2-8
Drive Chain
Drive chain condition and adjustment should be
inspected each day before the ATV is operated.
Always follow the following guidelines for inspecting
and servicing the drive chain.
INSPECTING
Inspect the drive chain for any of the following condi-
tions.
A. Loose pins.
B. Loose or cracked rollers.
C. Dry or rusted links.
D. Kinked or binding links.
E. Excessive wear.
The presence of any of the conditions requires drive
chain replacement.
NOTE: If the drive chain is worn or damaged, the
sprockets may also be worn or damaged. Inspect
the sprockets for worn, broken, or damaged teeth.
Always inspect the sprockets when a new drive
chain is being installed.
CLEANING AND LUBRICATING
The drive chain should be cleaned and lubricated fre-
quently to prolong chain and sprocket life. Use the fol-
lowing procedure to clean and lubricate the chain.
NOTE: This ATV is equipped with an O-ring type
roller chain. Each link incorporates small O-rings
to seal out water and dirt. Care should be taken to
choose cleaning solutions and lubricants that are
suitable for O-ring type chains.
1. Using a suitable, nonflammable cleaning solution,
thoroughly wash the chain and sprockets.
2. Allow the chain to dry; then apply a dry, graph-
ite-based lubricant to the chain.
NOTE: The drive chain should be lubricated with
a dry, graphite-based chain lubricant. By using a
dry, graphite-based chain lubricant, dirt build-up
on the drive chain will be minimized.
ADJUSTING TENSION
1. Loosen the four cap screws (1) on the axle hous-
ing; then loosen the nuts (2) on the adjuster bolt.
TR018A
2. Adjust the chain slack using the nuts on the
adjuster bolt to obtain 10-20 mm movement at the
mid-point of the chain.
3. Tighten the four cap screws to 50 ft-lb and the nuts
on the adjuster bolt securely.
Headlight/Taillight-
Brakelight
Each time the ATV is used, lights should be checked
for proper function. Turn the ignition switch to the
LIGHTS position; the headlights and taillight should
illuminate. Test the brakelight by compressing the
brake lever. The brakelight should illuminate.
HEADLIGHT
NOTE: The bulb portion of the headlight is frag-
ile. HANDLE WITH CARE. When replacing the
headlight bulb, do not touch the glass portion of
the bulb. If the glass is touched, it must be cleaned
with a dry cloth before installing. Skin oil residue
on the bulb will shorten the life of the bulb.
To replace the headlight bulb, use the following proce-
dure.
1. Remove the boot from the back of the headlight
housing; then remove the three-wire connector
from the bulb.
2. Using care not to bend or deform the spring clip,
release the two ends of the spring clip from the
light housing; then remove the bulb from the head-
light housing.
! WARNING
Failure to inspect and maintain the drive chain can be
hazardous. Operating the ATV with the drive chain in
poor condition or improperly adjusted can cause an
accident resulting in possible injury.
! WARNING
Do not attempt to remove the bulb when it is hot.
Severe burns may result.
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