Coolant ................................................................. 5-4
,
8-11
D
Drive chain ..................................................................... 5-5
Drive chain, lubricating ................................................. 8-40Drive chain slack .......................................................... 8-38
E
Engine break-in .............................................................. 6-4
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-28
Engine, starting a warm ................................................. 6-2
Engine stop switch ......................................................... 4-2
F
Fuel ................................................................................ 4-8
Fuel and 2-stroke engine oil mixing ratio ....................... 5-4
Fuel cock ........................................................................ 4-9
Fuel tank cap.................................................................. 4-7
H
Handlebar switches ........................................................ 4-2
Headlight beam, adjusting............................................ 8-47
Headlight bulb, replacing.............................................. 8-44
I
Identification numbers .................................................. 11-1
Instruments, lights and switches .................................... 5-8
K
Key identification number ............................................. 11-1
Kickstarter ...................................................................... 4-7
L
Label locations ............................................................... 2-1
Light switch .................................................................... 4-2
M
Main switch .....................................................................4-1
Model label....................................................................11-2
O
Owner’s manual and tool kit............................................8-1
P
Parking ............................................................................6-5
Parking brake ..................................................................4-5
Parking brake free play, adjusting.................................8-35
Parking on a slope ..........................................................6-6
Part locations ..................................................................3-1
Periodic maintenance and lubrication chart ....................8-3
Pre-operation check list ..................................................5-1
R
Riding your ATV ..............................................................7-1
S
Safety information ...........................................................1-1
Seat...............................................................................4-11
Shifting ............................................................................6-3
Shift pedal .......................................................................4-7
Shock absorber assemblies, adjusting the front ...........4-12
Shock absorber assembly, adjusting the rear ...............4-13
Spark arrester, cleaning ................................................8-19
Spark plugs, checking .....................................................8-7
Specifications ................................................................10-1
Speed limiter ...................................................................4-3
Starter (choke) ..............................................................4-10
Storage ...........................................................................9-2
Suspension, lubricating the upper and lower arm
pivots ..........................................................................8-43Suspension relay arm and connecting arm pivoting
points, lubricating the rear ......................................... 8-42
T
Tail/brake light bulb, replacing ..................................... 8-47
Throttle cable free play, adjusting ................................ 8-30
Throttle lever ...........................................................4-2
,
5-5
Throttle OverRide System.............................................. 4-3
Tire pressure, measuring ............................................... 5-7
Tires ............................................................................... 5-6
Tire wear limit................................................................. 5-7
Transmission oil ......................................................5-4
,
8-9
Troubleshooting ........................................................... 8-49
Troubleshooting charts ................................................ 8-51
V
Vehicle identification number ....................................... 11-1
W
Wheel bearings, checking ............................................ 8-42
Wheel, installing ........................................................... 8-49
Wheel, removing .......................................................... 8-48