8-12
1
2
3
4
5
6
78
9
10
11
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
9. Turn the engine off, wait at least ten minutes,
and then check the oil level and correct it if
necessary.
EBU23404
Final gear oil
The final gear case must be checked for oil leak-
age before each ride. If any leakage is found, have
a Yamaha dealer check and repair the ATV. In ad-
dition, the final gear oil level must be checked and
the oil changed as follows at the intervals specified
in the periodic maintenance and lubrication chart.
To check the final gear oil level
1. Place the ATV on a level surface.
TIP
The final gear oil level must be checked on a cold
engine.
2. Remove the final gear oil filler cap, wipe the
dipstick off with a clean rag, insert it back into
the oil filler hole (without screwing it in), and
then remove it again to check the oil level.
TIP
The final gear oil should be between the minimum
and maximum level marks.
3. If the oil is at or below the minimum level mark,
add sufficient oil of the recommended type to
raise it to the correct level.
4. Insert the dipstick into the oil filler hole, and
then tighten the oil filler cap.
1. Final gear oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
2 3
4
1
8-16
1
2
3
4
5
6
78
9
10
11
plode.
6. Squeeze the excess solvent out of the sponge
material and let it dry.
NOTICE
ECB00440
Do not twist the sponge material when squeez-
ing it.
7. Check the sponge material and replace it if
damaged.
8. Apply a quality foam air filter oil to the sponge
material.
TIP
The sponge material should be wet but not drip-
ping.
9. Install the sponge material into the air filter el-
ement.
10. Place the air filter element in the original posi-
tion, and then hook the holder.
11. Install the air filter case cover by hooking the
holders onto the air filter case.
12. Install the panel by installing the bolts.
TIP
The air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the ATV is operated in extremely dusty ar-
eas. Each time the air filter element maintenance
is performed, check the air inlet of the air filter case
for obstructions.
NOTICE
ECB00460
Make sure that the air filter element is prop-
erly seated in the air filter case.
Never operate the engine with the air filter el-
ement removed. This will allow unfiltered air
to enter the engine, causing rapid engine
wear and possible engine damage. Addition-
ally, operation without the air filter element
will affect carburetor jetting with subsequent
8-24
1
2
3
4
5
6
78
9
10
11
adjusting nut on the brake cable at the rear
wheel hub in direction (a), and to decrease it,
turn the nut in direction (b).
7. Tighten the locknut at the brake lever.
TIP
If the specified free play cannot be obtained as de-
scribed above or if the rear brake does not operate
correctly, have a Yamaha dealer check the internal
rear brake mechanism.
WARNING
EWB02080
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:
Make sure the brakes operate smoothly and
that the free play is correct.
Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
EBU24900
Checking and lubricating the cables
The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
1. Brake lever free play adjusting nut
1
(a)(b)
Recommended lubricant:
Engine oil
9-2
1
2
3
4
5
6
7
89
10
11
linings.
EBU25932
Storage
Short-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover.
NOTICE
ECB00720
Storing the ATV in a poorly ventilated room
or covering it with a tarp while it is still wet,
will allow water and humidity to seep in and
cause rust.
To prevent corrosion, avoid damp cellars,
stables (because of the presence of ammo-
nia) and areas where strong chemicals are
stored.
Long-term
Before storing your ATV for several months:
1. Follow all the instructions in the “Cleaning”
section of this chapter.
2. Turn the fuel cock lever to “OFF”.
3. Drain the carburetor float chamber by loosen-ing the drain bolt; this will prevent fuel deposits
from building up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel from deteriorat-
ing.
5. Perform the following steps to protect the cyl-
inder, piston rings, etc. from corrosion.
a. Remove the spark plug cap and spark
plug.
b. Pour a teaspoonful of engine oil into the
spark plug bore.
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 Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1 oz
of stabilizer to each gallon of fuel)
10-1
1
2
3
4
5
6
7
8
910
11
EBU25960
SPECIFICATIONS
EBU2597B
Dimensions:
Overall length:
1537 mm (60.5 in)
Overall width:
825 mm (32.5 in)
Overall height:
915 mm (36.0 in)
Seat height:
618 mm (24.3 in)
Wheelbase:
1030 mm (40.6 in)
Ground clearance:
75 mm (3.0 in)
Minimum turning radius:
2300 mm (91 in)
Weight:
With oil and fuel:
115.0 kg (254 lb)
Noise and vibration level:
Noise level (77/311/EEC):
76.7 dB(A) (EUR)
Vibration on seat (EN1032, ISO5008):
Will not exceed 0.5 m/s
2
(EUR)
Vibration on handlebar (EN1032, ISO5008):
Will not exceed 2.5 m/s
2
(EUR)
Engine:
Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
49.0 cm
3
Bore
×
stroke:
39.0
×
41.4 mm (1.54
×
1.63 in)
Compression ratio:
10.30 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:
Type:
SAE 5W-30 or SAE 10W-30 or SAE 10W-40 or SAE
15W-40 or SAE 20W-40 or SAE 20W-50
10-2
1
2
3
4
5
6
7
8
910
11
Recommended engine oil grade:
API service SG type or higher, JASO standard MA
Engine oil quantity:
Periodic oil change:
0.80 L (0.85 US qt, 0.70 Imp.qt)
Final gear oil:
Type:
SAE 80 API GL-4 Hypoid gear oil
Quantity:
0.12 L (0.13 US qt, 0.11 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Regular unleaded gasoline only (EUR)
Unleaded gasoline only (AUS)(NZL)
Fuel tank capacity:
6.8 L (1.80 US gal, 1.50 Imp.gal)
Fuel reserve amount:
0.9 L (0.24 US gal, 0.20 Imp.gal)
Carburetor:
Manufacturer:
MIKUNI
Type
×
quantity:
VM16SH x 1
Spark plug (s):
Manufacturer/model:
NGK/CR7HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic
Transmission:
Primary reduction system:
Spur gear
Primary reduction ratio:
65/20 (3.250)
Secondary reduction system:
Shaft drive
-20 -10 0
1020 304050 ˚C
SAE 15W-40
SAE 20W-40SAE 20W-50
SAE 10W-40
SAE 5W-30
SAE 10W-30
INDEX
A
Accessories and loading ................................................ 6-7
Air filter element, cleaning ............................................ 8-13
B
Battery .................................................................. 5-6
,
8-26
Brake lever free play, adjusting the front...................... 8-21
Brake lever free play (rear), adjusting .......................... 8-23
Brake lever, front ............................................................ 4-6
Brake lever, rear............................................................. 4-6
Brake levers, checking and lubricating......................... 8-25
Brakes, front and rear .................................................... 5-3
Brake shoes, checking the front and rear .................... 8-20
C
Cables, checking and lubricating ................................. 8-24
Carburetor, adjusting.................................................... 8-18
Chassis fasteners........................................................... 5-6
Choke ........................................................................... 4-10
Cleaning ......................................................................... 9-1
D
Drive select lever............................................................ 4-7
E
Engine break-in .............................................................. 6-5
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-18
Engine oil ............................................................... 5-3
,
8-9
Engine, starting a warm ................................................. 6-3Engine stop switch ......................................................... 4-2
Engine stop switch with lanyard ..................................... 4-2
F
Final gear oil......................................................... 5-3
,
8-12
Front knuckle pivots, lubricating ................................... 8-25
Fuel ........................................................................ 4-8
,
5-3
Fuel cock ........................................................................ 4-9
Fuel tank cap.................................................................. 4-7
Fuse, replacing............................................................. 8-28
H
Handlebar switches ........................................................ 4-2
I
Identification numbers .................................................. 11-1
Indicator light .................................................................. 4-1
Instruments, lights and switches .................................... 5-6
K
Key identification number ............................................. 11-1
L
Label locations ............................................................... 2-1
M
Main switch .................................................................... 4-1
Maintenance and lubrication chart ................................. 8-5
Maintenance chart, emission control system ................. 8-3
Model label ................................................................... 11-2
N
Neutral indicator light ..................................................... 4-1