YAMAHA YFM400 BIGBEAR YAMAHA YFM400 BIGBEAR KODIAK 2000 2001 REPAIR MANUAL Yamaha Kodiak YFM400 Service Repair Manual 2000 Onwards Service & repair manual Yamaha YFM400 Bigbear Kodiak 2000 YAMAHA KODIAK YFM400 SERVICE REPAIR MANUAL PDF 2000 ONWARDS Yamaha Kodiak 400 4x4 service manual repair 2000-2002 YFM400 2000 Yamaha YFM400 Bigbear Kodiak 400 ATV Service Repair Manual Download!!! 2000 ATV Yamaha YFM400 Bigbear Kodiak 400 Service Repair Manual Download YAMAHA YFM400 BIGBEAR KODIAK 400 SERVICE REPAIR PDF MANUAL 2000-2005 YAMAHA KODIAK 400 YFM400 SERVICE REPAIR MANUAL DOWNLOAD 2000-2006 2000 Yamaha YFM400 Bigbear Kodiak 400 ATV Service & Repair Manual - Download!

1. 2001 Yamaha Kodiak 400 Oil Filter Location
2. 2001 Yamaha Kodiak 400 4x4 Service Manual

Complete service repair workshop manual for the: Yamaha YFM400 Kodiak 400 This is the same manual dealerships use to repair your atv. Manual covers all the topics like: Engine Service, General Information, Transmission, Chassis, Lighting, Steering, Seats System, Clutch, Suspension, []. BRUIN 350 4WD. 2006 Yamaha BRUIN. 2002 Yamaha WR400F. 4 manuals 2001 Yamaha WR400F.

. READ THIS MANUAL CAREFULLY! It contains important safety information.

OWNER’S MANUAL YFM400FAP WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-15-19 5GH-28199-12. Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines.

With the purchase of this Yamaha, you can now appreciate the high degree of crafts- manship and reliability that have made Yamaha a leader in these fields. EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SE- RIOUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe WARNING. Please check your local riding laws and regulations before operating this machine. EBU00711 YFM400FAP OWNER’S MANUAL © 2001 by Yamaha Motor Corporation, AFFIX DEALER U.S.A.

2001 Yamaha Kodiak 400 Oil Filter Location

1st Edition, April 2001 LABEL HERE All rights reserved. Any reprinting. EBU00014 CONTROL FUNCTIONS.4-1 WARNING Main switch.4-1 Indicates a potential hazard that could Indicator lights.4-2 result in serious injury or death. Coolant temperature warning light checking method.4-4 Fuel gauge.4-5 CONTENTS Handlebar switches.4-6 Throttle lever.4-9 Speed limiter.4-10 LOCATION OF THE WARNING Front brake lever.4-11 AND SPECIFICATION LABELS. Rear shock absorber Drive select lever operation adjustment.4-20 and reverse driving.6-4 Auxiliary DC jack.4-21 Engine break-in.

6-7 Parking.6-8 PRE-OPERATION CHECKS. 5-1 Parking on a slope.6-9 Front and rear brakes. 5-2 Accessories and loading.6-10 Fuel.

PERIODIC MAINTENANCE AND Inspecting the brake fluid level.8-37 ADJUSTMENT.8-1 Brake fluid replacement.8-39 Owner’s manual and tool kit. 8-1 Front brake adjustment.8-39 Periodic maintenance/ Rear brake lever adjustment.8-41 lubrication.8-3 Adjusting the rear brake light Panel removal and installation.8-5 switch.8-42 Engine oil.

CLEANING AND STORAGE. Cleaning.9-1 B.

Storage.9-3 SPECIFICATIONS.10-1 NOISE REGULATION.11-1 MAINTENANCE RECORD. 12-1 ATV LIMITED WARRANTY. 13-1 YAMAHA EXTENDED SERVICE (Y.E.S.). EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.

LOAD LIMIT 40 kg (88 lbs) 4GB-24877-A0 WARNING NEVER sit here. LOAD LIMIT WARNING 80 kg (176 lbs) 4SH-24877-A0 UNDER Operating this ATV if you are under the age of 16 increases your chance MAXIMUM. LOADING LIMIT MAXIMUM.

LOADING LIMIT of severe injury or death. ( 5 0 0 k g f ) PULLING LOAD: 4900 N NEVER operate this ATV if you are. EBU00924 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars.

A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. Never operate an ATV without wearing an approved 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 follow proper procedures for climbing hills as described in this manual.

Check the ter- rain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward.

Never open the throttle suddenly or make sudden gear changes. Always be careful when skidding or sliding. Learn to safely control skidding or sliding by prac- ticing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con- trol. WARNING When transporting the ATV in another vehicle, be sure it is kept upright and POTENTIAL HAZARD that the fuel cock is in the “OFF” posi- Improper handling of gasoline. Otherwise, fuel may leak out of the WHAT CAN HAPPEN carburetor or fuel tank. WARNING POTENTIAL HAZARD Starting or running the engine in a closed area.

WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation. EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Rear spring preload 13. Fuses adjusting ring 14. Tail/brake light 2.

Spark arrester 15. V-belt cooling duct check hose 3. Storage compartment 16. Coolant reservoir and tool kit 17. Oil filter cartridge 4. Spark plug 18.

This number can be used for ordering a new when ordering spare parts from a Yamaha key. Dealer or for reference in case the vehicle is stolen. Record the information on this la- bel in the space provided. This information will be needed to order spare parts from your Yamaha dealer.

Vehicle identification number NOTE: The vehicle identification number is used to 1. EBU00039 CONTROL FUNCTIONS WARNING Indicates a potential hazard that could result in serious injury or death. EBU00041 Main switch Functions of the respective switch positions are as follows: 1. Main switch Engine can be started only at this position and the headlight and taillight come on when the light switch is on. EBU00043 EBU00602 Indicator lights Reverse indicator light “R” This indicator light comes on when the trans- mission is in reverse. EBU00603 Neutral indicator light “N” This indicator light comes on when the trans- mission is in neutral.

Park indicator light “P” 2. EBU00713 EBU00605 Coolant temperature warning light “ ” Four-wheel-drive indicator light “ ” When the coolant temperature reaches a This indicator light comes on when the specified level, this light comes on to warn 2WD/4WD switch is in the 4WD position. That the coolant temperature is too hot. Coolant temperature Coolant temperature warning light comes on warning light does not momentarily.

Coolant temperature and electrical circuit are OK. Ask a Yamaha dealer to Go ahead with riding. Inspect the electrical circuit. EBU00052 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank.

When the needle reaches the red line, refill the tank at the first opportunity. Fuel gauge 2.

Red line 5.5 L (1.21 Imp gal, 1.45 US gal) NOTE: If the machine runs out of fuel, move the fuel cock lever to the “RES”. EBU00053 Handlebar switches CAUTION: Do not use the headlight with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it.

EBU00849 Engine stop switch “. EBU00607 Start switch “ ” The starter motor cranks the engine when this switch is pushed.

CAUTION: See starting instructions prior to starting the engine. (See page 6-1 for details.). WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving. WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD in some circumstances. Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause 1.

Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you 1. Throttle lever can’t find or solve the problem yourself.

EBU00066 Speed limiter WARNING The speed limiter keeps the throttle from fully POTENTIAL HAZARD opening, even when the throttle lever is Improper adjustment of the speed limit- pushed to the maximum. Screwing in the ad- er and throttle. Juster limits the maximum engine power avail- WHAT CAN HAPPEN able and decreases the maximum speed of The throttle cable could be damaged. EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to ap- ply the front brake. Rear brake pedal 1. Front brake lever EBU00073 Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever is located on the left handlebar.

EBU00608 EBU00666 Drive select lever Recoil starter The drive select lever is used to shift your ma- Firmly grasp the handle and pull slightly until chine into the low, high, neutral, reverse and engagement can be felt. Then pull forcefully, park positions. EBU00092 Fuel tank cap WARNING Remove the fuel tank cap by turning it coun- POTENTIAL HAZARD terclockwise. Starting the engine in gear or starting the engine without shifting into the park position.

WHAT CAN HAPPEN The ATV could start to move unexpect- edly, which could cause an accident. EBU00093 Fuel cock OFF Position The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. EBU00095 Starter (choke) “ ” RES Position Starting a cold engine requires a richer air-fuel mixture.

A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). EBU00566 Seat To install the seat, insert the projection on the To remove the seat, pull the seat lock lever front of the seat into the seat holder and push upward and pull up the seat at the rear. Down on the seat at the rear. NOTE: Make sure that the seat is securely fitted.

EBU00581 EBU00582 Storage box Front carrier Maximum load limit: 2 kg (4.4 lb) Maximum load limit: 40 kg (88 lb) CAUTION: EBU00583 To protect from damage, do not put metal Rear carrier products, like tools or sharply edged prod- Maximum load limit: 80 kg (176 lb) ucts directly in the storage box. EBU00635 Front shock absorber adjustment Standard position: 2 The spring preload can be adjusted to suit the 1 - Minimum (Soft) rider’s weight and riding conditions. 5 - Maximum (Hard) Adjust the spring preload as follows: To increase the spring preload, turn the ad- juster in direction a. WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set- ting. NOTE: To decrease the spring preload, turn the ad- A special wrench can be obtained at a juster in direction b.

Yamaha dealer. Spring preload adjuster a. Increase spring preload b. Decrease spring preload 1.

Special wrench. EBU00748 Auxiliary DC jack Maximum rated capacity for the The auxiliary DC jack is located at the front auxiliary DC jack: right side of the ATV.

The auxiliary DC jack DC 12 V, 120 W (10 A) can be used for suitable work lights, radios, etc. Auxiliary DC jack EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death. PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE. Check operation, free play, fluid level and fluid leakage. 5-2 5-3, Brakes. Fill with DOT 4 brake fluid if necessary. 8-36 8-44.

Check fuel level. 5-4 5-5 Fuel. If not, have the machine inspect- HOW TO AVOID THE HAZARD ed by a Yamaha dealer. Always inspect your ATV each time you use it to make sure the ATV is in safe op- Brake fluid level erating condition.

2001 Yamaha Kodiak 400 4x4 Service Manual

If there is any brakes. Leaking, have the machine inspected by a WHAT CAN HAPPEN Yamaha dealer. You could lose braking ability, which could lead to an accident. Brake operation HOW TO AVOID THE HAZARD. EBU00886 Fuel Your Yamaha engine has been designed to Make sure there is sufficient gasoline in the use regular unleaded gasoline with a pump tank. Octane number (R+M/2) of 86 or higher, or research octane number of 91 or higher. Fuel can spill, which can cause a fire hol containing methanol is not recommended and severe injury.

By Yamaha because it may cause fuel system Fuel expands when it heats up. If the damage or vehicle performance problems. Fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. EBU00914 Engine oil CAUTION: Make sure the engine oil is at the specified Be sure to use motor oils that do not con- level. Add oil as necessary. (See page 8-12.) tain anti-friction modifiers. Passenger car motor oils (often labeled “ENERGY Recommended oil: CONSERVING II”) contain anti-friction ad.

EBU00493 EBU00678 Final gear oil Differential gear oil Make sure the final gear oil is at the specified Make sure the differential gear oil is at the level. Add oil as necessary. (See pages 8-15 specified level. Add oil as necessary.

(See 8-17 for details.) pages 8-18 8-19 for details.) Recommended oil. Always check the tightness of chassis fittings WARNING and fasteners before a ride. Take the machine POTENTIAL HAZARD to a Yamaha dealer or refer to the Service Operating this ATV with improper tires, Manual for correct tightening torque. Or with improper or uneven tire pres- sure.

The tires should be set to the rec- 4. Use no more than the following ommended pressure: pressures when seating the tire Recommended tire pressure beads. Front 25 kPa (0.25 kgf/cm, 3.6 psi) Front 250 kPa (2.5 kgf/cm, 36 psi) Rear 25 kPa (0.25 kgf/cm, 3.6 psi). EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment.

Make two measure- ments of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.

EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. 3 mm (0.12 in) 5-11.

Turn the fuel cock to “ON”. There is a control or function you do not 3.

Turn the main switch to “ON” and the en- understand, ask your Yamaha dealer. Gine stop switch to “ ”. Shift the drive select lever into the neutral. 25 °C (80 °F) and warm engine tral or park position, if either indicator light start position. Does not come on, ask a Yamaha dealer to inspect its electric circuit. The engine can be started in any gear if the rear brake lever is applied.

However, it is recommended to shift into neutral or park before starting the engine. NOTE: CAUTION: If the engine fails to start, release the See the “Engine break-in” section prior to start switch, then push the start switch operating the engine for the first time. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery en- EBU00180 ergy. EBU00846 Drive select lever operation and reverse driving CAUTION: Before shifting, you must stop the ma- chine and return the throttle lever to the closed position. Otherwise, the transmis- sion may be damaged.

Shifting: Neutral to High and High to Low 1. If the light does not the drive select lever along the shift come on, ask a Yamaha dealer to inspect guide. The reverse indicator light electrical cir- cuit. Open the throttle lever gradually and con- tinue to watch to the rear while backing.

WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person be- hind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind. For this reason, we ask that you carefully read build up of heat. If any abnormality is noticed the following material. Because the engine is during this period, consult a Yamaha dealer.

Brand new, you must not put an excessive 1. 0 10 hours: load on it for the first several hours of running. EBU00612 2. 10 20 hours: Parking Avoid prolonged operation above 3/4 When parking, stop the engine and shift the throttle. Rev the machine freely but do drive select lever into the park position, then not use full throttle at any time.

Turn the fuel cock to the “OFF”. EBU00615 Parking on a slope 1. Bring the machine to a stop by applying the brakes. Stop the engine. POTENTIAL HAZARD 3. With the rear brake applied, shift the Parking on a hill or other incline.

Drive select lever to the park position. WHAT CAN HAPPEN The ATV could roll out of control, in- creasing the chance of an accident. Choose only accessories designed for your dlebars which could make steering difficult, ATV. Your Yamaha dealer has a variety of an accessory that limits your ability to move genuine Yamaha accessories.

EBU00960 Loading Do not exceed the maximum tongue Cargo or a trailer can change the stability and weight. You can measure tongue weight handling of an ATV. You must use common with a bathroom scale. Put the tongue of sense and good judgment when carrying car- the loaded trailer on the scale with the go or towing a trailer. Ride more slowly than you would without a WARNING load. The more weight you carry, the slow- POTENTIAL HAZARD er you should go.

Although conditions vary, Overloading this ATV or carrying or tow- it is good practice not to exceed low range ing cargo improperly. EBU00937 WARNING Indicates a potential hazard that could result in serious injury or death.

Riding Your. WARNING Indicates a potential hazard that could result in serious injury or death. Owner’s Manual completely and understand GETTING TO KNOW YOUR ATV the operation of the controls.

Pay particular at- This ATV is for recreation and utility use. This tention to the safety information on pages 2-1 section, Riding your ATV, provides general 2-6.

JUDGEMENT Beginning and inexperienced operators should complete the certified training Get training if you are inexperienced. Course offered by Yamaha. They should Beginners should get training from a certified then regularly practice the skills learned instructor. In the course and the operating tech- Become familiar with this ATV at slow speeds niques described in this Owner’s Manu. Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommenda- tions for this ATV.

WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended for their age can lead to se- vere injury or death of the child. This ATV is designed to carry operator and cargo only – passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV.

WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. Apparel Operating without protective clothing WARNING increases your chances of severe injury in the event of an accident. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an Always wear an approved motorcycle approved motorcycle helmet, eye pro- helmet that fits properly. Do not operate after consuming alcohol or WARNING drugs.

POTENTIAL HAZARD Operator’s performance capability is reduced Operating this ATV after consuming al- by the influence of alcohol or drugs. Cohol or drugs.

WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Pre-operation checks WARNING Always perform the pre-operation checks list- POTENTIAL HAZARD ed on page 5-1 before riding for safety and Operating this ATV with improper tires, proper care of the ATV. Or with improper or uneven tire pres- WARNING sure. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before oper.

Speed limiter WARNING For riders less experienced with this model, Indicates a potential hazard that could this model is equipped with a speed limiter in result in serious injury or death. The throttle lever housing. The speed limiter keeps the throttle from fully opening, even Do not operate at speeds too fast for your when the throttle lever is pushed to the maxi- skills or the conditions. Loading and accessories WARNING Use extra caution when riding the ATV with POTENTIAL HAZARD additional loads, such as accessories or car- Overloading this ATV or carrying or tow- go. The ATV’s handling may be adversely af- ing cargo improperly. Reduce your speed when adding WHAT CAN HAPPEN additional loads. During operation WARNING Always keep your feet on the footboards dur- POTENTIAL HAZARD ing operation.

Otherwise your feet may con- Removing hands from handlebars or tact the rear wheels. Feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re- duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. Avoid wheelies and jumping.

You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, in- cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Never modify this ATV through improp- er installation or use of accessories.

All parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized ATV dealer. Exhaust system Do not touch the hot exhaust system.

The exhaust system on the ATV is very hot Do not park the ATV in a place where during and following operation. To prevent others might be likely to touch it. Burns, avoid touching the exhaust system. BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only.

Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of con. Do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt.

Know the terrain where you ride. Ride cau- tiously in unfamiliar areas.

Stay alert for holes, rocks, or roots in the terrain, and oth- er hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an acci- dent, including an overturn.

HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills neces. When riding in an area where you might not WHAT CAN HAPPEN easily be seen, such as desert terrain, mount You could be in a collision. You could a caution flag on the ATV. DO NOT use the be injured. Flag pole bracket as a trailer hitch. Select a large, flat area off-road to become fa- With the engine idling, shift the drive select le- miliar with your ATV.

Make sure that this area ver into the low “L” or the high “H” position. Is free of obstacles and other riders. You Apply the throttle slowly and smoothly. TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for road, the two rear wheels are mounted solidly turning as described in this Owner’s on one axle and turn together at the same Manual. Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. CLIMBING UPHILL HOW TO AVOID THE HAZARD Use proper riding techniques to avoid vehicle Never operate the ATV on hills too steep overturns on hills.

Be sure that you can ma- for the ATV or for your abilities. Practice neuver your ATV well on flat ground before at- on smaller hills before attempting large tempting any incline and then practice riding hills. WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other POTENTIAL HAZARD side of the hill. Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Own- er’s Manual.

If you are climbing a hill and you find that you WARNING have not properly judged your ability to make POTENTIAL HAZARD it to the top, you should turn the ATV around Improperly crossing hills or turning on while you still have forward motion (provided hills. When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

If your ATV has stalled or stopped and you and rear brakes gradually, or dismount the believe you can continue up the hill, restart ATV immediately on the uphill side. Carefully to make sure you do not lift the front WARNING wheels which could cause you to lose control. If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. 4WD: Apply both front and rear brakes gradually. When fully stopped, shift into the parking position.

Dismount on uphill side or to a side if pointed straight uphill. RIDING DOWNHILL When this ATV is in 4WD, all wheels (front When riding your ATV downhill, shift your and rear) are interconnected by the drive weight as far to the rear and uphill side of the train. This means that applying either the front ATV as possible.

WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for go- ing down hills as described in this Own- er’s Manual. Note: a special technique is required when braking as you go down a hill.

CROSSING A SLOPE WARNING Traversing a sloping surface on your ATV re- POTENTIAL HAZARD quires you to properly position your weight to Improperly crossing hills or turning on maintain proper balance. Be sure that you hills. Have learned the basic riding skills on flat WHAT CAN HAPPEN ground before attempting to cross a sloping Could cause loss of control or cause the.

CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have re- The ATV can be used to cross slow moving, duced stopping ability. Test your brakes shallow water of up to a maximum of 35 cm after leaving water. If necessary, apply (14 inches) in depth. Test your brakes after leaving the water. Do CAUTION: not continue to ride your ATV without verifying After riding your ATV in water, be sure to that you have regained proper braking ability. Drain the trapped water by removing the check hose at the bottom of the air filter case and the check hose on the V-belt cooling duct. V-belt cooling duct check hose (Left front side of ATV) 1.

Drive select lever box check hose 1. V-belt cooling intake box check hose (Above V-belt cooling duct) 7-36. RIDING OVER ROUGH TERRAIN WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could Improperly operating over obstacles. Cause damage to the ATV or could lead to an WHAT CAN HAPPEN upset or accident. Be sure to keep your feet Could cause loss of control or a colli- firmly mounted on the footboards at all times.

SLIDING AND SKIDDING If the rear wheels of your ATV start to slide Care should be used when riding on loose or sideways, control can usually be regained (if slippery surfaces since the ATV may slide. If there is room to do so) by steering in the direc- unexpected and uncorrected, sliding could tion of the slide. With practice, over a period of time, skill at WARNING controlled sliding can be developed. The ter- POTENTIAL HAZARD rain should be chosen carefully before at- Skidding or sliding improperly.

Tempting such maneuvers, since both stability WHAT CAN HAPPEN and control are reduced. Bear in mind that You may lose control of this ATV. WHAT TO DO IF.

If your ATV starts to slide sideways: This section is designed to be a reference Steer in the direction of the slide if you have guide only. Be sure to read each section on the room. Applying the brakes or accelerat- riding techniques completely. If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to main- tain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. EBU00515 PERIODIC MAINTENANCE AND Have a Yamaha dealer perform service if ADJUSTMENT you are not familiar with machine ser- vice. Periodic inspection, adjustment and lubrica- tion will keep your machine in the safest and EBU00535 most efficient condition possible.

Safety is an Owner’s manual and tool kit. HOW TO AVOID THE HAZARD during a service operation requiring one, take Never modify this ATV through improp- your machine to a Yamaha dealer to check er installation or use of accessories. All the torque settings and adjust them as neces- parts and accessories added to this ve- sary.

EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY ITEM ROUTINE month months months months year. Check valve clearance. Valves. Adjust if necessary. Check coolant leakage. Cooling system.

Repair if necessary. Replace coolant every 24 months. Check condition. Spark plug.

Replace if damaged. Check all chassis fittings and fasteners. Fittings and Fasteners. Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer. NOTE:. Recommended brake fluid: DOT 4.

Brake fluid replacement: 1. EBU00614 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled. EBU00700 Panel A, D To remove 1. Remove the seat. Pull outward on the areas shown, and then pull upward.

To install 1. Place the panel in its original position.

Install the seat. EBU00616 Panel B To remove Remove the bolts.

To install Place the panel in the original position and in- stall the bolts. Bolt (× 2).

EBU00617 Panel C To remove 1. Remove the front carrier bolts and the front carrier. Remove the quick fasteners and pull up- ward.

Bolt (× 2) 1. Bolt (× 4) 1. Quick fastener (× 2). EBU00616 To install Panel E 1.

Place the panel in the original position To remove and install the quick fasteners. Remove the bolts. Install the front carrier and the bolts, then To install tighten to the specified torque. Place the panel in the original position and in- stall the bolts. EBU00638 Panel F To install To remove Place the panel in its original position. Pull outward on the areas shown.

Panel F 8-11. EBU00847 NOTE: Engine oil Wait a few minutes until the oil level settles Oil level inspection before checking. Remove panel F. (See page 8-11 for panel removal and installation proce- 5. The oil level should be between the max- dures.) imum and minimum marks. Engine oil and oil filter cartridge replace- 5.

Remove the oil filter by using an oil filter ment wrench. Remove panels E and F. (See pages 8-10 and 8-11 for panel removal and installa- tion procedures.) 2. Warm up the engine for several minutes. Apply a light coat of engine oil to the O-ring NOTE: An oil filter wrench is available at a nearby of the new oil filter.

Yamaha dealer. NOTE: Make sure the O-ring is seated properly. Install the drain bolt and tighten it to the specified torque.

Fill the engine with sufficient oil to reach 10. Start the engine and warm it up for seve- the specified level. Install the dipstick and ral minutes. While warming up, check for tighten it.

If oil leakage is found, stop the engine immediately and check for the Recommended oil: cause. Final gear oil replacement 1. Remove the final gear case cover. Final gear oil 2. Final gear case filler bolt 3. Proper level 1. Final gear case cover 2.

Bolt (× 2) CAUTION: 2. Place the machine on a level place. Be sure no foreign material enters the final 3.

Recommended oil: See page 10-3. Oil quantity: Periodic oil change: 0.19 L (0.17 Imp qt, 0.2 US qt) Total amount: 0.22 L (0.19 Imp qt, 0.23 US qt) CAUTION: 1. Final gear case drain bolt Be sure no foreign material enters the final 5.

EBU00706 Differential gear oil 3. Install the oil filler bolt and tighten it to the Differential gear oil measurement specified torque. Place the machine on a level place. Tightening torque: 2. Remove the oil filler bolt and check the oil Oil filler bolt: level.

Install the drain bolt and tighten it to the CAUTION: specified torque. Be sure no foreign material enters the dif- ferential gear case. Tightening torque: Drain bolt: 6.

Install the filler bolt and tighten it to the 10 Nm (1.0 mkgf, 7 ftlb) specified torque. EBU00771 Cooling system 3. Remove the coolant reservoir cap, and 1. Check the coolant level in the coolant then add coolant or distilled water to raise reservoir when the engine is cold as the it to the specified level.

Coolant level will vary with engine tem- 4. Removing the radiator cap when the en- gine and radiator are still hot. NOTE: WHAT CAN HAPPEN If water is added, have a Yamaha dealer You could be burned by hot fluid and check the antifreeze content of the cool- steam blown out under pressure. Place the ATV on a level surface. Remove panels E and F. (See page 8-10 and 8-11 for panel removal and installa- tion procedures.) 3. Place a container under the engine, and then remove the coolant drain bolt.

(Use a trough or a similar object as shown to prevent coolant from spilling on the foot- rest.). 1. Radiator cap 1. Coolant reservoir drain hose 5. Remove the radiator cap. After draining the coolant, thoroughly 6.

Remove the coolant reservoir cap. Flush the cooling system with clean tap 7. Disconnect the hose on the coolant res- water. Total amount: NOTE: 1.1 L (0.97 Imp qt, 1.14 US qt) If any leakage is found, have a Yamaha deal- Coolant reservoir capacity er check the cooling system. (up to the maximum level mark): 0.25 L (0.22 Imp qt, 0.26 US qt) 16. Check the protective boots for holes or tears.

If any damage is found, have them replaced 1. Remove the spark plug cap. By a Yamaha dealer. Spark plug cap 2.

Use the spark plug wrench in the tool kit 1. ATV that is being ridden normally. Do not attempt to diagnose such problems yourself.

Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and de. NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. EBU00288 Air filter cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. Clip (× 4) 2.

WARNING POTENTIAL HAZARD Using low flash point solvents or gaso- line to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the 1. Apply Yamaha foam air filter oil or other NOTE: The air filter element should be cleaned every quality foam air filter oil to the element. If 20 40 hours. It should be cleaned and lubri- foam air filter oil is not available, motor oil may be used.

EBU00641 V-belt cooling duct check hose If dust or water collects in this hose, remove the hose and clean it. V-belt cooling intake box check hose (Above V-belt cooling duct) 1. V-belt cooling duct check hose (Left front side of ATV) 8-31. EBU00522 Spark arrester cleaning Select a well-ventilated area free of combusti- ble materials and make sure the exhaust and muffler are cool. Remove the bolt.

Remove the tailpipe by pulling it out of the muffler. Spark arrester 4. The carburetor is a vital part of the engine and POTENTIAL HAZARD requires very sophisticated adjustment.

Most Improperly purging the exhaust system adjusting should be left to a Yamaha dealer Hot exhaust system who has the professional knowledge and ex- WHAT CAN HAPPEN perience to do so. To prevent this, the valve clear- crease engine speed. Ance must be adjusted regularly. This adjust- ment however, should be left to a professional Specified idle speed: Yamaha service technician. 1,450 1,550 r/min 8-34. EBU00307 Throttle lever adjustment NOTE: Adjust the engine idling speed before adjust- ing the throttle lever free play. Loosen the locknut.

Turn the adjusting bolt until the throttle le- ver free play is 3 5 mm (0.12 0.20 in). Front brake pad inspection Inspect the brake pads for damage and wear. If the thickness is less than the specified val- ue, have a Yamaha dealer replace the pads. Wear limit: 1 mm (0.04 in) NOTE: The wheels need to be removed to inspect the brake pads. Inspect the grooves.

If they have al- EBU00622 most disappeared, ask a Yamaha dealer to Inspecting the brake fluid level replace the pad. Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Observe these precautions: FRONT 1.

When checking the fluid level, make sure the top of the master cylinder reservoir is level by turning the handlebars. Use only the designated quality brake flu- id.

Otherwise, the rubber seals may dete- riorate, causing leakage and poor brake performance. The front brake lever should have a free play spilled fluid immediately.

Of zero mm (zero in) at the lever end. Have a Yamaha dealer check the cause ask a Yamaha dealer to adjust it. If the brake fluid level goes down. Make sure the brakes do not drag. Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components re- quires professional knowledge.

These procedures should be performed by a Yamaha dealer. The top of the brake pedal should be posi- tioned 54 mm (2.13 in ) above the top of the footrest. If not, ask a Yamaha dealer to adjust 1. Adjusting bolt c. Free play: 0.5 2 mm (0.02 0.08 in) 2. Make sure the brakes do not drag. All air must be bled from the brake system.

Replacement of brake components re- quires professional knowledge. These procedures should be performed by a Yamaha dealer. Rear brake light switch 2. Adjusting nut 8-42. Inspect cables frequently. Replace dam- aged cables. Lubricate the inner cables and the cable ends.

If the cables do not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-43. EBU00373 Wheel removal 1. Elevate the wheel by placing a suitable stand under the frame. Remove the nuts from the wheel. Remove the wheel assembly.

Tapered nut (× 4) 8-44. EBU00828 Wheel installation 1. Tapered wheel nuts are used for both When installing a wheel, reverse the removal front and rear wheels. Install the nut with procedure. Its tapered side towards the wheel. NOTE: The arrow mark on the tire must point to- ward the rotating direction of the wheel. Keep out of reach of chil- tery.

If the battery seems to have discharged, dren. Consult a Yamaha dealer.

Antidote: EXTERNAL: Flush with water. CAUTION: INTERNAL: Drink large quantities of wa- Do not try to remove the sealing caps of ter or milk. Then turn on the switches.

If CAUTION: the fuse immediately blows again, con- A special battery charger (constant volt- sult a Yamaha dealer. Age/ampere or constant voltage) is re- quired recharging sealed-type battery. Spare fuse 1. Headlight fuse 2. Ignition fuse 3.

Auxiliary DC jack fuse 4. Four-wheel drive fuse 5. Signaling system fuse 6. Spare fuse (× 3) Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Four-wheel drive fuse: 1.

EBU00632 Replacing the headlight bulb WARNING If the headlight bulb burns out, replace it as POTENTIAL HAZARD follows: Using an improper fuse. Remove the cover at the rear of the WHAT CAN HAPPEN headlight. An improper fuse can cause damage to the electrical system which could lead to a fire. WARNING POTENTIAL HAZARD The headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flamma- ble. HOW TO AVOID THE HAZARD 1. Headlight beam adjustment Tail/brake light bulb replacement 1.

Remove the nuts together with the wash- CAUTION: ers. It is advisable to have a Yamaha dealer make this adjustment. Vertical adjustment: To raise the beam, turn the adjusting screw clockwise. Tail/brake light unit 2. Bulb holder 1.

Bulb holder 2. Remove the defective bulb from the bulb 4. Install a new bulb in the bulb holder by holder by pushing it inward and turning it pushing it inward and turning it clockwise. EBU00412 Troubleshooting WARNING Although Yamaha machines receive a rigid in- POTENTIAL HAZARD spection before shipment from the factory, Checking the fuel system while smok- trouble may occur during operation.

Any prob- ing or near an open flame. Lem in the fuel, compression, or ignition sys.

Compression There is compression. Compression normal. Use the electric starter to see if there is compression. Ask a Yamaha dealer to No compression. Ignition Wipe clean with dry cloth. Ignition system is Spark is good. Restart the engine.

If the engine overheats again, ask a Level is OK. Yamaha dealer to inspect and/or repair the cooling system. NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible. EBU00419 CLEANING AND STORAGE CAUTION: Excessive water pressure may cause wa- A.

CLEANING ter seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend bills have resulted from improper high the useful life of many components. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after wash- 7. Automotive type wax may be applied to ing. All painted and chrome plated surfaces.

WHAT CAN HAPPEN Avoid combination cleaner-waxes. Do not apply oil to fuel) any rubber parts or the seat cover. NOTE: Use of fuel stabilizer and conditioner elimi- nates the need to drain the fuel system. Con- sult a Yamaha dealer if the fuel system needs to be drained instead.

Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an ex- cessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine. EBU00428 SPECIFICATIONS Model YFM400FAP Dimensions: Overall length 1,965 mm (77.36 in) Overall width 1,070 mm (42.13 in) Overall height 1,120 mm (44.09 in) Seat height 820 mm (32.28 in) Wheelbase 1,225 mm (48.23 in) Minimum ground clearance 245 mm (9.65 in) Minimum turning radius 3,000 mm (118.11 in) Basic weight. Model YFM400FAP Engine oil: Type Recommended engine oil classification: 0˚ 10˚ 30˚ 70˚ 90˚ 110˚ 130˚F 50˚ YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20˚ -10˚ 0˚ 20˚ 30˚ 40˚ 50˚C 10˚ API Service SE, SF, SG type or higher CAUTION: Be sure to use motor oils that do not contain anti- friction modifiers.

Model YFM400FAP Final gear case oil: Type SAE80 API “GL-4” Hypoid gear oil Quantity: Periodic oil change 0.19 L (0.17 Imp qt, 0.2 US qt) Total amount 0.22 L (0.19 Imp qt, 0.23 US qt) Differential gear case oil: Type SAE80 API “GL-4”. Model YFM400FAP Spark plug: Type/manufacturer DR8EA / NGK Spark plug gap 0.6 0.7 mm (0.02 0.03 in) Clutch type Wet, centrifugal automatic Transmission: Primary reduction system V-belt Secondary reduction system Spur gear 39/24 × 24/18 × 33/9 (7.944) Secondary reduction ratio Transmission type V-belt automatic. Model YFM400FAP Brake: Front brake type Dual disc brake operation Right hand operation Rear brake type Single disc brake operation Left hand and right foot operation Suspension: Front suspension Double wishbone Rear suspension Swingarm (monocross) Shock absorber: Front shock absorber Coil spring / oil damper Rear shock absorber Coil spring / oil damper. Model YFM400FAP Bulb voltage, wattage × quantity: 12 V, 30 W/30 W × 2 Headlight 12 V, 5/21 W × 1 Tail/brake light 12 V, 1.7 W × 1 Neutral indicator light 12 V, 1.7 W × 1 Reverse indicator light 12 V, 1.7 W ×. EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. EBU00431 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work is required.

It is not acceptable proof of maintenance work. EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1. EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1.

EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD.

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001. 5 - 6.5 × 2 CR.