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8-14
8
9. 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.
10. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if
necessary.
EBU27026Transmission oil The transmission oil level should be checked be-
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 level1. 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, and then loosen the transmission oil check screw
located at the right side of the crankcase until
oil flows out. 4. If no oil flows out, remove the transmission oil
filler bolt and its gasket.
1. Transmission oil check screw
2. Gasket
3. Correct oil level
4. Transmission oil4 3 1
2
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Page 86 of 134
8-15
85. Pour the recommended type of oil in the trans-
mission oil filler hole until it flows out of the
check screw hole.
6. Tighten the oil check screw to the specified torque.
7. Check the oil filler bolt gasket for damage, and replace it if necessary. 8. Install the transmission oil filler bolt and its
gasket, and then tighten the bolt to the speci-
fied torque.
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 to col- lect the used oil.
4. Remove the transmission oil filler bolt, the transmission oil drain bolt and their gasket to
drain the oil from the transmission case.
1. Transmission oil filler bolt
2. GasketTightening torque:Transmission oil check screw:16 Nm (1.6 m·kgf, 12 ft·lbf)
1
2
Tightening torque: Transmission oil filler bolt:23 Nm (2.3 m·kgf, 17 ft·lbf)
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8-16
8
5. Install the drain bolt and its new gasket, and
then tighten the bolt to the specified torque.
6. Refill with the specified amount of the recom- mended transmission oil. NOTICE: Make
sure that no foreign material enters the
transmission case.
[ECB00791]
7. Check the oil filler bolt gasket for damage, and replace it if necessary.
8. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.NOTICEECB01061Make sure that no oil gets on the tires or
wheels.9. Start the engine, and then let it idle for severalminutes while checking the transmission for
oil leakage. If oil is leaking, immediately turn
off the engine and check for the cause.
10. Turn the engine off, and then check the oil lev- el and correct it if necessary.
1. Transmission oil drain bolt
2. GasketTightening torque:Transmission oil drain bolt:23 Nm (2.3 m·kgf, 17 ft·lbf)
12
Recommended transmission oil: See page 10-1.
Oil quantity: 0.6 L (0.63 US qt, 0.53 Imp.qt)
Tightening torque: Transmission oil filler bolt:23 Nm (2.3 m·kgf, 17 ft·lbf)
U1PY61E0.book Page 16 Wednesday, March 14, 2012 5:22 PM
Page 90 of 134
8-19
87. Squeeze the excess solvent out of the sponge
material and let it dry. NOTICE: Do not twist
the sponge material when squeezing it.
[ECB00441]
8. Check the sponge material and replace it if damaged.
9. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material.TIPThe sponge material should be wet but not drip-
ping.10. Pull the sponge material over the air filter ele- ment frame. 11. Apply all-purpose grease to the air filter ele-
ment seat.
12. Install the washer and screw. NOTICE: Be
sure to install the washer with its curved
side facing outward as shown.
[ECB00453]
1. Air filter element seat
1
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8-37
86. Tighten the hub stopper bolt and hub stopper
bolt locknut to the specified torques.
EBU24882Lubricating the drive chain The drive chain must be cleaned and lubricated at
the intervals specified in the periodic maintenance
and lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or wet areas.
Service the drive chain as follows.NOTICEECB00561The drive chain must be lubricated after wash-
ing the ATV or riding in the rain or wet areas.1. Clean the drive chain with kerosene and asmall soft brush. NOTICE: To prevent dam-
aging the O-rings, do not clean the drive
chain with steam cleaners, high-pressure
washers or inappropriate solvents.
[ECB00571]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. NOTICE: Do
not use engine oil or any other lubricants
for the drive chain, as they may contain
substances that could damage the O-
rings.
[ECB00581]
EBU24902
Checking and lubric ating the cables The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
Tightening torques:
Hub stopper bolt:16 Nm (1.6 m·kgf, 12 ft·lbf)
Hub stopper bolt locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf)1. O-ring
1
1
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8-38
8
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
WARNING
EWB02581●Inspect cables frequently and replace if dam-
aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could
restrict the operation of controls and lead to
an accident or injury.●Always make sure all control cables work
smoothly before you begin riding in cold
weather. If the control cables are frozen or do
not work smoothly, you could be unable to
control the ATV, which could lead to an acci-
dent or collision.
EBU28702Checking and lubric
ating the front and
rear brake levers The operation of the front and rear brake levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary.
Front brake lever
Recommended lubricant:
Yamaha Chain and Cable Lube or engine oilRecommended lubricant: Lithium-soap-based grease
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8-41
8
EBU25092Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha
dealer at the intervals specified in the periodic
maintenance and lubrication chart.TIPFor parts equipped with a grease nipple, use a
grease gun.
EBU2512ABattery The battery is located under the seat. (See page
4-10.)
A poorly maintained battery will corrode and dis-
charge quickly. The electrolyte level, battery lead
connections and breather hose routing should be
checked before each ride and at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
WARNING
EWB02160Battery electrolyte is poisonous and danger-
ous, as it contains sulfuric acid, which can
cause severe burns. Avoid contact with skin,
eyes or clothing. Always shield your eyes
when working near batteries.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg
or vegetable oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get
prompt medical attention.
Recommended lubricant:
Lithium-soap-based grease
1. Grease nipple
1
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9-2
9
EBU30360Storage Short-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover. NOTICE: Storing the ATV in a poorly ven-
tilated room or covering it with a tarp while it is
still wet, will allow water and humidity to seep
in and cause rust. To prevent corrosion, avoid
damp cellars, stables (because of the presence
of ammonia) and areas where strong chemi-
cals are stored.
[ECB00721]
Long-term
Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” section of this chapter.
2. Turn the fuel cock lever to “OFF”.
3. Drain the carburetor float chamber by loosen- ing the drain bolt; this will prevent fuel deposits
from building up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorat-
ing. 5. Perform the following steps to protect the cyl-
inder, piston rings, etc. from corrosion.a. Remove the spark plug cap and spark plug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with the starter. (This will coat the cylinder wall with
oil.)
e. Remove the spark plug cap from the spark plug, and then install the spark plug and
the spark plug cap.
6. Lubricate all control cables and the pivoting points of all levers.
7. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that
all of its wheels are off the ground. Alternative-
Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1
oz of stabilizer to each gallon of fuel)U1PY61E0.book Page 2 Wednesday, March 14, 2012 5:22 PM