Yamaha BIG BEAR YFM400S Owner'S Manual Download | Manualshive

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7-9

Pre-operation checks

Always perform the pre-operation checks list-
ed on page 5-1 before riding for safety and
proper care of the ATV.

WARNING

POTENTIAL HAZARD
Failure to inspect the ATV before oper-
ating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident
or equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you
use it to make sure the ATV is in safe op-
erating condition.
Always follow the inspection and main-
tenance procedures and schedules de-
scribed 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 THE HAZARD
Always use the size and type tires spec-
ified in the Owner’s Manual for this vehi-
cle on pages 5-9–5-10.
Always maintain proper tire pressure as
described in the Owner’s Manual on
page 5-11.

U5GW14.book Page 9 Thursday, April 10, 2003 3:49 PM

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Summary of Contents for BIG BEAR YFM400S

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Page 3: ...mation 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 MAKE...

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: ... all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU01067 YFM400S OWNER S MANUAL 2003 by Yamaha Motor Corporation U S A 1st edition April 2003 All rights reserved Any reprinting or unauthorized use without the written permission of U5GW14 book Page 2 Th...

Page 6: ...cation 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 6 Speed limiter 4 7 Front brake lever 4 8 Brake pedal and rear brake 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 ...

Page 7: ...re pressure 5 11 Tire wear limit 5 12 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 6 To decelerate 6 7 Engine break in 6 7 Parking 6 9 Parking on a slope 6 9 Accessories and loading 6 11 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 ...

Page 8: ... arrester cleaning 8 17 Carburetor adjustment 8 18 Idle speed adjustment 8 19 Brake fluid replacement 8 23 Front brake lever free play 8 24 Brake pedal and rear brake 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 8 31 Battery 8 32 ...

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 U5GW14 book Page 4 Thursday April 10 2003 3 49 PM ...

Page 10: ...EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5GW14 book Page 1 Thursday April 10 2003 3 49 PM ...

Page 11: ...abels from your ATV If a label becomes 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 WARNING U5GW14 book Page 2 Thursday April 10 2003 3 49 PM ...

Page 12: ...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 U5GW14 book Page 3 Thursday April 10 2003 3 49 PM ...

Page 13: ...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 U5GW14 book Page 4 Thursday April 10 2003 3 49 PM ...

Page 14: ...cedures 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 Nev...

Page 15: ...he conditions Always go at a speed that is proper for 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...

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: ...p 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 deeper...

Page 18: ...d 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 U5GW14 book Page 5 Thursday...

Page 19: ...f 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 gasoline ...

Page 20: ... 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 U5GW14 book Page 7 Thursday April 10 2003 3 49 PM ...

Page 21: ...rier 6 Brake pedal 7 Headlights 8 Fuel cock 9 Recoil starter 10 Tail brake light 11 Rear wheel 13 Front wheel 14 Rear brake lever 15 Parking brake lock plate 16 Starter choke 17 Speedometer 18 Reverse knob 19 Front brake lever 20 Throttle lever 21 Fuel gauge 22 Main switch 23 Left handlebar switches U5GW14 book Page 1 Thursday April 10 2003 3 49 PM ...

Page 22: ...om 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 U5GW14 book Page 2 Thursday April 10 2003 3 49 ...

Page 23: ...icle 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 U5GW14 book Page 3 Thursday April 10 2003 3 49 PM ...

Page 24: ...n 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 U5GW14 book Page 1 Thursday April 10 2003 3 49 PM ...

Page 25: ...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 the load to specification Restart after making sure that the...

Page 26: ... 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 U5GW14 book Page 3 Thursday April 10...

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 U5GW14 book Page ...

Page 28: ...e 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 more than thirty m...

Page 29: ...ng the engine 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 l...

Page 30: ...rew 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 mm ...

Page 31: ...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 U5GW14 book Page 8 Thursday April 10 2003 3 49 PM ...

Page 32: ...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 33: ...the engine Reverse is at the bot tom position Neutral is one position above re verse 1 Shift pedal EBU10280 Reverse knob REV The reverse knob is used to shift into reverse gear Refer to the Reverse knob operation and reverse driving section page 6 4 before operating this machine in reverse gear 1 Reverse knob REV U5GW14 book Page 10 Thursday April 10 2003 3 49 PM ...

Page 34: ...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 U5GW14 book Page 11 Thursday April 10 2003 3 49 PM ...

Page 35: ...EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap U5GW14 book Page 12 Thursday April 10 2003 3 49 PM ...

Page 36: ...ion 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 U5GW14 book Page 13 Thursday April 10 20...

Page 37: ... 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 U5GW14 book Page 14 Thursday April 10 2003 3 49 PM ...

Page 38: ...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 U5GW14 book Page 15 Thursday April 10 2003 3 49 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 U5GW14 book Page 16 Thursday April 10 2003 3 49 PM ...

Page 40: ... ring in direction b NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ 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 shock absorbers on the left an...

Page 41: ...reload 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 NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ Standard position B A Minimum soft E Maximum hard U5GW14 book Page 18 Thursday April 10 2003 3 49 PM ...

Page 42: ...e 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 U5GW14 book Page 19 Thursday April 10 2003 3 49 ...

Page 43: ...f 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 _ EBU00112 U5GW14 book Page 20 Thursday April 10 2003 3 49 PM ...

Page 44: ...y 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 10 8 12 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 and switches C...

Page 45: ...N 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 U5GW14 book Page 2 Thursday April 10 2003 3 49 PM ...

Page 46: ...e 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 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 U5GW14 book Page 4 Thursday April 10 2003 3 49 PM ...

Page 48: ...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 Reserv...

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: ...t 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 10 8 12 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 may also ...

Page 51: ... tightness of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque EBU01003 Lights Check the headlights and tail brake light to make sure they are in working condition Re pair as necessary for proper operation EBU01170 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for pr...

Page 52: ...ions are not recommended Manufacturer Size Type Front DUNLOP AT25 x 8 12 KT121 Rear DUNLOP AT25 x 11 10 KT125 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...

Page 53: ... 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 U5GW14 book Page 10 Thursday April 10 2003 3 49 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 U5GW14 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 U5GW14 book Page 12 Thursday April 10 2003 3 49 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: ...starting 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 cl...

Page 58: ... 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: ...verse 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 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 WHA...

Page 60: ...n and repeatedly depress the shift pedal until it stops To shift into reverse first shift into neutral and then turn the reverse knob as explained on page 6 4 Depress the shift pedal and then release the reverse knob 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 t...

Page 61: ...ease the throttle lever 5 Shift into second gear and release the shift pedal 6 Open the throttle gradually 7 Follow the same procedure when shifting to the next higher gear 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 shif...

Page 62: ...wing material Because the engine is brand new you must not put an excessive load on it for the first several hours of running During the first 20 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition which might result in ex cessive engine heating must be avoided However momentary ...

Page 63: ...d continuous operation above half throt tle Allow a cooling off period of five to ten min utes after every hour of operation Vary the speed of the machine from time to time Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at any time After break in Avoid prolonged full throt...

Page 64: ...HAT 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 easily U5GW14 book Page ...

Page 65: ...o a stop by applying the brakes in low gear 2 Stop the engine 3 With the rear brake lever and pedal ap plied apply the parking brake and slowly release the brake pedal U5GW14 book Page 10 Thursday April 10 2003 3 49 PM ...

Page 66: ... 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 attac...

Page 67: ...tch If you are carrying 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 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 MAXIM...

Page 68: ...ls and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the ATV EBU13441 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 distribut...

Page 69: ...7 Riding Your ATV U5GW14 book Page 1 Thursday April 10 2003 3 49 PM ...

Page 70: ...U5GW14 book Page 2 Thursday April 10 2003 3 49 PM ...

Page 71: ...riate 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 the...

Page 72: ...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 the skills lea...

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 U5GW14 book Page 5 Thursday April 10 2003 3 49 PM ...

Page 74: ...N 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 U5GW14 book Page 6 Thursday April 10 2003 3 49 PM ...

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

Page 76: ...RD 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 U5GW14 book Page 8 Thursday April 10 2003 3 49 PM ...

Page 77: ... 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 a...

Page 78: ...d 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 can...

Page 79: ...l 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: ...ven 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 U5...

Page 81: ... 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 U5GW14 book Page 13 Thursday April 10 2003 3 49 PM ...

Page 82: ...ause 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 U5GW14 book Page 14 Thursday April 10 2003 3 49 PM ...

Page 83: ...ely to touch it WARNING 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 U5GW14 book Page 15 Thursday April 10 2003 3 ...

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 U5GW14 book Page 16 Thursday April 10 2003 3 49 PM ...

Page 85: ...rating 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 U5GW14 book Page 17 Thursday April 10 2003 3 49 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 U5GW14 book Page 18 Thursday April 10 2003 3 49 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 U5GW14 book Page 19 Thursday April 10 2003 3 49 PM ...

Page 88: ...Do not ride in areas posted no trespassing Do not ride on private property without getting permission WARNING POTENTIAL HAZARD 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 U5GW14 book Page 20 Thursday April 10 2003 3 49 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 smoot...

Page 90: ...op 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 s...

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: ...proper 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 Av...

Page 93: ...tant 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 h...

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 U5GW14 book Page 26 Thursday April 10 2003 3 49 ...

Page 95: ... or turning on hills WHAT CAN HAPPEN Could cause loss of control 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 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 wei...

Page 96: ... the ATV in gear The ATV could easily tip over back wards 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 ...

Page 97: ...ismount 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 U5GW14 book Page 29 Thursday April 10 2003 3 49 PM ...

Page 98: ...ion Whenever possible ride your ATV straight downhill Avoid sharp angles which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you 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...

Page 99: ...U5GW14 book Page 31 Thursday April 10 2003 3 49 PM ...

Page 100: ...ng 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 hills WHAT CAN HAP...

Page 101: ... 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 U5GW14 book Page 33 Thursday April 10 2003 3 49 PM ...

Page 102: ... or upset 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 let f...

Page 103: ...gained 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 _ U5GW14 book Page 35 Thursday April 10 2003 3 49 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: ...U5GW14 book Page 37 Thursday April 10 2003 3 49 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 U5GW14 book Page 38 Thursday April 10 2...

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: ...f necessary gradually let off the throttle and or steer to the outside of the turn See pag 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 war...

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: ...ust if necessary Crankcase breather system Check 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 ...

Page 113: ...sion Check operation Correct if necessary Drive shaft universal joint Lubricate with lithium soap based grease Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check operation Adjust headlight beams ITEM ROUTINE INITIAL EVERY 1 month 3 months 6 months 6 months 1 year NOTE Recommended brake fluid DOT 4 Brake fluid replacement When disassemblin...

Page 114: ...en 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 filler cap NOTE _ The oil level should be between the minimum and maximum level marks _ 5 If the engine oil is a...

Page 115: ...several minutes and then turn it off 3 Place a container under the engine to collect the used oil 4 Remove the engine oil filler cap and then remove the engine oil drain bolt to drain the oil from the crankcase CAUTION _ When removing the engine oil drain bolt the compression spring oil strainer and O ring will fallout Take care nottolosethese parts _ NOTE _ Skip steps 5 9 if the oil filter elemen...

Page 116: ...he bolts and then remove the oil filter el ement 1 Engine oil filter cover 2 Engine oil filter cover bolt 3 6 Clean the oil strainer and oil filter element with solvent 7 Check the O ring for damage and re place it if necessary 8 Install the oil filter element and O ring U5GW14 book Page 7 Thursday April 10 2003 3 49 PM ...

Page 117: ... _ Before installing the engine oil drain bolt be sure to install the O ring compression spring and oil strainer _ 1 O ring 2 Engine oil filter element 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 Engine oil drain bolt 32 Nm 3 2 m kgf 23 ft lbf U...

Page 118: ...or higher 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 Recommended oil See page 10 2 Oil quantity Without oil filter element replacement 2 9 L 2 6 Imp qt 3 1 US qt With oil filter element replacem...

Page 119: ...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 _ 4 Install the oil filler bolt 1 Final gear oil 2 Correct oil level 3 Final gear oil filler bolt U5GW14 book Page 10 Thursday April 10 2003 3 49 PM ...

Page 120: ... Place the machine 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 U5GW14 book Page 11 Thursday April 10 2003 3 49 PM ...

Page 121: ...ndicate the condition of the engine For example a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder Do not attempt to diagnose such problems yourself Instead take the ATV to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode ...

Page 122: ...y grime from the threads and tight en it to the specified torque EBU01301 Air filter element cleaning NOTE _ There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seat See page 4 15 for Spark plug gap 0 6 0 7 mm 0 024 0 028 in U5GW14 book Page ...

Page 123: ...Air filter case cover 2 Holder 3 3 Pull the air filter element out 4 Remove the foam cover from the air filter element 1 Air filter element 2 Foam cover U5GW14 book Page 14 Thursday April 10 2003 3 49 PM ...

Page 124: ...cess water or solvent out of the foam cover and let it dry CAUTION _ Do not twist the foam cover when squeezing it Do not apply oil to the foam cover _ WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the foam cover WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the foam cover U...

Page 125: ...ions 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 _ CAUTION _ Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration withou...

Page 126: ...move 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 U5GW14 book Page 17 Thursday April 10 2003 3 49 PM ...

Page 127: ...e 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 t...

Page 128: ...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 U5GW14 book Page 19 Thursday Ap...

Page 129: ...regularly This adjust ment 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 U5GW14 book Page 20 Thursday April 10 2003 3 49 PM ...

Page 130: ...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 U5GW14 book Page 21 Thursday April 10 2003 3 49 PM...

Page 131: ... 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 132: ...es 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 U5GW14 book Page 23 Thursday April 10 2003 3 49 PM ...

Page 133: ...g 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 U5GW14 book Pag...

Page 134: ...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 2 in a Brake pedal free play U5GW14 book Page 25 Thursday April 10 2003 3 49 PM ...

Page 135: ...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 2 Lever 3 Pin a Gap U5GW14 book Page 26 Thursday April 10 2003 3 49 PM ...

Page 136: ...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 U5GW14 book Page 27 Thursd...

Page 137: ...lows 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 EBU00346 Clutch adjustment 1 Loosen the locknut 2 Slowly turn the adjusting bolt counter clockwise until resistance is felt Then turn it 1 8 turn clockwise 1 Locknut 2...

Page 138: ...torque 20 Nm 2 0 m kgf 15 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 U5GW14 book Page 29 Thursday...

Page 139: ... 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 U5GW14 book Page 30 Thursday April 10 2003 3 49 PM ...

Page 140: ...ered side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel _ 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 64 Nm 6 4 m kgf 46 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf U5GW14 book Page 31 Thursday April 10 2003 3 49 PM ...

Page 141: ...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 magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes a...

Page 142: ...rten 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 fus...

Page 143: ...ing 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 U5GW14 book Page 34 Thursday April 10 2003 3 49 PM ...

Page 144: ...e bulb as follows 1 Remove the headlight assembly by re moving the screws 2 Disconnect the headlight coupler 1 Screw 2 2 Headlight coupler 3 Remove the headlight unit from the headlight assembly by removing the screws 1 Screw 3 U5GW14 book Page 35 Thursday April 10 2003 3 49 PM ...

Page 145: ... headlight bulb into position and then secure it in place with the bulb holder 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 AVOID THE HAZARD Wait for the bulb to cool before touching or removing it U5GW14 book Page 36 Thursday April 10 200...

Page 146: ...nts on the headlight bulb 7 Install the headlight bulb holder cover CAUTION _ Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated against the reflector _ 8 Place the headlight unit in the original po sition and then install the screws 9 Connect the headlight coupler 10 Place the headlight assembly in the orig inal position and then install the screws 11 Adj...

Page 147: ...w in direction a To lower the beam turn the adjusting screw in direction b EBU09451 Tail brake light bulb replacement 1 Open the storage box See page 4 16 2 Remove the nuts together with the wash ers 1 Storage box 2 Nut 2 3 Remove the bulb holder together with the bulb by turning it counterclockwise U5GW14 book Page 38 Thursday April 10 2003 3 49 PM ...

Page 148: ...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 U5GW14 book Page 39 Thursday April 10 2003 3 49 PM ...

Page 149: ...ience 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 vere...

Page 150: ...there is compression There is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check 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 coc...

Page 151: ...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 er...

Page 152: ...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 U5GW14 ...

Page 153: ...blespoon 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 ai...

Page 154: ...ry 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 U5GW14 book Page 4 Thursday April 10 2003 3 49 PM ...

Page 155: ...6 1 in 855 mm 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 U5GW14 book Page 1 ...

Page 156: ... 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 U5GW14 book Page 2 Thursday April 10 2003 3 49 PM ...

Page 157: ...ment 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 U5GW14 book Page 3 Thursday April 10 2003 3 49 PM ...

Page 158: ...ear 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 1 889 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 MODEL YFM400 U5GW14 book Page 4 Thursday April 10 2003 3 49 PM ...

Page 159: ... 150 mm 5 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 12V 30 30W 2 12V 5 21W 1 12V 3 4W 1 12V 1 7W 1 12V 1 7W 1 MODEL YFM400 U5GW14 book Page 5 Thursday April 10 2003 3 49 PM ...

Page 160: ...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 U5GW14 book Page 6 Thursday April 10 2003 3 49 PM ...

Page 161: ...e 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 Muffl...

Page 162: ...e with 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 U5GW14 book Page 1 Thursday April 10 2003 3 49 PM ...

Page 163: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U5GW14 book Page 1 Thursday April 10 2003 3 49 PM ...

Page 164: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U5GW14 book Page 2 Thursday April 10 2003 3 49 PM ...

Page 165: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S U5GW14 book Page 1 Thursday April 10 2003 3 49 PM ...

Page 166: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U5GW14 book Page 2 Thursday April 10 2003 3 49 PM ...

Page 167: ...EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death U5GW14 book Page 3 Thursday April 10 2003 3 49 PM ...

Page 168: ...EBU00437 U5GW14 book Page 5 Thursday April 10 2003 3 49 PM ...

Page 169: ...EBU00438 ...

Page 170: ...Card fm Page 1 Wednesday June 13 2001 9 35 AM ...

Page 171: ...Card fm Page 2 Wednesday June 13 2001 9 35 AM ...

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