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
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
8-12
1
2
3
4
5
6
78
9
10
11
7. Start the engine, and then let it idle for several
minutes while checking the transmission for
oil leakage. If oil is leaking, immediately turn
the engine off and check for the cause.
8. Turn the engine off, and then check the oil lev-
el and correct it if necessary.
EBU23470
Coolant
The coolant level should be checked before each
ride. In addition, the coolant must be changed at
the intervals specified in the periodic maintenance
and lubrication chart.
EBU23501
To check the coolant level
1. Place the ATV on a level surface.
TIP
The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture.
2. Check the coolant level in the coolant reser-
voir.
TIP
The coolant should be between the minimum and
maximum level marks.
1. “CD” specification
2. “ENERGY CONSERVING II”
1
2
8-14
1
2
3
4
5
6
78
9
10
11
ter or salt water since it is harmful to the en-
gine.
If water has been used instead of coolant, re-
place it with coolant as soon as possible,
otherwise the cooling system will not be pro-
tected against frost and corrosion.
If water has been added to the coolant, have
a Yamaha dealer check the antifreeze con-
tent of the coolant as soon as possible, oth-
erwise the effectiveness of the coolant will
be reduced.
6. Close the coolant reservoir cover.
7. Install the seat.
TIP
If the engine overheats, see page 8-52 for further
instructions.
EBU23521
To change the coolant
WARNING
EWB01890
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 place a thick rag over the capwhen opening. Allow any remaining pressure
to escape before completely removing the cap.
1. Place the ATV on a level surface.
2. Remove the radiator cover by removing the
bolts.
3. Place a container under the engine and re-
move the coolant drain bolts.
1. Radiator cover
2. Radiator cover bolt
12
2
8-17
1
2
3
4
5
6
78
9
10
11
voir to the maximum level mark, and then in-
stall the reservoir cap.
11. Pour the recommended coolant into the radia-
tor until it is full.
NOTICE
ECB00401
If coolant is not available, use distilled water
or soft tap water instead. Do not use hard wa-
ter or salt water since it is harmful to the en-
gine.
If water has been used instead of coolant, re-
place it with coolant as soon as possible,
otherwise the cooling system will not be pro-tected against frost and corrosion.
If water has been added to the coolant, have
a Yamaha dealer check the antifreeze con-
tent of the coolant as soon as possible, oth-
erwise the effectiveness of the coolant will
be reduced.
12. Install the radiator cap, start the engine, let it
idle for several minutes, and then turn it off.
13. Remove the radiator cap to check the coolant
level in the radiator. If it is low, add sufficient
coolant until it reaches the top of the radiator,
and then install the radiator cap.
14. Start the engine, and then check for coolant
leakage.
TIP
If any leakage is found, have a Yamaha dealer
check the cooling system.
15. Install the radiator cover by installing the bolts.
EBU23622
Cleaning the air filter element
The air filter element should be cleaned at the in-
tervals specified in the periodic maintenance and
lubrication chart. Clean the air filter element more
frequently if you are riding in unusually wet or dusty Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol antifreeze con-
taining corrosion inhibitors for aluminum en-
gines
Coolant quantity:
Radiator capacity (including all routes):
1.50 L (1.59 US qt, 1.32 Imp.qt)
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.28 L (0.30 US qt, 0.25 Imp.qt)
8-53
1
2
3
4
5
6
78
9
10
11
Engine overheating
WARNING
EWB02290
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.
TIP
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec-
ommended coolant as soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer check
and repair the cooling system.Add coolant. (See TIP.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
INDEX
A
Accessories and loading ................................................ 6-6
Air filter element, cleaning ............................................ 8-17
B
Brake and clutch levers, checking and lubricating ....... 8-43
Brake fluid, changing.................................................... 8-35
Brake fluid level, checking............................................ 8-33
Brake lever ..................................................................... 4-5
Brake lever free play, checking the front ...................... 8-35
Brake light switches ..................................................... 8-38
Brake pads, checking the front and rear ...................... 8-32
Brake pedal .................................................................... 4-5
Brake pedal, checking and lubricating ......................... 8-43
Brake pedal position, checking .................................... 8-36
Brakes, front and rear .................................................... 5-3
C
Cables, checking and lubricating ................................. 8-43
Carburetor settings, changing ...................................... 8-22
Chassis fasteners........................................................... 5-7
Cleaning ......................................................................... 9-1
Clutch lever .................................................................... 4-4
Clutch lever free play, adjusting ................................... 8-39
Coolant ................................................................. 5-3
,
8-12
D
Drive chain ..................................................................... 5-4
Drive chain, lubricating ................................................. 8-42Drive chain slack .......................................................... 8-40
E
Engine break-in .............................................................. 6-4
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-30
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