Yamaha Big Bear 400 YFM40FBB Owner'S Manual Download

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This ATV should not be ridden by anyone under 16 years of age.

WARNING

OWNER’S MANUAL

4S1-F8199-15

LIT-11626-25-02

YFM40FBB

YFM40FBHB

READ THIS MANUAL CAREFULLY!

It contains important safety information.

DIC2342

Summary of Contents for Big Bear 400 YFM40FBB

Page 1: ...s ATV should not be ridden by anyone under 16 years of age WARNING OWNER S MANUAL 4S1 F8199 15 LIT 11626 25 02 YFM40FBB YFM40FBHB READ THIS MANUAL CAREFULLY It contains important safety information DIC2342 ...

Page 2: ...EBU17092 Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold U4S115E0 book Page 1 Tuesday February 15 2011 2 53 PM ...

Page 3: ... information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures 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 Make sure you underst...

Page 4: ...afety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol 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 inform...

Page 5: ...gulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17402 YFM40FBB YFM40FBHB OWNER S MANUAL 2011 by Yamaha Motor Corporation U S A 1st edition February 2011 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LI...

Page 6: ...uel gauge 4 4 Handlebar switches 4 5 Throttle lever 4 10 Speed limiter 4 11 Front brake lever 4 11 Brake pedal and rear brake lever 4 12 Parking brake 4 13 Shift pedal 4 13 Reverse knob REV 4 14 Recoil starter 4 14 Fuel tank cap 4 15 Fuel 4 15 Fuel cock 4 17 Starter choke 4 18 Seat 4 19 Storage compartment 4 20 Front carrier 4 20 Rear carrier 4 21 Auxiliary DC jack 4 21 PRE OPERATION CHECKS 5 1 Fu...

Page 7: ... 7 22 WHAT TO DO 7 22 PERIODIC MAINTENANCE AND ADJUSTMENT 8 1 Owner s manual and tool kit 8 2 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Checking the spark plug 8 9 Engine oil and oil filter element 8 11 Final gear oil 8 15 Differential gear oil 8 18 Cleaning the air filter element 8 20 Cleaning the spark arrester 8 24 Adjusting the...

Page 8: ...tabilizer bushes 8 40 Lubricating the rear knuckle pivots 8 40 Lubricating the steering shaft 8 41 Battery 8 41 Replacing a fuse 8 44 Replacing a headlight bulb 8 45 Adjusting a headlight beam 8 48 Replacing the tail brake light bulb 8 48 Removing a wheel 8 50 Installing a wheel 8 50 Troubleshooting 8 52 Troubleshooting chart 8 53 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10...

Page 9: ...1 1 1 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 3 4 5 6 7 8 9 10 U4S115E0 book Page 1 Tuesday February 15 2011 2 53 PM ...

Page 10: ...ation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer 5ND F4897 30 176 lbs 80 kg 5ND F4877 30 463 lbs 210 kg 5FU F816M 00 3 6 psi 25 kPa 3 6 psi 25 kPa 3 2 psi 22 kPa 3 2 psi 22 kPa 1 2 3 U4S115E0 book Page 2 Tuesday February 15 2011 2 53 PM ...

Page 11: ...16L 00 NEVER operate this ATV if you are under age 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death 16 UNDER 7 5 6 4 U4S115E0 book Page 3 Tuesday February 15 2011 2 53 PM ...

Page 12: ...ubject to an approved ATV action plan submitted by YAMAHA and on file with the U S Consumer Product safety Commission Certification of Compliance YAMAHA MOTOR CORPORATION U S A 6555 Katella Avenue Cypress California 90630 5101 U S A 10 8 9 U4S115E0 book Page 4 Tuesday February 15 2011 2 53 PM ...

Page 13: ...uld never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Never ...

Page 14: ...escribed in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrai...

Page 15: ...e the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in ...

Page 16: ...reas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do not ...

Page 17: ... MORE INFORMATION ABOUT ATV SAFE TY call the Consumer Products Safety Commis sion at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 U4S115E0 book Page 5 Tuesday February 15 2011 2 53 PM ...

Page 18: ...crew 4 Fuses 5 Battery 6 Storage compartment and tool kit 7 Clutch adjusting screw 8 Shift pedal 8 7 6 5 4 3 2 1 1 Spark arrester 2 Air filter case 3 Engine oil filler cap 4 Spark plug 5 Oil filter element 6 Brake pedal 7 Rear brake light switch 4 6 1 3 2 7 5 U4S115E0 book Page 1 Tuesday February 15 2011 2 53 PM ...

Page 19: ... brake lever 2 Parking brake lock plate 3 Starter choke 4 Speedometer 5 Reverse knob 6 Auxiliary DC jack 7 Front brake fluid reservoir 8 On Command four wheel drive differential gear lock switch 9 Front brake lever 10 Throttle lever 11 Fuel gauge 12 Main switch 13 Handlebar switches U4S115E0 book Page 2 Tuesday February 15 2011 2 53 PM ...

Page 20: ...in switch The positions of the main switch are as follows ON All electrical systems are supplied with power The headlights meter lighting and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U4S115E0 book Page 1 Tuesday February 15 2011 2 53 PM ...

Page 21: ...is warning light comes on when the engine over heats When this occurs stop the engine as soon as it is safe to do so and allow it to cool The electrical circuit of the warning light can be checked by turning the key to ON with the engine stop switch set to and then pushing the start switch If the warning light does not come on while the start switch is being pushed or if the warning light re mains...

Page 22: ...e 4WD position The On Command differential gear lock indicator light and the On Command four wheel drive indicator light come on when the On Com mand differential gear lock switch is set to the LOCK position TIP Due to the synchronizing mechanism in the differ ential gear case the light may not come on until the ATV starts moving EBU18022 Speedometer This speedometer is equipped with an odometer a...

Page 23: ... fill the tank at the first opportunity TIP If the ATV runs out of fuel move the fuel cock lever to the RES position Approximately 4 0 L 1 06 US gal 0 88 Imp gal of fuel will be remaining in the tank 1 Reset knob 2 Speedometer 3 Odometer 4 Tripmeter 1 Fuel gauge 2 Red line U4S115E0 book Page 4 Tuesday February 15 2011 2 53 PM ...

Page 24: ...62 Light switch OFF Set this switch to to turn on the low beams the taillight and the meter lighting Set the switch to to turn on the high beams the taillight and the meter lighting Set the switch to OFF to turn off all the lights NOTICE ECB00042 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to the point that the starter mo...

Page 25: ...ed the reverse in dicator light REVERSE will flash WARNING EWB00150 Always ride at a slow speed when the ATV is in four wheel drive differential gear lock and al low extra time and distance for maneuvers All wheels turn at the same speed when the dif ferential is locked so it takes more effort to turn the ATV The effort needed to turn increas es with the riding speed You may lose control and have ...

Page 26: ...using an accident This ATV is equipped with a switch to change from two wheel drive to four wheel drive and vice versa Select the appropriate drive according to the ter rain and the conditions 2WD two wheel drive Power is supplied to the rear wheels 4WD four wheel drive Power is supplied to the rear and front wheels To change from two wheel drive to four wheel drive stop the ATV and push the switc...

Page 27: ...ow extra time and distance for maneuvers All wheels turn at the same speed when the dif ferential gear is locked so it takes more effort to turn the ATV The effort needed to turn in creases with the riding speed You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling This ATV is equipped with a switch allowing you to lock the differential ge...

Page 28: ...ition a and then push the differential gear lock switch in to the LOCK position When the dif ferential gear is locked the differential gear lock in dicator light comes on 1 On Command four wheel drive switch 2WD 4WD 2 On Command differential gear lock switch 4WD LOCK 1 Differential gear lock lever 2 On Command four wheel drive switch 2WD 4WD U4S115E0 book Page 9 Tuesday February 15 2011 2 53 PM ...

Page 29: ...h 19 mi h However if conditions require full engine power to be available push and hold the override switch to disable the differ ential gear lock speed limiter See page 4 6 for a detailed explanation of this switch EBU18282 Throttle lever Once the engine is running pushing the throttle le ver will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the...

Page 30: ...nd the maximum speed of the ATV turn the adjusting screw in direction b Do not turn the adjusting screw out more than 12 mm 0 47 in or the throttle cable could be dam aged Always make sure the throttle lever free play is adjusted to 3 0 5 0 mm 0 12 0 20 in See page 8 27 WARNING Improper ad justment of the speed limiter and throttle could cause throttle cable damage or im proper throttle operation ...

Page 31: ...ht side of the ATV and the rear brake lever is located on the left handlebar To apply the rear brake push down on the brake pedal or pull the brake lever toward the handlebar grip 1 Front brake lever 1 Brake pedal 1 Rear brake lever U4S115E0 book Page 12 Tuesday February 15 2011 2 53 PM ...

Page 32: ...se loss of control or a collision Always be sure you have released the park ing brake before you begin to ride The brake could overheat if you ride the ATV without re leasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely EBU18560 Shift pedal This ATV is equipped with a constant mesh 5 speed forward and 1 speed reve...

Page 33: ...g in re verse section on page 6 4 before operating this ATV in reverse EBU27610 Recoil starter Firmly grasp the handle and pull slightly until en gagement can be felt Then pull forcefully being careful not to pull the rope all the way out 1 Shift pedal 1 Reverse knob REV U4S115E0 book Page 14 Tuesday February 15 2011 2 53 PM ...

Page 34: ... clockwise EBU18731 Fuel Make sure there is sufficient gasoline in the tank WARNING EWB02521 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling fol low these instructions 1 Before refueling turn off the engine and be sure that no one is sitting on the vehicle Nev er refuel while smoking or while in the vicinity 1 Recoi...

Page 35: ...teriorate painted surfaces or plastic parts ECB00981 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed WARNING EWB02531 Gasoline is poisonous and can cause injury 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 s...

Page 36: ...two types of gasohol gasohol contain ing ethanol and that containing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 E10 Gasohol contain ing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filterin...

Page 37: ... fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke 1 Arrow mark positioned over ON 1 Arrow mark po...

Page 38: ...8881 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear 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 Make sure that the seat is securely fitted 1 Starter choke 1 Seat lock lever U4S115E0 book Page 19 Tuesday February 15 2011 2 53 PM ...

Page 39: ...ng the stor age compartment Do not exceed the load limit of 2 0 kg 4 lb for the storage compartment Do not exceed the maximum load of 210 0 kg 463 lb for the ATV EBU18962 Front carrier Do not exceed the load limit of 40 0 kg 88 lb for the front carrier Do not exceed the maximum load of 210 0 kg 463 lb for the ATV 1 Seat holder 2 Projection 1 Storage compartment U4S115E0 book Page 20 Tuesday Februa...

Page 40: ...ight switch is set to OFF 1 Set the light switch to OFF 2 Turn the accessory off 3 Start the engine See page 6 1 4 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 5 Turn the accessory on 6 When the auxiliary DC jack is not being used cover it with the cap NOTICE ECB00120 Do not use accessories requiring more than the above maximum capacity This may overload t...

Page 41: ...nd engine start ing may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged WARNING EWB00011 Indicates a hazardous situation which if not avoided could result in death or serious injury U4S115E0 book Page 22 Tuesday February 15 2011 2 53 PM ...

Page 42: ...orrected 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 Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 15 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ...

Page 43: ... play and adjust if necessary 5 4 8 27 Control cables Make sure that operation is smooth Lubricate if necessary 8 37 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 8 39 Brake lever...

Page 44: ...k the brake system Check for correct free play in the rear brake lever and brake pedal If the free play is incorrect ad just it See page 8 31 Check operation of the levers and pedal They should move smoothly and there should be a firm feeling when the brake is applied If not have a Yamaha dealer check them Brake fluid level front brake Check the brake fluid level Add fluid if necessary See page 8 ...

Page 45: ...ual on both sides WARNING Operation of this vehicle with im proper tire pressure may cause severe injury or death from loss of control or rollover Tire pressure below the minimum specified could also cause the tire to dislodge from the rim un der severe riding conditions EWB02541 Set tire pressures to the following specifications The low pressure tire gauge is included as stan dard equipment Make ...

Page 46: ...ith valves WARNING EWB02551 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Manufacturing Corporation of America 1 Low pressure tire gauge 1 Tire wear limit U4S115E0 book Page 5 Tuesday February 15 2011 2 53 PM ...

Page 47: ... may not be appropriate EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary Front Manufacturer model ITP MUD LITE Size AT25 x 8 12 Type Tubeless Rear Manufacturer model ITP MUD LITE Size AT25 x 10 12 Type Tubeless U4S115E0 book Pa...

Page 48: ...he first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the key to ON and the engine stop switch to 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator light does not come on have a Yamaha deal er check the electrical circuit TIP The engine can be started under the following con ditions The transmission is in neutral The rear brake leve...

Page 49: ...coil starter to start the engine 7 If the engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly then return the starter choke to position 3 befor...

Page 50: ...ed or for starting accelerating climbing hills etc To shift into neutral release the throttle lever and repeatedly depress the shift pedal until it stops To shift into reverse first shift into neutral and then turn the reverse knob clockwise Depress the shift pedal and then release the reverse knob EBU20611 To start out and accelerate 1 Release the throttle lever NOTICE ECB00200 Always close the t...

Page 51: ... an accident WARNING EWB00710 Make sure the engine has sufficiently slowed before shifting to a lower gear Engaging a low er gear when the engine speed is too high could make the wheels stop rotating and lose traction This could cause loss of control an accident and injury It could also cause engine or drive train damage NOTICE ECB00190 Even with the transmission in the neutral posi tion do not co...

Page 52: ...heck the electrical circuit 4 Check behind you for people or obstacles and then release the rear brake lever or brake pedal 5 Open the throttle lever gradually and continue to watch to the rear while backing EBU20672 Engine break in TIP For ATVs equipped with an odometer or an hour meter follow the figures given in km mi or the figures given in hours For ATVs not equipped with an odometer or hour ...

Page 53: ...egularly Do not operate it at one set throttle position 160 320 km 100 200 mi or 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine through the gears freely but do not use full throttle at any time 320 km 200 mi or 20 hours and beyond The ATV can now be operated normally NOTICE ECB00220 If any engine trouble should occur during the engine break in period immediately have a Yam...

Page 54: ... Stop the engine 3 With the rear brake lever applied apply the parking brake and slowly release the brake le ver 4 Turn the fuel cock to OFF EBU20910 Accessories and loading EBU20921 Genuine Yamaha Accessories Choosing accessories for your ATV is an important decision Genuine Yamaha Accessories which are available only from a Yamaha dealer have been designed tested and approved by Yamaha for use o...

Page 55: ... you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when ridin...

Page 56: ... does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail er Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns un...

Page 57: ...6 10 6 WARNING EWB00011 Indicates a hazardous situation which if not avoided could result in death or serious injury U4S115E0 book Page 10 Tuesday February 15 2011 2 53 PM ...

Page 58: ...7 1 7 EBU21132 RIDING YOUR ATV U4S115E0 book Page 1 Tuesday February 15 2011 2 53 PM ...

Page 59: ...ve read this Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 5 Also read all warning and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01381 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accid...

Page 60: ...ator Not recommended for children under 16 years of age WARNING EWB01390 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift posi t...

Page 61: ...Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating with...

Page 62: ...h time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual WARNING Failure to inspect the ATV before operating it and to maintain it prop erly increases the possibility of an accident or equipment damage EWB01431 Speed limiter For rid...

Page 63: ...ntered side to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier vehicle tak...

Page 64: ... 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 EWB01471 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and t...

Page 65: ...e engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine pa...

Page 66: ...seriously af fect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01511 Do not ride on any public road street or highway Riding on public roads can result in collisions with other vehicles In many states it is illegal to operate ATVs on public streets roads and highways U4S115E0 book Pa...

Page 67: ...bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01531 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary to control the ATV on such terrain Always be especially cautious on these kinds of terrain WARNING Failure to use extra care wh...

Page 68: ...h WARNING You could collide with another vehicle if operating in off road ar eas where you cannot easily be seen Mount a caution flag on the ATV to make you more vis ible Watch carefully for other vehicles EWB01061 Do not ride in areas posted no trespassing Do not ride on private property without getting per mission U4S115E0 book Page 11 Tuesday February 15 2011 2 53 PM ...

Page 69: ...lting in a loss of directional control EWB02631 NOTICE Do not shift gears without releasing the throttle Damage to the engine or drive train may occur ECB01071 Use this same procedure as you move into the higher gears Be sure to coordinate the use of the throttle and shift pedal properly Avoid higher speeds until you are thoroughly famil iar with the operation of your ATV When slowing down or stop...

Page 70: ...eel on the inside of the turn slip slightly allowing the ATV to make the turn properly This procedure should be practiced at slow speed many times in a large off road area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippery or loose it may help to po...

Page 71: ... for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top ...

Page 72: ...omentum but not so fast that you cannot react to changes in the terrain as you climb It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steeper inclines standing on the footboards and leaning forward over the handlebars Whenev er possible ride straight up hills Slow down when you reach the crest of...

Page 73: ...ped apply the rear brake as well and then lock the parking brake If you are in 4WD or 4WD LOCK because all wheels are interconnected by the drive train ap plying either brake will brake all wheels therefore avoid sudden application of either the front or rear brake as the wheels on the uphill side could come off the ground The ATV could easily tip over back wards Apply both the front and rear brak...

Page 74: ...Move back on the seat and sit with your arms straight Engine compression will do most of the braking for you For maximum engine compres sion braking effect change to 4WD before begin ning to descend the hill Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction ...

Page 75: ...quires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose ...

Page 76: ...of an overturn The ATV can be used to cross slow moving shal low water of up to a maximum of 35 cm 14 in in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and care fully Test your brakes after leaving the water If neces sary apply them several times to let frict...

Page 77: ...ddy conditions RIDING OVER ROUGH TERRAIN WARNING EWB01651 Riding improperly over obstacles could cause loss of control or a collision Before operating in a new area check for obstacles Never at tempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done ...

Page 78: ...lowly and be very cautious in order to re duce the chance of skidding or sliding out of control Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help I...

Page 79: ...osition your weight over the front wheels for better control See page 7 12 If your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off the throttle and or steer to the outside of the turn See page 7 12 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recomme...

Page 80: ...on the uphill side See page 7 18 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter 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 until you have regained adequate braking ability See page 7 19 WARNING EWB00011 Indicates a hazardous situa...

Page 81: ... off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 4 for more information about carbon monoxide WARNING EWB02690 Bra...

Page 82: ...and the tools provided in the owner s tool kit are in tended to assist you in the performance of preven tive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s manual 1 Owner s tool ...

Page 83: ...e special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if...

Page 84: ...s and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U4S115E0 book Page 4 Tuesday February 15 2011 2 53 PM ...

Page 85: ... ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Clutch Check operation and adjust if necessary 3 Front brake Check operation and correct if necessary Check fluid level and ATV for f...

Page 86: ...rease 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 11 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 12 Stabilizer bushes Check for cracks or other damage and replace if necessary 13 Rear knuckle pivots Lubricate with lithium soap based grease 14 Steering shaft Lubricate with lithium soap ba...

Page 87: ...gine oil strainer Clean 20 Differential gear oil Change Check ATV for oil leakage and correct if neces sary 21 Final gear oil Change Check ATV for oil leakage and correct if neces sary 22 Moving parts and cables Lubricate 23 Reverse lock re lease cable Check operation and adjust or replace if neces sary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 32...

Page 88: ...e the brake hoses every four years and if cracked or damaged 24 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 25 Front and rear brake switches Check operation and correct if necessary 26 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev...

Page 89: ... cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit 1 Spark plug cap U4S...

Page 90: ...perly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spark plug wrench Specified spark plug NGK DR8EA 1 Spark plug gap Spark plug ga...

Page 91: ...il and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter element cleaned at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil leve...

Page 92: ...om mended type to raise it to the correct level NOTICE Be sure the engine oil is at the correct level otherwise engine damage may result ECB00851 6 Insert the dipstick into the oil filler hole and then tighten the engine oil filler cap To change the engine oil with or without oil fil ter element cleaning 1 Place the ATV on a level surface 1 Engine oil filler cap 1 Engine oil dipstick 2 Maximum lev...

Page 93: ...ng the engine oil drain bolt the compres sion spring oil strainer and O ring will fall out Take care not to lose these parts ECB00311 TIP Skip steps 5 9 if the oil filter element is not being cleaned 5 Remove the oil filter element cover by remov ing the bolts and then remove the oil filter el ement and the O ring 1 Engine oil drain bolt 2 O ring 3 Compression spring 4 Oil strainer 1 Oil filter el...

Page 94: ...n them to the speci fied torque 10 Apply a thin coat of clean engine oil to a new O ring 11 Install the oil strainer the compression spring the new O ring and the engine oil drain bolt Tighten the engine oil drain bolt to the speci fied torque NOTICE Before installing the 1 O ring 2 Oil filter element Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 Engine oil drain bol...

Page 95: ... II or higher Make sure that no foreign material enters the crankcase 13 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 14 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary EBU28564 Final gear oil The final gear case must be che...

Page 96: ...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 4 Install the oil filler bolt and its new O ring and then tighten the bolt to the specified torque To change the final gear oil 1 Place the ATV on a level surface 2 Remove the final gear case guard by remov ing the bolts 1 Final gear oil filler bolt 2 O ring 3 Final ge...

Page 97: ...mended final gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material enters the final gear case ECB00421 TIP If the recommended oil is not available SAE80W 90 API GL 5 Hypoid gear oil may be used instead 1 Final gear oil drain bolt 2 O ring Tightening torque Final gear oil drain bolt 24 Nm 2 4 m kgf 17 ft lbf 2 1 1 1 Final gear oil filler bolt 2 O ring 3 Final gear oil ...

Page 98: ...r check and repair the ATV In addition the differential gear oil level must be checked and the oil changed as follows at the in tervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface 2 Remove the differential gear oil filler bolt and its gasket and then check the oil level in the differential gear case The oil...

Page 99: ...ntial gear oil filler bolt the differential gear oil drain bolt and their gasket to drain the oil from the differential gear case 4 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended differential gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material en ters the differential gear case ECB00411 Tight...

Page 100: ...tenance and lubrication chart Clean or if necessary replace the air filter element more frequently if you are riding in unusually wet or dusty areas TIP There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air fil ter case 1 Differential gear oil filler bolt 2 Gasket 3 Differential gear oil 4 Correct o...

Page 101: ... 4 19 3 Remove the air filter case cover by unhooking the holders 4 Pull the air filter element assembly out of the air filter case 1 Air filter case check hose 1 Air filter case cover 2 Air filter case cover holder U4S115E0 book Page 21 Tuesday February 15 2011 2 53 PM ...

Page 102: ...flash point solvents or gasoline to clean the sponge material because the en gine could catch fire or explode EWB01951 7 Squeeze the excess water or solvent out of the sponge material and let it dry NOTICE Do not twist the sponge material when squeezing it Do not apply oil to the sponge material ECB00471 1 Air filter element assembly 1 Air filter element 2 Sponge material U4S115E0 book Page 22 Tue...

Page 103: ...air filter case and then install the air filter case cover by hooking the holders NOTICE Make sure that the air filter element is properly seated in the air filter case Never operate the engine with the air filter element re moved This will allow unfiltered air to en ter the engine causing rapid engine wear and possible engine damage Additionally operation without the air filter element will affec...

Page 104: ...fold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air en tering the engine EBU27082 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the tailpipe bolts 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any c...

Page 105: ...rburetor The carburetor should be checked and if neces sary adjusted at the intervals specified in the peri odic maintenance and lubrication chart The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment described in...

Page 106: ...lubrica tion chart TIP A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it up TIP The engine is warm when it quickly responds to the throttle 2 Attach the tachometer to the spark plug lead 3 Check the engine idling speed and if neces sary adjust it to specification by turning the throttle stop screw at the carburetor To in crease the engine idling speed turn th...

Page 107: ...tle le ver free play 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle lever free play turn the throttle lever free play adjusting bolt in di rection a To decrease the throttle lever free play turn the adjusting bolt in direction b 4 Tighten the locknut 5 Slide the rubber cover to its original position EBU24060 Valve clearance The valve clearance changes with use result...

Page 108: ...ould lead to a loss in braking ability and an accident EBU28413 Checking the front brake pads and rear brake friction plates The front brake pads and the rear brake friction plates must be checked for wear at the intervals specified in the periodic maintenance and lubrica tion chart TIP This ATV is equipped with a wet multiple disc type rear brake which is located inside of the final gear case EBU...

Page 109: ...n of the wear indicator while applying the brake If a brake friction plate has worn to the point that the wear indicator reaches the wear limit mark have a Yamaha dealer replace the brake friction plates as a set EBU29841 Checking the brake fluid level Before riding check that the brake fluid is above the minimum level mark Check the brake fluid lev el with the top of the reservoir level Replenish...

Page 110: ...water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock NOTICE ECB01160 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid im mediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indicate worn brake ...

Page 111: ...ust be checked at the intervals specified in the periodic maintenance and lubrication chart The brake lever should have no free play as shown If there is free play have a Yamaha dealer check the brake system EBU28614 Adjusting the brake pedal and rear brake lever free play The brake pedal and brake lever free play must be checked and if necessary adjusted at the inter vals specified in the periodi...

Page 112: ... brake When adjusting the rear brake be sure to adjust both the brake pedal and the brake lever Before adjusting the brake lever and brake pedal free play check the rear brake friction plates for wear 1 Brake pedal free play 1 Brake lever free play 1 U4S115E0 book Page 32 Tuesday February 15 2011 2 53 PM ...

Page 113: ...ke lever free play adjusting bolt 2 Fully loosen the brake lever free play adjust ing nut on the brake cable at the final gear case 1 Locknut 2 Brake lever free play adjusting bolt 1 Brake lever free play adjusting nut U4S115E0 book Page 33 Tuesday February 15 2011 2 53 PM ...

Page 114: ...0 12 in 4 Push the brake camshaft lever in direction a until it stops apply approximately 47 N 4 7 kgf 10 6 lbf of force and then turn the brake lever free play adjusting nut on the brake ca ble at the final gear case so that gap B mea sures 4 0 6 0 mm 0 16 0 24 in 1 Brake pedal free play adjusting nut 2 Brake camshaft lever 3 Gap A 1 Brake lever free play adjusting nut 2 Brake camshaft lever 3 Ga...

Page 115: ... TIP When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them re placed by a Yamaha dealer 1 Locknut 2 Brake lever free...

Page 116: ...ght 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 adjusting nut in direction b EBU24773 Adjusting the clutch free play The clutch free play must be adjusted periodically Adjust the free play as follows 1 Loosen the locknut 2 Slowly turn the clutch adjusting screw coun terclockwise until resistance is fel...

Page 117: ...ogether with the locknut EBU24901 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it 1 Locknut 2 Clutch adjusting screw Tightening torque Locknut 20 Nm 2 0 m kgf 14 ft lbf...

Page 118: ...n cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an acci dent or collision EBU28711 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary Front brake lever Recommended lubrican...

Page 119: ...shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary Brake pedal Shift pedal Recommended lubricant Lithium soap based grease U4S115E0 book Page 39 Tuesday February 15 2011 2 53 PM ...

Page 120: ...nce and lubrication chart TIP For parts equipped with a grease nipple use a grease gun EBU25022 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bush es if necessary EBU25052 Lubricating the rear knuckle pivots The rear knuckle pivots mus...

Page 121: ...88 Battery The battery is located under the seat See page 4 19 This model is equipped with a VRLA Valve Regu lated Lead Acid battery There is no need to check the electrolyte or to add distilled water However the battery lead connections need to be checked and if necessary tightened Recommended lubricant Lithium soap based grease 1 Grease nipple Recommended lubricant Lithium soap based grease U4S1...

Page 122: ...g nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN NOTICE ECB00620 Never attempt to remove the battery cell seals as this would permanently damage the battery To remove the battery 1 Remove the seat See page 4 19 2 Remove the battery holding plate by removing the bolts 3 Disconnect the negative battery lead first then the positive battery lead by remo...

Page 123: ...l dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00940 Always keep the battery charged Storing a dis charged battery can cause permanent 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 connec...

Page 124: ...seat See page 4 19 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits 1 Main fuse 2 Spare main fuse 3 Spare fuse 4 Four wheel drive motor fuse 5 Fuse box 1 Headlight fuse 2 Ignition fuse 3 Auxiliary DC jack fuse 4 Carburetor warmer fuse 5 Spare fuse U4S115E0 book Page 44 Tuesday February 15 2011 2 53 PM ...

Page 125: ...ould lead to a fire EWB02172 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU28443 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Disconnect the coupler shown 2 Remove the headlight assembly by removing the screws Specified fuses Main ...

Page 126: ...emoving the headlight beam adjusting screw and headlight unit screws 4 Remove the headlight bulb holder cover by pulling it off 1 Coupler 2 Screw 1 Headlight beam adjusting screw 2 Headlight unit screw U4S115E0 book Page 46 Tuesday February 15 2011 2 53 PM ...

Page 127: ...rom 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 fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner ECB00651 8 Install the bulb holder by pushing it in and turn ing it clockwise 1 Headlight bulb holder cover 1 Headlight bulb holder 1 Do not touch the glass part o...

Page 128: ...ection Adjusting a headlight beam EBU25551 Adjusting a headlight beam NOTICE ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25633 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows ...

Page 129: ...th the bulb by turning it counter clockwise 4 Remove the burnt out bulb by pushing it in and turning it counterclockwise 1 Storage compartment 2 Nut 1 Tail brake light bulb holder 2 Tail brake light assembly U4S115E0 book Page 49 Tuesday February 15 2011 2 53 PM ...

Page 130: ...51 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU25701 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP The arrow mark on the tire must point toward the rotating direction of the wheel 1 Tail brake light bulb hol...

Page 131: ...apered side to wards the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U4S115E0 book Page 51 Tuesday February 15 2011 2 53 PM ...

Page 132: ...y repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or ...

Page 133: ...he 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 ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the battery lead connections...

Page 134: ... dry out the linings EWB02311 NOTICE Excessive water pressure may cause water seepage and deteriora tion of wheel bearings brakes transmis sion seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applica tions such as those available in coin oper ated car washers ECB00711 4 Once most of the dirt has been hosed off wash all surfaces with warm...

Page 135: ...available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking...

Page 136: ...m entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery see page 8 41 TIP Make any necessary repairs before storing the ATV U4S115E0 book Page 3 Tuesday February 15 2011 2 53 PM ...

Page 137: ...ylinder arrangement Forward inclined single cylinder Displacement 387 cm Bore stroke 83 0 71 5 mm 3 27 2 81 in Compression ratio 8 60 1 Starting system Electric and recoil starter Lubrication system Wet sump Engine oil Recommended brand YAMALUBE Type SAE 5W 30 10W 30 10W 40 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA 0 10 30 50 70 90 110 130 ...

Page 138: ...commended fuel Unleaded gasoline only Fuel tank capacity 15 0 L 3 96 US gal 3 30 Imp gal Fuel reserve amount 4 0 L 1 06 US gal 0 88 Imp gal Carburetor Type quantity BSR33 x 1 Spark plug s Manufacturer model NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction system Spur gear Primary reduction ratio 76 24 3 167 Secondary red...

Page 139: ... and tongue Tire air pressure measured on cold tires Recommended Front 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum Front 22 0 kPa 0 220 kgf cm 3 2 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi Front wheel Wheel type Panel wheel Rim size 12 x 6 0AT Rear wheel Wheel type Panel wheel Rim size 12 x 7 5AT Front brake Type Disc brake Operation Right hand operation Specified brake f...

Page 140: ...e Krypton bulb Bulb voltage wattage quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 Meter lighting 12 V 1 7 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Oil temperature warning light 12 V 1 7 W 1 On command four wheel drive indicator light 12 V 1 7 W 1 Differential gear lock indicator light 12 V 1 7 W x 1 Fuses Main fuse 30 0 A Headlight fu...

Page 141: ...rence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key iden...

Page 142: ...be need ed when ordering spare parts from a Yamaha deal er EBU29662 Vehicle Emission Control Information label The Vehicle Emission Control Information label is affixed at the location in the illustration This label shows specifications related to exhaust emissions as required by federal law state law and Environ ment Canada 1 Vehicle identification number front left side 1 Model label U4S115E0 bo...

Page 143: ...11 3 11 1 Vehicle Emission Control Information label 1 U4S115E0 book Page 3 Tuesday February 15 2011 2 53 PM ...

Page 144: ...se of noise control prior to its sale or delivery to the ul timate 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 Muf...

Page 145: ...he maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 U4S11...

Page 146: ...equent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also warr...

Page 147: ...upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CUSTOMER SERVICE If your mach...

Page 148: ...to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 250 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodgin...

Page 149: ...within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 Indicates a hazardous situation which if not avoided could result in death or serious injury WAR...

Page 150: ...bricating 8 37 Carburetor adjusting 8 25 Carrier front 4 20 Carrier rear 4 21 Chassis fasteners 5 6 Cleaning 9 1 Clutch free play adjusting 8 36 D Differential gear oil 5 3 8 18 Drive shaft universal joint lubricating 8 40 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 26 Engine oil 5 3 Engine oil and oil filter element 8 11 Engine starting a warm 6 3 Engine stop switch 4 5 F Fi...

Page 151: ... 14 Reverse knob and driving in reverse 6 4 Reverse lock release cable adjusting 8 28 Riding your ATV 7 1 S Safety information 2 1 Seat 4 19 Shifting 6 3 Shift pedal 4 13 Spark arrester cleaning 8 24 Spark plug checking 8 9 Specifications 10 1 Speed limiter 4 11 Speedometer 4 3 Stabilizer bushes checking 8 40 Starter choke 4 18 Start switch 4 5 Steering shaft lubricating 8 41 Storage 9 2 Storage c...

Page 152: ...Wheel installing 8 50 Wheel removing 8 50 U4S115E0 book Page 3 Tuesday February 15 2011 2 53 PM ...

Page 153: ...nuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technician...

Page 154: ...ol Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR...

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Yamaha Big Bear 400 YFM40FBB, Owner'S Manual

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