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85. Install the drain bolt and its new gasket, and
then tighten the bolt to the specified torque.
6. Refill with the recommended final gear oil to the brim of the filler hole as shown. NOTICE:
Be sure no foreign material enters the final
gear case.
[ECB00421]
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.
1. Final gear oil drain bolt
2. GasketTightening torque:Final gear oil drain bolt:23 Nm (2.3 m·kgf, 17 ft·lbf)
12
1. Final gear oil filler bolt
2. Gasket
3. Final gear oil
4. Correct oil levelRecommended final gear oil:See page 10-1.
Tightening torque: Final gear oil filler bolt:23 Nm (2.3 m·kgf, 17 ft·lbf)1
23
4
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8
9. Check the final gear case for oil leakage. If oil
is leaking, check for the cause.
10. Install the final gear case guard by installing the bolts and tightening them to the specified
torque.
EBU23436Changing the differential gear oil The differential gear case must be checked for oil
leakage before each ride. If any leakage is found,
have a Yamaha dealer check and repair the ATV.
In addition, the differential gear oil must be
changed as follows at the intervals specified in the
periodic maintenance and lubrication chart.1. Place the ATV on a level surface.
2. Place an oil pan under the differential gear case to collect the used oil.
3. Remove the differential gear oil filler bolt, the differential gear oil drain bolt and their gasket
to drain the oil from the differential gear case.
Tightening torque:
Final gear case guard bolt:16 Nm (1.6 m·kgf, 12 ft·lbf)
1. Differential gear oil filler bolt
2. Gasket
1. Differential gear oil drain bolt
2. Gasket
21
12
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8-19
84. 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]
TIP●Do 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)
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8-22
8
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, and then install the lock plate.
11. Insert the air filter element into the air filter case, and then install the air filter case cover
by hooking the holders onto the air filter case.
NOTICE: Make sure that the air filter ele-
ment is properly seated in the air filter case. Never operate the engine with the air
filter element removed. This will allow un-
filtered air to enter the engine, causing rap-
id engine wear and possible engine
damage. Additionally, operation without
the air filter element will affect carburetor
jetting with subsequent poor performance
and possible engine overheating.
[ECB00461]
12. Install the seat.TIPThe air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the ATV is operated in extremely dusty ar-
eas. Each time the air filter element maintenance
is performed, check the air inlet of the air filter case
for obstructions. Check the air filter case rubber
joint to the carburetor fittings and the rubber joint
manifold fittings for an air-tight seal. Tighten all fit-
tings securely to avoid the possibility of unfiltered
air entering the engine.EBU27082Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be-
fore cleaning the spark arrester.
1. Remove the tailpipe bolts.
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8
EBU29841Checking the brake fluid level Before riding, check that the brake fluid is above
the minimum level mark. Check the brake fluid lev-
el with the top of the reservoir level. Replenish the
brake fluid if necessary.
WARNING
EWB02720Improper maintenance can result in loss of
braking ability. Observe these precautions:
●Insufficient brake fluid may allow air to enter
the brake system, reducing braking perfor-
mance.●Clean the filler cap before removing. Use
only DOT 4 brake fluid from a sealed contain-
er.●Use only the specified brake fluid; otherwise,
the rubber seals may deteriorate, causing
leakage.●Refill with the same type of brake fluid. Add-
ing a brake fluid other than DOT 4 may result
in a harmful chemical reaction.●Be careful that water does not enter the
brake fluid reservoir when refilling. Water
will significantly lower the boiling point of
the fluid and may result in vapor lock.NOTICEECB01160Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately.As the brake pads wear, it is normal for the brake
fluid level to gradually go down. A low brake fluid
level may indicate worn brake pads and/or brake
system leakage; therefore, be sure to check the
1. Minimum level markSpecified brake fluid:DOT 4
1
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8
brake pads for wear and the brake system for leak-
age. If the brake fluid level goes down suddenly,
have a Yamaha dealer check the cause before fur-
ther riding.
EBU24281Changing the brake fluid Have a Yamaha dealer change the brake fluid at
the intervals specified in the TIP after the periodic
maintenance and lubrication chart. In addition,
have the oil seals of the brake master cylinder and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.●Oil seals: Replace every two years.●Brake hoses: Replace every four years.EBU24394Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have no
free play as shown. If there is free play, have a
Yamaha dealer check the brake system.
EBU30690Adjusting the brake pedal height, and
the brake pedal and rear brake lever
free play The brake pedal height, brake pedal free play, and
rear brake lever free play must be checked and, if
necessary, adjusted at the intervals specified in the
periodic maintenance and lubrication chart.TIP●Always perform this maintenance completely in
the following order whenever adjusting the rear
brake.1. No brake lever free play
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8
The rear brake light switch for the brake pedal can
be adjusted as follows, but the other brake light
switches should be adjusted by a Yamaha dealer.
Turn the rear brake light switch adjusting nut while
holding the brake light switch in place. To make the
brake light come on earlier, turn the adjusting nut
in direction (a). To make the brake light come on
later, turn the adjusting nut in direction (b).
EBU24902Checking and lubricating 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- 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.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
Recommended lubricant:
Yamaha Chain and Cable Lube or engine oil
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8-39
8
EBU29189Battery The battery is located under the seat. (See page
4-14.)
This model is equipped with a VRLA (Valve Regu-
lated Lead Acid) battery. There is no need to check
the electrolyte or to add distilled water. However,
the battery lead connections need to be checked
and, if necessary, tightened.
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.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of ig-
nition away. Ventilate when charging or using
in an enclosed space.KEEP OUT OF REACH OF CHILDREN.
NOTICEECB00620Never attempt to remove the battery cell seals,
as this would permanently damage the battery.To remove the battery
1. Remove the seat. (See page 4-14.)
2. Remove the battery holding plate by removing the bolts.
3. Disconnect the negative battery lead first, then the positive battery lead by removing
their bolt. NOTICE: When removing the bat-
tery, the main switch must be off, and the
negative lead must be disconnected be-
fore the positive lead.
[ECB01001]
U1NS61E0.book Page 39 Tuesday, May 15, 2012 5:19 PM
