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
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 chart for the
emission control system .......................... 8-3
General maintenance and lubrication
chart ........................................................ 8-5Checking the spark plugs .......................... 8-8
Transmission oil ....................................... 8-10
Coolant .................................................... 8-12
Cleaning the air filter element .................. 8-17
Cleaning the spark arrester ..................... 8-21
Changing the carburetor settings ............. 8-22
Adjusting the engine idling speed ............ 8-30
Adjusting the throttle cable free play ........ 8-32
Checking the front and rear brake pads .. 8-32
Checking the brake fluid level .................. 8-33
Changing the brake fluid .......................... 8-35
Checking the front brake lever free play .. 8-35
Checking the brake pedal position ........... 8-36
Adjusting the parking brake free play ...... 8-37
Brake light switches ................................. 8-38
Adjusting the clutch lever free play .......... 8-39
Drive chain slack ...................................... 8-40
Lubricating the drive chain ....................... 8-42
Checking and lubricating the cables ........ 8-43
Checking and lubricating the brake and
clutch levers ........................................... 8-43
Checking the shift pedal .......................... 8-43
Checking and lubricating the brake
pedal ...................................................... 8-43
Checking the wheel hub bearings ............ 8-44
Lubricating the rear suspension relay arm
and connecting arm pivoting points ....... 8-44
Lubricating the upper and lower arm
pivots ..................................................... 8-45
1-3
1
2
3
4
5
6
7
8
9
10
11
backwards when climbing a hill. To avoid stall-
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 severaltimes 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-
4-3
1
2
34
5
6
7
8
9
10
11
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
WARNING
EWB00250
Malfunction of the throttle could make it diffi-
cult to speed up or slow down when you need
to. This could cause an accident. Check the op-
eration of the throttle lever before you start the
engine. If the throttle does not work smoothly,
check for the cause. Correct the problem be-
fore riding the ATV or consult a Yamaha dealer.
EBU18300
Throttle OverRide System
If during operation, the carburetor or the throttle ca-
ble should malfunction and will not close fully, take
your thumb off the throttle lever.
The throttle override system immediately cuts off
the ignition.WARNING
EWB00260
Riding with a malfunction increases the
chance for an accident and injury. Make sure
that the cause of the malfunction is corrected
before restarting the engine or have the ATV in-
spected by a Yamaha dealer.
EBU18321
Speed limiter
Your ATV was delivered with an adjustable speed
limiter. The speed limiter keeps the throttle from
fully opening, even when the throttle lever is
pushed to the maximum.
1. Loosen the locknut.
2. To increase the maximum engine power avail-
able and the maximum speed of the ATV, turn
the adjusting screw in direction (a). To de-
crease the maximum engine power available
1. Throttle lever
1
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.
NOTICE
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.)
TIP
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
6-5
1
2
3
4
56
7
8
9
10
11
hours. The various parts in the engine wear and
polish themselves to the correct operating clear-
ances. During this period, prolonged full-throttle
operation or any condition that might result in en-
gine overheating must be avoided.
0–160 km (0–100 mi) or 0–10 hours
Avoid prolonged operation above 1/2 throttle. Vary
the speed of the ATV regularly. Do not operate it at
one set throttle position.
160–320 km (100–200 mi) or 10–20 hours
Avoid prolonged operation above 3/4 throttle. Rev
the engine through the gears freely, but do not use
full throttle at any time.
320 km (200 mi) or 20 hours and beyond
The ATV can now be operated normally.
NOTICE
ECB00220
If any engine trouble should occur during the
engine break-in period, immediately have a
Yamaha dealer check the ATV.
EBU20721
Parking
When parking the ATV, stop the engine, shift intofirst gear, apply the parking brake, and then turn
the fuel cock to “OFF”.
1. Button
2. Parking brake lock plate
1
2
8-3
1
2
3
4
5
6
78
9
10
11
EBU21742
Periodic maintenance chart for the emission control system
TIP
For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
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 3201
*
Fuel line
Check fuel hoses for cracks or other damage, and
replace if necessary.
√√√
2 Spark plugs
Replace.
√√√√√
3
*
Carburetors
Check starter (choke) operation and correct if nec-
essary.
Check engine idling speed and synchronization,
and adjust if necessary.
√√√√
4
*
Crankcase breather
system
Check breather hose for cracks or other damage,
and replace if necessary.
√√√
5
*
Exhaust system
Check for leakage and replace gasket(s) if neces-
sary.
Check for looseness and tighten all screw clamps
and joints if necessary.
√√√
8-8
1
2
3
4
5
6
78
9
10
11
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.TIP
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