oil YAMAHA WOLVERINE 400 2004 User Guide

8-8
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
V-belt*Check operation.
Check for cracks or damage.Wheels*Check balance/damage/runout.
Repair if necessary.Wheel bearing*Check bearing assemblies for looseness/damage.
Replace if damaged.Front and rear
suspension*Check operation.
Correct if necessary.Steering system*Check operation./Replace if damaged.
Check toe-in./Adjust if necessary.Drive shaft universal
joint*Lubricate.Axle boots*Check operation.
Replace if damaged.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5TE61.book Page 8 Tuesday, May 6, 2003 4:40 PM

8-29 1. Engine oil filler cap
1. Bouchon de remplissage d’huile de moteur
1. Tapa de relleno de aceite de motor
1. Maximum level mark 2. Minimum level mark
1. Repère de niveau maximum 2. Repère de niveau minimum
1. Marca de nivel máximo 2. Marca de nivel mínimo
EBU10991
Engine oil and oil filter cartridge
The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
To check the engine oil level
1. Remove panel F. (See page 8-27 for panel
removal and installation procedures.)
2. Place the ATV on a level surface.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Wait a few minutes until the oil settles.
5. Remove the engine oil filler cap and wipe off
the dipstick with a clean rag.
6. Insert the dipstick in the oil filler hole (without
screwing it in), and then remove it again to
check the oil level.NOTE:_ The engine oil should be between the minimum
and maximum level marks. _
U5TE61.book Page 29 Tuesday, May 6, 2003 4:40 PM

8-31 1. Engine oil drain bolt
1. Boulon de vidange de l’huile
1. Perno de drenaje del aceite de motor
7. If the engine oil is at or below the minimum
level mark, add sufficient oil of the recom-
mended type to raise it to the correct level.
8. Insert the dipstick into the oil filler hole, and
then tighten the oil filler cap.
9. Install the panel.
To change the engine oil (with or without oil fil-
ter cartridge replacement)
1. Remove panel F. (See page 8-27 for panel
removal and installation procedures.)
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Place an oil pan under the engine to collect
the used oil, and then remove the engine oil
filler cap.
4. Remove the engine oil drain bolt to drain the
oil from the crankcase.
U5TE61.book Page 31 Tuesday, May 6, 2003 4:40 PM

8-33 1. Oil filter cartridge
1. Cartouche du filtre à huile
1. Cartucho del filtro de aceite
1. Oil filter wrench
1. Clé pour filtre à huile
1. Llave para filtros de aceite
NOTE:_ Skip steps 5–9 if the oil filter cartridge is not being
replaced. _5. Remove panel E. (See page 8-25 for panel
removal and installation procedures.)
6. Remove the oil filter cartridge with an oil filter
wrench.NOTE:_ An oil filter wrench is available at a nearby
Yamaha dealer. _
U5TE61.book Page 33 Tuesday, May 6, 2003 4:40 PM

8-35 1. O-ring
1. Joint torique
1. Junta tórica
1. Torque wrench
1. Clé dynamométrique
1. Llave de apriete
7. Apply a light coat of engine oil to the O-ring of
the new oil filter cartridge.NOTE:_ Make sure the O-ring is seated properly. _8. Install the new oil filter cartridge with an oil fil-
ter wrench, and then tighten it to the specified
torque with a torque wrench.
9. Install panel E.
10. Install the engine oil drain bolt, and then tight-
en it to the specified torque. Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
23 Nm (2.3 m·kgf)
U5TE61.book Page 35 Tuesday, May 6, 2003 4:40 PM

8-37
11. Add the specified amount of recommended
engine oil, and then install the engine oil filler
cap and tighten it.CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
Recommended engine oil:
See page 10-2.
Oil quantity:
Without oil filter cartridge replacement:
2.3 L
With oil filter cartridge replacement:
2.4 L
U5TE61.book Page 37 Tuesday, May 6, 2003 4:40 PM

8-39
‘1. Final gear oil
2. Final gear oil filler bolt
3. Proper oil level
1. Huile de transmission finale
2. Boulon de remplissage d’huile du carter de transmission finale
3. Niveau correct
1. Aceite de la transmisión final
2. Perno del orificio de llenado de aceite de la transmisión final
3. Nivel de aceite adecuado
12. Start the engine and warm it up for several
minutes. While warming up, check for oil
leakage. If oil leakage is found, turn the en-
gine off immediately and check for the cause.
13. Turn the engine off, and then check the oil
level and correct it if necessary.
14. Install panel F.
EBU01145
Final gear oil
Final gear oil measurement
1. Place the machine on a level surface.
2. Remove the oil filler bolt, and then check the
oil level in the final gear case.NOTE:_ The oil level should be at the brim of the filler hole. _3. If the oil is below the brim of the filler hole,
add sufficient oil of the recommended type to
raise it to the correct level.CAUTION:_ Be sure no foreign material enters the final
gear case. _4. Install the oil filler bolt.
U5TE61.book Page 39 Tuesday, May 6, 2003 4:40 PM

8-41 1. Final gear case cover 2. Bolt (× 2)
1. Couvercle du carter de transmission finale 2. Boulon (× 2)
1. Cubierta del cárter de la transmisión final 2. Perno (× 2)
1. Final gear oil drain bolt
1. Boulon de vidange du carter de transmission finale
1. Perno de drenaje del aceite del cárter de la transmisión final
Final gear oil replacement
1. Remove the final gear case cover by remov-
ing the bolts.
2. Place the machine on a level surface.
3. Place a container under the final gear case to
collect the used oil.
4. Remove the oil filler bolt and the drain bolt to
drain the oil.
5. Install the drain bolt, and then tighten it to the
specified torque.
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf)
U5TE61.book Page 41 Tuesday, May 6, 2003 4:40 PM

8-43
6. Add the recommended final gear oil to the
brim of the filler hole.CAUTION:_ Be sure no foreign material enters the final
gear case. _7. Install the oil filler bolt.
8. Check for oil leakage. If oil leakage is found,
check for the cause.
9. Install the final gear case cover bolts, and
then tighten them to the specified torque. Recommended oil:
See page 10-3.
Oil quantity:
0.23 L
Tightening torque:
Final gear case cover bolt:
16 Nm (1.6 m·kgf)
U5TE61.book Page 43 Tuesday, May 6, 2003 4:40 PM

8-45 1. Differential oil filler bolt
1. Boulon de l’orifice de remplissage d’huile de différentiel
1. Perno de relleno de aceite del diferencial
1. Differential gear oil drain bolt
1. Boulon de vidange de l’huile de différentiel
1. Perno de drenaje de aceite de engranajes del diferencial
EBU01241
Differential gear oil replacement
1. Place the machine on a level surface.
2. Place a container under the differential gear
case to catch the oil.
3. Remove the oil filler bolt and oil drain bolt to
drain the oil.
4. Install the oil drain bolt, and then tighten it to
the specified torque.
Tightening torque:
Drain bolt:
10 Nm (1.0 m·kgf)
U5TE61.book Page 45 Tuesday, May 6, 2003 4:40 PM