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
Indicator lights ........................................... 4-1
Handlebar switches ................................... 4-2
Throttle lever ............................................. 4-3
Speed limiter ............................................. 4-3
Front brake lever ....................................... 4-4
Rear brake lever ........................................ 4-4
Parking brake ............................................ 4-5
Drive select lever ....................................... 4-6
Fuel tank cap ............................................. 4-6
Fuel ........................................................... 4-6
Fuel cock ................................................... 4-8
Starter (choke) .......................................... 4-9Seat ......................................................... 4-10
Front carrier ............................................. 4-11
Rear carrier .............................................. 4-11
PRE-OPERATION CHECKS ..........................5-1
Fuel ............................................................ 5-3
Engine oil ................................................... 5-3
Transmission oil ......................................... 5-3
Front and rear brakes ................................ 5-3
Throttle lever .............................................. 5-3
Drive chain ................................................. 5-3
Tires ........................................................... 5-3
Chassis fasteners ...................................... 5-5
Instruments, lights and switches ................ 5-6
Battery ....................................................... 5-6
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-2
Operating the drive select lever and
driving in reverse .....................................6-3
Engine break-in .......................................... 6-4
Parking ....................................................... 6-5
Parking on a slope ..................................... 6-5
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 ............ 7-9
TURNING YOUR ATV ............................. 7-12
CLIMBING UPHILL .................................. 7-13
RIDING DOWNHILL................................. 7-16
CROSSING A SLOPE.............................. 7-17
CROSSING THROUGH SHALLOW
WATER ..................................................7-18
RIDING OVER ROUGH TERRAIN .......... 7-20
SLIDING AND SKIDDING ........................ 7-20
WHAT TO DO IF... ................................... 7-21
WHAT TO DO... ....................................... 7-21
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 plug ............................ 8-8
Engine oil .................................................. 8-9
Transmission oil ...................................... 8-12
Cleaning the engine and V-belt case air
filter elements ........................................ 8-15
Cleaning the spark arrester ..................... 8-21V-belt case drain screw ........................... 8-23
Adjusting the carburetor ........................... 8-24
Adjusting the engine idling speed ............ 8-24
Adjusting the throttle cable free play ........ 8-25
Valve clearance ....................................... 8-26
Brakes ...................................................... 8-26
Checking the front and rear brake
shoes .....................................................8-26
Adjusting the front brake lever free
play ........................................................8-27
Adjusting the rear brake lever free
play ........................................................ 8-32
Drive chain slack ...................................... 8-33
Lubricating the drive chain ....................... 8-35
Checking and lubricating the cables ........ 8-36
Checking and lubricating the front and
rear brake levers ....................................8-36
Checking the wheel hub bearings ............ 8-37
Lubricating the upper and lower arm
pivots ....................................................8-38
Lubricating the front knuckle pivots ......... 8-39
Lubricating the steering shaft ................... 8-39
Battery ..................................................... 8-40
Replacing the fuse ................................... 8-43
Replacing a headlight bulb ...................... 8-44
Adjusting a headlight beam ..................... 8-46
Replacing the tail/brake light bulb ............ 8-46
Removing a wheel ................................... 8-47
Installing a wheel ..................................... 8-47
3-1
1
23
4
5
6
7
8
9
10
11
EBU17680
DESCRIPTION
EBU17690
Left view
EBU17700
Right view
1. Front carrier
2. Starter (choke)
3. Fuel cock
4. Throttle stop screw
5. Tail/brake light
6. Rear carrier
7. Spark arrester
8. Footboard
123
5
6
7
8
4
1. Owner’s tool kit
2. Battery
3. Drive select lever
4. Spark plug
5. Headlight
6. Engine oil filler cap
7. Fuse
23
5
6
7
1
4
3-2
1
23
4
5
6
7
8
9
10
11
EBU17712
Controls and instruments
TIP
The ATV you have purchased may differ slightly
from the figures shown in this manual.
1. Rear brake lever
2. Parking brake
3. Reverse indicator light
4. Neutral indicator light
5. Front brake lever
6. Throttle lever
7. Main switch
8. Fuel tank cap
9. Handlebar switches
12
34
5
9876
4-1
1
2
34
5
6
7
8
9
10
11
EBU17733
INSTRUMENT AND CONTROL FUNCTIONS
EBU17760
Main switch
The positions of the main switch are as follows:
ON
All electrical systems are supplied with power. The
headlights and taillight come on when the light
switch is on, and the engine can be started. The
key cannot be removed.
OFF
All electrical systems are off. The key can be re-
moved.
EBU17793
Indicator lights
EBU17860
Neutral indicator light “”
This indicator light comes on when the transmis-
sion is in the neutral position.
EBU17830
Reverse indicator light “”
This indicator light comes on when the transmis-
sion is in the reverse position.
1. Main switch
OFF ON
1
1. Reverse indicator light “R”
2. Neutral indicator light “N”
1
2
4-2
1
2
34
5
6
7
8
9
10
11
EBU18061
Handlebar switches
EBU18080
Engine stop switch “/”
Set this switch to “ ” before starting the engine.
The engine stop switch controls the ignition and
stops the engine when it is running. Use this switch
to stop the engine in an emergency situation. The
engine will not start or run when this switch is set
to “ ”.
EBU18101
Start switch “”
Push this switch to crank the engine with the start-
er. See the starting instructions on page 6-1 prior
to starting the engine.
EBU18152
Light switch “/ /OFF”
Set this switch to “ ” to turn on the low beams
and the taillight. Set the switch to “ ” to turn on
the high beams and the taillight. Set the switch to
“OFF” to turn off all the lights.NOTICE
ECB00041
Do not use the headlights with the engine
turned off for an extended period of time, oth-
erwise the battery may discharge to the point
that the starter motor will not operate properly.
If this should happen, remove the battery and
recharge it. See page 8-40 for battery charging
information.
EBU18170
Horn switch “”
Press the switch to sound the horn.
1. Horn switch “ ”
2. Light switch “ / /OFF”
3. Engine stop switch “ / ”
4. Start switch “ ”
2
3
41
4-7
1
2
34
5
6
7
8
9
10
11
1. Before refueling, turn off the engine and be
sure that no one is sitting on the vehicle. Nev-
er refuel while smoking, or while in the vicinity
of sparks, open flames, or other sources of ig-
nition such as the pilot lights of water heaters
and clothes dryers.
2. Do not overfill the fuel tank. When refueling,
be sure to insert the pump nozzle into the fuel
tank filler hole. Stop filling when the fuel reach-
es the bottom of the filler tube. Because fuel
expands when it heats up, heat from the en-
gine or the sun can cause fuel to spill out of
the fuel tank.3. Wipe up any spilled fuel immediately.
NOTICE:
Immediately wipe off spilled
fuel with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces
or plastic parts.
[ECB00981]
4. Turn the fuel tank cap fully clockwise to make
sure it is securely closed.
WARNING
EWB02531
Gasoline is poisonous and can cause injury or
death. Handle gasoline with care. Never siphon
gasoline by mouth. If you should swallow
some gasoline or inhale a lot of gasoline vapor,
or get some gasoline in your eyes, see your
doctor immediately. If gasoline spills on your
skin, wash with soap and water. If gasoline
spills on your clothing, change your clothes.
1. Maximum fuel level
2. Fuel tank filler tube
Recommended fuel:
Regular unleaded gasoline only with a re-
search octane number of 91 or higher
Fuel tank capacity:
7.0 L (1.85 US gal, 1.54 Imp.gal)
Fuel reserve amount:
1.3 L (0.34 US gal, 0.29 Imp.gal)
5-2
1
2
3
45
6
7
8
9
10
11
Throttle lever
Make sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.
Check cable free play, and adjust if necessary.5-3, 8-25
Control cables
Make sure that operation is smooth. Lubricate if necessary. 8-36
Drive chain
Check chain slack, and adjust if necessary.
Check chain condition. Lubricate if necessary.5-3, 8-33, 8-35
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.5-3
Brake levers
Make sure that operation is smooth. Lubricate lever pivoting points
if necessary.8-36
Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened. 5-5
Instruments, lights and
switches
Check operation, and correct if necessary. 5-6
Battery
Check electrolyte level. Fill with distilled water if necessary. 5-6, 8-40
ITEM ROUTINE PAGE