Yamaha YFM400NN User Manual
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM400NN
WARNING
This ATV should not be ridden by anyone under 16 years of age.
5GW-F8199-11LIT-11626-14-22
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 pace-setting 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.
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 infor-
mation 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.
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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 notations:
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The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE: A NOTE provides key information to make procedures easier or clear-
Failure to follow WARNING instructions could result in severe injury
or death to the machine operator, a bystander or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that must be taken to avoid
damage to the machine.
er.
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.
Please check your local riding laws and regulations before operating this machine.
EBU00531
YFM400NN
AFFIX DEALER
LABEL HERE
© 2000 by Yamaha Motor Corporation,
All rights reserved. Any reprinting or
unauthorized use without the written
OWNER’S MANUAL
U.S.A.
1st Edition, April 2000
permission of
Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11626-14-22
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EBU00014
WARNING
Indicates a potential hazard that could
result in serious injury or death.
CONTENTS
LOCATION OF THE WARNING
1
AND SPECIFICATION LABELS .......1-1
SAFETY INFORMATION .................2-1
2
DESCRIPTION AND MACHINE
3
IDENTIFICATION.............................. 3-1
Identification number records ...... 3-2
Key identification number ............3-2
Vehicle identification number ......3-3
Model label.....................................3-3
CONTROL FUNCTIONS...................4-1
4
Main switch.....................................4-1
Indicator lights................................4-2
Oil temperature warning light
checking method ..........................4-3
Fuel gauge ......................................4-4
Handlebar switches .......................4-5
Throttle lever ..................................4-6
Speed limiter ..................................4-7
Front brake lever ............................4-8
Rear brake pedal and lever ...........4-8
Parking brake..................................4-9
Shift pedal.....................................4-10
Reverse knob ................................4-10
Recoil starter.................................4-11
Fuel tank cap.................................4-12
Fuel cock .......................................4-13
Starter (choke) ..............................4-14
Seat................................................4-15
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
OPERATION......................................6-1
6
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 pedal/
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
CLEANING AND STORAGE............9-1
9
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
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LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1-1
Read and understand all of the labels on
your machine. They contain important information for safe and proper operation of
your ATV.
1
1
2
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.
3
4
2
5
6
7
8
9
10
11
12
13
14
1-2
3
4
5
1-3
67
1-4
EBU00017
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differ-
ently 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-
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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 de-
scribed.
● 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, drive-
ways, parking 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 prop-
erly. 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 con-
dition. 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
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 excessive speed.
● Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on
smaller hills before attempting larger hills.
● Always follow proper procedures for climbing hills as described in this manual. Check
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the terrain 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. 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 de-
scribed 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. Always 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.
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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 distribut-
ed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.
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FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission 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. Rear carrier
2. Seat
3. Front carrier
4. Rear brake pedal
5. Headlight
6. Fuel cock
7. Recoil starter
8. Rear wheel
9. Shift pedal
10. Front wheel
NOTE:
The machine you have purchased may differ slightly from those shown in the figures of this manual.
3-1
11. Rear brake lever
12. Parking brake lock plate
13. Starter (choke)
14. Reverse knob
15. Front brake lever
16. Throttle lever
17. Fuel gauge
18. Main switch
19. Handlebar switch
3
3
3
4
5
6
7
8
9
30
33
33
33
34
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:
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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
Vehicle identification number
The vehicle identification number is
stamped into the frame.
1. Vehicle identification number
NOTE:
The vehicle identification number is used
to identify your machine.
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Model label
The model label is affixed to 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. 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
EBU00732
Oil temperature warning 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
warning 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.
4
4
4
4
5
1. Reverse indicator light “REVERSE”
2. Neutral indicator light “NEUTRAL”
3. Oil temperature warning light “OIL TEMP”
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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.
CAUTION:
● The engine may overheat if the ATV is
overloaded. If this happens, reduce
the load to specification.
● Restart after making sure that the
warning light is out. Continuous use
while the warning light is on may
cause damage to the engine.
4-2
6
7
8
9
40
44
44
44
44
EBU00733
ACB-10E
Oil temperature warning light checking method
Turn the main switch to “ON” and
the engine stop switch to “ ”.
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Engine oil temperature
and electrical circuit are
OK. Go ahead with riding.
Oil temperature warning
light does not come on.
Push start switch with the
transmission in neutral.
Oil temperature
warning light comes
on momentarily.
Oil temperature warning
light does not come on.
Ask a Yamaha dealer to
inspect the electrical circuit.
4-3
Oil temperature warning
light comes on.
Check engine oil temperature.
Oil temperature is low.
Oil temperature is high.
Allow to cool.
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. 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
“”.
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)
EBU00734
Light switch “LIGHTS”
Turn the switch to the “LO” position to
switch on the low beam and the taillight.
Turn the switch to the “HI” position to
switch on the high beam and the taillight.
Turn the switch to the “OFF” position to
switch off the headlight and the 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.
4-5
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
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