Instruction/ maintenance manual of the product 5GW-F8199-13 Yamaha
Go to page of 170
5GW-F8199-13 LIT-11626-16-12 READ THIS MANUAL CAREFULLY! It contains important safety information. This ATV should not be ridden by anyone under 16 years of age. WARNING YFM400R OWNER’S MANUAL PRINTED IN USA 2002.09-0.9 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO .
EBU00776.
EBU00941 1- INTRODUCTION Congratulations on your purchase of the Yamaha YFM400. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing ATVs.
EBU00801 1- IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINE D IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this man.
AFFIX DEALER LABEL HERE EBU00011 IMPORTANT NOTICE This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.
EBU00014 W ARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS LOCATION OF THE WAR NING AND SPECIFICATION LABELS ....... 1-1 SAFETY INFORMATION.................. 2-1 DESCRIPTION AND MA CHINE IDENTIFICATION ......
Rear shock absorber adjustment................................... 4-18 Auxiliary DC jack ........................... 4-19 PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ......... ............ 5-3 Fuel ......................................
Crossing through shallow water ..................... ....................... 7-34 Riding over rough terrain ............... 7-36 Sliding and skidding ...................... 7-38 What to do if ......................... ......... 7-40 What to do .......
CLEANING AND STORAGE ............ 9-1 A. Cleaning............ .......................... 9-1 B. Storage ........................... ............ 9-3 SPECIFICATIONS.. ........................ 10-1 NOISE REGULATION .................... 11-1 MAINTENANCE RECORD .
1-1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5GW13.book Page 1 Tuesd ay, July 30, 2002 2:23 PM.
1-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 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.
1-3 4 5 6 Overloading this A TV or carrying cargo improperly can change handling. stability and braking performance and can lead to an accident. Never e xceed the maximum rear cargo limit of : 80kg (176 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual.
1-4 78 PULLING LOAD: 4020 N ( 410kgf ) 904 l b f T ONGUE WEIGHT: 147 N ( 15kgf ) 3 3 lbf 5FU-F151K-00 MAXIMUM . LO ADING LIMIT MAXIMUM LO ADING LIMIT U5GW13.
2-1 SAFETY INFORMATION EBU00924 AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE . An ATV handles differently from other vehicles including motorcycles and cars. A collisi on 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.
2-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ● Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park- ing lots and streets. ● Never operate an ATV on any public street, road or highway, even a dirt or gravel one. ● Never operate an ATV without wearing an approved motorcycle helmet that fits properly.
2-3 ● Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. ● Never operate the ATV on hills too steep for the ATV or for your abilities.
2-4 ● Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall- ing, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll back- wards, follow the special procedure for braking described in this manual.
2-5 ● Always use the size and type tires specified in this manual. ● Always maintain proper tire pressure as described in this manual. ● Never modify an ATV through improper installation or use of accessories. ● Never exceed the stated load capacity for an ATV.
2-6 WA R N I N G POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refuel- ing. Do not refuel right after the engine has been running and is still very hot.
2-7 WA R N I N G 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.
3-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Rear carrier 2. Seat 3. Auxiliary DC ja ck 4. Front carrier 5. Brake pedal 6. Headlight 7. Fuel cock 8. Recoil sta rter 9. Tail/brake light 10. Rear wheel 11. Shift pedal 12.
3-2 EBU00600 Identification number records Record the key identification number, vehicle identification number and model label infor- mation in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.
3-3 EBU00036 Vehicle identification number The vehicle identification number is stamped into the frame. 1. Vehicle identification number N O TE: The vehicle identification number is used to identify your machine. EBU0078 7 Model label The model label is affixed to the location in the illustration.
4-1 EBU00039 CONTROL FUNCTIONS W ARNING Indicates a potential hazard that could result in serious injury or death. EBU00942 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on.
4-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00802 Indicator and warning lights 1. Reverse indicator light “ REV ERSE ” 2. Neutral indicator light “ NEUTRAL ” 3. Oil temp erature warn ing light “ OIL TEMP ” EBU00044 Reverse indicator light “ REVERSE ” This indicator light comes on when the trans- mission is in reverse.
4-3 EBU00733 Oil temperature warning light checking method ACB-10E Turn the main switch to “ ON ” and the engine stop switch to “” . Oil temperatur e warning light does not come on. Oil temperatur e warning light comes on. Check engin e oil temperat ure.
4-4 EBU00051 Speedometer The speedometer shows riding speed. This speedometer is equipped with an odometer and trip odometer. The trip odometer can be reset to “ 0 ” with the reset knob. Use the trip odometer to estimate how far you can ride on a tank of fuel before going to reserve.
4-5 EBU00053 Handlebar switches 1. Lights switch “ // O F F ” 2. Engine stop swit ch “” / “” 3. Start switch “” EBU01205 Engine stop switch “ / ” Make sure that the engine stop switch is set to “” before starting the engine.
4-6 EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.
4-7 EBU01159 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the ad- justing screw limits the maximum engine pow- er available and decreases the maximum speed of the ATV.
4-8 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. 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.
4-9 EBU00074 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to re- lease the parking brake.
4-10 EBU00084 Shift pedal This machine is equipped with a constant- mesh 5-speed forward and 1-speed reverse transmission. The shift pedal is located on the left side of the engine. Reverse is at the bot- tom position. Neutral is one position above re- verse.
4-11 EBU00590 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out. 1. Recoil starter WA R N I N G POTENTIAL HAZARD Starting the engine in gear and/or start- ing the engine without setting the park- ing brake.
4-12 EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun- terclockwise. 1. Fuel tank cap U5GW13.book Page 12 Tu esday, July 30, 2002 2 :23 PM.
4-13 EBU00093 Fuel cock 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.
4-14 EBU00095 Starter (choke) “” 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). Refer to “ Starting a cold engine ” fo r proper op- eration.
4-15 EBU00567 Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. 1. Seat lock leve r To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear.
4-16 EBU00581 Storage box CAUTION: To protect from damage, do not put metal products, like tools or sharply edged prod- ucts directly in the storage box. If they must be stored, wrap them in appropriate cushion material. EBU0058 2 Front carrier EBU0058 3 Rear carrier Maximum load limit: 2 kg (4.
4-17 EBU01104 Front shock absorber adjustment The spring preload can be adjusted to suit the rider ’ s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the ad- justing ring in direction a . To decrease the spring preload, turn the ad- justing ring in direction b .
4-18 EBU01103 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider ’ s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the ad- justing ring in direction a . To decrease the spring preload, turn the ad- justing ring in direction b .
4-19 EBU01002 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1. Set the light switch to “ OFF ” .
4-20 CAUTION: _ ● Do not use accessories requiring more than the above maximum capac- ity. This may overload the circuit and cause the fuse to blow. ● If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may be- come difficult.
5-1 PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Front brake • Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. 5-3 – 5-4, 8-21 – 8-28 Rear brake • Check operation, lever/peda l free play and pedal height.
5-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 WA R N I N G POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV.
5-3 EBU01252 Front and rear brakes Brake levers and brake pedal Check for correct free play in the front brake lever. If the free play is incorrect, have a Yamaha dealer adjust it. Check for correct free play in the rear brake lever and brake pedal. If the free play is incor- rect, adjust it.
5-4 WA R N I N G POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes.
5-5 EBU01085 Fuel Make sure there is sufficient gasoline in the tank. CAUTION: _ Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.
5-6 Gasohol There are two types of gasohol; gasohol con- taining ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gaso- hol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems.
5-7 EBU01084 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-5 – 8-9.) CAUTION: _ ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
5-8 EBU00493 Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-9 – 8-11 for details.) If desired, an SAE 80W90 hypoid gear oil may be used for all conditions. N O TE: GL-4 is a quality and additive rating, GL-5 or GL-6 rated hypoid gear oils may also be used.
5-9 EBU01003 Lights Check the headlights and tail/brake light to make sure they are in working condition. Re- pair as necessary for proper operation. EBU01170 Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation.
5-10 2. The tires should be set to the recom- mended pressure: ● Recommended tire pressure Front 25 kPa (0.25 kgf/cm 2 , 3.6 psi) Rear 25 kPa (0.25 kgf/cm 2 , 3.6 psi) ● Check and adjust tire pressures when the tires are cold. ● Tire pressures must be equal on both sides.
5-11 EBU00159 How to measure tire pressure Use the low-pressure tire gauge. N O TE: The low-pressure tire gauge is included as standard equipment. Make two measure- ments of the tire pressure and use th e second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.
5-12 EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. 3 mm (0.12 in) U5GW13.book Page 12 Tu esday, July 30, 2002 2 :23 PM.
6-1 EBU00161 OPERATION W ARNING Indicates a potential hazard that could result in serious injury or death. EBU00749 Starting a cold engine 1. Set the parking brake. 2. Turn the fuel cock to “ ON ” . 3. Turn the main switch to “ ON ” and the en- gine stop switch to “” .
6-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 NO TE: ● When the transmission is in neutral, the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. ● The engine can be started in any gear if the rear brake lever is applied.
6-3 NO TE: _ ● 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 en- ergy. Do not crank the engine more than 10 seconds on each attempt.
6-4 EBU00195 Reverse knob operation and reverse driving CAUTION: Before shifting, stop the machine and re- turn the throttle lever to its closed posi- tion. Otherwise the transmission may be damaged. 1. Bring the machine to a complete stop and return the throttle lever to the closed position with the transmission in neutral.
6-5 EBU01295 Shifting This model has a 5-speed forward and 1-speed reverse transmission with centrifugal automatic clutch. The transmission allows you to control the amount of power you have avail- able at a given speed or for starting, acceler- ating, climbing hills, etc.
6-6 4. Once the machine has attained adequate speed, release the throttle lever. 5. Shift into second gear and release the shift pedal. 6. Open the throttle gradually.
6-7 EBU00209 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running.
6-8 2. 10 – 20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throttle at any time. 3. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally. EBU0021 1 Parking When parking, stop the engine and shift into neutral.
6-9 EBU01296 Parking on a slope 1. Bring the ATV to a stop by applying the brakes in low gear. 2. Stop the engine. 3. With the rear brake lever and pedal ap- plied, apply the parking brake and slowly release the brake pedal. WA R N I N G POTENTIAL HAZARD Parking on a hill or other incline.
6-10 EBU00221 Accessories and loading EBU00222 Accessories Accessories can affect the handling and con- trol of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV.
6-11 EBU00588 Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judg- ment when carrying cargo or towing a trailer. Keep the following points in mind: ● Never exceed the weight limits shown.
6-12 ● Ride more slowly than you would without a load. The more weight you carry, the slow- er you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trailer. ● Allow more braking distance.
6-13 EBU01297 W ARNING _ Indicates a potential hazard that could result in serious injury or death. U5GW13.book Page 13 Tu esday, July 30, 2002 2 :23 PM.
7-1 7 Riding Your ATV U5GW13.book Page 1 Tuesd ay, July 30, 2002 2:23 PM.
7-2 U5GW13.book Page 2 Tuesd ay, July 30, 2002 2:23 PM.
7-3 W ARNING _ Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is mainly for utility use, but may also be used for recreation. This section, Riding your ATV, provides general ATV riding in- structions for recreational riding.
7-4 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator.
7-5 Not recommended for children under 16 years of age. WA R N I N G 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.
7-6 This ATV is designed to carry operator and cargo only - passengers prohibited. WA R N I N G 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.
7-7 Apparel WA R N I N G POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye pro- tection and protective clothing. WHAT CAN HAPPEN Operating without an approved motor- cycle helmet increa s- es your chances of a severe head injury or death in the even t of an accident.
7-8 Do not operate after consuming alcohol or drugs. Operator ’ s performance capability is reduced by the influence of alcohol or drugs. WA R N I N G POTENTIAL HAZARD Operating this ATV after consuming al- cohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment.
7-9 Pre-operation checks Always perform the pre-operation checks list- ed on page 5-1 before riding for safety and proper care of the ATV. WA R N I N G POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV.
7-10 W ARNING _ Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing.
7-11 Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or car- go. The ATV ’ s handling may be adversely af- fected.
7-12 During operation Always keep your feet on the footboards dur- ing operation. Otherwise your feet may con- tact the rear wheels. WA R N I N G POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation.
7-13 Avoid wheelies and jumping. You may lose control of the ATV or overturn. WA R N I N G 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.
7-14 Modifications WA R N I N G POTENTIAL HAZARD Operating this ATV with improper modi- fications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident.
7-15 Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. WA R N I N G POTENTIAL HAZARD Hot exhaust system.
7-16 BE CAREFUL WHERE YOU RID E This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WA R N I N G POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only.
7-17 Do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles. WA R N I N G POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle.
7-18 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. WA R N I N G POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
7-19 WA R N I N G 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.
7-20 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. Do not ride in areas posted “ no trespassing ” . Do not ride on private property without getting permission.
7-21 Select a large, flat area off-road to become fa- miliar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.
7-22 CAUTION: _ Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. _ When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear.
7-23 TURNING YOUR ATV To achieve maximum traction while riding off- road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the in- side of the turn is allowed to slip or lose some traction, the ATV will resist turning.
7-24 This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesn ’ t turn, come to a stop and then practice the procedure again.
7-25 CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can ma- neuver your ATV well on flat ground before at- tempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill.
7-26 WA R N I N G POTENTIAL HAZARD 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.
7-27 If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. WA R N I N G POTENTIAL HAZARD Improperly crossing hills or turning on hills.
7-28 If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dis- mount the ATV on the uphill side.
7-29 Dismount on uphill si de or to a side if pointed straight uphill. Turn the ATV around and remount, following the pro- cedure described in the Owner ’ s Manu- al.
7-30 RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you.
7-31 U5GW13.book Page 31 Tu esday, July 30, 2002 2 :23 PM.
7-32 CROSSING A SLOPE Traversing a sloping surface on your ATV re- quires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface.
7-33 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.
7-34 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
7-35 Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case.
7-36 RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times.
7-37 U5GW13.book Page 37 Tu esday, July 30, 2002 2 :23 PM.
7-38 SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, position- ing your weight over the front wheels will sometimes help.
7-39 With practice, over a period of time, skill at controlled sliding can be developed. The ter- rain should be chosen carefully before at- tempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost.
7-40 WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. WHAT TO DO ... ● If your ATV doesn ’ t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again.
7-41 ● 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.
8-1 EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment and lubrica- tion will keep your machine in the sa fest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, ad- justment and lubrication are explained on the following pages.
8-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1. Owner ’ s tool kit 2. Low-pressure tire gauge The service information included in this man- ual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor re- pairs.
8-3 EBU00261 PERIODIC MAINTENANCE/LUB RICATION ITEM ROUTINE INITIAL EVERY 1 month 3 months 6 months 6 months 1 year Valves* • Check valve clearance. • Adjust if ne cessary. Spark plug • Check condition. • Adjust gap and clean. • Replace if necessary.
8-4 * Items marked with an asterisk should be perform ed by a Yamaha dealer as they require special tools, data and tech nical skills . Reverse release cabl e* • Che ck operation. • Adjust if necessary. Wheels* • Check balance/damage/ru n out. • Replace if necessary.
8-5 EBU01181 Engine oil Engine oil level measurement 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes, and then stop it. 3. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. In- sert the dipstick in the filler hole without screwing it in.
8-6 6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. 1. Dipstick 2. Maximum level mark 3. Minimum level mark Engine oil replacement and oil filter ele- ment cleaning 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes and stop it.
8-7 1. Engine oil drain bolt 2. O-ring 3. Compression spring 4. Engine oil strainer 5. Remove the oil filter cover by removing the bolts and then remove the oil filter element. 1. Engine oil filter cover 2. Engine oil filter cover bolt ( × 3) 6. Clean the oil strainer and oil filter element with solvent.
8-8 1. O-ring 2. Engine oil filter element 11. Add the specified amount of the recom- mended engine oil, and then install the engine oil filler cap. CAUTION: _ ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
8-9 12. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 13. Turn the engine off, and then check the oil level and correct it if necessary.
8-10 1. Final gear oil 2. Correct oil level 3. Final gear oil filler bolt Final gear oil replacement 1. Remove the final gear case cover by re- moving the bolts.
8-11 2. Place the machine on a level surface. 3. Place a container under the final gear case to collect the used oil. 4. Remove the oil filler bolt and the drain bolt to drain the oil. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque.
8-12 EBU01182 Spark plug inspection The spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder.
8-13 EBU01301 Air filter element cleaning NO TE: _ 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. _ 1. Check hose 1. Remove the seat.
8-14 4. Remove the foam cover from the air filter element. 1. Air filter element 2. Foam cover 5. Tap the element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown. If the air filter element is damaged, replace it.
8-15 7. Squeeze the excess water or solvent out of the foam cover and let it dry. CAUTION: _ ● Do not twist the foam cover when squeezing it. ● Do not apply oil to the foam cover. _ 8. Inspect the foam cover. If damaged, re- place it. 9. Install the foam cover onto the air filter el- ement.
8-16 CAUTION: _ Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, op- eration without the air filter element will af- fect carburetor jetting with subsequent poor performance and possible engine overheating.
8-17 EBU00754 Spark arrester cleaning Select a well-ventilated area free of combusti- ble materials and make sure the exhaust pipe and muffler are cool.
8-18 EBU0029 6 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and ex- perience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine.
8-19 EBU01302 Idle speed adjustment NO TE: _ A diagnostic tachometer must be used for this procedure. _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle.
8-20 EBU00303 Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clear- ance must be adjusted regularly. This adjust- ment however, should be left to a professional Yamaha service technician.
8-21 EBU01303 Front brake pad check Inspect the brake pads for damage and wear. If the brake pad thickness is less than 1 mm (0.04 in), have a Yamaha dealer replace the pads. a. Brake pad thickness EBU00313 Rear brake shoe inspection A wear indicator is provided on the rear brake.
8-22 EBU01304 Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary.
8-23 ● Brake fluid may deteriorate painted surfac- es or plastic parts. Always clean up spilled fluid immediately. ● Have a Yamaha dealer check the cause if the brake fluid level goes down. EBU01186 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel.
8-24 EBU01189 Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer adjust it. a. Front brake lever free play WA R N I N G POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes.
8-25 EBU01305 Rear brake pedal and lever adjustment Brake pedal free play adjustment 1. Fully loosen the adjusting nut on the brake cable. 1. Adjusting nut (brake cable) 2. Adjusting nut (brake rod) 2. Turn the adjusting nut on the brake rod until the free play is 20 – 30 mm (0.
8-26 Brake lever free play adjustment 1. Loosen the locknut and fully turn in the adjusting bolt at the brake lever. 1. Locknut 2. Adjusting bolt 2. Turn in the adjusting nut on brake cable to provide a gap of 0 – 1 mm (0 – 0.04 in) between the lever and the pin.
8-27 3. Turn the adjusting bolt until the free play at the brake lever pivot is 5 – 7 mm (0.20 – 0.28 in). 1. Locknut 2. Adjusting bolt a. Rear brake lever free play 4. Tighten the locknut. WA R N I N G POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes.
8-28 EBU00834 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and brake levers, is prop- erly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows.
8-29 3. Tighten the locknut to specification. N O TE: Turn the adjusting bolt counterclockwise to decrease the clutch free play and turn it clock- wise to increase the free play. EBU00356 Cable inspection and lubrication Tightening torque: 15 Nm (1.5 m · kgf, 11 ft · lbf) WA R N I N G POTENTIAL HAZARD Damaged control cables.
8-30 Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. EBU00727 Brake and shift pedal/brake lever lubrication Lubricate the pivoting parts of each lever and pedal. EBU0111 2 Wheel removal 1.
8-31 EBU01121 Wheel installation 1. Install the wheel and the nuts. NO TE: _ ● Tapered nuts are used for both the front and rear wheels. Install the nut with its ta- pered side towards the wheel. ● The arrow mark on the tire must point toward the rotating direction of the wheel.
8-32 EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the bat- tery. If the battery seems to have discharged, consult a Yamaha dealer. CAUTION: Do not try to remove the sealing caps of the battery cells.
8-33 EBU00385 Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. CAUTION: A special battery charger (constant volt- age/ampere or constant voltage) is re- quired for recharging a sealed-type battery.
8-34 1. Main fuse 2. Spare main fuse 1. Headlight fuse 2. Ignition fuse 3. Auxiliary DC jack fuse 4. Carburetor warmer fuse 5. Spare fuse ( × 2) CAUTION: _ To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse.
8-35 EBU01306 Replacing a headlight bulb If a headlight bulb burns out, replace the bulb as follows. 1. Remove the headlight assembly by re- moving the screws. 2. Disconnect the headlight coupler. 3. Remove the headlight unit from the headlight assembly by removing the screw.
8-36 6. Put a new headlight bulb into position, and then secure it in place with the bulb holder. 7. Install the headlight bulb holder cover. CAUTION: _ Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated against the reflector.
8-37 EBU01089 Headlight beam adjustment CAUTION: _ It is advisable to have a Ya maha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction a . To lower the beam, turn the adjusting screw in direction b . 1. Adjusting screw ( × 2) EBU00945 Tail/brake light bulb replacement 1.
8-38 1. Tail/brake light bulb holder 4. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 1. Tail/brake light bulb holder 2. Bulb 5. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise.
8-39 EBU00412 Troubleshooting Although Yamaha machines receive a rigid in- spection before shipment from the factory, trouble may occur during operation. Any prob- lem in the fuel, compression, or ignition sys- tems can cause poor starting and loss of power.
8-40 EBU00440 Troubleshooting chart 1. Fuel Check if there is fuel in the fuel tank. There is fuel. Turn the fuel cock to “OFF”. Remove the fuel pipe. Fuel cock clogged. Clean fuel cock. Some fuel. Turn the fuel cock to “RES”. Restart engine. No fuel.
9-1 EBU00419 CLEANING AND STORAGE A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water entry.
9-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish.
9-3 EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive proce- dures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1.
9-4 7. 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)). N O TE: Make any necessary repairs before storing the machine.
10-1 EBU00428 SPECIFICATIONS MODEL YFM400 Dimension: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turning radius 2,007 mm ( 79.0 i n) 1,125 mm ( 44.3 i n) 1,172 mm ( 46.1 i n) 855 mm ( 33.7 in) 1,230 mm ( 48.
10-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Engine oil: Type Recommended e ngine oil clas sification API Service SE, SF, SG o r higher Quantity: Periodic oil change With oil fi lter replacement Total amount 2.9 L (2.6 Imp qt, 3.1 US qt) 3.0 L (2.6 Imp qt, 3.
10-3 Final gear oil: Type Quanti ty P eri odic oil change T otal amou nt SAE 80 API “ GL-4 ” Hypoid gear oil 0.23 L (0 .20 lmp qt, 0. 24 US qt) 0.25 L (0 .22 lmp qt, 0. 26 US qt) Air filter: Dry element Fuel: Type Tank capacity Reserve amount UNLEADED GASOLINE ONLY 15 L (3.
10-4 Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction rati o Transmission type Operation Gear raito: 1st 2nd 3rd 4th 5th Reverse Spur gear 76/24 (3.166) Shaft drive 28/24 × 24/18 × 33/09 (5.
10-5 Suspension: Front Rear Double wishbone Swingarm (monocross) Shock absorber: Front Rear Coil spring/oil damper Coil spring/oil damper Wheel travel: Front wheel travel Rear wheel travel 150 mm (5.91 in) 150 mm (5.91 in) Electrical: Ignition system Generator system Battery type/voltage capacity DC.
10-6 Fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse 30 A 15 A 10 A 10 A 10 A MODEL YFM400 U5GW13.book Page 6 Tuesd ay, July 30, 2002 2:23 PM.
11-1 EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYS TEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any perso.
12-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00431 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and insta ll 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.
13-1 EBU00432 YAMAHA MOTOR CORPORATION, U.S. A. ATV LIMITED WARRANTY U5GW13.book Page 1 Tuesd ay, July 30, 2002 2:23 PM.
13-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 U5GW13.book Page 2 Tuesd ay, July 30, 2002 2:23 PM.
14-1 EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) U5GW13.book Page 1 Tuesd ay, July 30, 2002 2:23 PM.
14-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 U5GW13.book Page 2 Tuesd ay, July 30, 2002 2:23 PM.
EBU00436 W ARNING Indicates a potential hazard that could result in serious injury or death. U5GW13.book Page 3 Tuesd ay, July 30, 2002 2:23 PM.
EBU00437 U5GW13.book Page 5 Tuesd ay, July 30, 2002 2:23 PM.
5GW-F8199-13 LIT-11626-16-12 READ THIS MANUAL CAREFULLY! It contains important safety information. This ATV should not be ridden by anyone under 16 years of age. WARNING YFM400R OWNER’S MANUAL PRINTED IN USA 2002.09-0.9 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO .
Card.fm Page 1 Wednesday, June 13, 200 1 9:35 AM.
Card.fm Page 2 Wednesday, June 13, 200 1 9:35 AM.
An important point after buying a device Yamaha 5GW-F8199-13 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Yamaha 5GW-F8199-13 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Yamaha 5GW-F8199-13 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Yamaha 5GW-F8199-13 you will learn all the available features of the product, as well as information on its operation. The information that you get Yamaha 5GW-F8199-13 will certainly help you make a decision on the purchase.
If you already are a holder of Yamaha 5GW-F8199-13, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Yamaha 5GW-F8199-13.
However, one of the most important roles played by the user manual is to help in solving problems with Yamaha 5GW-F8199-13. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Yamaha 5GW-F8199-13 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
