2004 YAMAHA WOLVERINE 400 engine oil

EBU00015
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ...................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION ................................... 3-1
Identification number records ............... 3-3
Key identification number ..................... 3-5
Vehicle identification number ............... 3-7
Model label ........................................... 3-9
CONTROL FUNCTIONS ........................ 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-3
Speedometer ........................................ 4-7
Fuel gauge ........................................... 4-9
Handlebar switches ............................ 4-11
Throttle lever ...................................... 4-15
Speed limiter ...................................... 4-17
Front brake lever ................................ 4-19
Brake pedal and rear brake lever ....... 4-21
Parking brake ..................................... 4-23
Drive select lever ................................ 4-25
1234
Recoil starter ...................................... 4-27
Fuel tank cap ..................................... 4-27
Fuel cock............................................ 4-29
Starter (choke) ................................... 4-31
Seat.................................................... 4-33
Storage box........................................ 4-35
Front carrier ....................................... 4-37
Rear carrier ........................................ 4-37
Front shock absorber adjustment ...... 4-39
Rear shock absorber adjustment ....... 4-41
Auxiliary DC jack ................................ 4-43
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel .................................................... 5-11
Engine oil ........................................... 5-15
Final gear oil ...................................... 5-17
Coolant............................................... 5-19
Throttle lever ...................................... 5-21
Fittings and fasteners......................... 5-23
Lights ................................................. 5-23
Switches............................................. 5-23
Tires ................................................... 5-25
How to measure tire pressure ............ 5-29
5
U5VH61.book Page 1 Friday, May 2, 2003 2:19 PM

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 .................................7-59
Crossing 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
67
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 and oil filter cartridge ......... 8-29
Final gear oil ....................................... 8-39
Cooling system ................................... 8-45
Changing the coolant.......................... 8-49
Spark plug inspection ......................... 8-57
Air filter element cleaning ................... 8-63
V-belt cooling duct check hose ........... 8-71
V-belt case drain plug ......................... 8-71
Carburetor adjustment ........................ 8-73
Idle speed adjustment ........................ 8-75
Valve clearance adjustment ............... 8-77
Throttle lever adjustment .................... 8-79
Front brake pad check ........................ 8-81
Rear brake shoe inspection ................ 8-81
Brake fluid level check ........................ 8-83
Brake fluid replacement ...................... 8-87
Front brake lever free play.................. 8-89
Rear brake pedal and lever
adjustment ........................................ 8-91
Adjusting the rear brake light switch ... 8-97
Cable inspection and lubrication......... 8-99
8
U5VH61.book Page 2 Friday, May 2, 2003 2:19 PM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber
assembly spring preload
adjusting ring
2. Storage box and tool kit
3. Spark plug
4. Front shock absorber
assembly spring preload
adjusting ring
5. Brake pedal
6. V-belt case
7. Radiator cap
8. Fuel cock
9. Air filter case
10. Fuses
11. Tail/brake light
12. Front shock absorber
assembly spring preload
adjusting ring13. V-belt cooling duct check
hose
14. Coolant reservoir
15. Oil filter cartridge
16. Engine oil dipstick
17. Rear brake lever
18. Left handlebar switches
19. Starter (choke)
20. Horn switch
21. Drive select lever
22. Speedometer
23. Main switch
24. Fuel tank cap
25. Auxiliary DC jack
26. Throttle lever
27. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5VH61.book Page 1 Friday, May 2, 2003 2:19 PM

4-27 1. Recoil starter
1. Lanceur à réenroulement
1. Arranque por tracción de cable
1. Fuel tank cap
1. Bouchon du réservoir de carburant
1. Tapón del depósito de combustible
EBU01264
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.
WARNING
_ Shift the drive select lever into the neutral po-
sition and apply the parking brake before start-
ing the engine or the ATV could start to move
unexpectedly, which could cause an accident. _
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it counter-
clockwise.
U5VH61.book Page 27 Friday, May 2, 2003 2:19 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-9,
8-81–8-89
Rear brakeCheck operation, condition and free play.
Adjust if necessary.5-5–5-9,
8-81, 8-91–8-95
FuelCheck fuel level.
Fill with fuel if necessary.5-11–5-13
Engine oilCheck oil level.
Fill with oil if necessary.5-15, 8-29–8-39
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.5-19–5-21,
8-45–8-55
Final gear oilCheck for leakage. 5-17, 8-39–8-43
ThrottleCheck for proper throttle cable operation. 5-21, 8-79
Wheels and tiresCheck tire pressure, wear and damage.5-25–5-31,
8-103–8-105
Fittings and fastenersCheck all fittings and fasteners. 5-23
Lights and switchesCheck for proper operation.5-23, 8-97,
8-117–8-121
U5VH61.book Page 1 Friday, May 2, 2003 2:19 PM

5-15
EBU10842
Engine oil
Make sure the engine oil is at the specified level.
Add oil as necessary. (See pages 8-29–8-39.)CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
Recommended engine oil type and quantity:
See page 10-2.
U5VH61.book Page 15 Friday, May 2, 2003 2:19 PM

6-7 a. Starter (choke)
1. Fully open
2. Half open
3. Closed
a. Starter (enrichisseur)
1. Complètement ouvert
2. Mi-ouvert
3. Fermé
a. Arrancador (choke)
1. Abre completamente
2. Semiabierto
3. Cerrado
NOTE:_

If the engine fails to start, release the start
switch, then push the start switch again.
Pause a few seconds before the next at-
tempt. 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.
_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 en-
gine. If the engine is started with the starter
(choke) in position
2, keep the starter
(choke) in this position to warm up the en-
gine.
8. Continue warming up the engine until it idles
smoothly and return the starter (choke) to po-
sition
3 before riding.CAUTION:_ See the “Engine break-in” section prior to op-
erating the engine for the first time. _
U5VH61.book Page 7 Friday, May 2, 2003 2:19 PM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*Check valve clearance.
Adjust if necessary.
Cooling systemCheck coolant leakage.
Repair if necessary.
Replace coolant every 24 months.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check and adjust idle speed/starter operation.
Adjust if necessary.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.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 oilCheck oil level/oil leakage.
Replace every 12 months.Front brake*Check operation/fluid leakage. (See NOTE page 8-8.)
Correct if necessary.Rear brakeCheck operation.
Adjust if necessary.U5VH61.book Page 7 Friday, May 2, 2003 2:19 PM