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8
2. Check the brake pedal height.
If the brake pedal height is correct, skip steps
3–5.
3. Loosen the locknut. 4. Turn the adjusting bolt in or out until the brake
pedal height is within the specified limits.
5. Tighten the locknut.
6. Install the footboard by installing the bolts and nuts, and then tighten the bolts to the
specified torques.
1. Footboard
2. Bolt and nut
3. Bolt22
31
1. Locknut
2. Adjusting boltTightening torque:Locknut:7 Nm (0.7 m·kgf, 5.1 ft·lbf)
1
2
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8-34
8
Adjusting the brake lever free play
The brake lever free play should measure 3.0–5.0
mm (0.12–0.20 in) as shown. If the free play is in-
correct, adjust it as follows. 1. Loosen the locknut at the brake lever and fully
turn in the brake lever free play adjusting bolt.
2. Turn the brake lever free play adjusting nut on the brake cable at the rear wheel hub so that
gap “A” measures 0–1 mm (0–0.04 in).
1. Brake pedal free play adjusting nut
2. Brake lever free play adjusting nut
1. Brake lever free play
2. Locknut
3. Brake lever free play adjusting bolt
U1NS63E0.book Page 34 Monday, March 10, 2014 9:05 AM
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8-35
83. Turn the brake lever free play adjusting bolt at
the brake lever in direction (a) to increase the
free play, and in direction (b) to decrease it. 4. Tighten the locknut at the brake lever.
5. Check gap “A” again and, if necessary, adjust
it.
TIPWhen adjusting the rear brake lever free play:
Be sure not to step on the brake pedal.
Make sure the brake pedal does not move.
1. Brake lever free play adjusting nut
2. Gap “A”
1. Locknut
2. Brake lever free play adjusting bolt
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8
EBU30661Replacing a headlight bulbIf a headlight bulb burns out, replace it as follows.1. Remove the cover at the rear of the headlight by pulling it off.
2. Remove the headlight bulb holder cover by pulling it off. 3. Remove the headlight bulb holder by pushing
it in and turning it counterclockwise.1. Cover at the rear of the headlight
1. Headlight bulb holder cover
1. Headlight bulb holder
1
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8-45
84. Remove the burnt-out bulb by pulling it out.
5. Place a new headlight bulb into position.
NOTICE: Do not touch the glass part of the
headlight bulb to keep it free from oil, oth-
erwise the transparency of the glass, the
luminosity of the bulb, and the bulb life will
be adversely affected. Thoroughly clean
off any dirt and fingerprints on the head-
light bulb using a cloth moistened with al-
cohol or thinner.
[ECB00652]
6. Install the bulb holder by pushing it in and turning it clockwise. 7. Install the bulb holder cover and the cover at
the rear of the headlight. NOTICE: Make
sure the headlight bulb holder cover is se-
curely fitted over the bulb holder and seat-
ed properly.
[ECB00672]
8. Adjust the headlight beam if necessary.EBU25552Adjusting a headlight beamNOTICEECB00691It is advisable to have a Yamaha dealer make
this adjustment. To raise a headlight beam, turn the headlight
beam adjusting screw in direction (a).
To lower a headlight beam, turn the adjusting
screw in direction (b).
1. Do not touch the glass part of the bulb.U1NS63E0.book Page 45 Monday, March 10, 2014 9:05 AM
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9-1
9
EBU25861
CLEANING AND STORAGE
EBU25882CleaningFrequent, 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
degreaser 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 re-
duced stopping ability, increasing the
chance of an accident. Test the brakes af-
ter washing. Apply the brakes several
times at slow speeds to let friction dry out
the linings.
[EWB02312]
NOTICE: Excessive wa-
ter pressure may cause water seepage and deterioration of wheel bearings,
brakes, transmission seals and electrical
devices. Many expensive repair bills have
resulted from improper high-pressure de-
tergent applications such as those avail-
able in coin-operated car washers.
[ECB00712]
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
bottle brush is handy for hard-to-reach pla-
ces.
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.
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9-2
9
EBU25934StorageShort-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.
[ECB00722]
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 depos-
its 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 and pedals.
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. Alterna-
Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1
oz of stabilizer to each gallon of fuel)U1NS63E0.book Page 2 Monday, March 10, 2014 9:05 AM
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