READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM400FV WARNING LIT-11626-19-08 This ATV should not be ridden by anyone under 16 years of age.
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EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00941 INTRODUCTION 1- Congratulations on your purchase of the Yamaha YFM400F. 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.
EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00801 IMPORTANT MANUAL INFORMATION 1- FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
EE.book Page 2 Thursday, March 31, 2005 2:01 PM EBU15000 IMPORTANT NOTICE 2- This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV 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 ATV.
EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1 2 SAFETY INFORMATION.................. 2-1 3 DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2 Key identification number................ 3-2 Vehicle identification number .......... 3-3 Model label ............................
EE.book Page 2 Thursday, March 31, 2005 2:01 PM Front shock absorber adjustment................................... 4-17 Rear shock absorber adjustment................................... 4-18 Auxiliary DC jack........................... 4-19 5 PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-3 Fuel ................................................. 5-5 Engine oil ........................................ 5-7 Final gear oil....................................
EE.book Page 3 Thursday, March 31, 2005 2:01 PM Crossing through shallow water.... 7-34 Riding over rough terrain............... 7-36 Sliding and skidding ...................... 7-38 What to do if .................................. 7-40 What to do ..................................... 7-40 8 PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1 Owner’s manual and tool kit............ 8-1 Periodic maintenance chart for the emission control system..........
EETOC.fm Page 4 Monday, April 4, 2005 8:47 AM Tail/brake light bulb replacement ................................ 8-44 Troubleshooting ............................ 8-46 Troubleshooting chart ................... 8-47 9 CLEANING AND STORAGE............ 9-1 A. Cleaning...................................... 9-1 B. Storage ....................................... 9-3 10 SPECIFICATIONS.......................... 10-1 11 NOISE REGULATION.................... 11-1 12 MAINTENANCE RECORD ............
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EE.book Page 2 Thursday, March 31, 2005 2:01 PM Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 1 2 3 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.
EE.book Page 3 Thursday, March 31, 2005 2:01 PM 3 5 WARNING MAXIMUM .LOADING LIMIT O ve r l o a d i n g t h i s AT V o r c a r r y i n g c a r g o i m p r o p e r l y c a n c h a n g e h a n d l i n g , s t a b i l i t y a n d b ra k i n g p e r fo r m a n c e a n d c a n l e a d t o a n a c c i d e n t . N eve r ex c e e d t h e m a x i mu m r e a r c a r g o l i m i t o f : 80kg (176 lbs) N E V E R s i t o n t h e c a r r i e r.
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EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU13351 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.
EE.book Page 2 Thursday, March 31, 2005 2:01 PM ● ● ● ● ● ● ● ● ● ● 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. 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.
EE.book Page 3 Thursday, March 31, 2005 2:01 PM ● ● ● ● ● 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. Always follow proper procedures for climbing hills as described in this manual.
EE.book Page 4 Thursday, March 31, 2005 2:01 PM ● ● ● ● ● 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.
EE.book Page 5 Thursday, March 31, 2005 2:01 PM ● ● ● ● 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.
EE.book Page 6 Thursday, March 31, 2005 2:01 PM WARNING 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.
EE.book Page 7 Thursday, March 31, 2005 2:01 PM WARNING 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.
EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1 2 3 4 5 6 7 1. Spark arrester 2. Rear carrier 3. Seat 4. Auxiliary DC jack 5. Front carrier 6. Brake pedal 7. Headlights 8. Fuel cock 9. Recoil starter 10. Tail/brake light 11. Rear wheel 12. Shift pedal 13. Front wheel 14. Rear brake lever 15. Parking brake lock plate 16. Starter (choke) 17. Speedometer 18. Reverse knob 19. On-Command four-wheel drive switch 20. Front brake lever 21. Throttle lever 22.
EE.book Page 2 Thursday, March 31, 2005 2:01 PM EBU00600 EBU00035 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: Key identification number The key identification number is stamped on the key as shown in the following illustration.
EE.book Page 3 Thursday, March 31, 2005 2:01 PM EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. 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. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 1.
EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00039 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.
EE.book Page 2 Thursday, March 31, 2005 2:01 PM EBU00802 EBU01140 Indicator and warning lights Oil temperature warning light “ ” When the oil temperature reaches a specified level, this light comes on to warn that the engine oil 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: 1 2 3 4 5 _ ● 1. 2. 3. 4.
EE.book Page 3 Thursday, March 31, 2005 2:01 PM EBU00733 Oil temperature warning light checking method ACB-10E Turn the main switch to “ON” and the engine stop switch to “ ”. Oil temperature warning light does not come on. Oil temperature warning light comes on. Push start switch with the transmission in neutral. Check engine oil temperature. Oil temperature warning light comes on momentarily. Oil temperature warning light does not come on. Oil temperature is low. Oil temperature is high.
EE.book Page 4 Thursday, March 31, 2005 2:01 PM EBU00051 EBU00052 Speedometer The speedometer shows riding speed. This speedometer is equipped with an odometer and trip odometer. The trip odometer can be reset to “0” with the reset knob. Use the trip odometer to estimate how far you can ride on a tank of fuel before going to reserve. This information will enable you to plan fuel stops in the future. Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank.
EE.book Page 5 Thursday, March 31, 2005 2:01 PM EBU00053 EBU00607 Handlebar switches 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.) _ 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.
EE.book Page 6 Thursday, March 31, 2005 2:01 PM EBU00601 On-Command four-wheel drive switch “2WD/4WD” To change from two-wheel drive (2WD) to four-wheel drive (4WD), stop the ATV and set the switch to the 4WD position. To change from four-wheel drive (4WD) to two-wheel drive (2WD), stop the ATV and set the switch to the 2WD position. WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving.
EE.book Page 7 Thursday, March 31, 2005 2:01 PM 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. Before starting the engine, check the throttle to be sure it is operating smoothly.
EE.book Page 8 Thursday, March 31, 2005 2:01 PM EBU11590 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. WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result.
EE.book Page 9 Thursday, March 31, 2005 2:01 PM 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. Brake pedal 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.
EE.book Page 10 Thursday, March 31, 2005 2:01 PM EBU00074 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine.
EE.book Page 11 Thursday, March 31, 2005 2:01 PM EBU00084 EBU01028 Shift pedal This machine is equipped with a constantmesh 5-speed forward and 1-speed reverse transmission. The shift pedal is located on the left side of the engine. Reverse is at the bottom position. Neutral is one position above reverse. Reverse knob “REV” The reverse knob is used to shift into reverse gear. Refer to the “Reverse knob operation and reverse driving” section (page 6-4) before operating this machine in reverse gear. 1.
EE.book Page 12 Thursday, March 31, 2005 2:01 PM EBU00590 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. WARNING POTENTIAL HAZARD Starting the engine in gear and/or starting the engine without setting the parking brake. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident.
EE.book Page 13 Thursday, March 31, 2005 2:01 PM EBU00092 EBU00093 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 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.
EE.book Page 14 Thursday, March 31, 2005 2:01 PM 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 pages 6-1–6-3.) 1.
EE.book Page 15 Thursday, March 31, 2005 2:01 PM EBU00567 Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. 1. Seat holder (× 2) 1. 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. 4-15 2.
EE.book Page 16 Thursday, March 31, 2005 2:01 PM EBU00581 EBU00582 Storage box Front carrier Maximum load limit: 2.0 kg (4.4 lb) Maximum load limit: 40 kg (88 lb) CAUTION: EBU00583 To protect from damage, do not put metal products, like tools or sharply edged products directly in the storage box. If they must be stored, wrap them in appropriate cushion material.
EE.book Page 17 Thursday, March 31, 2005 2:01 PM EBU01104 Front shock absorber adjustment The spring preload can be adjusted to suit the rider’s 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. Standard position: B A - Minimum (soft) E - Maximum (hard) 1. Special wrench 1. Spring preload adjusting ring 2.
EE.book Page 18 Thursday, March 31, 2005 2:01 PM EBU01103 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s 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. WARNING POTENTIAL HAZARD Improper shock absorber adjustment.
EE.book Page 19 Thursday, March 31, 2005 2:01 PM EBU01002 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”. 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.
EE.book Page 20 Thursday, March 31, 2005 2:01 PM CAUTION: _ ● ● 1. Auxiliary DC jack 2. Auxiliary DC jack cap ● 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.
EE.book Page 1 Thursday, March 31, 2005 2:01 PM PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Front brake • Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. 5-3–5-4, 8-25–8-28 Rear brake • Check operation, condition and free play. • Adjust if necessary. Fuel • Check fuel level. • Fill with fuel if necessary. Engine oil • Check oil level. • Fill with oil if necessary.
EE.book Page 2 Thursday, March 31, 2005 2:01 PM WARNING 1 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 Owner’s Manual.
EE.book Page 3 Thursday, March 31, 2005 2:01 PM EBU12521 Brake fluid leakage (front brake) Check to see if any brake fluid is leaking out of the hose, joint or brake fluid reservoir of the front brake. Apply the brake 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. Front and rear brakes Brake levers and brake pedal ● Check for correct free play in the front brake lever.
EE.book Page 4 Thursday, March 31, 2005 2:01 PM WARNING 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.
EE.book Page 5 Thursday, March 31, 2005 2:01 PM EBU01085 Fuel Make sure there is sufficient gasoline in the tank. 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.
EE.book Page 6 Thursday, March 31, 2005 2:01 PM 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 WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury.
EE.book Page 7 Thursday, March 31, 2005 2:01 PM EBU10842 EBU00493 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-6– 8-10.) Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-11– 8-13 for details.) CAUTION: Recommended oil: SAE 80 API GL-4 Hypoid gear oil _ ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
EE.book Page 8 Thursday, March 31, 2005 2:01 PM EBU00678 EBU10030 Differential gear oil Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-14–8-16 for details.) Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation. Recommended oil: SAE 80 API GL-4 Hypoid gear oil EBU11700 Switches Check the operation of all switches.
EE.book Page 9 Thursday, March 31, 2005 2:01 PM EBU00157 Tires 2. The tires should be set to the recommended pressure: ● Recommended tire pressure Front 25 kPa (0.25 kgf/cm2, 3.6 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) ● Check and adjust tire pressures when 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/cm2, 3.
EE.book Page 10 Thursday, March 31, 2005 2:01 PM 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 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.
EE.book Page 11 Thursday, March 31, 2005 2:01 PM 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: Recommended pressure Minimum Maximum Front 25 kPa (0.25 kgf/cm2, 3.6 psi) 22 kPa (0.
EE.book Page 12 Thursday, March 31, 2005 2:01 PM EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a.
EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00161 EBU00749 OPERATION Starting a cold engine WARNING WARNING 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. Indicates a potential hazard that could result in serious injury or death.
EE.book Page 2 Thursday, March 31, 2005 2:01 PM Position 3: Cold engine start- ambient temperature above 25 °C (80 °F) and warm engine start position. NOTE: ● When the transmission is in neutral, the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. ● The engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral before starting the engine. _ 1 2 3 4 5 6 _ 7 5.
EE.book Page 3 Thursday, March 31, 2005 2:01 PM 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. CAUTION: _ _ See the “Engine break-in” section prior to operating the engine for the first time.
EE.book Page 4 Thursday, March 31, 2005 2:01 PM EBU01952 Reverse knob operation and reverse driving 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 ATV. _ CAUTION: _ Before shifting, stop the ATV and return the throttle lever to its closed position. Otherwise the transmission may be damaged. _ 4. Check behind you for people or obstacles, then release the brake. 5.
EE.book Page 5 Thursday, March 31, 2005 2:01 PM EBU12951 Shifting This model has a 5-speed forward and 1-speed reverse transmission with centrifugal automatic clutch. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to the closed position and repeatedly depress the shift pedal until it stops.
EE.book Page 6 Thursday, March 31, 2005 2:01 PM EBU00207 To decelerate: When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident. 4. Once the machine has attained adequate speed, release the throttle lever. 5.
EE.book Page 7 Thursday, March 31, 2005 2:01 PM EBU02092 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.
EE.book Page 8 Thursday, March 31, 2005 2:01 PM EBU02111 10–20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throttle at any time. Parking When parking, stop the engine and shift into first gear. Turn the fuel cock to “OFF” and apply the parking brake. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally. 1.
EE.book Page 9 Thursday, March 31, 2005 2:01 PM EBU12960 Parking on a slope 1. Bring the ATV to a stop by applying the brakes in low gear. 2. Stop the engine. 3. With the rear brake lever and pedal applied, apply the parking brake and slowly release the brake pedal. WARNING 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.
EE.book Page 10 Thursday, March 31, 2005 2:01 PM 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.
EE.book Page 11 Thursday, March 31, 2005 2:01 PM EBU05881 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.
EE.book Page 12 Thursday, March 31, 2005 2:01 PM ● ● ● ● 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 2nd gear 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.
EE.book Page 13 Thursday, March 31, 2005 2:01 PM EBU13451 WARNING _ Indicates a potential hazard that could result in serious injury or death.
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EE.book Page 3 Thursday, March 31, 2005 2:01 PM 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.
EE.book Page 4 Thursday, March 31, 2005 2:01 PM RIDE WITH CARE AND GOOD JUDGEMENT 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 Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Get training if you are inexperienced.
EE.book Page 5 Thursday, March 31, 2005 2:01 PM Not recommended for children under 16 years of age. WARNING 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.
EE.book Page 6 Thursday, March 31, 2005 2:01 PM This ATV is designed to carry operator and cargo only – passengers prohibited. WARNING 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.
EE.book Page 7 Thursday, March 31, 2005 2:01 PM Apparel 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 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
EE.book Page 8 Thursday, March 31, 2005 2:01 PM Do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. WARNING 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.
EE.book Page 9 Thursday, March 31, 2005 2:01 PM Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. WARNING 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.
EE.book Page 10 Thursday, March 31, 2005 2:01 PM 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 the adjusting screw in 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.
EE.book Page 11 Thursday, March 31, 2005 2:01 PM Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads. WARNING 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.
EE.book Page 12 Thursday, March 31, 2005 2:01 PM During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING 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.
EE.book Page 13 Thursday, March 31, 2005 2:01 PM Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING 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. Don’t try to show off.
EE.book Page 14 Thursday, March 31, 2005 2:01 PM Modifications WARNING 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.
EE.book Page 15 Thursday, March 31, 2005 2:01 PM 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. WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire.
EE.book Page 16 Thursday, March 31, 2005 2:01 PM BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING 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.
EE.book Page 17 Thursday, March 31, 2005 2:01 PM Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING 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.
EE.book Page 18 Thursday, March 31, 2005 2:01 PM Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING 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.
EE.book Page 19 Thursday, March 31, 2005 2:01 PM WARNING 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.
EE.book Page 20 Thursday, March 31, 2005 2:01 PM 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. 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”.
EE.book Page 21 Thursday, March 31, 2005 2:01 PM With the engine idling, lift the shift pedal to the 1st gear position and then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. Once the ATV has attained adequate speed, release the throttle and lift the shift pedal to the 2nd gear position. Release the shift pedal and apply the throttle smoothly. Use this same procedure as you move into the higher gears.
EE.book Page 22 Thursday, March 31, 2005 2:01 PM CAUTION: WARNING _ Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear.
EE.book Page 23 Thursday, March 31, 2005 2:01 PM TURNING YOUR ATV To achieve maximum traction while riding offroad, the two rear wheels are mounted solidly on one axle and 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 that this skill be learned first at low speed.
EE.book Page 24 Thursday, March 31, 2005 2:01 PM 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.
EE.book Page 25 Thursday, March 31, 2005 2:01 PM 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.
EE.book Page 26 Thursday, March 31, 2005 2:01 PM WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 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 Owner’s Manual. Always check the terrain carefully before you start up any hill.
EE.book Page 27 Thursday, March 31, 2005 2:01 PM 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. When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
EE.book Page 28 Thursday, March 31, 2005 2:01 PM 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.
EE.book Page 29 Thursday, March 31, 2005 2:01 PM Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s Manual. If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. When fully stopped, apply the rear brake as well, and then lock the parking brake. 4WD: Apply both front and rear brakes gradually.
EE.book Page 30 Thursday, March 31, 2005 2:01 PM RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, change to 4WD before beginning to descend the hill and choose a low gear which will allow the engine compression to do most of the braking for you.
EE.book Page 31 Thursday, March 31, 2005 2:01 PM WARNING POTENTIAL HAZARD Going down a hill 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 going down hills as described in this Owner’s Manual. Note: a special technique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.
EE.book Page 32 Thursday, March 31, 2005 2:01 PM CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path.
EE.book Page 33 Thursday, March 31, 2005 2:01 PM When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
EE.book Page 34 Thursday, March 31, 2005 2:01 PM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
EE.book Page 35 Thursday, March 31, 2005 2:01 PM Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. _ 1.
EE.book Page 36 Thursday, March 31, 2005 2:01 PM RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision.
EE.book Page 38 Thursday, March 31, 2005 2:01 PM SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.
EE.book Page 39 Thursday, March 31, 2005 2:01 PM With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
EE.book Page 40 Thursday, March 31, 2005 2:01 PM WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. ● WHAT TO DO ... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-23–7-24.
EE.book Page 41 Thursday, March 31, 2005 2:01 PM ● ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32– 7-33.
EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Have a Yamaha dealer perform service if you are not familiar with machine service. Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.
EE.book Page 2 Thursday, March 31, 2005 2:01 PM WARNING 1. Owner’s tool kit 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.
EE.book Page 3 Thursday, March 31, 2005 2:01 PM EBU15731 Periodic maintenance chart for the emission control system NOTE: _ ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
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EE.book Page 5 Thursday, March 31, 2005 2:01 PM ITEM Axle boots* Fittings and fasteners* Lights and switches* Whichever month comes first km (mi) hours ROUTINE • • • • • • 1 320 (200) 20 INITIAL 3 1,300 (800) 80 6 2,500 (1,600) 160 EVERY 6 12 2,500 5,000 (1,600) (3,200) 160 320 Check operation. Replace if damaged. Check all chassis fittings and fasteners. Correct if necessary. Check operation. Adjust headlight beams.
EE.book Page 6 Thursday, March 31, 2005 2:01 PM EBU11812 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes, and then turn it off. 3. Wait a few minutes until the oil level settles before checking. 4.
EE.book Page 7 Thursday, March 31, 2005 2:01 PM NOTE: The oil level should be between the minimum and maximum level marks. To change the engine oil (with or without oil filter element cleaning) 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes, and then turn it off. 3. Place a container under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase. _ _ 5.
EE.book Page 8 Thursday, March 31, 2005 2:01 PM 6. Clean the oil strainer and oil filter element with solvent. 7. Check the O-ring for damage and replace it if necessary. CAUTION: _ When removing the engine oil drain bolt, the compression spring, oil strainer and O-ring will fall out. Take care not to lose these parts. _ NOTE: Skip steps 5–9 if the oil filter element is not being cleaned. _ _ 5. Remove the oil filter cover by removing the bolts, and then remove the oil filter element. 1. O-ring 2.
EE.book Page 9 Thursday, March 31, 2005 2:01 PM 9. Install the oil filter cover by installing the bolts, and then tighten them to the specified torque. 11. Add the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap. Tightening torque: Oil filter cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Recommended oil: See page 10-2. Oil quantity: Without oil filter element replacement: 2.90 L (2.55 Imp qt, 3.07 US qt) With oil filter element replacement: 3.00 L (2.
EE.book Page 10 Thursday, March 31, 2005 2:01 PM 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 enters the crankcase. _ 12.
EE.book Page 11 Thursday, March 31, 2005 2:01 PM EBU11453 Final gear oil Checking the final gear oil 1. Place the ATV on a level surface. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. NOTE: The oil level should be at the brim of the filler hole. _ _ 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 1. Final gear oil 3. Final gear oil filler bolt 2. Correct oil level 4.
EE.book Page 12 Thursday, March 31, 2005 2:01 PM Replacing the final gear oil 1. Remove the final gear case cover by removing the bolts. 1. Final gear case cover 2. Place the ATV on a level surface. 3. Place a container under the final gear case to collect the used oil. 4. Remove the oil filler bolt and the drain bolt to drain the oil. 2. Bolt (× 2) 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque.
EE.book Page 13 Thursday, March 31, 2005 2:01 PM 6. Add the recommended final gear oil to the brim of the filler hole. Tightening torque: Final gear case cover bolt: 17 Nm (1.7 m·kgf, 13 ft·lbf) Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.23 L (0.20 Imp qt, 0.24 US qt) CAUTION: _ Be sure no foreign material enters the final gear case. _ 7. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 23 Nm (2.
EE.book Page 14 Thursday, March 31, 2005 2:01 PM EBU07063 Differential gear oil Checking the differential gear oil 1. Place the ATV on a level surface. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to the brim of the filler hole. If the level is low, add sufficient oil of the recommended type to raise it to the specified level. CAUTION: _ 1. Differential gear oil filler bolt 2. Correct oil level 3.
EE.book Page 15 Thursday, March 31, 2005 2:01 PM Replacing the differential gear oil 1. Place the ATV on a level surface. 2. Place a container under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil. 4. Install the differential gear oil drain bolt and tighten it to the specified torque. Tightening torque: Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7 ft·lbf) 5.
EE.book Page 16 Thursday, March 31, 2005 2:01 PM EBU00862 6. Install the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. 7. Check for oil leakage. If oil leakage is found, check for the cause. 1. Axle boot (× 2) 8-16 1.
EE.book Page 17 Thursday, March 31, 2005 2:01 PM EBU11820 Spark plug inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer.
EE.book Page 18 Thursday, March 31, 2005 2:01 PM EBU13011 Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. _ _ 1. Air filter case cover 2. Holder (× 3) 3. Pull the air filter element out. 1. Check hose 1. Remove the seat. (See page 4-15 for seat removal and installation procedures.) 2. Remove the air filter case cover by unhooking the holders. 1.
EE.book Page 19 Thursday, March 31, 2005 2:01 PM 4. Remove the foam cover from the air filter element. 1. Air filter element WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the foam cover. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the foam cover. 6. Squeeze the excess water or solvent out of the foam cover and let it dry. 2. Foam cover 5.
EE.book Page 20 Thursday, March 31, 2005 2:01 PM 7. Tap the element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown. If the air filter element is damaged, replace it. 8. Install the foam cover onto the air filter element. 9. Install the air filter element. 10. Install the air filter case cover by fastening the holders. 11. Install the seat. NOTE: The air filter element should be cleaned every 20–40 hours.
EE.book Page 21 Thursday, March 31, 2005 2:01 PM EBU00754 Spark arrester cleaning Select a well-ventilated area free of combustible materials and make sure the exhaust pipe and muffler are cool. 1. Remove the purging bolt. CAUTION: _ Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage.
EE.book Page 22 Thursday, March 31, 2005 2:01 PM EBU00296 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine. WARNING POTENTIAL HAZARD Improperly purging the exhaust system. Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes.
EE.book Page 23 Thursday, March 31, 2005 2:01 PM EBU13020 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. _ _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw.
EE.book Page 24 Thursday, March 31, 2005 2:01 PM EBU00303 EBU00307 Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2.
EE.book Page 25 Thursday, March 31, 2005 2:01 PM EBU13031 EBU00313 Front brake pad check Inspect the brake pads for damage and wear. If the brake pad thickness is less than 1 mm (0.04 in), have a Yamaha dealer replace the pads as a set. Rear brake shoe inspection A wear indicator is provided on the rear brake. This indicator allows checking of brake shoe wear without disassembling the brake. Apply the rear brake and check the position of the indicator.
EE.book Page 26 Thursday, March 31, 2005 2:01 PM EBU13040 Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.
EE.book Page 27 Thursday, March 31, 2005 2:01 PM EBU11860 ● ● Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. ● Replace the oil seals every two years. ● Replace the brake hoses every four years. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
EE.book Page 28 Thursday, March 31, 2005 2:01 PM EBU11870 Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer check the brake system. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: sure the brakes operate ● Make smoothly and that the free play is correct.
EE.book Page 29 Thursday, March 31, 2005 2:01 PM EBU13052 Brake pedal and rear brake lever adjustment Brake pedal free play adjustment 1. Fully loosen the adjusting nut on the brake cable. 2. Turn the adjusting nut on the brake rod until the free play is 20–30 mm (0.79– 1.18 in). a. Brake pedal free play 1. Adjusting nut (brake cable) 2.
EE.book Page 30 Thursday, March 31, 2005 2:01 PM Brake lever free play adjustment 1. Loosen the locknut and fully turn in the adjusting bolt at the brake lever. 1. Locknut 2. Turn in the adjusting nut on brake cable to provide a gap of 0–1 mm (0–0.04 in) between the camshaft lever and the pin. 2. Adjusting bolt 1. Adjusting nut (brake cable) 8-30 a.
EE.book Page 31 Thursday, March 31, 2005 2:01 PM 3. Turn the adjusting bolt until the free play at the brake lever pivot is 5–7 mm (0.20– 0.28 in). WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag.
EE.book Page 32 Thursday, March 31, 2005 2:01 PM EBU00834 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and brake levers, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction a.
EE.book Page 33 Thursday, March 31, 2005 2:01 PM EBU00346 Clutch adjustment 1. Loosen the locknut. 2. Slowly turn the adjusting bolt counterclockwise until resistance is felt. Then, turn it 1/8 turn clockwise. 1. Locknut 3. Tighten the locknut to specification. Tightening torque: 20 Nm (2.0 m·kgf, 15 ft·lbf) NOTE: Turn the adjusting bolt counterclockwise to decrease the clutch free play and turn it clockwise to increase the free play. 2.
EE.book Page 34 Thursday, March 31, 2005 2:01 PM EBU00356 Cable inspection and lubrication Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury.
EE.book Page 35 Thursday, March 31, 2005 2:01 PM EBU01112 EBU11211 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Wheel installation 1. Install the wheel and the nuts. NOTE: ● The arrow mark on the tire must point toward the rotating direction of the wheel. ● Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. _ _ 1.
EE.book Page 36 Thursday, March 31, 2005 2:01 PM 1. Tapered nut 2. Lower the ATV so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 64 Nm (6.4 m·kgf, 46 ft·lbf) Rear: 55 Nm (5.
EE.book Page 37 Thursday, March 31, 2005 2:01 PM EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water.
EE.book Page 38 Thursday, March 31, 2005 2:01 PM EBU00385 Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. CAUTION: A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type battery. Using a conventional battery charger may shorten the battery life. 2.
EE.book Page 39 Thursday, March 31, 2005 2:01 PM EBU00853 Fuse replacement 1. The main fuse case and the fuse box are located under the seat. 2. If a fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches. If the fuse immediately blows again, consult a Yamaha dealer. Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Carburetor warmer fuse: Four-wheel-drive fuse: 1. Main fuse 30 A 15 A 10 A 10 A 10 A 3A 2.
EE.book Page 40 Thursday, March 31, 2005 2:01 PM WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse. CAUTION: _ To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse.
EE.book Page 41 Thursday, March 31, 2005 2:01 PM EBU15961 Replacing a headlight bulb If a headlight bulb burns out, replace the bulb as follows. 1. Disconnect the coupler shown. 2. Remove the headlight assembly by removing the screws. 1. Screw (× 3) 4. Disconnect the headlight coupler by lifting the tab as shown and pulling out the coupler. 1. Screw (× 2) 2. Coupler 3. Remove the headlight unit from the headlight assembly by removing the screws. 8-41 1.
EE.book Page 42 Thursday, March 31, 2005 2:01 PM 5. Remove the headlight bulb holder assembly by turning it counterclockwise. WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. 1. Headlight bulb holder assembly 6.
EE.book Page 43 Thursday, March 31, 2005 2:01 PM 8. Place the headlight unit in the original position, and then install the screws. 9. Place the headlight assembly in the original position, and then install the screws. 10. Connect the coupler which was disconnected in step “1”. 11. Adjust the headlight beam if necessary. 1. Do not touch the glass part of the bulb.
EE.book Page 44 Thursday, March 31, 2005 2:01 PM EBU01089 EBU09452 Headlight beam adjustment Tail/brake light bulb replacement 1. Open the storage box. (See page 4-16.) 2. Remove the nuts together with the washers. CAUTION: _ It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. 1. Storage box 2. Nut (× 2) 3.
EE.book Page 45 Thursday, March 31, 2005 2:01 PM 1. Bulb holder 1. Bulb holder 4. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 2. Bulb 5. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 6. Install the bulb holder (together with the bulb) by turning it clockwise. 7. Install the washers, and then install the nuts. 8. Close the storage box.
EE.book Page 46 Thursday, March 31, 2005 2:01 PM EBU00412 Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer.
EE.book Page 47 Thursday, March 31, 2005 2:01 PM EBU00440 Troubleshooting chart Turn the fuel cock lever to “ON”. There is fuel. Turn the fuel cock lever to “OFF”. Remove the fuel hose from the fuel cock. Some fuel. Turn the fuel cock lever to “RES”. Restart the engine. No fuel. Supply fuel. 1. Fuel Check if there is fuel in the fuel tank. 2. Compression Use the electric starter to see if there is compression. 3. Ignition There is compression. Compression normal. No compression.
EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00419 CLEANING AND STORAGE CAUTION: 1- Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A.
EE.book Page 2 Thursday, March 31, 2005 2:01 PM 6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. WARNING POTENTIAL HAZARD Operation with wet brakes after washing.
EE.book Page 3 Thursday, March 31, 2005 2:01 PM EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product. 2.
EE.book Page 4 Thursday, March 31, 2005 2:01 PM 7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine.
EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00428 SPECIFICATIONS 1 MODEL YFM400F Dimension: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turning radius 2,007 mm ( 79.0 in) 1,111 mm ( 43.7 in) 1,172 mm ( 46.1 in) 855 mm ( 33.7 in) 1,230 mm ( 48.4 in) 245 mm ( 9.65 in) 3,150 mm (124.
EE.book Page 2 Thursday, March 31, 2005 2:01 PM MODEL YFM400F Engine oil: Type 0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20˚ Recommended engine oil classification: -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
EE.book Page 3 Thursday, March 31, 2005 2:01 PM MODEL YFM400F Final gear oil: Type Quantity SAE 80 API GL-4 Hypoid gear oil 0.23 L (0.20 lmp qt, 0.24 US qt) Differential gear oil: Type Quantity SAE 80 API GL-4 Hypoid gear oil 0.35 L (0.31 Imp qt, 0.37 US qt) Air filter: Dry element Fuel: Type Tank capacity Reserve amount UNLEADED GASOLINE ONLY 15.0 L (3.30 Imp gal, 3.96 US gal) 4.0 L (0.88 Imp gal, 1.
EE.book Page 4 Thursday, March 31, 2005 2:01 PM MODEL Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear raito: YFM400F Spur gear 76/24 (3.166) Shaft drive 28/24 × 24/18 × 33/09 (5.703) Constant mesh 5-speed forward, 1-speed reverse Left foot operation 40/12 (3.333) 34/18 (1.888) 30/22 (1.363) 25/26 (0.961) 19/27 (0.703) 22/17 × 35/15 (3.
EE.book Page 5 Thursday, March 31, 2005 2:01 PM MODEL YFM400F Suspension: Front Rear Double wishbone Swingarm (monocross) Shock absorber: Front Rear Coil spring / oil damper Coil spring / oil damper Wheel travel: Front wheel travel Rear wheel travel 150 mm (5.91 in) 150 mm (5.91 in) Electrical: Ignition system Generator system Battery type/voltage, capacity DC. C.D.I. A.C.
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EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU15740 1- MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00432 YAMAHA MOTOR CORPORATION, U.S.A.
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EE.book Page 1 Thursday, March 31, 2005 2:01 PM EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.
EE.book Page 2 Thursday, March 31, 2005 2:01 PM 1 2 3 4 5 6 7 8 9 10 9 9 9 EBU00436 14 WARNING Indicates a potential hazard that could result in serious injury or death.
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EBU00438 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.
