U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00941 INTRODUCTION 1- Congratulations on your purchase of the Yamaha YFM400FA. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
U5TE10.book Page 2 Wednesday, April 10, 2002 10:32 AM EBU00011 IMPORTANT NOTICE This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with 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.
U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS................ 1-1 2 SAFETY INFORMATION.................. 2-1 3 DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2 Key identification number................ 3-2 ber .......... 3-3 4 CONTROL FUNCTIONS...................
EETOC.fm Page 2 Wednesday, April 10, 2002 11:33 AM 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 Rear shock absorber adjustment................................... 4-20 Auxiliary DC jack........................... 4-21 5 PRE-OPERATION CHECKS ...........
U5TE10.book Page 3 Wednesday, April 10, 2002 10:32 AM 8 PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1 Owner’s manual and tool kit............ 8-1 Periodic maintenance/ lubrication ...................................... 8-3 Panel removal and installation ........ 8-5 Engine oil....................................... 8-12 Final gear oil .................................. 8-16 Differential gear oil replacement ... 8-19 Cooling system..............................
U5TE10.book Page 4 Wednesday, April 10, 2002 10:32 AM 9 CLEANING AND STORAGE............ 9-1 A. Cleaning...................................... 9-1 B. Storage ....................................... 9-3 10 SPECIFICATIONS.......................... 10-1 11 NOISE REGULATION.................... 11-1 12 MAINTENANCE RECORD ............ 12-1 13 ATV LIMITED WARRANTY............ 13-1 14 YAMAHA EXTENDED SERVICE (Y.E.S.) ...........................................
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U5TE10.book Page 2 Wednesday, April 10, 2002 10:32 AM Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 1 2 3 Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 4 5 6 1 2 WARNING O v e r l o a d i n g t h i s AT V o r c a r r y i n g c a r g o improperly can change handling.
U5TE10.book Page 3 Wednesday, April 10, 2002 10:32 AM 3 5 MAXIMUM .LOADING LIMIT PULLING LOAD: TONGUE WEIGHT: 4900 1102 147 33 (500kgf) N lbf ( 15kgf) N lbf 5ND-F151K-00 6 4 WARNING O v e r l o a d i n g t h i s AT V o r c a r r y i n g c a r g o improperly can change handling. stability and b r a k i n g p e r fo r m a n c e a n d c a n l e a d t o a n a c c i d e n t . N e v e r ex c e e d t h e m a x i m u m r e a r c a r g o l i m i t o f : 80kg (176 lbs) N E V E R s i t o n t h e c a r r i e r.
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U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00924 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.
U5TE10.book Page 2 Wednesday, April 10, 2002 10:32 AM ● ● ● ● ● ● ● ● Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions.
U5TE10.book Page 3 Wednesday, April 10, 2002 10:32 AM ● ● ● ● Always follow proper procedures for climbing hills as described in this manual. 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. 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.
U5TE10.book Page 4 Wednesday, April 10, 2002 10:32 AM ● ● ● ● ● ● ● Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual.
U5TE10.book Page 5 Wednesday, April 10, 2002 10:32 AM WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling.
U5TE10.book Page 6 Wednesday, April 10, 2002 10:32 AM WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.
U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1- 1. Rear spring preload adjusting ring 2. Spark arrester 3. Storage compartment and tool kit 4. Spark plug 5. Front spring preload adjusting ring 6. Brake pedal 7. V-belt case 8. Radiator cap 9. Fuel cock 10. Air filter case 11. Fuses 13. Front spring preload adjusting ring 14. V-belt cooling duct check hose 15. Coolant reservoir 16. Oil filter cartridge 17. Engine oil dipstick 18.
U5TE10.book Page 2 Wednesday, April 10, 2002 10:32 AM EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: Key identification number The key identification number is stamped on the key as shown in the following illustration.
U5TE10.book Page 3 Wednesday, April 10, 2002 10:32 AM EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number (front left side) NOTE: The vehicle identification number is used to identify your machine. 1.
U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00039 CONTROL FUNCTIONS 1- 1 WARNING 2 Indicates a potential hazard that could result in serious injury or death. 3 4 EBU00942 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position. 5 6 1.
U5TE10.book Page 2 Wednesday, April 10, 2002 10:32 AM EBU00043 EBU01223 Indicator lights Coolant temperature warning light “ ” When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.
U5TE10.book Page 3 Wednesday, April 10, 2002 10:32 AM EBU00602 EBU00605 Reverse indicator light “R” This indicator light comes on when the transmission is in reverse. Four-wheel-drive indicator light “ ” This indicator light comes on when the 2WD/ 4WD switch is in the 4WD position. EBU00603 Neutral indicator light “N” This indicator light comes on when the transmission is in neutral.
U5TE10.book Page 4 Wednesday, April 10, 2002 10:32 AM EBU00447 EBU00052 Speedometer The speedometer shows riding speed. This speedometer is equipped with a trip odometer. The trip odometer can be reset to “0” with the reset knob. Use the trip odometer to estimate how far you can ride on a tank of fuel before going to reserve. This information will enable you to plan fuel stops in the future. Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank.
U5TE10.book Page 5 Wednesday, April 10, 2002 10:32 AM EBU00053 Handlebar switches CAUTION: _ Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. _ EBU00849 1. Light switch “ / /OFF” 2. Engine stop switch “ ”/“ ” 3.
U5TE10.book Page 6 Wednesday, April 10, 2002 10:32 AM EBU00607 Start switch “ ” The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine. (See page 6-1 for details.) 1. Four-wheel drive switch “2WD/4WD” EBU00060 On command four-wheel drive switch “2WD/4WD” To change from two-wheel drive (2WD) to four-wheel drive (4WD), stop the ATV and set the switch to the 4WD position.
U5TE10.book Page 7 Wednesday, April 10, 2002 10:32 AM WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving. WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD in some circumstances. Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and increase the risk of losing control and an accident.
U5TE10.book Page 8 Wednesday, April 10, 2002 10:32 AM EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly.
U5TE10.book Page 9 Wednesday, April 10, 2002 10:32 AM EBU01159 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. 1. Locknut 2. Adjusting screw WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged.
U5TE10.book Page 10 Wednesday, April 10, 2002 10:32 AM EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Brake pedal 1.
U5TE10.book Page 11 Wednesday, April 10, 2002 10:32 AM EBU00074 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. 1. Lock plate WARNING POTENTIAL HAZARD Improper use of the parking brake.
U5TE10.book Page 12 Wednesday, April 10, 2002 10:32 AM EBU01106 EBU01107 Drive select lever The drive select lever is used to shift your machine into the forward, neutral and reverse positions. (Refer to page 6-4 for the drive select lever operation.) 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. Drive select lever 1.
U5TE10.book Page 13 Wednesday, April 10, 2002 10:32 AM EBU00092 WARNING POTENTIAL HAZARD Starting the engine without shifting into the neutral position. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Shift the drive select lever into the neutral position and apply the parking brake before starting the engine. Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1.
U5TE10.book Page 14 Wednesday, April 10, 2002 10:32 AM EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve.
U5TE10.book Page 15 Wednesday, April 10, 2002 10:32 AM EBU00095 RES Position 1. Arrow mark pointing to “RES” Starter (choke) “ ” Starting a cold engine requires a richer 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 operation. (See page 6-1.
U5TE10.book Page 16 Wednesday, April 10, 2002 10:32 AM EBU00566 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 projection on the front of the seat into the seat holder and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. 1. Seat 2.
U5TE10.book Page 17 Wednesday, April 10, 2002 10:32 AM EBU00581 EBU00582 Storage box Front carrier Maximum load limit: 2 kg (4.4 lb) Maximum load limit: 40 kg (88 lb) CAUTION: To protect from damage, do not put metal products, like tools or sharply edged products directly in the storage box. If they must be stored, wrap them in appropriate cushion material.
U5TE10.book Page 18 Wednesday, April 10, 2002 10:32 AM EBU01104 Front shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b. NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment.
U5TE10.book Page 19 Wednesday, April 10, 2002 10:32 AM 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 setting.
U5TE10.book Page 20 Wednesday, April 10, 2002 10:32 AM EBU01103 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b. NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment.
U5TE10.book Page 21 Wednesday, April 10, 2002 10:32 AM EBU00748 Auxiliary DC jack The auxiliary 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 can only be used when the main switch is in the “ON” position. 1. Turn the headlight switch to the “OFF” position. Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A) 4. When the auxiliary DC jack is not being used, cover it with the cap.
U5TE10.book Page 22 Wednesday, April 10, 2002 10:32 AM 1.
U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM 1- PRE-OPERATION CHECKS 1 Before using this machine, check the following points: 2 ITEM ROUTINE Brakes • Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. Fuel • Check fuel level. • Fill with fuel if necessary. Engine oil • Check oil level. • Fill with oil if necessary. Coolant reservoir • Check coolant level. • Fill with coolant if necessary.
U5TE10.book Page 2 Wednesday, April 10, 2002 10:32 AM EBU01101 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
U5TE10.book Page 3 Wednesday, April 10, 2002 10:32 AM Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If there is any leakage, the brake system should be inspected by a Yamaha dealer. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brake pads for wear. (See page 8-37.
U5TE10.book Page 4 Wednesday, April 10, 2002 10:32 AM EBU01085 Fuel Make sure there is sufficient gasoline in the tank. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total: 15 L (3.3 Imp gal, 3.9 US gal) Reserve: 4.5 L (0.99 Imp gal, 1.19 US gal) CAUTION: _ Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.
U5TE10.book Page 5 Wednesday, April 10, 2002 10:32 AM Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. be WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury.
U5TE10.book Page 6 Wednesday, April 10, 2002 10:32 AM EBU01084 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See page 8-12.
U5TE10.book Page 7 Wednesday, April 10, 2002 10:32 AM EBU00493 EBU00678 Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-16– 8-18 for details.) Differential gear oil Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-19–8-20 for details.) Recommended oil: SAE 80 API GL-4 Hypoid gear oil If desired, an SAE 80W90 hypoid gear oil may be used for all conditions.
U5TE10.book Page 8 Wednesday, April 10, 2002 10:32 AM CAUTION: _ Hard water or salt water is harmful to the engine. You may use distilled water if you cannot get soft water. _ Coolant reservoir capacity: 0.25 L (0.22 Imp qt, 0.26 US qt) WARNING POTENTIAL HAZARD Removing the radiator cap when the engine 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 removing the radiator cap.
U5TE10.book Page 9 Wednesday, April 10, 2002 10:32 AM EBU01083 EBU01082 Throttle lever Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation. Switches Check the operation of all switches. Repair as necessary for proper operation. EBU00152 Fittings and Fasteners Always check the tightness of chassis fittings and fasteners before a ride.
U5TE10.book Page 10 Wednesday, April 10, 2002 10:32 AM EBU00157 Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD 1. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recommended.
U5TE10.book Page 11 Wednesday, April 10, 2002 10:32 AM 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst.
U5TE10.book Page 12 Wednesday, April 10, 2002 10:32 AM EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second 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 specifications: ACE-02EACE-02E Front Recommended pressure Minimum Maximum 25 kPa (0.25 kgf/cm2, 3.
U5TE10.book Page 13 Wednesday, April 10, 2002 10:32 AM EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. 3 mm (0.
U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00161 EBU01109 OPERATION 1- Starting a cold engine WARNING WARNING Indicates a potential hazard that could result in serious injury or death. WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.
U5TE10.book Page 2 Wednesday, April 10, 2002 10:32 AM NOTE: When the drive select lever is in the neutral position, if the indicator light does not come on, ask a Yamaha dealer to inspect its electric circuit. _ Position 3: Cold engine startambient temperature above 25 °C (80 °F) and warm engine start position. 1 2 3 _ 4 5. Use the starter (choke) in reference to the figure: Position 1: Cold engine startambient temperature below 5 °C (40 °F).
U5TE10.book Page 3 Wednesday, April 10, 2002 10:32 AM NOTE: ● If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. ● If the battery is discharged, pull the recoil starter to start the engine. CAUTION: _ _ 7.
U5TE10.book Page 4 Wednesday, April 10, 2002 10:32 AM EBU01225 Drive select lever operation and reverse driving CAUTION: _ Before shifting, you must stop the machine and return the throttle lever to its closed position. Otherwise, the transmission may be damaged. _ 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 lever along the shift guide.
U5TE10.book Page 5 Wednesday, April 10, 2002 10:32 AM Shifting: reverse 1. Bring the machine to a complete stop and return the throttle lever to the closed position. 2. Apply the parking brake. 3. Shift the gear from neutral to reverse and vice versa by moving the drive select lever along the shift guide. NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the ATV. _ 1. Drive select lever 4.
U5TE10.book Page 6 Wednesday, April 10, 2002 10:32 AM WARNING POTENTIAL HAZARD Improper operation in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind 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 slowly.
U5TE10.book Page 7 Wednesday, April 10, 2002 10:32 AM EBU00210 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances.
U5TE10.book Page 8 Wednesday, April 10, 2002 10:32 AM EBU00211 2. 10–20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time. 3. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally. Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF” and apply the parking brake.
U5TE10.book Page 9 Wednesday, April 10, 2002 10:32 AM EBU00215 Parking on a slope WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing 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 incline, apply the parking brake, and block the front and rear wheels with rocks or other objects.
U5TE10.book Page 10 Wednesday, April 10, 2002 10:32 AM EBU00221 Accessories and loading ● EBU00222 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market.
U5TE10.book Page 11 Wednesday, April 10, 2002 10:32 AM EBU00960 Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable.
U5TE10.book Page 12 Wednesday, April 10, 2002 10:32 AM ● ● ● ● 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 low range whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully.
U5TE10.book Page 13 Wednesday, April 10, 2002 10:32 AM EBU01226* WARNING _ Indicates a potential hazard that could result in serious injury or death.
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U5TE10.book Page 3 Wednesday, April 10, 2002 10:32 AM WARNING _ Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time.
U5TE10.book Page 4 Wednesday, April 10, 2002 10:32 AM RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the ATV’s handling and performance characteristics. WARNING POTENTIAL HAZARD Operating this ATV without proper instruction.
U5TE10.book Page 5 Wednesday, April 10, 2002 10:32 AM Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe 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.
U5TE10.book Page 6 Wednesday, April 10, 2002 10:32 AM This ATV is designed to carry operator and cargo only - passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN 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.
U5TE10.book Page 7 Wednesday, April 10, 2002 10:32 AM Apparel WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident.
U5TE10.book Page 8 Wednesday, April 10, 2002 10:32 AM Do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.
U5TE10.book Page 9 Wednesday, April 10, 2002 10:32 AM Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
U5TE10.book Page 10 Wednesday, April 10, 2002 10:32 AM WARNING _ Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident.
U5TE10.book Page 11 Wednesday, April 10, 2002 10:32 AM Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads. MAXIMUM LOADING LIMIT ● Vehicle loading limit: 210 kg (463 lb) * Total weight of cargo, rider and accessories, and trailer hitch vertical load. ● Front carrier: 40 kg (88 lb) ● Rear carrier: 80 kg (176 lb) ● Storage box: 2.0 kg (4.
U5TE10.book Page 12 Wednesday, April 10, 2002 10:32 AM During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
U5TE10.book Page 13 Wednesday, April 10, 2002 10:32 AM Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
U5TE10.book Page 14 Wednesday, April 10, 2002 10:32 AM Modifications WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
U5TE10.book Page 15 Wednesday, April 10, 2002 10:32 AM Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire.
U5TE10.book Page 16 Wednesday, April 10, 2002 10:32 AM BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
U5TE10.book Page 17 Wednesday, April 10, 2002 10:32 AM Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate 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.
U5TE10.book Page 18 Wednesday, April 10, 2002 10:32 AM Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.
U5TE10.book Page 19 Wednesday, April 10, 2002 10:32 AM WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, 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 necessary to control the ATV on such terrain.
U5TE10.book Page 20 Wednesday, April 10, 2002 10:32 AM When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. 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 carefully for other vehicles. Do not ride in areas posted “no trespassing”.
U5TE10.book Page 21 Wednesday, April 10, 2002 10:32 AM Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement.
U5TE10.book Page 22 Wednesday, April 10, 2002 10:32 AM TURNING YOUR ATV To achieve maximum traction while riding offroad, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed.
U5TE10.book Page 23 Wednesday, April 10, 2002 10:32 AM Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight.
U5TE10.book Page 24 Wednesday, April 10, 2002 10:32 AM CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
U5TE10.book Page 25 Wednesday, April 10, 2002 10:32 AM WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. 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.
U5TE10.book Page 26 Wednesday, April 10, 2002 10:32 AM If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
U5TE10.book Page 27 Wednesday, April 10, 2002 10:32 AM When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
U5TE10.book Page 28 Wednesday, April 10, 2002 10:32 AM If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. If you start to roll backwards, DO NOT apply either brake abruptly. If you are in 2WD, apply only the front brake.
U5TE10.book Page 29 Wednesday, April 10, 2002 10:32 AM If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. 4WD: Apply both front and rear brakes gradually. When fully stopped, apply the parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s Manual.
U5TE10.book Page 30 Wednesday, April 10, 2002 10:32 AM RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, change to 4WD before beginning to descend the hill. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces.
U5TE10.book Page 31 Wednesday, April 10, 2002 10:32 AM 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 going down hills as described in this Owner’s Manual. Note: a special technique is required when braking as you go down a hill. HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.
U5TE10.book Page 32 Wednesday, April 10, 2002 10:32 AM CROSSING A SLOPE Traversing a sloping surface on your ATV requires 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 slippery surfaces or rough terrain that may upset your balance. As you travel across a slope, lean your body in the uphill direction.
U5TE10.
U5TE10.book Page 34 Wednesday, April 10, 2002 10:32 AM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) 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 carefully. WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water.
U5TE10.book Page 35 Wednesday, April 10, 2002 10:32 AM Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case and the check hose on the V-belt cooling duct. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions.
U5TE10.book Page 36 Wednesday, April 10, 2002 10:32 AM 1. V-belt cooling duct check hose (left front side of ATV) 1.
U5TE10.book Page 37 Wednesday, April 10, 2002 10:32 AM RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision.
U5TE10.book Page 38 Wednesday, April 10, 2002 10:32 AM SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected 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.
U5TE10.book Page 39 Wednesday, April 10, 2002 10:32 AM With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
U5TE10.book Page 40 Wednesday, April 10, 2002 10:32 AM WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. ● WHAT TO DO ... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-22–7-23.
U5TE10.book Page 41 Wednesday, April 10, 2002 10:32 AM ● ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32– 7-33.
U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT 1- Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages. WARNING POTENTIAL HAZARD Servicing an engine while it is running.
U5TE10.book Page 2 Wednesday, April 10, 2002 10:32 AM The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the Owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts.
E-8.fm Page 3 Monday, April 22, 2002 5:06 PM EBU00261 PERIODIC MAINTENANCE/LUBRICATION ITEM Valves* Cooling system Spark plug Air filter element Carburetor* Crankcase breather system* Exhaust system* Spark arrester Fuel line* Engine oil Engine oil filter cartridge Engine oil strainer* ROUTINE • • • • • • • • • • • • • • • • • • • • • • • Check valve clearance. Adjust if necessary. Check coolant leakage. Repair if necessary. Replace coolant every 24 months. Check condition. Adjust gap and clean.
E-8.fm Page 4 Monday, April 22, 2002 5:06 PM ITEM ROUTINE • Check operation. • Check for cracks or damage. • Check balance/damage/runout. Wheels* • Repair if necessary. • Check bearing assemblies for looseness/damage. Wheel bearing* • Replace if damaged. Front and rear • Check operation. suspension* • Correct if necessary. • Check operation./Replace if damaged. Steering system* • Check toe-in./Adjust if necessary. • Check operation. Axle boots* • Replace if damaged.
U5TE10.book Page 5 Wednesday, April 10, 2002 10:32 AM EBU00614 Panel removal and installation The panels illustrated 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 C 3. Panel E 1. Panel A 2. Panel B 2. Panel D 4.
U5TE10.book Page 6 Wednesday, April 10, 2002 10:32 AM EBU00700 Panel A, D To remove 1. Remove the seat. 2. Pull outward on the areas shown, and then pull upward.
U5TE10.book Page 7 Wednesday, April 10, 2002 10:32 AM To install 1. Place the panel in its original position. 2. Install the seat.
U5TE10.book Page 8 Wednesday, April 10, 2002 10:32 AM EBU01147 Panel B To remove Remove the bolt, and then take the panel off. To install Place the panel in the original position and install the bolt. CAUTION: _ When installing the panel, be sure not to pinch the cables or wires.
U5TE10.book Page 9 Wednesday, April 10, 2002 10:32 AM EBU00617 Panel C To remove 1. Remove the front carrier bolts and the front carrier. 2. Remove the quick fasteners and pull upward. 1. Bolt (× 2) (under fenders) 1.
U5TE10.book Page 10 Wednesday, April 10, 2002 10:32 AM EBU01013 To install 1. Place the panel in the original position and install the quick fasteners. 2. Install the front carrier and the bolts, then tighten to the specified torque. Tightening torque: Carrier bolts: 19 Nm (1.9 m·kgf, 13 ft·lbf) Panel E To remove Remove the bolts, and then take the panel off. To install Place the panel in the original position, and then install the bolts. 1. Panel E 2.
U5TE10.book Page 11 Wednesday, April 10, 2002 10:32 AM EBU00638 Panel F To remove Pull outward on the areas shown. 1. Panel F To install Place the panel in its original position.
U5TE10.book Page 12 Wednesday, April 10, 2002 10:32 AM EBU01099 Engine oil Engine oil level measurement 1. Remove panel F. (See page 8-11 for panel removal and installation procedures.) 2. Place the ATV on a level surface and warm up the engine for several minutes. 3. Stop the engine. 4. Remove the engine oil filler cap and wipe off the dipstick with a clean rag. 5. Insert the dipstick in the filler hole without screwing it in. NOTE: Wait a few minutes until the oil level settles before checking.
U5TE10.book Page 13 Wednesday, April 10, 2002 10:32 AM Engine oil and oil filter cartridge replacement 1. Remove panels E and F. (See pages 8-10 and 8-11 for panel removal and installation procedures.) 2. Warm up the engine for several minutes. 3. Stop the engine. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap. 4. Remove the drain bolt and drain the oil. 5. Remove the oil filter cartridge with an oil filter wrench. 1.
U5TE10.book Page 14 Wednesday, April 10, 2002 10:32 AM 1. Oil filter wrench NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 1. Torque wrench 7. Apply a light coat of engine oil to the Oring of the new oil filter cartridge. _ _ NOTE: Make sure the O-ring is seated properly. _ 6. Install the drain bolt and tighten it to the specified torque. Tightening torque: _ 8. Install the oil filter cartridge, and then tighten it to the specified torque with a torque wrench.
U5TE10.book Page 15 Wednesday, April 10, 2002 10:32 AM 9. Fill the engine with sufficient oil to reach the specified level. Install the engine oil filler cap and tighten it. Recommended engine oil: See page 5-6. Oil quantity: Total amount: 2.6 L (2.3 Imp qt, 2.7 US qt) Periodic oil change: 2.3 L (2.0 Imp qt, 2.4 US qt) With oil filter cartridge replacement: 2.4 L (2.1 Imp qt, 2.
U5TE10.book Page 16 Wednesday, April 10, 2002 10:32 AM 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 final gear case. NOTE: The oil level should be at the brim of the filler hole. _ _ 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. CAUTION: _ Be sure no foreign material enters the final gear case. _ 4.
U5TE10.book Page 17 Wednesday, April 10, 2002 10:32 AM Final gear oil replacement 1. Remove the final gear case cover by removing the bolts. 1. Final gear case drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 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 Tightening torque: Final gear oil drain bolt: 23 Nm (2.
U5TE10.book Page 18 Wednesday, April 10, 2002 10:32 AM Recommended oil: See page 5-7. Oil quantity: 0.25 L (0.22 Imp qt, 0.26 US qt) CAUTION: _ Be sure no foreign material enters the final gear case. _ 7. Install the oil filler 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.
U5TE10.book Page 19 Wednesday, April 10, 2002 10:32 AM EBU01241 Differential gear oil replacement 1. Place the machine on a level surface. 2. Place a container under the differential gear case to catch the oil. 3. Remove the oil filler bolt and oil drain bolt to drain the oil. 1. Differential gear oil drain bolt 4. Install the oil drain bolt, and then tighten it to the specified torque. 1. Differential case oil filler bolt Tightening torque: Drain bolt: 10 Nm (1.
U5TE10.book Page 20 Wednesday, April 10, 2002 10:32 AM 5. Fill the differential gear case with the specified amount of the recommended oil. NOTE: ● Do not exceed the specified differential gear oil quantity when filling. Overfilling will cause the oil to seep out of the breather hose during and after riding. ● The differential gear oil level cannot be checked.
U5TE10.book Page 21 Wednesday, April 10, 2002 10:32 AM EBU01068 Cooling system 1. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. The coolant level should be between the maximum and minimum marks. 1. Coolant reservoir cap level mark 3. Remove the coolant reservoir cap, and then add coolant or distilled water to raise it to the specified level. 4. Install the coolant reservoir cap. 5. Install the panel.
U5TE10.book Page 22 Wednesday, April 10, 2002 10:32 AM EBU00887 CAUTION: Changing the coolant _ Hard water or salt water is harmful to the engine. You may use soft water if you can’t get distilled water. _ NOTE: ● If water is added, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible. ● The radiator fan operation is completely automatic. It is switched on or off according to the coolant temperature in the radiator.
U5TE10.book Page 23 Wednesday, April 10, 2002 10:32 AM 1. Place the ATV on a level surface. 2. Remove panels E and F. (See pages 8-10 and 8-11 for panel removal and installation procedures.) 3. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object as shown to prevent coolant from spilling on the footrest.) 1. Trough 4. Remove the front carrier and panel C. (See page 8-9 for removal and installation procedures.
U5TE10.book Page 24 Wednesday, April 10, 2002 10:32 AM 1. Radiator cap 5. Remove the radiator cap. 6. Remove the coolant reservoir cap. 7. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 1. Coolant reservoir drain hose 8. After draining the coolant, thoroughly flush the cooling system with clean tap water. 9. Replace the coolant drain bolt washer if it is damaged, and then tighten the coolant drain bolt to the specified torque.
E-8.fm Page 25 Friday, April 26, 2002 6:05 PM 10. Install the coolant reservoir hose. 11. Pour the recommended coolant into the radiator until it is full. Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. Antifreeze and water mixing ratio: 1:1 Total amount: 1.3 L (1.14 Imp qt, 1.37 US qt) Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.22 Imp qt, 0.26 US qt) CAUTION: _ Hard water or salt water is harmful to the 12.
U5TE10.book Page 26 Wednesday, April 10, 2002 10:32 AM EBU00862 EBU00864 Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. Spark plug inspection Removal 1. Remove panel A. (See pages 8-6–8-7 for panel removal and installation procedures.) 2. Remove the spark plug cap. 1. Axle boot (× 2 each side) 1. Spark plug cap 3.
U5TE10.book Page 27 Wednesday, April 10, 2002 10:32 AM Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. 1. Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect.
U5TE10.book Page 28 Wednesday, April 10, 2002 10:32 AM NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. _ _ 4. Install the spark plug cap. 5. Install the panel. 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.
U5TE10.book Page 29 Wednesday, April 10, 2002 10:32 AM EBU01133 Air filter element cleaning NOTE: 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 filter case. _ _ 1. Holder (× 4) 2. Air filter case cover 3. Remove the air filter element, and then remove it from its frame. 1.
U5TE10.book Page 30 Wednesday, April 10, 2002 10:32 AM WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline 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. 1. Air filter element frame 4. Wash the element gently but thoroughly in solvent. 5. Squeeze the excess solvent out of the air filter element and let it dry.
U5TE10.book Page 31 Wednesday, April 10, 2002 10:32 AM 7. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element. If foam air filter oil is not available, engine oil may be used. NOTE: The air filter element should be wet but not dripping. _ _ 8. Pull the air filter element over its frame. 9. Install the air filter element assembly. 10. Install the air filter case cover. NOTE: The air filter element should be cleaned every 20–40 hours.
U5TE10.book Page 32 Wednesday, April 10, 2002 10:32 AM EBU00641 V-belt cooling duct check hose If dust or water collects in this hose, remove the hose and clean it. 1.
U5TE10.book Page 33 Wednesday, April 10, 2002 10:32 AM EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 1. Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install and tighten the bolts. 1. Bolt (× 3) 2. Tailpipe 3.
U5TE10.book Page 34 Wednesday, April 10, 2002 10:32 AM EBU00296 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 poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the exhaust system.
U5TE10.book Page 35 Wednesday, April 10, 2002 10:32 AM EBU00657 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Remove panel D. (See pages 8-6–8-7 for removal and installation procedures.) 3.
U5TE10.book Page 36 Wednesday, April 10, 2002 10:32 AM EBU00307 Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3–5 mm (0.12–0.20 in). 3. Tighten the locknut. a.
U5TE10.book Page 37 Wednesday, April 10, 2002 10:32 AM EBU00312 EBU00313 Front brake pad inspection Inspect the brake pads for damage and wear. If the thickness is less than the specified value, have a Yamaha dealer replace the pads. 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 indicator.
U5TE10.book Page 38 Wednesday, April 10, 2002 10:32 AM EBU00755 Brake fluid level inspection Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the lower level and replenish when necessary. FRONT Observe these precautions: 1. When checking the fluid level, make sure the top of the master cylinder is level by turning the handlebars. 2. Use only the designated quality brake fluid.
U5TE10.book Page 39 Wednesday, April 10, 2002 10:32 AM EBU01113 5. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. 6. Have a Yamaha dealer check the cause if the brake fluid level goes down. Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer check the brake system. EBU01118 Brake fluid replacement 1.
U5TE10.book Page 40 Wednesday, April 10, 2002 10:32 AM WARNING POTENTIAL HAZARD Operating 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.
U5TE10.book Page 41 Wednesday, April 10, 2002 10:32 AM EBU01239 Rear brake pedal and lever adjustment Brake pedal free play adjustment 1. Fully loosen the adjusting nut on the brake lever cable at the rear wheel. 2. Turn the adjusting nut on the brake pedal cable until the free play is 20–30 mm (0.8–1.18 in). a. Frre play 1. Adjusting nut (brake pedal cable) 2.
U5TE10.book Page 42 Wednesday, April 10, 2002 10:32 AM Brake lever free play adjustment 1. Loosen the locknut and fully turn in the adjusting bolt at the brake lever. 1. Locknut 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. 2. Adjusting bolt 1. Adjusting nut (brake lever cable) a.
U5TE10.book Page 43 Wednesday, April 10, 2002 10:32 AM 3. Turn the adjusting bolt at the brake lever until the free play at the brake lever pivot is 5–7 mm (0.20–0.28 in). 1. Locknut a. Free play 2. Adjusting bolt 4. Tighten the locknut. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.
U5TE10.book Page 44 Wednesday, April 10, 2002 10:32 AM EBU01120 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and rear brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Remove panel B. (See page 8-8 for panel removal and installation procedures.) 2. Turn the adjusting nut while holding the rear brake light switch in place.
U5TE10.book Page 45 Wednesday, April 10, 2002 10:32 AM EBU00356 EBU00717 Cable inspection and lubrication Brake lever and brake pedal lubrication Lubricate the pivoting parts. WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently.
U5TE10.book Page 46 Wednesday, April 10, 2002 10:32 AM EBU01112 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.
U5TE10.book Page 47 Wednesday, April 10, 2002 10:32 AM EBU01121 Wheel installation 1. Install the wheel and the nuts. 2. Lower the ATV so that the wheel is on the ground. NOTE: ● Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. ● The arrow mark on the tire must point toward the rotating direction of the wheel. _ _ 1. Tapered nut 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.
U5TE10.book Page 48 Wednesday, April 10, 2002 10:32 AM EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. CAUTION: Do not try to remove the sealing caps of the battery cells. You may damage the battery. WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully.
U5TE10.book Page 49 Wednesday, April 10, 2002 10:32 AM EBU00385 EBU00876* Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. 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.
U5TE10.book Page 50 Wednesday, April 10, 2002 10:32 AM 1. Main fuse 2. Spare main fuse 1. 2. 3. 4. 5. 6.
U5TE10.book Page 51 Wednesday, April 10, 2002 10:32 AM EBU01063 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 rating. Never use a material in place of the proper fuse. Replacing a headlight bulb If a headlight bulb burns out, replace it as follows: 1. Remove the cover at the rear of the headlight by pulling it off.
U5TE10.book Page 52 Wednesday, April 10, 2002 10:32 AM WARNING 1. Headlight bulb holder 2. Remove the headlight bulb holder by turning it counterclockwise. 3. Remove the defective bulb by pushing it in and turning it counterclockwise. POTENTIAL HAZARD The headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable.
U5TE10.book Page 53 Wednesday, April 10, 2002 10:32 AM EBU01089 EBU01105 Headlight beam adjustment Tail/brake light bulb replacement If the tail/brake light bulb burns out, have a Yamaha dealer replace it. CAUTION: _ It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b.
U5TE10.book Page 54 Wednesday, April 10, 2002 10:32 AM EBU00412 Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer.
U5TE10.book Page 55 Wednesday, April 10, 2002 10:32 AM EBU00806 Troubleshooting charts Starting problems or poor engine performance Turn the fuel cock lever to “ON”. There is fuel. Turn the fuel cock lever to “OFF”. Remove the fuel hose from the fuel cock. Some fuel. Turn the fuel cock lever to “RES”. Restart the engine. No fuel. Supply fuel. 1. Fuel Check if there is fuel in the fuel tank. 2. Compression Use the electric starter to see if there is compression. 3.
U5TE10.book Page 56 Wednesday, April 10, 2002 10:32 AM Engine overheating WARNING Engine overheating POTENTIAL HAZARD Removing the radiator cap when the engine 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 removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. Leakage.
U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00419 CLEANING AND STORAGE 1- A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. b. Make sure the spark plug and all filler caps are properly installed. 2.
U5TE10.book Page 2 Wednesday, April 10, 2002 10:32 AM 6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. WARNING POTENTIAL HAZARD Operation with wet brakes after washing.
U5TE10.book Page 3 Wednesday, April 10, 2002 10:32 AM EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product. Specified amount: 1 oz of stabilizer to each gallon of fuel (or 7.
U5TE10.book Page 4 Wednesday, April 10, 2002 10:32 AM 7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine.
U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00428 SPECIFICATIONS 1- Model Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement YFM400FAR 1,984 mm (78.1 in) 1,085 mm (42.7 in) 1,120 mm (44.09 in) 827 mm (32.6 in) 1,233 mm (48.5 in) 245 mm (9.65 in) 3,000 mm (118.
U5TE10.book Page 2 Wednesday, April 10, 2002 10:32 AM Model YFM400FAR 1 Engine oil: Type 2 0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F 3 4 YAMALUBE 4 (20W40) or SAE 20W40 5 YAMALUBE 4 (10W30) or SAE 10W30 6 SAE 5W30 -20˚ Recommended engine oil classification: -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
E-10.fm Page 3 Friday, April 26, 2002 6:06 PM Model Final gear case oil: Type Quantity: Periodic oil change Total amount Differential gear case oil: Type Quantity: Periodic oil change Total amount Radiator capacity (including all routes): Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: YFM400FAR SAE80 API “GL-4” Hypoid gear oil 0.23 L (0.20 Imp qt, 0.24 US qt) 0.25 L (0.22 Imp qt, 0.26 US qt) SAE80 API “GL-4” Hypoid gear oil 0.35 L (0.31 Imp qt, 0.37 US qt) 0.40 L (0.
U5TE10.book Page 4 Wednesday, April 10, 2002 10:32 AM Model Spark plug: Type/manufacturer Spark plug gap Clutch type Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio Chassis: Frame type Caster angle Trail Tire: YFM400FAR DR8EA / NGK 0.6–0.7 mm (0.02–0.03 in) Wet, centrifugal automatic V-belt Spur gear 39/24 × 24/18 × 33/9 (7.944) V-belt automatic Left hand operation 29/17 (1.706) 38/23 (1.
U5TE10.book Page 5 Wednesday, April 10, 2002 10:32 AM Model Brake: Front brake Rear brake Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system YFM400FAR type operation type operation Dual disc brake Right hand operation Drum brake Left hand and right foot operation Double wishbone Swingarm (monocross) Coil spring / oil damper Coil spring / oil damper 160 mm (6.
U5TE10.book Page 6 Wednesday, April 10, 2002 10:32 AM Model Bulb voltage, wattage × quantity: Headlight Tail/brake light Meter lighting Neutral indicator light Reverse indicator light Coolant temperature warning light Four-wheel drive indicator light Fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel drive fuse Signaling system fuse YFM400FAR 12 V, 30/30 W × 2 12 V, 5/21 W × 1 14 V, 3 W × 1 12 V, 1.7 W × 1 12 V, 1.7 W × 1 12 V, 1.7 W × 1 12 V, 1.
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E-12.fm Page 1 Monday, April 22, 2002 5:06 PM EBU00431* 1- MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00432 YAMAHA MOTOR CORPORATION, U.S.A.
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U5TE10.book Page 1 Wednesday, April 10, 2002 10:32 AM EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.
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EBU00438
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