Owners Manual
Page 6
......1-1 SAFETY INFORMATION...2-1 DESCRIPTION AND MACHINE IDENTIFICATION ...3-1 Identification number records...3-2 Key identification number...3-2 Vehicle identification number ...3-3 Model label ...3-3 2 3 CONTROL FUNCTIONS...4-1 Main switch ...4-1 Indicator lights...4-2 Coolant temperature warning light checking method ...4-4 Fuel gauge ...4-5 Handlebar switches ...4-6 Throttle lever ...4-9 Speed limiter ...4-10 Front brake lever...4-11 Rear brake pedal and lever ...4-11 Drive select lever ...4-12 Recoil starter...4-12 Fuel tank cap ...4-13 Fuel cock...4-14 Starter (choke) " " ...4-15 Seat...
......1-1 SAFETY INFORMATION...2-1 DESCRIPTION AND MACHINE IDENTIFICATION ...3-1 Identification number records...3-2 Key identification number...3-2 Vehicle identification number ...3-3 Model label ...3-3 2 3 CONTROL FUNCTIONS...4-1 Main switch ...4-1 Indicator lights...4-2 Coolant temperature warning light checking method ...4-4 Fuel gauge ...4-5 Handlebar switches ...4-6 Throttle lever ...4-9 Speed limiter ...4-10 Front brake lever...4-11 Rear brake pedal and lever ...4-11 Drive select lever ...4-12 Recoil starter...4-12 Fuel tank cap ...4-13 Fuel cock...4-14 Starter (choke) " " ...4-15 Seat...
Owners Manual
Page 7
... absorber adjustment...4-20 Auxiliary DC jack...4-21 5 PRE-OPERATION CHECKS ...5-1 Front and rear brakes ...5-2 Fuel ...5-4 Engine oil ...5-6 Final gear oil...5-7 Differential gear oil ...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 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 7 RIDING YOUR...
... absorber adjustment...4-20 Auxiliary DC jack...4-21 5 PRE-OPERATION CHECKS ...5-1 Front and rear brakes ...5-2 Fuel ...5-4 Engine oil ...5-6 Final gear oil...5-7 Differential gear oil ...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 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 7 RIDING YOUR...
Owners Manual
Page 8
... kit...8-1 Periodic maintenance/ lubrication ...8-3 Panel removal and installation ...8-5 Engine oil...8-12 Final gear oil ...8-15 Differential gear oil...8-18 Cooling system...8-20 Changing the coolant ...8-21 Axle boots...8-25 Spark plug inspection...8-25 Air filter cleaning ...8-28 V-belt cooling duct check hose...8-31 Spark arrester cleaning ...8-32 Carburetor adjustment...8-33 Idle speed adjustment ...8-34 Valve clearance adjustment ...8-34 Throttle lever adjustment...8-35 Front brake pad inspection...8-36 Rear brake pad inspection ...8-37 Inspecting the brake fluid level ...8-37 Brake...
... kit...8-1 Periodic maintenance/ lubrication ...8-3 Panel removal and installation ...8-5 Engine oil...8-12 Final gear oil ...8-15 Differential gear oil...8-18 Cooling system...8-20 Changing the coolant ...8-21 Axle boots...8-25 Spark plug inspection...8-25 Air filter cleaning ...8-28 V-belt cooling duct check hose...8-31 Spark arrester cleaning ...8-32 Carburetor adjustment...8-33 Idle speed adjustment ...8-34 Valve clearance adjustment ...8-34 Throttle lever adjustment...8-35 Front brake pad inspection...8-36 Rear brake pad inspection ...8-37 Inspecting the brake fluid level ...8-37 Brake...
Owners Manual
Page 20
.... Rear brake fluid reservoir 6. Spark plug 5. EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Storage compartment and tool kit 4. Fuel cock 12. V-belt case 9. Front spring preload adjusting ring 11. Air filter case 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Radiator cap 7. Fuses Tail/brake light V-belt cooling duct check hose Coolant reservoir Oil filter cartridge Engine oil dipstick Rear brake lever Left handlebar switches Starter (choke) Drive select lever Speedometer Main switch Fuel tank cap Auxiliary...
.... Rear brake fluid reservoir 6. Spark plug 5. EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Storage compartment and tool kit 4. Fuel cock 12. V-belt case 9. Front spring preload adjusting ring 11. Air filter case 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Radiator cap 7. Fuses Tail/brake light V-belt cooling duct check hose Coolant reservoir Oil filter cartridge Engine oil dipstick Rear brake lever Left handlebar switches Starter (choke) Drive select lever Speedometer Main switch Fuel tank cap Auxiliary...
Owners Manual
Page 25
... the load to specification. Four-wheel-drive indicator light " " This indicator light comes on when the 2WD/4WD switch is on to the engine. 4-3 If this light comes on may cause damage to warn that the light is too hot. NOTE: Due to the synchronizing mechanism in the 4WD position. Continuous use while the light is in the differential gear case, the light may overheat if...
... the load to specification. Four-wheel-drive indicator light " " This indicator light comes on when the 2WD/4WD switch is on to the engine. 4-3 If this light comes on may cause damage to warn that the light is too hot. NOTE: Due to the synchronizing mechanism in the 4WD position. Continuous use while the light is in the differential gear case, the light may overheat if...
Owners Manual
Page 28
... more than thirty minutes. Start switch " " " EBU00735 Light switch Turn the switch to the " " position to " ". If this should happen, remove the battery and recharge it. Engine stop switch is in an emergency. EBU00849 1. EBU00053 Handlebar switches CAUTION: Do not use the headlight with the engine turned off the headlight and the taillight. 4-6 Engine stop switch " "/" " Make sure that the starter motor will not start or run when the engine stop switch " "/" 3.
... more than thirty minutes. Start switch " " " EBU00735 Light switch Turn the switch to the " " position to " ". If this should happen, remove the battery and recharge it. Engine stop switch is in an emergency. EBU00849 1. EBU00053 Handlebar switches CAUTION: Do not use the headlight with the engine turned off the headlight and the taillight. 4-6 Engine stop switch " "/" " Make sure that the starter motor will not start or run when the engine stop switch " "/" 3.
Owners Manual
Page 31
... a Yamaha dealer if you start the engine. EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will return to an idle any time the hand is removed from the throttle lever. This could be sure it returns to the idle position as soon as the lever is spring-loaded, the machine will decelerate, and the engine will increase the engine speed...
... a Yamaha dealer if you start the engine. EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will return to an idle any time the hand is removed from the throttle lever. This could be sure it returns to the idle position as soon as the lever is spring-loaded, the machine will decelerate, and the engine will increase the engine speed...
Owners Manual
Page 47
... brakes at slow speed after starting out to an accident. Apply the brakes firmly for wear. (See pages 8-36 ~ 8-37.) WARNING POTENTIAL HAZARD Riding with the brakes. If there is leaking out of every ride. If the brakes do not provide proper braking performance, inspect the brake pads for one minute. If a problem cannot be corrected by the adjustment procedures provided in this manual...
... brakes at slow speed after starting out to an accident. Apply the brakes firmly for wear. (See pages 8-36 ~ 8-37.) WARNING POTENTIAL HAZARD Riding with the brakes. If there is leaking out of every ride. If the brakes do not provide proper braking performance, inspect the brake pads for one minute. If a problem cannot be corrected by the adjustment procedures provided in this manual...
Owners Manual
Page 52
...; 10-12 Type KT123 KT127 5-8 HOW TO AVOID THE HAZARD 1. EBU00153 Tires WARNING POTENTIAL HAZARD Operating this ATV with improper or uneven tire pressure. EBU00152 EBU00157 Fittings and Fasteners Always check the tightness of the headlight switch, engine stop switch and any other switches. Other tire combinations are in working condition. ACE-01E Lights Check the headlight and taillight to the Service Manual for proper operation.
...; 10-12 Type KT123 KT127 5-8 HOW TO AVOID THE HAZARD 1. EBU00153 Tires WARNING POTENTIAL HAZARD Operating this ATV with improper or uneven tire pressure. EBU00152 EBU00157 Fittings and Fasteners Always check the tightness of the headlight switch, engine stop switch and any other switches. Other tire combinations are in working condition. ACE-01E Lights Check the headlight and taillight to the Service Manual for proper operation.
Owners Manual
Page 56
... the rear brake lever. 2. Turn the main switch to "ON" and the engine stop switch to "ON". 3. If there is a control or function you begin riding. 1. Turn the fuel cock to " ". 4. HOW TO AVOID THE HAZARD Read the Owner's Manual carefully. Shift the drive select lever into the neutral or park position. EBU00161 EBU00672 OPERATION WARNING Indicates a potential hazard that could result in cold weather. Starting a cold engine WARNING POTENTIAL...
... the rear brake lever. 2. Turn the main switch to "ON" and the engine stop switch to "ON". 3. If there is a control or function you begin riding. 1. Turn the fuel cock to " ". 4. HOW TO AVOID THE HAZARD Read the Owner's Manual carefully. Shift the drive select lever into the neutral or park position. EBU00161 EBU00672 OPERATION WARNING Indicates a potential hazard that could result in cold weather. Starting a cold engine WARNING POTENTIAL...
Owners Manual
Page 57
... gear if the rear brake lever is applied. Fully open 1. However, it is in the neutral or park position, if either indicator light does not come on, ask a Yamaha dealer to inspect its electric circuit. NOTE: G When the drive select lever is recommended to shift into neutral or park before starting the engine. 5. G The engine can be started in reference to the figure: Position 1 : Cold engine...
... gear if the rear brake lever is applied. Fully open 1. However, it is in the neutral or park position, if either indicator light does not come on, ask a Yamaha dealer to inspect its electric circuit. NOTE: G When the drive select lever is recommended to shift into neutral or park before starting the engine. 5. G The engine can be started in reference to the figure: Position 1 : Cold engine...
Owners Manual
Page 60
... on until the ATV starts moving the drive select lever along the shift guide. 1. G Due to the synchronizing mechanism in reverse, the reverse indicator light should be shifted into or from reverse to the closed position. 2. Check behind for people or obstacles, then release the rear brake pedal. 6-5 Drive select lever NOTE: G When in the engine, the light may not come on...
... on until the ATV starts moving the drive select lever along the shift guide. 1. G Due to the synchronizing mechanism in reverse, the reverse indicator light should be shifted into or from reverse to the closed position. 2. Check behind for people or obstacles, then release the rear brake pedal. 6-5 Drive select lever NOTE: G When in the engine, the light may not come on...
Owners Manual
Page 112
...; Replace. • Clean. • Check oil level/oil leakage. • Replace every 12 months. • Check operation/fluid leakage/see NOTE page 8-4. • Correct if necessary. Every 20~40 hours (More often in wet or dusty areas.) ROUTINE 1 month EVERY 1 year 3 6 6 months months months Spark plug Air filter Carburetor* Crankcase breather system* Exhaust system* Spark arrester Fuel line* Engine oil Engine oil filter cartridge Engine oil strainer* Final gear oil Differential gear oil Front brake...
...; Replace. • Clean. • Check oil level/oil leakage. • Replace every 12 months. • Check operation/fluid leakage/see NOTE page 8-4. • Correct if necessary. Every 20~40 hours (More often in wet or dusty areas.) ROUTINE 1 month EVERY 1 year 3 6 6 months months months Spark plug Air filter Carburetor* Crankcase breather system* Exhaust system* Spark arrester Fuel line* Engine oil Engine oil filter cartridge Engine oil strainer* Final gear oil Differential gear oil Front brake...
Owners Manual
Page 129
... the engine is low, remove panel D. (See pages 8-6 ~ 8-7 for panel removal and installation procedures.) 8-20 Install the panel. Coolant reservoir drain hose 2. Remove the coolant reservoir cap, and then add coolant or distilled water to raise it to the specified level. 4. Minimum level mark 1. Maximum level mark 3. EBU00771 Cooling system 1. The coolant level should be between the maximum and minimum marks. 3. Coolant reservoir capacity...
... the engine is low, remove panel D. (See pages 8-6 ~ 8-7 for panel removal and installation procedures.) 8-20 Install the panel. Coolant reservoir drain hose 2. Remove the coolant reservoir cap, and then add coolant or distilled water to raise it to the specified level. 4. Minimum level mark 1. Maximum level mark 3. EBU00771 Cooling system 1. The coolant level should be between the maximum and minimum marks. 3. Coolant reservoir capacity...
Owners Manual
Page 132
Coolant reservoir drain hose 5. Radiator cap 1. Remove the coolant reservoir cap. 7. Tightening torque: Coolant drain bolt: 10 Nm (1.0 m·kgf, 7 ft·lb) 8-23 Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 8. 1. Replace the coolant drain bolt washer if it is damaged, and then tighten the coolant drain bolt to the specified torque. After draining the coolant, thoroughly flush the cooling system with clean tap water. 9. Remove the radiator cap. 6.
Coolant reservoir drain hose 5. Radiator cap 1. Remove the coolant reservoir cap. 7. Tightening torque: Coolant drain bolt: 10 Nm (1.0 m·kgf, 7 ft·lb) 8-23 Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 8. 1. Replace the coolant drain bolt washer if it is damaged, and then tighten the coolant drain bolt to the specified torque. After draining the coolant, thoroughly flush the cooling system with clean tap water. 9. Remove the radiator cap. 6.
Owners Manual
Page 151
Adjusting the rear brake light switch The rear brake light switch, which could lead to an accident. To make the brake light come on earlier, turn the adjusting nut in place. G All air must be performed by the brake pedal and brake levers, is correct. To make the brake light come on just before braking takes effect. Remove panel B. (See page 8-8 for panel removal and installation procedures.) 2. WHAT CAN HAPPEN You...
Adjusting the rear brake light switch The rear brake light switch, which could lead to an accident. To make the brake light come on earlier, turn the adjusting nut in place. G All air must be performed by the brake pedal and brake levers, is correct. To make the brake light come on just before braking takes effect. Remove panel B. (See page 8-8 for panel removal and installation procedures.) 2. WHAT CAN HAPPEN You...
Owners Manual
Page 152
... to replace them. Operation of control cables becomes damaged. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Cables can result when the outer covering of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-43 Brake...
... to replace them. Operation of control cables becomes damaged. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Cables can result when the outer covering of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-43 Brake...
Owners Manual
Page 157
Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel drive fuse Signaling system fuse Spare fuse (× 3) 1. Fuse box Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Four-wheel drive fuse: Signaling system fuse: 8-48 30A 15A 10A 10A 3A 10A Spare fuse 1. 2. 3. 4. 5. 6. Main fuse 2. 1.
Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel drive fuse Signaling system fuse Spare fuse (× 3) 1. Fuse box Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Four-wheel drive fuse: Signaling system fuse: 8-48 30A 15A 10A 10A 3A 10A Spare fuse 1. 2. 3. 4. 5. 6. Main fuse 2. 1.
Owners Manual
Page 160
Headlight beam adjusting screw 8-51 Remove the nuts together with the bulb) by turning it counterclockwise. 1. Nut (× 2) 2. Tail/brake light bulb replacement 1. Remove the bulb holder (together with the washers. 1. Vertical adjustment: To raise the beam, turn the screw counterclockwise. To lower the beam, turn the adjusting screw clockwise. Tail/brake light unit 2. EBU00409 EBU00964 Headlight beam adjustment CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 1.
Headlight beam adjusting screw 8-51 Remove the nuts together with the bulb) by turning it counterclockwise. 1. Nut (× 2) 2. Tail/brake light bulb replacement 1. Remove the bulb holder (together with the washers. 1. Vertical adjustment: To raise the beam, turn the screw counterclockwise. To lower the beam, turn the adjusting screw clockwise. Tail/brake light unit 2. EBU00409 EBU00964 Headlight beam adjustment CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 1.
Owners Manual
Page 165
... hard-to prevent water entry. CAUTION: Excessive water pressure may be used. Rinse the machine off the end of wheel bearings, brakes, transmission seals and electrical devices. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of the dirt has been hosed off with warm water and mild...
... hard-to prevent water entry. CAUTION: Excessive water pressure may be used. Rinse the machine off the end of wheel bearings, brakes, transmission seals and electrical devices. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of the dirt has been hosed off with warm water and mild...