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

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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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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:

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.

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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.

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YFM400NN

AFFIX DEALER

LABEL HERE

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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WARNING

Indicates a potential hazard that could result in serious injury or death.

CONTENTS

LOCATION OF THE WARNING

AND SPECIFICATION LABELS .......1-1

SAFETY INFORMATION .................2-1

DESCRIPTION AND MACHINE

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

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

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

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

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

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

A. Cleaning .....................................9-1

B. Storage ....................................... 9-3

SPECIFICATIONS...........................10-1

NOISE REGULATION ....................11-1

MAINTENANCE RECORD ............. 12-1

ATV LIMITED WARRANTY ...........13-1

YAMAHA EXTENDED SERVICE

(Y.E.S.) ............................................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.

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.

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1-3

1-4

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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-

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.

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● 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.

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● 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

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.

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● 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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● 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.

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.

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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.

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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.

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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.

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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

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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

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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

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CONTROL FUNCTIONS

WARNING

Indicates a potential hazard that could result in serious injury or death.

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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.

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Indicator lights

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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.

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.

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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.

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ACB-10E

Oil temperature warning light checking method

Turn the main switch to “ON” and the engine stop switch to “ ”.

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.

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Oil temperature warning light comes on.

Check engine oil temperature.

Oil temperature is low.

Oil temperature is high.

Allow to cool.

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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

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Handlebar switches

1. Lights switch

2. Engine stop switch

3. Start switch

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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 “”.

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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)

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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.

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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.

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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.

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