Yamaha KODIAK 400 Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND
ADJUSTMENT.................................. 8-1

Owner’s manual and tool kit............ 8-1
Periodic maintenance/

lubrication ...................................... 8-3

Panel removal and installation ........ 8-6
Engine oil and oil filter cartridge .... 8-12
Final gear oil .................................. 8-18
Differential gear oil replacement ... 8-21
Cooling system.............................. 8-23
Changing the coolant .................... 8-24
Axle boots...................................... 8-28
Spark plug inspection .................... 8-29
Air filter element cleaning .............. 8-31
V-belt cooling duct check hose ..... 8-34
V-belt case drain plug.................... 8-35
Spark arrester cleaning ................. 8-35
Carburetor adjustment................... 8-37
Idle speed adjustment ................... 8-37
Valve clearance adjustment .......... 8-38
Throttle lever adjustment............... 8-38
Select lever safety system cable

adjustment................................... 8-39

Front brake pad check ...................8-39
Rear brake pad check....................8-40
Inspecting the brake fluid level ......8-41
Brake fluid replacement .................8-43
Front brake lever free play.............8-43
Adjusting the rear brake lever and

brake pedal ..................................8-44

Adjusting the rear brake light

switch ...........................................8-47

Cable inspection and

lubrication.....................................8-48

Lubricating the brake levers and

brake pedal ..................................8-48

Rear knuckle upper and lower

pivot lubrication ............................8-49

Wheel removal ...............................8-50
Wheel installation...........................8-50
Battery............................................8-51
Battery maintenance......................8-53
Fuse replacement ..........................8-53
Replacing a headlight bulb ............8-55
Headlight beam adjustment...........8-58

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U1P110.book Page 3 Thursday, May 27, 2004 10:08 AM

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Summary of Contents for KODIAK 400

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

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

Page 5: ...l applicable OFF ROAD noise level and spark arrester laws and regu lations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU01067 YFM400FAT OWNER S MANUAL 2004 by Yamaha Motor Corporation U S A 1st edition May 2004 All rights reserved Any reprinting or unauthorized use without the written permission of U1P110 book Page 2 Thursday...

Page 6: ...tification 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 6 Fuel gauge 4 6 Handlebar switches 4 7 Throttle lever 4 10 Speed limiter 4 11 Front brake lever 4 12 Brake pedal and rear brake lever 4 12 Drive select lever 4 13 Recoil starter 4 13 Fuel tank cap 4 14 Fuel cock 4 15 Starter choke 4 16 Seat 4 17 Front ...

Page 7: ...ting a cold engine 6 1 Starting a warm engine 6 3 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 22 Climbing uphill 7 24 Riding downhill 7 30 Crossing a slope 7 32 Crossing through shallow water 7 34 Riding over rough terrain 7 37 Sliding and skidding 7 38 W...

Page 8: ...ck hose 8 34 V belt case drain plug 8 35 Spark arrester cleaning 8 35 Carburetor adjustment 8 37 Front brake pad check 8 39 Rear brake pad check 8 40 Inspecting the brake fluid level 8 41 Brake fluid replacement 8 43 Front brake lever free play 8 43 Adjusting the rear brake lever and brake pedal 8 44 Adjusting the rear brake light switch 8 47 Cable inspection and lubrication 8 48 Lubricating the b...

Page 9: ...roubleshooting charts 8 62 CLEANING AND STORAGE 9 1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE 9 10 11 12 13 14 U1P110 book Page 4 Thursday May 27 2004 10 08 AM ...

Page 10: ...EBU00464 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS U1P110 book Page 1 Thursday May 27 2004 10 08 AM ...

Page 11: ...difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an accident Never exceed the maximum front cargo limit of 40kg 88 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4877 00 WARNING U1P110 book Page 2 Thursday ...

Page 12: ...ever exceed the maximum rear cargo limit of 80kg 176 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4897 00 WARNING 5 6 PULLING LOAD 4900 N 5 0 0 k g f 1102 l b f TONGUE WEIGHT 147 N 1 5 k g f 33 l b f 5ND F151K 00 MAXIMUM LOADING LIMIT MAXIMUM LOADING LIMIT U1P110 book Page 3 Thursday May 27 2004 10 08 AM ...

Page 13: ...7 8 U1P110 book Page 4 Thursday May 27 2004 10 08 AM ...

Page 14: ...ut proper training or instruction Take a Training Course Begin ners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc Never allow a child under age 16 to operate an...

Page 15: ...ou 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 operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV ...

Page 16: ...w proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures...

Page 17: ...sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly d...

Page 18: ...lames or other sources of ignition such as the pilot When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some ga...

Page 19: ...n a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation U1P110 book Page 6 Thursday May 27 2004 10 08 AM ...

Page 20: ...preload adjusting ring 7 Brake pedal 8 V belt case 9 Radiator cap 10 Fuel cock 11 Air filter case 14 Engine oil dipstick 15 Oil filter cartridge 16 Coolant reservoir 17 V belt cooling duct check hose 18 Rear brake lever 19 Left handlebar switches 20 Starter choke 21 Drive select lever 22 Speedometer 23 Main switch 24 Fuel tank cap 25 Auxiliary DC jack 26 Right handlebar switch 27 Throttle lever U1...

Page 21: ...g spare parts 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 U1P110 book Page 2 Thursday May...

Page 22: ...E The 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 U1P110 book Page 3 Thursday May 27 2004 10 08 AM ...

Page 23: ...ain switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights taillight and meter lighting come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position 1 Main switch U1P110 book Page 1 Thursday May 27 2004 10 08 AM ...

Page 24: ... the coolant temperature is too hot If the 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 The electrical circuit of the warning light can be checked according to the following proce dures 1 Set the engine stop switch to and turn the key to ON 2 Shift the drive select lever into the neutral position or park posi...

Page 25: ...the ATV is overloaded If this happens reduce the load to specification Restart after making sure that the light is out Continuous use while the light is on may cause damage to the en gine _ U1P110 book Page 3 Thursday May 27 2004 10 08 AM ...

Page 26: ...ture warning light comes on Coolant temperature warning light does not come on Coolant temperature and electrical circuit are OK Go ahead with riding Push the start switch with the transmission in the neutral position or park position Ask a Yamaha dealer to inspect the electrical circuit Coolant temperature warning light comes on momentarily U1P110 book Page 4 Thursday May 27 2004 10 08 AM ...

Page 27: ...s indicator light comes on when the 2WD 4WD switch is in the 4WD position NOTE Due to the synchronizing mechanism in the differential gear case the light may not come on until the ATV starts moving EBU09720 Neutral indicator light N This indicator light comes on when the drive select lever is in the N position U1P110 book Page 5 Thursday May 27 2004 10 08 AM ...

Page 28: ... fore going to reserve This information will enable you to plan fuel stops in the future 1 Speedometer 2 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 2 Red line NOTE If the machine runs out of fuel move the fuel cock lever to the RES position Approxi U1P110 b...

Page 29: ...he battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it _ EBU12050 Engine stop switch Make sure that the engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run wh...

Page 30: ...starting the engine See page 6 1 for details 1 Four wheel drive switch 2WD 4WD EBU00601 On Command four wheel drive switch 2WD 4WD To change from two wheel drive 2WD to four wheel drive 4WD stop the ATV and set the switch to the 4WD position To change from four wheel drive 4WD to U1P110 book Page 8 Thursday May 27 2004 10 08 AM ...

Page 31: ...n some circumstances Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause the ATV to unexpectedly handle differ ently This could distract the operator and increase the risk of losing control and an accident HOW TO AVOID THE HAZARD Always stop the ATV before changing from 2WD to 4WD or vice versa U1P110 book Page 9 Thursday May 27 2004 10 08 AM ...

Page 32: ...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 33: ...more than 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to 3 ...

Page 34: ...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 U1P110 book Page 12 Thursday May 27 2004 10 08 AM ...

Page 35: ...rk positions Refer to page 6 4 for the drive select lever operation 1 Drive select lever EBU08550 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt Then pull forcefully being careful not to pull the rope all the way out 1 Recoil starter U1P110 book Page 13 Thursday May 27 2004 10 08 AM ...

Page 36: ...D Starting the engine without setting the drive select lever to the park position P WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Set the drive select lever to the park po sition before starting the engine U1P110 book Page 14 Thursday May 27 2004 10 08 AM ...

Page 37: ...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 1 Arrow mark pointing to OFF OFF Position ON Position U1P110 book P...

Page 38: ...air fuel mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 RES Position U1P110 book Page 16 Thursday May 27 2004 10 08 AM ...

Page 39: ...e rear 1 Seat 2 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 U1P110 book Page 17 Thursday May 27 2004 10 08 AM ...

Page 40: ...re to wrap them in a plas tic bag so that they will not get wet When washing the ATV be careful not to let any wa ter enter the storage compartment NOTE _ There is a check hose at the bottom of the storage compartment If any water collects in this hose remove the hose empty it and then install it _ Maximum load limit 40 kg 88 lb Maximum load limit 80 kg 176 lb Maximum load limit 2 0 kg 4 lb U1P110...

Page 41: ...can be adjusted to suit the rider s weight and riding conditions Adjust the spring preload as follows To increase the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b U1P110 book Page 19 Thursday May 27 2004 10 08 AM ...

Page 42: ... ring 2 Position indicator NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ 1 Special wrench Standard position 2 1 Minimum soft 5 Maximum hard U1P110 book Page 20 Thursday May 27 2004 10 08 AM ...

Page 43: ...when the engine is running 1 Set the light switch to OFF 1 Auxiliary DC jack cap WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set ting U1P110 book Page 21 Thursday May 27 2004 ...

Page 44: ...the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may be come difficult Do not use an automotive cigarette 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A U1P110 book Page 22 Thursday May 27 2004 10 08 AM ...

Page 45: ... 5 3 8 40 8 46 Fuel Check fuel level Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 6 8 12 8 17 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 8 8 23 8 27 Final gear oil and differential gear oil Check for leakage 5 6 5 7 8 18 8 22 Throttle Check for proper throttle cable operation and free play 5 9 8 38 Wheels and t...

Page 46: ...d pedal They should move smoothly and there should be a firm feeling when the brakes are applied If not have a Yamaha dealer inspect the brake system Brake fluid level 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 ...

Page 47: ...y are working properly If the brakes do not provide proper braking per formance inspect the brake pads for wear See pages 8 39 8 40 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with ...

Page 48: ...igned to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 15 0 L 3 30 Imp gal 3 96 US gal Reser...

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

Page 50: ...on do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ EBU00493 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 18 8 20 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils m...

Page 51: ...l gear oil Make sure the differential gear oil is at the specified level Add oil as necessary See pages 8 21 8 22 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil U1P110 book Page 7 Thursday May 27 2004 10 08 AM ...

Page 52: ...years See pages 8 23 8 27 for details CAUTION _ Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water _ Coolant reservoir capacity WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the...

Page 53: ...ers 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 tightening torque EBU10030 Lights Check the headlights and tail brake light to make sure they are in working condition Re EBU11700 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for proper operation U1P1...

Page 54: ... Ltd for this model Other tire combina tions are not recommended ACE 01E 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 25 kPa 0 25 kgf cm2 3 6 psi Rear 25 kPa 0 25 kgf cm2 3 6 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dislodge fro...

Page 55: ... 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 U1P110 book Page 11 Thursday May 27 2004 10 08 AM ...

Page 56: ... reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifica tions ACE 02EACE 02E 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 25 kPa 22 kPa 28 kPa U1P110 book Page 12 Thursday May 27 2004 10 08 AM...

Page 57: ...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 U1P110 book Page 13 Thursday May 27 2004 10 08 AM ...

Page 58: ...liar with all 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 HO...

Page 59: ... shift into neutral or park before 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 Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 6 ...

Page 60: ...e If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it CAUTION _ See the Engine break in section prior to operating the engine for the first time _ EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used The...

Page 61: ...aged _ Shifting Neutral to Forward 1 Bring the ATV to a complete stop and re turn the throttle lever to the closed posi tion 2 Apply the brakes then shift by moving the drive select lever along the shift guide NOTE _ Make sure that the drive select lever is com pletely shifted into position 1 Drive select lever 3 Open the throttle lever gradually U1P110 book Page 4 Thursday May 27 2004 10 08 AM ...

Page 62: ... brake pedal 3 Shift from neutral to reverse or from re verse to park and vice versa by moving the drive select lever along the shift guide 1 Drive select lever 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 electrical circuit Due to the synchronizing mechanism in the engine the light may not come on un til the ATV s...

Page 63: ...properly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slow ly U1P110 book Page 6 Thursday May 27 2004 10 08 AM ...

Page 64: ...ch 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 p...

Page 65: ...ll throttle at any time After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU06120 Parking When parking stop the engine and shift the drive select lever into the park position then turn the fuel cock to the OFF position U1P110 book Page 8 Thursday May 27 2004 10 08 AM ...

Page 66: ... 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 place the machine transversely across the in cline 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 easi...

Page 67: ...a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object atta...

Page 68: ...ng cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an a...

Page 69: ...fects 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 and securely attached Reduce speed when carrying cargo or pulling a ...

Page 70: ...EBU15250 WARNING _ Indicates a potential hazard that could result in serious injury or death U1P110 book Page 13 Thursday May 27 2004 10 08 AM ...

Page 71: ...7 Riding Your ATV U1P110 book Page 1 Thursday May 27 2004 10 08 AM ...

Page 72: ...pes 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 activity providing you with hours of pleasure Owner s Manual completely and understand the operation of the controls Pay particular at tention to the safety info...

Page 73: ... 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 le...

Page 74: ...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 90 cc U1P110 book Page 5 Thursday May 27 2004 10 08 AM ...

Page 75: ...EN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers U1P110 book Page 6 Thursday May 27 2004 10 08 AM ...

Page 76: ...accident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long slee...

Page 77: ...ARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV U1P110 book Page 8 Thursday May 27 2004 10 08 AM ...

Page 78: ... 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 79: ...i mum Turning in the adjusting screw 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 See page 4 11 for details 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...

Page 80: ...ailer hitch Pulling load 500 kgf 1 102 lbf Total weight of trailer and cargo Tongue weight 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 secu...

Page 81: ...even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation U...

Page 82: ...G POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off U1P110 book Page 13 Thursday May 27 2004 10 08 AM ...

Page 83: ...cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed U1P110 book Page 14 Thursday May 27 2004 10 08 AM ...

Page 84: ...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 touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it U1P110 book Page 15 Thursday...

Page 85: ... 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 U1P110 book Page 16 Thursday May 27 2004 10 08 AM ...

Page 86: ...erating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways U1P110 book Page 17 Thursday May 27 2004 10 08 AM ...

Page 87: ...NG 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 overturn ing or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar terrain U1P110 book Page 18 Thursday May 27 2004 10 08 AM ...

Page 88: ...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 U1P110 book Page 19 Thursday May 27 2004 10 08 AM ...

Page 89: ...er hitch Do not ride in areas posted no trespassing Do not ride on private property without getting permission WARNING WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles U1P110 book Page 20 Thursday May 27 2004 10 08 AM ...

Page 90: ... riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling return the starter choke to the closed position and shift the drive select lever into the forward position Ap ply the throttle slowly and smoothly The cen trifugal clutch will engage and you will start to accelerate If the throttle is applied too abrupt ly the front wheels may lift ...

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

Page 92: ...mproper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember A...

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

Page 94: ...as 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 The ATV could flip over backwards An obstacle a sharp drop or another vehicle or person could be on the other side of the hill U1P110 book Page 25 Thursday May 27 2004 10 08 AM...

Page 95: ...ENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible U1P1...

Page 96: ...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 U1P110 book Page 27 Thursday May 27 2004 10 08 AM ...

Page 97: ... nected by the drive train This means that ap plying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid and rear brakes gradually or dismount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbin...

Page 98: ...topped shift to the parking position P 4WD Apply both front and rear brakes gradually When fully stopped shift to the parking position P 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 U1P110 book Page 29 Thursday May 27 2004 10 08 AM ...

Page 99: ... a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake le ver or the brake pedal will brake the wheels on the downhill side Avoid sudden applica tion of either the front or rear brake because the wheels on the uphill s...

Page 100: ...ing down hills as described in this Own er s Manual Note a special technique is required when braking as you go down a hill HOW TO AVOID THE HAZARD Always check the terrain carefully be fore you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that U1P110 book Page 31 Thursday May 27 2004 10 08 AM ...

Page 101: ...y 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 WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill unt...

Page 102: ...U1P110 book Page 33 Thursday May 27 2004 10 08 AM ...

Page 103: ...ery or up set the ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to l...

Page 104: ...ed water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hose and the storage compartment check hose Also remove the V belt case drain plug to drain any water that may have accumulated Wash the ATV in fresh water if it has been operated in salt water or muddy conditions _ U1P110 book Page 35 Thursday May 27 2004 10...

Page 105: ...1 V belt cooling duct check hose left front side of ATV 1 Storage compartment check hose U1P110 book Page 36 Thursday May 27 2004 10 08 AM ...

Page 106: ...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 107: ...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 U1P110 book Page 38 Thursday May 27 200...

Page 108: ...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 109: ...If necessary gradually let off the throttle and or steer to the outside of the turn See If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerat ing is not recommended until you have cor rected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for ward...

Page 110: ...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 111: ...manual 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 under the seat 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 c...

Page 112: ...our 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 inst...

Page 113: ...ITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours More often in we...

Page 114: ...ck for cracks or damage Wheels Check balance damage runout Repair if necessary Wheel bearing Check bearing assemblies for looseness damage Replace if damaged Front and rear suspension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Rear upper and lower knuckle pivots Lubricate with lithium soap based grease Drive shaft univer...

Page 115: ...er and cal iper replace the oil seals every two years Replace the brake hoses every four years or if cracked or damaged WARNING _ Indicates a potential hazard that could result in serious injury or death Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check operation Adjust headlight beams ITEM ROUTINE Whichever comes first INITIAL EVERY mon...

Page 116: ...d need to be removed to perform some of the maintenance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 1 Panel A 2 Panel B 1 Panel C 2 Panel D 3 Panel E 4 Panel F U1P110 book Page 6 Thursday May 27 2004 10 08 AM ...

Page 117: ...EBU00700 Panel A D To remove 1 Remove the seat 2 Pull outward on the areas shown and then pull upward U1P110 book Page 7 Thursday May 27 2004 10 08 AM ...

Page 118: ...To install 1 Place the panel in its original position 2 Install the seat U1P110 book Page 8 Thursday May 27 2004 10 08 AM ...

Page 119: ...al position and in stall the bolt CAUTION _ When installing the panel be sure not to pinch the cables or wires _ EBU15370 Panel C To remove 1 Remove the top carrier bolts 1 Carrier bolt 4 2 Remove the carrier bolts under the fend ers and then take the carrier off U1P110 book Page 9 Thursday May 27 2004 10 08 AM ...

Page 120: ...the quick fastener screws 2 Place the carrier in the original position and then install the carrier bolts under the fenders 3 Install the top carrier bolts and then tight en all bolts to the specified torques Tightening torque Carrier bolt top 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt under fenders 7 Nm 0 7 m kgf 5 1 ft lbf U1P110 book Page 10 Thursday May 27 2004 10 08 AM ...

Page 121: ... and then take the panel off To install Place the panel in the original position and then install the bolts 1 Panel E 2 Bolt 3 EBU00638 Panel F To remove Pull outward on the areas shown 1 Panel F U1P110 book Page 11 Thursday May 27 2004 10 08 AM ...

Page 122: ...cartridge replaced at the inter vals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Remove panel F See pages 8 11 8 12 for panel removal and installation proce dures 2 Place the ATV on a level surface 3 Start the engine warm it up for several minutes and then turn it off 4 Wait a few minutes until the oil settles U1P110 book Page 12 Thursday May 27 2004...

Page 123: ...dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level NOTE _ The engine oil should be between the mini mum and maximum level marks _ 1 Maximum level mark 2 Minimum level mark 7 If the engine oil is at or below the mini U1P110 book Page 13 Thursday May 27 2004 10 08 AM ...

Page 124: ...1 Remove panel F See pages 8 11 8 12 for panel removal and installation proce dures 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to col lect the used oil and then remove the en gine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase U1P110 book Page 14 Thursday May 27 2004 10 08 AM ...

Page 125: ...tallation procedures 6 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter wrench NOTE _ An oil filter wrench is available at a nearby Yamaha dealer _ 7 Apply a light coat of engine oil to the O ring of the new oil filter cartridge NOTE _ Make sure the O ring is seated properly _ U1P110 book Page 15 Thursday May 27 2004 10 08 AM ...

Page 126: ...ter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf U1P110 book Page 16 Thursday May 27 2004 10 08 AM ...

Page 127: ...not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ 12 Start the engine and warm it up for seve ral minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 13 Turn the engine off and then check the Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 16 ft lbf Recomm...

Page 128: ...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 and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 16 ft lbf U1P110 book Page 18 Thursday May 27 ...

Page 129: ...ace the ATV on a level surface 3 Place a container under the final gear case to collect the used oil 4 Remove the oil filler bolt and the drain 1 Final gear oil drain bolt 5 Install the drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 16 ft lbf U1P110 book Page 19 Thursday May 27 2004 10 08 AM ...

Page 130: ... and the final gear case guard by installing the bolts and then tightening them to the specified torques Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 23 L 0 20 Imp qt 0 24 US qt Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 16 ft lbf Tightening torques Engine guard bolt 7 0 Nm 0 7 m kgf 5 1 ft lbf Final gear case guard bolt 7 0 Nm 0 7 m kgf 5 1 ft lbf U1P110 book P...

Page 131: ... used oil 3 Remove the oil filler bolt and oil drain bolt to drain the oil 1 Differential case oil filler bolt 1 Differential gear oil drain bolt 4 Install the oil drain bolt and then tighten it to the specified torque Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf U1P110 book Page 21 Thursday May 27 2004 10 08 AM ...

Page 132: ...y is greater than the recommended oil quantity therefore the oil level cannot be accurately checked from the oil filler cap hole _ CAUTION _ Be sure no foreign material enters the dif ferential gear case _ 6 Install the oil filler bolt and then tighten it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil ...

Page 133: ...n the minimum and maximum level marks _ 3 If the coolant is at or below the minimum level mark remove panel D See pages 8 7 8 8 for panel removal and installa tion procedures remove the reservoir cap add coolant to the maximum level mark install the reservoir cap and then install the panel Coolant reservoir capacity up to the maximum level mark 0 25 L 0 22 Imp qt 0 26 US qt U1P110 book Page 23 Thu...

Page 134: ...temperature in the radi ator _ If your ATV overheats see page 8 62 for de tails EBU12572 Changing the coolant WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag ov...

Page 135: ... 3 Place a container under the engine and then remove the coolant drain bolt Use a trough or a similar object as shown to prevent coolant from spilling on the foot rest 1 Trough 4 Remove the front carrier and panel C See pages 8 9 8 10 for removal and in stallation procedures U1P110 book Page 25 Thursday May 27 2004 10 08 AM ...

Page 136: ...coolant res ervoir side and then drain the coolant from the coolant reservoir 1 Coolant reservoir hose 9 After draining the coolant thoroughly flush the cooling system with clean tap water 10 Replace the coolant drain bolt washer if it is damaged install the coolant drain bolt and then tighten it to the specified torque Tightening torque U1P110 book Page 26 Thursday May 27 2004 10 08 AM ...

Page 137: ...l minutes Stop the engine and then check the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator 15 Check for coolant leakage NOTE _ If any leakage is found have a Yamaha deal er check the cooling system _ 16 Install the panels and the front carrier Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for al...

Page 138: ...ts Check the protective boots for holes or tears If any damage is found have them replaced by a Yamaha dealer 1 Front axle boot 2 each side 1 Rear axle boot 2 each side U1P110 book Page 28 Thursday May 27 2004 10 08 AM ...

Page 139: ... wrench in the tool kit 1 Spark plug wrench Inspection The spark plug is an important engine compo nent and is easy to inspect The condition of the spark plug can indicate the condition of the engine The ideal color on the white insulator around the center electrode is a medium to light tan color for a ATV that is being ridden normally U1P110 book Page 29 Thursday May 27 2004 10 08 AM ...

Page 140: ...ce the spark plug with the specified plug Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification a Spark plug gap 2 Clean the gasket surface Wipe off any grime from the threads 3 Install the spark plug and tighten it to the specified torque Specified spark plug DR8EA NGK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Tightening torque Spark ...

Page 141: ...torque as soon as possible _ 4 Install the spark plug cap 5 Install the panel EBU15140 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 17 for U1P110 book Page 31 Thursday May 27 2004 10 0...

Page 142: ...r element assembly 4 Pull off the lock plate and then remove the air filter element from its frame 1 Air filter element frame 2 Air filter element 3 Lock plate 5 Wash the element gently but thoroughly in solvent U1P110 book Page 32 Thursday May 27 2004 10 08 AM ...

Page 143: ...ter element over its frame and then install the lock plate 10 Install the air filter element assembly 11 Install the air filter case cover by hooking the fasteners onto the air filter case 12 Install the seat WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOI...

Page 144: ...tight seal Tighten all fittings securely to avoid the possibility of unfiltered 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 without the air filter element will af EBU06411 V belt cooling duct check hose If dust or water collects i...

Page 145: ...r re moving the plug have a Yamaha dealer in spect the ATV as the water may affect other engine parts _ EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the bolts 2 Remove the tailpipe by pulling it out of the muffler 1 Bolt 3 2 Tailpipe 3 Tap the tailpipe lightly and then use a U1P110 book Page 35 Thursday May 27 2004 10 08...

Page 146: ...ust 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 or to touching exhaust components Do not start the engine when cleaning the exhaust system U1P110 book Page 36 Thursday May 27 2004 10 08 AM ...

Page 147: ...poor engine perfor mance and damage may result EBU12580 Idle speed adjustment NOTE _ A diagnostic tachometer must be used for this procedure _ 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Remove panel D See pages 8 7 8 8 for removal and inst...

Page 148: ...e To prevent this the valve clear ance must be adjusted regularly This adjust 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 0 5 0 mm 0 12 0 20 in 3 Tighten the locknut U1P110 book Page 38 Thursday May 27 2004 10 08 AM ...

Page 149: ...be adjusted regu larly This adjustment however should be left to a Yamaha dealer EBU13090 Front brake pad check Check the brake pads for damage and wear If a brake pad thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the pads as a set a Brake pad thickness NOTE _ The wheels need to be removed to check the U1P110 book Page 39 Thursday May 27 2004 10 08 AM ...

Page 150: ...ut disassembling the brake Check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared ask a Yamaha dealer to replace the pads as a set NOTE _ The wheels need to be removed to check the brake pads See pages 8 50 8 51 for wheel removal and installation procedures _ U1P110 book Page 40 Thursday May 27 2004 10 08 AM ...

Page 151: ...eplenish when necessary A low brake fluid level may indicate worn brake pads and or brake sys tem leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage The rear brake fluid master cylinder reservoir is located under panel C See pages 8 9 8 10 for panel re moval and installation procedures 1 Minimum level mark FRONT REAR U1P110 book Page 4...

Page 152: ...s may result in a harmful chemical reaction and lead to poor brake perfor mance Be careful that water does not enter the master cylinder reservoirs when refilling Water will significantly lower the boiling point of the fluid and may result in vapor Brake fluid may deteriorate painted surfac es or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer check the cause if the br...

Page 153: ...odic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years EBU11870 Front brake lever free play The front brake lever should have a free play of zero mm zero in at the lever end If not have a Yamaha dealer check the brake sys tem a Front brake lever free play U1P110 book Page 43 Thursday May 27 2004 10 08 AM ...

Page 154: ... to WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of...

Page 155: ...er free play Be sure not to step on the brake pedal Make sure the brake pedal does not move _ Adjusting the brake pedal The top of the brake pedal should be posi tioned 72 mm 2 83 in above the top of the footrest If not ask a Yamaha dealer to adjust it a Brake pedal position U1P110 book Page 45 Thursday May 27 2004 10 08 AM ...

Page 156: ...could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag All air must be bled from the brake system Replacement of brake components re quires professional knowledge These U1P110 book Page 46 Thursday May 27 2004 10 08 AM ...

Page 157: ...ake light switch as follows 1 Remove panel B See page 8 9 for pan el removal and installation procedures 2 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 adjust ing nut in direction b 3 Install the panel 1 Rear brake light switch 2 Adjusting nut U1...

Page 158: ... 8 9 for panel removal and in stallation procedures _ 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 Recomme...

Page 159: ...pper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun 1 Upper knuckle 2 Lower knuckle Recommended lubricant Lithium soap based grease U1P110 book Page 49 Thursday May 27 2004 10 08 AM ...

Page 160: ... 4 Remove the wheel 1 Nut 4 EBU11211 Wheel installation 1 Install the wheel and the nuts NOTE _ The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its ta pered side towards the wheel _ U1P110 book Page 50 Thursday May 27 2004 10 08 AM ...

Page 161: ... sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the bat tery If the battery seems to have discharged consult a Yamaha dealer 1 Negative battery terminal 2 Positive battery terminal Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf U1P110 book Page 51 Thursday May 27 2004 10 08 AM ...

Page 162: ...ARD 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 and get prompt medical attention Keep batteries away from sparks fl...

Page 163: ... Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU08762 Fuse replacement 1 The main fuse and the fuse box are locat ed under the seat 2 If a fuse is blown turn off the main switch and the switch of the circuit in question Then install a new fuse of the specified amperage Turn on the main...

Page 164: ...ht fuse 2 Ignition fuse 3 Auxiliary DC jack fuse 4 Four wheel drive fuse 5 Signaling system fuse 6 Spare fuse 3 Specified fuses Main fuse 30 0A Headlight fuse 15 0A Ignition fuse 10 0A U1P110 book Page 54 Thursday May 27 2004 10 08 AM ...

Page 165: ...e bulb holder cover at the rear of the headlight by pulling it off 1 Headlight bulb holder cover 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 U1P110 book Page 55 Thursday May 27 2...

Page 166: ...ht bulb holder by turning it counterclockwise 1 Headlight bulb holder 3 Remove the defective bulb by unhooking the headlight bulb holder tabs 1 Headlight bulb holder tab 2 U1P110 book Page 56 Thursday May 27 2004 10 08 AM ...

Page 167: ...ass the luminos ity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb 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 befo...

Page 168: ... at the rear of the headlight EBU01089 Headlight beam adjustment CAUTION _ It is advisable to have a Yamaha dealer make this adjustment _ To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b U1P110 book Page 58 Thursday May 27 2004 10 08 AM ...

Page 169: ...ight unit 2 Nut 2 2 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Tail brake light unit 2 Tail brake light bulb holder 3 Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise U1P110 book Page 59 Thursday May 27 2004 10 08 AM ...

Page 170: ...l a new bulb in the bulb holder by pushing it inward and turning it clockwise 5 Install the bulb holder together with the bulb by turning it clockwise 6 Install the washers and then install the nuts U1P110 book Page 60 Thursday May 27 2004 10 08 AM ...

Page 171: ...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 172: ...the electric starter to see if there is compression There is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap Check the fuel flow T...

Page 173: ...ver the cap Al low any remaining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the coolant reservoir and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See NOTE Restart the engine If the engine overheats again ask...

Page 174: ... to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash e...

Page 175: ...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 U1P110 ...

Page 176: ...ablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing in a humid or salt a...

Page 177: ...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 U1P110 book Page 4 Thursday May 27 2004 10 08 AM ...

Page 178: ...830 mm 32 7 in Wheelbase 1 233 mm 48 5 in Minimum ground clearance 245 mm 9 65 in Minimum turning radius 3 000 mm 118 1 in Basic weight With oil and full fuel tank 279 0 kg 615 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 401 0 cm3 Bore stroke 84 5 71 5 mm 3 33 2 81 in U1P110 book Page 1 Thursday May 27 2004 10 08 AM ...

Page 179: ...0 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher U1P110 book Page 2 Thursday May 27 2004 10 08 AM ...

Page 180: ...riodic oil change 0 35 L 0 31 Imp qt 0 37 US qt Radiator capacity including all routes 1 32 L 1 16 Imp qt 1 40 US qt Air filter Wet element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 15 0 L 3 30 lmp gal 3 96 US gal Fuel reserve amount 4 5 L 0 99 lmp gal 1 19 US gal Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Model YFM400FA U1P110 book Page 3 Thursday May 27 2004 10 08 AM ...

Page 181: ...lt Secondary reduction system Shaft drive Secondary reduction ratio 39 24 24 18 33 9 7 944 Transmission type V belt automatic Operation Left hand operation Reverse gear 29 17 1 706 Forward gear 38 23 1 652 Chassis Frame type Steel tube frame Caster angle 2 5 Trail 8 5 mm 0 33 in Tire Type Tubeless Model YFM400FA U1P110 book Page 4 Thursday May 27 2004 10 08 AM ...

Page 182: ...uble wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 160 0 mm 6 30 in Rear wheel travel 180 0 mm 7 09 in Electrical Ignition system DC C D I Generator system A C magneto Battery type YTX14AH Model YFM400FA U1P110 book Page 5 Thursday May 27 2004 10 08 AM ...

Page 183: ...tor light 12 V 1 7 W 1 Coolant temperature warning light 12 V 1 7 W 1 Park position indicator light 12 V 1 7 W 1 Four wheel drive indicator light 12 V 1 7 W 1 Fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Four wheel drive fuse 3 0 A Signaling system fuse 10 0 A Model YFM400FA U1P110 book Page 6 Thursday May 27 2004 10 08 AM ...

Page 184: ...se of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muff...

Page 185: ...e minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 06E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 200 750 75 6 2 400 1 500 150 12 4 800 3 000 300 18 7 200 4 500 450 24 9 600 6 000 600 30 12 000 7 500 750 36 14 400 9 000 900 42 16 800 10 500 1 050 48 19 200 12 000 1 2...

Page 186: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U1P110 book Page 1 Thursday May 27 2004 10 08 AM ...

Page 187: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U1P110 book Page 2 Thursday May 27 2004 10 08 AM ...

Page 188: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S U1P110 book Page 1 Thursday May 27 2004 10 08 AM ...

Page 189: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U1P110 book Page 2 Thursday May 27 2004 10 08 AM ...

Page 190: ...EBU00437 U1P110 book Page 3 Thursday May 27 2004 10 08 AM ...

Page 191: ...EBU00438 ...

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