Page 96 of 120
8
8-23
Adjusting the front brake lever free
playThe brake lever free play must be checked and, if
necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
1
The brake lever free play should measure 4.0–
6.0 mm (0.16–0.24 in) as shown. If the free play
is incorrect, adjust it as follows.101. Loosen the upper locknut and fully turn in the upper adjusting bolt.
2. Loosen the lower locknut.
3. Turn the lower adjusting bolt in direction (a) to increase the free play, and in direction (b) to
decrease it.
1. Brake lever free play
TIPBefore adjusting the brake lever free play, checkthe front brake shoes for wear.
3
3. No more than 12 mm (0.47 in)
1. Upper adjusting bolt
2. Lower adjusting bolt
2 1
to check the brake shoe wear without having to
disassemble the brake. To check the brake shoe
wear, there are two adjusting bolts to indicate brake
shoe wear. If the positions of adjusting bolts reach to
12mm (0.47in), the brake shoes should be replaced
as a set by Yamaha dealer.
Page 97 of 120
4. Tighten the lower locknut.
5. While applying the front brake, turn out the up-per adjusting bolt until the upper and lower ca-
ble lengths are equal. The cable joint will
become vertical.1. Upper locknut
2. Upper adjusting bolt
3. Lower locknut
4. Lower adjusting bolt
12
4
3 (a)(b)
(a)
(b)
11. Cable joint6. Tighten the upper locknut.
8-24
8
WARNING
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
Page 98 of 120
8-25
The rear brake pads must be checked for wear at the
intervals specified in the periodic maintenance and
lubrication chart. Each brake pad is provided with
wear indicator grooves, which allow you to check the
brake pad wear without having to disassemble the
brake. If a brake pad has worn to the point that the
wear indicator grooves have almost disappeared,
have a Yamaha dealer replace the brake pads as a
set.Checking the rear brake pads
Insufficient brake fluid may allow air to enter the brake
system, possibly causing it to become ineffective.
Before riding, check that the brake fluid is above the
minimum level mark and replenish if necessary.
A low brake fluid level may indicate worn brake pads
and/or brake system leakage. If the brake fluid level
is low, be sure to check the brake pads for wear and
the brake system for leakage.Checking the brake fluid level 1. Wear indicator groove
8
1
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 proceduresshould be performed by a Yamaha dealer.
Page 99 of 120
Changing the rear brake fluidChecking the rear brake lever free play
The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever free play should
measure 0 – 1.5 mm (0 – 0.06 in) as shown. If
the free play is incorrect, have a Yamaha dealer
check the brake system.
1
LOWER
1
8-26
8
Recommended brake fluid:
DOT4
1. Brake lever free play
1. Minimum level mark
Have a Yamaha dealer change the rear brake fluid
at the intervals specified in the TIP after the periodic
maintenance and lubrication chart. In addition,
have the oil seals of the master cylinders and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are damaged
or leaking.
Oil seals: Replace every two years.Brake hoses: Replace every four years.
Page 100 of 120
8-27
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.
Checking and lubricating the front and
rear brake levers The operation of the front and rear brake levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary.Recommended lubricant:
Engine oil
8
WARNING
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.Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These proceduresshould be performed by a Yamaha dealer.
WARNING
Inspect cables frequently and replace if dam-
aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could re-
strict the operation of controls and lead to anaccident or injury.
Page 101 of 120
8-28
8
Checking the wheel hub bearings The front and rear wheel hub bearings must be
checked at the intervals specified in the periodic
maintenance and lubrication chart. If there is play
in a wheel hub or if a wheel does not turn smoothly,
have a Yamaha dealer check the wheel hub bearings.1. Lever pivot
BatteryT h i s m o d e l i s e q u i p p e d w i t h a V R L A ( V a l v e
Regulated Lead Acid) battery. There is no need to
check the electrolyte or to add distilled water.
However, the battery lead connections need to be
checked and, if necessary, tightened.
Recommended lubricant:Front brake lever: Lithium-soap-based grease
N O T I C E Never attempt to remove the battery cell seals,
as this would permanently damage the battery.
1
WARNING
Battery electrolyte is poisonous and danger-
ous, as it contains sulfuric acid, which can
cause severe burns. Avoid contact with skin,
eyes or clothing. Always shield your eyes
when working near batteries.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg
or vegetable oil. Call a physician immediately.
Rear brake lever:
Silicone grease
Page 109 of 120
9-1
CLEANING AND STORAGE
CleaningFrequent, 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 toprevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plug 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 wheel axles.
3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job.N O T I C EExcessive 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. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.
7. 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.
9
Page 110 of 120
9-2
StorageShort-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover.N O T I C EStoring 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 arestored. 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 sparkplug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark
Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1 oz
of stabilizer to each gallon of fuel)
9
WARNING
Wet brakes may have reduced stopping ability,
increasing the chance of an accident. Test the
brakes after washing. Apply the brakes several
times at slow speeds to let friction dry out thelinings.
