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Yamaha KODIAK 4X4 Ultramatic, Owner'S Manual

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Yamaha KODIAK 4X4 Ultramatic Owner'S Manual Download Page 131

8-22

1. Place the ATV on a level surface.
2. Remove panels E and F. (See page 8-10

and 8-11 for panel removal and installa-
tion procedures.)

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. Coolant drain bolt

1. Trough

4. Remove the front carrier and panel C.

(See page 8-9 for removal and installa-
tion procedures.)

EE.book  Page 22  Monday, June 18, 2001  10:05 AM

Summary of Contents for KODIAK 4X4 Ultramatic

Page 1: ......

Page 2: ......

Page 3: ...tant safety information 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 OPERAT...

Page 4: ...Symbol 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 cleare...

Page 5: ...th 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 EBU00711 YFM400FAP OWNER S MANUAL 2001 by Yamaha Motor Corporation U S A 1st Edition April 2001 All rights reserved Any reprinting or unauthorized use without the written permission of EE book Page 2 Mo...

Page 6: ...tion number 3 2 Vehicle identification number 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator lights 4 2 Coolant temperature warning light checking method 4 4 Fuel gauge 4 5 Handlebar switches 4 6 Throttle lever 4 9 Speed limiter 4 10 Front brake lever 4 11 Rear brake pedal and lever 4 11 Drive select lever 4 12 Recoil starter 4 12 Fuel tank cap 4 13 Fuel cock 4 14 Starter choke 4 15 Sea...

Page 7: ...asure tire pressure 5 10 Tire wear limit 5 11 Drive select lever operation and reverse driving 6 4 Engine break in 6 7 Parking 6 8 Parking on a slope 6 9 Accessories and loading 6 10 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 22 Climbing uphill 7 24 Riding downhill 7 30 Crossing a slope 7 32 Crossing thro...

Page 8: ...e 8 31 Spark arrester cleaning 8 32 Carburetor adjustment 8 33 Inspecting the brake fluid level 8 37 Brake fluid replacement 8 39 Front brake adjustment 8 39 Rear brake lever adjustment 8 41 Adjusting the rear brake light switch 8 42 Cable inspection and lubrication 8 43 Brake lever and brake pedal lubrication 8 43 Wheel removal 8 44 Wheel installation 8 45 Battery 8 46 Battery maintenance 8 47 Fu...

Page 9: ... 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 EE book Page 4 Monday June 18 2001 10 05 AM ...

Page 10: ...EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS EE book Page 1 Monday June 18 2001 10 05 AM ...

Page 11: ...ortant information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 3 4 40 kg 88 lbs 4GB 24877 A0 LOAD LIMIT WARNING EE book Page 2 Monday June 18 2001 10 05 AM ...

Page 12: ...147 N 1 5 k g f 33 l b f 5GH 2151K 00 MAXIMUM LOADING LIMIT MAXIMUM LOADING LIMIT 7 8 UNDER WARNING 5FE 21697 01 NEVER operate this ATV if you are under age 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death EE book Page 3 Monday June 18 2001 10 05 AM ...

Page 13: ...9 EE book Page 4 Monday June 18 2001 10 05 AM ...

Page 14: ...thout 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...

Page 15: ... you use it to make sure it is in safe operating condition Al ways follow the inspection and maintenance procedures and schedules described in this man ual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the AT...

Page 16: ...down the hill where possible Always follow 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...

Page 17: ... be 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 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 ...

Page 18: ...urces of ignition such as the pi lot lights of water heaters and clothes 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 19: ... in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation EE book Page 6 Monday June 18 2001 10 05 AM ...

Page 20: ...d adjusting ring 8 V belt case 9 Rear brake pedal 10 Front spring preload adjusting ring 13 Fuses 14 Tail brake light 15 V belt cooling duct check hose 16 Coolant reservoir 17 Oil filter cartridge 18 Engine oil dipstick 19 Rear brake lever 20 Left handlebar switches 21 Starter choke 22 Drive select lever 23 Speedometer 24 Main switch 25 Fuel tank cap 26 Auxiliary DC jack EE book Page 1 Monday June...

Page 21: ...ing 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 EE book Page 2 Monday June 18...

Page 22: ...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 EE book Page 3 Monday June 18 2001 10 05 AM ...

Page 23: ... EBU00041 Main switch Functions of the respective switch positions are as follows ON Engine can be started only at this position and the headlight 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 1 Main switch EE book Page 1 Monday June 18 2001 10 05 AM ...

Page 24: ...wheel drive indicator light EBU00609 Park indicator light P This indicator light comes on when the drive EBU00602 Reverse indicator light R This indicator light comes on when the trans mission is in reverse EBU00603 Neutral indicator light N This indicator light comes on when the trans mission is in neutral EE book Page 2 Monday June 18 2001 10 05 AM ...

Page 25: ...an be checked according to the procedure on page 4 4 CAUTION The engine may overheat if the ATV is overloaded If this happens reduce the load to specification Restart after making sure that the light is out Continuous use while the light is on may cause damage to the en EBU00605 Four wheel drive indicator light This indicator light comes on when the 2WD 4WD switch is in the 4WD position NOTE Due t...

Page 26: ...ight does not come on Coolant temperature warning light comes on Coolant temperature warning light does not come on Coolant temperature and electrical circuit are OK Push the start switch with the transmission in the neutral position Ask a Yamaha dealer to Coolant temperature warning light comes on momentarily EE book Page 4 Monday June 18 2001 10 05 AM ...

Page 27: ...ount 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 5 5L 1 21Impgal 1 45USgal NOTE If the machine runs out of fuel move the fuel EE book Page 5 Monday June 18 2001 10 05 AM ...

Page 28: ...nutes The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU00849 Engine stop switch Make sure that the engine stop switch is in the position 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 when the engine...

Page 29: ...7 Start switch The starter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engine See page 6 1 for details EE book Page 7 Monday June 18 2001 10 05 AM ...

Page 30: ...m 2WD to 4WD or from 4WD to 2WD while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD in some circumstances Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause the ATV to unexpectedly handle differ ently This could distract the operator and increase the risk of losing control and an accident HOW TO AVOID THE HAZARD Always stop the ATV before changing...

Page 31: ... 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 lever b...

Page 32: ...usting bolt 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 speed adjuster out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjusted to 3 5 mm 0 11 0 20...

Page 33: ...he front brake lever is located on the right handlebar Pull it toward the handlebar to ap ply the front brake 1 Front brake lever EBU00073 Rear brake pedal and lever 1 Rear brake pedal EE book Page 11 Monday June 18 2001 10 05 AM ...

Page 34: ... park positions Refer to page 6 4 for the drive select lever operation 1 Drive select lever EBU00666 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 EE book Page 12 Monday June 18 2001 10 05 AM ...

Page 35: ...gine in gear or starting the engine without shifting into the park position WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Shift the transmission in neutral or set the shift lever to the park position be fore starting the engine EE book Page 13 Monday June 18 2001 10 05 AM ...

Page 36: ...ine 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 1 Arrow mark OFF Position ON Position EE book Page 14 Mo...

Page 37: ...uel mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 RES Position EE book Page 15 Monday June 18 2001 10 05 AM ...

Page 38: ...ull up the seat at the rear 1 Seat 2 Seat lock lever To install the seat insert the projection on the front of the seat into the seat holder and push down on the seat at the rear NOTE Make sure that the seat is securely fitted EE book Page 16 Monday June 18 2001 10 05 AM ...

Page 39: ...rply edged prod ucts directly in the storage box If they must be stored wrap them in appropriate cushion material EBU00582 Front carrier EBU00583 Rear carrier Maximum load limit 2 kg 4 4 lb Maximum load limit 40 kg 88 lb Maximum load limit 80 kg 176 lb EE book Page 17 Monday June 18 2001 10 05 AM ...

Page 40: ...conditions Adjust the spring preload as follows To increase the spring preload turn the ad juster in direction a To decrease the spring preload turn the ad juster in direction b 1 Spring preload adjuster 1 Special wrench Standard position 2 1 Minimum Soft 5 Maximum Hard EE book Page 18 Monday June 18 2001 10 05 AM ...

Page 41: ...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 EE book Page 19 Monday June 18 2001 10 05 AM ...

Page 42: ...ing preload as follows To increase the spring preload turn the ad juster in direction a To decrease the spring preload turn the ad juster in direction b 1 Spring preload adjuster EBU00643 NOTE A special wrench can be obtained at a Yamaha dealer Standard position 2 1 Minimum Soft 5 Maximum Hard EE book Page 20 Monday June 18 2001 10 05 AM ...

Page 43: ... cap 4 When the auxiliary DC jack is not being used cover it with the cap CAUTION Do not use accessories requiring more than the above maximum capac ity This may overload the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlight turned on the battery will lose its charge and engine starting may be come difficult Do not use an automotive cigaret...

Page 44: ...1 Auxiliary DC jack EE book Page 22 Monday June 18 2001 10 05 AM ...

Page 45: ...ck oil level Fill with oil if necessary 5 6 8 12 8 15 Coolant reservoir Check coolant level Fill with coolant if necessary 8 20 8 21 Final gear oil Differential gear oil Check for leakage 5 7 8 15 8 19 Throttle Check for proper throttle cable operation 5 7 8 35 Wheels and tires Check tire pressure wear and damage 5 8 5 11 8 44 8 45 Fittings and Fasteners Check all fittings and fasteners 5 8 Lights...

Page 46: ...er Brake fluid level Check the brake fluid level Add fluid if neces sary See pages 8 37 8 39 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 A...

Page 47: ... provide proper braking per formance inspect the brake pads for wear See pages 8 36 8 37 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected...

Page 48: ... 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 3 9 US gal Reserve 4 5 L ...

Page 49: ...ZARD 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 the ...

Page 50: ...nd or starter clutch slippage resulting in re duced component life and poor engine performance _ Recommended oil Recommended engine oil classification API Service SE SF SG type or higher 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 Oil quantity Periodic oil change 2 3 L 2 0 Imp qt 2 4 US qt With oil filter replacement 2 4 ...

Page 51: ...also be used EBU00678 Differential gear oil Make sure the differential gear oil is at the specified level Add oil as necessary See pages 8 18 8 19 for details EBU00151 Throttle lever Check to see that the throttle lever operates correctly It must open smoothly and spring back to idle position when released Repair as necessary for proper operation Recommended oil SAE 80 API GL 4 Hypoid gear oil Rec...

Page 52: ...ht switch engine stop switch and any other switches Repair as necessary for proper operation EBU00157 Tires 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 acci dent HOW TO AVOI...

Page 53: ...ied could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 22 kPa 0 22 kgf cm2 3 2 psi Rear 22 kPa 0 22 kgf cm2 3 2 psi 4 Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully ...

Page 54: ...ond 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 EE book Page 10 Monday June 18 2001 10 05 AM ...

Page 55: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a 3 mm 0 12 in EE book Page 11 Monday June 18 2001 10 05 AM ...

Page 56: ...AN 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 HAZARD When ri...

Page 57: ...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 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: ... 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 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 throttle should be ope...

Page 59: ...on may be damaged _ Shifting Neutral to High and High to Low 1 Bring the machine to a complete stop and return the throttle lever to the closed position 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 1 Drive select lever 3 Open the throttle lever gradually EE book Page 4 Monday June 18 2001 10 05 AM ...

Page 60: ...he rear 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 reverse indicator light electrical cir cuit Due to the synchronizing mechanism in the engine the light ...

Page 61: ...Improperly 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 EE book Page 6 Monday June 18 2001 10 05 AM ...

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

Page 63: ... full throttle at any time 3 After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00612 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 EE book Page 8 Monday June 18 2001 10 05 AM ...

Page 64: ...N 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 eas...

Page 65: ...e 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 at...

Page 66: ...hitch 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 MAX...

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

Page 68: ...EBU00937 WARNING _ Indicates a potential hazard that could result in serious injury or death EE book Page 13 Monday June 18 2001 10 05 AM ...

Page 69: ...7 Riding Your ATV EE book Page 1 Monday June 18 2001 10 05 AM ...

Page 70: ...EE book Page 2 Monday June 18 2001 10 05 AM ...

Page 71: ...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 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 in...

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

Page 73: ...ecommenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc EE book Page 5 Monday June 18 2001 10 05 AM ...

Page 74: ...PPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers EE book Page 6 Monday June 18 2001 10 05 AM ...

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

Page 76: ...AZARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV EE book Page 8 Monday June 18 2001 10 05 AM ...

Page 77: ... op erating condition Always follow the in spection and maintenance procedures 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 th...

Page 78: ...er is pushed to the maxi mum Screwing in the adjuster limits the max imum engine power available and decreases the maximum speed of the ATV Turning the 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 resu...

Page 79: ...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 80: ...g 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...

Page 81: ...ING 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 EE book Page 13 Monday June 18 2001 10 05 AM ...

Page 82: ...y 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 EE book Page 14 Monday June 18 2001 10 05 AM ...

Page 83: ...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 touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it EE book Page 15 Monday Ju...

Page 84: ...ng 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 EE book Page 16 Monday June 18 2001 10 05 AM ...

Page 85: ...Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways EE book Page 17 Monday June 18 2001 10 05 AM ...

Page 86: ...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 Always be EE book Page 18 Monday June 18 2001 10 05 AM ...

Page 87: ...n or vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain EE book Page 19 Monday June 18 2001 10 05 AM ...

Page 88: ...ailer 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 EE book Page 20 Monday June 18 2001 10 05 AM ...

Page 89: ...en riding and after wards do not allow skin or clothing to come in contact with these components With the engine idling shift the drive select le ver into the low L or the high H position Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of d...

Page 90: ...ion 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 cont...

Page 91: ... Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember...

Page 92: ...portant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or smal...

Page 93: ...ls 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 EE book Page 25 Monday June 18 2001 10 05 AM ...

Page 94: ...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 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 E...

Page 95: ...f 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 EE book Page 27 Monday June 18 2001 10 05 AM ...

Page 96: ...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 climbing a hill...

Page 97: ...the front brake 4WD Apply both front and rear brakes gradually When fully stopped shift into the parking position 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 EE book Page 29 Monday June 18 2001 10 05 AM ...

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

Page 99: ...go ing down hills as described in this Own er s Manual Note a special technique is required when braking as you go down a hill 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 EE book Page 31 Monday June 18 2001 10 05 AM ...

Page 100: ...htly 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 ...

Page 101: ...EE book Page 33 Monday June 18 2001 10 05 AM ...

Page 102: ...ppery 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...

Page 103: ...ng 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 and the check hose on the V belt cooling duct Wash the ATV in fresh water if it has been operated in salt water or muddy conditions _ EE book Page 35 Monday June 18 2001 10 05 AM ...

Page 104: ...1 V belt cooling duct check hose Left front side of ATV 1 Drive select lever box check hose EE book Page 36 Monday June 18 2001 10 05 AM ...

Page 105: ...ntrol and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper proc...

Page 106: ...t wheels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide EE book Page 38 Monday June 18 2001 ...

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

Page 108: ... If 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 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...

Page 109: ...s cover 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 ...

Page 110: ...er s manual and tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it un der the seat as shown Put the owner 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 can...

Page 111: ...e your 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 ins...

Page 112: ...Air filter Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check and adjust idle speed starter operation Adjust if necessary Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Retighten if necessary Replace gasket s if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or...

Page 113: ...age 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 Aaxle boots Check operation Replace if damaged Fittings and Fasteners Check all chassis fittings and fasteners Correct if necessary ITEM ROUTINE INITIAL EVERY 1 month 3 months 6 months 6 months 1 year NOTE Recommended brake fluid ...

Page 114: ...ted 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 EE book Page 5 Monday June 18 2001 10 05 AM ...

Page 115: ...EBU00700 Panel A D To remove 1 Remove the seat 2 Pull outward on the areas shown and then pull upward EE book Page 6 Monday June 18 2001 10 05 AM ...

Page 116: ...To install 1 Place the panel in its original position 2 Install the seat EE book Page 7 Monday June 18 2001 10 05 AM ...

Page 117: ...EBU00616 Panel B To remove Remove the bolts To install Place the panel in the original position and in stall the bolts 1 Panel B 2 Bolt 2 EE book Page 8 Monday June 18 2001 10 05 AM ...

Page 118: ...EBU00617 Panel C To remove 1 Remove the front carrier bolts and the front carrier 2 Remove the quick fasteners and pull up ward 1 Bolt 4 1 Bolt 2 EE book Page 9 Monday June 18 2001 10 05 AM ...

Page 119: ...ront carrier and the bolts then tighten to the specified torque EBU00616 Panel E To remove Remove the bolts To install Place the panel in the original position and in stall the bolts 1 Panel E 2 Bolt 3 Tightening torque Carrier bolts 19 Nm 1 9 m kgf 13 ft lb EE book Page 10 Monday June 18 2001 10 05 AM ...

Page 120: ...EBU00638 Panel F To remove Pull outward on the areas shown 1 Panel F To install Place the panel in its original position EE book Page 11 Monday June 18 2001 10 05 AM ...

Page 121: ...ove the dipstick and wipe it off with a clean rag Insert the dipstick in the filler hole without screwing it in NOTE _ Wait a few minutes until the oil level settles before checking _ 5 The oil level should be between the max imum and minimum marks If the level is low fill the engine with sufficient oil to reach the specified level 1 Maximum level mark 2 Minimum level mark EE book Page 12 Monday J...

Page 122: ...oval and installa tion procedures 2 Warm up the engine for several minutes 3 Stop the engine Place an oil pan under the engine and remove the dipstick 4 Remove the drain bolt and drain the oil 5 Remove the oil filter by using an oil filter wrench 1 Oil filter element EE book Page 13 Monday June 18 2001 10 05 AM ...

Page 123: ...en it to the specified torque 1 Torque wrench 7 Apply a light coat of engine oil to the O ring of the new oil filter NOTE _ Make sure the O ring is seated properly _ 8 Install the oil filter and tighten it to the specified torque with a torque wrench Tightening torque Drain bolt EE book Page 14 Monday June 18 2001 10 05 AM ...

Page 124: ... stop the engine immediately and check for the cause 11 Install the panels EBU00825 Final gear oil Final gear oil measurement 1 Place the machine on a level place 2 Remove the oil filler bolt and check the oil level It should be up to the brim of the hole If the level is low add oil to raise it to the proper level Recommended oil See page 10 2 Oil quantity Total amount 2 6 L 2 3 Imp qt 2 7 US qt P...

Page 125: ...bolt and tighten it to the specified torque Final gear oil replacement 1 Remove the final gear case cover 1 Final gear case cover 2 Bolt 2 2 Place the machine on a level place 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 EE book Page 16 Monday June 18 2001 10 05 AM ...

Page 126: ... case _ 7 Install the filler bolt and tighten to the specified torque Tightening torque Drain bolt final gear case 23 Nm 2 3 m kgf 16 ft lb Recommended oil See page 10 3 Oil quantity Periodic oil change 0 19 L 0 17 Imp qt 0 2 US qt Total amount 0 22 L 0 19 Imp qt 0 23 US qt Tightening torque Filler bolt final gear case 23 Nm 2 3 m kgf 16 ft lb EE book Page 17 Monday June 18 2001 10 05 AM ...

Page 127: ...the specified level 1 Differential gear oil 2 Differencial case oil filler bolt 3 Install the oil filler bolt and tighten it to the specified torque Differential gear oil replacement 1 Place the machine on a level place 2 Place a container under the differential gear case to catch the oil 3 Remove the filler bolt and drain bolt to drain the oil Tightening torque Oil filler bolt 23 Nm 2 3 m kgf 16 ...

Page 128: ...Install the filler bolt and tighten it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Tightening torque Drain bolt 10 Nm 1 0 m kgf 7 ft lb Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity Periodic oil change 0 35 L 0 31 Imp qt 0 37 US qt Total amount 0 42 L 0 35 Imp qt 0 42 US qt EE book Page 19 Monday June 18 2001 10 05 AM ...

Page 129: ...hould be be tween the maximum and minimum marks 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 3 Remove the coolant reservoir cap and then add coolant or distilled water to raise it to the specified level 4 Install the panel 1 Coolant reservoir drain hose Coolant reservoir capacity 0 25 L 0 22 Imp qt 0 26 US qt EE book Page 20 Monday June 18 2001 10 05 AM ...

Page 130: ...temperature in the radi ator If your ATV overheats see page 4 3 for de tails EBU00887 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 over ...

Page 131: ...cedures 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 page 8 9 for removal and installa tion procedures EE book Page 22 Monday June 18 2001 10 05 AM ...

Page 132: ...in the coolant from the coolant reservoir 1 Coolant reservoir drain hose 8 After draining the coolant thoroughly flush the cooling system with clean tap water 9 Replace the coolant drain bolt washer if it is damaged and then tighten the coolant drain bolt to the specified torque Tightening torque EE book Page 23 Monday June 18 2001 10 05 AM ...

Page 133: ... Fill the coolant reservoir with coolant up to the maximum level 15 Install the coolant reservoir cap and 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 aluminum engines Antifreeze and water mixing ...

Page 134: ...e is found have them replaced by a Yamaha dealer 1 Axle boot 2 each side EBU00680 Spark plug inspection Removal 1 Remove the spark plug cap 1 Spark plug cap 2 Use the spark plug wrench in the tool kit to remove the spark plug as shown EE book Page 25 Monday June 18 2001 10 05 AM ...

Page 135: ...r a ATV that is being ridden normally posits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace 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 Specified spark plug DR8EA NGK Spark ...

Page 136: ... a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible 4 Install the spark plug cap Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 5 ft lb EE book Page 27 Monday June 18 2001 10 05 AM ...

Page 137: ...ilter 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 Clip 4 2 Air filter cover 3 Remove the air filter element and sepa rate it from the guide EE book Page 28 Monday June 18 2001 10 05 AM ...

Page 138: ...twist the filter element when squeezing it 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 AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element EE book Page 29 Monday June 18 2001 10 05 AM ...

Page 139: ...if the machine is operated in extremely dusty areas Each time filter ele ment maintenance is performed check the air inlet to the filter case for obstructions Check the air cleaner rubber joint to the carburetor and manifold fittings for an airtight seal Tight en all fittings securely to avoid the possibility of unfiltered air entering the engine CAUTION Never operate the engine with the air filte...

Page 140: ...ose If dust or water collects in this hose remove the hose and clean it 1 V belt cooling duct check hose Left front side of ATV 1 V belt cooling intake box check hose Above V belt cooling duct EE book Page 31 Monday June 18 2001 10 05 AM ...

Page 141: ...out of the muffler 1 Bolt 2 Tailpipe 3 Purging bolt 1 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the bolt and tighten it 6 Remove the purging bolt 7 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 EE book Page 32 Monday June 18 2001 10 05 AM ...

Page 142: ...are 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 purging the exhaust system Always let ...

Page 143: ...8 7 for removal and installation procedures 3 Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in to increase engine speed and out to de crease engine speed 1 Throttle stop screw 4 Install the panel EBU00303 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine...

Page 144: ...ling 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 a Free play 3 5 mm 0 12 0 20 in EE book Page 35 Monday June 18 2001 10 05 AM ...

Page 145: ...mage and wear If the thickness is less than the specified val ue have a Yamaha dealer replace the pads a Wear limit 1 mm 0 04 in NOTE The wheels need to be removed to inspect the brake pads See page 8 44 for removal proce EE book Page 36 Monday June 18 2001 10 05 AM ...

Page 146: ... NOTE The wheel needs to be removed to inspect the brake pad See page 8 44 for removal proce dures EBU00622 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the lower level and replenish when necessary The rear brake fluid master cylin der reservoir is loc...

Page 147: ...dete riorate causing leakage and poor brake performance 3 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance 4 Be careful that water does not enter the master cylinder reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor FRONT REAR Recommended brake fluid DOT 4...

Page 148: ...done only by trained Yamaha service personnel 2 Have a Yamaha dealer replace the fol lowing components during periodic main tenance or when they are damaged or leaking Replace all rubber seals every two years Replace all hoses every four years EBU00623 Front brake adjustment The front brake lever should have a free play of zero mm zero in at the lever end If not ask a Yamaha dealer to adjust it a ...

Page 149: ...h 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 brake components re EE book Page 40 Monday June 18 2001 10 05 AM ...

Page 150: ... 2 Turn the adjusting bolt in direction a to increase free play and in direction b to decrease free play Rear brake pedal height adjustment NOTE Adjust the rear brake before inspecting the rear brake pads The top of the brake pedal should be posi tioned 54 mm 2 13 in above the top of the footrest If not ask a Yamaha dealer to adjust it EE book Page 41 Monday June 18 2001 10 05 AM ...

Page 151: ...ce 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 WARNING l POTENTIAL HAZARD Operating with improperly serviced or adjusted brake 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 t...

Page 152: ...ING 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 Recommended lubricant Lithium soap based grease all purpose greas...

Page 153: ...00373 Wheel removal 1 Elevate the wheel by placing a suitable stand under the frame 2 Remove the nuts from the wheel 3 Remove the wheel assembly 1 Tapered nut 4 EE book Page 44 Monday June 18 2001 10 05 AM ...

Page 154: ...o ward the rotating direction of the wheel _ 1 Arrow mark 1 Tapered wheel nuts are used for both front and rear wheels Install the nut with its tapered side towards the wheel 1 Tapered nut 2 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lb EE book Page 45 Monday June 18 2001 10 05 AM ...

Page 155: ...AT 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 minute...

Page 156: ...a sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU00876 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 f...

Page 157: ...eadlight 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 30A Headlight fuse 15A Ignition fuse 10A EE book Page 48 Monday June 18 2001 10 05 AM ...

Page 158: ...ws 1 Remove the cover at the rear of the headlight 1 Cover 2 Remove the 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 EE book Page 49 Monday June 18 2001 10 05 AM...

Page 159: ...ing 5 Install the bulb holder cover WARNING POTENTIAL HAZARD The 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 EE book Page 50 Monday June 18 2001 10 05 AM ...

Page 160: ...he beam turn the adjusting screw clockwise To lower the beam turn the screw coun terclockwise EBU00964 Tail brake light bulb replacement 1 Remove the nuts together with the wash ers 1 Tail brake light unit 2 Nut 2 2 Remove the bulb holder together with the bulb by turning it counterclockwise EE book Page 51 Monday June 18 2001 10 05 AM ...

Page 161: ...rd and turning it counterclockwise 1 Bulb holder 2 Bulb 4 Install 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 EE book Page 52 Monday June 18 2001 10 05 AM ...

Page 162: ...perience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se v...

Page 163: ... Use 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 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 ...

Page 164: ... thick rag over the cap Allow any re maining 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 overhea...

Page 165: ...er 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...

Page 166: ... paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings EE b...

Page 167: ... tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing in a humid or salt...

Page 168: ...a dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine EE book Page 4 Monday June 18 2001 10 05 AM ...

Page 169: ...EE book Page 5 Monday June 18 2001 10 05 AM ...

Page 170: ...8 in Wheelbase 1 225 mm 48 23 in Minimum ground clearance 245 mm 9 65 in Minimum turning radius 3 000 mm 118 11 in Basic weight With oil and full fuel tank 262 kg 578 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 401 cm3 Bore stroke 84 5 71 5 mm 3 33 2 81 in EE book Page 1 Monday June 18 2001 10 05 AM ...

Page 171: ... SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Energy Conserving contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component life and poor engine performance EE book Page 2 Monday June 18 2001 10 05 AM ...

Page 172: ...PI GL 4 Hypoid gear oil Quantity Periodic oil change 0 35 L 0 31 Imp qt 0 37 US qt Total amount 0 42 L 0 35 Imp qt 0 45US qt Air filter Wet type element Fuel Type Unleaded gasoline only Fuel tank capacity 15 L 3 3 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 YFM400FAP EE book Page 3 Monday June 18 2001 10 05 AM ...

Page 173: ...ondary reduction system Spur gear 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 Sub transmission ratio low 45 16 2 813 high 38 23 1 652 Chassis Frame type Steel tube frame Caster angle 4 0 Trail 21 mm 0 83 in Tire Model YFM400FAP EE book Page 4 Monday June 18 2001 10 05 AM ...

Page 174: ...Double wishbone Rear suspension Swingarm monocross Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 160 mm 6 3 in Rear wheel travel 180 mm 7 09 in Electrical Ignition system DC C D I Generator system A C magneto Battery type YTX20L BS Model YFM400FAP EE book Page 5 Monday June 18 2001 10 05 AM ...

Page 175: ... 12 V 5 21 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Coolant temperature warning light 12 V 1 7 W 1 Park indicator light 12 V 1 7 W 1 Four wheel drive indicator light 12 V 1 7 W 1 Model YFM400FAP EE book Page 6 Monday June 18 2001 10 05 AM ...

Page 176: ...pose 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 Mu...

Page 177: ...e 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 ACL 02EACL 02E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months 54 Months EE book Page 1 Monday June 18 2001 10 05 A...

Page 178: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY EE book Page 1 Monday June 18 2001 10 05 AM ...

Page 179: ...1 2 3 4 5 6 7 8 9 10 11 12 13 EE book Page 2 Monday June 18 2001 10 05 AM ...

Page 180: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S EE book Page 1 Monday June 18 2001 10 05 AM ...

Page 181: ...1 2 3 4 5 6 7 8 9 10 11 12 13 EE book Page 2 Monday June 18 2001 10 05 AM ...

Page 182: ...EBU00437 EE book Page 3 Monday June 18 2001 10 05 AM ...

Page 183: ......

Page 184: ...Card fm Page 1 Wednesday June 13 2001 9 35 AM ...

Page 185: ...Card fm Page 2 Wednesday June 13 2001 9 35 AM ...

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