EBU17420
TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ..................................................... 3-1
Right view................................................... 3-1
Controls and instruments ........................... 3-2
INSTRUMENT AND CONTROL
FUNCTIONS .................................................. 4-1
Main switch ............................................... 4-1
Handlebar switches ................................... 4-2
Throttle lever ............................................. 4-2
Throttle OverRide System ......................... 4-3
Speed limiter ............................................. 4-3
Clutch lever ............................................... 4-4
Brake lever ................................................ 4-5
Brake pedal ............................................... 4-5
Parking brake ............................................ 4-5
Shift pedal ................................................. 4-7
Kickstarter ................................................. 4-7
Fuel tank cap ............................................. 4-7
Fuel ........................................................... 4-8Fuel cock ................................................... 4-9
Starter (choke) ......................................... 4-10
Seat ......................................................... 4-11
Adjusting the front shock absorber
assemblies .............................................4-12
Adjusting the rear shock absorber
assembly ................................................4-13
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ............................. 5-1
Fuel and 2-stroke engine oil mixing ratio ... 5-4
Transmission oil ......................................... 5-4
Coolant ...................................................... 5-4
Front and rear brakes ................................ 5-4
Throttle lever .............................................. 5-5
Drive chain ................................................. 5-5
Tires ........................................................... 5-6
Measuring the tire pressure ....................... 5-7
Tire wear limit ............................................ 5-7
Chassis fasteners ...................................... 5-8
Instruments, lights and switches ................ 5-8
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-2
Shifting ....................................................... 6-3
Engine break-in ......................................... 6-4
Parking ...................................................... 6-5
Parking on a slope .................................... 6-6
Accessories and loading ........................... 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV.............. 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT ...........................................7-2
BE CAREFUL WHERE YOU RIDE ............ 7-8
TURNING YOUR ATV ............................. 7-12
CLIMBING UPHILL .................................. 7-14
RIDING DOWNHILL................................. 7-16
CROSSING A SLOPE.............................. 7-17
CROSSING THROUGH SHALLOW
WATER ..................................................7-18
RIDING OVER ROUGH TERRAIN .......... 7-20
SLIDING AND SKIDDING ........................ 7-20
WHAT TO DO IF... ................................... 7-21
WHAT TO DO... ....................................... 7-21
PERIODIC MAINTENANCE AND MINOR
REPAIR .......................................................... 8-1
Owner’s manual and tool kit ...................... 8-1
Periodic maintenance and lubrication
chart ........................................................ 8-3
Checking the spark plugs .......................... 8-7
Transmission oil ........................................ 8-9
Coolant .................................................... 8-11Cleaning the air filter element .................. 8-16
Cleaning the spark arrester ..................... 8-19
Changing the carburetor settings ............. 8-21
Adjusting the engine idling speed ............ 8-28
Adjusting the throttle cable free play ........ 8-30
Checking the front and rear brake
pads .......................................................8-31
Checking the brake fluid level .................. 8-32
Changing the brake fluid .......................... 8-33
Checking the front brake lever free
play ........................................................8-33
Checking the brake pedal position ........... 8-34
Adjusting the parking brake free play ...... 8-35
Brake light switches ................................. 8-37
Adjusting the clutch lever free play .......... 8-37
Drive chain slack ...................................... 8-38
Lubricating the drive chain ....................... 8-40
Checking and lubricating the cables ........ 8-41
Checking and lubricating the brake and
clutch levers ...........................................8-42
Checking and lubricating the brake and
shift pedals .............................................8-42
Checking the wheel bearings ................... 8-42
Lubricating the rear suspension relay
arm and connecting arm pivoting
points .....................................................8-42
Lubricating the upper and lower arm
pivots .....................................................8-43
Replacing a headlight bulb ...................... 8-44
1-3
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4
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ing, use the proper gear and maintain a steady
speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for
braking described in this manual. Dismount on
the uphill side or to a side if pointed straight up-
hill. Turn the ATV around and remount, following
the procedure described in this manual.
Always check for obstacles before operating in a
new area.
Never attempt to operate over large obstacles,
such as large rocks or fallen trees. Always follow
proper procedures when operating over obsta-
cles as described in this manual.
Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to re-
duce the chance of skidding or sliding out of con-
trol.
Never operate an ATV in fast flowing water or in
water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.
Always use the size and type of tires specified in
this manual.
Always maintain proper tire pressure as de-
scribed in this manual.
Never modify an ATV through improper installa-
tion or use of accessories.
Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow in-
structions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for brak-
ing.WARNING
EWB00061
Always turn off the engine when refueling.
Do not refuel right after the engine has been
running and is still very hot.
Do not spill gasoline on the engine or ex-
haust pipe/muffler when refueling. Never re-
fuel while smoking, or in the vicinity of
sparks, open flames, or other sources of ig-
nition such as the pilot lights of water heat-
ers and clothes dryers. Gasoline can catch
fire and you could be burned.
When transporting the ATV in another vehi-
cle, be sure it is kept upright and that the fuel
8-7
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EBU28320
Checking the spark plugs
The spark plugs are important engine compo-
nents, which are easy to check. Since heat and de-
posits will cause any spark plug to slowly erode,
the spark plugs should be removed and checked in
accordance with the periodic maintenance and lu-
brication chart. In addition, the condition of the
spark plugs can reveal the condition of the engine.
To remove a 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 toolkit.
To check the spark plugs
1. Check that the porcelain insulator around the
center electrode of each spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).
2. Check that all spark plugs installed in the en-
gine have the same color.NOTE:
If any spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. In-
1. Spark plug cap
1
1. Spark plug wrench
1
8-29
1
2
3
4
5
6
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tion chart.
NOTE:
A diagnostic tachometer is needed to make this
adjustment.
The carburetor synchronization and the throttle
cable free play must be checked, and adjusted if
necessary, before adjusting the engine idling
speed.
1. Start the engine and warm it up.
NOTE:
The engine is warm when it quickly responds to the
throttle.
2. Attach the tachometer to the spark plug lead.
3. Turn in both pilot air screws until they lightly
seat.
4. Turn out both pilot air screws to specification.
(See the “Changing the carburetor settings”
section on the page 8-21.)5. Remove the seat. (See page 4-11.)
6. Check the engine idling speed and, if neces-
sary, adjust it to specification by turning the
throttle stop screws at the carburetors. To in-
crease the engine idling speed, turn the throt-
tle stop screws in direction (a), and to
decrease it, turn the screws in direction (b).
1. Pilot air screw
1
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