EBU17420
TABLE OF CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 1-1
SAFETY INFORMATION .............................. 2-1
DESCRIPTION .............................................. 3-1Left view ...................................................... 3-1
Right view.................................................... 3-1
Controls and instruments ............................ 3-2
INSTRUMENT AND CONTROL
FUNCTIONS .................................................. 4-1 Main switch ................................................ 4-1
Indicator lights ............................................ 4-2
Handlebar switches .................................... 4-2
Throttle lever .............................................. 4-3
Speed limiter .............................................. 4-4
Front brake lever ........................................ 4-4
Rear brake lever ......................................... 4-5
Parking brake ............................................. 4-5
Drive select lever ........................................ 4-6
Fuel tank cap .............................................. 4-7
Fuel ............................................................ 4-7
Fuel cock .................................................... 4-8 Starter (choke) ..........................................4-10
Seat ..........................................................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 .......................................5-6
Instruments, lights and switches .................5-6
Battery ........................................................5-6
OPERATION...................................................6-1 Starting a cold engine .................................6-1
Starting a warm engine ...............................6-3
Operating the drive select lever and driving in reverse ......................................6-3
Engine break-in ...........................................6-4
Parking ........................................................6-5U1PY61E0.book Page 1 Wednesday, March 14, 2012 5:22 PM
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 ................................... 7-14
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... .................................... 7-22
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 ..................................................8-11
Transmission oil ........................................8-14
Cleaning the engine and V-belt case air
filter elements .........................................8-17
Cleaning the spark arrester ......................8-23
V-belt case drain screw ............................8-24
Adjusting the carburetor ............................8-25
Adjusting the engine idling speed .............8-26
Adjusting the throttle lever free play .........8-26
Valve clearance ........................................8-27
Brakes .......................................................8-28
Checking the front and rear brake shoes ......................................................8-28
Adjusting the front brake lever free play ...8-29
Adjusting the rear brake lever free play ....8-33
Drive chain slack .......................................8-34
Lubricating the drive chain ........................8-37
Checking and lubricating the cables .........8-37
Checking and lubricating the front and rear brake levers .....................................8-38
Checking the wheel hub bearings .............8-39
Lubricating the lower arm pivots ...............8-39
Lubricating the front knuckle pivots ..........8-40
Lubricating the steering shaft ....................8-41
Battery ......................................................8-41
Replacing the fuse ....................................8-44
Replacing a headlight bulb .......................8-45
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3-1
3
EBU17680
DESCRIPTION
EBU17690Left view
EBU17700Right 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
56 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
2 3
5
6
7
1
4
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4-3
4
EBU18101Start 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.EBU18154Light 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.NOTICEECB00043Do 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 8-41.)EBU18170Horn switch “ ”
Press the switch to sound the horn.
EBU18282Throttle lever Once the engine is running, pushing the throttle le-
ver will increase the engine speed.
Regulate the speed of the ATV by varying the
throttle position. Because the throttle is spring-
loaded, the ATV will decelerate, and the engine will
return to an idle any time the throttle lever is re-
leased.
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.1. Throttle lever
1
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5-2
5
Rear brake Check operation, and correct if necessary.
Lubricate cable if necessary.
Check lever free play, and adjust if necessary. 5-3, 8-28, 8-33
Throttle lever Make sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.
Check lever free play, and adjust if necessary. 5-3, 8-26
Control cables Make sure that operation is smooth. Lubricate if necessary. 8-37
Drive chain Check chain slack, and adjust if necessary.
Check chain condition. Lubricate if necessary. 5-3, 8-34, 8-37
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. 8-38
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. 5-6
Battery Check electrolyte level. Fill with distilled water if necessary. 5-6, 8-41
ITEM ROUTINE PAGE
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5-6
5
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.
EBU19840Chassis fasteners Make sure that all nuts, bolts and screws are prop-
erly tightened.
EBU19850Instruments, lights and switches Check that all instruments, lights and switches are
working properly. Correct if necessary.EBU19860Battery Check the fluid level in the battery. Fill with distilled
water if necessary. (See page 8-41.)
Fro nt:
Manufacturer/model:DURO/DI-K635A
Size: AT20 x 7-8
Ty p e : Tu b e l e s s
Rear: Manufacturer/model:DURO/DI-K735A
Size: AT22 x 10-8
Ty p e : Tu b e l e s s
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6-2
6
Position (3):
Cold engine start with ambient temperature
above 25 °C (80 °F).
Ambient temp./starter (choke) position
6. Completely close the throttle lever and start the engine by pushing the start switch.
TIP●If the engine fails to start, release the start
switch, then push it again. Pause a few seconds
before the next attempt. Each cranking should be as short as possible to preserve battery ener-
gy. Do not crank the engine more than 10 sec-
onds on each attempt.
●If the battery is discharged, pull the recoil starter
to start the engine.7. If the engine is started with the starter (choke)
in position (1), the starter (choke) should be
returned to position (2) to warm up the engine.
If the engine is started with the starter (choke)
in position (2), keep the starter (choke) in this
position to warm up the engine.
8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to
position (3) before riding.TIPThe engine is warm when it responds quickly to the
throttle with the starter (choke) turned off.NOTICEECB00163For maximum engine life, never accelerate
hard when the engine is cold!
1. Fully open
2. Half open
3. Closed
4. Starter (choke)
1 2 3
123 4
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8-8
8
EBU23061TIPSome maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or
muddy areas, or at full-throttle.23*Battery Check electrolyte level and specific gravity, and
correct if necessary.
Make sure that the breather hose is properly rout- ed. √√√√√
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 320U1PY61E0.book Page 8 Wednesday, March 14, 2012 5:22 PM