2004 YAMAHA WOLVERINE 450 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 unit ................................. 4-9
Fuel gauge ......................................... 4-15
Handlebar switches ............................ 4-17
Throttle lever ...................................... 4-35
Speed limiter ...................................... 4-37
Front brake lever ................................ 4-39
Brake pedal and rear brake lever ....... 4-41
Drive select lever ................................ 4-43
Recoil starter ...................................... 4-43
1234
Fuel tank cap ..................................... 4-45
Fuel cock............................................ 4-47
Starter (choke) ................................... 4-49
Seat.................................................... 4-51
Storage compartment ........................ 4-53
Front carrier ....................................... 4-55
Rear carrier ........................................ 4-55
Front shock absorber adjustment ...... 4-57
Rear shock absorber adjustment ....... 4-61
Auxiliary DC jack ................................ 4-63
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............................................... 5-19
Throttle lever ...................................... 5-21
Fittings and fasteners......................... 5-21
Lights ................................................. 5-23
Switches............................................. 5-23
Tires ................................................... 5-25
How to measure tire pressure ............ 5-29
5
U5ND61.book Page 1 Thursday, June 5, 2003 7:02 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 ......... 8-31
Final gear oil ....................................... 8-41
Differential gear oil.............................. 8-47
Cooling system ................................... 8-53
Changing the coolant.......................... 8-57
Axle boots ........................................... 8-63
Spark plug inspection ......................... 8-65
Air filter element cleaning ................... 8-71
V-belt cooling duct check hose ........... 8-79
V-belt case drain plug ......................... 8-79
Carburetor adjustment ........................ 8-81
Idle speed adjustment ........................ 8-83
Valve clearance adjustment ............... 8-85
Throttle lever adjustment .................... 8-87
Front brake pad check ........................ 8-89
Rear brake pad check ........................ 8-91
Inspecting the brake fluid level ........... 8-93
Brake fluid replacement ...................... 8-97
Front brake lever free play.................. 8-99
Rear brake lever adjustment ............ 8-101
Brake pedal position adjustment ...... 8-101
8
U5ND61.book Page 2 Thursday, June 5, 2003 7:02 PM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber
assembly spring preload
adjusting ring
2. Storage compartment
and tool kit
3. Spark plug
4. Rear brake fluid reservoir
5. Radiator cap
6. Front shock absorber
assembly spring preload
adjusting ring
7. V-belt case
8. Brake pedal
9. Front shock absorber
assembly spring preload
adjusting ring
10. Fuel cock
11. Air filter case
12. Fuses13. Tail/brake light
14. V-belt cooling duct check
hose
15. Coolant reservoir
16. Oil filter cartridge
17. Engine oil dipstick
18. Rear brake lever
19. Left handlebar switches
20. Starter (choke)
21. Horn switch
22. Drive select lever
23. Speedometer unit
24. Main switch
25. Fuel tank cap
26. Auxiliary DC jack
27. Right handlebar switch
28. Throttle lever
29. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5ND61.book Page 1 Thursday, June 5, 2003 7:02 PM

4-43 1. Drive select lever
1. Levier de présélection
1. Palanca de selección de marcha
1. Recoil starter
1. Lanceur à réenroulement
1. Arranque por tracción de cable
EBU00608
Drive select lever
The drive select lever is used to shift your machine
into the low, high, neutral, reverse and park posi-
tions. (Refer to pages 6-11–6-15 for the drive se-
lect lever operation.)
EBU00975
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
_ Always shift the drive select lever to “P” park
position before starting the engine, otherwise
the ATV could start to move unexpectedly,
which could cause an accident. _
U5ND61.book Page 43 Thursday, June 5, 2003 7:02 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-89, 8-93–8-99
Rear brakeCheck operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-91–8-97,
8-101–8-103
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-31–8-41
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.5-19–5-21,
8-53–8-63
Final gear oil and
differential gear oilCheck for leakage.5-15–5-17,
8-41–8-51
ThrottleCheck for proper throttle cable operation and free play. 5-21, 8-87
Wheels and tiresCheck tire pressure, wear and damage.5-25–5-31,
8-111–8-113
Fittings and fastenersCheck all fittings and fasteners. 5-21
Lights and switchesCheck for proper operation.5-23, 8-105,
8-125–8-129
Axle bootsCheck for damage. 8-63
U5ND61.book Page 1 Thursday, June 5, 2003 7:02 PM

5-13
EBU10842
Engine oil
Make sure the engine oil is at the specified level.
Add oil as necessary. (See pages 8-31–8-41.)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.
U5ND61.book Page 13 Thursday, June 5, 2003 7:02 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. Starter (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 attempt.
Each cranking should be as short as possible
to preserve battery energy. Do not crank the
engine more than 10 seconds on each at-
tempt.


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.
U5ND61.book Page 7 Thursday, June 5, 2003 7:02 PM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
km 320 1,200 2,400 2,400 4,800
hours 20 75 150 150 300
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 month.Differential gear oil
Front brake*Check operation/fluid leakage. (See NOTE page 8-8.)
Correct if necessary.Rear brake*Check operation/fluid leakage.(See NOTE page 8-8.)
Correct if necessary.U5ND61.book Page 7 Thursday, June 5, 2003 7:02 PM