2004 YAMAHA WOLVERINE 400 coolant reservoir

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 ring
13. V-belt cooling duct check
hose14. 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. Right handlebar
switch
27. Throttle lever
28. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
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5-1
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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
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5-17
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Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-45–
8-49 for details.)
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Coolant
Check the coolant level in the coolant reservoir
when the engine is cold. (The coolant level will
vary with engine temperature.) The coolant level is
satisfactory if it is between the minimum and max-
imum level marks on the coolant reservoir. If the
coolant level is at or below the minimum level
mark, add distilled water to bring the level up to the
maximum level mark. Change the coolant every
two years. (See pages 8-51–8-61 for details.) Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
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5-19
CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you cannot get
distilled water. _
WARNING
_ Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always put a thick rag over the cap
when opening. Allow any remaining pressure
to escape before completely removing the cap. _
EBU01083
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha
dealer repair as necessary for proper operation.Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
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8-51 1. Coolant reservoir cap
2. Maximum level mark
3. Minimum level mark
1. Bouchon du vase d’expansion
2. Repère de niveau maximum
3. Repère de niveau minimum
1. Tapa del depósito de refrigerante
2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU13210
Cooling system
1. Place the ATV on a level surface.
2. Check the coolant level in the coolant reser-
voir when the engine is cold as the coolant
level will vary with engine temperature.NOTE:_ The coolant level should be between the minimum
and maximum level marks. _3. If the coolant is at or below the minimum level
mark, remove panel D. (See pages 8-17–
8-19 for panel removal and installation proce-
dures.)
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8-53
4. Remove the reservoir cap, add coolant to the
maximum level mark, install the reservoir
cap, and then install the panel.CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you cannot 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 auto-
matic. It is switched on or off according to the
coolant temperature in the radiator.
_If your ATV overheats, see page 8-132 for details. Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
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8-57 1. Radiator cap
1. Bouchon du radiateur
1. Tapa del radiador
1. Coolant reservoir hose
1. Flexible du vase d’expansion
1. Manguera del depósito de refrigerante
5. Remove the radiator cap.
6. Remove panel D. (See page 8-17 for panel
removal and installation procedures.)
7. Remove the coolant reservoir cap.
8. Disconnect the hose on the coolant reservoir
side, and then drain the coolant from the
coolant reservoir.
9. After draining the coolant, thoroughly flush
the cooling system with clean tap water.
10. Replace the coolant drain bolt washer if it is
damaged, install the coolant drain bolt, and
then tighten it to the specified torque.
11. Connect the coolant reservoir hose.Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf)
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8-59
12. Pour the recommended coolant into the res-
ervoir to the maximum level mark, and then
install the reservoir cap and panel D.
13. Pour the recommended coolant into the radi-
ator until it is full, and then install the radiator
cap.CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you cannot get
distilled water. _
Recommended antifreeze:
High quality ethylene glycol antifreeze
containing corrosion inhibitors for
aluminum engines.
Antifreeze and water mixing ratio:
1:1
Total amount:
1.32 L
Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
U5TE61.book Page 59 Tuesday, May 6, 2003 4:40 PM