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EBU20650
To decelerate
When slowing down or stopping, release the throt-
tle and apply the brakes smoothly and evenly. As
you slow down, shift to a lower gear. Be sure that
the engine has sufficiently slowed before engaging
a lower gear. Improper use of the brakes or shifting
can cause the tires to lose traction, reducing con-
trol and increasing the possibility of an accident.
WARNING
EWB00710
Make sure the engine has sufficiently slowed
before shifting to a lower gear. Engaging a low-
er gear when the engine speed is too high
could make the wheels stop rotating and lose
traction. This could cause loss of control, an
accident and injury. It could also cause engine
or drive train damage.
NOTICE
ECB00180
Even with the transmission in the neutral po-
sition, do not coast for long periods of time
with the engine off, and do not tow the ATV
for long distances. The transmission is prop-
erly lubricated only when the engine is run-
ning. Inadequate lubrication may damagethe transmission.
Always use the clutch when changing gears.
The engine, transmission and drive train are
not designed to withstand the shock of
forced shifting and can be damaged by shift-
ing without using the clutch.
EBU20672
Engine break-in
TIP
For ATVs equipped with an odometer or an hour
meter, follow the figures given in km (mi) or the
figures given in hours.
For ATVs not equipped with an odometer or
hour meter, follow the figures given in hours.
There is never a more important period in the life of
your engine than the first 320 km (200 mi) or 20
hours of riding. For this reason, you should read
the following material carefully.
Since the engine is brand new, do not put an ex-
cessive load on it for the first 320 km (200 mi) or 20
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-
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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
19
*
Moving parts and
cables
Lubricate.
√√√√
20
*
Throttle lever hous-
ing and cable
Check operation and correct if necessary.
Check throttle cable free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.
√√√√√
21
*
Front and rear brake
switches
Check operation and correct if necessary.
√√√√√
22
*
Lights and switches
Check operation and correct if necessary.
Adjust headlight beams.
√√√√√
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
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attempt to diagnose such problems yourself. In-
stead, have a Yamaha dealer check the ATV.
3. Check each spark plug for electrode erosion
and excessive carbon or other deposits, and
replace it if necessary.
4. Measure the spark plug gap with a wire thick-
ness gauge and, if necessary, adjust the gap
to specification.
To install a spark plug
1. Clean the surface of the spark plug gasket
and its mating surface, and then wipe off any
grime from the spark plug threads.
2. Install the spark plug with the spark plug
wrench, and then tighten it to the specified
torque.TIP
If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque as
soon as possible.
3. Install the spark plug cap.
EBU23344
Transmission oil
The transmission oil level should be checked be- Specified spark plug:
NGK/BR8ES
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
20 Nm (2.0 m·kgf, 14 ft·lbf)
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fore each ride. In addition, the transmission oil
must be changed at the intervals specified in the
periodic maintenance and lubrication chart.
To check the transmission oil level
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Wait a few minutes until the oil settles, remove
the 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 transmission oil should be between the mini-
mum and maximum level marks.
4. 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.
5. Insert the dipstick into the oil filler hole, and
then tighten the oil filler cap.
1. Dipstick
2. Maximum level mark
3. Minimum level mark
4. Transmission oil filler cap
12
34
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To change the transmission oil
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Place an oil pan under the transmission case
to collect the used oil.
4. Remove the oil filler cap and the drain bolt to
drain the oil from the transmission case.
5. Install the drain bolt, and then tighten it to the
specified torque.6. Refill with the specified amount of the recom-
mended transmission oil, and then install and
tighten the oil filler cap.TIP
Be sure to wipe off spilled oil on any parts after the
engine and exhaust system have cooled down.NOTICE
ECB00430
In order to prevent clutch slippage (since the
transmission oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD” or
oils of a higher quality than specified. In ad-
dition, do not use oils labeled “ENERGY
CONSERVING II” or higher.
Make sure that no foreign material enters the
1. Transmission oil drain bolt
1
Tightening torque:
Transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Recommended transmission oil:
See page 10-1.
Oil quantity:
1.5 L (1.59 US qt, 1.32 Imp.qt)
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EBU25860
CLEANING AND STORAGE
EBU25921
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.
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 the lin-
ings.
[EWB02311]
NOTICE:
Excessive water pres-sure may cause water seepage and
deterioration of wheel bearings, brakes,
transmission seals and electrical devices.
Many expensive repair bills have resulted
from improper high-pressure detergent
applications such as those available in
coin-operated car washers.
[ECB00711]
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.
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EBU25960
SPECIFICATIONS
EBU2597F
Dimensions:
Overall length:
1855 mm (73.0 in)
Overall width:
1100 mm (43.3 in)
Overall height:
1080 mm (42.5 in)
Seat height:
800 mm (31.5 in)
Wheelbase:
1280 mm (50.4 in)
Ground clearance:
135 mm (5.3 in)
Minimum turning radius:
3600 mm (142 in)
Weight:
With oil and fuel:
187.0 kg (412 lb)
Noise and vibration level:
Noise level (77/311/EEC):
82.7 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:
Liquid cooled 2-stroke
Cylinder arrangement:
Forward-inclined parallel 2-cylinder
Displacement:
347 cm
3
Bore
×
stroke:
64.0
×
54.0 mm (2.52
×
2.13 in)
Compression ratio:
6.50 :1
Starting system:
Kickstarter
Lubrication system:
Premix
Type:
YAMALUBE 2-R, Castrol R30, A545, A747
Engine oil quantity:
Premix ratio (1):
YAMALUBE R 24:1
Transmission oil:
Type:
SAE 10W-30 type SE motor oil (EUR)
YAMALUBE 4 (10W-40) or SAE 10W-40 type SE motor
oil (AUS)(NZL)
Quantity:
1.5 L (1.59 US qt, 1.32 Imp.qt)
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Cooling system:
Coolant reservoir capacity (up to the maximum level mark):
0.28 L (0.30 US qt, 0.25 Imp.qt)
Radiator capacity (including all routes):
1.50 L (1.59 US qt, 1.32 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
12.0 L (3.17 US gal, 2.64 Imp.gal)
Fuel reserve amount:
2.5 L (0.66 US gal, 0.55 Imp.gal)
Carburetor:
Type
×
quantity:
VM26SS x 2
Spark plug (s):
Manufacturer/model:
NGK/BR8ES
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system:
Helical gear
Primary reduction ratio:
66/23 (2.869)Secondary reduction system:
Chain drive
Secondary reduction ratio:
41/14 (2.929)
Transmission type:
Constant mesh 6-speed
Operation:
Left foot operation
1st:
32/13 (2.461)
2nd:
29/16 (1.812)
3rd:
27/18 (1.500)
4th:
25/20 (1.250)
5th:
23/22 (1.045)
6th:
21/24 (0.875)
Chassis:
Frame type:
Steel tube frame
Caster angle:
9.0 °
Trail:
40.0 mm (1.57 in)
Front tire:
Type:
Tubeless
Size:
AT21 x 7-10
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