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 and warning lights .............. 4-2
Multi-function display .................................. 4-5
Handlebar switches .................................... 4-7
Throttle lever ............................................ 4-13
Speed limiter ............................................ 4-13
Front brake lever ...................................... 4-14
Brake pedal and rear brake lever ............. 4-14
Drive select lever ...................................... 4-15
Fuel tank cap ............................................ 4-15
Fuel .......................................................... 4-16
Seat .......................................................... 4-18 Storage compartments .............................4-18
Front carrier ..............................................4-21
Rear carrier ...............................................4-21
Adjusting the front and rear shock
absorber assemblies ...............................4-21
Auxiliary DC jack .......................................4-23
PRE-OPERATION CHECKS ..........................5-1 Fuel .............................................................5-3
Engine oil ....................................................5-3
Final gear oil ...............................................5-3
Differential gear oil ......................................5-3
Coolant .......................................................5-3
Front and rear brakes .................................5-3
Throttle lever ...............................................5-4
Tires ............................................................5-4
Chassis fasteners .......................................5-7
Instruments, lights and switches .................5-7
OPERATION...................................................6-1 Starting the engine ......................................6-1
Operating the drive select lever and driving in reverse ......................................6-2
Engine break-in ...........................................6-4U2BG60E0.book Page 1 Monday, May 20, 2013 3:04 PM
3-1
3
EBU17680
DESCRIPTION
EBU17690Left view
EBU17700Right view
1. Radiator cap
2. Battery
3. Fuses
4. Air filter case
5. Spark arrester
6. Engine oil dipstick
7. Oil filter cartridge
8. Coolant reservoir
5
1. Rear shock absorber assembly spring preload adjusting ring
2. Rear storage compartment and tool kit
3. Fuel tank cap cover
4. Front shock absorber assembly spring preload adjusting ring
5. Spark plug
6. Brake pedal
7. V-belt case drain plug
U2BG60E0.book Page 1 Monday, May 20, 2013 3:04 PM
4-21
4
EBU18962Front carrier ●Do not exceed the load limit of 45.0 kg (99 lb) for
the front carrier.●Do not exceed the maximum load of 220.0 kg
(485 lb) for the ATV.EBU18972Rear carrier ●Do not exceed the load limit of 85.0 kg (187 lb)
for the rear carrier.●Do not exceed the maximum load of 220.0 kg
(485 lb) for the ATV.EBU19146Adjusting the front and rear shock ab-
sorber assemblies The spring preload can be adjusted to suit the rid-
er’s weight and the riding conditions.
WARNING
EWB00400Always adjust the shock absorber assemblies
on the left and right side to the same setting.
Uneven adjustment can cause poor handling
and loss of stability, which could lead to an ac-
cident.
1. Storage compartment drain plug
1. Storage compartment drain plugU2BG60E0.book Page 21 Monday, May 20, 2013 3:04 PM
4-22
4Adjust the spring preload as follows.
Turn the spring preload adjusting ring in direction
(a) to increase the spring preload and thereby
harden the suspension, and in direction (b) to de-
crease the spring preload and thereby soften the
suspension.
Align the appropriate notch in the adjusting ring
with the position indicator on the shock absorber.
TIPA special wrench can be obtained at a Yamaha
dealer to make this adjustment.1. Spring preload adjusting ring
2. Position indicator
1. Special wrenchSpring preload setting:
Minimum (soft):1
Standard: 2
Maximum (hard): 5
U2BG60E0.book Page 22 Monday, May 20, 2013 3:04 PM
8-7
8
11*Shock absorber as-
semblies Check operation and correct if necessary.
Check for oil leakage and replace if necessary.
√√√
12 *Stabilizer bushes Check for cracks or other damage, and replace if
necessary. √√√
13 *Rear knuckle pivots Lubricate with lithium-soap-based grease. √√√
14 *Steering shaft Lubricate with lithium-soap-based grease. √√√
15 *Steering system Check operation and repair or replace if damaged.
Check toe-in and adjust if necessary.
√√√√√
16 *Engine mount Check for cracks or other damage, and replace if
necessary. √√√
17 *Axle boots Check for cracks or other damage, and replace if
necessary. √√√√√
18 Engine oil Change.
Check ATV for oil leakage, and correct if neces-
sary. √ √√√
19 Engine oil filter car-
tridge Replace.
√√√
20 Differential gear oil Change.
Check ATV for oil leakage, and correct if neces-
sary. √√
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 320U2BG60E0.book Page 7 Monday, May 20, 2013 3:04 PM
9-1
9
EBU25860
CLEANING AND STORAGE
EBU25881Cleaning Frequent, thorough cleaning of your ATV will not
only enhance its appearance but will improve its
general performance and extend the useful life of
many components.1. Before cleaning the ATV: a. Block off the end of the exhaust pipe toprevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plug and all filler caps are properly installed.
2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply de-
greaser to the wheel axles.
3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job.
WARNING! Wet brakes may have reduced
stopping ability, increasing the chance of
an accident. Test the brakes after washing.
Apply the brakes several times at slow
speeds to let friction dry out the linings.
[EWB02311]
NOTICE: Excessive water pressure
may cause water seepage and deteriora- tion of wheel bearings, brakes, transmis-
sion seals and electrical devices. Many
expensive repair bills have resulted from
improper high-pressure detergent applica-
tions such as those available in coin-oper-
ated car washers.
[ECB00711]
4. Once most of the dirt has been hosed off,
wash all surfaces with warm water and mild,
detergent-type soap. An old toothbrush or bot-
tle brush is handy for hard-to-reach places.
5. Rinse the ATV off immediately with clean wa- ter and dry all surfaces with a chamois, clean
towel or soft absorbing cloth.
6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.
7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protec-
tive finish. When finished cleaning, start the
engine and let it idle for several minutes.
U2BG60E0.book Page 1 Monday, May 20, 2013 3:04 PM
10-4
10
Tire air pressure (measured on cold tires):Recommended:Front: 35.0 kPa (0.350 kgf/cm², 5.0 psi)
Rear: 30.0 kPa (0.300 kgf/cm², 4.4 psi)
Minimum:
Front: 32.0 kPa (0.320 kgf/cm², 4.6 psi)
Rear:
27.0 kPa (0.270 kgf/cm², 4.0 psi)Front wheel:Wheel type:Panel wheel
Rim size:
12 x 6.0ATRear wheel:Wheel type:Panel wheel
Rim size:
12 x 7.5ATFront brake:Type:Disc brake
Operation:
Right hand operation
Specified brake fluid: DOT 4Rear brake:Type:
Disc brake Operation:
Left hand and right foot operation
Specified brake fluid: DOT 4
Front suspension:Type:Double wishbone
Spring/shock absorber type: Coil spring/oil damper
Wheel travel:
193 mm (7.6 in)Rear suspension:Type:Double wishbone
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel: 232 mm (9.1 in)Electrical system:Ignition system:
TCI
Charging system: AC magnetoBattery:Model:
YTX20L-BS
Voltage, capacity: 12 V, 18.0 AhHeadlight:Bulb type:
Halogen bulb
U2BG60E0.book Page 4 Monday, May 20, 2013 3:04 PM
Light switch .................................................................... 4-8
Low-range indicator light ................................................ 4-2MMain switch .................................................................... 4-1
Maintenance and lubrication chart ................................. 8-5
Maintenance chart, emission control system ................. 8-3
Model label ................................................................... 11-1
Multi-function display ...................................................... 4-5NNeutral indicator light ..................................................... 4-2OOn-Command differential gear lock switch .................. 4-10
On-Command four-wheel-drive switch ........................... 4-9
Override switch .............................................................. 4-8
Owner’s manual and tool kit ........................................... 8-2PPanels, removing and installing ................................... 8-10
Park indicator light .......................................................... 4-2
Parking ........................................................................... 6-5
Parking on a slope ......................................................... 6-5
Part locations ................................................................. 3-1RRadiator grills, removing .............................................. 8-19
Rear knuckle pivots, lubricating ................................... 8-54
Reverse indicator light .................................................... 4-2
Riding your ATV ............................................................. 7-1SSafety information .......................................................... 2-1
Seat .............................................................................. 4-18
Shock absorber assemblies, adjusting the front and rear ............................................................................. 4-21
Spark arrester, cleaning ............................................... 8-42 Spark plug, checking .................................................... 8-20
Specifications ............................................................... 10-1
Speed limiter ................................................................ 4-13
Stabilizer bushes, checking .......................................... 8-54
Starting the engine ......................................................... 6-1
Start switch ..................................................................... 4-8
Steering shaft, lubricating ............................................. 8-55
Storage ........................................................................... 9-2
Storage compartments ................................................. 4-18
TTail/brake light bulb, replacing ..................................... 8-63
Throttle lever ......................................................... 4-13, 5-4
Throttle lever free play, adjusting ................................. 8-44
Tires ............................................................................... 5-4
Troubleshooting ........................................................... 8-65
Troubleshooting charts ................................................. 8-66VValve clearance ............................................................ 8-45
V-belt case drain plug .................................................. 8-44
Vehicle identification number ....................................... 11-1WWheel hub bearings, checking ..................................... 8-54
Wheel, installing ........................................................... 8-64
Wheel, removing .......................................................... 8-64
U2BG60E0.book Page 2 Monday, May 20, 2013 3:04 PM