6-3
6
EBU20522Shifting This ATV has a 5-speed forward transmission. The
transmission allows you to control the amount of
power you have available at a given speed or for
starting, accelerating, climbing hills, etc.
To shift into neutral, release the throttle lever, ap-
ply the clutch, and then repeatedly depress the
shift pedal until it stops.
When it stops, it will be in first gear. Raise the pedal
slightly to reach the neutral position, and then re-
lease the clutch.
EBU20593To start out and accelerate1. Release the throttle lever, apply the front or rear brake, and then release the parking
brake.
2. Pull the clutch lever to disengage the clutch.
3. Shift into first gear, and then release the brake. NOTICE: Always close the throttle
before shifting gears, otherwise damage to
the engine and drive train may result.
[ECB00201]
4. Open the throttle gradually and at the same time, release the clutch lever slowly.
WARNING! Opening the throttle abruptly or releasing the clutch lever too quickly
could make the ATV wheelie, which would
increase the chance of an accident, includ-
ing an overturn.
[EWB00731]
5. Once the ATV has attained adequate speed, release the throttle, and at the same time,
quickly pull in the clutch lever.
6. Shift the transmission into second gear. (Make sure not to shift the transmission into
neutral.)
7. Open the throttle part way and gradually re- lease the clutch lever.
1. Shift pedal
2. Neutral position
1
2
2 3 4 5N1
U1BT63E0.book Page 3 Friday, March 9, 2012 11:22 AM
7-12
7trol.
[EWB02631]
NOTICE: Do not shift gears without
releasing the throttle. Damage to the engine or
drive train may occur.
[ECB01071]
Use this same procedure as you move into the
higher gears. Be sure to coordinate the use of the
throttle and shift pedal properly.
Avoid higher speeds until you are thoroughly famil-
iar with the operation of your ATV.
When slowing down or stopping, release the throt-
tle and apply the brakes smoothly and evenly. As
you slow down, shift to a lower gear. Be sure that
the engine has sufficiently slowed before engaging
a lower gear. Improper use of the brakes or shifting
can cause the tires to lose traction, reducing con-
trol and increasing the possibility of an accident.
TURNING YOUR ATV
WARNING
EWB01771Always follow proper procedures for turning
as described in this Owner’s Manual. Practice
turning at low speeds before attempting to turn
at faster speeds. Do not turn at speeds too fast
for your skills or the conditions. ATV could go
out of control, causing a collision or overturn.
To achieve maximum traction on unpaved surfac-
es, the two rear wheels turn together at the same
speed. Therefore, unless the wheel on the inside
of the turn is allowed to slip or lose some traction,
the ATV will resist turning. A special turning tech-
nique must be used to allow the ATV to make turns
quickly and easily. It is essential that this skill be
learned first at low speed.
As you approach a curve, slow down and begin to
turn the handlebars in the desired direction. As you
do so, put your weight on the footrest to the outside
of the turn (opposite your desired direction) and
lean your upper body into the turn. Use the throttle
to maintain an even speed through the turn. This
maneuver will let the wheel on the inside of the turn
slip slightly, allowing the ATV to make the turn
properly.
U1BT63E0.book Page 12 Friday, March 9, 2012 11:22 AM
8-7
8
14*Chassis fasteners Make sure that all nuts, bolts, and screws are
properly tightened. √√√√√
15 *Shock absorber as-
semblies Check operation and correct if necessary.
Check for oil leakage and replace if necessary.
√√√
16 *Steering shaft Lubricate with lithium-soap-based grease. √√√
17 *Steering system Check operation and repair or replace if damaged.
Check toe-in and adjust if necessary. √√√√√
18 Engine oil Change.
Check ATV for oil leakage, and correct if neces-
sary. √ √√√
19 Engine oil filter ele-
ment Replace.
√√√
20 *Moving parts and
cables Lubricate.
√√√√
21 *Throttle lever Check operation.
Check throttle lever free play, and adjust if neces-
sary.
Lubricate cable and lever housing. √√√√√
22 *Front and rear brake
switches Check operation and correct if necessary.
√√√√√
23 *Lights and switches Check operation and correct if necessary.
Adjust headlight beams. √√√√√
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 320U1BT63E0.book Page 7 Friday, March 9, 2012 11:22 AM
8-27
8
TIPIf the cable length cannot be adjusted to specifica-
tion, consult a Yamaha dealer.6. Tighten the locknut on the brake cable.
7. Slide the rubber cover to its original position.
8. Turn in the adjusting bolt at the rear brake cal-iper until it feels tight, then turn it out 1/8 turn
and tighten its locknut to the specified torque.
NOTICE: When tightening the locknut, hold the adjusting bolt with a wrench so
that it does not turn together with the lock-
nut.
[ECB00521]
WARNING
EWB02090Operating with improperly serviced or adjust-
ed brakes could cause the brakes to malfunc-
tion, resulting in reduced braking
performance. This could increase the chance
of a collision or accident. After adjusting the
parking brake free play, block the rear of the
ATV off the ground and spin the rear wheels.
Check to make sure there is no brake drag. If
brake drag is noticed, perform the adjustment
again.EBU24743Brake light switches The brake light, which is activated by the brake
pedal and brake lever, should come on just before
braking takes effect.
1. Rubber cover
2. Parking brake free play adjusting nut
3. Locknut
2
3
1(a) (b)
Tightening torque:
Locknut (rear brake caliper):16 Nm (1.6 m·kgf, 12 ft·lbf)
U1BT63E0.book Page 27 Friday, March 9, 2012 11:22 AM
8-28
8
The brake light switch for the brake pedal can be
adjusted as follows, but the front brake light switch
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).
EBU24813Adjusting the clutch lever free play The clutch lever free play must be checked and, if
necessary, adjusted at the intervals specified in the
periodic maintenance and lubrication chart. The clutch lever free play should measure 5.0–
10.0 mm (0.20–0.39 in) as shown. If the free play
is incorrect, adjust it as follows.
1. Slide the rubber cover back.
2. Loosen the locknut at the clutch lever.
3. To increase the clutch lever free play, turn the clutch lever free play adjusting bolt in direction
(a), and to decrease it, turn the bolt in direction
(b).
4. Tighten the locknut.1. Rear brake light switch
2. Rear brake light switch adjusting nut
12
(b)
(a)
1. Clutch lever free play
2. Locknut
3. Clutch lever free play adjusting bolt
4. Rubber cover1
3
4
(a)
(b)
2
U1BT63E0.book Page 28 Friday, March 9, 2012 11:22 AM
8-41
86. Install the headlight bulb holder by pushing it
in and turning it clockwise.
7. Install the headlight bulb holder cover.
8. Connect the headlight coupler.
9. Place the headlight unit in the original posi- tion, and then install the bolt.
10. Adjust the headlight beam if necessary.
EBU25561Adjusting a headlight beam NOTICEECB00690It is advisable to have a Yamaha dealer make
this adjustment.
To raise a headlight beam, turn the headlight beam
adjusting bolt in direction (a).
To lower a headlight beam, turn the adjusting bolt
in direction (b).EBU25580Replacing the tail/brake light bulb If the tail/brake light bulb burns out, have a
Yamaha dealer replace it.EBU25651Removing a wheel 1. Place the ATV on a level surface.
2. Loosen the wheel nuts.
1. Do not touch the glass part of the bulb.
1
1. Headlight beam adjusting bolt
1 (a)
(b)
U1BT63E0.book Page 41 Friday, March 9, 2012 11:22 AM
10-4
10
Specified brake fluid:DOT 4Rear brake:Type:
Disc brake
Operation: Right foot operation
Specified brake fluid: DOT 4Front suspension:Type:Double wishbone
Spring/shock absorber type: Coil spring/oil damper
Wheel travel:
190 mm (7.5 in)Rear suspension:Type:Swingarm
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel: 200 mm (7.9 in)Electrical system:Ignition system:
DC CDI
Charging system: AC magnetoBattery:Model:
YTZ7S Voltage, capacity:
12 V, 6.0 Ah
Headlight:Bulb type:
Krypton bulbBulb voltage, wattage × quantity:Headlight:
12 V, 30.0/30.0 W × 2
Tail/brake light:
12 V, 5.0/21.0 W × 1
Neutral indicator light: 12 V, 1.7 W × 1Fuse:Fuse:
15.0 AEBU30401For Europe only
The figures quoted are emission levels and are not
necessarily safe working levels. Whilst there is a
correlation between the emission and exposure
levels, this cannot be used reliably to determine
whether or not further precautions are required.
Factors that influence the actual level of exposure
of work-force include the characteristics of the
work room, the other sources of noise, etc. i.e. the
number of machines and other adjacent process-
es, and the length of time for which an operator is
U1BT63E0.book Page 4 Friday, March 9, 2012 11:22 AM
INDEX
AAccessories and loading ................................................ 6-6
Air filter element, cleaning ............................................ 8-14BBattery .......................................................................... 8-35
Brake and clutch levers, checking and lubricating ....... 8-32
Brake fluid, changing .................................................... 8-25
Brake fluid level, checking ............................................ 8-23
Brake lever ..................................................................... 4-5
Brake lever free play, checking the front ...................... 8-25
Brake light switches ..................................................... 8-27
Brake pads, checking the front and rear ...................... 8-22
Brake pedal .................................................................... 4-5
Brake pedal, checking and lubricating ......................... 8-33
Brake pedal height, checking ....................................... 8-25
Brakes .......................................................................... 8-22
Brakes, front and rear .................................................... 5-3CCables, checking and lubricating ................................. 8-31
Carburetor, adjusting .................................................... 8-20
Chassis fasteners ........................................................... 5-6
Cleaning ......................................................................... 9-1
Clutch lever .................................................................... 4-4
Clutch lever free play, adjusting ................................... 8-28DDrive chain ..................................................................... 5-4
Drive chain, lubricating ................................................. 8-31
Drive chain slack .......................................................... 8-29
EEngine break-in .............................................................. 6-4
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-20
Engine oil ....................................................................... 5-3
Engine oil and oil filter element .................................... 8-11
Engine, starting a warm ................................................. 6-2
Engine stop switch ......................................................... 4-2FFuel ......................................................................... 4-8, 5-3
Fuel cock ........................................................................ 4-9
Fuel tank cap .................................................................. 4-7
Fuse, replacing ............................................................. 8-38HHandlebar switches ........................................................ 4-2
Headlight beam, adjusting ............................................ 8-41
Headlight bulb, replacing .............................................. 8-39IIdentification numbers .................................................. 11-1
Indicator light .................................................................. 4-2
Instruments, lights and switches .................................... 5-6LLabel locations ............................................................... 1-1
Light switch .................................................................... 4-3MMain switch .................................................................... 4-1
Maintenance and lubrication chart ................................. 8-5
Maintenance chart, emission control system ................. 8-3
U1BT63E0.book Page 1 Friday, March 9, 2012 11:22 AM