OPERATION .................................................. 6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Operating the drive select lever and
driving in reverse ...................................... 6-3
Shifting ....................................................... 6-4
Engine break-in .......................................... 6-6
Parking ....................................................... 6-7
Parking on a slope ..................................... 6-8
Accessories and loading ............................ 6-9
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 ............. 7-9
TURNING YOUR ATV .............................. 7-13
CLIMBING UPHILL ................................... 7-14
RIDING DOWNHILL.................................. 7-17
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH SHALLOW
WATER ................................................... 7-19
RIDING OVER ROUGH TERRAIN ........... 7-21
SLIDING AND SKIDDING ......................... 7-22
WHAT TO DO IF... .................................... 7-23
WHAT TO DO... ........................................ 7-23PERIODIC MAINTENANCE AND MINOR
REPAIR ..........................................................8-1
Owner’s manual and tool kit .......................8-1
Periodic maintenance and lubrication
chart ..........................................................8-3
Checking the spark plug .............................8-8
Engine oil and oil filter element .................8-10
Cleaning the air filter element ...................8-13
Cleaning the spark arrester ......................8-16
Adjusting the carburetor ............................8-17
Adjusting the engine idling speed .............8-17
Adjusting the throttle cable free play .........8-19
Valve clearance ........................................8-19
Checking the front and rear brake pads ...8-20
Checking the brake fluid level ...................8-21
Changing the brake fluid ...........................8-22
Checking the front brake lever free play ...8-22
Checking the brake pedal position ............8-23
Adjusting the parking brake free play .......8-24
Brake light switches ..................................8-25
Adjusting the clutch lever free play ...........8-26
Drive chain slack .......................................8-27
Lubricating the drive chain ........................8-30
Checking and lubricating the cables .........8-30
Checking and lubricating the brake and
clutch levers ............................................8-31U10P60E0.book Page 2 Thursday, June 15, 2006 4:19 PM
5-1
5
EBU19200
PRE-OPERATION CHECKS
EBU19220Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table.NOTE:The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic
maintenance and lubrication chart” on page 8-3 to determine which service should be performed by aYamaha dealer.
ITEM ROUTINE PAGE
FuelCheck fuel level in fuel tank, and add recommended fuel if neces-
sary.
Check fuel line for leakage. Correct if necessary.4-10, 5-3
Engine oilCheck oil level in engine, and add recommended oil to specified lev-
el if necessary.
Check ATV for oil leakage. Correct if necessary.5-3, 8-10
Front brakeCheck operation. If soft or spongy, have Yamaha dealer bleed hy-
draulic system.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-3, 8-20, 8-21, 8-22
Rear brakeCheck operation. If soft or spongy, have Yamaha dealer bleed hy-
draulic system.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-3, 8-20, 8-21, 8-23
U10P60E0.book Page 1 Thursday, June 15, 2006 4:19 PM
5-3
5
EBU19540Fuel Make sure that there is sufficient fuel in the tank.
(See page 4-10.)
WARNING
EWB00520Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is overfilled,
fuel could spill out due to heat from the en-
gine or the sun.Be careful not to spill fuel, especially on the
engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.Do not refuel right after the engine has been
running and is still very hot.Be sure the fuel tank cap is closed securely.EBU19560Engine oil Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-10.)
EBU19710Front and rear brakes Brake lever and brake pedalCheck that there is no free play in the brake le-
ver. If there is free play, have a Yamaha dealer
check the brake system.Check for correct brake pedal height. (See page
8-23.) If the pedal height is incorrect, have a
Yamaha dealer adjust it.Check the operation of the lever and pedal. They
should move smoothly and there should be a
firm feeling when the brakes are applied. If not,
have a Yamaha dealer check the brake system.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See page 8-21.)
Recommended brake fluid:
DOT 4
U10P60E0.book Page 3 Thursday, June 15, 2006 4:19 PM
8-10
8
NOTE:If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque assoon as possible.
4. Install the spark plug cap.EBU23273Engine oil and oil filter element The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter element cleaned at the intervals speci-
fied in the periodic maintenance and lubrication
chart.
To check the engine oil level
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Wait a few minutes until the oil settles before
checking.
4. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.5. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.
NOTE:The engine oil should be between the minimumand maximum level marks.
6. If the engine oil is at or below the minimum
level mark, add sufficient oil of the recom-
mended type to raise it to the correct level.1. Dipstick
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler cap
U10P60E0.book Page 10 Thursday, June 15, 2006 4:19 PM
8-11
8 7. Insert the dipstick into the oil filler hole, and
then tighten the engine oil filler cap.
To change the engine oil (with or without oil fil-
ter element cleaning)
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Place an oil pan under the engine to collect
the used oil.
4. Remove the engine oil filler cap, and then re-
move the engine oil drain bolt to drain the oil
from the crankcase.
CAUTION:ECB00310When removing the engine oil drain bolt, the
compression spring, oil strainer and O-ring willfall out. Take care not to lose these parts.NOTE:Skip steps 5–9 if the oil filter element is not beingcleaned.1. Engine oil drain bolt
2. O-ring
3. Compression spring
4. Oil strainer
U10P60E0.book Page 11 Thursday, June 15, 2006 4:19 PM
8-22
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.
EBU24290Changing 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.EBU24390Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have a
free play of zero mm (zero in) as shown. If the free
play is incorrect, have a Yamaha dealer check the
brake system. Recommended brake fluid:
DOT 4
U10P60E0.book Page 22 Thursday, June 15, 2006 4:19 PM
INDEX
AAccessories and loading ................................................ 6-9
Air filter element, cleaning ............................................ 8-13
Auxiliary light bulb ........................................................ 8-40BBattery .......................................................................... 8-35
Brake and clutch levers, checking and lubricating ....... 8-31
Brake and shift pedals, checking and lubricating ......... 8-32
Brake fluid, changing ................................................... 8-22
Brake fluid level, checking ........................................... 8-21
Brake lever ..................................................................... 4-6
Brake lever free play, checking the front ...................... 8-22
Brake light switches ..................................................... 8-25
Brake pads, checking the front and rear ...................... 8-20
Brake pedal .................................................................... 4-7
Brake pedal position, checking .................................... 8-23
Brakes, front and rear .................................................... 5-3CCables, checking and lubricating ................................. 8-30
Carburetor, adjusting ................................................... 8-17
Chassis fasteners .......................................................... 5-7
Cleaning ......................................................................... 9-1
Clutch lever .................................................................... 4-6
Clutch lever free play, adjusting ................................... 8-26DDrive chain ..................................................................... 5-4
Drive chain, lubricating ................................................. 8-30
Drive chain slack .......................................................... 8-27Drive select lever ........................................................... 4-9
Drive select lever and driving in reverse ........................ 6-3
EEngine break-in .............................................................. 6-6
Engine, cold start ........................................................... 6-1
Engine idling speed ..................................................... 8-17
Engine oil ....................................................................... 5-3
Engine oil and oil filter element .................................... 8-10
Engine, starting a warm ................................................. 6-3
Engine stop switch ......................................................... 4-3FFuel ....................................................................... 4-10, 5-3
Fuel cock ..................................................................... 4-11
Fuel tank cap ................................................................. 4-9
Fuses, replacing .......................................................... 8-37HHandlebar switches ....................................................... 4-3
Hazard switch ................................................................ 4-4
Headlight beam ............................................................ 8-38
Headlight bulb .............................................................. 8-38
High beam indicator light ............................................... 4-2
Horn switch .................................................................... 4-4IIdentification numbers .................................................. 11-1
Indicator lights ................................................................ 4-2
Instruments, lights and switches .................................... 5-7LLabel locations ............................................................... 2-1
U10P60E0.book Page 1 Thursday, June 15, 2006 4:19 PM