Yamaha WOLVERINE 2015 Owner'S Manual Download Page 120

Page: 120 / 192

8-5

Exhaust system

• Check for leakage.
• Check for looseness and tighten all screw

clamps and joints if necessary.

• Replace gasket(s) if necessary.

√

Air induction sys-
tem

• Check the air cut-off valve, reed valve, and

hose for damage.

• Replace any damaged parts if necessary.

√

Spark arrester

• Clean.

√

NO.

ITEM

ROUTINE

INITIAL

EVERY

Whichev-
er comes

first

month

(mi)

320

(200)

1200
(750)

2400

(1500)

2400

(1500)

4800

(3000)

hours

150

300

UBN57AE0.book Page 5 Tuesday, November 24, 2015 1:42 PM

Summary of Contents for WOLVERINE 2015

Page 1: ...DIC183 BN5 F8199 7A YXE70WPSG OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ...nlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title and or num...

Page 3: ...the features and operation of this vehicle It also includes basic maintenance and inspection procedures If you have any ques tions regarding the operation or maintenance of your vehicle please consult a Yamaha dealer WARNING EWB03490 Please read this manual carefully before operating this vehicle Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and ...

Page 4: ...fety alert symbol It is used to alert you to poten tial personal injury hazards Obey all safety messages that fol low this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key informa...

Page 5: ...ns in force before choosing where to operate this vehicle It is illegal to operate this vehicle on public lands where vehicles its size are prohibited EBU33130 YXE70WPSG OWNER S MANUAL 2015 by Yamaha Motor Co Ltd 1st edition November 2015 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A UBN57AE0 bo...

Page 6: ...ccelerator pedal 4 12 Brake pedal 4 12 Parking brake lever 4 13 Drive select lever 4 14 Fuel tank cap 4 14 Doors 4 15 Seats 4 15 Adjusting the driver seat position 4 16 Seat belts 4 17 Glove compartment 4 17 Storage compartments 4 18 Cup holders 4 21 Cargo bed 4 22 Adjusting the front shock absorber assemblies 4 23 Adjusting the rear shock absorber assemblies 4 28 Trailer hitch bracket and receive...

Page 7: ... KNOW YOUR VEHICLE 7 1 LEARNING TO OPERATE YOUR VEHICLE 7 12 PERIODIC MAINTENANCE AND ADJUSTMENT 8 1 Owner s manual and tool kit 8 2 Periodic maintenance chart for the emission control system 8 4 General maintenance and lubrication chart 8 6 Hood 8 10 Panels 8 11 Engine oil and oil filter cartridge 8 14 Final gear oil 8 20 Differential gear oil 8 22 Coolant 8 25 Axle boots 8 31 Spark plug inspecti...

Page 8: ...r pivot lubrication left and right 8 46 Steering shaft lubrication 8 47 Wheel removal 8 47 Checking and tightening the bead lock 8 48 Tire replacement 8 48 Wheel installation 8 49 Battery 8 50 Jump starting 8 53 Fuse replacement 8 54 Replacing a headlight bulb 8 57 Headlight beam adjustment 8 59 Tail brake light bulb replacement 8 60 Troubleshooting 8 60 Troubleshooting charts 8 62 CLEANING AND ST...

Page 9: ...labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer UBN57AE0 book Page 1 Tuesday November 24 2015 1 42 PM ...

Page 10: ...1 2 1 For Europe 2 3 4 5 6 10 10 11 12 13 14 17 6 10 10 18 21 19 20 1 7 8 16 7 15 9 UBN57AE0 book Page 2 Tuesday November 24 2015 1 42 PM ...

Page 11: ...1 3 1 23 22 24 25 26 UBN57AE0 book Page 3 Tuesday November 24 2015 1 42 PM ...

Page 12: ...egs or head outside of the vehicle can be crushed by the cage frame If you think or feel that the vehicle may tip or roll brace your feet on the floor or footrests and keep your hands on the steering wheel or handhold Never hold cage Do not try to stop a vehicle tipover using your arm or leg 1 2 UBN57AE0 book Page 4 Tuesday November 24 2015 1 42 PM ...

Page 13: ...blics à moins que les véhicules hors route y soient autorisés les collisions avec voitures et camions arrivent en un clin d œil Ne pas dépasser le nombre de places disponibles 1 passager Être préparé Attacher la ceinture de sécurité Porter un casque homologué une protection pour les yeux et une tenue de protection Le conducteur doit pouvoir rejoindre aisément toutes les commandes alors qu il est e...

Page 14: ...ins et bras dans l habitacle et agripper le volant ou la poignée de maintien YAMAHA 1XD K7761 10 AVERTISSEMENT Toute partie du corps bras jambes tête se trouvant hors de l habitacle risque d être é crasée par l arceau de protection Si une roulade ou un capotage semble imminent caler les pieds sur le plancher ou sur les repose pieds et agripper le volant ou la poignée de maintien Ne jamais agripper...

Page 15: ... and strike occupants Keep weight in the cargo bed centered side to side and as low as possible Top heavy loads increase the risk of a rollover Do not tow or pull objects from any point other than the trailer hitch bracket or winch if installed Read Owner s Manual before loading towing or pulling objects Improper use of cargo bed or cage frame can result in severe injury or death from loss of cont...

Page 16: ...le voire mortelle ne jamais stocker de carburant ni de liquide inflammable dans ce compartiment de rangement 1XP F151F 10 WARNING Storage should not exceed 10 lbs 4 5 kg Fuel vapors can be a fire or explosion hazard To avoid injury or death never store fuel or flammable liquids in this storage compartment 1XP F151F 00 11 12 UBN57AE0 book Page 8 Tuesday November 24 2015 1 42 PM ...

Page 17: ...ds du véhicule du conducteur du passager des accessoires de l équipement et le cas échéant du timon PRESSION DE SERVICE DES PNEUS Régler les pneus à froid YAMAHA 2MB F1696 10 WARNING Improper tire pressure or overloading this vehicle may cause severe injury or death from loss of control or rollover Never set or allow tire pressure to be below the minimum Tire may dislodge from rim VEHICLE LOAD of ...

Page 18: ... objet d un point autre que la fixation du timon ou le treuil le cas échéant Le mauvais usage de la caisse de chargement ou de l arceau de protection peut provoquer de graves blessures ou la mort par suite d une perte de contrôle d un capotage ou d un accident quelconque Aucun passager dans la caisse de chargement YAMAHA 1XD K7762 00 WARNING Any part of your body arms legs or head outside of the v...

Page 19: ...gement afin de l immobiliser Ne jamais dépasser le poids en flèche de 490 N 50 kgf 110 lbf du dispositif d attelage Ne pas remorquer une charge totale de plus de 6664 N 680 kgf 1500 lbf remorque plus chargement N attacher charge ou remorque qu au support de fixation d attelage Lire le manuel du propriétaire avant de charger le véhicule et de remorquer ou tirer une charge 18 19 UBN57AE0 book Page 1...

Page 20: ...urn or other accidents Secure load to prevent it from shifting Never load more than 490 N 50 kgf 110 lbf tongue weight on towing bracket Do not tow more than 6664 N 680 kgf 1500 lbf rolling weight trailer plus cargo Tow or pull only from hitch bracket Read Owner s Manual before loading towing or pulling objects 20 21 UBN57AE0 book Page 12 Tuesday November 24 2015 1 42 PM ...

Page 21: ...eet flat on floor and sitting upright with back against seat Driver must be able to comfor tably reach all controls while sitting upright with back against seat Wear an approved helmet eye protection and protective gear Fasten seat belts Do not allow anyone to ride in the cargo bed Avoid side hilling riding across slopes Plan for hills rough terrain ruts and other changes in traction and terrain A...

Page 22: ...s prêts à encaisser le choc portière fermée 1XD F8446 00 Be Prepared Adjust lock and never remove handhold Always use handhold Never hold cage Always wear seatbelt and helmet 1XD F8446 10 Toujours prévoir l imprévu Régler et verrouiller la poignée de maintien ne jamais la retirer Toujours agripper la poignée de maintien non l arceau de protection Toujours porter la ceinture de sécurité et un casqu...

Page 23: ...1 15 1 For Oceania 1 3 10 9 5 5 6 8 3 5 5 4 7 2 UBN57AE0 book Page 15 Tuesday November 24 2015 1 42 PM ...

Page 24: ...1 16 1 12 11 13 UBN57AE0 book Page 16 Tuesday November 24 2015 1 42 PM ...

Page 25: ...ot try to stop a vehicle tipover using your arm or leg YAMAHA 1XD K8483 00 WARNING Do not rest hands or arms on door or shoulder bolster To avoid Injury keep hands and arms completely Inside the vehicle by holding the steering wheel or handhold WARNING Storage should not exceed 10 lbs 4 5 kg Fuel vapors can be a fire or explosion hazard To avoid injury or death never store fuel or flammable liquid...

Page 26: ... and strike occupants Keep weight in the cargo bed centered side to side and as low as possible Top heavy loads increase the risk of a rollover Do not tow or pull objects from any point other than the trailer hitch bracket or winch if installed Read Owner s Manual before loading towing or pulling objects Improper use of cargo bed or cage frame can result in severe injury or death from loss of cont...

Page 27: ...eight of operator passengers accessories cargo and if applicable trailer tongue weight Do not exceed maximum vehicle load Gross Vehicle Weight Rating 975 kg 2150 lbs maximum including vehicle weight of operator passengers accessories cargo and if applicable trailer tongue weight OPERATING TIRE PRESSURE With tires cold set as follows WARNING Fuel vapors can be a fire or explosion hazard To avoid in...

Page 28: ...00 lbf rolling weight trailer plus cargo Tow or pull only from hitch bracket Read Owner s Manual before loading towing or pulling objects YAMAHA 1XD K7762 00 WARNING Any part of your body arms legs or head outside of the vehicle can be crushed by the cage frame If you think or feel that the vehicle may tip or roll brace your feet on the floor or footrests and keep your hands on the steering wheel ...

Page 29: ...cle Passenger must be able to reach the handhold while keeping feet flat on floor and sitting upright with back against seat Driver must be able to comfor tably reach all controls while sitting upright with back against seat Wear an approved helmet eye protection and protective gear Fasten seat belts Do not allow anyone to ride in the cargo bed Avoid side hilling riding across slopes Plan for hill...

Page 30: ...these two chapters and the labels on the vehicle to instruct new operators and passengers Do not allow anyone else to operate your vehicle or ride as a passenger if you are unsure that he she is willing and able to follow these instructions Get to know your vehicle This off road vehicle will handle and maneuver differently from cars ATVs go carts golf cars and grounds keeping vehicles Follow these...

Page 31: ...uld wear seat belts properly Both driver and passenger must be able to put both feet flat on the floorboard while seated upright with their backs against the backrests Passenger must be able to reach and hold the passenger handhold within the cage frame Both driver and passenger should wear an approved motorcycle helmet that fits properly Both driver and passenger should also wear eye protection g...

Page 32: ...or cargo bed load limit Refer to label next to hitch for tongue weight and trailer load limits Keep weight in the cargo bed centered side to side and as low and as far forward as possible Secure cargo so that it will not shift a loose load could change handling unexpectedly or be thrown forward and strike occupants While using your Yamaha Wolverine Keep your body completely inside the vehicle at a...

Page 33: ... rollover Avoid sideways sliding skidding or back wheel sliding and never do donuts Slow down before entering a turn and avoid hard braking in a turn When making tight turns from a stop or at slow speeds avoid sudden or hard acceleration Drive straight up and down inclines not across them If crossing a hill is unavoidable drive slowly and turn downhill immediately if you feel the vehicle may tip A...

Page 34: ...void sharp drop offs large rocks or slippery surfaces Operating this vehicle through deep or fast flowing water can lead to loss of control or overturn To reduce your risk of drowning or other injuries use care when crossing through water When loaded with cargo or towing a trailer Reduce speed operate in low gear only and allow more room to stop Avoid hills and rough terrain Use extreme caution wh...

Page 35: ...rtially enclosed areas such as barns garages or carports Do not run engine outdoors where engine exhaust can be drawn into a building through open ings such as windows and doors Genuine Yamaha Accessories Choosing accessories for your Wolverine is an important decision Genuine Yamaha Accesso ries which are available only from a Yamaha dealer have been designed tested and approved by Yamaha for use...

Page 36: ...ny of the vehicle s design or operation char acteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Aftermarket tires and rims The tires and rims that came with your Wolverine were designed to match the performance ca pabilities and to provide the best combination of handling braking and comfort Other tires r...

Page 37: ...ock absorber assembly 2 Radiator cap 3 Brake fluid reservoir 4 Driver seat 5 Air filter 6 Shoulder bolster 7 Driver seat belt 8 Cargo bed 9 Tail brake light 10 Rear shock absorber assembly 11 Spark plug 12 Storage compartment 13 Door UBN57AE0 book Page 1 Tuesday November 24 2015 1 42 PM ...

Page 38: ... 7 2 1 Spark arrester 2 Passenger seat belt 3 Engine oil dipstick 4 Storage compartment 5 Battery 6 Fuses 7 Headlight 8 Coolant reservoir 9 Passenger seat 10 Fuel tank cap 11 Oil filter cartridge UBN57AE0 book Page 2 Tuesday November 24 2015 1 42 PM ...

Page 39: ...ight switch 2 On Command drive knob 3 Steering wheel 4 Main switch 5 Helmet indicator light 6 Seat belt indicator light 7 Multi function meter unit 8 Auxiliary DC jack 9 Passenger handhold 10 Glove compartment 11 Storage compartment 12 Drive select lever 13 Parking brake lever 14 Accelerator pedal 15 Brake pedal 16 Horn switch UBN57AE0 book Page 3 Tuesday November 24 2015 1 42 PM ...

Page 40: ...ot be removed TIP The helmet indicator light comes on and stays on while the key is turned to on EBU31240 off All electrical circuits are switched off The key can be removed EBU31250 start The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts 1 Main switch 2 off 3 on 4 start 1 2 3 4 UBN57AE0 book Page 1 Tuesday November 24 2015 1 42 ...

Page 41: ...ferential gear lock indicator light DIFF LOCK 2 Low range indicator light L 3 High range indicator light H 4 Neutral indicator light N 5 Reverse indicator light R 6 Parking brake indicator light 7 On Command four wheel drive differential gear lock indicator 8 Engine trouble warning light 9 Coolant temperature warning light 10 Electric Power Steering warning light EPS 3 5 6 4 2 1 7 8 10 9 1 Helmet ...

Page 42: ...On Command differential gear lock indicator and the On Command differen tial gear lock indicator light DIFF LOCK come on when the On Command drive knob 2WD 4WD DIFF LOCK is set to the DIFF LOCK position TIP Due to the synchronizing mechanism in the differential gear case the four wheel drive indicator may not come on until the vehicle starts moving When the On Command drive knob 2WD 4WD DIFF LOCK ...

Page 43: ...overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the warning light is out Continuous use while this warning light is on may cause damage to the engine EBU31340 Engine trouble warning light This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine When this occurs have a Yamah...

Page 44: ...or snow the power assist is reduced to protect the EPS motor from overheating EBU31360 Helmet indicator light The indicator light comes on and stays on while the key is turned to on to remind the occupants to always wear a helmet If the indicator light does not come on when the key is turned to on have a Yamaha dealer check the electrical circuit EBU31370 Seat belt indicator light The indicator li...

Page 45: ...s the total time the engine has been running a voltage display which shows the battery voltage a fuel meter a self diagnosis device Odometer and tripmeter modes 1 CLOCK button 2 RESET button 3 SELECT button 4 Speedometer 5 Fuel meter 6 Clock Hour meter Voltage display 7 Odometer Tripmeter A Tripmeter B 3 2 1 4 5 6 7 1 SELECT button 2 RESET button 3 Odometer Tripmeter A Tripmeter B 1 2 3 UBN57AE0 b...

Page 46: ...th a full tank of fuel This information enables you to plan fu ture fuel stops TIP To switch the display between mph and km h turn the key to off then push and hold the SELECT button while turning the key to on Clock hour meter and voltage display modes Pushing the CLOCK button switches the display between the clock mode CLOCK the hour meter mode HOUR and the volt age display mode in the following...

Page 47: ...rt flashing 5 Push the RESET button to set the minu tes 6 Push the SELECT button and then re lease it to start the clock Voltage display mode This display shows the battery voltage appears for 1 second when the volt age display mode is first selected and then appears and the battery voltage is displayed If the battery voltage is less than 10 volts LO is displayed and if the voltage is above 16 vol...

Page 48: ...ppear from F full towards E empty as the fuel level decreases When the E segment disappears and the fuel level warning indicator flashes refuel as soon as possible TIP This fuel meter is equipped with a self diag nosis system If a problem is detected in an electrical circuit all the display segments and fuel level warning indicator start flashing If this occurs have a Yamaha dealer check the elect...

Page 49: ...error code note the code number and then have a Yamaha dealer check the vehicle NOTICE ECB00812 If the multi function display indicates an error code the vehicle should be checked as soon as possible in order to avoid en gine damage EBU31390 Light switch Set the switch to to turn on the low beam and the taillights Set the switch to to turn on the high beam and the taillights 1 Error code display 2...

Page 50: ...ery and recharge it EBU31400 On Command drive knob 2WD 4WD DIFF LOCK This vehicle is equipped with an On Com mand drive knob to select the drive mode The knob has three positions 2WD 4WD and DIFF LOCK Select the appropriate drive according to terrain and conditions 2WD two wheel drive Power is supplied to the rear wheels only 4WD four wheel drive Power is sup plied to the rear and front wheels 1 O...

Page 51: ...n switch Press the switch to sound the horn EBU31411 Accelerator pedal Press the accelerator pedal to increase en gine speed Spring tension returns the pedal to the rest position when released Always check that the accelerator pedal returns nor mally before starting the engine EBU31420 Brake pedal Press the brake pedal to slow or stop the ve hicle 1 Horn switch 1 1 Accelerator pedal 1 UBN57AE0 boo...

Page 52: ...e pull the lever rear ward completely To release the parking brake pull rearward on the lever press the release button and then push the lever all the way forward TIP Spring tension helps return the lever to the released position If you drive the vehicle with the parking brake engaged a buzzer will sound 1 Brake pedal 1 1 Release button 2 Parking brake lever 2 1 UBN57AE0 book Page 13 Tuesday Novem...

Page 53: ... reverse po sitions Refer to page 6 3 for the drive select lever operation EBU31450 Fuel tank cap To open Remove the fuel tank cap by turning it coun terclockwise To close Install the fuel tank cap by turning it clock wise 1 Drive select lever 1 1 Fuel tank cap 1 UBN57AE0 book Page 14 Tuesday November 24 2015 1 42 PM ...

Page 54: ... seat cushion insert the projec tions on the rear of the seat cushion under the seat frame and then insert the projection on the front of the cushion into the grommet while pushing the cushion downward Make sure the seats are properly secured before starting off WARNING A loose seat could cause the operator to lose control or cau se the operator or passenger to fall EWB03510 1 Door 2 Latch 2 1 1 D...

Page 55: ...reference Adjust the driver seat position as follows 1 Remove the driver seat cushion See the previous section Seats 2 Remove the bolts 3 Move the seat frame to the desired posi tion and align the bolt holes in the seat frame with the bolt holes in the vehicle frame 1 Bolt 1 1 UBN57AE0 book Page 16 Tuesday November 24 2015 1 42 PM ...

Page 56: ... vehicle See page 7 5 for more information EBU31501 Glove compartment This vehicle is equipped with a glove com partment When storing any documents in the glove compartment be sure to wrap them in a plas tic bag so that they will not get wet When washing the vehicle be careful not to let any water enter the glove compartment Tightening torque Driver seat bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Seat belt ...

Page 57: ...access an un der seat storage compartment remove the seat cushion see page 4 15 for more infor mation When storing any documents in the storage compartments be sure to wrap them in a plastic bag so that they will not get wet When washing the vehicle be careful not to let any water enter the storage compartments NOTICE ECB02241 To protect from damage do not put metal items like tools or sharply edg...

Page 58: ...4 19 4 1 Storage compartment 1 Storage compartment 1 1 1 Storage compartment 1 Storage compartment 1 1 UBN57AE0 book Page 19 Tuesday November 24 2015 1 42 PM ...

Page 59: ... maximum load limit for this storage compartment ECB02090 A drain plug is fitted at the bottom of this stor age compartment If any water collects in the storage compartment remove the drain plug drain the water and then install the drain plug from inside the storage compartment Maximum load limit Storage compartment between the driver seat and the passenger seat 6 4 kg 13 5 lb Storage compartment ...

Page 60: ...in the cup holders otherwise the contents may spill and the glass contain ers may be thrown about and break and possibly injure people in the vehicle dur ing sudden braking or an accident Do not place any other items than seal able plastic containers in the cup hold ers otherwise they may be thrown about and possibly injure people in the vehicle during sudden braking or an ac cident 1 Drain plug 1...

Page 61: ...f control because of improper weight balance There are six cargo hooks in the cargo bed For additional loading information see page 6 7 Removing and installing the tailgate To remove the tailgate Unhook the latches and then pull up the tail gate 1 Cargo hook 1 1 Cargo hook Maximum load limit 136 0 kg 300 lb 1 UBN57AE0 book Page 22 Tuesday November 24 2015 1 42 PM ...

Page 62: ...11 Adjusting the front shock absorber as semblies These shock absorber assemblies are equipped with a spring preload adjusting nut a rebound damping force adjusting screw a compression damping force adjusting bolt for fast compression damping and a com pression damping force adjusting screw for slow compression damping 1 Tailgate 2 Latch 2 2 1 1 Tailgate 2 Latch 2 2 1 UBN57AE0 book Page 23 Tuesday...

Page 63: ...ettings TIP Although the total number of clicks or turns of a damping force adjusting mechanism may not exactly match the following specifications due to small differences in production the ac tual number of clicks or turns always repre sents the entire adjusting range To obtain a precise adjustment it would be advisable to check the number of clicks or turns of each damping force adjusting mechan...

Page 64: ... turn of the adjusting nut distance A is changed by 1 5 mm 0 06 in 3 Tighten the locknut to the specified torque NOTICE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque ECB00082 1 Special wrench 2 Locknut 3 Spring preload adjusting nut 2 1 3 a b Spring preload setting Minimum soft Distance A 313 5 mm 12 34 in Standard Distance A 305 5 mm 12 03 in Max...

Page 65: ...and thereby harden the compression damp ing turn the compression damping force ad justing bolt in direction a To decrease the compression damping force and thereby soften the compression damping turn the adjusting bolt in direction b Tightening torque Locknut 30 Nm 3 0 m kgf 22 ft lbf 1 Rebound damping force adjusting screw 1 a b Rebound damping setting Minimum soft 30 click s in direction b Stand...

Page 66: ...ssion damping turn the adjusting screw in direction b 1 Compression damping force adjusting bolt for fast compression damping Compression damping setting for fast com pression damping Minimum soft 2 turn s out from the fully turned in posi tion Standard 1 1 4 turn s out from the fully turned in position Maximum hard Adjusting bolt fully turned in 1 a b 1 Compression damping force adjusting screw f...

Page 67: ...he shock absorber assembly to a Yamaha dealer for any service EBU33620 Adjusting the rear shock absorber as semblies These shock absorber assemblies are equipped with a spring preload adjusting nut a rebound damping force adjusting screw a compression damping force adjusting bolt for fast compression damping and a com pression damping force adjusting screw for slow compression damping WARNING EWB0...

Page 68: ...amping force adjusting mechanism may not exactly match the following specifications due to small differences in production the ac tual number of clicks or turns always repre sents the entire adjusting range To obtain a precise adjustment it would be advisable to check the number of clicks or turns of each damping force adjusting mechanism and to modify the specifications as necessary Spring preloa...

Page 69: ... turn of the adjusting nut distance A is changed by 1 5 mm 0 06 in 3 Tighten the locknut to the specified torque NOTICE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque ECB00082 1 Locknut 2 Spring preload adjusting nut 3 Special wrench 1 3 2 a b Spring preload setting Minimum soft Distance A 386 0 mm 15 20 in Standard Distance A 378 0 mm 14 88 in Max...

Page 70: ...and thereby harden the compression damp ing turn the compression damping force ad justing bolt in direction a To decrease the compression damping force and thereby soften the compression damping turn the adjusting bolt in direction b Tightening torque Locknut 30 Nm 3 0 m kgf 22 ft lbf 1 Rebound damping force adjusting screw 1 a b Rebound damping setting Minimum soft 30 click s in direction b Stand...

Page 71: ...ssion damping turn the adjusting screw in direction b 1 Compression damping force adjusting bolt for fast compression damping Compression damping setting for fast com pression damping Minimum soft 2 turn s out from the fully turned in posi tion Standard 1 1 4 turn s out from the fully turned in position Maximum hard Adjusting bolt fully turned in 1 a b 1 Compression damping force adjusting screw f...

Page 72: ...amping performance Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EBU31550 Trailer hitch bracket and receiver This vehicle is equipped with a trailer hitch bracket and a 5 cm 2 in receiver for a stan dard trailer hitch Trailer towing equipment can be obtained at a Yamaha dealer See page 6 7 for precaution...

Page 73: ...more than the stated maximum capacity Do ing so may overload the circuit and cau se the fuse to blow If accessories are used without the en gine running the battery may discharge Do not use an automotive cigarette light er or other accessories with a plug that gets hot because the jack can be dam aged 1 Set the light switch to 2 Turn the accessory off 3 Start the engine See page 6 2 4 Open the aux...

Page 74: ...hen the auxiliary DC jack is not being used cover it with the cap 1 Auxiliary DC jack cap 2 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12 V 10 A 120 W 2 1 UBN57AE0 book Page 35 Tuesday November 24 2015 1 42 PM ...

Page 75: ...perate the vehicle if you find any problem If a problem can not be corrected by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Brakes Check operation free play fluid level and fluid leakage Fill with DOT 4 brake fluid if necessary 5 3 8 41 8 44 Parking brake Check for proper operation 8 44 ...

Page 76: ...on and belt wear 5 7 Passenger handhold Check for stability and proper fastening 5 7 7 8 Steering Check for proper operation 5 7 Fittings and fasteners Check all fittings and fasteners 5 8 Instruments lights and switches Check operation and correct if necessary 5 8 8 57 8 59 8 60 Wheels and tires Check tire pressure and for wear and damage 5 8 8 47 8 49 Axle boots Check for damage 8 31 ITEM ROUTIN...

Page 77: ...age 8 42 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Apply the brakes firmly for one minute If there is any leakage have the vehicle inspected by a Yamaha dealer Brake operation Check the operation of the brakes at the start of every ride Test the brakes at slow speed after starting out to make sure they are work ing properly I...

Page 78: ...d fuel immediately 4 Be sure the fuel tank cap is closed se curely WARNING EWB02532 Gasoline is poisonous and can cause inju ry or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spill...

Page 79: ...ark and ignite the gasoline EWB03270 EBU31750 Engine oil Make sure the engine oil is at the specified level Add oil as necessary See page 8 14 NOTICE ECB00301 In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils la...

Page 80: ...mful to the engine You may use soft water if you can not get distilled water EBU31771 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See page 8 20 for details If desired an SAE 80W 90 hypoid gear oil may be used instead TIP GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used EBU31780 Differential gear oil Make sure ...

Page 81: ...ler repair as necessary for proper operation A crash can damage the restraint systems in your vehicle A damaged restraint system may not properly protect the person using it resulting in serious injury or death in a crash To help make sure your restraint systems are working properly after a crash have them in spected and any necessary replacements made as soon as possible EBU31810 Passenger handho...

Page 82: ...e in cold weather and you could be unable to control the vehicle EWB03280 EBU33480 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use the tire pressure gauge to check and ad just tire pressures when the tires are cold Tire pressures must be equal on both sides WARNING Operation of this vehicle with improper tire...

Page 83: ... due to wear replace the tire Recommended tire pressure Vehicle load 0 maximum Front 75 0 kPa 0 750 kgf cm 11 psi Rear 75 0 kPa 0 750 kgf cm 11 psi Minimum tire pressure Vehicle load 0 maximum Front 70 0 kPa 0 700 kgf cm 10 psi Rear 70 0 kPa 0 700 kgf cm 10 psi Maximum vehicle load 327 0 kg 721 lb Total weight of operator passenger acces sories cargo and if applicable trailer tongue weight 1 Tire ...

Page 84: ...5 10 5 1 Tire wear limit 1 UBN57AE0 book Page 10 Tuesday November 24 2015 1 42 PM ...

Page 85: ...parts in the engine wear and polish them selves to achieve the correct operating clear ances During this period prolonged full throttle op eration or any condition that might result in excessive 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 substant...

Page 86: ... the neutral indicator light should come on If the neutral indi cator light does not come on ask a Yamaha dealer to inspect the electric circuit The engine can be started in any gear if the brake pedal is applied However it is recommended to shift into neutral before starting the engine 4 With your foot off the accelerator pedal start the engine by turning the key to start If the engine fails to s...

Page 87: ...le speed Damage to the engine or drive train may occur Shifting neutral to high and high to low 1 Stop the vehicle and take your foot off the accelerator pedal 2 Apply the brake pedal then shift by mov ing the drive select lever along the shift guide Make sure that the drive select le ver is completely shifted into position 3 Release the parking brake if applied 4 Release the brake pedal and press...

Page 88: ...e shift guide When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to in spect the reverse indicator light electri cal circuit Due to the synchronizing mechanism in the engine the light may not come on until the vehicle starts moving 4 Release the parking brake if applied 5 Check behind the vehicle for people or obstacles and then release the b...

Page 89: ...he different drive indicators and the differential gear lock indicator light DIFF LOCK come on as follows Knob position Indication Drive mode No indicator light 2WD two wheel drive Power is supplied to the rear wheels 4WD four wheel drive Power is supplied to the rear and front wheels DIFF LOCK four wheel drive with the differential gear locked Power is supplied to the rear and front wheels and th...

Page 90: ...tor light are flashing turning the steering wheel back and forth will help the differential gear lock to engage or disengage Riding before the differential gear is properly engaged or disengaged e g when the indicator and indicator light are flashing will cause the vehicle speed to be limited until the differential gear is completely engaged or disengaged UBN57AE0 book Page 6 Tuesday November 24 2...

Page 91: ...overturn or other accident Do not exceed the Maximum Loading Limits for the vehicle see MAXIMUM LOADING LIMIT in this section and ve hicle labeling Keep weight in the cargo bed centered side to side and as low and as far for ward as possible Top heavy loads in crease the risk of overturn Be sure cargo is secured a loose load could change handling unexpectedly or strike occupants Do not exceed the ...

Page 92: ...w gear whenever you are carrying heavier loads or when towing a trailer WARNING EWB03320 Carrying loads or towing a trailer can in crease the risk of loss of control an over turn or other accident To reduce the risk of an accident Reduce speed operate in low gear only and allow more room to stop A heavier vehicle takes longer to stop Avoid hills and rough terrain Choose terrain carefully Use extre...

Page 93: ...s for that product and only attach to the hitch or hitch bracket of the Wolverine WARNING Improperly pulling can cause serious injury or death Never exceed the pulling load limit of the Wolverine Avoid pulling on inclines EWB03330 Pulling objects on the ground can be more hazardous than pulling a trailer It may be dif ficult to predict how the load will affect vehicle operation That effect could a...

Page 94: ...U33510 KNOW YOUR VEHICLE This off road vehicle will handle and maneu ver differently from cars ATVs go carts golf cars and grounds keeping vehicles The Wolverine has higher ground clearance and other features to handle rugged terrain and as a result can overturn in situations where some vehicles may not This would include vehicles made primarily for pavement roads improved paths or grounds keeping...

Page 95: ...or older with a valid motor ve hicle license Check country laws for mini mum age requirements The driver must be able to place both feet flat on the floorboard while seated upright with his her back against the backrest Do not drive after using drugs or alcohol Remove the ignition key when the vehicle is not in use to prevent unauthorized use of the machine Parents Many countries have implemented ...

Page 96: ... passenger handhold Allow only one passenger in the vehicle and only in the designated passenger seat Do not carry any other passengers Do not car ry passengers in the cargo bed Do not allow someone to ride as a passen ger who has been using drugs or alcohol Do not allow children who need child safety seats or booster seats in the Wolverine The seat belt is not designed to restrain auto motive chi...

Page 97: ...work together and when properly used these features will help protect the occupants in the event of an accident If these features are not used prop erly they can cause injury 1 Seat belt 2 Shoulder bolster 3 Door 1 2 3 1 1 Passenger handhold 2 Shoulder bolster 3 Door 1 2 3 UBN57AE0 book Page 4 Tuesday November 24 2015 1 42 PM ...

Page 98: ... outside of the vehicle can be crushed by the vehicle cage frame Seat belts Seat belts should be worn by the driver and passenger The driver must be sure that the passenger is belted before driving Be sure the seat belt is not twisted is close fitting across the hips and chest and is latched securely Do not wear the seat belt across the abdo men or stomach Do not put the seat belt behind the back ...

Page 99: ...elt properly do the follow ing 1 Hold the latch plate as you pull the belt across your lap and chest Make sure the belt is not twisted and is not caught on any portion of the vehicle your clothing or any equipment you are carrying 2 If the latch plate is not positioned in the correct location along the seat belt squeeze the latch plate ends together along its long edges in order to more eas ily ad...

Page 100: ...r your shoulder and across your chest The shoulder belt should fit against your chest If it is loose pull the belt out all the way and then let it retract 6 Check if the seat belt shoulder position suits the size of the driver and passenger To lower the belt insert the belt into the seat belt height adjuster slot as shown To raise the belt remove the belt from the height adjuster slot 1 Buckle 2 L...

Page 101: ...rm or hand on the door during operation Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover Passenger handhold The passenger handhold is provided to grip during operation to maintain proper position and balance Holding onto the handhold helps to reduce the likelihood that the pas senger puts a hand outside the vehicle if the vehicle begins t...

Page 102: ...passenger s preference Adjust the handhold position as follows 1 Remove the locking pins 2 Slide the handhold to the desired position and align the holes in the handhold bar with the holes in the handhold supports 1 Passenger handhold 2 Locking pin 2 1 UBN57AE0 book Page 9 Tuesday November 24 2015 1 42 PM ...

Page 103: ...ats and shoulder bolsters are designed to help keep you in the vehicle Do not put your hand or arm on or outside of the shoul der bolster during operation Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover 1 Handhold support 2 Handhold bar 2 1 1 1 Wire loop 1 UBN57AE0 book Page 10 Tuesday November 24 2015 1 42 PM ...

Page 104: ... palms on the out side of the steering wheel Similar to other off road vehicles if the Wolverine hits a deep rut or large obstacle the steering wheel could briefly jerk in one direction or back and forth as the tires and vehicle respond to the obsta cle This quick motion could injure your thumbs or wrist if your thumbs or hand s are inside the steering wheel Grip the steering wheel so that your th...

Page 105: ...lowing to reduce risk of injury in an accident Approved motorcycle helmet that fits prop erly CORRECT GRIP EXAMPLE INCORRECT GRIP EXAMPLE 1 Approved motorcycle helmet 2 Eye protection 3 Long sleeved shirt or jacket 4 Gloves 5 Long pants 6 Over the ankle boots 1 2 3 4 5 6 UBN57AE0 book Page 12 Tuesday November 24 2015 1 42 PM ...

Page 106: ... such as a face shield or goggles may reduce the risk of for eign material getting in your eyes and help prevent loss of vision Practice for new Yamaha Wolverine users You should become familiar with the perfor mance characteristics of the vehicle in a lar ge flat area that is free of obstacles and other vehicles Practice controlling the accelerator pedal brakes steering and drive select lever Dri...

Page 107: ...ns turning the steering wheel too far or too fast can result in loss of control or a rollover Slow down before entering turns When making tight turns from a stand still or at slow speeds avoid sudden or hard acceleration Driving aggressively or making abrupt maneuvers even on flat open areas can cause side rollovers Avoid sideways slid ing skidding or back wheel sliding and nev er do donuts If you...

Page 108: ...moothly The centrifugal clutch will engage and the vehicle will begin to accelerate Avoid higher speeds and sudden or hard ac celeration until you are thoroughly familiar with the operation of your vehicle Avoid sud den or hard acceleration in any turn Braking When slowing down or stopping take your foot off the accelerator pedal and press the brake pedal smoothly Improper use of the brakes can ca...

Page 109: ...to try to stop the vehicle Parking on a flat area When parking on a flat area stop the engine and shift the drive select lever into the neutral position Apply the parking brake to help pre vent the vehicle from rolling Parking on a slope The parking brake acts only on the rear wheels when in 2WD For the parking brake to take effect on all four wheels shift to DIFF LOCK before stopping the engine I...

Page 110: ...s bumps or holes without enough time to react To avoid loss of control or rollover always be alert to changing surfaces or terrain when operating the vehicle Your Yamaha Wolverine has higher ground clearance and other features to handle rug ged terrain and as a result can overturn in situations where some vehicles may not Abrupt maneuvers or aggressive driving can cause loss of control including r...

Page 111: ...ncreases your risk of roll over Practice first on gentle slopes before at tempting steeper hills Always check the terrain carefully before attempting any hill To climb a hill you need traction momentum and steady throttle For more traction and control for climbing steeper and or rougher slopes shift into low gear and select 4WD or DIFF LOCK Travel fast enough to main tain momentum but not so fast ...

Page 112: ... the brakes which could cause the vehicle to slide If you are sliding or skidding try to steer in the direction the vehicle is sliding to regain con trol For example if you feel the back of the vehicle start to slide to your right steer to the right If you must turn on the hill to avoid an obsta cle do so slowly and carefully If the vehicle starts to tip immediately steer in the downhill direction...

Page 113: ... drowning or other injuries use care when crossing through water Wet brakes may have reduced effectiveness After leaving the water test your brakes If necessary apply the brakes several times to let friction dry out the linings NOTICE ECB02170 After driving your vehicle in water be sure to drain the trapped water by removing the check hoses at the bottom of the air filter case and air duct and the...

Page 114: ...opped To reduce the risk of fire during operation or after leaving the vehicle do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to other hot parts Check under the vehicle after operating in areas where combustible materials may have collected Do not idle or park the vehicle in long dry grass or other dry ground cover Encountering obstacl...

Page 115: ...ion about your ability to maneuver safely over the obstacle you should turn around if the ground is flat and you have the room or back up until you find a less difficult path UBN57AE0 book Page 22 Tuesday November 24 2015 1 42 PM ...

Page 116: ...ile using the ve hicle If you are not familiar with vehicle service have a Yamaha dealer perform the service WARNING EWB02563 Turn off the engine when performing main tenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or...

Page 117: ...ce information included in this man ual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor repairs The tools provided in the owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts 1 Owner s manual 1 1 Owner s tool kit 2 Tire pressure gauge 1 2 UBN57AE...

Page 118: ...have a torque wrench available during a service operation requiring one take your vehicle to a Yamaha dealer to check the torque settings and adjust them as neces sary UBN57AE0 book Page 3 Tuesday November 24 2015 1 42 PM ...

Page 119: ...ollowed Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM ROUTINE INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1200 750 2400 1500 2400 1500 4800 3000 hours 20 75 150 150 300 1 Fuel line Check fuel hose for cracks or damage Replace if necessary 2 Valves Check valve clearance Adjust if necessary...

Page 120: ...6 Air induction sys tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary 7 Spark arrester Clean NO ITEM ROUTINE INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1200 750 2400 1500 2400 1500 4800 3000 hours 20 75 150 150 300 UBN57AE0 book Page 5 Tuesday November 24 2015 1 42 PM ...

Page 121: ... necessary Every 20 40 hours more often in wet or dusty areas 3 Engine oil Change warm engine before draining 4 Engine oil filter cartridge Replace 5 Final gear oil Dif ferential gear oil Check oil level oil leakage Change 6 Front brake Check operation brake pad wear fluid leak age see page 8 8 Correct if necessary Replace pads if worn to the limit 7 Rear brake Check operation brake pad wear fluid...

Page 122: ...eck and tighten the bead lock for equipped models Every 500 km 300 mi 13 Wheel bearings Check bearing assemblies for loose ness damage Replace if damaged 14 Front and rear suspension Check operation and for oil leakage Correct if necessary 15 Steering system Check operation and for looseness Replace if damaged Check toe in Adjust if necessary NO ITEM ROUTINE INITIAL EVERY Whichev er comes first mo...

Page 123: ...18 Drive shaft uni versal joint Lubricate with lithium soap based grease 19 Engine mount Check for cracks or damage Check bolt tightness 20 Front and rear axle boots Check for cracks or other damage and re place if necessary 21 Fittings and fas teners Check all chassis fittings and fasteners Correct if necessary NO ITEM ROUTINE INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 12...

Page 124: ...orrect the brake fluid level Every two years replace the internal components of the brake master cylinder and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged UBN57AE0 book Page 9 Tuesday November 24 2015 1 42 PM ...

Page 125: ...40 Hood To remove 1 Pull the tab on each hood lock up and then turn the hood locks 1 4 turn clock wise 2 Remove the hood 1 Tab 1 1 Tab 2 Hood lock 1 Hood 1 2 1 UBN57AE0 book Page 10 Tuesday November 24 2015 1 42 PM ...

Page 126: ...he tab on each hood lock down so that it is pointing rear ward Make sure that the hood is securely installed NOTICE ECB02180 Do not drive the vehicle with the hood open unlatched or removed EBU33602 Panels Left panel To remove the left panel 1 Remove the bolts 2 Open the driver door and then remove the quick fastener screws 1 Bolt 2 Left panel 1 2 UBN57AE0 book Page 11 Tuesday November 24 2015 1 4...

Page 127: ...anel in the original position and then install the bolts and quick fastener screws Right panel To remove the right panel 1 Remove the bolts 2 Open the passenger door and then re move the quick fastener screws 1 Quick fastener screw 1 1 1 Bolt 2 Right panel 1 2 UBN57AE0 book Page 12 Tuesday November 24 2015 1 42 PM ...

Page 128: ...e bolts and quick fastener screws 3 Install the fuel tank cap Right rear panel To remove the right rear panel 1 Remove the right panel 2 Remove the quick fastener screws and then take the panel off To install the right rear panel 1 Place the panel in the original position and then install the quick fastener screws 2 Install the right panel 1 Quick fastener screw 1 1 1 Right rear panel 2 Quick fast...

Page 129: ...surface 2 Check the engine oil level on a cold en gine TIP If the engine was started before checking the oil level be sure to warm up the engine suffi ciently and then wait at least 10 minutes until the oil settles for an accurate reading 3 Remove the passenger seat cushion see page 4 15 for more information 4 Remove the rubber cover 5 Remove the engine oil dipstick and wipe it with a clean rag 1 ...

Page 130: ...e mini mum and maximum level marks 7 If the engine oil is at or below the mini mum level mark add sufficient oil of the recommended type to raise it to the cor rect level 8 Install the dipstick with the arrow pointing in the direction shown 1 Engine oil dipstick 2 Arrow mark 1 2 1 Engine oil dipstick 2 Maximum level mark 3 Minimum level mark 1 2 3 1 UBN57AE0 book Page 15 Tuesday November 24 2015 1...

Page 131: ...eral minutes and then turn it off 3 Remove the passenger seat cushion see page 4 15 for more information 4 Remove the rubber cover 5 Remove the engine oil dipstick 6 Place an oil pan under the engine to col lect the used oil 7 Remove the engine oil drain bolt and its gasket to drain the oil from the crank case 1 Engine oil dipstick 2 Arrow mark 1 2 1 Rubber cover 1 UBN57AE0 book Page 16 Tuesday No...

Page 132: ...ridge If the O ring remains attached to the crankcase oil leakage may occur TIP An oil filter wrench is available from a Yamaha dealer 9 Apply a light coat of clean engine oil to the O ring of the new oil filter cartridge TIP Make sure that the O ring is properly seated 1 Engine oil drain bolt 2 Gasket 1 2 1 Oil filter cartridge 2 Oil filter wrench 2 1 UBN57AE0 book Page 17 Tuesday November 24 201...

Page 133: ...en the bolt to the specified torque 12 Refill with the specified amount of recom mended engine oil into the oil filler hole 13 Install the dipstick with the arrow pointing in the direction shown 1 O ring Tightening torque Oil filter cartridge 15 Nm 1 5 m kgf 11 ft lbf 1 1 Torque wrench Tightening torque Engine oil drain bolt 22 Nm 2 2 m kgf 16 ft lbf 1 UBN57AE0 book Page 18 Tuesday November 24 201...

Page 134: ...use oils la beled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase 14 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 1 Engine oil dipstick 2 Arrow mark Recommended engine oil See page 10 1 Oil quantity Without oil filter cartridge replacement...

Page 135: ... the final gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level NOTICE Be sure no foreign material enters the final gear case ECB00422 4 Check the gasket for damage and re place it if necessary 5 Install the oil filler bolt and its gasket and then tighten the bo...

Page 136: ...bolt the fi nal gear oil drain bolt and their gasket to drain the oil 5 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Rear bottom panel 2 Bolt 2 2 1 1 Final gear oil drain bolt 2 Gasket Tightening torque Final gear oil drain bolt 22 Nm 2 2 m kgf 16 ft lbf 2 1 UBN57AE0 book Page 21...

Page 137: ...panel by installing the bolts and then tightening them to the specified torque EBU36082 Differential gear oil Checking the differential gear oil level 1 Park the vehicle on a level surface 2 Remove the differential gear oil filler bolt and its gasket and then check the oil lev el It should be up to the brim of the filler hole Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 64 L 0 68...

Page 138: ...then tighten the bolt to the specified torque Changing the differential gear oil 1 Park the vehicle on a level surface 2 Remove the front bottom panel by re moving the bolts 3 Place an oil pan under the differential gear case to collect the used oil 1 Differential gear oil filler bolt 2 Gasket 3 Differential gear oil 4 Correct oil level 1 2 3 4 Tightening torque Differential gear oil filler bolt 2...

Page 139: ...il filler bolt gasket for dam age and replace it if necessary 8 Install the differential gear oil filler bolt and its gasket and then tighten the bolt to the specified torque 9 Check for oil leakage If oil leakage is found check for the cause 1 Differential gear oil drain bolt 2 Gasket Tightening torque Differential gear oil drain bolt 9 8 Nm 0 98 m kgf 7 1 ft lbf 1 2 Recommended oil SAE 80 API GL...

Page 140: ... The coolant level should be checked before each ride In addition the coolant must be changed at the intervals specified in the peri odic maintenance and lubrication chart 1 Front bottom panel 2 Bolt Tightening torques Front bottom panel bolt 7 Nm 0 7 m kgf 5 1 ft lbf 2 2 1 1 Front bottom panel 2 Bolt Tightening torques Front bottom panel bolt 9 Nm 0 9 m kgf 6 5 ft lbf 2 1 UBN57AE0 book Page 25 Tu...

Page 141: ...ging the coolant WARNING EWB01891 Wait for the engine and radiator to cool be fore removing the radiator cap You could be burned by hot fluid and steam blown out under pressure Always place a thick rag over the cap when opening Allow any remaining pressure to escape before com pletely removing the cap 1 Park the vehicle on a level surface 2 Remove the hood See page 8 10 for hood removal and instal...

Page 142: ...r under the engine to col lect the used coolant 5 Remove the radiator cap 6 Remove the coolant drain bolt and its gasket to drain the coolant from the en gine and radiator 1 Center bottom panel 2 Bolt 2 2 2 2 1 1 Radiator cap 1 UBN57AE0 book Page 27 Tuesday November 24 2015 1 42 PM ...

Page 143: ...n the coolant from the cool ant reservoir 10 After draining the coolant thoroughly flush the cooling system with clean tap water 11 Install the coolant drain bolt and its new gasket and then tighten the bolt to the specified torque 1 Coolant drain bolt 2 Gasket 1 2 1 Coolant reservoir cap 2 Coolant reservoir hose 1 2 UBN57AE0 book Page 28 Tuesday November 24 2015 1 42 PM ...

Page 144: ...nel and right rear panel See page 8 11 for right panel and right rear panel removal and installation procedures 16 Loosen the water pump air bleed bolt without removing it to allow all of the air to escape from the air bleed bolt hole Tightening torque Coolant drain bolt 8 Nm 0 8 m kgf 5 8 ft lbf Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol antifreeze con ...

Page 145: ... the bolt hole tighten the cylinder head air bleed bolt to the specified torque 20 Start the engine and let it idle for ten mi nutes 21 Rev the engine five times 22 Pour additional coolant into the radiator until it is full 1 Water pump air bleed bolt Tightening torque Water pump air bleed bolt 8 Nm 0 8 m kgf 5 8 ft lbf 1 1 Cylinder head air bleed bolt Tightening torque Cylinder head air bleed bol...

Page 146: ...l the cap 25 Start the engine and then check for cool ant leakage TIP If any leakage is found have a Yamaha dealer check the cooling system 26 Install the center bottom panel by install ing the bolts and then tightening them to the specified torque 27 Install the panels and the hood EBU32400 Axle boots Check the axle boots for holes or tears If any damage is found have them replaced by a Yamaha de...

Page 147: ...tion Removal 1 Remove the spark plug cap 2 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1 Rear axle boot 1 1 1 Spark plug cap 1 Spark plug wrench 1 1 UBN57AE0 book Page 32 Tuesday November 24 2015 1 42 PM ...

Page 148: ...s ex cessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification Installation 1 Clean the surface of the spark plug gas ket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug and tighten it ...

Page 149: ... element rubber joint to the throttle body and manifold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the en gine NOTICE ECB02270 Never operate the engine with the air filter element removed Doing so would allow unfiltered air to enter causing rapid en gine wear and possible engine damage Additionally the fuel injection system woul...

Page 150: ... Remove the air filter element 4 While pushing the projections on the air filter frame inward remove the air filter el ement holder 1 Air filter case cover 2 Air filter case cover holder 1 2 2 1 Air filter element 1 UBN57AE0 book Page 35 Tuesday November 24 2015 1 42 PM ...

Page 151: ...an the air fil ter element can cause a fire or explo sion which could lead to serious injury EWB03360 7 Squeeze the excess solvent out of the sponge material NOTICE Do not twist the sponge material when squeezing it ECB00442 1 Air filter element holder 2 Projection 1 2 1 Air filter element holder 2 Sponge material 3 Air filter frame 3 2 1 UBN57AE0 book Page 36 Tuesday November 24 2015 1 42 PM ...

Page 152: ... Thoroughly apply Yamaha foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge material The sponge material should be wet but not dripping 12 Pull the sponge material over its frame 13 Install the air filter element holder 14 Install the air filter element 15 Fit the holders on the air filter case cover onto the projections on the air filter case and then ins...

Page 153: ...om of the air filter case and at the bottom of the air duct To access the check hoses remove the center bottom panel by removing the bolts If dust or water collects in a check hose emp ty the hose and clean the air filter element and air filter case 1 Center bottom panel 2 Bolt 2 2 2 2 1 UBN57AE0 book Page 38 Tuesday November 24 2015 1 42 PM ...

Page 154: ...ding in water deep enough to allow wa ter to enter the V belt case remove the drain plug to drain any water from the case If water drains from the V belt case after re moving the drain plug have a Yamaha dealer inspect the vehicle as the water may affect other engine parts 1 Air duct check hose 2 Air filter case check hose Tightening torques Center bottom panel bolt 9 Nm 0 9 m kgf 6 5 ft lbf 2 1 1...

Page 155: ...move the tailpipe by pulling it out of the muffler and then remove the gasket 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Install the gasket and then insert the tail pipe into the muffler and align the bolt holes 5 Install the bolts and tighten them to the specified torque 1...

Page 156: ...ould lead to a loss in brak ing ability and an accident EBU32480 Checking the front and rear brake pads Each brake pad is provided with wear indica tor grooves which allow you to check the brake pad wear without having to disassem ble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indi cator grooves have almost disappeared ...

Page 157: ...vel Replenish the brake fluid if necessary WARNING EWB02721 Improper maintenance can result in loss of braking ability Observe these precau tions Insufficient brake fluid may allow air to enter the brake system reducing brak ing performance 1 Brake pad wear indicator groove 1 1 Minimum level mark Specified brake fluid DOT 4 1 UBN57AE0 book Page 42 Tuesday November 24 2015 1 42 PM ...

Page 158: ... brake fluid level to gradually go down A low brake fluid level may indicate worn brake pads and or brake system leakage therefore be sure to check the brake pads for wear and the brake system for leakage If the brake fluid level goes down suddenly have a Yamaha dealer check the cause before further riding EBU32520 Brake fluid replacement Complete fluid replacement should be done only by trained Y...

Page 159: ... Yamaha dealer check and adjust the park ing brake at the intervals specified in the peri odic maintenance and lubrication chart EBU32550 Brake light switch adjustment The brake light switch which is activated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while hold...

Page 160: ...les becomes damaged Cables can also become frayed or kinked Lubricate the cable ends If the cables do not operate smoothly ask a Yamaha dealer to re place them EBU32570 Brake pedal and accelerator pedal lu brication Lubricate the pivoting parts 1 Brake light switch 2 Adjusting nut a b 1 2 Recommended lubricant Yamalube LubezAll synthetic lubricant spray with PTFE Recommended lubricant Lithium soap...

Page 161: ...rvals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bushes if necessary EBU32590 Rear knuckle upper and lower pivot lu brication left and right Lubricate the knuckle upper and lower pivots with a grease gun UBN57AE0 book Page 46 Tuesday November 24 2015 1 42 PM ...

Page 162: ...l 1 Loosen the wheel nuts 2 Elevate the vehicle and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease UBN57AE0 book Page 47 Tuesday November 24 2015 1 42 PM ...

Page 163: ...ced Tighten the bead lock bolts to the specified torque in a crisscross pattern EBU32620 Tire replacement Always use the same size and type of tires recommended in this owner s manual The tires that came with your Yamaha Wolverine 1 Wheel nut 1 1 1 Bead lock 2 Bolt Tightening torque Bead lock bolts 17 Nm 1 7 m kgf 12 ft lbf 1 2 2 2 2 UBN57AE0 book Page 48 Tuesday November 24 2015 1 42 PM ...

Page 164: ...loss of control The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model EBU33090 Wheel installation 1 Install the wheel and the nuts 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts in a crisscross pattern to the specified torque WARNING EWB03400 Do not reverse the rims on your Yamaha Wolverine to widen the track ...

Page 165: ...ed by the sulfuric acid in battery electrolyte In case of accidental contact with battery electrolyte EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt medical attention WARNING EWB03420 Batteries may produce explosive gases Ventilate wh...

Page 166: ...f and the negative lead must be dis connected before the positive lead ECB01002 6 Pull the battery out of its compartment To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have dis charged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories 1 Quick fastener screw 2 Air intake du...

Page 167: ...onth and fully charge it if necessary NOTICE ECB00941 Always keep the battery charged Storing a discharged battery can cause perma nent battery damage To install the battery TIP Be sure the battery is fully charged 1 Place the battery in its compartment 2 Connect the positive battery lead first then the negative battery lead by install ing their bolt NOTICE When installing the battery the main swi...

Page 168: ...ry Do not touch the positive lead of the jumper cable to the negative lead Do not reverse the polarity of the jumper cables when connecting to the batteries However if the vehicle must be jump started proceed as follows 1 Turn the key to off 2 Remove the hood See page 8 10 for hood removal and installation proce dures 3 Using a charged 12 volt battery connect the positive lead of the jumper cable ...

Page 169: ...tarts disconnect the negative lead of the jumper cable from the frame and charged battery and then disconnect the positive lead of the jump er cable from the charged battery and the battery in the vehicle 7 Install the hood EBU33100 Fuse replacement The main fuse the fuel injection system fuse the EPS fuse and the fuse box are located under the hood See page 8 10 for hood re moval and installation...

Page 170: ...injection system fuse 5 Fuel injection system spare fuse 1 3 2 4 5 1 Backup fuse BACK UP for clock 2 Ignition fuse IGNITION 3 Four wheel drive motor fuse DIFF 4 Auxiliary DC jack fuse TERMINAL 5 Signaling system fuse SIGNAL 6 Headlight fuse HEAD 7 Spare fuse 8 Radiator fan motor fuse FAN 1 2 3 4 5 6 8 7 7 UBN57AE0 book Page 55 Tuesday November 24 2015 1 42 PM ...

Page 171: ...se of the specified amperage Never use any material in place of the proper fuse Using an improper fuse can cause damage to the electrical system and may lead to a fire EWB03440 Specified fuses Main fuse 40 0 A Fuel injection system fuse 10 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Signaling system fuse 10 0 A Four wheel drive motor fuse 10 0 A Radiator fan motor ...

Page 172: ...ystem 5 Install the hood EBU32670 Replacing a headlight bulb If a headlight bulb burns out replace it as fol lows 1 Remove the cover at the rear of the head light by pulling it off 2 Remove the headlight bulb cover by pull ing it off 3 Disconnect the headlight coupler 1 Cover at the rear of the headlight 1 1 Headlight bulb cover 1 UBN57AE0 book Page 57 Tuesday November 24 2015 1 42 PM ...

Page 173: ... holder NOTICE Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with alcohol or thin ner ECB00652 1 Headlight coupler 1 Headlight bulb holder 1 1 UBN57AE0 book Page 58 ...

Page 174: ... the headlight beam if necessary EBU32681 Headlight beam adjustment NOTICE ECB00691 It is advisable to have a Yamaha dealer make this adjustment To raise the beam turn the headlight beam adjusting screw in direction a To lower the beam turn the headlight beam adjusting screw in direction b 1 Do not touch the glass part of the bulb 1 1 Headlight beam adjusting screw 1 a b UBN57AE0 book Page 59 Tues...

Page 175: ...before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your vehicle requires any repair take it to a Yamaha deal er The skilled technicians at a Yamaha dealer ship have the tools experience and know how to pro...

Page 176: ...oke and make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces Gasoline or gasoline vapors can ignite or explode causing severe injury or property damage UBN57AE0 book Page 61 Tuesday November 24 2015 1 42 PM ...

Page 177: ...maha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is good Dry Wet Operate the elec...

Page 178: ...e recommended coolant tap water can be used temporarily provided that it is changed to the recommended coolant as soon as possible 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 TIP Restart t...

Page 179: ...nough pressure to do the job WARNING Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry the brakes Wet brakes may have reduced stopping ability in creasing the chance of an accident EWB03471 NOTICE Excessive water pres sure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electri cal devices Many expensive repair...

Page 180: ...for several minutes EBU36120 Storage Long term storage 60 days or more of your vehicle will require some preventive proce dures to guard against deterioration Make any necessary repairs before storing the vehi cle After thoroughly cleaning the vehicle prepare for storage as follows 1 Fill the fuel tank with fresh fuel and add the specified amount of Fuel Med Rx or another high quality fuel stabili...

Page 181: ...6 If storing in a humid or salt air atmo sphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 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 ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F Use of fuel stabilizer eliminates the need to ...

Page 182: ...nt 3 0 dB A EUR FRA GBR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s EUR FRA GBR Uncertainty of measurement 0 0 m s EUR FRA GBR Vibration on handle EN1032 ISO5008 Will not exceed 2 5 m s EUR FRA GBR Uncertainty of measurement 0 5 m s EUR FRA GBR Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder Displacement 708 cm Bore stroke 103 0 85 0 mm 4 06 3 35 in...

Page 183: ...nt quantity Coolant reservoir up to the maximum level mark 0 28 L 0 30 US qt 0 25 Imp qt Radiator including all routes 2 85 L 3 01 US qt 2 51 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 37 L 9 77 US gal 8 14 Imp gal Fuel injection Throttle body ID mark 2MB1 00 Spark plug s Manufacturer model NGK CPR7EA 9 Spark plug gap 0 ...

Page 184: ...Type Tubeless Size 26 x 10 12NHS Manufacturer model MAXXIS MU10 Loading Maximum loading limit 327 0 kg 721 lb Total weight of operator passengers cargo accessories and tongue Tire air pressure measured on cold tires Recommended Vehicle load 0 maximum Front 75 0 kPa 0 750 kgf cm 11 psi Rear 75 0 kPa 0 750 kgf cm 11 psi Minimum Vehicle load 0 maximum Front 70 0 kPa 0 700 kgf cm 10 psi Rear 70 0 kPa ...

Page 185: ...tem Ignition system TCI Charging system AC magneto Battery Model U1 H11L Voltage capacity 12 V 28 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 35 0 35 0 W 2 Tail brake light 12 V 5 0 21 0 W 2 Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Parking brake indicator light LED On Comman...

Page 186: ...t there is a correlation between the emission and exposure levels this cannot be used reli ably to determine whether or not further pre cautions are required Factors that influence the actual level of exposure of work force in clude the characteristics of the work room the other sources of noise etc i e the num ber of machines and other adjacent process es and the length of time for which an opera...

Page 187: ...ATION NUMBER MODEL LABEL INFORMATION EBU32800 Vehicle identification number The vehicle identification number is stamped into the frame The vehicle identification number is used to identify your vehicle EBU33331 Model label The model label can be found under the driver seat Record the information on this label in the space provided This information will be needed to order spare parts from your Yam...

Page 188: ...11 2 11 1 Model label 1 UBN57AE0 book Page 2 Tuesday November 24 2015 1 42 PM ...

Page 189: ...ation check 5 6 Coolant temperature warning light 4 4 Cup holders 4 21 D Differential gear oil Periodic maintenance 8 22 Differential gear oil Pre operation check 5 6 Doors 4 15 Driver seat position 4 16 Drive select lever 4 14 Drive select lever operation and reverse driving 6 3 E Engine break in 6 1 Engine oil and oil filter cartridge Periodic maintenance 8 14 Engine oil Pre operation check 5 5 ...

Page 190: ...4 3 Parking brake lever 4 13 Passenger handhold Pre operation check 5 7 R Rear knuckle upper and lower pivot lubrication 8 46 Reverse indicator light 4 3 S Safety information 2 1 Seat belt indicator light 4 5 Seat belts 4 17 Seat belts Pre operation check 5 7 Seats 4 15 Shock absorber assemblies adjusting the front 4 23 Shock absorber assemblies adjusting the rear 4 28 Spark arrester cleaning 8 40...

Page 191: ...12 3 12 V belt case drain plug 8 39 Vehicle identification number 11 1 W Wheel installation 8 49 Wheel removal 8 47 UBN57AE0 book Page 3 Tuesday November 24 2015 1 42 PM ...

Page 192: ...Original instructions PRINTED IN USA 2015 12 0 3 1 CR E UBN57AE0 book Page 1 Tuesday November 24 2015 1 42 PM ...

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Yamaha WOLVERINE 2015, Owner'S Manual

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