2015 YAMAHA WOLVERINE brakes

EBU31120
CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ....................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION......................................... 3-1Left view ............................................... 3-1
Right view ............................................. 3-2
Controls and instruments ..................... 3-3
INSTRUMENT AND CONTROL
FUNCTIONS............................................ 4-1 Main switch .......................................... 4-1
Indicator lights and warning lights ....... 4-2
Multi-function meter unit ...................... 4-6
Light switch ........................................ 4-10
On-Command drive knob “2WD/4WD/DIFF LOCK” .................. 4-11
Horn switch ........................................ 4-12
Accelerator pedal ............................... 4-12
Brake pedal ........................................ 4-12 Parking brake lever ............................ 4-13
Drive select lever ................................ 4-13
Fuel tank cap...................................... 4-14
Doors .................................................. 4-14
Seats .................................................. 4-15
Adjusting the driver seat position....... 4-16
Seat belts ........................................... 4-17
Glove compartment ........................... 4-17
Storage compartments ...................... 4-18
Cup holders ........................................ 4-19
Cargo bed .......................................... 4-20
Adjusting the front shock absorber
assemblies ....................................... 4-22
Adjusting the rear shock absorber
assemblies ....................................... 4-27
Trailer hitch bracket and receiver....... 4-32
Auxiliary DC jack ................................ 4-32
FOR YOUR SAFETY –
PRE-OPERATION CHECKS.................... 5-1 Front and rear brakes ........................... 5-3
Fuel....................................................... 5-3
Engine oil.............................................. 5-5U2MB7AE0.book Page 1 Thursday, January 29, 2015 3:42 PM

Valve clearance .................................. 8-38
Brakes ................................................ 8-38
Checking the front and rear brake pads.................................................. 8-38
Checking the brake fluid level ............ 8-39
Brake fluid replacement ..................... 8-40
Checking the brake pedal .................. 8-40
Parking brake ..................................... 8-41
Brake light switch adjustment ............ 8-41
Cable inspection and lubrication........ 8-42
Brake pedal and accelerator pedal
lubrication ......................................... 8-42
Checking the stabilizer bushes .......... 8-43
Rear knuckle upper and lower pivot
lubrication (left and right) .................. 8-43
Steering shaft lubrication ................... 8-44
Wheel removal.................................... 8-44
Tire replacement ................................ 8-45
Wheel installation ............................... 8-46
Battery ................................................ 8-46
Jump-starting ..................................... 8-50
Fuse replacement............................... 8-51
Replacing a headlight bulb................. 8-54 Headlight beam adjustment ...............8-56
Tail/brake light bulb replacement .......8-57
Troubleshooting ..................................8-57
Troubleshooting charts .......................8-59
CLEANING AND STORAGE ....................9-1 Cleaning................................................9-1
Storage .................................................9-2
SPECIFICATIONS..................................10-1
CONSUMER INFORMATION ................11-1 Identification number records.............11-1
INDEX ....................................................12-1
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5-1
5
EBU31570
FOR YOUR SAFETY – PRE-OPERATION CHECKS
EBU31580Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Own-
er’s Manual.
WARNING
EWB00482Failure to inspect or maintain the vehicle properly increases the possibility of an accident
or equipment damage. Do not operate the vehicle if you find any problem. If a problem can-
not be corrected by the procedures provided in this manual, have the vehicle inspected by
a Yamaha dealer. Before using this vehicle, check the following points:
ITEM ROUTINE PAGE
Brakes • Check operation, free play, fluid level, and fluid leakage.
• Fill with DOT 4 brake fluid if necessary. 5-3, 8-38, 8-41
Parking brake • Check for proper operation. 8-41
Fuel • Check fuel level.
• Fill with the recommended fuel if necessary. 5-3
Engine oil • Check oil level.
• Fill with oil to proper level if necessary. 5-5, 8-14
U2MB7AE0.book Page 1 Thursday, January 29, 2015 3:42 PM

5-3
5
EBU31730Front and rear brakesBrake pedal
Check that there is no free play in the brake
pedal. If there is free play, have a Yamaha
dealer check the brake system. (See page
8-40.)
 Check the operation of the brake pedal. It
should move smoothly and there should be
a firm feeling when the brakes are applied.
If not, have the vehicle inspected by a
Yamaha dealer.
Brake fluid level
Check the brake fluid level. Add fluid if neces-
sary. (See page 8-39.) Brake fluid leakage
Check to see if any brake fluid is leaking out
of the pipe joints or the brake fluid reservoir.
Apply the brakes firmly for one minute. If there
is any leakage, have the vehicle inspected by
a Yamaha dealer.
Brake operation
Check the operation of the brakes at the start
of every ride. Test the brakes at slow speed
after starting out to make sure they are work-
ing properly. If the brakes do not provide
proper braking performance, inspect the
brake system. (See page 8-38.)
EBU33200FuelMake sure there is sufficient fuel in the tank.
Specified brake fluid: DOT 4
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Eye protection (goggles, helmet face shield,
or protective eyewear)
 Over-the-ankle boots, gloves, long-sleeved
shirt or jacket, and long pants
An approved helmet and other personal pro-
tective equipment can help in a variety of
ways, including:
 Reduce the severity of injuries if any part of
you is outside the vehicle cage/frame pro-
tective structure during a rollover.
 Help protect you if outside objects intrude
inside the vehicle during operation.
 Help protect you in the event of vehicle im-
pact with an obstacle.
Wear eye protection when operating or riding
the vehicle to reduce the risk of a serious ac-
cident or injury. Eye protection, such as a face
shield or goggles, may reduce the risk of for-
eign material getting in your eyes and help
prevent loss of vision. Practice for new Yamaha Wolverine users
You should become familiar with the perfor-
mance characteristics of the vehicle in a
large, flat area that is free of obstacles and
other vehicles. Practice controlling the accel-
erator pedal, brakes, steering, and drive se-
lect lever. Drive at slow speeds with gradual
acceleration and turning. Practice smooth
throttle application. Practice slowing down
before turning. Practice maintaining a steady
throttle through the turn. Avoid higher speeds
until you are thoroughly familiar with the oper-
ation of your vehicle. Remember, driving ag-
gressively or making abrupt maneuvers even
on flat, open areas can cause side rollovers.U2MB7AE0.book Page 13 Thursday, January 29, 2015 3:42 PM

7-15
7
If you think or feel that the vehicle may tip or
roll, keep your body completely inside the
protective structure of the vehicle:
Brace yourself by pressing your feet firmly
on the floorboard and keep a firm grip on
the steering wheel or passenger handhold.
 Do not put your hands or feet outside of the
vehicle for any reason. Do not try to stop a
tipover using your arm or leg.
Accelerating
With the engine idling in neutral and your foot
on the brake, shift the drive select lever into
low or high. NOTICE: Do not shift from low
to high or vice versa without coming to a
complete stop and waiting for the engine
to return to normal idle speed – damage to
the engine or drive train may occur. Then
release the parking brake.
[ECB02160]
Press the
accelerator pedal slowly and smoothly. The
centrifugal clutch will engage and the vehicle
will begin to accelerate. Avoid higher speeds and sudden or hard ac-
celeration until you are thoroughly familiar
with the operation of your vehicle. Avoid sud-
den or hard acceleration in any turn.
Braking
When slowing down or stopping, take your
foot off the accelerator pedal and press the
brake pedal smoothly. Improper use of the
brakes can cause the tires to lose traction, re-
ducing control of the vehicle and increasing
the possibility of an accident.
Braking ability is affected by type of terrain. In
most cases, gradual application of the brakes
is more effective than
abrupt braking, partic-
ularly on loose surfaces, such as gravel. Al-
ways allow for greater braking distance on
rough, loose, or slippery surfaces.
Engine braking
Engine compression braking is designed to
assist you when operating your Wolverine off-
road. With this feature, the engine helps slow
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7-16
7
the vehicle down after you take your foot off
the accelerator. Engine braking is more no-
ticeable in four-wheel drive. Application of ve-
hicle brakes provides additional stopping
power.
Leaving the vehicle
Do not get out of the vehicle while the engine
is running and the drive select lever is in any
gear. There is a risk of injury because:
 Children or others may accidentally press
the accelerator pedal.
 Objects tossed into the vehicle may strike
the accelerator pedal.
 The parking brake may not keep the vehicle
from accelerating.
Unwanted vehicle movement can cause seri-
ous injury or death, and it may be dangerous
to try to stop the vehicle. Parking on a flat area
When parking on a flat area, stop the engine
and shift the drive select lever into the neutral
position. Apply the parking brake to help pre-
vent the vehicle from rolling.
Parking on a slope
The parking brake acts only on the rear
wheels when in “2WD”. For the parking brake
to take effect on all four wheels, shift to “DIFF
LOCK” before stopping the engine.
If you park on a hill that is too steep, the vehi-
cle may roll out of control. Never park on hills
that are so steep you cannot walk up them
easily. If you must park on an incline, follow
these instructions:
1. Bring the vehicle to a stop by applying the brake pedal.
2. Put the vehicle in “DIFF LOCK”.
3. Turn the key to “ ” (off).
4. With the brake pedal applied, set the parking brake.U2MB7AE0.book Page 16 Thursday, January 29, 2015 3:42 PM

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7
to see far enough ahead of you. Use common
sense and remember that some hills are too
steep for you to climb or descend. Use proper
driving techniques to avoid rearward, for-
ward, or sideways rollovers on hills and
slopes.
Drive straight up and down inclines, not
across them. If crossing a hill is unavoidable,
drive slowly. Turn downhill immediately if you
feel the vehicle may tip.
If you think or feel the vehicle may tip or
roll:
Brace yourself by pressing your feet firmly
on the floorboard and keep a firm grip on
the steering wheel or passenger handhold.
 Do not put your hands or feet outside of the
vehicle for any reason.
Uphill
Do not attempt to climb hills until you have
mastered basic maneuvers on flat ground.
Drive straight up hills, and avoid crossing the side of a hill, which increases your risk of roll-
over. Practice first on gentle slopes before at-
tempting steeper hills. Always check the
terrain carefully before attempting any hill.
To climb a hill, you need traction, momentum,
and steady throttle. For more traction and
control for climbing steeper and/or rougher
slopes, shift into low gear and select “4WD”
or “DIFF LOCK”. Travel fast enough to main-
tain momentum, but not so fast that you can-
not react to changes in the terrain as you
climb.
Slow down when you reach the crest of the
hill if you cannot see clearly what is on the
other side – there could be another person, an
obstacle, or a sharp drop-off.
If you start to lose traction or momentum
when climbing, and decide you will be unable
to continue, use the brakes to stop. Do not at-
tempt to turn the vehicle around. With your
foot on the brake pedal, look behind you and
plan your descent. Shift the drive select lever
into reverse so you can use engine braking toU2MB7AE0.book Page 18 Thursday, January 29, 2015 3:42 PM