Page 9 of 142
Starting a warm engine .............................. 6-3
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 ........... 7-21
SLIDING AND SKIDDING ......................... 7-21
WHAT TO DO IF... .................................... 7-22
WHAT TO DO... ........................................ 7-22
PERIODIC MAINTENANCE AND
ADJUSTMENT ............................................... 8-1 Owner’s manual and tool kit ....................... 8-2 Periodic maintenance chart for the
emission control system ...........................8-3
General maintenance and lubrication chart ..........................................................8-5
Checking the spark plug .............................8-9
Engine oil and oil filter cartridge ................8-11
Final gear oil .............................................8-15
Changing the differential gear oil ..............8-18
Cleaning the air filter element ...................8-19
Cleaning the spark arrester ......................8-22
V-belt cooling duct check hose .................8-24
V-belt case drain plug ...............................8-24
Adjusting the carburetor ............................8-25
Adjusting the engine idling speed .............8-25
Adjusting the throttle lever free play .........8-26
Valve clearance ........................................8-27
Adjusting the drive select lever safety system cable ...........................................8-27
Brakes .......................................................8-27
Checking the front brake pads and rear brake shoes ............................................8-27
Checking the brake fluid level ...................8-29
Changing the brake fluid ...........................8-30
Checking the front brake lever free play ...8-30
Adjusting the brake pedal height, and the brake pedal and rear brake lever free
play .........................................................8-30
U1NS60E0.book Page 2 Monday, August 1, 2011 4:12 PM
Page 24 of 142
3-1
3
EBU17680
DESCRIPTION
EBU17690Left view
EBU17700Right view
1. Fuel cock
2. Throttle stop screw
3. Air filter case
4. Fuses
5. Battery
6. Tail/brake light
7. Engine oil filler cap
8. Oil filter cartridge
9. V-belt cooling duct check hose
3
4,5
1
26
987
1. Rear shock absorber assembly spring preload adjusting ring
2. Spark arrester
3. Storage compartment and tool kit
4. Spark plug
5. Front shock absorber assembly spring preload adjusting ring
6. Rear brake light switch
7. Brake pedal
8. V-belt case drain plug12 3 4 5
678
U1NS60E0.book Page 1 Monday, August 1, 2011 4:12 PM
Page 87 of 142
8-7
8
14*Engine mount
Check for cracks or other damage, and replace if
necessary. √√√
15 *Axle boots
Check for cracks or other damage, and replace if
necessary. √√√√√
16 Engine oil
Change.
Check ATV for oil leakage, and correct if neces-
sary. √ √√√
17 Engine oil filter car-
tridge
Replace. √√√
18 Differential gear oil
Change.
Check ATV for oil leakage, and correct if neces-
sary. √√
19 Final gear oil
Change.
Check ATV for oil leakage, and correct if neces-
sary. √√
20 *Moving parts and
cables
Lubricate. √√√√
21 *Drive select lever
safety system cable
Check operation and adjust or replace if neces-
sary. √√√
22 *Throttle lever
Check operation.
Check throttle lever free play, and adjust if neces-
sary.
Lubricate cable and lever housing. √√√√√
NO. ITEM
CHECK OR MAINTENANCE
JOB INITIAL EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U1NS60E0.book Page 7 Monday, August 1, 2011 4:12 PM
Page 91 of 142
8-11
8
TIPIf a torque wrench is not available when installing
the 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.EBU23319Engine oil and oil filter cartridge The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals spec-
ified in the periodic maintenance and lubrication
chart.
To check the engine oil level 1. Place the ATV on a level surface.
2. Check the engine oil level on a cold engine.
TIPIf the engine was started before checking the oil
level, be sure to warm up the engine sufficiently,
and then wait at least ten minutes until the oil set-
tles for an accurate reading.3. Remove the engine oil filler cap, and then wipe the engine oil dipstick off with a clean
rag.
4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to
check the oil level.
Tightening torque:
Spark plug:18 Nm (1.8 m ·kgf, 13 ft ·lbf)1. Engine oil filler cap
U1NS60E0.book Page 11 Monday, August 1, 2011 4:12 PM
Page 93 of 142
8-13
8
TIPSkip steps 5–7 if the oil filter cartridge is not being
replaced.5. Remove the oil filter cartridge with an oil filter wrench.
TIPAn oil filter wrench is available at a nearby Yamaha
dealer.6. Apply a thin coat of engine oil to the O-ring ofthe new oil filter cartridge.TIPMake sure that the O-ring is properly seated.
1. Oil filter cartridge
1
1. Oil filter wrench
1
U1NS60E0.book Page 13 Monday, August 1, 2011 4:12 PM
Page 94 of 142
8-14
87. Install the new oil filter cartridge with an oil fil-
ter wrench, and then tighten it to the specified
torque with a torque wrench.
8. Install the engine oil drain bolt and its newgasket, and then tighten the bolt to the speci-
fied torque.
1. O-ring
1. Torque wrenchTightening torque:Oil filter cartridge:17 Nm (1.7 m ·kgf, 12 ft· lbf)
Tightening torque: Engine oil drain bolt:23 Nm (2.3 m ·kgf, 17 ft· lbf)
1
U1NS60E0.book Page 14 Monday, August 1, 2011 4:12 PM
Page 95 of 142
8-15
8
9. Refill with the specified amount of the recom-
mended engine oil, and then install and tight-
en the engine oil filler cap.
TIPBe sure to wipe off spilled oil on any parts after the
engine and exhaust system have cooled down.NOTICEECB00300In order to prevent clutch slippage (since the
engine 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 addition,
do not use oils labeled “ENERGY CONSERV-
ING II ” or higher.
Make sure that no foreign material enters the
crankcase.10. Start the engine, and then let it idle for several
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
11. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if
necessary.EBU23386Final gear oil The final gear case must be checked for oil leak-
age before each ride. If any leakage is found, have
a Yamaha dealer check and repair the ATV. In ad-
dition, the final gear oil level must be checked and
the oil changed as follows at the intervals specified
in the periodic maintenance and lubrication chart.
To check the final gear oil level1. Place the ATV on a level surface.
2. Remove the final gear oil filler bolt and its gas- ket, and then check the oil level in the final
gear case. The oil level should be at the brim
of the filler hole.
Recommended oil:
See page 10-1.
Oil quantity: Without oil filter cartridge replacement:2.20 L (2.33 US qt, 1.94 Imp.qt)
With oil filter cartridge replacement: 2.30 L (2.43 US qt, 2.02 Imp.qt)
U1NS60E0.book Page 15 Monday, August 1, 2011 4:12 PM
Page 99 of 142
8-19
8
4. Install the drain bolt and its new gasket, and
then tighten the bolt to the specified torque.
5. Refill with the specified amount of the recom- mended differential gear oil. NOTICE: Be
sure no foreign material enters the differ-
ential gear case.
[ECB00411]
TIPDo not exceed the specified differential gear oil
quantity when filling. Overfilling will cause the oil
to seep out of the breather hose during and after
riding.The differential gear case capacity is greater
than the recommended oil quantity, therefore
the oil level cannot be accurately checked from
the oil filler hole.
6. Check the oil filler bolt gasket for damage, and replace it if necessary.
7. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.
8. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause.EBU23646Cleaning the air filter element The air filter element should be cleaned at the in-
tervals specified in the periodic maintenance and
lubrication chart. Clean or, if necessary, replace
the air filter element more frequently if you are
riding in unusually wet or dusty areas.TIPThere is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-
ter case.
Tightening torque:Differential gear oil drain bolt:10 Nm (1.0 m ·kgf, 7.2 ft· lbf)
Recommended differential gear oil: See page 10-1.
Oil quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt)
Tightening torque:Differential gear oil filler bolt:23 Nm (2.3 m ·kgf, 17 ft ·lbf)
U1NS60E0.book Page 19 Monday, August 1, 2011 4:12 PM
