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 .......................................................... 5-3
Transmission oil ......................................... 5-3
Coolant ...................................................... 5-3
Front and rear brakes ................................ 5-3
Throttle lever .............................................. 5-4
Drive chain ................................................. 5-4
Tires ........................................................... 5-5
Measuring the tire pressure ....................... 5-6
Tire wear limit ............................................ 5-6
Chassis fasteners ...................................... 5-7
Instruments, lights and switches ................ 5-7
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-2
3-1
1
23
4
5
6
7
8
9
10
11
EBU17680
DESCRIPTION
EBU17690
Left view
EBU17700
Right view
1. Front shock absorber assembly
2. Radiator
3. Fuel cock
4. Rear shock absorber assembly
5. Spark arrester
6. Starter (choke)
7. Shift pedal
12
34
5
7
6
1. Tail/brake light
2. Seat
3. Kickstarter
4. Fuel tank cap
5. Headlight
6. Brake pedal
7. Brake light switch
12
3
45
6
7
4-12
1
2
34
5
6
7
8
9
10
11
EBU18991
Adjusting the front shock absorber
assemblies
The spring preload can be adjusted to suit the rid-
er’s weight and the riding conditions.
Adjust the spring preload as follows.
Turn the adjusting ring in direction (a) to increase
the spring preload and thereby harden the suspen-
sion, and in direction (b) to decrease the spring
preload and thereby soften the suspension.
TIP
A special wrench can be obtained at a Yamaha
dealer to make this adjustment.
1. Projection
2. Seat holder
1
2
1. Spring preload adjusting ring
2. Position indicator
Spring preload setting:
Minimum (soft):
1
Standard:
3
Maximum (hard):
5
1
2
3
4
5
12
(a)
(b)
4-13
1
2
34
5
6
7
8
9
10
11
WARNING
EWB00400
Always adjust the shock absorber assemblies
on the left and right side to the same setting.
Uneven adjustment can cause poor handling
and loss of stability, which could lead to an ac-
cident.
EBU19100
Adjusting the rear shock absorber
assembly
The spring preload, rebound damping and com-
pression damping forces of the rear shock absorb-
er assembly can be adjusted to suit the rider’s
weight and the riding conditions.
WARNING
EWB00430
This shock absorber assembly contains highly
pressurized nitrogen gas. Read and under-
stand the following information before han-
dling the shock absorber assembly.
Do not tamper with or attempt to open the
cylinder assembly.
Do not subject the shock absorber assembly
to an open flame or other high heat source.
This may cause the unit to explode due to ex-cessive gas pressure.
Do not deform or damage the cylinder in any
way. Cylinder damage will result in poor
damping performance.
Do not dispose of a damaged or worn out
shock absorber assembly yourself. Take the
shock absorber assembly to a Yamaha deal-
er for any service.
Spring preload
1. Loosen the locknut.
2. Turn the adjusting nut in direction (a) to in-
crease the spring preload and thereby harden
the suspension, and in direction (b) to de-
crease the spring preload and thereby soften
the suspension.
8-6
1
2
3
4
5
6
78
9
10
11
9
*
Wheel hub bearings
Check for looseness or damage, and replace if
necessary.
√ √√√
10
*
Upper and lower
arm pivots
Lubricate with lithium-soap-based grease.
√√√
11 Drive chain
Check chain slack and adjust if necessary.
Check rear wheel alignment and correct if necess-
sary.
Clean and lubricate.
√ √√√
12
*
Drive chain rollers
Check for wear and replace if necessary.
√√√
13
*
Chassis fasteners
Make sure that all nuts, bolts, and screws are
properly tightened.
√√√√√
14
*
Shock absorber
assemblies
Check operation and correct if necessary.
Check for oil leakage and replace if necessary.
√√√
15
*
Rear suspension
relay arm and con-
necting arm pivot-
ing points
Check operation and correct if necessary.
Lubricate with lithium-soap-based grease.
√√√√
16
*
Steering system
Check operation and repair or replace if damaged.
Check toe-in and adjust if necessary.
√√√√√
17 Transmission oil
Change.
Check ATV for oil leakage, and correct if neces-
sary.
√ √√√
18 Cooling system
Check coolant level and ATV for coolant leakage,
and correct if necessary.
√√√√√
Replace coolant. Every 2 years
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
9-1
1
2
3
4
5
6
7
89
10
11
EBU25860
CLEANING AND STORAGE
EBU25920
Cleaning
Frequent, thorough cleaning of your ATV will not
only enhance its appearance but will improve its
general performance and extend the useful life of
many components.
1. Before cleaning the ATV:
a. Block off the end of the exhaust pipe to
prevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plugs and all filler
caps are properly installed.
2. If the engine case is excessively greasy, apply
degreaser with a paint brush. Do not apply de-
greaser to the chain, sprockets or wheel ax-
les.
3. Rinse the dirt and degreaser off with a garden
hose. Use only enough pressure to do the job.
NOTICE
ECB00710
Excessive water pressure may cause water
seepage and deterioration of wheel bearings,
brakes, transmission seals and electrical de-
vices. Many expensive repair bills have result-ed from improper high-pressure detergent
applications such as those available in coin-
operated car washers.
4. Once most of the dirt has been hosed off,
wash all surfaces with warm water and mild,
detergent-type soap. An old toothbrush or bot-
tle brush is handy for hard-to-reach places.
5. Rinse the ATV off immediately with clean wa-
ter and dry all surfaces with a chamois, clean
towel or soft absorbing cloth.
6. Dry the chain and lubricate it to prevent it from
rusting.
7. Clean the seat with a vinyl upholstery cleaner
to keep the cover pliable and glossy.
8. Automotive type wax may be applied to all
painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protec-
tive finish. When finished cleaning, start the
engine and let it idle for several minutes.WARNING
EWB02310
Wet brakes may have reduced stopping ability,
10-3
1
2
3
4
5
6
7
8
910
11
Size:
AT21 x 7-10
Manufacturer/model:
DUNLOP/KT851B
Rear tire:
Type:
Tubeless
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:
30.0 kPa (0.300 kgf/cm
2
, 4.4 psi)
Rear:
30.0 kPa (0.300 kgf/cm
2
, 4.4 psi)
Minimum:
Front:
27.0 kPa (0.270 kgf/cm
2
, 4.0 psi)
Rear:
27.0 kPa (0.270 kgf/cm
2
, 4.0 psi)
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
M
Main switch .................................................................... 4-1
Maintenance and lubrication chart ................................. 8-5
Maintenance chart, emission control system ................. 8-3
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 ................................ 8-37
Parking on a slope ......................................................... 6-6
Part locations ................................................................. 3-1
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
Shift pedal, checking .................................................... 8-43
Shock absorber assemblies, adjusting the front .......... 4-12
Shock absorber assembly, adjusting the rear .............. 4-13
Spark arrester, cleaning ............................................... 8-21
Spark plugs, checking .................................................... 8-8
Specifications ............................................................... 10-1
Speed limiter .................................................................. 4-3
Starter (choke) ............................................................. 4-10
Steering shaft, lubricating............................................. 8-45
Storage........................................................................... 9-2Suspension, lubricating the upper and lower arm
pivots.......................................................................... 8-45
Suspension relay arm and connecting arm pivoting
points, lubricating the rear.......................................... 8-44
T
Tail/brake light bulb, replacing ..................................... 8-49
Throttle cable free play, adjusting ................................ 8-32
Throttle lever .......................................................... 4-2
,
5-4
Throttle OverRide System .............................................. 4-3
Tire pressure, measuring ............................................... 5-6
Tires ............................................................................... 5-5
Tire wear limit ................................................................. 5-6
Transmission oil ................................................... 5-3
,
8-10
Troubleshooting ........................................................... 8-51
Troubleshooting charts................................................. 8-52
V
Vehicle identification number ....................................... 11-1
W
Wheel hub bearings, checking ..................................... 8-44
Wheel, installing ........................................................... 8-50
Wheel, removing .......................................................... 8-49