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
1-5
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**.* kPa
*.** kgf/cm²
*.* psi**.* kPa
*.** kgf/cm²
*.* psi
NEVER use with drugs or alcohol.
NEVER store fuel or flammable liquids.
This unit contains high-pressure nitrogen
gas.
Mishandling can cause an explosion. Do not
incinerate, puncture or open.
Use unleaded gasoline only.
Measure the tire pressure when the tires are
cold.Adjust the tire pressure.
Improper tire pressure can cause loss of
control.
Loss of control can result in severe injury or
death.
Turning the ATV in 4WD-LOCK
(“DIFF.LOCK”) takes more effort.
Operate at a slow speed and allow extra
time and distance for maneuvers to avoid
loss of control.
This pictogram shows the loading limits
and/or maximum load capacity for this ATV.
Follow all load limits and other loading
guidelines in this manual.
Load may include the driver, passenger,
human protective gear, accessories, goods,
luggage, and all other load related items.
Make sure you do not exceed the load limits.
Overloading can cause loss of control.
Loss of control can result in severe injury or
death.
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WA RN ING
Imprope r tire pressure o r over loa ding can cause
loss of cont rol.
Loss of control can result in severe injury or
death.
OPERATING TIRE PRESSURE : Set with tires cold
LO ADI NGRe com m ended : F r o nt : 30.0 k Pa ( 4.4 ps i )
Re ar : 30.0 k Pa ( 4.4 ps i )
Min imum : F r o nt : 27.0 k Pa ( 4.0 ps i )
Re ar : 27.0 k Pa ( 4.0 ps i )
Neve r set tire pressure below minimum.
It could cause the tire to dislodge from the rim.
Ma ximu m weigh t cap ac it y : 100 kg ( 220 Ibs.)
Inclu des weight of operat or, cargo and accessories.
3B5-2816M-00
WARNINGNEVER ride as a
passenger.Passengers can cause
a loss of control,
resulting in SEVERE
INJURY or DEATH.5FE-2151H-01
3
Operating t his ATV if you are under
the age of 16 increases your
chance of severe injury or death.
WARNING
NEVE R operate this ATV if you are
under age 16.
UNDER16 4D3-2816L-00
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speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for
braking described in this manual. Dismount on
the uphill side or to a side if pointed straight up-
hill. Turn the ATV around and remount, following
the procedure described in this manual.
Always check for obstacles before operating in a
new area.
Never attempt to operate over large obstacles,
such as large rocks or fallen trees. Always follow
proper procedures when operating over obsta-
cles as described in this manual.
Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to re-
duce the chance of skidding or sliding out of con-
trol.
Never operate an ATV in fast flowing water or in
water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.
Always use the size and type of tires specified inthis manual.
Always maintain proper tire pressure as de-
scribed in this manual.
Never modify an ATV through improper installa-
tion or use of accessories.
Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow in-
structions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for brak-
ing.
WARNING
EWB00071
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon monoxide,
a deadly gas. Breathing carbon monoxide can
cause headaches, dizziness, drowsiness, nau-
sea, confusion, and eventually death.
Carbon Monoxide is a colorless, odorless,
tasteless gas which may be present even if you
do not see or smell any engine exhaust. Deadly
levels of carbon monoxide can collect rapidly
and you can quickly be overcome and unable
to save yourself. Also, deadly levels of carbon
monoxide can linger for hours or days in en-
closed or poorly ventilated areas. If you experi-
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Rear brake
Check operation. If soft or spongy, have Yamaha dealer bleed
hydraulic system.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-3, 8-35, 8-36, 8-38
Clutch
Check operation, and correct if necessary.
Lubricate cable if necessary.
Check lever free play, and adjust if necessary.8-41
Throttle lever
Make sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.
Check lever free play, and adjust if necessary.5-4, 8-34
Control cables
Make sure that operation is smooth. Lubricate if necessary. 8-45
Drive chain
Check chain slack, and adjust if necessary.
Check chain condition. Lubricate if necessary.5-4, 8-43, 8-45
Wheels and tires
Check wheel condition, and replace if damaged.
Check tire condition and tread depth. Replace if necessary.
Check air pressure. Correct if necessary.5-4
Shift pedal
Make sure that operation is smooth.
Correct if necessary.8-46
Brake pedal
Make sure that operation is smooth. Lubricate pedal pivoting point if
necessary.8-46
Brake and clutch levers
Make sure that operation is smooth. Lubricate lever pivoting points
if necessary.8-46
Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened. 5-6
Instruments, lights and
switches
Check operation, and correct if necessary. 5-7
ITEM ROUTINE PAGE
5-4
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(See page 8-36.)
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or brake fluid reservoirs. Apply the
brakes firmly for one minute. If there is any leak-
age, have a Yamaha dealer check the brake sys-
tem.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, check
the brake pads for wear. (See page 8-35.)
EBU19761
Throttle lever
Check the operation of the throttle lever. It must
open smoothly and spring back to the idle position
when released. Have a Yamaha dealer correct if
necessary.
EBU19770
Drive chain
Check the condition of the drive chain and check
the drive chain slack. Lubricate and adjust the
drive chain as necessary. (See page 8-43.)
EBU19794
Tires
Check tire pressure regularly to make sure it is at
the recommended specifications. Also check for
wear and damage.
Tire pressure
Use the low-pressure tire gauge to check and ad-
just tire pressures when the tires are cold. Tire
pressures must be equal on both sides.
WARNING! Operation of this vehicle with im-
proper tire pressure may cause severe injury
or death from loss of control or rollover. Tire
pressure below the minimum specified could
also cause the tire to dislodge from the rim un-
der severe riding conditions.
[EWB02541]
Set tire pres-
sures to the following specifications: Recommended brake fluid:
DOT 4
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Tire information
This ATV is equipped with tubeless tires with
valves.
WARNING
EWB02551
Use of improper tires on this ATV may cause
loss of control, increasing your risk of an acci-
dent.
After extensive tests, only the tires listed below
have been approved for this model by Yamaha
Motor Co., Ltd.
Aftermarket tires and rims
The tires and rims that came with your ATV were
designed to match the performance capabilities
and to provide the best combination of handling,
braking, and comfort. Other tires, rims, sizes, and
combinations may not be appropriate.
EBU19840
Chassis fasteners
Make sure that all nuts, bolts and screws are prop-
erly tightened.
1. Tire wear limit
Front:
Manufacturer/model:
DUNLOP/KT851B
Size:
AT21 x 7-10
Type:
Tubeless
Rear:
Manufacturer/model:
DUNLOP/KT877A
Size:
AT20 x 10-9
Type:
Tubeless
6-4
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the next higher gear.
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 damage
the 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-