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Yamaha Big Bear YFM400R, Owner'S Manual

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Yamaha Big Bear YFM400R Owner'S Manual Download Page 135

8-26

Brake lever free play adjustment

1. Loosen the locknut and fully turn 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 lever and the pin.

1. Adjusting nut (brake cable)

2. Lever

3. Pin

a. Gap

U5GW13.book  Page 26  Tuesday, July 30, 2002  2:23 PM

Summary of Contents for Big Bear YFM400R

Page 1: ...r riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passe...

Page 2: ...EBU00776 ...

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

Page 4: ...ymbol 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: ...k arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU01067 YFM400R OWNER S MANUAL 2002 by Yamaha Motor Corporation U S A 1st edition June 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U...

Page 6: ... 3 Model label 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 6 Speed limiter 4 7 Front brake lever 4 8 Rear brake pedal and lever 4 8 Parking brake 4 9 Shift pedal 4 10 Reverse knob 4 10 Recoil starter 4 11 Fuel tank cap 4 12 Fuel cock 4 13 Starter choke 4 14 Seat 4 15 Storage box 4 16 Front c...

Page 7: ... 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 and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 23 Climb...

Page 8: ...justment 8 20 Front brake pad check 8 21 Rear brake shoe inspection 8 21 Brake fluid level check 8 22 Brake fluid replacement 8 23 Front brake lever free play 8 24 Rear brake pedal and lever adjustment 8 25 Adjusting the rear brake light switch 8 28 Clutch adjustment 8 28 Cable inspection and lubrication 8 29 Brake and shift pedal brake lever lubrication 8 30 Wheel removal 8 30 Wheel installation ...

Page 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 U5GW13 book Page 4 Tuesday July 30 2002 2 23 PM ...

Page 10: ...1 1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5GW13 book Page 1 Tuesday July 30 2002 2 23 PM ...

Page 11: ...es difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 3 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 U5GW13 book Page 2 Tues...

Page 12: ...ge handling stability and braking performance and can lead to an accident Never exceed the maximum rear cargo limit of 80kg 176 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4897 00 WARNING U5GW13 book Page 3 Tuesday July 30 2002 2 23 PM ...

Page 13: ...1 4 7 8 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 U5GW13 book Page 4 Tuesday July 30 2002 2 23 PM ...

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

Page 15: ...the terrain visibility and 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 both feet on the footboards of the ATV during operati...

Page 16: ...op 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 foll...

Page 17: ...n 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 control 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 U5GW13 book Page 5 Tuesda...

Page 19: ...s of ignition such as the pi lot lights of water heaters and clothes dryers When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF 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 gasoli...

Page 20: ... 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 U5GW13 book Page 7 Tuesday July 30 2002 2 23 PM ...

Page 21: ...9 Tail brake light 10 Rear wheel 11 Shift pedal 12 Front wheel 13 Rear brake lever 14 Parking brake lock plate 15 Starter choke 16 Speedometer 17 Reverse knob 18 Front brake lever 19 Throttle lever 20 Fuel gauge 21 Main switch 22 Handlebar switches NOTE The machine you have purchased may differ slightly from those shown in the figures of this manual U5GW13 book Page 1 Tuesday July 30 2002 2 23 PM ...

Page 22: ... from 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 U5GW13 book Page 2 Tuesday July 30 2002 2 23...

Page 23: ...vehicle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label U5GW13 book Page 3 Tuesday July 30 2002 2 23 PM ...

Page 24: ...Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position U5GW13 book Page 1 Tuesday July 30 2002 2 23 PM ...

Page 25: ...U00732 Oil temperature warning light OIL TEMP When the oil temperature reaches a specified level this light comes on to warn that the en gine oil temperature is too hot If the warning light comes on during operation stop the en gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes CAUTION The engine may overheat if the ATV is overloaded If this happens reduce t...

Page 26: ...eck engine oil temperature Oil temperature warning light does not come on Engine oil temperature and electrical circuit are OK Go ahead with riding 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 U5GW13 book Page 3 Tuesday July 3...

Page 27: ...tion will enable you to plan fuel stops in the future 1 Reset knob 2 Speedometer 3 Odometer 4 Trip odometer 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 NOTE If the machine runs out of fuel move the fuel cock lever to the RES position Approxi mately 4 0 L 0 9 Imp gal 1 1 U...

Page 28: ... cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engine See page 6 1 for details _ EBU01204 Light switch OFF Set the switch to to turn on the low beam and the taillight Set the switch to to turn on the high beam and the taillight Set the switch to OFF to turn off all the lights CAUTION _ Do not use the headlights with the engine turned off for m...

Page 29: ... 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 before you start the engine If...

Page 30: ... screw a 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 adjusted to 3 5 ...

Page 31: ...e 1 Front brake lever EBU00073 Rear brake pedal and lever The brake pedal is located on the right side of the machine and the 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 Rear brake pedal 1 Rear brake lever U5GW13 book Page 8 Tuesday July 30 2002 2 23 PM ...

Page 32: ...PEN 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 Always set the parking bra...

Page 33: ...ide of the engine Reverse is at the bot tom position Neutral is one position above re verse 1 Shift pedal EBU01028 Reverse knob 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 Reverse knob U5GW13 book Page 10 Tuesday July 30 2002 2 23 PM ...

Page 34: ...ecoil 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 U5GW13 book Page 11 Tuesday July 30 2002 2 23 PM ...

Page 35: ...4 12 EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap U5GW13 book Page 12 Tuesday July 30 2002 2 23 PM ...

Page 36: ...sition when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON position U5GW13 book Page 13 Tuesday July 30 2...

Page 37: ...uel 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 op eration See page 6 1 U5GW13 book Page 14 Tuesday July 30 2002 2 23 PM ...

Page 38: ...eat 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 Make sure that the seat is securely fitted 1 Projection 2 2 Seat holder 2 U5GW13 book Page 15 Tuesday July 30 2002 2 23 PM ...

Page 39: ...rply 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 kg 4 4 lb Maximum load limit 40 kg 88 lb Maximum load limit 80 kg 176 lb U5GW13 book Page 16 Tuesday July 30 2002 2 23 PM ...

Page 40: ...TE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ 1 Spring preload adjusting ring 2 Position indicator Standard position B A Minimum soft E Maximum hard 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 ...

Page 41: ...crease the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ 1 Spring preload adjusting ring 2 Position indicator Standard position B A Minimum soft E Maximum hard U5GW13 book Page 18 Tuesday July 30 2002 2 23 PM ...

Page 42: ...y 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 4 When the auxiliary DC jack is not being used cover it with the cap 1 Auxiliary DC jack 2 Cap Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A U5GW13 book Page 19 Tuesday July 30 2002 2 23...

Page 43: ...ine 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 _ EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death U5GW13 book Page 20 Tuesday July 30 2002 2 23 PM ...

Page 44: ...al height Fuel Check fuel level Fill with fuel if necessary 5 5 5 6 Engine oil Check oil level Fill with oil if necessary 5 7 8 5 8 9 Final gear oil Check for leakage 5 8 8 9 8 11 Throttle Check for proper throttle cable operation and free play 5 8 8 19 Wheels and tires Check tire pressure wear and damage 5 9 5 12 8 30 8 31 Fittings and fasteners Check all fittings and fasteners 5 8 Lights Check f...

Page 45: ...AT 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 op erating condition Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual U5GW13 book Page 2 Tuesday July 30 2002 2 23 PM ...

Page 46: ...ake Check the brake fluid level Add fluid if neces sary See pages 8 22 8 23 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...

Page 47: ...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 ad justment procedures provided in this manual have a Yamaha dealer check for the cause U5GW13 book Page 4 Tuesday July 30 2002 2 23 PM ...

Page 48: ...en 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 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 15 L 3 3 Imp gal 4 0 US gal Res...

Page 49: ...AL 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...

Page 50: ...n addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ Recommended oil Recommended engine oil classification API Service SE SF SG type or higher 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 Oil quantity Periodic oil change 2 9 L 2 6 Imp qt 3 1 US qt With...

Page 51: ...083 Throttle lever Check to see that the throttle lever operates correctly It must open smoothly and spring back to the idle position when released Have a Yamaha dealer repair as necessary for proper operation EBU01162 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tigh...

Page 52: ...ven tire pressure 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 accident HOW TO AVOID THE HAZARD 1 The tires listed below have been ap proved by Yamaha Motor Co Ltd for this model Other tire combinations are not recommended Manufacturer Size Type Front DUNLOP AT25 x 8 12 KT121 Rea...

Page 53: ...ed could cause the tire to dis lodge from the rim under severe riding conditions The following are minimums Front 22 kPa 0 22 kgf cm2 3 2 psi Rear 22 kPa 0 22 kgf cm2 3 2 psi 4 Use no more than the following pres sures 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...

Page 54: ...n the 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 U5GW13 book Page 11 ...

Page 55: ...5 12 EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a 3 mm 0 12 in U5GW13 book Page 12 Tuesday July 30 2002 2 23 PM ...

Page 56: ... controls 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 TH...

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

Page 58: ...2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding CAUTION _ See the Engine break in section prior to operating the engine for the first time _ EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not b...

Page 59: ...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 machine 4 Check behind you for people or obsta cles then release the rear brake lever 5 Open the throttle lever gradually and con tinue to watch to the rear while backing WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You c...

Page 60: ...se the pedal slightly to neutral 1 Shift pedal N Neutral position R Reverse position 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 Release the throttle lever CAUT...

Page 61: ...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 the throttle Open the throttle gradually WARNING POTENTIAL HAZARD Engaging a lower gea...

Page 62: ...ich 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 ...

Page 63: ...but do not use full throttle at any time 3 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 Lock plate U5GW13 book Page 8 Tuesday July 30 2002 2 23 PM ...

Page 64: ...a hill 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...

Page 65: ...se 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 a...

Page 66: ... 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 front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with controls or your ability to see where y...

Page 67: ...oid 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...

Page 68: ...6 13 EBU01297 WARNING _ Indicates a potential hazard that could result in serious injury or death U5GW13 book Page 13 Tuesday July 30 2002 2 23 PM ...

Page 69: ...7 1 7 Riding Your ATV U5GW13 book Page 1 Tuesday July 30 2002 2 23 PM ...

Page 70: ...7 2 U5GW13 book Page 2 Tuesday July 30 2002 2 23 PM ...

Page 71: ...ractice 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 activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s...

Page 72: ...ttempting 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 creased if the operator does not know how to operate the ATV properly in dif ferent situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course o...

Page 73: ...ecommenda 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 U5GW13 book Page 5 Tuesday July 30 2002 2 23 PM ...

Page 74: ...PPEN 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 U5GW13 book Page 6 Tuesday July 30 2002 2 23 PM ...

Page 75: ...dent Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots...

Page 76: ...AZARD 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 U5GW13 book Page 8 Tuesday July 30 2002 2 23 PM ...

Page 77: ...lways follow the in spection and maintenance procedures and schedules described in the Owner s Manual 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 T...

Page 78: ...d of the ATV Turning the adjusting screw in decreases top speed and turning it out increases top speed See page 4 7 for details 1 Locknut 2 Adjusting screw 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 can result in an accident HOW TO AVOID THE HAZARD Always go at a speed t...

Page 79: ...t 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 and sec...

Page 80: ...ng 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 operatio...

Page 81: ...NING 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 U5GW13 book Page 13 Tuesday July 30 2002 2 23 PM ...

Page 82: ...u 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 and used according to instructions If you have questions consult an autho rized ATV dealer U5GW13 book Page 14 Tue...

Page 83: ... 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 brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in...

Page 84: ...ing 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 U5GW13 book Page 16 Tuesday July 30 2002 2 23 PM ...

Page 85: ...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 high ways U5GW13 book Page 17 Tuesday July 30 2002 2 23 PM ...

Page 86: ...se 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 erating on unfamiliar terrain Always be alert to changing terrain con ditions when operating the ATV U5GW13 book Page 18 Tuesd...

Page 87: ...n or 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 U5GW13 book Page 19 Tuesday July 30 2002 2 23 PM ...

Page 88: ...espassing Do not ride on private property without getting permission WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles U5GW13 book Page 20 Tuesday July 30 2002 2 ...

Page 89: ...n or clothing to come in contact with these components 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 ped...

Page 90: ...Improp 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 Ma...

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 properly WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of...

Page 92: ... 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 in side It may also be necessary to gradually let o...

Page 93: ...portant 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 smal...

Page 94: ...l 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 could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill U5GW13 b...

Page 95: ...ontrol or cause 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 Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoi...

Page 96: ...ards Instead dismount the ATV immediate ly on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are...

Page 97: ...9 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 U5GW13 book Page 29 Tuesday July 30 2002 2 23 PM ...

Page 98: ...les which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for go ing down hills as described in this Own er s Manual Note...

Page 99: ...7 31 U5GW13 book Page 31 Tuesday July 30 2002 2 23 PM ...

Page 100: ... 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 hills WHAT CAN HAPPEN Could cause loss of control or cause ...

Page 101: ...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 weight to the uphill side of the ATV U5GW13 book Page 33 Tuesday July 30 2002 2 23 PM ...

Page 102: ...NG 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 Never operate this ATV in fast flowing water or in water deeper than that spec ified in your Owner s Manual Remember that wet brakes may have re duced stopping ability Test your brakes after le...

Page 103: ...ned 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 _ 1 Check hose U5GW13 book Page 35 Tuesday July 30 2002 2 23 PM ...

Page 104: ...ntrol 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 proc...

Page 105: ...7 37 U5GW13 book Page 37 Tuesday July 30 2002 2 23 PM ...

Page 106: ...t wheels 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 U5GW13 book Page 38 Tuesday July 30 ...

Page 107: ... control 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 cautio...

Page 108: ...ecessary gradually let off the throttle and or steer to the outside of the turn See pag es 7 23 7 24 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 ha...

Page 109: ...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 pages 7 34 7 35 WARNING _ Indicates a ...

Page 110: ...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 1 Owner s manual 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 can start fires HOW TO AVOID THE HAZAR...

Page 111: ... machine to a Yamaha dealer to check the torque settings and adjust them as neces sary _ 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 install...

Page 112: ...k breather hose for cracks or damage Replace if necessary Exhaust system Check leakage Tighten if necessary Replace gasket s if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace warm engine before draining Engine oil filter element Clean Replace if necessary Engine oil strainer Clean Final gear oil Check oil level oil leakage Repl...

Page 113: ...ngs and fasteners Check all chassis fittings and fasteners Correct if necessary ITEM ROUTINE INITIAL EVERY 1 month 3 months 6 months 6 months 1 year NOTE Recommended brake fluid DOT 4 Brake fluid replacement When disassembling the master cylinder or caliper cylinder replace the brake flu id Normally check the brake fluid level and add fluid as required On the inner parts of the master cylinder and...

Page 114: ... screwing it in 1 Engine oil filler cap NOTE _ Wait a few minutes until the oil level settles before checking _ 4 Remove the dipstick and then check the oil level NOTE _ The oil level should be between the maximum and minimum level marks _ 5 If the engine oil is below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct lev el CAUTION _ Be sure no foreign m...

Page 115: ...e the ATV on a level surface 2 Warm up the engine for several minutes and stop it 3 Place a container under the engine to collect the used oil 4 Remove the engine oil filler cap and then remove the drain bolt to drain the oil CAUTION _ When removing the drain bolt the com pression spring oil strainer and O ring will fall out Take care not to lose these parts _ U5GW13 book Page 6 Tuesday July 30 20...

Page 116: ...nt with solvent 7 Check the O ring for damage and re place it if necessary 8 Install the oil filter element and O ring 9 Install the oil filter cover by installing the bolts 10 Install the oil strainer compression spring O ring and drain bolt Tighten the drain bolt and oil filter cover bolts to the specified torques CAUTION _ Before installing the drain bolt be sure to install the O ring compressi...

Page 117: ...ion of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ Tightening torques Drain bolt 32 Nm 3 2 m kgf 23 ft lbf Filter cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf Recommended oil See page 10 2 Oil quantity Periodic oil change 2 9 L 2 6 Imp qt 3 1 US qt With oil filter replacement 3...

Page 118: ...inal gear oil measurement 1 Place the machine 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 CAUTION _ Be sure no foreign material enters the final gear case...

Page 119: ...oil 2 Correct oil level 3 Final gear oil filler bolt Final gear oil replacement 1 Remove the final gear case cover by re moving the bolts 1 Final gear case cover 2 Bolt 2 U5GW13 book Page 10 Tuesday July 30 2002 2 23 PM ...

Page 120: ...he filler hole CAUTION _ Be sure no foreign material enters the final gear case _ 7 Install the oil filler bolt 8 Check for oil leakage If oil leakage is found check for the cause 9 Install the final gear case cover bolts and then tighten them to the specified torque Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf Recommended oil See page 10 3 Oil quantity 0 25 L 0 22 Imp qt ...

Page 121: ... 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 gasket surface and its mating s...

Page 122: ...the hose and clean the air filter element and air filter case _ 1 Check hose 1 Remove the seat See page 4 15 for seat removal and installation proce dures 2 Remove the air filter case cover by un hooking the holders 1 Air filter case cover 2 Holder 3 3 Pull the air filter element out 1 Air filter element U5GW13 book Page 13 Tuesday July 30 2002 2 23 PM ...

Page 123: ...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 U5GW13 book Page 14 Tuesday July 30 2002 2 23 PM ...

Page 124: ...aned more often if the ATV is operated in extremely dusty 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 HA...

Page 125: ... allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration without the air filter element will af fect carburetor jetting with subsequent poor performance and possible engine overheating _ U5GW13 book Page 16 Tuesday July 30 2002 2 23 PM ...

Page 126: ... 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 with a shop towel 3 Stop the engine and allow the exhaust pipe to cool 4 Install the purging bolt and tighten it U5GW13 book Page 17 Tuesday July 30 2002 2 23 PM ...

Page 127: ...ut 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 the exhaust system cool pri o...

Page 128: ...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 1 450 1 550 r min U5GW13 book Page 19...

Page 129: ...ent however should be left to a professional Yamaha service technician 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 ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut 1 Locknut 2 Adjusting bolt a Throttle lever free play U5GW13 book Page 20 Tuesday J...

Page 130: ...BU00313 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 U5GW13 book Page 21 Tuesday July 30 2002 2 23 PM ...

Page 131: ... 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 formance 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 mance Be...

Page 132: ... goes down EBU01186 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 U5GW13 book Page 23 Tuesday July 30 2002 2 23 PM ...

Page 133: ...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 quires professional knowledge These procedures should be perf...

Page 134: ...justment 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 8 1 2 in a Rear brake pedal free play U5GW13 book Page 25 Tuesday July 30 2002 2 23 PM ...

Page 135: ... 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 lever and the pin 1 Adjusting nut brake cable 2 Lever 3 Pin a Gap U5GW13 book Page 26 Tuesday July 30 2002 2 23 PM ...

Page 136: ...rly 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 Replacement of brake components re quires professional knowledge These procedures should be performed by a Yamaha dealer U5GW13 book Page 27 Tu...

Page 137: ...sting 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 1 Rear brake light switch 2 Adjusting nut EBU00346 Clutch adjustment 1 Loosen the locknut 2 Slowly turn the adjusting bolt counter clockwise until resistance is felt Then turn it 1 8 tu...

Page 138: ...ng torque 15 Nm 1 5 m kgf 11 ft lbf 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 HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables U5GW13 book Page 29 Tuesd...

Page 139: ...the pivoting parts of each lever and pedal EBU01112 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 Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil Recommended lubricant Lithium soap based grease all purpose grease U5GW13 book Page 30 Tuesday July 30 2002 2 23 PM ...

Page 140: ...d side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel _ 1 Arrow mark 2 Lower the ATV so that the wheel is on the ground 1 Tapered nut 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf U5GW13 book Page 31 Tuesday July 30 2002 2 23 PM ...

Page 141: ...be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases 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 magne sia beaten egg or vegetable oil Get prompt medic...

Page 142: ... shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine 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 con sult a Yamaha dealer Specified...

Page 143: ...ing turn off the main switch when checking or replacing a fuse _ 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 rat ing Never use a material in place of the proper fuse U5GW13 book Page 34 Tuesday July 30 2002 2 23 PM ...

Page 144: ...nect the headlight coupler 3 Remove the headlight unit from the headlight assembly by removing the screw 4 Remove the headlight bulb holder cover 5 Push the headlight bulb holder inward turn it counterclockwise and then re move the defective bulb 1 Screw 2 2 Headlight coupler 1 Screw 3 1 Headlight bulb holder cover U5GW13 book Page 35 Tuesday July 30 2002 2 23 PM ...

Page 145: ...and then install the screw 9 Connect the headlight coupler 10 Place the headlight unit assembly in the original position and then install the screws 11 Adjust the headlight beam if necessary 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 ble HOW TO AVO...

Page 146: ... direction a To lower the beam turn the adjusting screw in direction b 1 Adjusting screw 2 EBU00945 Tail brake light bulb replacement 1 Open the storage box See page 4 16 2 Remove the nuts together with washers 1 Storage box 2 Nut 2 3 Remove the bulb holder together with the bulb by turning it counterclockwise U5GW13 book Page 37 Tuesday July 30 2002 2 23 PM ...

Page 147: ...rd and turning it counterclockwise 1 Tail brake light bulb holder 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 7 Install the washers and then install the nuts U5GW13 book Page 38 Tuesday July 30 2002 2 23 PM ...

Page 148: ...perience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se v...

Page 149: ...pression 3 Ignition Remove the plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach plug cap and ground to chassis Use the electric starter Spark good Ignition system normal Spark weak Adjust plug gap or replace plug No spark Ask a Yamaha dealer to inspect 4 Battery Use the electric starter Engine turns over quickly Battery good Engine turns over slowly Check fuel flow Turn the f...

Page 150: ...les 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 ers 4 Once the ma...

Page 151: ...hich 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 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 ...

Page 152: ...move the spark plug pour about one tablespoon 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 enteri...

Page 153: ...a 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 U5GW13 book Page 4 Tuesday July 30 2002 2 23 PM ...

Page 154: ...m 33 7 in 1 230 mm 48 4 in 245 mm 9 65 in 3 000 mm 118 1 in Basic weight With oil and full fuel tank 252 kg 556 lb Engine Type Cylinder arrangement Displacement Bore stroke Compression ratio Starting system Lubrication system Air cooled 4 stroke SOHC Forward inclined single cylinder 386 cm3 83 0 71 5 mm 3 27 2 81 in 8 6 1 Electric starter and recoil starter Wet sump U5GW13 book Page 1 Tuesday July...

Page 155: ... qt MODEL YFM400 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 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...

Page 156: ...S qt Air filter Dry element Fuel Type Tank capacity Reserve amount UNLEADED GASOLINE ONLY 15 L 3 3 Imp gal 4 0 US gal 4 0 L 0 9 Imp gal 1 1 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 YFM400 U5GW13 book Page 3 Tuesday July 30 2002 2 23 PM ...

Page 157: ... 5 speed forward 1 speed reverse Left foot operation 40 12 3 333 34 18 1 889 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 4 21 mm 0 83 in Tire Type Size Front Size Rear Tubeless AT25 8 12 AT25 11 10 Brake Front brake type Operation Rear brake type Operation Dual disk brake Right hand operation Drum brake Left hand and right foot operation M...

Page 158: ...91 in Electrical Ignition system Generator system Battery type voltage capacity DC C D I A C magneto YTX20L BS 12V 18Ah Headlight type Krypton bulb Bulb voltage wattage quantity Headlight Tail brake light Meter lighting Indicator and warning lights Neutral Reverse Oil temperature 12V 30 30W 2 12V 5 21W 1 12V 3 4W 1 12V 1 7W 1 12V 1 7W 1 12V 1 7W 1 MODEL YFM400 U5GW13 book Page 5 Tuesday July 30 20...

Page 159: ...10 6 Fuses Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse 30 A 15 A 10 A 10 A 10 A MODEL YFM400 U5GW13 book Page 6 Tuesday July 30 2002 2 23 PM ...

Page 160: ...rpose 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 M...

Page 161: ...h the warranty The chart below is printed only as a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months 54 Months 60 Months U5GW13 book Page 1 Tuesday July 30 2002 2 2...

Page 162: ...13 1 EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U5GW13 book Page 1 Tuesday July 30 2002 2 23 PM ...

Page 163: ...13 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 U5GW13 book Page 2 Tuesday July 30 2002 2 23 PM ...

Page 164: ...14 1 EBU00435 YAMAHA EXTENDED SERVICE Y E S U5GW13 book Page 1 Tuesday July 30 2002 2 23 PM ...

Page 165: ...14 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 U5GW13 book Page 2 Tuesday July 30 2002 2 23 PM ...

Page 166: ...EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death U5GW13 book Page 3 Tuesday July 30 2002 2 23 PM ...

Page 167: ...EBU00437 U5GW13 book Page 5 Tuesday July 30 2002 2 23 PM ...

Page 168: ...r riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passe...

Page 169: ...Card fm Page 1 Wednesday June 13 2001 9 35 AM ...

Page 170: ...Card fm Page 2 Wednesday June 13 2001 9 35 AM ...

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