2004 YAMAHA WOLVERINE 400 check engine light

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
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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
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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.
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4-3 1. Coolant temperature warning light “”
2. Reverse indicator light “R”
3. Neutral indicator light “N”
1. Témoin d’avertissement de la température du liquide de
refroidissement “”
2. Témoin de marche arrière “R”
3. Témoin de point mort “N”
1. Luz de aviso de la temperatura del refrigerante “”
2. Luz de control de marcha atrás “R”
3. Luz de control de punto muerto “N”
EBU00802
Indicator and warning lights
EBU01223
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.
To check the coolant temperature warning light,
shift the drive select lever into neutral, turn the key
to “ON”, and then press the start switch. If the light
does not come on, have a Yamaha dealer inspect
the electrical circuit.CAUTION:_

The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.


Restart after making sure that the light is
out. Continuous use while the light is on
may cause damage to the engine.
_
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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
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6-9
EBU00180
Starting a warm engine
To start a warm engine, refer to the “Starting a cold
engine” section. The starter (choke) should not be
used. The throttle should be opened slightly.
EBU00182
Warming up
To get maximum engine life, always warm up the
engine before starting off. Never accelerate hard
with a cold engine! To see whether or not the en-
gine is warm, check if it responds to the throttle
normally with the starter (choke) turned off.
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6-13 1. Drive select lever
a. F (Forward)
b. N (Neutral)
c. R (Reverse)
1. Levier de présélection
a. F (Marche avant)
b. N (Point mort)
c. R (Marche arrière)
1. Palanca de selección de marcha
a. F (Avance)
b. N (Punto muerto)
c. R (Marcha atrás)
Shifting: reverse
1. Bring the machine to a complete stop and re-
turn 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 machine. _4. Check behind for people or obstacles, then
release the parking brake.
5. Open the throttle lever gradually and contin-
ue to watch to the rear while backing.NOTE:_ If the drive select lever is shifted into reverse while
the engine is running, the engine will stop unless
the parking brake or rear brake lever is applied. _
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