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 chart for the
emission control system .......................... 8-3
General maintenance and lubrication
chart ........................................................ 8-5
Checking the spark plugs .......................... 8-8Transmission oil ....................................... 8-10
Coolant .................................................... 8-12
Cleaning the air filter element .................. 8-17
Cleaning the spark arrester ..................... 8-20
Changing the carburetor settings ............. 8-22
Adjusting the engine idling speed ............ 8-29
Adjusting the throttle cable free play ........ 8-31
Checking the front and rear brake
pads .......................................................8-32
Checking the brake fluid level .................. 8-33
Changing the brake fluid .......................... 8-34
Checking the front brake lever free
play ........................................................8-34
Checking the brake pedal position ........... 8-35
Adjusting the parking brake free play ...... 8-36
Brake light switches ................................. 8-38
Adjusting the clutch lever free play .......... 8-38
Drive chain slack ...................................... 8-39
Lubricating the drive chain ....................... 8-41
Checking and lubricating the cables ........ 8-42
Checking and lubricating the brake and
clutch levers ...........................................8-43
Checking and lubricating the brake and
shift pedals .............................................8-43
Checking the wheel hub bearings ............ 8-43
Lubricating the rear suspension relay arm
and connecting arm pivoting points .......8-43
Lubricating the upper and lower arm
pivots .....................................................8-44
5-3
1
2
3
45
6
7
8
9
10
11
EBU19550
Fuel and 2-stroke engine oil mixing
ratio
If Yamalube “R” oil is not available, select an oil
from the following list.
CAUTION:
ECB00140
Never mix two types of 2-stroke engine oil in
the same batch. Always use the same type of
oil to ensure maximum engine performance.
EBU19580
Transmission oil
Make sure that the transmission oil is at the speci-
fied level. Add oil as necessary. (See page 8-10.)
EBU19630
Coolant
Make sure that the coolant is at the specified level.
Add coolant as necessary. (See page 8-12.)
NOTE:
The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture.WARNING
EWB00510
Wait 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 put a thick rag over the cap
when opening. Allow any remaining pressure
to escape before completely removing the cap.
EBU19710
Front and rear brakes
Brake lever and brake pedal
Check 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 Recommended 2-stroke engine oil:
Yamalube “R” (Yamalube Racing 2-cycle oil)
Mixing ratio:
24:1
Recommended 2-stroke engine oil Mixing ratio
Castrol R30
20:1 Castrol A545
Castrol A747
5-4
1
2
3
45
6
7
8
9
10
11
page 8-35.) 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 8-33.)
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or brake fluid reservoirs. Apply the
brakes firmly for one minute. If there is any leak-
age, have a Yamaha dealer check the brake sys-
tem.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, check
the brake pads for wear. (See page 8-32.)
WARNING
EWB00580
Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual, have
a Yamaha dealer check for the cause.
EBU19761
Throttle lever
Check the operation of the throttle lever. It must
open smoothly and spring back to the idle position
when released. Have a Yamaha dealer correct if
necessary.
EBU19770
Drive chain
Check the condition of the drive chain and check
the drive chain slack. Lubricate and adjust the
drive chain as necessary. (See page 8-39.) Recommended brake fluid:
DOT 4
8-7
1
2
3
4
5
6
78
9
10
11
EBU23070
NOTE:
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.
19
*
Throttle lever hous-
ing and cable
Check operation and correct if necessary.
Check throttle cable free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.
√√√√√
20
*
Front and rear brake
switches
Check operation and correct if necessary.
√√√√√
21
*
Lights and switches
Check operation and correct if necessary.
Adjust headlight beams.
√√√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth 1 3 6 6 12
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320
8-33
1
2
3
4
5
6
78
9
10
11
without having to disassemble the brake. To check
the brake pad wear, check the position of the wear
indicator while applying the brake. If a brake pad
has worn to the point that the wear indicator almost
touches the brake disc, have a Yamaha dealer re-
place the brake pads as a set.
EBU24251
Checking the brake fluid level
Insufficient brake fluid may allow air to enter the
brake system, possibly causing it to become inef-
fective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish if neces-sary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
Front brake
1. Wear indicator
11
1. Minimum level mark
LOWER
1
8-34
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
10-3
1
2
3
4
5
6
7
8
910
11
Size:
AT20 x 10-9
Manufacturer/model:
DUNLOP/KT877A
Loading:
Maximum loading limit:
100.0 kg (220 lb)
(Total weight of rider, cargo, accessories, and tongue)
Tire air pressure (measured on cold tires):
Recommended:
Front:
30 kPa (4.4 psi) (0.30 kgf/cm
2
)
Rear:
30 kPa (4.4 psi) (0.30 kgf/cm
2
)
Minimum:
Front:
27 kPa (3.9 psi) (0.27 kgf/cm
2
)
Rear:
27 kPa (3.9 psi) (0.27 kgf/cm
2
)
Maximum:
Front:
33 kPa (4.8 psi) (0.33 kgf/cm
2
)
Rear:
33 kPa (4.8 psi) (0.33 kgf/cm
2
)
Front wheel:
Wheel type:
Panel wheel
Rim size:
10 x 6.0AT
Rear wheel:
Wheel type:
Panel wheel
Rim size:
9 x 8.5AT
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Double wishbone
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
230 mm (9.1 in)
Rear suspension:
Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
INDEX
A
Accessories and loading ................................................ 6-6
Air filter element, cleaning ............................................ 8-17
B
Brake and clutch levers, checking and lubricating ....... 8-43
Brake and shift pedals, checking and lubricating ......... 8-43
Brake fluid, changing.................................................... 8-34
Brake fluid level, checking............................................ 8-33
Brake lever ..................................................................... 4-5
Brake lever free play, checking the front ...................... 8-34
Brake light switches ..................................................... 8-38
Brake pads, checking the front and rear ...................... 8-32
Brake pedal .................................................................... 4-5
Brake pedal position, checking .................................... 8-35
Brakes, front and rear .................................................... 5-3
C
Cables, checking and lubricating ................................. 8-42
Carburetor settings, changing ...................................... 8-22
Chassis fasteners........................................................... 5-7
Cleaning ......................................................................... 9-1
Clutch lever .................................................................... 4-4
Clutch lever free play, adjusting ................................... 8-38
Coolant ................................................................. 5-3
,
8-12
D
Drive chain ..................................................................... 5-4
Drive chain, lubricating ................................................. 8-41Drive chain slack .......................................................... 8-39
E
Engine break-in .............................................................. 6-4
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-29
Engine, starting a warm ................................................. 6-2
Engine stop switch ......................................................... 4-2
F
Fuel ................................................................................ 4-8
Fuel and 2-stroke engine oil mixing ratio ....................... 5-3
Fuel cock ........................................................................ 4-9
Fuel tank cap.................................................................. 4-7
H
Handlebar switches ........................................................ 4-2
Headlight beam, adjusting............................................ 8-48
Headlight bulb, replacing.............................................. 8-45
I
Identification numbers .................................................. 11-1
Instruments, lights and switches .................................... 5-7
K
Key identification number ............................................. 11-1
Kickstarter ...................................................................... 4-7
L
Label locations ............................................................... 2-1
Light switch .................................................................... 4-2