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9-39
96. Wash the sponge material gently but thor-
oughly in solvent. WARNING! Always use
parts cleaning solvent. Never use low-
flash-point solvents or gasoline because
the engine could catch fire or explode.
[EWB01943]
7. Squeeze the excess solvent out of the sponge material and let it dry. NOTICE: Do
not twist the sponge material when
squeezing it.
[ECB00442]
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
1. Air filter element frame
2. Sponge material
3. Air filter element lock plate
3
2
1
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9-42
9
EBU29705Adjusting the throttle lever free playPeriodically check the throttle lever free play and
adjust if necessary.1. Slide the rubber cover back.
2. Loosen the locknut. 3. To increase the throttle lever free play, turn
the throttle lever free play adjusting bolt in di-
rection (a). To decrease the throttle lever free
play, turn the adjusting bolt in direction (b).
4. Tighten the locknut.
5. Slide the rubber cover to its original position.
EBU24062Valve clearanceThe valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance chart.EBU29602BrakesReplacement of brake components requires pro-
fessional knowledge. Brake service should be
performed by a Yamaha dealer.
WARNING
EWB02572Operating with improperly serviced or adjust-
ed brakes could lead to a loss in braking ability
and an accident.
1. Rubber cover
2. Throttle lever free play adjusting bolt
3. Locknut
4. Throttle lever free playThrottle lever free play: 3.0–5.0 mm (0.12–0.20 in)
2WD
4WD
3
2
1
4
(b)
(a)
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9-45
9brake pads for wear and the brake system for
leakage. If the brake fluid level suddenly goes
down, have a Yamaha dealer check the brake sys-
tem before further riding.
WARNING
EWB02721Improper 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 flu-
id and may result in vapor lock.
EBU24294Changing the brake fluidHave a Yamaha dealer change the brake fluid at
the intervals specified in the periodic maintenance
chart. In addition, have the oil seals of the master
cylinders and calipers as well as the brake hoses
replaced at the intervals listed below or whenever
they are damaged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.
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9-47
9
EBU29077Adjusting the brake pedal free playPeriodically check the brake pedal free play and
adjust if necessary.TIPAlways perform this maintenance completely in
the following order whenever adjusting the rear
brake.
Before adjusting the brake pedal free play,
check the rear brake pads for wear.
1. Remove panel G. (See page 9-10.)
2. Loosen the locknut.
3. Turn the brake pedal free play adjusting nut in
direction (a) to increase the free play, and in
direction (b) to decrease it.
4. Tighten the locknut.
5. After adjusting, there should be slight play at the brake pedal cable joint as shown. If there
is no play, repeat steps 2 to 4.
1. Brake pedal free playBrake pedal free play:1.0–6.0 mm (0.04–0.24 in)
1
1. Brake pedal free play adjusting nut
2. Locknut
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9-59
92. Remove the bulb cover by pulling it off. 3. Remove the socket by pushing it in and turn-
ing it counterclockwise.
4. Remove the burnt-out bulb.
5. Place a new bulb into position. NOTICE: Do
not touch the glass part of the bulb. Oil
from your fingers or other contamination
will adversely affect the transparency of
the glass, luminosity of the bulb, and bulb
life. Thoroughly clean off any dirt and fin-
gerprints using a cloth moistened with al-
cohol or thinner.
[ECB00653]
1. Handlebar-mounted light cover
2. Quick fastener
1. Bulb cover
1
2
2
1
1. Socket
1
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9-60
9
6. Install the socket by pushing it in and turning
it clockwise.
7. Install the bulb cover. NOTICE: Make sure
the bulb cover is securely fitted over the
socket and seated properly.
[ECB03320]
8. Install the handlebar-mounted light cover as shown, and then install the quick fasteners. 9. Adjust the handlebar-mounted light beam if
necessary.
EBU25553Adjusting 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.
1
1. Handlebar-mounted light cover
1
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10-1
10
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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10-2
10
EBU27264StorageShort-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. Make any necessary repairs and perform all outstanding maintenance.
2. Follow all the instructions in the Cleaning sec- tion of this chapter.
3. Fill up the fuel tank and add fuel stabilizer (Fu- el Med Rx if available), and then run the en-
gine for 5 minutes to distribute the treated
fuel. 4. Perform the following steps to protect the en-
gine from internal 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.
5. Lubricate all control cables and the pivoting points of all levers and pedals.
6. Put the frame on stands or blocks to raise all wheels off the ground. (Alternatively, turn the
wheels each month to prevent the tires from
degrading in one spot.)
7. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.
Specified amount:
7.5 ml per liter of fuel (1 oz per gallon)UBFE60E0.book Page 2 Tuesday, August 18, 2020 10:50 AM