Yamaha YFM400NM User Manual

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YFM400NM(C)

WARNING

This ATV should not be ridden by anyone under 16 years of age.

LIT-11626-13-34

5GW-F8199-10

EBU00001

INTRODUCTION

Congratulations on your purchase of the Yamaha YFM400N. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. E This manual will provide you with a good basic understanding of the features and operation of this machine. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your machine. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your machine, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:

●READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR MACHINE. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

●PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MACHINE.

●NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-447-4700 FOR MORE INFORMATION.

●THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.

EBU00010

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following nota-

E	tions:	The Safety Alert Symbol means ATTENTION! BECOME ALERT!
		YOUR SAFETY IS INVOLVED!
		Failure to follow WARNING instructions could result in severe injury
	WARNING
		or death to the machine operator, a bystander or a person inspecting
		or repairing the machine.

CAUTION:

NOTE:

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

A NOTE provides key information to make procedures easier or clearer.

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.	E
Please check your local riding laws and regulations before operating this machine.
EBU00531

AFFIX DEALER

LABEL HERE

YFM400NM (C)

OWNER’S MANUAL

1999 by Yamaha Motor Corporation,

U.S.A.

1st Edition, September 1999

All rights reserved. Any reprinting or unauthorized use without the written permission of

Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N LIT-11626-13-34

EBU00014
									CONTROL FUNCTIONS	4-1
								4
				WARNING
									Main switch	4-1
									Indicator lights	4-2
	Indicates a potential hazard that could re-
sult in serious injury or death.									Oil temperature indicator light
									checking method..........................	4-3
									Fuel gauge ......................................	4-4
				CONTENTS					Handlebar switches .......................	4-5
									Throttle lever ..................................	4-6
				LOCATION OF THE WARNING					Speed limiter ..................................	4-7
		1							Front brake lever	4-8
				AND SPECIFICATION LABELS		1-1
									Rear brake pedal and lever	4-8
				SAFETY INFORMATION		2-1			Parking brake..................................	4-9
2									Shift pedal	4-10
				DESCRIPTION AND MACHINE					................................Reverse knob	4-10
3									Recoil starter	4-11
				IDENTIFICATION		3-1
									Fuel tank cap	4-12
				Identification number records		3-2
									Fuel cock	4-13
				Key identification number		3-2
									Starter (choke)	4-14
				Vehicle identification number		3-3
									Seat	4-15
				Model label		3-3
									Storage box	4-16
									Front carrier ..................................	4-16
									Rear carrier ...................................	4-16

		Front shock absorber
		adjustment .................................	4-17
		Rear shock absorber
		adjustment .................................	4-18
		Auxiliary DC jack..........................	4-19
		PRE-OPERATION CHECKS	5-1
	5
		Front and rear brakes	5-3
		Fuel..................................................	5-5
		Engine oil........................................	5-7
		Final gear oil...................................	5-8
		Throttle lever..................................	5-8
		Fittings and Fasteners ...................	5-8
		Lights...............................................	5-9
		Switches .........................................	5-9
		Tires.................................................	5-9
		How to measure tire
		pressure......................................	5-11
		Tire wear limit ..............................	5-12

	6	......................................OPERATION	6-1
		Starting a cold engine	6-1
		Starting a warm engine.................	6-3
		Warming up....................................	6-3
		Reverse knob operation and
		reverse driving .............................	6-4
		Shifting............................................	6-5
		To start out and accelerate............	6-5
		To decelerate ..................................	6-6
		Engine break-in ..............................	6-7
		Parking ............................................	6-8
		Parking on a slope .........................	6-9
		Accessories and loading .............	6-10
		RIDING YOUR ATV	7-1
	7
		Getting to know your ATV	7-3
		Ride with care and good
		judgement.....................................	7-4
		Be careful where you ride ...........	7-16
		Turning your ATV ........................	7-23
		Climbing uphill.............................	7-25
		Riding downhill ............................	7-30
		Crossing a slope...........................	7-32

		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 ....................................	7-40
		PERIODIC MAINTENANCE AND
	8
		ADJUSTMENT	8-1
		Owner’s manual and tool kit ........	8-1
		Periodic maintenance/
		lubrication.....................................	8-3
		Engine oil........................................	8-5
		Final gear oil...................................	8-9
		Spark plug inspection..................	8-11
		Air filter cleaning..........................	8-12
		Spark arrester cleaning ...............	8-15
		Carburetor adjustment................	8-16
		Idle speed adjustment.................	8-17
		Valve clearance adjustment........	8-18
		Throttle lever adjustment............	8-18
		Front brake pad inspection .........	8-19
		Rear brake shoe inspection ........	8-19

Front brake fluid level
inspection....................................	8-20
Brake fluid replacement ..............	8-21
Rear brake pedal and lever
adjustment..................................	8-23
Clutch adjustment........................	8-26
Cable inspection and
lubrication...................................	8-27
Brake and shift pedals/
brake lever lubrication...............	8-27
Wheel removal .............................	8-28
Wheel installation ........................	8-28
Battery ...........................................	8-29
Battery maintenance....................	8-30
Fuse replacement.........................	8-31
Replacing the headlight bulb......	8-33
Headlight beam adjustment .......	8-35
Troubleshooting...........................	8-35
Troubleshooting chart .................	8-37

9		............CLEANING AND STORAGE	9-1
		A. Cleaning	9-1
		B. Storage.......................................	9-3
		SPECIFICATIONS	10-1
10
		NOISE REGULATION	11-1
11
		MAINTENANCE RECORD	12-1
12
		ATV LIMITED WARRANTY	13-1
13
		YAMAHA EXTENDED SERVICE
14
		(Y.E.S.)	14-1

EBU00464

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

1		2				3		4

567

1-1

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.

1LOAD LIMIT WARNING

40kg (88lbs) NEVER sit here.

5FU-F4877-00

2

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL.

LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH.

OPERATING TIRE PRESSURE: Set with tires cold

•	Recommended : FRONT : 25kPa, {0.25kgf/cm			2}, 3.6psi
		REAR	: 25kPa, {0.25kgf/cm2}, 3.6psi
•	Minimum	: FRONT : 22kPa, {0.22kgf/cm		2}, 3.2psi
		REAR	: 22kPa, {0.22kgf/cm2}, 3.2psi

•Never set tire pressure below minimum.It could cause the tire to dislodge from the rim.

LOADING/TRAILER TOWING

•Cargo or a trailer can affect stability and handling. Read owner's manual before loading or towing.

•When riding with cargo or towing a trailer : Reduce speed and allow more room to stop. Avoid hills and rough terrain.

•Maximum Vehicle Load : 210 kg, (463 lbs). Includes weight of operator, cargo and accessories (and if applicable, trailer tongue weight).

5FU-F1696-00

1

2

3

4

5

6

7

8

9

10

11

12

13

14

1-2

3

5

4LOAD LIMIT WARNING

80kg (176lbs) NEVER sit here.

5FU-F4897-00

1-3

6	7 SHIFT PATTERN

5

4

3

2

1 N R

5FU-F1578-00

1-4

EBU00017

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 obsta-

E cles, if you fail to take proper precautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

●Read this manual and all labels carefully and follow the operating procedures described.

●Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-447-4700 to find out about the training courses nearest you.

●Always follow the age recommendation:

– A child under 16 years old should never operate an ATV with engine size greater than 90cc.

●Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

●Never carry passenger on an ATV.

2-1

●Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

●Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 2

●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, longsleeved 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 go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.

●Never attempt wheelies, jumps, or other stunts.

●Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

●Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.

●Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

●Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

2

3

4

5

6

7

8

9

20

22

22

23

24

2-2

	● 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 exces-
		sive speed.
	● Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on
		smaller hills before attempting larger hills.
E	●	Always follow proper procedures for climbing hills as described in this manual. Check
		the terrain carefully before you start up any hill. Never climb hills with excessively slip-

pery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

● Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

● Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

2-3

●Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.

●Always check for obstacles before operating in a new area.

Never attempt to operate over large obstacles, such as large rocks or fallen trees. Al- E ways follow proper procedures when operating over obstacles as described in this manual.

●Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing 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 control.

●Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

●Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly.

2-4

●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. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for car-

	E	rying cargo or pulling a trailer. Allow greater distance for braking.
		FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Com-
		mission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.

2-5

WARNING

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 refueling.

Do not refuel right after the engine has been running and is still very hot.

Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or while in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers.

When transporting the machine in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

2-6

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 machine in an area with adequate ventilation.

2-7

EBU00032

DESCRIPTION AND MACHINE IDENTIFICATION

1

2

3

5

67

8

3

4	>		9
	1.	Rear carrier	11.	Rear brake lever
	2.	Seat	12.	Parking brake lock plate
	3.	Front carrier	13.	Starter (choke)
	4.	Rear brake pedal	14.	Reverse knob
	5.	Headlight	15.	Front brake lever
	6.	Fuel cock	16.	Throttle lever
	7.	Recoil starter	17.	Fuel gauge
	8.	Rear wheel	18.	Main switch
	9.	Shift pedal	19.	Handlebar switch
	10.	Front wheel

NOTE:

The machine you have purchased may differ slightly from those shown in the figures of this manual.

3-1

EBU00600

Identification number records

Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.

1.KEY IDENTIFICATION NUMBER:

2.VEHICLE IDENTIFICATION NUMBER:

3.MODEL LABEL INFORMATION:

EBU00035

Key identification number

The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key.

1. Key identification number

3-2

EBU00036		EBU00038
Vehicle identification number		Model label
The vehicle identification number is		The model label is affixed to the frame.
stamped into the frame.		Record the information on this label in the
		space provided. This information will be
		needed to order spare parts from your
		Yamaha dealer.

1. Vehicle identification number

NOTE:

The vehicle identification number is used to identify your machine.

1. Model label

3-3

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:

ON:

Engine can be started only at this position and the headlight and taillight come on when the light switch is on.

OFF:

All electrical circuits are switched off. The key can be removed in this position.

4-1

EBU00043

Indicator lights

1.Reverse indicator light “REVERSE”

2.Neutral indicator light “NEUTRAL”

3.Oil temperature indicator light “OIL TEMP”

EBU00044

Reverse indicator light “REVERSE”

This indicator light comes on when the transmission is in reverse.

EBU00045

Neutral indicator light “NEUTRAL”

This indicator light comes on when the transmission is in neutral.

EBU00047

Oil temperature indicator light “OIL TEMP”

When the oil temperature reaches a specified level, this light comes on to warn that the engine oil temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.

CAUTION:

●The engine may overheat if the ATV is overloaded. If this happens, reduce the load to specification.

●Restart after making sure that the light is out. Continuous use while the light is on may cause damage to the engine.

4-2

4

4

4

4

5

6

7

8

9

40

44

44

44

44

EBU00049*

Oil temperature indicator light checking method

ACB-06EACB-06E

Turn the main switch to “ON” and

E

the engine stop switch to “

”.

Oil temperature indicator

Oil temperature indicator

light does not come on.

light comes on.

Push start switch with the

Check engine oil temperature.

transmission in neutral.

Oil temperature

Oil temperature indicator

Oil tempera-

Oil tempera-

indicator light comes

light does not come on.

ture is low.

ture is high.

on momentarily.

Allow to cool.

Engine oil temperature

Ask a Yamaha dealer to

and electrical circuit are

inspect the electrical circuit.

OK. Go ahead with riding.

4-3

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.

1. Fuel gauge

NOTE:

If the machine runs out of fuel, move the fuel cock lever to the “RES” position. Approximately 4.0 L (0.9 Imp gal, 1.1 US gal) of fuel will be remaining in the tank.

4-4

EBU00053

Handlebar switches

1

OFF

2

3

1.Lights switch

2.Engine stop switch

3.Start switch

EBU00054*
Engine stop switch “	”

Make sure that the engine stop switch is in the “” position. The engine stop switch

controls ignition and can be used at all
times to stop the engine, especially in an
emergency. The engine will not start or run
when the engine stop switch is turned to
“ ”.	4-5

EBU00055*

Start switch “”

The starter motor cranks the engine when this switch is pushed.

CAUTION:

See starting instructions prior to starting engine. (see page 6-1 for details)

EBU00058*

Lights switch “LIGHTS”

Turn the switch to “” for the low beam and taillight.

Turn the switch to “” for the high beam and taillight.

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.

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.

1. Throttle lever

Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released.

WARNING

POTENTIAL HAZARD

Malfunction of throttle.

WHAT CAN HAPPEN

The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident.

HOW TO AVOID THE HAZARD

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 can’t find or solve the problem yourself.

4-6

EBU00066

Speed limiter

The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV.

1. Locknut

2. Adjuster

a. 12 mm (0.47 in)

WARNING

POTENTIAL HAZARD

Improper adjustment of the speed limiter and throttle.

WHAT CAN HAPPEN

The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured.

HOW TO AVOID THE HAZARD

Do not turn the speed adjuster out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3 ~ 5 mm (0.12 ~ 0.20 in). See page 8-18.

4-7

EBU00070

Front brake lever

The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.

1

1

1. 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. Push down on the pedal or pull the lever toward the handlebar to apply the rear brake.

1. Rear brake lever

4-8