Yamaha YFM400AS Owner'S Manual Download Page 137 | Manualshive

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8-30

1. Air filter element frame

2. Air filter element

4. Wash the element gently but thoroughly

in solvent.

5. Squeeze the excess solvent out of the air

filter element and let it dry.

CAUTION:

_

Do not twist the air filter element when
squeezing it.

_

6. Inspect the air filter element and replace

it if damaged.

WARNING

POTENTIAL HAZARD
Using low flash point solvents or gaso-
line to clean the air filter element.
WHAT CAN HAPPEN
Low flash point solvents or gasoline can
catch fire or explode.
HOW TO AVOID THE HAZARD
Use parts cleaning solvent to clean the
air filter element.

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Summary of Contents for YFM400AS

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

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

Page 5: ... all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU01067 YFM400AS OWNER S MANUAL 2003 by Yamaha Motor Corporation U S A 1st edition March 2003 All rights reserved Any reprinting or unauthorized use without the written permission of U5VH11 book Page 2 F...

Page 6: ...ication number 3 2 Vehicle identification number 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator and warning lights 4 2 Speedometer 4 3 Fuel gauge 4 4 Handlebar switches 4 4 Throttle lever 4 6 Speed limiter 4 7 Front brake lever 4 8 Rear brake pedal and lever 4 8 Parking brake 4 9 Drive select lever 4 10 Recoil starter 4 10 Fuel tank cap 4 11 Fuel cock 4 12 Starter choke 4 13 Seat 4 14 S...

Page 7: ...Tire wear limit 5 12 Drive select lever operation and reverse driving 6 4 Engine break in 6 7 Parking 6 8 Parking on a slope 6 9 Accessories and loading 6 10 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 22 Climbing uphill 7 24 Riding downhill 7 30 Crossing a slope 7 32 Crossing through shallow water 7 34 Ri...

Page 8: ...justment 8 35 Valve clearance adjustment 8 35 Throttle lever adjustment 8 36 Front brake pad check 8 37 Rear brake pedal and lever adjustment 8 41 Adjusting the rear brake light switch 8 44 Cable inspection and lubrication 8 45 Lubricating the brake levers and brake pedal 8 45 Wheel removal 8 46 Wheel installation 8 47 Battery 8 48 Battery maintenance 8 49 Fuse replacement 8 49 Replacing a headlig...

Page 9: ... 1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 9 10 11 12 13 14 U5VH11 book Page 4 Friday March 28 2003 2 47 PM ...

Page 10: ...EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5VH11 book Page 1 Friday March 28 2003 2 47 PM ...

Page 11: ...difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an accident Never exceed the maximum front cargo limit of 40kg 88 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4877 00 WARNING U5VH11 book Page 2 Friday Ma...

Page 12: ...ident Never exceed the maximum rear cargo limit of 80kg 176 lbs NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4897 00 WARNING 5 6 PULLING LOAD 4900 N 5 0 0 k g f 1102 l b f TONGUE WEIGHT 147 N 1 5 k g f 33 l b f 5ND F151K 00 MAXIMUM LOADING LIMIT MAXIMUM LOADING LIMIT U5VH11 book Page 3 Friday March 28 2003 2 47 PM ...

Page 13: ...7 8 U5VH11 book Page 4 Friday March 28 2003 2 47 PM ...

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

Page 15: ...rating condition Al ways follow the inspection and maintenance procedures and schedules described in this man ual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never operate on excessively rough slipp...

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

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

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

Page 19: ...n a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation U5VH11 book Page 6 Friday March 28 2003 2 47 PM ...

Page 20: ...elt case 8 Radiator cap 9 Fuel cock 10 Air filter case 11 Fuses 12 Tail brake light 13 Front shock absorber assembly spring preload adjusting ring 14 V belt cooling duct check hose 15 Coolant reservoir 16 Oil filter cartridge 17 Engine oil dipstick 18 Rear brake lever 19 Left handlebar switches 20 Starter choke 21 Drive select lever 22 Speedometer 23 Main switch 24 Fuel tank cap 25 Auxiliary DC ja...

Page 21: ...g spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number U5VH11 book Page 2 Friday March...

Page 22: ...E The vehicle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label U5VH11 book Page 3 Friday March 28 2003 2 47 PM ...

Page 23: ...ain switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights taillight and meter lighting come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position 1 Main switch U5VH11 book Page 1 Friday March 28 2003 2 47 PM ...

Page 24: ...eration stop the en gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes To check the coolant temperature warning light shift the drive select lever into neutral turn the key to ON and then press the start switch If the light does not come on have a Yamaha dealer inspect the electrical circuit CAUTION _ The engine may overheat if the ATV is overloaded If this ...

Page 25: ... N position EBU00447 Speedometer The speedometer shows riding speed This speedometer is equipped with a trip odome ter The trip odometer can be reset to 0 with the reset knob Use the trip odometer to esti mate how far you can ride on a tank of fuel be fore going to reserve This information will enable you to plan fuel stops in the future 1 Speedometer 2 Trip odometer U5VH11 book Page 3 Friday Marc...

Page 26: ...nity 1 Fuel gauge 2 Red line NOTE If the machine runs out of fuel move the fuel cock lever to the RES position Approxi EBU00053 Handlebar switches 1 Light switch OFF 2 Engine stop switch 3 Start switch EBU01251 Light switch OFF Set the switch to to turn on the low beams the taillight and the meter lighting U5VH11 book Page 4 Friday March 28 2003 2 47 PM ...

Page 27: ...re that the engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is set to EBU00607 Start switch The starter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engi...

Page 28: ...ing the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle ...

Page 29: ...crew a 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to 3 5 m...

Page 30: ...The front brake lever is located on the right handlebar Pull it toward the handlebar to ap ply the front brake 1 Front brake lever EBU00073 Rear brake pedal and lever 1 Brake pedal U5VH11 book Page 8 Friday March 28 2003 2 47 PM ...

Page 31: ...e of the parking brake WHAT CAN HAPPEN The ATV could start moving unexpect edly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking perfor mance which could cause an accident You could also wear out the brakes pre maturely HOW TO AVOID T...

Page 32: ... po sitions Refer to page 6 4 for the drive select lever operation 1 Drive select lever EBU01107 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt Then pull forcefully being careful not to pull the rope all the way out 1 Recoil starter U5VH11 book Page 10 Friday March 28 2003 2 47 PM ...

Page 33: ...ng the engine without shifting into the neutral position WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Shift the drive select lever into the neu tral position and apply the parking brake before starting the engine U5VH11 book Page 11 Friday March 28 2003 2 47 PM ...

Page 34: ... running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON position 1 Arrow mark pointing to OFF OFF Position ON Position U5VH11 book ...

Page 35: ... air fuel mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 RES Position U5VH11 book Page 13 Friday March 28 2003 2 47 PM ...

Page 36: ...he rear 1 Seat 2 Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE _ Make sure that the seat is securely fitted _ 1 Projection 2 2 Seat holder 2 U5VH11 book Page 14 Friday March 28 2003 2 47 PM ...

Page 37: ...ly edged prod ucts directly in the storage box If they must be stored wrap them in appropriate cushion material EBU00582 Front carrier EBU00583 Rear carrier Maximum load limit 2 kg 4 4 lb Maximum load limit 40 kg 88 lb Maximum load limit 80 kg 176 lb U5VH11 book Page 15 Friday March 28 2003 2 47 PM ...

Page 38: ...crease the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ 1 Special wrench Standard position 2 1 Minimum soft 5 Maximum hard U5VH11 book Page 16 Friday March 28 2003 2 47 PM ...

Page 39: ...a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set ting U5VH11 book Page ...

Page 40: ...DC jack is located at the front right side of the ATV The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Set the light switch to OFF 1 Auxiliary DC jack cap Standard position 2 1 Minimum soft 5 Maximum hard U5VH11 book Page 18 Friday March 28 2003 2 47 PM ...

Page 41: ...circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may be come difficult Do not use an automotive cigarette 1 Auxiliary DC jack EBU00112 Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A U5VH11 book Page 19 Friday March 28 2003 2 47 PM ...

Page 42: ...Fuel Check fuel level Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 6 8 13 8 18 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 7 8 21 8 25 Final gear oil Check for leakage 5 6 8 18 8 20 Throttle Check for proper throttle cable operation 5 8 8 36 Wheels and tires Check tire pressure wear and damage 5 9 5 12 8 46 8 47...

Page 43: ...ake is applied If not have a Yamaha dealer in spect them Brake fluid level front brake Check the brake fluid level Add fluid if neces sary See pages 8 38 8 39 WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper ating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time...

Page 44: ...ake sure they are working properly If the brakes do not provide proper braking per formance inspect the brake pads and shoes for wear See page 8 37 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find a...

Page 45: ...esigned to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 15 L 3 30 Imp gal 3 96 US gal Reser...

Page 46: ... HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure t...

Page 47: ...ot use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ EBU00493 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 18 8 20 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also...

Page 48: ... years See pages 8 21 8 25 for details CAUTION _ Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water _ Coolant reservoir capacity WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for th...

Page 49: ...ners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque EBU01003 Lights Check the headlights and tail brake light to make sure they are in working condition Re EBU01170 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for proper operation U5V...

Page 50: ...o Ltd for this model Other tire combina tions are not recommended ACE 01E 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 25 kPa 0 25 kgf cm2 3 6 psi Rear 25 kPa 0 25 kgf cm2 3 6 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dislodge fr...

Page 51: ...e tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst U5VH11 book Page 10 Friday March 28 2003 2 47 PM ...

Page 52: ...d reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifica tions ACE 02EACE 02E 1 Low pressure tire gauge Recommended pressure Minimum Maximum Front 25 kPa 0 25 kgf cm2 3 6 psi 22 kPa 0 22 kgf cm2 3 2 psi 28 kPa 0 28 kgf cm2 4 0 psi 25 kPa 22 kPa 28 kPa U5VH11 book Page 11 Friday March 28 2003 2 47 PM...

Page 53: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit U5VH11 book Page 12 Friday March 28 2003 2 47 PM ...

Page 54: ...th all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW TO AV...

Page 55: ...e to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warming up position Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 6 Completely close the throttle lever and start the engine by pushing the start...

Page 56: ...e If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it CAUTION _ See the Engine break in section prior to operating the engine for the first time _ EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used The...

Page 57: ..._ Shifting forward 1 Bring the machine to a complete stop and return the throttle lever to the closed position 2 Shift the gear from neutral to forward and vice versa by moving the drive select le ver along the shift guide NOTE _ Make sure that the drive select lever is com pletely shifted into position 1 Drive select lever 3 Open the throttle lever gradually U5VH11 book Page 4 Friday March 28 200...

Page 58: ...reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the ATV _ 1 Drive select lever 4 Check behind for people or obstacles then release the parking brake 5 Open the throttle lever gradually and con tinue to watch to the rear while backing NOTE _ If the drive select lever is shifted into reverse while the engine is running the engine will stop unless the...

Page 59: ...EN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slow ly U5VH11 book Page 6 Friday March 28 2003 2 47 PM ...

Page 60: ...ch might result in ex cessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this p...

Page 61: ...o not use full throttle at any time After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00211 Parking When parking stop the engine and shift into neutral Turn the fuel cock to OFF and apply the parking brake U5VH11 book Page 8 Friday March 28 2003 2 47 PM ...

Page 62: ...ncline 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 If you must park on an incline place the machine transversely across the in cline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not wa...

Page 63: ...a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object atta...

Page 64: ...tch If you are carrying cargo and towing a trail er include the tongue weight in the maxi mum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent MAXIM...

Page 65: ...ffects the sta bility and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a...

Page 66: ...EBU13561 WARNING _ Indicates a potential hazard that could result in serious injury or death U5VH11 book Page 13 Friday March 28 2003 2 47 PM ...

Page 67: ...7 Riding Your ATV U5VH11 book Page 1 Friday March 28 2003 2 47 PM ...

Page 68: ...U5VH11 book Page 2 Friday March 28 2003 2 47 PM ...

Page 69: ...ypes of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure Owner s Manual completely and understand the operation of the controls Pay particular at tention to the safety inf...

Page 70: ... time Take the time to learn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills le...

Page 71: ...ommenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc U5VH11 book Page 5 Friday March 28 2003 2 47 PM ...

Page 72: ...EN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers U5VH11 book Page 6 Friday March 28 2003 2 47 PM ...

Page 73: ...accident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long slee...

Page 74: ...ARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV U5VH11 book Page 8 Friday March 28 2003 2 47 PM ...

Page 75: ...p erating condition Always follow the in spection and maintenance procedures WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use the ...

Page 76: ...o the maxi mum Turning the adjusting screw in limits the maximum engine power available and de creases the maximum speed of the ATV Turning the adjusting screw in decreases the top speed and turning it out increases the top speed WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV whic...

Page 77: ...ler hitch Pulling load 500 kgf 1 102 lbf Total weight of trailer and cargo Tongue weight 15 kgf 33 lbf WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and secure...

Page 78: ...even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation U...

Page 79: ...G POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off U5VH11 book Page 13 Friday March 28 2003 2 47 PM ...

Page 80: ...cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed U5VH11 book Page 14 Friday March 28 2003 2 47 PM ...

Page 81: ... WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it U5VH11 book Page 15 Friday ...

Page 82: ... this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets U5VH11 book Page 16 Friday March 28 2003 2 47 PM ...

Page 83: ...erating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways U5VH11 book Page 17 Friday March 28 2003 2 47 PM ...

Page 84: ...TENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturn ing or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar terrain Always be U5VH11 book Page 18 Friday March 28 2003 2 47 PM ...

Page 85: ...or vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain U5VH11 book Page 19 Friday March 28 2003 2 47 PM ...

Page 86: ...ler hitch Do not ride in areas posted no trespassing Do not ride on private property without getting permission WARNING WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles U5VH11 book Page 20 Friday March 28 2003 2 47 PM ...

Page 87: ... wards do not allow skin or clothing to come in contact with these components With the engine idling return the starter choke to the closed position and shift the drive select lever into the forward position Then release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to acceler ate If the throttle is applied too abruptly the front whe...

Page 88: ...n As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of contro...

Page 89: ...mproper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember A...

Page 90: ...rtant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small ...

Page 91: ... as described in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards An obstacle a sharp drop or another vehicle or person could be on the other side of the hill U5VH11 book Page 25 Friday March 28 2003 2 47 PM...

Page 92: ...TENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible U5V...

Page 93: ...a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV U5VH11 book Page 27 Friday March 28 2003 2 47 PM ...

Page 94: ...ds DO NOT apply the rear brake to stop The ATV could easily tip over backwards Instead apply the front brake gradually or dismount the ATV immedi ately on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If you lose a...

Page 95: ...pply the front brake When fully stopped apply the rear brake as well and then lock the park ing brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu al U5VH11 book Page 29 Friday March 28 2003 2 47 PM ...

Page 96: ...which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn Always follow proper procedures for go ing down hills as described in this Own er s Manual Note a special technique is ...

Page 97: ...U5VH11 book Page 31 Friday March 28 2003 2 47 PM ...

Page 98: ...ly up hill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill un...

Page 99: ...U5VH11 book Page 33 Friday March 28 2003 2 47 PM ...

Page 100: ...ery or up set the ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to l...

Page 101: ...o drain the trapped water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose and the drive select lever box check hose Also remove the V belt case drain plug to drain any water that may have accumulat ed Wash the ATV in fresh water if it has been operated in salt water or muddy con ditions _ U5VH11 book Page 35 Friday March 28 2003 2 47 PM ...

Page 102: ...1 V belt cooling duct check hose left front side of ATV 1 V belt case drain plug U5VH11 book Page 36 Friday March 28 2003 2 47 PM ...

Page 103: ...rol and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper proced...

Page 104: ...wheels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide U5VH11 book Page 38 Friday March 28 20...

Page 105: ...ontrol may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious...

Page 106: ... If necessary gradually let off the throttle and or steer to the outside of the turn See If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerat ing is not recommended until you have cor rected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for war...

Page 107: ...cover that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV un til you have regained adequate braking ability Se...

Page 108: ...anual and tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it on the bottom of the seat as shown Put the own er s tool kit and low pressure tire gauge in the storage box WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks o...

Page 109: ...your machine to a Yamaha dealer to check the torque settings and adjust them as neces sary _ WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er ins...

Page 110: ...ten in wet or dusty areas Carburetor Check and adjust idle speed starter operation Adjust if necessary Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine befor...

Page 111: ... necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Drive shaft universal joint Lubricate Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check operation Adjust headlight beams ITEM ROUTINE INITIAL EVERY 1 month 3 months 6 months 6 months 1 year NOTE Recommended brake fluid DOT 4 Brake fluid replace...

Page 112: ...d need to be removed to perform some of the maintenance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 1 Panel A 2 Panel B 1 Panel C 2 Panel D 3 Panel E 4 Panel F U5VH11 book Page 5 Friday March 28 2003 2 47 PM ...

Page 113: ...EBU00700 Panel A D To remove 1 Remove the seat 2 Pull outward on the areas shown and then pull upward U5VH11 book Page 6 Friday March 28 2003 2 47 PM ...

Page 114: ...To install 1 Place the panel in its original position 2 Install the seat U5VH11 book Page 7 Friday March 28 2003 2 47 PM ...

Page 115: ...he bolt and then take the panel off To install Place the panel in the original position and in stall the bolt CAUTION _ When installing the panel be sure not to pinch the cables or wires _ U5VH11 book Page 8 Friday March 28 2003 2 47 PM ...

Page 116: ...Panel C To remove 1 Remove the front carrier by removing the carrier bolts 1 Carrier bolt 4 2 Remove the bolts at the bottom of the fenders 1 Bolt 2 under fenders U5VH11 book Page 9 Friday March 28 2003 2 47 PM ...

Page 117: ... original position and install the quick fasteners 2 Install the bolts at the bottom of the fend ers 3 Install the front carrier by installing the carrier bolts and then tighten them to the specified torque Tightening torque Carrier bolt 34 Nm 3 4 m kgf 25 ft lbf U5VH11 book Page 10 Friday March 28 2003 2 47 PM ...

Page 118: ... and then take the panel off To install Place the panel in the original position and then install the bolts 1 Panel E 2 Bolt 3 EBU00638 Panel F To remove Pull outward on the areas shown 1 Panel F U5VH11 book Page 11 Friday March 28 2003 2 47 PM ...

Page 119: ...To install Place the panel in its original position U5VH11 book Page 12 Friday March 28 2003 2 47 PM ...

Page 120: ...nd lubrication chart To check the engine oil level 1 Remove panel F See pages 8 11 8 12 for panel removal and installation proce dures 2 Place the ATV on a level surface 3 Start the engine warm it up for several minutes and then turn it off 4 Wait a few minutes until the oil settles 5 Remove the engine oil filler cap and wipe off the dipstick with a clean rag 1 Engine oil filler cap U5VH11 book Pa...

Page 121: ...ini mum and maximum level marks _ 1 Maximum level mark 2 Minimum level mark 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 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 9 Install the panel U5VH11 book Page 14 Friday March 28 2003 2 47 PM ...

Page 122: ...Place an oil pan under the engine to col lect the used oil and then remove the en gine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase NOTE _ Skip steps 5 9 if the oil filter cartridge is not being replaced _ 5 Remove panel E See page 8 11 for panel removal and installation proce dures 6 Remove the oil filter cartridge with an oil filter wrench U5VH11 book Pag...

Page 123: ...ter wrench is available at a nearby Yamaha dealer _ 7 Apply a light coat of engine oil to the O ring of the new oil filter cartridge NOTE _ Make sure the O ring is seated properly _ 1 O ring U5VH11 book Page 16 Friday March 28 2003 2 47 PM ...

Page 124: ...cified amount of recommend ed engine oil and then install the engine oil filler cap and tighten it Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 16 ft lbf Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 2 3 L 2 0 Imp qt 2 4 US qt With oil filter cartridge replacement 2 4 L 2 1 Imp ...

Page 125: ... en ters the crankcase _ 12 Start the engine and warm it up for seve ral minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 13 Turn the engine off and then check the EBU01145 Final gear oil Final gear oil measurement 1 Place the machine on a level surface 2 Remove the oil filler bolt and then check the oil level in the fin...

Page 126: ... the final gear case _ 4 Install the oil filler bolt Final gear oil replacement 1 Remove the final gear case cover by re moving the bolts 1 Final gear case cover 2 Bolt 2 2 Place the machine on a level surface 3 Place a container under the final gear case to collect the used oil 4 Remove the oil filler bolt and the drain U5VH11 book Page 19 Friday March 28 2003 2 47 PM ...

Page 127: ...ler bolt 8 Check for oil leakage If oil leakage is found check for the cause 9 Install the final gear case cover bolts and then tighten them to the specified torque Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 16 ft lbf Recommended oil See page 10 3 Oil quantity 0 19 L 0 17 Imp qt 0 20 US qt Tightening torque Final gear case cover bolt 16 Nm 1 6 m kgf 12 ft lbf U5VH11 book Page 20 F...

Page 128: ...en the minimum and maximum level marks _ 3 If the coolant is at or below the minimum level mark remove panel D See pages 8 6 8 7 for panel removal and installa tion procedures remove the reservoir cap add coolant to the maximum level mark install the reservoir cap and then install the panel Coolant reservoir capacity up to the maximum level mark 0 25 L 0 22 Imp qt 0 26 US qt U5VH11 book Page 21 Fr...

Page 129: ...temperature in the radi ator _ If your ATV overheats see page 8 57 for de tails EBU12571 Changing the coolant WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag ov...

Page 130: ...res 3 Place a container under the engine and then remove the coolant drain bolt Use a trough or a similar object as shown to prevent coolant from spilling on the foot rest 1 Trough 4 Remove the front carrier and panel C See pages 8 9 8 10 for removal and in stallation procedures U5VH11 book Page 23 Friday March 28 2003 2 47 PM ...

Page 131: ...coolant res ervoir side and then drain the coolant from the coolant reservoir 1 Coolant reservoir hose 9 After draining the coolant thoroughly flush the cooling system with clean tap water 10 Replace the coolant drain bolt washer if it is damaged install the coolant drain bolt and then tighten it to the specified torque Tightening torque U5VH11 book Page 24 Friday March 28 2003 2 47 PM ...

Page 132: ...it idle for several minutes Stop the engine and then check the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator 15 Check for coolant leakage NOTE _ If any leakage is found have a Yamaha deal er check the cooling system _ 16 Install the panels and the front carrier Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion...

Page 133: ...g wrench in the tool kit 1 Spark plug wrench Inspection The spark plug is an important engine compo nent and is easy to inspect The condition of the spark plug can indicate the condition of the engine The ideal color on the white insulator around the center electrode is a medium to light tan color for a ATV that is being ridden normally U5VH11 book Page 26 Friday March 28 2003 2 47 PM ...

Page 134: ...ace the spark plug with the specified plug Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification a Spark plug gap 2 Clean the gasket surface Wipe off any grime from the threads 3 Install the spark plug and tighten it to the specified torque Specified spark plug DR8EA NGK Spark plug gap 0 6 0 7 mm 0 02 0 03 in Tightening torque Spark p...

Page 135: ...ing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible _ 4 Install the spark plug cap 5 Install the panel U5VH11 book Page 28 Friday March 28 2003 2 47 PM ...

Page 136: ...r water collects in this hose empty the hose and clean the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seat See page 4 14 for 1 Holder 4 2 Air filter case cover 3 Remove the air filter element and then remove it from its frame U5VH11 book Page 29 Friday March 28 2003 2 47 PM ...

Page 137: ...AUTION _ Do not twist the air filter element when squeezing it _ WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element U5VH11 book Page 30 Friday March 28 2003 2 47 PM ...

Page 138: ... lubri cated more often if the machine is operated in extremely dusty areas Each time the air filter element maintenance is performed check the air inlet to the filter case for obstructions Check the air filter case rubber joint to the car buretor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine _ CAUTION _ Neve...

Page 139: ...left front side of ATV V belt case drain plug After riding in water deep enough to allow it to enter the V belt case remove this plug to drain the water from the case NOTE _ If water drains from the V belt case after re moving the plug have a Yamaha dealer in spect the ATV as the water may affect other engine parts _ U5VH11 book Page 32 Friday March 28 2003 2 47 PM ...

Page 140: ...arrester 1 Remove the bolts 2 Remove the tailpipe by pulling it out of the muffler 1 Bolt 3 2 Tailpipe 3 Tap the tailpipe lightly and then use a 1 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install and tighten the bolts U5VH11 book Page 33 Friday March 28 2003 2 47 PM ...

Page 141: ...tests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the s...

Page 142: ...val and installation procedures 3 Connect the tachometer to the spark plug lead and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction a to increase the engine speed and in direc 1 Throttle stop screw 4 Install the panel EBU00303 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air suppl...

Page 143: ...ling speed before adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle le ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut a Throttle lever free play U5VH11 book Page 36 Friday March 28 2003 2 47 PM ...

Page 144: ...removed to check the EBU00313 Rear brake shoe inspection A wear indicator is provided on the rear brake This indicator allows checking of brake shoe wear without disassembling the brake Apply the rear brake and check the position of the in dicator If the indicator reaches the wear limit line ask a Yamaha dealer to replace shoes as a set 1 Wear limit line 2 Wear indicator U5VH11 book Page 37 Friday...

Page 145: ...serve these precautions When checking the brake fluid level make sure the top of the brake fluid reservoir is level Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid Mix ing fluids may result in a harmful chemical reaction and lead to poor brake perfor mance Be careful that wa...

Page 146: ...oes down EBU01186 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years U5VH11 book Page 39 Friday March 28 2003 2 47 PM ...

Page 147: ...ing with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re U5VH11 book Pa...

Page 148: ...the adjusting nut on the brake lever cable at the rear wheel 1 Adjusting nut brake pedal cable 2 Adjusting nut brake lever cable 2 Turn the adjusting nut on the brake pedal cable until the free play is 20 30 mm 0 79 1 18 in a Brake pedal free play U5VH11 book Page 41 Friday March 28 2003 2 47 PM ...

Page 149: ...e adjusting bolt at the brake lever 1 Locknut 2 Adjusting bolt 2 Turn in the adjusting nut on brake cable to provide a gap of 0 1 mm 0 0 04 in between the brake camshaft lever and the pin 1 Adjusting nut brake lever cable a Gap U5VH11 book Page 42 Friday March 28 2003 2 47 PM ...

Page 150: ...improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components re quires professional knowledge These procedures should be performed by a Yamaha dealer U5VH11 book Page...

Page 151: ...ake light switch as follows 1 Remove panel B See page 8 8 for pan el removal and installation procedures 2 Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjust ing nut in direction b 3 Install the panel 1 Rear brake light switch 2 Adjusting nut U5...

Page 152: ...e 8 8 for panel removal and installation procedures _ WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Recomme...

Page 153: ...2 Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 U5VH11 book Page 46 Friday March 28 2003 2 47 PM ...

Page 154: ...pered side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel _ 2 Lower the ATV so that the wheel is on the ground 1 Tapered nut 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf U5VH11 book Page 47 Friday March 28 2003 2 47 PM ...

Page 155: ... CAN HAPPEN You could be poisoned You could be HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes ...

Page 156: ...sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU00829 Fuse replacement 1 The main fuse case and the fuse box are located under the seat 2 If a fuse is blown turn off the main switch and install a new fuse of the specified amperage Then turn on the switches If the fus...

Page 157: ...in fuse 1 Headlight fuse 2 Ignition fuse 3 Auxiliary DC jack fuse 4 Signaling system fuse 5 Spare fuse 2 Specified fuses Main fuse 30 A Headlight fuse 15 A Ignition fuse 10 A U5VH11 book Page 50 Friday March 28 2003 2 47 PM ...

Page 158: ...e bulb holder cover at the rear of the headlight by pulling it off 1 Headlight bulb holder cover WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse U5VH11 book Page 51 Friday March 28 2...

Page 159: ...to the bulb holder push it in and then turn it clock wise until it stops WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it U5VH11 book Page 52 Friday March 28 2003 2 47 P...

Page 160: ...se the transparency of the glass the luminos ity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb 5 Install the bulb holder by turning it clock wise 6 Install the bulb holder cover at the rear of the headlight U5VH11 book Page 53 Friday March 28 2003 2 47 PM ...

Page 161: ...is adjustment _ To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b EBU01105 Tail brake light bulb replacement If the tail brake light bulb burns out have a Yamaha dealer replace it U5VH11 book Page 54 Friday March 28 2003 2 47 PM ...

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

Page 163: ...se the electric starter to see if there is compression There is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap Check the fuel flow Tu...

Page 164: ...ver the cap Allow any re maining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the coolant reservoir and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See NOTE Restart the engine If the engine overheats again ask...

Page 165: ...r to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash ...

Page 166: ...aint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings U5VH11...

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

Page 168: ...dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine U5VH11 book Page 4 Friday March 28 2003 2 47 PM ...

Page 169: ...eight 827 mm 32 6 in Wheelbase 1 233 mm 48 5 in Ground clearance 245 mm 9 65 in Minimum turning radius 3 000 mm 118 1 in Basic weight With oil and full fuel tank 250 kg 551 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 401 cm3 Bore stroke 84 5 71 5 mm 3 33 2 81 in U5VH11 book Page 1 Friday March 28 2003 2 47 PM ...

Page 170: ...0 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher U5VH11 book Page 2 Friday March 28 2003 2 47 PM ...

Page 171: ...capacity including all routes 1 3 L 1 2 Imp qt 1 4 US qt Air filter Wet element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 15 L 3 30 lmp gal 3 96 US gal Fuel reserve amount 4 5 L 0 99 lmp gal 1 19 US gal Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Model YFM400A U5VH11 book Page 3 Friday March 28 2003 2 47 PM ...

Page 172: ...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 Forward gear 38 23 1 652 Reverse gear 29 17 1 706 Chassis Frame type Steel tube frame Caster angle 4 Trail 21 mm 0 83 in Tire Type Tubeless Model YFM400A U5VH11 book Page 4 Friday March 28 2003 2 47 PM ...

Page 173: ...le wishbone Rear suspension Swingarm monocross Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 160 mm 6 30 in Rear wheel travel 180 mm 7 09 in Electrical Ignition system DC C D I Generator system A C magneto Battery type YTX14AH Model YFM400A U5VH11 book Page 5 Friday March 28 2003 2 47 PM ...

Page 174: ... 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 Meter lighting 14 V 3 W 1 Fuse Main fuse 30 A Headlight fuse 15 A Ignition fuse 10 A Auxiliary DC jack fuse 10 A Signaling system fuse 10 A Model YFM400A U5VH11 book Page 6 Friday March 28 2003 2 47 PM ...

Page 175: ...se of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muff...

Page 176: ...nce with the warranty The chart below is printed only as a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 04E MAINTENANCE INTERVAL DATE OF SERVICE SERVICING DEALER NAME AND ADDRESS REMARKS 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months U5VH11 book Page 1 Friday March 28 2003 2 47 PM ...

Page 177: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U5VH11 book Page 1 Friday March 28 2003 2 47 PM ...

Page 178: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U5VH11 book Page 2 Friday March 28 2003 2 47 PM ...

Page 179: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S U5VH11 book Page 1 Friday March 28 2003 2 47 PM ...

Page 180: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U5VH11 book Page 2 Friday March 28 2003 2 47 PM ...

Page 181: ...EBU00437 U5VH11 book Page 3 Friday March 28 2003 2 47 PM ...

Page 182: ...EBU00438 ...

Page 183: ...Card fm Page 1 Wednesday June 13 2001 9 35 AM ...

Page 184: ...Card fm Page 2 Wednesday June 13 2001 9 35 AM ...

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