EBU17420
TABLE OF CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 1-1
SAFETY INFORMATION .............................. 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 ................................................ 4-4
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) ......................................... 4-11
Seat ......................................................... 4-11
Adjusting the front shock absorber
assemblies ............................................. 4-12
Adjusting the rear shock absorber
assembly ................................................ 4-13
PRE-OPERATION CHECKS ..........................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 ........................................................... 5-4
Chassis fasteners ...................................... 5-6
Instruments, lights and switches ................ 5-7
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-2
Shifting ....................................................... 6-2
Engine break-in .......................................... 6-4
Parking ....................................................... 6-5
Parking on a slope ..................................... 6-6
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Accessories and loading ........................... 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV.............. 7-2
RIDE WITH CARE AND GOOD
JUDGMENT ............................................. 7-2
BE CAREFUL WHERE YOU RIDE ............ 7-8
TURNING YOUR ATV ............................. 7-11
CLIMBING UPHILL .................................. 7-12
RIDING DOWNHILL................................. 7-15
CROSSING A SLOPE.............................. 7-16
CROSSING THROUGH SHALLOW
WATER .................................................. 7-17
RIDING OVER ROUGH TERRAIN .......... 7-18
SLIDING AND SKIDDING ........................ 7-19
WHAT TO DO IF... ................................... 7-20
WHAT TO DO... ....................................... 7-20
PERIODIC MAINTENANCE AND
ADJUSTMENT ............................................... 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 ........................................................ 8-5
Checking the spark plugs .......................... 8-9
Transmission oil ...................................... 8-10
Coolant .................................................... 8-13
Cleaning the air filter element ................. 8-18Cleaning the spark arrester ..................... 8-21
Changing the carburetor settings ............. 8-23
Adjusting the engine idling speed ............ 8-31
Adjusting the throttle cable free play ........ 8-33
Brakes ...................................................... 8-33
Checking the front and rear brake
pads ....................................................... 8-34
Checking the brake fluid level .................. 8-35
Changing the brake fluid .......................... 8-37
Checking the front brake lever free
play ........................................................ 8-37
Checking the brake pedal position ........... 8-37
Adjusting the parking brake free play ...... 8-38
Brake light switches ................................. 8-40
Adjusting the clutch lever free play .......... 8-41
Drive chain slack ...................................... 8-41
Lubricating the drive chain ....................... 8-43
Checking and lubricating the cables ........ 8-44
Checking and lubricating the brake and
clutch levers ........................................... 8-44
Checking the shift pedal .......................... 8-45
Checking and lubricating the brake
pedal ...................................................... 8-45
Checking the wheel hub bearings ............ 8-45
Lubricating the rear suspension relay
arm and connecting arm pivoting
points ..................................................... 8-45
Lubricating the upper and lower arm
pivots ..................................................... 8-46
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8-9
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2
3
4
5
6
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9
10
11
EBU28321
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 thespark plug wrench included in the owner’s tool
kit.
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
1. Spark plug cap
1
1. Spark plug wrench
1
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1
2
3
4
5
6
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10
11
5. Move the throttle lever a few times and re-
check the position.
6. Install the fuel tank, side cover, radiator cover
and air filter case cover.
7. Connect the fuel hoses.
8. Install the seat.
EBU24020
Adjusting the engine idling speed
The engine idling speed must be checked and, if
necessary, adjusted as follows at the intervals
specified in the periodic maintenance and lubrica-tion chart.TIP
A diagnostic tachometer is needed to make this
adjustment.
The carburetor synchronization and the throttle
cable free play must be checked, and adjusted if
necessary, before adjusting the engine idling
speed.
1. Start the engine and warm it up.
TIP
The engine is warm when it quickly responds to the
throttle.
2. Attach the tachometer to the spark plug lead.
3. Turn in both pilot air screws until they lightly
seat.
4. Turn out both pilot air screws to specification.
(See the “Changing the carburetor settings”
section on the page 8-23.)
1. Adjusting nut
2. Locknut
1
2
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INDEX
A
Accessories and loading ................................................ 6-6
Air filter element, cleaning ............................................ 8-18
B
Brake and clutch levers, checking and lubricating ....... 8-44
Brake fluid, changing.................................................... 8-37
Brake fluid level, checking............................................ 8-35
Brake lever ..................................................................... 4-4
Brake lever free play, checking the front ...................... 8-37
Brake light switches ..................................................... 8-40
Brake pads, checking the front and rear ...................... 8-34
Brake pedal .................................................................... 4-5
Brake pedal, checking and lubricating ......................... 8-45
Brake pedal position, checking .................................... 8-37
Brakes .......................................................................... 8-33
Brakes, front and rear .................................................... 5-3
C
Cables, checking and lubricating ................................. 8-44
Carburetor settings, changing ...................................... 8-23
Chassis fasteners........................................................... 5-6
Cleaning ......................................................................... 9-1
Clutch lever .................................................................... 4-4
Clutch lever free play, adjusting ................................... 8-41
Coolant ................................................................. 5-3
,
8-13
D
Drive chain ..................................................................... 5-4
Drive chain, lubricating ................................................. 8-43
Drive chain slack .......................................................... 8-41
E
Engine break-in .............................................................. 6-4
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-31
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............................................ 8-49
Headlight bulb, replacing.............................................. 8-47
I
Identification numbers .................................................. 11-1
Instruments, lights and switches .................................... 5-7
K
Key identification number ............................................. 11-1
Kickstarter ...................................................................... 4-7
L
Label locations ............................................................... 1-1
Light switch .................................................................... 4-2
M
Main switch .................................................................... 4-1
Maintenance and lubrication chart ................................. 8-5
Maintenance chart, emission control system ................. 8-3
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