Yamaha KODIAK 450 User Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM450FAS
WARNING
This ATV should not be ridden by anyone under 16 years of age.
5ND-F8199-11LIT-11626-17-25
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EBU00776
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EBU00941
1-

INTRODUCTION

Congratulations on your purchase of the Yamaha YFM450FA. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of crafts­manship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV.
This manual includes important safety information. It provides information about
special techniques and skills necessary to ride your ATV.
It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION.
THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.
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EBU00801
WARNING
CAUTION:
NOTE:
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SE­RIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.
A CAUTION indicates special precautions that must be taken to avoid damage to the machine.
A NOTE provides key information to make procedures easier or clearer.
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EBU00011
IMPORTANT NOTICE
This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this machine.
EBU01067
YFM450FAS
OWNER’S MANUAL
AFFIX DEALER
LABEL HERE
©2003 by Yamaha Motor Corporation,
U.S.A.
1st edition, April 2003 All rights reserved. Any reprinting or unauthorized use without the written
permission of
Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11626-17-25
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EBU00014
WARNING
Indicates a potential hazard that could result in serious injury or death.
CONTENTS
LOCATION OF THE WARNING
1
AND SPECIFICATION LABELS....... 1-1
SAFETY INFORMATION.................. 2-1
2
DESCRIPTION AND MACHINE
3
IDENTIFICATION ............................. 3-1
Identification number records.......... 3-2
Key identification number................ 3-2
Vehicle identification number .......... 3-3
Model label ...................................... 3-3
CONTROL FUNCTIONS .................. 4-1
4
Main switch...................................... 4-1
Indicator and warning lights.............4-2
Fuel gauge .......................................4-4
Speedometer unit ............................4-4
Handlebar switches .........................4-6
Throttle lever ..................................4-13
Speed limiter ..................................4-14
Front brake lever............................4-15
Brake pedal and rear brake
lever .............................................4-15
Drive select lever ...........................4-16
Recoil starter..................................4-16
Fuel tank cap .................................4-17
Fuel cock........................................4-18
Starter (choke) ...............................4-19
Seat................................................4-20
Storage compartment ....................4-21
Front carrier ...................................4-22
Rear carrier ....................................4-22
Front shock absorber
adjustment ...................................4-22
Rear shock absorber
adjustment ...................................4-24
Auxiliary DC jack............................4-25
Page 7
PRE-OPERATION CHECKS ........... 5-1
5
Front and rear brakes ..................... 5-2
Fuel ................................................. 5-4
Engine oil ........................................ 5-6
Final gear oil.................................... 5-6
Differential gear oil .......................... 5-6
Coolant............................................ 5-7
Throttle lever ................................... 5-7
Fittings and fasteners...................... 5-8
Lights............................................... 5-8
Switches.......................................... 5-8
Tires ................................................ 5-8
How to measure tire pressure....... 5-10
Tire wear limit................................ 5-11
OPERATION..................................... 6-1
6
Starting a cold engine ..................... 6-1
Starting a warm engine................... 6-3
Warming up..................................... 6-3
Drive select lever operation and
reverse driving............................... 6-4
Engine break-in............................... 6-7
Parking ............................................ 6-8
Parking on a slope........................... 6-9
Accessories and loading ...............6-10
RIDING YOUR ATV ..........................7-1
7
Getting to know your ATV ...............7-3
Ride with care and good
judgement...................................... 7-4
Be careful where you ride.............. 7-16
Turning your ATV ..........................7-22
Climbing uphill ............................... 7-24
Riding downhill ..............................7-30
Crossing a slope............................ 7-32
Crossing through shallow
water............................................ 7-34
Riding over rough terrain............... 7-37
Sliding and skidding.......................7-38
What to do if...................................7-40
What to do ..................................... 7-40
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PERIODIC MAINTENANCE AND
8
ADJUSTMENT.................................. 8-1
Owner’s manual and tool kit............ 8-1
Periodic maintenance/
lubrication ...................................... 8-3
Panel removal and installation ........ 8-5
Engine oil and oil filter cartridge .... 8-12
Final gear oil .................................. 8-17
Differential gear oil......................... 8-19
Cooling system.............................. 8-21
Changing the coolant ....................8-23
Axle boots...................................... 8-26
Spark plug inspection.................... 8-27
Air filter element cleaning.............. 8-29
V-belt cooling duct check hose .....8-32
V-belt case drain plug.................... 8-33
Spark arrester cleaning ................. 8-33
Carburetor adjustment................... 8-35
Idle speed adjustment ................... 8-35
Valve clearance adjustment.......... 8-36
Throttle lever adjustment............... 8-37
Front brake pad check .................. 8-38
Rear brake pad check ................... 8-38
Inspecting the brake fluid level ......8-39
Brake fluid replacement .................8-41
Front brake lever free play.............8-41
Rear brake lever adjustment .........8-42
Brake pedal position
adjustment ...................................8-43
Adjusting the rear brake light
switch ...........................................8-44
Cable inspection and
lubrication.....................................8-45
Brake lever and brake pedal
lubrication.....................................8-45
Wheel removal...............................8-46
Wheel installation...........................8-47
Battery............................................8-48
Battery maintenance......................8-49
Fuse replacement ..........................8-49
Replacing a headlight bulb ............8-51
Headlight beam adjustment...........8-54
Tail/brake light bulb
replacement .................................8-54
Troubleshooting .............................8-55
Troubleshooting charts ..................8-56
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CLEANING AND STORAGE............ 9-1
9
A. Cleaning...................................... 9-1
B. Storage ....................................... 9-3
SPECIFICATIONS.......................... 10-1
10
NOISE REGULATION.................... 11-1
11
MAINTENANCE RECORD ............ 12-1
12
ATV LIMITED WARRANTY............ 13-1
13
YAMAHA EXTENDED SERVICE
14
(Y.E.S.) ........................................... 14-1
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EBU00464
1-
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1-1
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Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
3
1
WARNING
Overloading this ATV or carrying cargo improperly can change handling. stability and braking performance and can lead to an accident. Never exceed the maximum front cargo limit of
: 40kg (88 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
5ND-F4877-00
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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4
WARNING
Overloading this ATV or carrying cargo improperly can change handling. stability and braking performance and can lead to an accident. Never exceed the maximum rear cargo limit of
: 80kg (176 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
5ND-F4897-00
5
MAXIMUM.LOADING LIMITMAXIMUM LOADING LIMIT
15kgf
5ND-F151K-00
)
)
PULLING LOAD: 4900 N(500kgf
TONGUE WEIGHT: 147 N
1102 l b f
33 lbf
(
6
1-3
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78
WARNING
UNDER
Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
NEVER operate this ATV if you are under age 16.
YAMAHA 4XE-F415A-00
9
WARNING
Turning the ATV in 4WD-LOCK(“DIFF. LOCK”
takes more effort.
Operate at a slow speed and allow
extra time and distance for maneuvers
to avoid loss of control.
1-4
)
5ND-F1558-00
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SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this manual and all labels carefully and follow the operating procedures described.
Never operate an ATV without proper training or instruction.
Take a Training Course.
Begin­ners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you.
Always follow the age recommendation: – A child under 16 years old should never operate an ATV with engine size greater than 90cc.
Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.
Never carry a passenger on an ATV.
Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park­ing lots and streets.
Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
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Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.
Never consume alcohol or drugs before or while operating this ATV.
Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
Always inspect your ATV each time you use it to make sure it is in safe operating condition. Al­ways follow the inspection and maintenance procedures and schedules described in this man­ual.
Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
Never operate on excessively rough, slippery or loose terrain until you have learned and prac­ticed the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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Always follow proper procedures for climbing hills as described in this manual. Check the ter­rain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.
Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight back­ward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall­ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.
Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when op­erating over obstacles as described in this manual.
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Always be careful when skidding or sliding. Learn to safely control skidding or sliding by prac­ticing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con­trol.
Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.
Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly.
Always use the size and type of tires specified in this manual.
Always maintain proper tire pressure as described in this manual.
Never modify an ATV through improper installation or use of accessories.
Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY,
call the Consumer Products Safety Com-
mission at 1-800-638-2772, or the ATV Distributors Safety Hotline at 1-800-852-5344.
2-4
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WARNI NG
POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refuel­ing. Do not refuel immediately after the en­gine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or in the vi­cinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dry­ers.
When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” posi­tion. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.
2-5
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WARNI NG
POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.
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EBU00032
1-
DESCRIPTION AND MACHINE IDENTIFICATION
1. Rear shock absorber assembly spring preload adjusting ring
2. Spark arrester
3. Storage compartment and tool kit
4. Spark plug
5. Rear brake fluid reservoir
6. Radiator cap
7. Front shock absorber assembly spring preload adjusting ring
8. V-belt case
9. Brake pedal
10. Front shock absorber assembly spring preload adjusting ring
11. Fuel cock
12. Air filter case
13. Fuses
14. Tail/brake light
15. V-belt cooling duct check hose
16. Coolant reservoir
17. Oil filter cartridge
18. Engine oil dipstick
19. Rear brake lever
20. Left handlebar switches
21. Starter (choke)
22. Drive select lever
23. Speedometer unit
24. Main switch
25. Fuel tank cap
26. Auxiliary DC jack
27. Right handlebar switch
28. Throttle lever
29. Front brake lever
NOTE:
The machine you have purchased may differ slightly from those shown in the figures of this manual.
3-1
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EBU00600
Identification number records
Record the key identification number, vehicle identification number and model label infor­mation in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.
1. KEY IDENTIFICATION NUMBER:
2. VEHICLE IDENTIFICATION NUMBER:
EBU00035
Key identification number
The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key.
1
2
3
4
5
6
7
8
9
10
3. MODEL LABEL INFORMATION:
1. Key identification number
3-2
11
12
13
14
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EBU00036
Vehicle identification number
The vehicle identification number is stamped into the frame.
1. Vehicle identification number
NOTE:
The vehicle identification number is used to identify your machine.
EBU00787
Model label
The model label is affixed to the location in the illustration. Record the information on this la­bel in the space provided. This information will be needed to order spare parts from your Yamaha dealer.
1. Model label
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EBU00039
1-
CONTROL FUNCTIONS
WARNING
Indicates a potential hazard that could result in serious injury or death.
EBU12490
Main switch
Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights, taillight and meter lighting come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.
1. Main switch
1
2
3
4
5
6
7
8
9
10
11
12
13
14
4-1
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EBU08020
Indicator and warning lights
1. Differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. Park indicator light “P”
7. Differential gear lock indicator “”
8. Coolant temperature warning light “”
DIFF. LOCK
EBU10601
Differential gear lock indicator light “DIFF. LOCK
This indicator light and the differential gear lock indicator in the display come on when the differential gear lock switch is set to the “4WD- LOCK position.
NOTE:
_
When the switch is set to “LOCK”, the differ­ential gear lock indicator light will flash until the differential gear is locked.
_
EBU11220
Low-range indicator light “L”
This indicator light comes on when the drive select lever is in the “L” position.
EBU01064
High-range indicator light “H”
This indicator light comes on when the drive select lever is in the “H” position.
4-2
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EBU09720
Neutral indicator light “N”
This indicator light comes on when the drive select lever is in the “N” position.
EBU12500
Reverse indicator light “R”
This indicator light comes on when the drive select lever is in the “R” position.
EBU00609
Park indicator light “P”
This indicator light comes on when the drive select lever is in the “P” (park) position.
EBU00860
Coolant temperature warning light “”
When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the en­gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.
CAUTION:
_
The engine may overheat if the ATV is
overloaded. If this happens, reduce the load to specification. After restarting, make sure that the
light is out. Continuous use while the light is on may cause damage to the engine.
_
4-3
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EBU00052
Fuel gauge
The fuel gauge indicates the amount of fuel in the fuel tank. When the needle reaches the red line, refill the tank at the first opportunity.
1. Speedometer 2. Odometer/Tripmeter A/Tripmeter B
3. Clock/Hour meter 4. TRIP/ODO button
5. Clock/Hour button “”/“”
6. “H” button 7. “M” button
1. Fuel gauge 2. Red line
NOTE:
_
If the machine runs out of fuel, move the fuel cock lever to the “RES” position. Approxi­mately 4.5 L (0.99 Imp gal, 1.19 US gal) of fuel will be remaining in the tank.
_
EBU11321
Speedometer unit
The speedometer unit is equipped with the following:
a speedometer (which shows the riding speed)
an odometer (which shows the total dis­tance traveled)
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two tripmeters (which show the distance traveled since they were last set to zero)
a clock
an hour meter (which shows the total time the key has been turned to “ON”)
Odometer and tripmeter modes
Pushing the “TRIP/ODO” button switches the display between the odometer mode “ODO” and the tripmeter modes “A” and “B” in the fol­lowing order: ODO→TRIP A→TRIP B→ODO To reset a tripmeter, select it by pushing the TRIP/ODO button, and then push the TRIP/ ODO button for at least three seconds. The tripmeters can be used to estimate the dis­tance that can be traveled with a full tank of fu­el. This information will enable you to plan future fuel stops.
NOTE:
_
Holding in the “TRIP/ODO” button and then turning the key to “ON” switches the display between mph and km/h.
_
4-5
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Clock mode
Pushing the “”/“” button switches the display between the clock mode “CLOCK” and the hour meter mode “HOUR” in the fol­lowing order: CLOCK→HOUR→CLOCK
To set the clock
1. Push the “”/“” button until the clock starts flashing.
2. Set the hours by pushing the “H” button.
3. Set the minutes by pushing the “M” but­ton.
4. Push the “”/“” button, and then re- lease it to start the clock.
EBU00053
Handlebar switches
1. Light switch //OFF
2. Start switch “”
3. Engine stop switch /
4. Override switch “OVERRIDE”
EBU12510
Light switch //OFF
Set the switch to “” to turn on the low beams, the taillight and the meter lighting. Set the switch to “” to turn on the high beams, the taillight and the meter lighting. Set the switch to “OFF” to turn off all the lights.
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CAUTION:
_
Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it.
_
EBU12050
Engine stop switch /
Make sure that the engine stop switch is set to “” before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not start or run when the engine stop switch is set to “”.
EBU00607
Start switch “”
The starter motor cranks the engine when this switch is pushed.
CAUTION:
See starting instructions prior to starting the engine. (See page 6-1 for details.)
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1. Override switch “OVERRIDE”
EBU13781
Override switch “OVERRIDE”
Top speed is normally limited when operating in 4WD-LOCK. If conditions require more en­gine power when riding forward, push and hold this switch to override the 4WD-LOCK speed limiting function. (See page 4-11 for a detailed explanation about the differential gear lock switch and its function.) Releasing the switch restores the speed limiting function. While this switch is pushed, the segments of the speedometer digits will appear as shown in the figure.
NOTE:
_
If the digits of the speedometer appear as shown when the switch is NOT being pushed, this could indicate a malfunction in the electri­cal system. In this case, take the ATV to a Yamaha dealer at the first opportunity.
_
4-8
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WARNI NG
POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The amount of effort is more the faster you go. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in 4WD-LOCK, and allow extra time and distance for maneuvers.
1. On-command four-wheel drive switch “2WD”/“4WD”
2. Differential gear lock switch “LOCK”/“4WD
EBU14090
On-command four-wheel drive and differ­ential gear lock switches
This ATV is equipped with an on-command four-wheel drive switch 2WD”/“4WD and a differential gear lock switch “LOCK”/“4WD”. Select the appropriate drive according to ter­rain and the conditions.
Two-wheel drive (2WD): Power is supplied to the rear wheels only.
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Four-wheel drive (4WD): Power is supplied to the rear and front wheels.
Four-wheel drive with the differential gear locked (4WD-LOCK): Power is supplied to the rear and front wheels when the differen­tial gear is locked (“DIFF.LOCK”). Unlike the 4WD mode, all wheels turn at the same speed.
WARNI NG
POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 4WD-LOCK (DIFF.LOCK), or vice-versa while the ATV is moving. WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD and in 4WD-LOCK in some circumstances. Changing from 2WD to 4WD or from 4WD to 4WD-LOCK, or vice-versa while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and in­crease the risk of losing control and an accident. HOW TO AVOID THE HAZARD Always stop the ATV before changing from 2WD to 4WD or from 4WD to 4WD-LOCK, or vice-versa.
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1. Lever
2. On-command four-wheel drive switch “2WD”/“4WD”
On-command four-wheel drive switch 2WD/4WD
To change from 2WD to 4WD, stop the ATV, and then set the switch to “4WD”. When the ATV is in 4WD, the 4WD indicator “” will come on in the speedometer unit display. To change from 4WD to 2WD, stop the ATV, be sure the lever is set to position a, and then set the switch to 2WD”.
1. Differential gear lock switch “LOCK”/“4WD
2. Lever
Differential gear lock switch LOCK/4WD
To lock the differential gear in 4WD, make sure the on-command four-wheel-drive switch is set to 4WD, stop the ATV, move the lever to po­sition b, and then set the switch to “LOCK”. When the differential gear is locked, the differ­ential gear lock indicator (“DIFF.LOCK”) light will come on along with the indicator “” in the speedometer unit display. To release the differential gear lock, stop the ATV and set the switch to “4WD”.
4-11
DIFF. LOCK
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WARNI NG
POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The amount of effort is more the faster you go. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in 4WD-LOCK, and allow extra time and distance for maneuvers.
NOTE:
_
When the switch is set to “LOCK”, the dif­ferential gear lock indicator light will flash until the differential gear is locked.
When the indicator light is flashing, turn­ing the handlebar back and forth will help the differential gear lock to engage.
Riding before the differential gear lock is properly engaged (e.g., when the indica­tor light is flashing) will cause the engine speed to be limited until engagement is complete.
When the ATV is in 4WD-LOCK, the maximum traveling speed is limited to 35 km/h (22 mph). However, if conditions require full engine power to be available, push and hold the override switch to dis­able the 4WD-LOCK speed limiter. (See page 4-8 for a detailed explanation of this switch.)
_
4-12
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EBU00062
Throttle lever
Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.
1. Throttle lever
Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the le­ver is released.
WARNI NG
POTENTIAL HAZARD Malfunction of throttle.
WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident.
HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you cant find or solve the problem yourself.
4-13
Page 36
EBU01159
Speed limiter
The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the ad­justing screw limits the maximum engine pow­er available and decreases the maximum speed of the ATV.
1. Locknut 2. Adjusting screw a. 12 mm (0.47 in)
WARNI NG
POTENTIAL HAZARD Improper adjustment of the speed limit­er and throttle.
WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an acci­dent or be injured.
HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjust­ed to 3–5 mm (0.12–0.20 in). See page 8-37.
4-14
Page 37
EBU00070
Front brake lever
The front brake lever is located on the right handlebar. Pull it toward the handlebar to ap­ply the front brake.
1. Front brake lever
EBU00732
Brake pedal and rear brake lever
The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. Push down on the pedal or pull the lever toward the handlebar to apply the rear brake.
1. Brake pedal
1. Rear brake lever
4-15
Page 38
EBU00608
Drive select lever
The drive select lever is used to shift your ma­chine into the low, high, neutral, reverse and park positions. (Refer to page 6-4 for the drive select lever operation.)
EBU00855
Recoil starter
Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out.
1. Drive select lever
1. Recoil starter
4-16
Page 39
WARNI NG
POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position P. WHAT CAN HAPPEN The ATV could start to move unexpect­edly, which could cause an accident. HOW TO AVOID THE HAZARD Set the drive select lever to the park po­sition before starting the engine.
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it coun­terclockwise.
1. Fuel tank cap
4-17
Page 40
EBU00093
Fuel cock
The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will
not flow. Always turn the lever to this position when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done with the lever in this position.
RES: This indicates reserve. If you run out of
fuel while riding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY. After refuelling, return the fuel cock lever to the ON position.
OFF Position
1. Arrow mark pointing to “OFF”
ON Position
1. Arrow mark pointing to “ON”
4-18
Page 41
RES Position
1. Arrow mark pointing to “RES”
EBU00095
Starter (choke) “”
Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to Starting a cold engine for proper op­eration. (See page 6-1.)
1. Starter (choke) “”
4-19
Page 42
EBU05670
Seat
To remove the seat, pull the seat lock lever upward and pull up the seat at the rear.
1. Seat 2. Seat lock lever
To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear.
NOTE:
_
Make sure that the seat is securely fitted.
_
1. Projection (× 2) 2. Seat holder (× 2)
4-20
Page 43
EBU01062
Storage compartment
The storage compartment is located under the seat. (See page 4-20 for seat removal and installation procedures.) When storing any documents in the storage compartment, be sure to wrap them in a plas­tic bag so that they will not get wet. When washing the ATV, be careful not to let any wa­ter enter the storage compartment.
NOTE:
_
There is a check hose at the bottom of the storage compartment. If any water collects in this hose, remove the hose, empty it, and then install it.
_
1. Storage compartment
1. Storage compartment check hose
4-21
Page 44
EBU00582
Front carrier
Maximum load limit: 40 kg (88 lb)
EBU00583
Rear carrier
Maximum load limit: 80 kg (176 lb)
EBU01104
Front shock absorber adjustment
The spring preload can be adjusted to suit the riders weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the ad­justing ring in direction a. To decrease the spring preload, turn the ad­justing ring in direction b.
1. Spring preload adjusting ring
2. Position indicator
4-22
Page 45
NOTE:
_
A special wrench can be obtained at a Yamaha dealer to make this adjustment.
_
Standard position: 2
1 - Minimum (soft) 5 - Maximum (hard)
1. Special wrench
WARNI NG
POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set­ting.
4-23
Page 46
EBU01103
Rear shock absorber adjustment
The spring preload can be adjusted to suit the riders weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the ad­justing ring in direction a. To decrease the spring preload, turn the ad­justing ring in direction b.
NOTE:
_
A special wrench can be obtained at a Yamaha dealer to make this adjustment.
_
Standard position: 2
1 - Minimum (soft) 5 - Maximum (hard)
1. Spring preload adjusting ring
2. Position indicator
1. Special wrench
4-24
Page 47
EBU10020
Auxiliary DC jack
The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running.
1. Set the light switch to “OFF”.
1. Auxiliary DC jack cap
2. Start the engine. (See pages 6-1–6-3.)
3. Open the auxiliary DC jack cap, and then insert the accessory power plug into the jack.
Maximum rated capacity for the auxiliary DC jack:
DC 12 V, 120 W (10 A)
4. When the auxiliary DC jack is not being used, cover it with the cap.
CAUTION:
_
Do not use accessories requiring
more than the above maximum capac­ity. This may overload the circuit and cause the fuse to blow. If accessories are used without the
engine running or with the headlights turned on, the battery will lose its charge and engine starting may be­come difficult. Do not use an automotive cigarette
lighter or other accessories with a plug that gets hot because the jack can be damaged.
_
4-25
Page 48
1. Auxiliary DC jack
EBU00112
WARNING
Indicates a potential hazard that could result in serious injury or death.
4-26
Page 49
1-
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brake
Rear brake
Fuel
Engine oil
Coolant reservoir
Final gear oil and differential gear oil
Throttle
Wheels and tires
Fittings and fasteners
Lights and switches
Axle boots
Check operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.
Check operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.
Check fuel level.
Fill with fuel if necessary.
Check oil level.
Fill with oil if necessary.
Check coolant level in reservoir.
Fill with coolant if necessary.
Check for leakage. 5-6, 8-178-21
Check for proper throttle cable operation and free play. 5-7, 8-37
Check tire pressure, wear and damage. 5-85-11, 8-468-47
Check all fittings and fasteners. 5-8
Check for proper operation. 5-8, 8-44, 8-518-54
Check for damage. 8-26
5-2–5-3, 8-38–8-42
5-2–5-3, 8-38–8-43
5-4–5-5
5-6, 8-12–8-16
5-7, 8-21–8-26
1
2
3
4
5
6
7
8
9
10
11
12
13
14
5-1
Page 50
WARNI NG
POTENTIAL HAZARD Failure to inspect the ATV before oper­ating. Failure to properly maintain the ATV.
WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage.
HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op­erating condition. Always follow the inspection and main­tenance procedures and schedules de­scribed in the Owners Manual.
EBU11011
Front and rear brakes Brake levers and brake pedal
Check that there is no free play in the front brake lever. If there is free play, have a Yamaha dealer adjust it.
Check for correct free play in the rear brake lever. If the free play is incorrect, adjust it. (See page 8-42.)
Check for correct brake pedal height. If the pedal height is incorrect, have a Yamaha dealer adjust it.
Check the operation of the brake levers and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have a Yamaha dealer inspect the brake system.
Brake fluid level
Check the brake fluid level. Add fluid if neces­sary. (See pages 8-39–8-41.)
Recommended brake fluid: DOT 4
5-2
Page 51
Brake fluid leakage
Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be inspected by a Yamaha dealer.
Brake operation
Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking per­formance, inspect the brake pads for wear. (See pages 8-38–8-39.)
WARNI NG
POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the ad­justment procedures provided in this manual, have a Yamaha dealer check for the cause.
5-3
Page 52
EBU01085
Fuel
Make sure there is sufficient gasoline in the tank.
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
Total:
15 L (3.3 Imp gal, 3.96 US gal)
Reserve:
4.5 L (0.99 Imp gal, 1.19 US gal)
CAUTION:
_
Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.
_
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.
5-4
Page 53
Gasohol
There are two types of gasohol; gasohol con­taining ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gaso­hol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems.
1. Fuel level 2. Fuel tank filler tube
WARNI NG
POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot.
5-5
Page 54
EBU10842
Engine oil
Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-12– 8-16.)
EBU00493
Final gear oil
Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-17– 8-19 for details.)
CAUTION:
_
In order to prevent clutch slippage
(since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a high­er quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II or higher. Make sure that no foreign material en-
ters the crankcase.
_
Recommended engine oil type and quantity:
See page 10-2.
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
If desired, an SAE 80W90 hypoid gear oil may be used for all conditions.
NOTE:
GL-4 is a quality and additive rating, GL-5 or GL-6 rated hypoid gear oils may also be used.
EBU00678
Differential gear oil
Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-19–8-21 for details.)
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
5-6
Page 55
EBU12530
Coolant
Check the coolant level in the coolant reser­voir when the engine is cold. (The coolant lev­el will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir. If the coolant level is at or below the minimum level mark, add distilled water to bring the level up to maximum level mark. Change the coolant every two years. (See pages 8-21–8-26 for details.)
CAUTION:
_
Hard water or salt water is harmful to the engine. You may use soft water if you can­not get distilled water.
_
Coolant reservoir capacity (up to the maximum level mark):
0.25 L (0.22 Imp qt, 0.26 US qt)
WARNI NG
POTENTIAL HAZARD Removing the radiator cap when the en­gine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before re­moving the radiator cap. Always use a thick rag over the cap. Allow any re­maining pressure to escape before completely removing the cap.
EBU01083
Throttle lever
Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation.
5-7
Page 56
EBU11620
Fittings and fasteners
Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque.
EBU10030
Lights
Check the headlights and tail/brake light to make sure they are in working condition. Re­pair as necessary for proper operation.
EBU11700
Switches
Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation.
EBU00157
Tires
WARNI NG
POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pres­sure.
WHAT CAN HAPPEN Use of improper tires on this ATV, or op­eration of this ATV with improper or un­even tire pressure, may cause loss of control, increasing your risk of acci­dent.
HOW TO AVOID THE HAZARD
1. The tires listed below have been ap­proved by Yamaha Motor Co., Ltd. for this model. Other tire combina­tions are not recommended.
ACE-01E
Manufacturer Size Type
Front MAXXIS AT25 × 8-12 M911Y
Rear MAXXIS AT25 × 10-12 M912Y
5-8
Page 57
2. The tires should be set to the rec­ommended pressure:
Recommended tire pressure
Front 25 kPa (0.25 kgf/cm Rear 25 kPa (0.25 kgf/cm
Check and adjust tire pressures when
2
, 3.6 psi)
2
, 3.6 psi)
the tires are cold. Tire pressures must be equal on both
sides.
3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums:
Front 22 kPa (0.22 kgf/cm Rear 22 kPa (0.22 kgf/cm
2
, 3.2 psi)
2
, 3.2 psi)
4. Use no more than the following pressures when seating the tire beads.
Front 250 kPa (2.5 kgf/cm Rear 250 kPa (2.5 kgf/cm
2
, 36 psi)
2
, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst.
5-9
Page 58
EBU00159
How to measure tire pressure
Use the low-pressure tire gauge.
NOTE:
The low-pressure tire gauge is included as standard equipment. Make two measure­ments of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.
Set pressure with tires cold. Set tire pressures to the following specifica­tions:
ACE-02E
Front
Rear
ACE-02E
Recommended
pressure
25 kPa
(0.25 kgf/cm
3.6 psi)
25 kPa
(0.25 kgf/cm
3.6 psi)
2
2
Minimum Maximum
(0.22 kgf/cm
,
(0.22 kgf/cm
,
22 kPa
3.2 psi)
22 kPa
3.2 psi)
2
,
2
,
28 kPa
(0.28 kgf/cm
4.0 psi)
28 kPa
(0.28 kgf/cm
4.0 psi)
2
2
1. Low-pressure tire gauge
,
,
5-10
Page 59
EBU00160
Tire wear limit
When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire.
a. Tire wear limit
5-11
Page 60
EBU00161
1-
OPERATION
WARNING
Indicates a potential hazard that could result in serious injury or death.
WARNI NG
POTENTIAL HAZARD Operating ATV without being familiar with all controls.
WHAT CAN HAPPEN Loss of control, which could cause an accident or injury.
HOW TO AVOID THE HAZARD Read the Owners Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.
EBU00672
Starting a cold engine
WARNI NG
POTENTIAL HAZARD Freezing control cables in cold weather.
WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or colli­sion.
HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding.
1. Apply the rear brake lever.
2. Turn the fuel cock to “ON”.
3. Turn the main switch to “ON” and the en­gine stop switch to “”.
4. Shift the drive select lever into the neutral or park position.
6-1
Page 61
NOTE:
When the drive select lever is in the neu­tral or park position, if either indicator light does not come on, ask a Yamaha dealer to inspect its electric circuit.
The engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral or park before starting the engine.
5. Use the starter (choke) in reference to the figure:
Position 1 : Cold engine start-
ambient temperature below 5 °C (40 °F).
Position 2 : Cold engine start-
ambient temperature at 0 °C (30 °F)–30 °C (90 °F) and warm- ing up position.
Position 3 : Cold engine start-
ambient temperature above 25 °C (80 °F) and warm engine start position.
a. Starter (choke) 1. Fully open
2. Half open 3. Closed
6. Completely close the throttle lever and start the engine by pushing the start switch.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
6-2
Page 62
NOTE:
If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery en­ergy. Do not crank the engine more than 10 seconds on each attempt.
If the battery is discharged, pull the recoil starter to start the engine.
7. If the engine is started with the starter (choke) in position 1, the starter (choke) should be returned to position 2 to warm up the engine. If the engine is started with the starter (choke) in position 2, keep the starter (choke) in this position to warm up the engine.
8. Continue warming up the engine until it idles smoothly and return the starter (choke) to position 3 before riding.
CAUTION:
See the Engine break-in section prior to operating the engine for the first time.
EBU00180
Starting a warm engine
To start a warm engine, refer to the Starting a cold engine section. The starter (choke) should not be used. The throttle should be opened slightly.
EBU00182
Warming up
To get maximum engine life, always warm up the engine before starting off. Never acceler­ate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off.
6-3
Page 63
EBU00846
Drive select lever operation and reverse driving
CAUTION:
Before shifting, you must stop the ma­chine and return the throttle lever to the closed position. Otherwise, the transmis­sion may be damaged.
_
Shifting: Neutral to High and High to Low
1. Bring the machine to a complete stop and return the throttle lever to the closed position.
2. Apply the brakes, then shift by moving the drive select lever along the shift guide.
NOTE:
Make sure that the drive select lever is com­pletely shifted into position.
_
1. Drive select lever
3. Open the throttle lever gradually.
6-4
Page 64
Shifting: Neutral to Reverse and Reverse to Park
NOTE:
_
The drive select lever cannot be shifted into or from reverse or park without applying the rear brake.
_
1. Bring the machine to a complete stop and return the throttle lever to the closed position.
2. Apply the rear brake pedal.
3. Shift from neutral to reverse or from re­verse to park and vice versa by moving the drive select lever along the shift guide.
1. Drive select lever
NOTE:
_
When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the reverse indicator light electrical cir­cuit.
Due to the synchronizing mechanism in the engine, the light may not come on un­til the ATV starts moving.
_
4. Check behind for people or obstacles, then release the rear brake pedal.
6-5
Page 65
5. Open the throttle lever gradually and con­tinue to watch to the rear while backing.
WARNI NG
POTENTIAL HAZARD Improperly operating in reverse.
WHAT CAN HAPPEN You could hit an obstacle or person be­hind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slow­ly.
6-6
Page 66
EBU02101
Engine break-in
There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle oper­ation or any condition which might result in ex­cessive engine heating must be avoided. However, momentary (2–3 seconds maxi­mum) full throttle operation under load does not harm the engine.
Each full throttle acceleration sequence should be followed with a substantial rest pe­riod for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this peri­od, consult a Yamaha dealer.
0–10 hours:
Avoid continuous operation above half throt­tle. Allow a cooling off period of five to ten min­utes after every hour of operation. Vary the speed of the machine from time to time. Do not operate it at one set throttle position.
6-7
Page 67
10–20 hours:
Avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time.
After break-in:
Avoid prolonged full throttle operation. Vary speeds occasionally.
EBU00612
Parking
When parking, stop the engine and shift the drive select lever into the park position, then turn the fuel cock to the “OFF” position.
6-8
Page 68
EBU06151
Parking on a slope
WARNI NG
POTENTIAL HAZARD Parking on a hill or other incline.
WHAT CAN HAPPEN The ATV could roll out of control, in­creasing the chance of an accident.
HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the machine transversely across the in­cline, apply the parking brake, and block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily.
1. Bring the machine to a stop by applying the brakes.
2. Stop the engine.
3. With the brake pedal applied, shift the drive select lever to the park position “P”.
6-9
Page 69
EBU00221

Accessories and loading

EBU00222
Accessories
Accessories can affect the handling and con­trol of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories.
Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other ac­cessories may also be available on the market. However, it is not possible for Yamaha to test all non-Yamaha accesso­ries, nor have any control over the quality or suitability of them. Choose a genuine Yamaha accessory, or one that is equiva­lent in design and quality.
Accessories should be rigidly and securely mounted. An accessory which can shift po­sition or come off while you are riding could affect your ability to control the ATV.
Do not mount an accessory where it could interfere with your ability to control the ATV. Examples include (but are not limited to) a heavy or bulky object attached to the han­dlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view.
Use extra caution when riding an ATV with accessories. The ATV may handle differ­ently than it does without accessories.
6-10
Page 70
EBU09601
Loading
Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying car­go or towing a trailer. Keep the following points in mind:
Never exceed the weight limits shown. An overloaded ATV can be unstable.
MAXIMUM LOADING LIMIT
Vehicle loading limit (total weight of cargo, rider and accessories, and tongue weight): 210 kg (463 lb)
Front carrier: 40 kg (88 lb)
Rear carrier: 80 kg (176 lb)
Storage box: 2.0 kg (4.4 lb)
Trailer hitch: Pulling load (total weight of trailer and cargo): 500 kgf (1,102 lbf) Tongue weight (vertical weight on trailer hitch point): 15 kgf (33 lbf)
Do not exceed the maximum tongue weight. You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Adjust the load in the trailer, if necessary, to reduce the weight on hitch. If you are carrying cargo and towing a trail­er, include the tongue weight in the maxi­mum vehicle load limit.
Load cargo on the carrier as close to the center of the vehicle as possible. Put cargo at the rear of the front carrier and at the front of the rear carrier. Center the load from side to side.
Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an acci­dent.
Make sure the load does not interfere with controls or your ability to see where you are going.
6-11
Page 71
Ride more slowly than you would without a load. The more weight you carry, the slow­er you should go. Although conditions vary, it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer.
Allow more braking distance. A heavier ve­hicle takes longer to stop.
Avoid making sharp turns unless at very slow speeds.
Avoid hills and rough terrain. Choose ter­rain carefully. Added weight affects the sta­bility and handling of the ATV.
WARNI NG
POTENTIAL HAZARD Overloading this ATV or carrying or tow­ing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle han­dling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
6-12
Page 72
EBU14480
WARNING
_
Indicates a potential hazard that could result in serious injury or death.
6-13
Page 73
Riding
1-
Your
ATV
7-1
7
Page 74
7-2
Page 75
WARNING
_
Indicates a potential hazard that could result in serious injury or death.

GETTING TO KNOW YOUR ATV

This ATV is mainly for utility use, but may also be used for recreation. This section, Riding your ATV, provides general ATV riding in­structions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time. Take the time to learn the basic tech­niques well before attempting more difficult maneuvers.
Riding your new ATV can be a very enjoyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely. Before you
begin to ride, be sure you have read this Own­ers Manual completely and understand the operation of the controls. Pay particular atten­tion to the safety information on pages 2-1– 2-6. Please also read all caution and warning labels on your ATV.
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RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced.
Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum perfor­mance until you are totally familiar with the ATVs handling and performance characteris­tics.
WARNI NG
POTENTIAL HAZARD Operating this ATV without proper in­struction. WHAT CAN HAPPEN The risk of an accident is greatly in­creased if the operator does not know how to operate the ATV properly in dif­ferent situations and on different types of terrain.
HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating tech­niques described in this Owners Manu­al. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887.
Riding your ATV requires skills acquired through practice over a period of time.
Take the time to learn the basic techniques well before attempting more difficult maneu­vers.
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Not recommended for children under 16 years of age.
WARNI NG
POTENTIAL HAZARD Failure to follow the age recommenda­tions for this ATV.
WHAT CAN HAPPEN Use by children of ATVs that are not rec­ommended for their age can lead to se­vere injury or death of the child.
HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc.
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Page 78
This ATV is designed to carry operator and cargo only – passengers prohibited.
WARNI NG
POTENTIAL HAZARD Carrying a passenger on this ATV.
WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
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Page 79
Apparel
WARNI NG
POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye pro­tection and protective clothing.
WHAT CAN HAPPEN Operating without an approved motor­cycle helmet in­creases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can re­sult in an accident and increases your chances of a severe injury in the event of an accident.
Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear:
eye protection
(goggles or face shield) gloves boots long-sleeved shirt or jacket long pants
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Do not operate after consuming alcohol or drugs.
Operators performance capability is reduced by the influence of alcohol or drugs.
WARNI NG
POTENTIAL HAZARD Operating this ATV after consuming al­cohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and percep­tion. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
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Pre-operation checks
Always perform the pre-operation checks list­ed on page 5-1 before riding for safety and proper care of the ATV.
WARNI NG
POTENTIAL HAZARD Failure to inspect the ATV before oper­ating. Failure to properly maintain the ATV.
WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage.
HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op­erating condition. Always follow the inspection and main­tenance procedures and schedules de­scribed in the Owners Manual.
WARNI NG
POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pres­sure. WHAT CAN HAPPEN Use of improper tires on this ATV, or op­eration of this ATV with improper or un­even tire pressure, may cause loss of control, increasing your risk of an acci­dent. HOW TO AVOID THE HAZARD Always use the size and type tires spec­ified in the Owners Manual for this vehi­cle on pages 5-8–5-10. Always maintain proper tire pressure as described in the Owners Manual on page 5-10.
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WARNING
_
Indicates a potential hazard that could result in serious injury or death.
Do not operate at speeds too fast for your skills or the conditions.
WARNI NG
POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing con­trol of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating con­ditions, and your experience.
Speed limiter
For riders less experienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maxi­mum. Turning in the adjusting screw limits the maximum engine power available and de­creases the maximum speed of the ATV. Turning the adjusting screw in decreases top speed and turning it out increases top speed. (See page 4-14 for details.)
1. Locknut 2. Adjusting screw
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Loading and accessories
Use extra caution when riding the ATV with additional loads, such as accessories or car­go. The ATVs handling may be adversely af­fected. Reduce your speed when adding additional loads.
MAXIMUM LOADING LIMIT
Vehicle loading limit: 210 kg (463 lb)
* Total weight of cargo, rider and
accessories, and trailer hitch vertical load.
Front carrier: 40 kg (88 lb)
Rear carrier: 80 kg (176 lb)
Storage box: 2.0 kg (4.4 lb)
Trailer hitch: Pulling load: 500 kg (1,102 lb) Total weight of trailer and cargo. Tongue weight: 15 kg (33 lb) Vertical weight on trailer hitch point.
WARNI NG
POTENTIAL HAZARD Overloading this ATV or carrying or tow­ing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle han­dling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owners Manual for carrying cargo or pulling a trailer.
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During operation
Always keep your feet on the footboards dur­ing operation. Otherwise your feet may con­tact the rear wheels.
WARNI NG
POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re­duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handle­bars and both feet on the footboards of your ATV during operation.
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Avoid wheelies and jumping. You may lose control of the ATV or overturn.
WARNI NG
POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts.
WHAT CAN HAPPEN Increases the chance of an accident, in­cluding an overturn.
HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Dont try to show off.
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Modifications
WARNI NG
POTENTIAL HAZARD Operating this ATV with improper modi­fications.
WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ­ations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improp­er installation or use of accessories. All parts and accessories added to this ve­hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho­rized ATV dealer.
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Exhaust system
The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it.
WARNI NG
POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en­gine area could catch fire. Someone touching the exhaust system during or after operation could be burned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material.
Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it.
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BE CAREFUL WHERE YOU RIDE

This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control.
WARNI NG
POTENTIAL HAZARD Operating this ATV on paved surfaces.
WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of con­trol.
HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.
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Do not ride on any public road, street, or high­way. Riding on public roads can result in collisions with other vehicles.
WARNI NG
POTENTIAL HAZARD Operating this ATV on public streets, roads or highways.
WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
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Page 90
Know the terrain where you ride. Ride cau­tiously in unfamiliar areas. Stay alert for
holes, rocks, or roots er hidden hazards
which may cause the ATV
in the terrain, and
oth-
to upset.
WARNI NG
POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturn­ing or going out of control.
HOW TO AVOID THE HAZARD Go slowly and be extra careful when op­erating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
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Page 91
WARNI NG
POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an acci­dent, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills neces­sary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
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When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch.
WARNI NG
POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles.
WHAT CAN HAPPEN You could be in a collision. You could be injured.
HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch care­fully for other vehicles.
Do not ride in areas posted no trespassing”. Do not ride on private property without getting permission.
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Page 93
Select a large, flat area off-road to become fa­miliar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the ATV is designed for off-road use only, and handling maneuvers are more difficult to per­form on pavement.
Shift to the parking position “P” and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components.
With the engine idling, shift the drive select le­ver to the low position “L” or the high position H. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground resulting in a loss of directional con­trol. Avoid higher speeds until you are thor­oughly familiar with the operation of your ATV.
When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. Improper use of the brakes can cause the tires to lose traction, reducing control and increasing the possibility of an accident.
CAUTION:
_
Do not shift from drive position low “L” to high “H” or vice versa without coming to a complete stop. Damage to the engine or drive train may occur.
_
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TURNING YOUR ATV

To achieve maximum traction while riding off­road in 2WD or 4WD, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Furthermore, when riding in 4WD-LOCK (DIFF. LOCK), the front wheels also 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 technique must be used to allow the ATV to make turns quickly and easily. It is essential
HOW TO AVOID THE HAZARD Always 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. Operate at a slow speed and allow extra time and distance for maneuvers when in 4WD-LOCK (DIFF. LOCK”).
that this skill be learned first at low speed. As you approach a curve, slow down and be-
WARNI NG
gin to turn the handlebars in the desired direc­tion. As you do so, put your weight on the
POTENTIAL HAZARD Turning improperly.
WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn.
footboard 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.
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This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesnt turn, come to a stop and then practice the procedure again. If the riding sur­face is slippery or loose, it may help to posi­tion more of your weight over the front wheels by moving forward on the seat.
Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves.
Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the in­side. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.
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Page 96

CLIMBING UPHILL

Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can ma­neuver your ATV well on flat ground before at­tempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose sur­faces, or obstacles that might cause you to lose control.
WARNI NG
POTENTIAL HAZARD Operating on excessively steep hills.
WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur­faces or small hills.
HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills.
It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by lean­ing forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars.
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WARNI NG
POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Own­ers Manual. Always check the terrain carefully be­fore you start up any hill. Never climb hills with excessively slip­pery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed.
An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
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Page 98
If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.
WARNI NG
POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owners Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.
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Page 99
When crossing the side of a hill: Always follow proper procedures as de­scribed in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
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Page 100
If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dis­mount the ATV on the uphill side. Physically turn the ATV around and then descend the hill.
If you start to roll backwards, DO NOT apply either brake abruptly. If you are in 2WD, apply only the front brake. When this ATV is in 4WD or 4WD-LOCK, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake ped­al will brake the wheels on the downhill side. Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground. The ATV could easily tip over backwards. Apply both
the front and rear brakes gradually, or dis­mount the ATV immediately on the uphill side.
WARNI NG
POTENTIAL HAZARD Stalling, rolling backwards or improper­ly dismounting while climbing a hill.
WHAT CAN HAPPEN Could result in ATV overturning.
HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill.
If you lose all forward speed:
Keep weight uphill. Apply the brakes. Shift to the parking position “P” after you are stopped.
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