2004 YAMAHA WOLVERINE 400 boot

How to measure tire pressure .............5-27
Tire wear limit......................................5-29
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
Differential gear oil replacement ......... 8-45
Cooling system ................................... 8-51
Changing the coolant.......................... 8-55
Axle boots ........................................... 8-61
Spark plug inspection ......................... 8-63
Air filter element cleaning ................... 8-69
V-belt cooling duct check hose ........... 8-77
V-belt case drain plug ......................... 8-77
Carburetor adjustment ........................ 8-79
Idle speed adjustment ........................ 8-81
Valve clearance adjustment ............... 8-83
Throttle lever adjustment .................... 8-85
Front brake pad check ........................ 8-87
Rear brake shoe inspection ................ 8-87
Brake fluid level check ........................ 8-89
Brake fluid replacement ...................... 8-93
Front brake lever free play.................. 8-95
8
U5TE61.book Page 2 Tuesday, May 6, 2003 4:40 PM

2-3

Never carry a passenger on an ATV.


Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, park-
ing lots and streets.


Never operate an ATV on any public street,
road or highway, even a dirt or gravel one.


Never operate an ATV without wearing an ap-
proved 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. Always go at a speed that is
proper for the terrain, visibility and operating
conditions, and your experience.


Never attempt wheelies, jumps, or other stunts.
U5TE61.book Page 3 Tuesday, May 6, 2003 4:40 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.5-5–5-7,
8-87–8-95
Rear brakeCheck operation, condition and free play.
Adjust if necessary.5-5–5-7,
8-87, 8-97–8-101
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-29–8-39
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.8-51–8-61
Final gear oil and
differential gear oilCheck for leakage.5-15–5-17,
8-39–8-49
ThrottleCheck for proper throttle cable operation. 5-19, 8-85
Wheels and tiresCheck tire pressure, wear and damage.5-23–5-29,
8-109–8-111
Fittings and fastenersCheck all fittings and fasteners. 5-21
Lights and switchesCheck for proper operation. 5-21, 8-123–8-127
Axle bootsCheck for damage. 8-61
U5TE61.book Page 1 Tuesday, May 6, 2003 4:40 PM

7-11 1. Protective clothing 2. Goggles
3. Gloves 4. Boots
5. Helmet
1. Vêtement de protection 2. Lunettes
3. Gants 4. Bottes
5. Casque
1. Vestimenta adecuada 2. Gafas
3. Guantes 4. Botas
5. Homologado
Apparel
Always wear an approved helmet that fits properly.
You should also wear:
eye protection
(goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
long pants
WARNING
_ Never operate this ATV without wearing an ap-
proved motorcycle helmet, eye protection and
protective clothing. Operating without an ap-
proved motorcycle helmet increases your
chances of a severe head injury or death in the
event of an accident. Operating without eye
protection can result in an accident and in-
creases your chances of a severe injury in the
event of an accident. Operating without protec-
tive clothing increases your chances of severe
injury in the event of an accident. _
U5TE61.book Page 11 Tuesday, May 6, 2003 4:40 PM

8-8
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
V-belt*Check operation.
Check for cracks or damage.Wheels*Check balance/damage/runout.
Repair if necessary.Wheel bearing*Check bearing assemblies for looseness/damage.
Replace if damaged.Front and rear
suspension*Check operation.
Correct if necessary.Steering system*Check operation./Replace if damaged.
Check toe-in./Adjust if necessary.Drive shaft universal
joint*Lubricate.Axle boots*Check operation.
Replace if damaged.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5TE61.book Page 8 Tuesday, May 6, 2003 4:40 PM

8-61 1. Axle boot (× 2 each side)
1. Soufflet d’axe (× 2 de chaque côté)
1. Guardapolvo de eje (× 2 en cada lado)
14. Start the engine and let it idle for several min-
utes. Stop the engine, and then check the
coolant level in the radiator. If it is low, add
more coolant until it reaches the top of the ra-
diator.
15. Check for coolant leakage.NOTE:_ If any leakage is found, ask a Yamaha dealer to in-
spect the cooling system. _16. Install the panels and the front carrier.
EBU00862
Axle boots
Check the protective boots for holes or tears. If any
damage is found, have them replaced by a
Yamaha dealer.
U5TE61.book Page 61 Tuesday, May 6, 2003 4:40 PM