Yamaha KODIAK ULTRAMATIC YFM400FWAN 2000 Owner'S Manual Download Page 4 | Manualshive

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DATA_Disk:KAYO_DATA:HM00B060_YFM400FWA-11:English:E-INT.frame

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EBU00010

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN
SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following nota-
tions:

The Safety Alert 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 clear-
er.

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Summary of Contents for KODIAK ULTRAMATIC YFM400FWAN 2000

Page 1: ...NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passe...

Page 2: ...Yuki_Data Yuki_data Yuki Yuki_1 OM hyoushi forPDF B6 Hyo2 frame...

Page 3: ...ety information It provides infor mation about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regar...

Page 4: ...s manual by the following nota tions The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death...

Page 5: ...FF 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 AFFIX DEALER...

Page 6: ...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 Seat 4 16 Storage...

Page 7: ...imit 5 11 OPERATION 6 1 Starting a cold engine 6 1 Starting a warm engine 6 3 Warming up 6 3 Drive select lever operation and reverse driving 6 4 Engine break in 6 7 Parking 6 8 Parking on a slope 6 9...

Page 8: ...ent 8 33 Idle speed adjustment 8 34 Valve clearance adjustment 8 34 Throttle lever adjustment 8 35 Front brake pad inspection 8 36 Rear brake pad inspection 8 37 Inspecting the brake fluid level 8 37...

Page 9: ...M400FWA 11 English EETOC frame R 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 SERVI...

Page 10: ...E 1 1 DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 1 frame L EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS...

Page 11: ...e labels on your machine They contain important in formation 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 replace...

Page 12: ...A 11 English E 1 frame L 5 6 80 kg 176 lbs 4SH 24877 A0 LOAD LIMIT 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...

Page 13: ...1 4 DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 1 frame R 8...

Page 14: ...without proper training or instruction Take a Training Course Be ginners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 447 4700 to find out about...

Page 15: ...ction and maintenance procedures and schedules de scribed in this manual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be ex...

Page 16: ...for crossing the side of a hill as described in this man ual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV aroun...

Page 17: ...eral times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in re verse When it is safe to proceed in reverse go slowly Always use the si...

Page 18: ...the vicinity of sparks open flames or other sources of ignition such as the pi lot lights of water heaters and clothes dryers When transporting the machine in an other vehicle be sure it is kept upri...

Page 19: ...NING POTENTIAL HAZARD Starting or running the engine 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 HAZ...

Page 20: ...brake pedal 10 Front spring preload adjusting ring 11 Fuel cock 12 Air filter case 13 Fuses 14 V belt cooling duct check hose 15 Coolant reservoir 16 Oil filter cartridge 17 Engine oil dipstick 18 Re...

Page 21: ...ation in the spaces provided for as sistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3...

Page 22: ...s stamped into the frame 1 Vehicle identification number NOTE The vehicle identification number is used to identify your machine EBU00038 Model label The model label is affixed to the frame Record the...

Page 23: ...al hazard that could re sult in serious injury or death EBU00041 Main switch Functions of the respective switch posi tions are as follows ON Engine can be started only at this position and the headlig...

Page 24: ...temperature warning light 5 Four wheel drive indicator light EBU00609 Park indicator light P This indicator light comes on when the drive select lever is in the P park posi tion EBU00602 Reverse indi...

Page 25: ...tes The coolant temperature warning light circuit can 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 spec...

Page 26: ...oolant temperature warning light 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 Go ahe...

Page 27: ...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...

Page 28: ...to switch off the headlight and the taillight CAUTION Do not use the headlight with the engine turned off for more than thirty minutes The battery may discharge to the point that the starter motor wil...

Page 29: ...PDF HM00B060_YFM400FWA 11 English E 4 frame R EBU00607 Start switch The starter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engine See pa...

Page 30: ...stop the ATV and set the switch to the 2WD position WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD tha...

Page 31: ...ever Before starting the engine check the throt tle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released WARNING POTENTIAL HAZARD Malfunction...

Page 32: ...creases the maxi mum speed of the ATV 1 Locknut 2 Adjusting bolt WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Imp...

Page 33: ...Pull it toward the handlebar to apply the front brake 1 Front brake lever EBU00073 Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever is locat e...

Page 34: ...ift your machine into the low high neutral re verse and 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 p...

Page 35: ...Fuel tank cap WARNING POTENTIAL HAZARD Starting the engine 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...

Page 36: ...ays turn the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indica...

Page 37: ...Starting a cold engine requires a richer air fuel mixture A separate starter circuit sup plies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter...

Page 38: ...o remove the seat pull the seat lock lever upward and pull 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...

Page 39: ...age do not put metal products like tools or sharply edged prod ucts directly in the storage box If they must be stored wrap them in appropriate cushion material 1 Storage box EBU00582 Front carrier EB...

Page 40: ...he rider s weight and riding 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 adjuster in direct...

Page 41: ...G POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor han dling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always ad...

Page 42: ...itions 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 adjuster in direction b 1 Spring preload adjuster a...

Page 43: ...the auxiliary DC jack cap and in sert the accessory power plug into the jack 4 When the auxiliary DC jack is not be ing used cover it with the cap CAUTION Do not use accessories requiring more than th...

Page 44: ...4 22 Yuki_DATA2 ATV PDF HM00B060_YFM400FWA 11 English E 4 frame L 1 Auxiliary DC jack EBU00112 WARNING Indicates a potential hazard that could re sult in serious injury or death...

Page 45: ...l Fill with fuel if necessary 5 4 5 5 Engine oil Check 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...

Page 46: ...brakes are applied If not have the ma chine inspected by a Yamaha dealer 2 Brake fluid level Check the brake fluid level Add fluid if necessary See pages 8 37 8 39 WARNING POTENTIAL HAZARD Failure to...

Page 47: ...o make sure they are working properly If the brakes do not provide proper braking performance inspect the brake pads for wear See page 8 36 8 37 WARNING POTENTIAL HAZARD Riding with improperly operati...

Page 48: ...ill give you longer spark plug life and reduced mainte nance cost If unleaded gasoline is not available then leaded regular gasoline can be used Gasohol There are two types of gasohol gasohol containi...

Page 49: ...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 e...

Page 50: ...ain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component life and poor engine performance 0 10 30 50 70 90 110 YAMALUBE 4 10W30 or SAE 10W30 20...

Page 51: ...ditive rating GL 5 or GL 6 rated hypoid gear oils may 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...

Page 52: ...of the headlight 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 improp...

Page 53: ...on both sides 3 Tire pressure below the minimum specified could cause the tire to dis lodge from the rim under severe riding conditions The following are minimums Front 22 kPa 0 22 kgf cm2 3 2 psi Rea...

Page 54: ...sure and use the sec ond reading Dust or dirt in the gauge could cause the first reading to be incor rect Set pressure with tires cold Set tire pressures to the following specifi cations ACE 02EACE 02...

Page 55: ...5 11 DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 5 frame R 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...

Page 56: ...WARNING POTENTIAL HAZARD Operating ATV without being familiar 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...

Page 57: ...How ever it is recommended to shift into neutral or park before starting the en gine 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F...

Page 58: ...e 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 idles smoothly and return the starter c...

Page 59: ...losed position Otherwise the transmis sion may be damaged 1 Shifting Neutral to High and High to Low a Bring the machine to a complete stop and return the throttle lever to the closed position b Apply...

Page 60: ...ply the rear brake pedal c Shift from neutral to reverse or from reverse to park and vice versa by mov ing the drive select lever along the shift guide 1 Drive select lever NOTE When in reverse the re...

Page 61: ...ch to the rear while backing WARNING POTENTIAL HAZARD 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 HAZAR...

Page 62: ...prolonged full throttle operation or any condition which might re sult in excessive engine heating must be avoided However momentary 2 3 sec onds maximum full throttle operation un der load does not...

Page 63: ...ve 3 4 throttle Rev the machine freely but do not use full throttle at any time 3 After break in Avoid prolonged full throttle opera tion Vary speeds occasionally EBU00612 Parking When parking stop th...

Page 64: ...NTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines...

Page 65: ...y control over the quality or suitability of them Choose a genuine Yamaha accessory or one that is equivalent in design and quality Accessories should be rigidly and se curely mounted An accessory whi...

Page 66: ...g car go 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 car go at the front of the rea...

Page 67: ...top Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING POTENTIAL HAZARD Overl...

Page 68: ...6 13 DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 6 frame L EBU00723 WARNING Indicates a potential hazard that could re sult in serious injury or death...

Page 69: ...7 1 E DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 7 frame R Riding Your ATV 7 Riding Your ATV 7 1...

Page 70: ...7 2 DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 7 frame L...

Page 71: ...ires special skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult ma neuvers Riding your new ATV can be a very enjoy...

Page 72: ...e Take the time to learn the basic techniques well before attempting more difficult ma neuvers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an ac...

Page 73: ...e WARNING POTENTIAL HAZARD Failure to follow the age recommenda 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 o...

Page 74: ...TIAL HAZARD Carrying a passenger on this ATV WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an ac cident resulting in harm to you and or your passenger HOW TO...

Page 75: ...a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operatin...

Page 76: ...y the influence of alcohol or drugs WARNING POTENTIAL HAZARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slo...

Page 77: ...to make sure the ATV is in safe op erating condition Always follow the in spection and maintenance procedures and schedules described in the Owner s Manual WARNING POTENTIAL HAZARD Operating this ATV...

Page 78: ...ng even when the throttle lever is pushed to the maximum Screwing in the adjuster limits the maximum engine power avail able and decreases the maximum speed of the ATV Turning the screw in decreases t...

Page 79: ...lb Storage box 2 0 kg 4 4 lb Trailer hitch Pulling load 500 kg 1 102 lb Total weight of trailer and cargo Tongue weight 15 kg 33 lb Vertical weight on trailer hitch point WARNING POTENTIAL HAZARD Ove...

Page 80: ...om footboards during operation WHAT CAN HAPPEN Removing 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...

Page 81: ...ping You may lose control of the machine or overturn WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW...

Page 82: ...vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts a...

Page 83: ...uching the exhaust system Park the machine in a place where pedestrians or children are not likely to touch it WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust...

Page 84: ...an cause loss of control WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control...

Page 85: ...lli sions with other vehicles WARNING POTENTIAL HAZARD 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...

Page 86: ...e machine to upset WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to...

Page 87: ...ose terrain WHAT CAN HAPPEN Could cause loss of traction or vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slipper...

Page 88: ...as a trailer hitch WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles Do not ride in areas posted no trespass ing Do not ride on private property with...

Page 89: ...l be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling shift the drive select lever into low or high Then release the parking...

Page 90: ...egin to turn the handlebars in the desired direction 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...

Page 91: ...s by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes e...

Page 92: ...bstacles that might cause you to lose control It is important when climbing a hill to make sure that your weight is transferred for ward on the ATV This can be accom plished by leaning forward and on...

Page 93: ...per procedures for climbing hills 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 S...

Page 94: ...ou have the room to do so and go down the hill 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 AV...

Page 95: ...M400FWA 11 English E 7 frame R When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your w...

Page 96: ...applying 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 sudden appli...

Page 97: ...ver apply the rear brake while rolling backwards Apply 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...

Page 98: ...adversely affected by these surfaces Im proper braking may also cause a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applyi...

Page 99: ...ures for going down hills as described in this Owner s Manual Note a special tech nique is required when braking as you go down a hill HOW TO AVOID THE HAZARD Always check the terrain carefully be for...

Page 100: ...ther up or down hill If your ATV does begin to tip over gradual ly steer in the downhill direction if there are no obstacles in your path As you re gain proper balance gradually steer again in the dir...

Page 101: ...7 33 DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 7 frame R...

Page 102: ...slippery or upset the ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of...

Page 103: ...ifying that you have regained proper braking ability CAUTION After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case and the c...

Page 104: ...sk KAYO_DATA HM00B060_YFM400FWA 11 English E 7 frame L 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 1 Drive select lever box...

Page 105: ...boards at all times Avoid jumping the ATV as loss of control and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control o...

Page 106: ...lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery condi tions positioning your weight over the front wheels will sometimes help If the rear wheels of your...

Page 107: ...d on extremely slippery surfaces such as ice since all 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...

Page 108: ...turning Lean more into the turn to regain bal ance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 7 22 7 23 If your ATV starts to slide sideways Steer i...

Page 109: ...ance If you discover that the ATV is going to tip over dismount 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...

Page 110: ...ou are recommended to put this owner s manual in the vinyl bag and always carry it under the seat as shown Put the owner s tool kit and low pressure tire gauge in the storage box 1 Owner s manual 2 Ow...

Page 111: ...peration requiring one take your machine to a Yamaha deal er to check the torque settings and adjust them as necessary WARNING POTENTIAL HAZARD Operating this ATV with improper mod ifications WHAT CAN...

Page 112: ...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...

Page 113: ...ng system Check operation Replace if damaged Check toe in Adjust if necessary Front axle boots Check operation Replace if damaged Fittings and Fasteners Check all chassis fittings and fasteners Correc...

Page 114: ...614 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance de scribed in this chapter Refer to this section each time a panel has to be removed or...

Page 115: ...8 6 DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 8 frame R EBU00700 Panel A D To remove 1 Remove the seat 2 Pull outward on the areas shown and then pull upward...

Page 116: ...8 7 DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 8 frame L To install 1 Place the panel in its original position 2 Install the seat...

Page 117: ...8 DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 8 frame R EBU00616 Panel B To remove Remove the bolts To install Place the panel in the original position and install the bolts 1 Panel B 2 Bolt...

Page 118: ...AYO_DATA HM00B060_YFM400FWA 11 English E 8 frame L EBU00617 Panel C To remove 1 Remove the front carrier bolts and the front carrier 2 Remove the quick fasteners and pull upward 1 Bolt 4 1 Bolt 2 1 Qu...

Page 119: ...position and install the quick fasteners 2 Install the front 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 or...

Page 120: ...8 11 DATA_Disk KAYO_DATA HM00B060_YFM400FWA 11 English E 8 frame L EBU00638 Panel F To remove Pull outward on the areas shown 1 Panel F To install Place the panel in its original position...

Page 121: ...ine 3 Remove the dipstick and wipe it off with a clean rag Insert the dipstick in the filler hole without screwing it in 1 Engine oil dipstick NOTE Wait a few minutes until the oil level settles befor...

Page 122: ...See pages 8 10 8 11 for removal and installa tion procedures 2 Warm up the engine for several min utes 3 Stop the engine Place an oil pan un der the engine and remove the dip stick 4 Remove the drain...

Page 123: ...bolt and tighten 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...

Page 124: ...or several minutes While warming up check for oil leakage If oil leakage is found stop the engine immediately and check for the cause 11 Install the panels EBU00705 Final gear oil Final gear oil measu...

Page 125: ...ters the final gear case 3 Install the oil filler bolt and tighten to the specified torque Final gear oil replacement 1 Remove the final gear case cover 1 Bolt 2 2 Place the machine on a level place 3...

Page 126: ...Install the filler bolt and tighten to the specified torque 8 Check for oil leakage If oil leakage is found check for the cause 9 Install the final gear case cover Tightening torque Drain bolt final...

Page 127: ...ecified level 1 Differential gear oil 2 Differencial case oil filler bolt 3 Specified level CAUTION Be sure no foreign material enters the dif ferential gear case 3 Install the oil filler bolt and tig...

Page 128: ...foreign material enters the dif ferential gear case 6 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 tor...

Page 129: ...el should be between the maximum and mini mum marks 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 2 If the level is low remove panel D See pages 8 6 8 7 for panel removal and insta...

Page 130: ...tic It is switched on or off according to the coolant tempera ture in the radiator If your ATV overheats see page 4 3 for de tails EBU00773 Changing the coolant WARNING POTENTIAL HAZARD Removing the r...

Page 131: ...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 spill...

Page 132: ...olant reservoir side and then drain the cool ant from the coolant reservoir 1 Coolant reservoir drain hose 8 After draining the coolant thoroughly flush the cooling system with clean tap water 9 Repla...

Page 133: ...coolant level in the ra diator If it is low add more coolant until it reaches the top of the radiator 14 Fill the coolant reservoir with coolant up to the maximum level 15 Install the coolant reservoi...

Page 134: ...ck 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 EBU00680 Spark plug inspection Removal 1 Remove the spark plug cap...

Page 135: ...ormally Do not attempt to diagnose such problems yourself Instead take the ATV to a Yamaha dealer You should periodically remove and inspect the spark plug be cause heat and deposits will cause the sp...

Page 136: ...ark plug and tighten it to the specified torque NOTE If a torque wrench is not available when you are installing a spark plug a good esti mate of the correct torque is 1 4 to 1 2 turn past finger tigh...

Page 137: ...ottom 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 2 Remove the air...

Page 138: ...er and let it dry CAUTION Do not twist the filter element when squeezing it 6 Inspect the element If damaged re place it WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean t...

Page 139: ...bricated more often if the machine is op erated in extremely dusty areas Each time filter element maintenance is performed check the air inlet to the filter case for ob structions Check the air cleane...

Page 140: ...nglish E 8 frame L EBU00641 V belt cooling duct check hose If dust or water collects in this hose re move the hose and clean it 1 V belt cooling duct check hose Left front side of ATV 1 V belt cooling...

Page 141: ...tailpipe lightly then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe 1 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5...

Page 142: ...ny tests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result WARNING POTENTIAL HAZARD Improperly purging the exhaust system H...

Page 143: ...8 7 for removal and installation proce dures 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 an...

Page 144: ...Throttle lever adjustment NOTE Adjust the engine idling speed before ad justing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throt tle lever free play is 3 5 m...

Page 145: ...nt brake pad inspection Inspect the brake pads for damage and wear If the thickness is less than the spec ified value have a Yamaha dealer replace the pads a Wear limit 1 mm 0 04 in NOTE The wheels ne...

Page 146: ...k a Yamaha dealer to replace the pad 1 Wear indicator 3 NOTE The wheel needs to be removed to inspect the brake pad See page 8 44 for removal procedures EBU00622 Inspecting the brake fluid level Insuf...

Page 147: ...designated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake performance 3 Refill with the same type of brake fluid Mixing fluids may result in a harmful c...

Page 148: ...d replacement 1 Complete fluid replacement should be done only by trained Yamaha service personnel 2 Have a Yamaha dealer replace the fol lowing components during periodic maintenance or when they are...

Page 149: ...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 b...

Page 150: ...t in direction a to increase free play and in direction b to decrease free play 3 Tighten the locknut If correct free play cannot be obtained ask a Yamaha dealer to make that adjustment Rear brake ped...

Page 151: ...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 d...

Page 152: ...pivoting parts 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 Op...

Page 153: ...KAYO_DATA HM00B060_YFM400FWA 11 English E 8 frame R EBU00373 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...

Page 154: ...OTE The arrow mark on the tire must point toward 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 tow...

Page 155: ...ully WHAT CAN HAPPEN You could be poisoned You could be se verely burned by the sulfuric acid in bat tery electrolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin...

Page 156: ...re or constant voltage is re quired for recharging a sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting t...

Page 157: ...frame R 1 Main fuse 2 Spare fuse 1 Fuse box 1 Headlight fuse 2 Ignition fuse 3 Auxiliary DC jack fuse 4 Four wheel drive fuse 5 Spare fuse 3 Specified fuses Main fuse 30A Headlight fuse 15A Ignition f...

Page 158: ...eadlight bulb burns out replace it as follows 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...

Page 159: ...into position and se cure it in place with the bulb holder spring 5 Install the bulb holder cover WARNING POTENTIAL HAZARD The headlight bulb is hot when it is on and immediately after it is turned o...

Page 160: ...aler make this adjustment 1 Vertical adjustment To raise the beam turn the adjusting screw clockwise To lower the beam turn the screw counterclockwise 1 Headlight beam adjusting screw EBU00639 Taillig...

Page 161: ...00B060_YFM400FWA 11 English E 8 frame R 1 Taillight bulb 3 Install a new bulb by pushing it inward and turning it clockwise 4 Install the lense and tighten the screws CAUTION Do not over tighten the s...

Page 162: ...technicians at a Yamaha dealer ship have the tools experience and know how to properly service your machine Use only genuine Yamaha parts on your ma chine Imitation parts may look like Yamaha parts b...

Page 163: ...re 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 s...

Page 164: ...recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Level is OK Level is low check the cooling system for leakage No...

Page 165: ...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 rad...

Page 166: ...a paint brush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pres sure to do the job CAUTION Excessive water pressure may cause wa ter...

Page 167: ...void combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation...

Page 168: ...if the fuel system needs to be drained instead 2 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug Ground the spark pl...

Page 169: ...frame R 7 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 C 30 F or more than 30 C 90 F...

Page 170: ...mm 32 28 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 Liq...

Page 171: ...ice SE SF SG type or higher Quantity Periodic oil change 2 3 L 2 0 Imp qt 2 4 US qt With oil filter replacement 2 4 L 2 1 Imp qt 2 5 US qt Total amount 2 6 L 2 3 Imp qt 2 7 US qt Model YFM400FWAN C CA...

Page 172: ...Imp qt 0 23 US qt Differential gear case oil Type SAE80 API 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 ty...

Page 173: ...reduction system V belt Secondary 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...

Page 174: ...pension Front suspension 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 whe...

Page 175: ...age quantity Headlight 12 V 30 W 30 W 2 Tail light 12 V 7 5 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...

Page 176: ...f design incorporated into any new vehicle for the purpose 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...

Page 177: ...nce with the warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 02EACL 02E MAINTENANCE INTERVAL DATE...

Page 178: ...Yuki_DATA2 ATV PDF HM00B060_YFM400FWA 11 English E 13 frame L 13 1 EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY...

Page 179: ...13 2 Yuki_DATA2 ATV PDF HM00B060_YFM400FWA 11 English E 13 frame R 13 13 13 13 13 13 13 13 13 130 1313 1313 13 1313...

Page 180: ...Yuki_DATA2 ATV PDF HM00B060_YFM400FWA 11 English E 14 frame L 14 1 EBU00435 YAMAHA EXTENDED SERVICE Y E S...

Page 181: ...Yuki_DATA2 ATV PDF HM00B060_YFM400FWA 11 English E 14 frame R 14 14 14 14 14 14 14 14 14 140 1414 1414 1414 14 EBU00436 WARNING Indicates a potential hazard that could re sult in serious injury or de...

Page 182: ...Yuki_DATA2 ATV PDF HM00B060_YFM400FWA 11 English E 14 frame L 14 3 EBU00437...

Page 183: ...Yuki_Data Yuki_data Yuki Yuki_1 ATV HM00C054_YFM600FWAN 12 English shiro frame...

Page 184: ...NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passe...

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