Page 89 of 158

8-5
8
EBU21863General maintenance and lubrication chart NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320
1 Air filter elementClean and replace if necessary.Every 20–40 hours (more often in wet or
dusty areas)
2*Front brakeCheck operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
3*Rear brakeCheck operation and correct if necessary.
Check brake lever free play and adjust if neces-
sary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
4*Brake hosesCheck for cracks or other damage, and replace if
necessary.√√√√
Replace. Every 4 years
5*WheelsCheck runout and for damage, and replace if nec-
essary.√ √√√
6*TiresCheck tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if
necessary.√ √√√
7*Wheel hub bearingsCheck for looseness or damage, and replace if
necessary.√ √√√
U23D60E0.book Page 5 Thursday, March 15, 2007 7:59 PM
Page 145 of 158

9-3
9 c. Install the spark plug cap onto the spark
plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with the
starter. (This will coat the cylinder wall with
oil.)
e. Remove the spark plug cap from the spark
plug, and then install the spark plug and
the spark plug cap.
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.
9. Remove the battery and fully charge it. Store
it in a cool, dry place and charge it once a
month. Do not store the battery in an exces-
sively cold or warm place [less than 0 °C (30°F) or more than 30 °C (90 °F)]. For more in-
formation on storing the battery, see page
8-48.
NOTE:Make any necessary repairs before storing theATV.
U23D60E0.book Page 3 Thursday, March 15, 2007 7:59 PM
Page 148 of 158

10-3
10
Clutch:Clutch type:
Wet, centrifugal automaticTransmission:Primary reduction system:
V-belt
Secondary reduction system:
Shaft drive
Secondary reduction ratio:
41/21 × 24/18 × 33/9 (9.544)
Transmission type:
V-belt automatic
Operation:
Left hand operation
Reverse gear:
25/17 (1.471)
Low range:
35/17 (2.058)
High range:
26/21 (1.238)Chassis:Frame type:
Steel tube frame
Caster angle:
5.0 °
Trail:
26.0 mm (1.02 in)Front tire:Type:
TubelessSize:
AT25 x 8-12
Manufacturer/model:
CHENG SHIN/C828-4P (AUS)(NZL)
DUNLOP/KT131 (EUR)
Rear tire:Type:
Tubeless
Size:
AT25 x 10-12
Manufacturer/model:
CHENG SHIN/C828-4P (AUS)(NZL)
DUNLOP/KT135 (EUR)Loading:Maximum loading limit:
220.0 kg (485 lb)
(Total weight of rider, cargo, accessories, and tongue)Tire air pressure (measured on cold tires):Recommended:
Front:
35.0 kPa (5.0 psi) (0.350 kgf/cm²)
Rear:
30.0 kPa (4.3 psi) (0.300 kgf/cm²)
Minimum:
Front:
32.0 kPa (4.6 psi) (0.320 kgf/cm²)
Rear:
27.0 kPa (3.9 psi) (0.270 kgf/cm²)
Maximum:
Front:
38.0 kPa (5.5 psi) (0.380 kgf/cm²)
U23D60E0.book Page 3 Thursday, March 15, 2007 7:59 PM
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IIdentification numbers .................................................. 11-1
Indicator lights and warning light .................................... 4-2
Instruments, lights and switches .................................... 5-7KKey identification number ............................................. 11-1LLabel locations ............................................................... 2-1
Light switch .................................................................... 4-6
Low-range indicator light ................................................ 4-3MMain switch .................................................................... 4-1
Maintenance and lubrication chart ................................. 8-5
Maintenance chart, emission control system ................. 8-3
Model label ................................................................... 11-2
Multifunction display ....................................................... 4-4NNeutral indicator light ..................................................... 4-2OOn-Command differential gear lock switch .................... 4-9
On-Command four-wheel-drive switch ........................... 4-8
Override switch .............................................................. 4-7
Owner’s manual and tool kit ........................................... 8-1PPanels, removing and installing ..................................... 8-9
Park indicator light ......................................................... 4-3
Parking ........................................................................... 6-6
Parking on a slope ......................................................... 6-6
Part locations ................................................................. 3-1
Pre-operation check list ................................................. 5-1
RRear knuckle pivots, lubricating ................................... 8-47
Recoil starter ................................................................ 4-14
Reverse indicator light ................................................... 4-2
Riding your ATV ............................................................. 7-1SSafety information .......................................................... 1-1
Seat ............................................................................. 4-18
Shock absorber assemblies,
adjusting the front and rear ........................................ 4-20
Spark arrester, cleaning ............................................... 8-34
Spark plug, checking ................................................... 8-16
Specifications ............................................................... 10-1
Speed limiter ................................................................ 4-12
Stabilizer bushes, checking ......................................... 8-47
Starter (choke) ............................................................. 4-17
Start switch .................................................................... 4-6
Steering shaft, lubricating ............................................ 8-48
Storage .......................................................................... 9-2
Storage compartment .................................................. 4-19TTail/brake light bulb, replacing ..................................... 8-53
Throttle cable free play, adjusting ................................ 8-37
Throttle lever ......................................................... 4-11, 5-5
Tire pressure, measuring ............................................... 5-6
Tires ............................................................................... 5-5
Tire wear limit ................................................................ 5-7
Troubleshooting ........................................................... 8-56
Troubleshooting charts ................................................ 8-57VValve clearance ........................................................... 8-38
V-belt case drain plug .................................................. 8-35
U23D60E0.book Page 2 Thursday, March 15, 2007 7:59 PM