2001 YAMAHA YFM400F maintenance

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INTRODUCTION
Congratulations on your purchase of the
Yamaha YFM400FA/YFM400FWA. It repre-
sents the result of many years of Yamaha ex-
perience in the production of fine sporting,
touring, and pacesetting racing machines.
With the purchase of this Yamaha, you can
now appreciate the high degree of craftsman-
ship and reliability that have made Yamaha a
leader in these fields.
This manual will provide you with a good basic
understanding of the features and operation of
this machine.
This manual includes important
safety information. It provides information
about special techniques and skills necessary
to ride your machine.
It also includes basic
maintenance and inspection procedures. If you
have any questions regarding the operation or
maintenance of your machine, please consult a
Yamaha dealer.

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Lights ................................................ 5-23
Switches ........................................... 5-23
Tires .................................................. 5-25
How to measure tire pressure ........ 5-29
Tire wear limit .................................. 5-31
OPERATION ........................................... 6-1
Starting a cold engine ....................... 6-3
Starting a warm engine ..................... 6-9
Warming up ........................................ 6-9
Drive select lever operation and
reverse driving ............................... 6-11
Engine break-in ................................ 6-17
Parking .............................................. 6-19
Parking on a slope ........................... 6-21
Accessories and loading ................. 6-23
RIDING YOUR ATV ................................ 7-1
Getting to know your ATV ................. 7-3
Ride with care and good
judgement ........................................ 7-5
Be careful where you ride ............... 7-27
Turning your ATV ............................ 7-39
Climbing uphill ................................. 7-45
Riding downhill ................................ 7-55
Crossing a slope ............................... 7-59Crossing through shallow
water ............................................... 7-63
Riding over rough terrain ................ 7-69
Sliding and skidding ........................ 7-71
What to do if ..................................... 7-75
What to do... ..................................... 7-75
PERIODIC MAINTENANCE AND
ADJUSTMENT ....................................... 8-1
Owner’s manual and tool kit ............. 8-3
Periodic maintenance/
lubrication ........................................ 8-7
Panel removal and installation ....... 8-15
Engine oil .......................................... 8-31
Final gear oil ..................................... 8-41
Differential gear oil .......................... 8-47
Cooling system ................................ 8-53
Changing the coolant ...................... 8-57
Front axle boots ............................... 8-63
Spark plug ........................................ 8-65
Air filter cleaning.............................. 8-71
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V-belt cooling duct check hose ....... 8-77
Carburetor adjustment..................... 8-81
Idle speed adjustment...................... 8-83
Valve clearance adjustment ............ 8-85
Throttle lever adjustment ................ 8-87
Front brake pad inspection .............. 8-89
Rear brake pad inspection ............... 8-89
Inspecting the brake fluid level ....... 8-91
Brake fluid replacement ................... 8-95
Front brake adjustment.................... 8-97
Rear brake lever adjustment ........... 8-99
Cable inspection and
lubrication ..................................... 8-103
Brake lever and brake pedal
lubrication ..................................... 8-105
Wheel removal ............................... 8-107
Wheel installation........................... 8-109
Battery ............................................. 8-111
Battery maintenance ...................... 8-115
Fuse replacement ........................... 8-117
Replacing the headlight bulb ........ 8-121
Headlight beam adjustment .......... 8-125
Taillight bulb replacement............. 8-127
Troubleshooting ............................. 8-129
Troubleshooting chart ................... 8-131CLEANING AND STORAGE................... 9-1
A. Cleaning ......................................... 9-1
B. Storage ........................................... 9-7
SPECIFICATIONS ................................. 10-1
HOW TO USE THE CONVERSION
TABLE ................................................... 11-1
91011

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l
Always inspect your ATV each time you use
it to make sure it is in safe operating condi-
tion. Always follow the inspection and
maintenance procedures and schedules de-
scribed in this manual.
l
Always keep both hands on the handlebars
and both feet on the footboards of the ATV
during operation.
l
Always go slowly and be extra careful when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions when
operating the ATV.
l
Never operate on excessively rough, slip-
pery or loose terrain until you have learned
and practiced the skills necessary to control
the ATV on such terrain. Always be espe-
cially cautious on these kinds of terrain.
l
Always follow proper procedures for turn-
ing as described in this manual. Practice
turning at low speeds before attempting to
turn at faster speeds. Do not turn at exces-
sive speed.

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WARNING

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 Own-
er’s Manual. Failure to inspect increases the possibility of an accident or equipment damage.

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PERIODIC MAINTENANCE AND
ADJUSTMENT
Periodic inspection, adjustment and lubrica-
tion will keep your machine in the safest and
most efficient condition possible. Safety is an
obligation of the machine owner. The most im-
portant points of machine inspection, adjust-
ment and lubrication are explained on the
following pages.
WARNING

Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or can start fires. Turn off the
engine when performing maintenance unless
otherwise specified. Have a Yamaha dealer
perform service if you are not familiar with
machine service.

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1. Owner’s manual
2. Owner’s tool kit
3. Low-pressure tire gauge
1. Manuel du propriétaire
2. Manuel du trousse à outils
3. Manomètre basse pression pour pneus
1. Manual del propietario
2. Manual del juego de herramientas
3. Manómetro de baja presión
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Owner’s manual and tool kit
You are recommended to put this owner’s
manual in the vinyl bag and always carry it un-
der the seat as shown. Put the owner’s tool kit
and low-pressure tire gauge in the storage
box.
The service information included in this manu-
al is intended to provide you, the owner, with
the necessary information for completing your
own preventive maintenance and minor re-
pairs. 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.
NOTE:

If you do not have a torque wrench available
during a service operation requiring one, take
your machine to a Yamaha dealer to check the
torque settings and adjust them as necessary.

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PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*

• Check valve clearance.
• Adjust if necessary.
Cooling system
• Check coolant leakage.
• Repair if necessary.
• Replace coolant every 24 months.
Spark plug
• Check condition.
• Adjust gap and clean.
• Replace if necessary.
Air filter
• Clean.
• Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Crankcase breather
system*

• Check breather hose for cracks or damage.
• Replace if necessary.

Exhaust system*

• Check for leakage.
• Retighten if necessary.
• Replace gasket(s) if necessary.

Carburetor*

• Check and adjust idle speed/starter operation.
• Adjust if necessary.

Fuel line*

• Check fuel hose for cracks or damage.
• Replace if necessary.

Engine oil

• Replace (Warm engine before draining).

Engine oil filter cartridge

• Replace.

Engine oil strainer*

• Clean.

Final gear oil

• Check oil level/oil leakage.
• Replace every 12 months.

Differential gear oil
Front brake*

• Check operation/fluid leakage/see NOTE page 8-8.
• Correct if necessary.

Rear brake*

• Check operation/fluid leakage/see NOTE page 8-8.
• Correct if necessary.