warning YAMAHA WOLVERINE 2016 Service Manual

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EBU31950
BASIC GUIDE FOR SAFE USE
EBU31960As a Wolverine owner you are responsible for
the safe and proper operation of this vehicle.
Read this chapter and review the safety in-
structions in Chapter 2 before operating the
vehicle. Use these chapters and the labels on
the vehicle to instruct new operators and pas-
sengers. Do not allow anyone else to operate
the vehicle or ride as a passenger if you are
unsure that he/she is willing and able to follow
these instructions.
WARNING
EWB03340Follow these instructions to reduce your
risk of an accident and to reduce the risk
of serious injury or death in the event of an
accident.
EBU33510KNOW YOUR VEHICLEThis off-road vehicle will handle and maneu-
ver differently from cars, ATVs, go-carts, golf-
cars and grounds-keeping vehicles. The
Wolverine has higher ground clearance and other features to handle rugged terrain, and,
as a result, can overturn in situations where
some vehicles may not. This would include
vehicles made primarily for pavement, roads,
improved paths, or grounds-keeping. If you
do not use care in maneuvering the
Wolverine, you can cause it to roll over even on flat, open areas.
Doing things with a Wolverine that some peo-
ple do for thrills in other vehicles (such as
sideways sliding, skidding, back-wheel slid-
ing, or donuts) have led to side rollovers.
These rollovers can resu lt in crushed limbs
and other serious injuries or death to drivers
or passengers.
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biles, to promote safe driving behaviors, you
should supervise younger drivers and consid-
er setting rules and putting limits on how,
when, and where the Wolverine can be used.
Passenger requirements
This vehicle is designed for the operator and
one passenger. Allowing passengers to ride
improperly can lead to serious injury or death.
As the operator, you are responsible for your
passenger.
Your passenger must be able to place both
feet on the floorboard while seated upright
with his/her back against the backrest.
 Your passenger must be able to reach and
hold the passenger handhold.
 Allow only one passenger in the vehicle and
only in the designated passenger seat. Do
not carry any other passengers. Do not car-
ry passengers in the cargo bed.
 Do not allow someone to ride as a passen-
ger who has been using drugs or alcohol. 
Do not allow children who need child safety
seats or booster seats in the Wolverine. The
seat belt is not designed to restrain auto-
motive child safety seats.
Occupant protection system
WARNING
EWB03350Do not make changes to the occupant pro-
tection system. If you install aftermarket
products or have your vehicle modified,
you may put yourself and others at greater
risk of serious injury or death. You are re-
sponsible for any such changes to the ve-
hicle.
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EBU32002PERIODIC MAINTENANCE AND ADJUSTMENTEBU32010Periodic inspection, adjustment, and lubrica-
tion will keep your vehicle in the safest and
most efficient condition possible. Safety is an
obligation of the vehicle owner/operator. The
most important points of vehicle inspection,
adjustment, and lubrication are explained on
the following pages.
WARNING
EWB01842Failure to properly maintain the vehicle or
performing maintenance activities incor-
rectly may increase your risk of injury or
death during service or while using the ve-
hicle. If you are not familiar with vehicle
service, have a Yamaha dealer perform the
service.
WARNING
EWB02563Turn off the engine when performing main-
tenance unless otherwise specified.
A running engine has moving parts that
can catch on body parts or clothing and
electrical parts that can cause shocks or
fires.
 Running the engine while servicing can
lead to eye injury, burns, fire, or carbon
monoxide poisoning - possibly leading
to death. See page 2-5 for more informa-
tion about carbon monoxide.
WARNING
EWB02691Brake discs, calipers, drums, and linings
can become very hot during use. To avoid
possible burns, let brake components cool
before touching them.
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Checking the coolant level1. Park the vehicle on a level surface.
2. Check the coolant level in the coolant
reservoir when the engi ne is cold as the
coolant level varies with engine tempera-
ture.TIPThe coolant should be between the minimum
and maximum level marks.
3. If the coolant is at or below the minimum level mark, remove the coolant reservoir
cap, add coolant to the maximum level
mark, and install the reservoir cap.
Changing the coolant
WARNING
EWB01891Wait for the engine and radiator to cool be-
fore removing the radiator cap. You could
be burned by hot fluid and steam blown
out under pressure. Always place a thick
rag over the cap when opening. Allow any
remaining pressure to escape before com-
pletely removing the cap. 1. Park the vehicle on a level surface.
2. Remove the hood. (See page 8-10 for hood removal and installation proce-
dures.)
1. Coolant reservoir cap
2. Maximum level mark
3. Minimum level mark
123
Coolant reservoir capacity (up to the maxi-
mum level mark):0.28 L (0.30 US qt, 0.25 Imp.qt)
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5. Remove the sponge material from the airfilter frame. 6. Wash the sponge material gently but
thoroughly in parts cleaning solvent.
WARNING! Using gasoline or other flammable solvents to clean the air fil-
ter element can cause a fire or explo-
sion, which could lead to serious
injury.
[EWB03360]
7. Squeeze the excess solvent out of the
sponge material. NOTICE: Do not twist
the sponge material when squeezing
it.
[ECB00442]
1. Air filter element holder
2. Projection
1
2
1. Air filter element holder
2. Sponge material
3. Air filter frame
3
2
1
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EBU32450Cleaning the spark arrester
WARNING
EWB03370Hot exhaust system may cause burns. To
avoid burns or fires, make sure that the en-
gine is stopped and the exhaust system is
cool before cleaning the spark arrester. Do
not start the engine while cleaning the ex-
haust system. 1. Remove the tailpipe bolts.2. Remove the tailpipe by pulling it out of
the muffler, and then remove the gasket.
3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon depos-
its from the spark arrester portion of the
tailpipe and inside of the tailpipe housing.
4. Install the gasket, and then insert the tail- pipe into the muffler and align the bolt
holes.
5. Install the bolts and tighten them to the
specified torque.1. Tailpipe bolt
1
1
1. Gasket
2. Spark arrester
3. Tailpipe
3
2
1
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EBU32460Valve clearanceThe correct valve clearance changes with
use, resulting in improper fuel/air supply or
engine noise. To prevent this, the valve clear-
ance must be adjusted regularly. This adjust-
ment however, should be left to a
professional Yamaha service technician.EBU32470BrakesReplacement of brake components requires
professional knowledge. Brake service
should be performed by a Yamaha dealer.
WARNING
EWB02572Operating with improperly serviced or ad-
justed brakes could lead to a loss in brak-
ing ability and an accident.
EBU32480Checking the front and rear brake padsEach brake pad is provided with wear indica-
tor grooves, which allow you to check the
brake pad wear without having to disassem-
ble the brake. To check the brake pad wear,
check the wear indicator grooves. If a brake
pad has worn to the point that the wear indi-
cator grooves have almost disappeared, have
a Yamaha dealer replace the brake pads as a
set.
The wheels need to be removed to check the
brake pads. (See pages 8-47, 8-49 for wheel
removal and installation procedures.)
Tightening torque: Tailpipe bolt:10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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EBU32500Checking the brake fluid levelBefore riding, check that the brake fluid is
above the minimum level mark. Check the
brake fluid level with the top of the reservoir
level. Replenish the brake fluid if necessary.
WARNING
EWB02721Improper maintenance can result in loss of
braking ability. Observe these precau-
tions:
Insufficient brake fluid may allow air to
enter the brake system, reducing brak-
ing performance.
1. Brake pad wear indicator groove
1
1. Minimum level markSpecified brake fluid: DOT 4
1
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EBU35930Cable inspection and lubrication
WARNING
EWB03380Damaged cables could restrict operation,
which may cause an accident or injury. In-
spect control cables frequently and re-
place damaged cables. Corrosion can
result when the outer covering of control
cables becomes damaged. Cables can
also become frayed or kinked.
Lubricate the cable ends. If the cables do not
operate smoothly, ask a Yamaha dealer to re-
place them.EBU32570Brake pedal and accelerator pedal lu-
bricationLubricate the pivoting parts.
1. Brake light switch
2. Adjusting nut
(a)
(b)
1
2
Recommended lubricant:Yamalube LubezAll (synthetic lubricant
spray with PTFE)
Recommended lubricant: Lithium-soap-based grease
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were designed to match the performance ca-
pabilities and to provide the best combination
of handling, braking, and comfort. It is best to
replace all four tires at the same time. If that is
not possible, you must replace the tires in
pairs (front or rear) with tires of the same size
and type as the originals. Never replace just
one tire.
WARNING
EWB03390Installing improper tires on your Yamaha
Wolverine can affect handling and stabili-
ty. This can cause a loss of control. The tires listed below have been approved by
Yamaha Motor Manufacturing Corporation of America for this model.
EBU33090Wheel installation1. Install the wheel and the nuts.
2. Lower the vehicle so that the wheel is on the ground.
3. Tighten the wheel nuts in a crisscross pattern to the specified torque.
WARNING
EWB03400Do not reverse the rims on your Yamaha
Wolverine to widen the track width. Install-
ing wheels improperly increases the risk of
wheel failure and accidents. Front tire:Size:26 x 8-12NHS
Manufacturer/model: MAXXIS/MU09
Rear tire: Size:26 x 10-12NHS
Manufacturer/model: MAXXIS/MU10
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