Yamaha BIG BEAR 400 Owner'S Manual Download Page 128

Page: 128 / 176

8-19

4. Remove the foam cover from the air filter

element.

1. Air filter element

2. Foam cover

5. 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.

6. Wash the foam cover gently but thor-

oughly in water or solvent.

U5FU15.book Page 19 Thursday, April 8, 2004 1:29 PM

Summary of Contents for BIG BEAR 400

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Page 3: ...nformation It provides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV ...

Page 4: ...mbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer ...

Page 5: ...ise level and spark arrester laws and regu lations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU01067 AFFIX DEALER LABEL HERE YFM400FT OWNER S MANUAL 2004 by Yamaha Motor Corporation U S A 1st edition April 2004 All rights reserved Any reprinting or unauthorized use without the written permission of U5FU15 book Page 2 Thursda...

Page 6: ...ntification number 3 2 Vehicle identification number 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator and warning lights 4 2 Speedometer 4 4 Fuel gauge 4 4 Handlebar switches 4 5 Throttle lever 4 7 Speed limiter 4 8 Front brake lever 4 9 Brake pedal and rear brake lever 4 9 Parking brake 4 10 Shift pedal 4 11 Reverse knob 4 11 Recoil starter 4 12 Fuel tank cap 4 13 Fuel cock 4 13 Starter ...

Page 7: ...Switches 5 8 Tires 5 9 How to measure tire pressure 5 11 OPERATION 6 1 Starting a cold engine 6 1 Starting a warm engine 6 3 Warming up 6 3 Reverse knob operation and reverse driving 6 4 Shifting 6 5 To start out and accelerate 6 5 To decelerate 6 6 Engine break in 6 7 Parking 6 8 Parking on a slope 6 9 Accessories and loading 6 10 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care an...

Page 8: ...lter element cleaning 8 18 Spark arrester cleaning 8 21 Throttle lever adjustment 8 24 Front brake pad check 8 25 Rear brake shoe inspection 8 25 Brake fluid level check 8 26 Brake fluid replacement 8 27 Front brake lever free play 8 28 Brake pedal and rear brake lever adjustment 8 29 Adjusting the rear brake light switch 8 32 Clutch adjustment 8 33 Cable inspection and lubrication 8 34 Brake and ...

Page 9: ...7 CLEANING AND STORAGE 9 1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 9 10 11 12 13 14 U5FU15 book Page 4 Thursday April 8 2004 1 29 PM ...

Page 10: ...EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5FU15 book Page 1 Thursday April 8 2004 1 29 PM ...

Page 11: ...icult to read or comes off a replacement label is available from your Yamaha dealer 1 2 Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an accident Never exceed the maximum front cargo limit of 40kg 88 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4877 00 WARNING YAMAHA U5FU15 book Page 2 Thursd...

Page 12: ...ever exceed the maximum rear cargo limit of 80kg 176 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4897 00 WARNING YAMAHA PULLING LOAD 4020 N 4 1 0 k g f 904 l b f TONGUE WEIGHT 147 N 1 5 k g f 33 l b f 5FU F151K 00 MAXIMUM LOADING LIMIT MAXIMUM LOADING LIMIT U5FU15 book Page 3 Thursday April 8 2004 1 29 PM ...

Page 13: ...6 7 8 U5FU15 book Page 4 Thursday April 8 2004 1 29 PM ...

Page 14: ...cedures described Never operate an ATV without proper training or instruction Take a Training Course Begin ners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc Ne...

Page 15: ...or the conditions Always go at a speed that is proper for the terrain visibility operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Al ways follow the inspection and maintenance procedures and schedules described in this man ual Always keep both hands on the handlebars and...

Page 16: ... of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight back ward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow...

Page 17: ... op erating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by prac ticing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water dee...

Page 18: ...ted load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Products Safety Com mission at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 U5FU15 book Page 5 Thursd...

Page 19: ...lames or other sources of ignition such as the pilot When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion 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 ga...

Page 20: ...n 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 U5FU15 book Page 7 Thursday April 8 2004 1 29 PM ...

Page 21: ...7 Headlights 8 Fuel cock 9 Recoil starter 10 Tail brake light 11 Rear wheel 12 Shift pedal 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 Fuel gauge 23 Main switch 24 Left handlebar switches U5FU15 book Page 1 Thursday April 8 2004 1 29 PM ...

Page 22: ...rom a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number U5FU15 book Page 2 Thursday April 8 2004 1 29 ...

Page 23: ...hicle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label U5FU15 book Page 3 Thursday April 8 2004 1 29 PM ...

Page 24: ...h 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 U5FU15 book Page 1 Thursday April 8 2004 1 29 PM ...

Page 25: ...ecified level this light comes on to warn that the en gine 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 en gine to cool down for about 10 minutes CAUTION _ The engine may overheat if the ATV is overloaded If this happens reduce the load to specification Restart after making sure that the light is out Continuous use w...

Page 26: ... on Check engine oil temperature Oil temperature warning light does not come on Engine oil temperature and electrical circuit are OK Go Push start switch with the transmission in neutral Ask a Yamaha dealer to inspect the electrical circuit Oil tempera ture is low Allow to cool Oil tempera ture is high Oil temperature warning light comes on momentarily U5FU15 book Page 3 Thursday April 8 2004 1 29...

Page 27: ... on a tank of fuel before going to reserve This in formation will enable you to plan fuel stops in the future EBU00052 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank When the needle reaches the red line refill the tank at the first opportunity 1 Fuel gauge 2 Red line NOTE If the machine runs out of fuel move the fuel cock lever to the RES position Approxi U5FU15 book Page ...

Page 28: ... 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 Set the switch to OFF to turn off all the lights CAUTION _ Do not use the headlights with the engine turned off f...

Page 29: ...D WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD in some circumstances Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause the ATV to unexpectedly handle differ ently This could distract the operator and increase the risk of losing control and an accident HOW TO AVOID THE HAZ...

Page 30: ...ngine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever bef...

Page 31: ...No more than 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to...

Page 32: ... front brake lever is located on the right handlebar Pull it toward the handlebar to ap ply the front brake 1 Front brake lever EBU00732 Brake pedal and rear brake lever 1 Brake pedal U5FU15 book Page 9 Thursday April 8 2004 1 29 PM ...

Page 33: ...arking brake WHAT CAN HAPPEN The ATV could start moving unexpect edly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prema turely HOW TO AVOID THE HAZARD A...

Page 34: ...s at the bot tom position Neutral is one position above re verse 1 Shift pedal N Neutral position R Reverse position EBU01028 Reverse knob REV The reverse knob is used to shift into reverse gear Refer to the Reverse knob operation and re verse driving section page 6 4 before oper ating this machine in reverse gear 1 Reverse knob REV U5FU15 book Page 11 Thursday April 8 2004 1 29 PM ...

Page 35: ...il starter WARNING POTENTIAL HAZARD Starting the engine in gear and or start ing the engine without setting the park ing brake WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Put the transmission in neutral and set the parking brake before starting the en gine U5FU15 book Page 12 Thursday April 8 2004 1 29 PM ...

Page 36: ...ill not flow Always turn the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON p...

Page 37: ...ixture 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 op eration See pages 6 1 6 3 U5FU15 book Page 14 Thursday April 8 2004 1 29 PM ...

Page 38: ... and pull up the seat at the rear 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 1 Seat holder 2 2 Projection 2 U5FU15 book Page 15 Thursday April 8 2004 1 29 PM ...

Page 39: ... edged prod ucts directly in the storage box If they must be stored wrap them in appropriate cushion material EBU00582 Front carrier EBU00583 Rear carrier Maximum load limit 2 0 kg 4 4 lb Maximum load limit 40 kg 88 lb Maximum load limit 80 kg 176 lb U5FU15 book Page 16 Thursday April 8 2004 1 29 PM ...

Page 40: ...spring preload as follows To increase the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Standard position B A Minimum soft E Maximum hard U5FU15 book Page 17 Thursday April 8 2004 1 29 PM ...

Page 41: ...se the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring 2 Position indicator WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set ting U5FU15 ...

Page 42: ...sed 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 4 When the auxiliary DC jack is not being used cover it with the cap Standard position B A Minimum soft E Maximum hard Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A U5FU15 book Page 19 Thursda...

Page 43: ...nd 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 be come difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged _ U5FU15 book Page 20 Thursday April 8 2004 1 29 PM ...

Page 44: ...level Fill with fuel if necessary 5 5 5 6 Engine oil Check oil level Fill with oil if necessary 5 7 8 6 8 10 Final gear oil Differential gear oil Check for leakage 5 7 5 8 8 11 8 16 Throttle Check for proper throttle cable operation and free play 5 8 8 24 Wheels and tires Check tire pressure wear and damage 5 9 5 12 8 35 8 36 Fittings and fasteners Check all fittings and fasteners 5 8 Lights and s...

Page 45: ...AN 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 op erating condition Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual U5FU15 book Page 2 Thursday April 8 2004 1 29 PM ...

Page 46: ...e Check the brake fluid level Add fluid if neces sary See pages 8 26 8 27 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 d...

Page 47: ...d 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 ad justment procedures provided in this manual have a Yamaha dealer check for the cause U5FU15 book Page 4 Thursday April 8 2004 1 29 PM ...

Page 48: ...igned 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 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 15 0 L 3 30 Imp gal 3 96 US gal Reser...

Page 49: ...HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure th...

Page 50: ...on do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ EBU00493 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 If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils m...

Page 51: ...le position when released Have a Yamaha dealer repair as necessary for proper operation EBU11620 Fittings and fasteners EBU10030 Lights Check the headlights and tail brake light to make sure they are in working condition Re pair as necessary for proper operation EBU11700 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for proper operation Recommended oil SAE 8...

Page 52: ...r this model Other tire combinations are not recommended Manufacturer Size Type 2 The tires should be set to the recom mended 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 dis l...

Page 53: ...e 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 U5FU15 book Page 10 Thursday April 8 2004 1 29 PM ...

Page 54: ...he gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifications 1 Low pressure tire gauge Recommended pressure Minimum Maximum Front 25 kPa 0 25 kgf cm2 3 6 psi 22 kPa 0 22 kgf cm2 3 2 psi 28 kPa 0 28 kgf cm2 4 0 psi Rear 25 kPa 0 25 kgf cm2 3 6 psi 22 kPa 0 22 kgf cm2 3 2 psi 28 kPa 0 28 kgf cm2 4 0 psi U5FU15 book Page 11 Thu...

Page 55: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit U5FU15 book Page 12 Thursday April 8 2004 1 29 PM ...

Page 56: ...ntrols WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer 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 colli sion HOW TO AVOID THE H...

Page 57: ...rting the engine _ 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient tem perature below 5 C 40 F Position 2 Cold engine start ambient tem perature at 0 C 30 F 30 C 90 F and warming up position Position 3 Cold engine start ambient tem perature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 6 Completely close the...

Page 58: ...e If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it CAUTION _ See the Engine break in section prior to operating the engine for the first time _ EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used The...

Page 59: ...sion into reverse by pressing down on the shift pedal 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 _ 4 Check behind you for people or obsta cles then release the brake 5 Open the throttle lever gradually and con tinue to watch to the rear while backing WARNING POTENTIAL HAZARD Improperly operating in reverse WH...

Page 60: ...l and then turn the reverse knob as explained on page 6 4 Depress the shift pedal and then release the reverse knob CAUTION _ Do not coast for long periods with the en gine off and do not tow the ATV a long dis tance Even in the neutral position the transmission is only properly lubricated when the engine is running Inadequate lu brication may cause damage _ EBU00205 To start out and accelerate 1 ...

Page 61: ...r use of the brakes or shifting can cause the tires to lose traction reducing control and in creasing the possibility of an accident WARNING POTENTIAL HAZARD Opening the throttle before releasing the shift pedal WHAT CAN HAPPEN The machine could wheelie This would increase the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Release the shift pedal before opening WARNING POTENTIAL...

Page 62: ...h might result in ex cessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this pe...

Page 63: ...o not use full throttle at any time After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00211 Parking When parking stop the engine and shift into neutral Turn the fuel cock to OFF and apply the parking brake 1 Locked position U5FU15 book Page 8 Thursday April 8 2004 1 29 PM ...

Page 64: ...ill or other incline WHAT CAN HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline put the ATV in low gear apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them ea...

Page 65: ...a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object atta...

Page 66: ...arrying cargo and towing a trail er include the tongue weight in the maxi mum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cau...

Page 67: ...d hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed a...

Page 68: ...EBU13451 WARNING _ Indicates a potential hazard that could result in serious injury or death U5FU15 book Page 13 Thursday April 8 2004 1 29 PM ...

Page 69: ...7 1 Riding Your ATV U5FU15 book Page 1 Thursday April 8 2004 1 29 PM ...

Page 70: ...U5FU15 book Page 2 Thursday April 8 2004 1 29 PM ...

Page 71: ...priate for all types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable begin to ride be sure you have read this Own er s Manual completely and understand the operation of the controls Pay particular atten tion to th...

Page 72: ...a period of time Take the time to learn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice th...

Page 73: ...mmenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere 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 U5FU15 book Page 5 Thursday April 8 2004 1 29 PM ...

Page 74: ...EN 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 U5FU15 book Page 6 Thursday April 8 2004 1 29 PM ...

Page 75: ... accident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event 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 sle...

Page 76: ...ARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV U5FU15 book Page 8 Thursday April 8 2004 1 29 PM ...

Page 77: ...V is in safe op erating condition Always follow the inspection and main WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use the size ...

Page 78: ...ed to the maxi mum Turning the adjusting screw in limits the maximum engine power available and de creases the maximum speed of the ATV Turning the adjusting screw in decreases top speed and turning it out increases top speed WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV which ca...

Page 79: ...al weight of trailer and cargo 410 kgf 904 lbf Tongue weight vertical weight on trailer hitch point 15 kgf 33 lbf WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed...

Page 80: ...even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation U...

Page 81: ...G POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off U5FU15 book Page 13 Thursday April 8 2004 1 29 PM ...

Page 82: ...cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed U5FU15 book Page 14 Thursday April 8 2004 1 29 PM ...

Page 83: ...NING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass U5FU15 book Page 15 Thurs...

Page 84: ... 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 con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets U5FU15 book Page 16 Thursday April 8 2004 1 29 PM ...

Page 85: ...erating 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 U5FU15 book Page 17 Thursday April 8 2004 1 29 PM ...

Page 86: ... 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 HOW TO AVOID THE HAZARD Go slowly and be extra careful when op U5FU15 book Page 18 Thursday April 8 2004 1 29 PM ...

Page 87: ...r vehicle control which could result in an acci dent 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 neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain U5FU15 book Page 19 Thursday April 8 2004 1 29 PM ...

Page 88: ...er hitch Do not ride in areas posted no trespassing Do not ride on private property without getting permission WARNING 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 care fully for other vehicles U5FU15 book Page 20 Thursday April 8 2004 1 29 PM ...

Page 89: ... afterwards do not allow 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 at tained adequate speed release the throttle and lift the shift pedal to the 2nd gear position Release the shift pedal and apply the throttle smoo...

Page 90: ...rop er use of the brakes or shifting can cause the tires to lose traction reducing control and in creasing the possibility of an accident WARNING 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 ...

Page 91: ... As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control...

Page 92: ...mproper 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 in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember A...

Page 93: ...rtant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small ...

Page 94: ...s described in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV An obstacle a sharp drop or another vehicle or person could be on the other side of the hill U5FU15 book Page 26 Thursday April 8 2004 1 29 P...

Page 95: ...or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your ...

Page 96: ...re interconnected by the drive train This means that applying ei ther the front brake or the rear will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden ap plication of either the front or rear brake be WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a hill WHAT CA...

Page 97: ...ply the rear brake as well and then lock the parking brake 4WD Apply both front and rear brakes gradually When fully stopped lock the parking brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu al U5FU15 book Page 29 Thursday April 8 2004 1 29 PM ...

Page 98: ...by these surfaces Improper braking may also cause a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake le ver or the brake pedal will brake the wheels on the downhill side Avoid sudden applica tion of either the front...

Page 99: ...roper procedures for go ing down hills as described in this Own er s Manual Note a special technique is required when braking as you go down a hill Always check the terrain carefully be fore you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that U5FU15 book Page 31 Thursday April 8 2004 1 29 PM ...

Page 100: ... faces by pointing the front wheels slightly up hill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hi...

Page 101: ...a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV U5FU15 book Page 33 Thursday April 8 2004 1 29 PM ...

Page 102: ...ery or up set the ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to l...

Page 103: ...egained 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 con ditions _ U5FU15 book Page 35 Thursday April 8 2004 1 29 PM ...

Page 104: ...ol and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper procedu...

Page 105: ...U5FU15 book Page 37 Thursday April 8 2004 1 29 PM ...

Page 106: ...heels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help 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 direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide U5FU15 book Page 38 Thursday April 8 20...

Page 107: ...ntrol may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious ...

Page 108: ... If necessary gradually let off the throttle and or steer to the outside of the turn See If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for ward ...

Page 109: ...over that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV un til you have regained adequate braking ability See...

Page 110: ...ual and tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it on the bottom of the seat as shown Put the own er s tool kit and low pressure tire gauge in the storage box WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or ...

Page 111: ...rque wrench available during a service operation requiring one take WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of acces...

Page 112: ...INE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check and adjust idle speed start...

Page 113: ... if necessary Wheels Check balance damage runout Repair if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Front and rear suspension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Drive shaft universal joint Lubricate with lithium soap based grease ITEM ROUTINE Whichever comes first ...

Page 114: ...ed On the inner parts of the master cylinder and cal iper replace the oil seals every two years Replace the brake hoses every four years or if cracked or damaged WARNING _ Indicates a potential hazard that could result in serious injury or death Lights and switches Check operation Adjust headlight beams ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400...

Page 115: ...eck 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 set tles before checking 4 Remove the engine oil filler cap and then wipe the dipstick off with a clean rag In sert the dipstick in the filler hole without screwing it in and then remove it again to check the oil level 1 Engine oil fille...

Page 116: ... Insert the dipstick into the oil filler hole and then tighten the engine oil filler cap 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 drai...

Page 117: ...t be ing cleaned _ 5 Remove the oil filter cover by removing the bolts and then remove the oil filter el ement 6 Clean the oil strainer and oil filter element with solvent 7 Check the O ring for damage and re place it if necessary 1 O ring 2 Oil filter element 8 Install the oil filter element and O ring NOTE _ Make sure the O ring is seated properly _ U5FU15 book Page 8 Thursday April 8 2004 1 29 ...

Page 118: ... be sure to install the O ring compression spring and oil strainer _ 11 Add the specified amount of the recom mended 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 Tightening torque 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 elem...

Page 119: ...In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ 12 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 13 Turn the engine off and then check the oil level and correct it if necessary U5FU15 book Page 10 Thurs...

Page 120: ...il is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level CAUTION _ Be sure no foreign material enters the final gear case _ 1 Final gear oil 2 Correct oil level 3 Final gear oil filler bolt 4 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf U5FU15...

Page 121: ... 2 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 1 Final gear oil drain bolt 5 Install the drain bolt and then tighten it to the specified torque U5FU15 book Page 12 Thursday April 8 2004 1 29 PM ...

Page 122: ...the oil filler bolt and then tighten it to the specified torque Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 23 L 0 20 Imp qt 0 24 US qt Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf Tightening torque Final gear case cover bolt 17 Nm 1 7 m kgf 13 ft lbf U5FU15 book Page 13 Thursday April 8 2004 1 29 PM ...

Page 123: ...fficient oil of the recommend ed type to raise it to the specified level CAUTION _ Be sure no foreign material enters the dif ferential gear case _ 1 Differential gear oil filler bolt 2 Proper oil level 3 Differential gear oil 3 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 U5F...

Page 124: ...ial gear oil drain bolt 4 Install the differential gear oil drain bolt and tighten it to the specified torque 5 Fill the differential gear case with the rec ommended oil CAUTION _ Be sure no foreign material enters the dif ferential gear case _ Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 ft lbf Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 35 L 0 31 Imp qt...

Page 125: ...ge If oil leakage is found check for the cause EBU00862 Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by a Yamaha dealer 1 Axle boot 2 Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf U5FU15 book Page 16 Thursday April 8 2004 1 29 PM ...

Page 126: ...emove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes ex cessive you should replace the spark plug with one of the proper type Before installing the spark plug measure the electrode gap with a wire thickness gauge and adjust it to specification a Spark plug gap When installing the spark plug always clean the...

Page 127: ...r filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case _ 1 Check hose 1 Remove the seat See page 4 15 for 1 Air filter case cover 2 Holder 3 3 Pull the air filter element out U5FU15 book Page 18 Thursday April 8 2004 1 29 PM ...

Page 128: ...er 5 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 6 Wash the foam cover gently but thor oughly in water or solvent U5FU15 book Page 19 Thursday April 8 2004 1 29 PM ...

Page 129: ...sty ar eas Each time air filter element maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter ele ment rubber joint to the carburetor and mani fold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfil tered air entering the engine _ WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to cl...

Page 130: ...subsequent poor performance and possible engine overheating _ EBU00754 Spark arrester cleaning Select a well ventilated area free of combusti ble materials and make sure the exhaust pipe and muffler are cool 1 Remove the purging bolt 1 Purging bolt 2 Start the engine and rev it up approxi mately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler...

Page 131: ... disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result WARNING POTENTIAL HAZARD Improperly purging the exhaust system Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let th...

Page 132: ...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 Turn the screw in direction a to increase the engine speed and in direc tion b to decrease the engine speed 1 Throttle stop screw Specified idle speed U5FU15 book Page 23 Thursday Ap...

Page 133: ...ease cable adjustment The reverse lock release cable stretches with use resulting in improper function To prevent this the cable must be adjusted regularly This adjustment however should be left to a Yamaha dealer EBU00307 Throttle lever adjustment NOTE Adjust the engine idling speed before adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle le...

Page 134: ...U00313 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 If the indicator reaches the wear limit line ask a Yamaha dealer to replace shoes as a set 1 Wear indicator 2 Wear limit line U5FU15 book Page 25 Thursday April 8 2004 1 29 PM ...

Page 135: ... leakage Observe these precautions When checking the brake fluid level make sure the top of the brake fluid reservoir is level Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per 1 Minimum level mark Refill with the same type of brake fluid Mix ing fluids may result in a harmful chemical reaction and lead to poor brake perfor m...

Page 136: ...oes down 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 U5FU15 book Page 27 Thursday April 8 2004 1 29 PM ...

Page 137: ...ng 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 cor rect Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re U5FU15 book Pa...

Page 138: ...adjustment 1 Fully loosen the adjusting nut on the brake cable 1 Adjusting nut brake cable 2 Adjusting nut brake rod 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 U5FU15 book Page 29 Thursday April 8 2004 1 29 PM ...

Page 139: ...in the adjusting bolt at the brake lever 1 Locknut 2 Adjusting bolt 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 1 Adjusting nut brake cable a Gap U5FU15 book Page 30 Thursday April 8 2004 1 29 PM ...

Page 140: ... 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 Replacement of brake components re quires professional knowledge These procedures should be performed by a Yamaha dealer U5FU15 book Page 31 Thursd...

Page 141: ... 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 To make the brake light come on later turn the adjusting nut in direction b U5FU15 book Page 32 Thursday April 8 2004 1 29 PM ...

Page 142: ...lt Then turn it 1 8 turn clockwise 1 Locknut 2 Adjusting bolt 3 Tighten the locknut to specification NOTE Turn the adjusting bolt counterclockwise to decrease the clutch free play and turn it clock wise to increase the free play Tightening torque 20 Nm 2 0 m kgf 15 ft lbf U5FU15 book Page 33 Thursday April 8 2004 1 29 PM ...

Page 143: ...aged 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 HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil Recommended lubr...

Page 144: ...heel 4 Remove the wheel EBU01121 Wheel installation 1 Install the wheel and the nuts NOTE _ Tapered nuts are used for both the front and rear wheels Install the nut with its ta pered side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel _ U5FU15 book Page 35 Thursday April 8 2004 1 29 PM ...

Page 145: ... 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 5 m kgf 40 ft lbf U5FU15 book Page 36 Thursday April 8 2004 1 29 PM ...

Page 146: ... CAN HAPPEN You could be poisoned You could be HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes a...

Page 147: ...tery before reinstallation CAUTION A special battery charger constant volt age ampere or constant voltage is re quired for recharging a sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine U5FU15 book Page 38 Thursday April 8 2004 1 29 PM ...

Page 148: ...the specified amperage Then turn on the switches If the fuse immediately blows again con sult a Yamaha dealer 1 Main fuse 2 Four wheel drive fuse 3 Spare main fuse Specified fuses Main fuse 30 A Headlight fuse 15 A Ignition fuse 10 A Auxiliary DC jack fuse 10 A Carburetor warmer fuse 10 A Four wheel drive fuse 3 A U5FU15 book Page 39 Thursday April 8 2004 1 29 PM ...

Page 149: ...RNING 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 rat ing Never use a material in place of the proper fuse U5FU15 book Page 40 Thursday April 8 2004 1 29 PM ...

Page 150: ...by re moving the screws 2 Disconnect the headlight coupler 1 Screw 2 2 Headlight coupler 3 Remove the headlight unit from the 1 Screw 3 4 Remove the headlight bulb holder cover 5 Push the headlight bulb holder inward turn it counterclockwise and then re move the defective bulb U5FU15 book Page 41 Thursday April 8 2004 1 29 PM ...

Page 151: ...lb CAUTION _ Do not touch the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the luminos 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 flamma U5FU15 book Page 42 Thursday April 8 2004 1 29 PM ...

Page 152: ...e screws 9 Connect the headlight coupler 10 Place the headlight assembly in the orig inal position and then install the screws 11 Adjust the headlight beam if necessary EBU01089 Headlight beam adjustment 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 U5FU15 ...

Page 153: ...ts together with the wash ers 1 Storage box 2 Nut 2 3 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Bulb holder 4 Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise U5FU15 book Page 44 Thursday April 8 2004 1 29 PM ...

Page 154: ...ob lem in the fuel compression or ignition sys tems 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 The skilled technicians at a Yamaha dealer ship have the tools experience and know how to properly service your machine Use only genuine Yamaha parts on your machine ...

Page 155: ...PEN Fuel can ignite or explode causing se vere injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnac es U5FU15 book Page 46 Thursday April 8 2004 1 29 PM ...

Page 156: ...here is compression There is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap No spark 4 Battery Check the fuel flow Turn the fuel ...

Page 157: ... to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter 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 wash e...

Page 158: ...int or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings U5FU15 ...

Page 159: ...ablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing in a humid or salt a...

Page 160: ...dry place and recharge it once a month Do not store the battery in an ex cessively 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 U5FU15 book Page 4 Thursday April 8 2004 1 29 PM ...

Page 161: ... in 855 mm 33 7 in 1 230 mm 48 4 in 245 mm 9 65 in 3 150 mm 124 0 in Basic weight With oil and full fuel tank 266 kg 586 lb Engine Engine type Cylinder arrangement Displacement Bore Stroke Compression ratio Starting system Lubrication system Air cooled 4 stroke SOHC Single cylinder Forward inclined 386 cm3 83 0 71 5 mm 3 27 2 81 in 8 6 1 Electric starter and recoil starter Wet sump U5FU15 book Pag...

Page 162: ... 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION In order to prevent clutch slippage since the en gine 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 U5FU15 book Page 2 Thursday April 8 2004 1 29 PM ...

Page 163: ...p 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 06 US gal Carburetor Type manufacturer BSR33 MIKUNI Spark plug Type manufacturer Gap DR8EA NGK 0 6 0 7 mm 0 024 0 028 in Clutch type Wet centrifugal automatic MODEL YFM400F U5FU15 book Page 3 Thursday April 8 2004 1 29 PM ...

Page 164: ...ar 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 3 019 Chassis Frame type Caster angle Trail Steel tube frame 4 21 mm 0 83 in Tire Type Size Front Size Rear Tubeless AT25 8 12 AT25 10 12 Brake MODEL YFM400F U5FU15 book Page 4 Thursday April 8 2004 1 29 PM ...

Page 165: ...m 5 91 in Electrical Ignition system Generator system Battery type voltage capacity DC C D I A C magneto YTX20L BS 12 V 18 Ah Headlight type Krypton bulb Bulb voltage wattage quantity Headlight Tail brake light Meter lighting Indicator warning light Neutral Reverse 12 V 30 W 30 W 2 12 V 5 W 21 W 1 12 V 3 4 W 1 12 V 1 7 W 1 12 V 1 7 W 1 MODEL YFM400F U5FU15 book Page 5 Thursday April 8 2004 1 29 PM...

Page 166: ...ied fuses Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse Four wheel drive fuse 30 A 15 A 10 A 10 A 10 A 3 A MODEL YFM400F U5FU15 book Page 6 Thursday April 8 2004 1 29 PM ...

Page 167: ...se of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muff...

Page 168: ...e minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 06E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 200 750 75 6 2 400 1 500 150 12 4 800 3 000 300 18 7 200 4 500 450 24 9 600 6 000 600 30 12 000 7 500 750 36 14 400 9 000 900 42 16 800 10 500 1 050 48 19 200 12 000 1 2...

Page 169: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U5FU15 book Page 1 Thursday April 8 2004 1 29 PM ...

Page 170: ...1 2 3 4 5 6 7 8 9 10 9 9 13 U5FU15 book Page 2 Thursday April 8 2004 1 29 PM ...

Page 171: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S U5FU15 book Page 1 Thursday April 8 2004 1 29 PM ...

Page 172: ...1 2 3 4 5 6 7 8 9 10 9 9 9 U5FU15 book Page 2 Thursday April 8 2004 1 29 PM ...

Page 173: ...EBU00437 U5FU15 book Page 3 Thursday April 8 2004 1 29 PM ...

Page 174: ...EBU00438 ...

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