8-32
8
TIPFor parts equipped with a grease nipple, use a
grease gun. EBU36400BatteryThe battery is located under panel A. (See page
8-9.)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
EWB02161Battery electrolyte is poisonous and danger-
ous, as it contains sulfuric acid, which can cau-
se 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
ignition away. Ventilate when charging or using
in an enclosed space.
KEEP OUT OF REACH OF CHILDREN.
Recommended lubricant:
Lithium-soap-based grease
UBW460E0.book Page 32 Monday, May 23, 2016 11:12 AM
9-2
9abrasives which may mar the paint or protec-
tive finish. When finished cleaning, start the
engine and let it idle for several minutes.
EBU30361StorageShort-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.
Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1
oz of stabilizer to each gallon of fuel)UBW460E0.book Page 2 Monday, May 23, 2016 11:12 AM
10-1
10
EBU25962
SPECIFICATIONS
Dimensions:Overall length:1250 mm (49.2 in)
Overall width: 820 mm (32.3 in)
Overall height:
770 mm (30.3 in)
Seat height: 585 mm (23.0 in)
Wheelbase: 830 mm (32.7 in)
Ground clearance:
88 mm (3.5 in)
Minimum turning radius: 2300 mm (91 in)Weight:Curb weight:
100.0 kg (220 lb)Noise and vibration level:Noise level (77/311/EEC):74.0 dB(A) (EUR, FRA, GBR)
Uncertainty of measurement:
2.0 dB(A) (EUR, FRA, GBR)
Vibration on seat (EN1032, ISO5008): Will not exceed 0.5 m/s² (EUR, FRA, GBR)
Uncertainty of measurement: 0.1 m/s² (EUR, FRA, GBR) Vibration on handle (EN1032, ISO5008):
4.7 m/s² (EUR, FRA, GBR)
Uncertainty of measurement: 0.4 m/s² (EUR, FRA, GBR)
Engine:Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement: Single cylinder
Displacement: 49 cm³
Bore × stroke:
39.0 × 41.4 mm (1.54 × 1.63 in)
Compression ratio: 8.5 : 1
Starting system: Electric starter and kickstarter
Lubrication system:
Wet sumpEngine oil:Recommended brand:YAMALUBE
UBW460E0.book Page 1 Monday, May 23, 2016 11:12 AM
10-2
10
Type:SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W-
50
Recommended engine oil grade: API service SG type or higher, JASO standard MA
Engine oil quantity: Periodic oil change:0.90 L (0.95 US qt, 0.79 Imp.qt)Transmission oil:Type:
SAE 80W-90
Quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt)Air filter:Air filter element:
Wet element
Fuel:Recommended fuel:Regular unleaded gasoline only
Fuel tank capacity:
5.6 L (1.48 US gal, 1.23 Imp.gal)
Fuel reserve amount: 0.7 L (0.18 US gal, 0.15 Imp.gal)Carburetor:Type × quantity:
VM12Spark plug (s):Manufacturer/model: NGK/CR6HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:Dry, centrifugal automaticTransmission:Secondary reduction system:Chain drive
Secondary reduction ratio: 38/13 (2.920)
Transmission type:
V-belt automatic
Operation: Centrifugal automatic typeChassis:Frame type:
Steel tube frame
0 10 30 50 70 90 110 130 ˚F
–20 –10 0 10 20 30 40 50 ˚CSAE 5W-30
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40SAE 20W-50
UBW460E0.book Page 2 Monday, May 23, 2016 11:12 AM
10-3
10
Caster angle:1.10 °
Trail: 10.4 mm (0.41 in)Front tire:Type:Tubeless
Size: AT16 x 6.5-7
Manufacturer/model:
DURO/DI2040Rear tire:Type:Tubeless
Size:
AT16 x 7-7
Manufacturer/model: DURO/DI2041Loading:Maximum loading limit:
41.0 kg (90 lb)
(Total weight of rider, cargo, accessories, and tongue)Tire air pressure (measured on cold tires):Recommended:Front:
13.8 kPa (0.14 kgf/cm², 2.0 psi)
Rear: 13.8 kPa (0.14 kgf/cm², 2.0 psi)
Minimum: Front: 12.4 kPa (0.124 kgf/cm², 1.8 psi) Rear:
12.4 kPa (0.124 kgf/cm², 1.8 psi)
Front wheel:Wheel type:
Panel wheel
Rim size: 7 x 5.2ATRear wheel:Wheel type:
Panel wheel
Rim size: 7 x 5.2ATFront brake:Type:
Mechanical leading, trailing drum brake
Operation: Right hand operationRear brake:Type:
Mechanical leading, trailing drum brake
Operation: Left hand operationFront suspension:Type:
Swing axle
Spring/shock absorber type: Coil spring/oil damper
Wheel travel: 60 mm (2.4 in)
UBW460E0.book Page 3 Monday, May 23, 2016 11:12 AM
10-4
10
Rear suspension:Type:Swingarm
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel: 51 mm (2.0 in)Electrical system:Ignition system:
CDI
Charging system: AC magnetoBattery:Model:
GTX5L-BS
Voltage, capacity: 12 V, 4.0 AhFuse:Fuse:
7.5 AEBU30402For 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
exposed to the noise. Also the permissible expo-
sure level can vary from country. This information,
however, will enable the user of the machine to
make a better evaluation of the hazard and risk.UBW460E0.book Page 4 Monday, May 23, 2016 11:12 AM
12-1
12
INDEX
AAccessories and loading ................................................ 6-5
Air filter element, cleaning ............................................ 8-16BBattery .......................................................................... 8-32
Brake lever free play, adjusting the front ..................... 8-23
Brake lever free play (rear), adjusting ........................... 8-25
Brake lever, front ............................................................ 4-5
Brake lever, rear ............................................................. 4-6
Brake levers, checking and lubricating ........................ 8-29
Brakes .......................................................................... 8-22
Brakes, front and rear .................................................... 5-3CCables, checking and lubricating ................................. 8-29
Carburetor, adjusting ...................................................8-20
Chassis fasteners ........................................................... 5-6
Cleaning ......................................................................... 9-1DDrive chain ..................................................................... 5-3
Drive chain, cleaning and lubricating ........................... 8-28
Drive chain slack .......................................................... 8-26EEngine break-in .............................................................. 6-3
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-20
Engine oil .............................................................. 5-3, 8-11
Engine, starting a warm ................................................. 6-3
Engine stop switch ......................................................... 4-1
Engine stop switch with lanyard .................................... 4-2
FFront and rear brake shoes, checking ......................... 8-22
Front arm pivots, lubricating ........................................ 8-30
Front knuckle pivots, lubricating .................................. 8-31
Fuel ........................................................................ 4-8, 5-3
Fuel cock ...................................................................... 4-10
Fuel tank cap ................................................................. 4-8
Fuse, replacing ............................................................. 8-35HHandlebar switches ....................................................... 4-1IIdentification numbers ................................................. 11-1
Instruments and switches .............................................. 5-6KKickstarter ...................................................................... 4-7LLabel locations ............................................................... 1-1MMain switch .................................................................... 4-1
Maintenance and lubrication chart ................................ 8-5
Maintenance chart, emission control system ................ 8-3
Model label .................................................................. 11-1OOwner’s manual and tool kit .......................................... 8-2PPanel, removing and installing ....................................... 8-9
Parking ........................................................................... 6-3
Parking brake ................................................................. 4-6
Parking on a slope ......................................................... 6-4
UBW460E0.book Page 1 Monday, May 23, 2016 11:12 AM
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12
Part locations ................................................................. 3-1RRiding your ATV ............................................................. 7-1SSafety information .......................................................... 2-1
Seat .............................................................................. 4-12
Shock absorber assembly, adjusting the rear ............. 4-13
Spark arrester, cleaning ............................................... 8-19
Spark plug, checking ..................................................... 8-9
Specifications .............................................................. 10-1
Speed limiter .................................................................. 4-3
Starter (choke) ............................................................. 4-11
Start switch .................................................................... 4-2
Steering shaft, lubricating ............................................ 8-31
Storage .......................................................................... 9-2TThrottle lever ...........................................................4-3, 5-3
Throttle lever free play, adjusting ................................ 8-21
Tires ............................................................................... 5-3
Transmission oil ....................................................5-3, 8-14
Troubleshooting ........................................................... 8-37
Troubleshooting chart .................................................. 8-38VValve clearance ............................................................ 8-22
Vehicle identification number ...................................... 11-1WWheel hub bearings, checking .................................... 8-30
Wheel, installing ........................................................... 8-36
Wheel, removing .......................................................... 8-35
UBW460E0.book Page 2 Monday, May 23, 2016 11:12 AM