2004 YAMAHA WOLVERINE 400 differential

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 ...................................... 4-17
Speed limiter ...................................... 4-19
Front brake lever ................................ 4-21
Brake pedal and rear brake lever ....... 4-23
Parking brake ..................................... 4-25
Drive select lever ................................ 4-27
1234
Recoil starter ...................................... 4-29
Fuel tank cap ..................................... 4-29
Fuel cock............................................ 4-31
Starter (choke) ................................... 4-33
Seat.................................................... 4-35
Storage box........................................ 4-37
Front carrier ....................................... 4-39
Rear carrier ........................................ 4-39
Front shock absorber adjustment ...... 4-41
Rear shock absorber adjustment ....... 4-43
Auxiliary DC jack ................................ 4-45
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Final gear oil ...................................... 5-15
Differential gear oil ............................. 5-17
Coolant............................................... 5-17
Throttle lever ...................................... 5-19
Fittings and fasteners......................... 5-21
Lights ................................................. 5-21
Switches............................................. 5-21
Tires ................................................... 5-23
5
U5TE61.book Page 1 Tuesday, May 6, 2003 4:40 PM

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

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

5-17
EBU00678
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.)
EBU13160
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
U5TE61.book Page 17 Tuesday, May 6, 2003 4:40 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.
Retighten 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 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 brakeCheck operation.
Adjust if necessary.U5TE61.book Page 7 Tuesday, May 6, 2003 4:40 PM

8-45 1. Differential oil filler bolt
1. Boulon de l’orifice de remplissage d’huile de différentiel
1. Perno de relleno de aceite del diferencial
1. Differential gear oil drain bolt
1. Boulon de vidange de l’huile de différentiel
1. Perno de drenaje de aceite de engranajes del diferencial
EBU01241
Differential gear oil replacement
1. Place the machine on a level surface.
2. Place a container under the differential gear
case to catch the oil.
3. Remove the oil filler bolt and oil drain bolt to
drain the oil.
4. Install the oil drain bolt, and then tighten it to
the specified torque.
Tightening torque:
Drain bolt:
10 Nm (1.0 m·kgf)
U5TE61.book Page 45 Tuesday, May 6, 2003 4:40 PM

8-47
5. Fill the differential gear case with the speci-
fied amount of the recommended oil.NOTE:_

Do not exceed the specified differential gear
oil quantity when filling. Overfilling will cause
the oil to seep out of the breather hose during
and after riding.


The differential gear oil level cannot be
checked. The differential gear case capacity
is greater than the recommended oil quantity,
therefore the oil level cannot be accurately
checked from the oil filler cap hole.
_
Recommended oil:
SAE 80 API “GL-4” Hypoid gear oil
Oil quantity:
0.35 L
U5TE61.book Page 47 Tuesday, May 6, 2003 4:40 PM

10-3
Final gear oil:
Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.23 L
Differential gear oil:
Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.35 L
Radiator capacity (including all routes): 1.32 L
Air filter: Wet element
Fuel:
Type Unleaded gasoline only
For Europe: Regular unleaded gasoline only with a
research octane number of 91 or higher
Fuel tank capacity 15 L
Fuel reserve amount 4.5 L
Carburetor:
Type/quantity BSR33/1
Manufacturer MIKUNI
Spark plug:
Type/manufacturer DR8EA / NGK
Spark plug gap 0.6–0.7 mm
Clutch type: Wet, centrifugal automaticModel YFM400FA
U5TE61.book Page 3 Tuesday, May 6, 2003 4:40 PM