Yamaha YFM400S User Manual
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM400S
WARNING
This ATV should not be ridden by anyone under 16 years of age.
5GW-F8199-14LIT-11626-17-08
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.
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
ATV.
This manual includes important safety information. It provides information about
special techniques and skills necessary to ride your ATV.
It also includes basic maintenance
and inspection procedures. If you have any questions regarding the operation or maintenance of
your ATV, 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 ATV. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
●
PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
●
NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE
TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887
FOR MORE INFORMATION.
●
THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE
UNDER 16 YEARS OF AGE.
EBU00801
WARNING
CAUTION:
NOTE:
1-
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!
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.
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.
Please check your local riding laws and regulations before operating this machine.
EBU01067
YFM400S
OWNER’S MANUAL
AFFIX DEALER
LABEL HERE
©2003 by Yamaha Motor Corporation,
U.S.A.
1st edition, April 2003
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-11626-17-08
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 and warning lights.............4-2
Speedometer ...................................4-4
Fuel gauge .......................................4-4
Handlebar switches .........................4-5
Throttle lever ....................................4-6
Speed limiter ....................................4-7
Front brake lever..............................4-8
Brake pedal and rear brake 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.................................... 5-7
Throttle lever ................................... 5-8
Fittings and fasteners...................... 5-8
Lights............................................... 5-8
Switches.......................................... 5-8
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.............. 6-6
To decelerate................................... 6-7
Engine break-in ...............................6-7
Parking............................................. 6-9
Parking on a slope........................... 6-9
Accessories and loading ...............6-11
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 and oil filter element ....... 8-5
Final gear oil .................................. 8-10
Spark plug inspection.................... 8-12
Air filter element cleaning.............. 8-13
Spark arrester cleaning ................. 8-17
Carburetor adjustment................... 8-18
Idle speed adjustment ................... 8-19
Valve clearance adjustment.......... 8-20
Throttle lever adjustment............... 8-20
Front brake pad check .................. 8-21
Rear brake shoe inspection ..........8-21
Brake fluid level check................... 8-22
Brake fluid replacement .................8-23
Front brake lever free play.............8-24
Brake pedal and rear brake lever
adjustment ...................................8-25
Adjusting the rear brake light
switch ...........................................8-28
Clutch adjustment ..........................8-28
Cable inspection and
lubrication.....................................8-29
Brake and shift pedal/
brake lever lubrication..................8-30
Wheel removal...............................8-30
Wheel installation...........................8-31
Battery............................................8-32
Battery maintenance......................8-33
Fuse replacement ..........................8-33
Replacing a headlight bulb ............8-35
Headlight beam adjustment...........8-38
Tail/brake light bulb
replacement .................................8-38
Troubleshooting .............................8-40
Troubleshooting chart ....................8-41
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
EBU00464
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.
2
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.
1
WARNING
Overloading this ATV or carrying cargo improperly can change
handling. stability and braking performance and can lead to an
accident. Never exceed the maximum front cargo limit of
: 40kg (88 lbs)
NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
5ND-F4877-00
1-2
3
3
4
5
6
7
8
9
10
11
12
13
14
4
WARNING
Overloading this ATV or carrying cargo improperly can change
handling. stability and braking performance and can lead to an
accident. Never exceed the maximum rear cargo limit of
: 80kg (176 lbs)
NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
5ND-F4897-00
5
6
1-3
78
MAXIMUM.LOADING LIMITMAXIMUM LOADING LIMIT
15kgf
5FU-F151K-00
)
)
PULLING LOAD: 4020 N(410kgf
TONGUE WEIGHT: 147 N
904 l b f
33 lbf
(
1-4
EBU00924
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently
from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even
during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take
proper precautions. 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 1-800-887-2887 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.
●
Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or
jacket, and long pants.
●
Never consume alcohol or drugs before or while operating this ATV.
●
Never operate at speeds too fast for your skills or the conditions. Always 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.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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 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 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. 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.
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 carrying 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
WARNI NG
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 ATV 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
WARNI NG
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.
2-7
EBU00032
DESCRIPTION AND MACHINE IDENTIFICATION
1. Spark arrester
2. Rear carrier
3. Seat
4. Auxiliary DC jack
5. Front carrier
6. Brake pedal
7. Headlights
8. Fuel cock
9. Recoil starter
10. Tail/brake light
11. Rear wheel
12. Shift pedal
NOTE:
The machine you have purchased may differ slightly
from those shown in the figures of this manual.
13. Front wheel
14. Rear brake lever
15. Parking brake lock plate
16. Starter (choke)
17. Speedometer
18. Reverse knob
19. Front brake lever
20. Throttle lever
21. Fuel gauge
22. Main switch
23. Left handlebar switches
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
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.
EBU00787
Model label
The model label is affixed to the location in the
illustration. 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.
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.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
4-1
EBU00802
Indicator and warning 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.
1
2
3
4
5
1. Reverse indicator light “REVERSE”
2. Neutral indicator light “NEUTRAL”
3. Oil temperature warning 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.
4-2
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.
6
7
8
9
10
11
12
13
14
EBU00733
ACB-10E
Oil temperature warning light checking method
Turn the main switch to “ON” and the
engine stop switch to “”.
Oil temperature warning
light does not come on.
Push start switch with the
transmission in neutral.
Oil temperature
warning light comes
on momentarily.
Engine oil temperature and
electrical circuit are OK. Go
ahead with riding.
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.
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. This information will enable you to plan fuel stops in
the future.
1. Reset knob 2. Speedometer
3. Odometer 4. Trip odometer
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 2. Red line
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 “ //OFF”
2. Engine stop switch “”/“”
3. Start switch “”
EBU01205
Engine stop switch “ / ”
Make sure that the engine stop switch is set to
“” before starting the engine. 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 set to “”.
EBU00607
Start switch “”
The starter motor cranks the engine when this
switch is pushed.
CAUTION:
See starting instructions prior to starting
the engine. (See page 6-1 for details.)
_
EBU01204
Light switch “ //OFF”
Set the switch to “” to turn on the low beam
and the taillight.
Set the switch to “” to turn on the high
beam and the taillight.
Set the switch to “OFF” to turn off all the lights.
CAUTION:
_
Do not use the headlights 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.
WARNI NG
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
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 adjusting screw limits the maximum engine power available and decreases the maximum
speed of the ATV.
1. Locknut 2. Adjusting screw a. 12 mm (0.47 in)
WARNI NG
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 adjusting screw 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 8-20.
4-7
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