air filter YAMAHA WOLVERINE 400 2004 Owners Manual

How to measure tire pressure .............5-27
Tire wear limit......................................5-29
OPERATION ...........................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Warming up...........................................6-9
Drive select lever operation and
reverse driving ..................................6-11
Engine break-in ...................................6-17
Parking ................................................6-19
Parking on a slope ..............................6-21
Accessories and loading .....................6-23
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good judgement .....7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-39
Climbing uphill.....................................7-45
Riding downhill ....................................7-55
Crossing a slope .................................7-59
Crossing through shallow water ..........7-63
Riding over rough terrain ....................7-69
Sliding and skidding ............................7-71
What to do if ........................................7-75
What to do...........................................7-75
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ........................................ 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Panel removal and installation............ 8-15
Engine oil and oil filter cartridge ......... 8-29
Final gear oil ....................................... 8-39
Differential gear oil replacement ......... 8-45
Cooling system ................................... 8-51
Changing the coolant.......................... 8-55
Axle boots ........................................... 8-61
Spark plug inspection ......................... 8-63
Air filter element cleaning ................... 8-69
V-belt cooling duct check hose ........... 8-77
V-belt case drain plug ......................... 8-77
Carburetor adjustment ........................ 8-79
Idle speed adjustment ........................ 8-81
Valve clearance adjustment ............... 8-83
Throttle lever adjustment .................... 8-85
Front brake pad check ........................ 8-87
Rear brake shoe inspection ................ 8-87
Brake fluid level check ........................ 8-89
Brake fluid replacement ...................... 8-93
Front brake lever free play.................. 8-95
8
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3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber
assembly spring preload
adjusting ring
2. Storage box and tool kit
3. Spark plug
4. Front shock absorber
assembly spring preload
adjusting ring
5. Brake pedal
6. V-belt case
7. Radiator cap
8. Fuel cock
9. Air filter case
10. Fuses
11. Tail/brake light
12. Front shock absorber
assembly spring preload
adjusting ring
13. V-belt cooling duct check
hose14. Coolant reservoir
15. Oil filter cartridge
16. Engine oil dipstick
17. Rear brake lever
18. Left handlebar switches
19. Starter (choke)
20. Horn switch
21. Drive select lever
22. Speedometer
23. Main switch
24. Fuel tank cap
25. Auxiliary DC jack
26. Right handlebar
switch
27. Throttle lever
28. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5TE61.book Page 1 Tuesday, May 6, 2003 4:40 PM

7-65
1. Air filter case check hose
1. Flexible de contrôle du boîtier de filtre à air
1. Manguera de comprobación de la caja del filtro de aire
Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that
you have regained proper braking ability.CAUTION:_ After riding your ATV in water, be sure to drain
the trapped water by removing the check hose
at the bottom of the air filter case, the V-belt
cooling duct check hose and the drive select
lever box check hose. Also, remove the V-belt
case drain plug to drain any water that may
have accumulated. Wash the ATV in fresh wa-
ter if it has been operated in salt water or mud-
dy conditions. _
U5TE61.book Page 65 Tuesday, May 6, 2003 4:40 PM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*Check valve clearance.
Adjust if necessary.
Cooling systemCheck coolant leakage.
Repair if necessary.
Replace coolant every 24 months.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check and adjust idle speed/starter operation.
Adjust if necessary.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Retighten if necessary.
Replace gasket(s) if necessary.Fuel line*Check fuel hose for cracks or damage.
Replace if necessary.Engine oil
Replace. (Warm engine before draining.)Engine oil filter cartridge
Replace.Engine oil strainer*
Clean.Final gear oil
Check oil level/oil leakage.
Replace every 12 months.Differential gear oil
Front brake*Check operation/fluid leakage. (See NOTE page 8-8.)
Correct if necessary.Rear brakeCheck operation.
Adjust if necessary.U5TE61.book Page 7 Tuesday, May 6, 2003 4:40 PM

8-69 1. Air filter case check hose
1. Flexible de contrôle du boîtier de filtre à air
1. Manguera de comprobación de la caja del filtro de aire
1. Holder (× 4) 2. Air filter case cover
1. Support (× 4) 2. Couvercle du boîtier de filtre à air
1. Soporte (× 4) 2. Cubierta de la caja del filtro de aire
EBU13270
Air filter element cleaningNOTE:_ There is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-
ter case. _1. Remove the seat. (See page 4-35 for seat re-
moval and installation procedures.)
2. Remove the air filter case cover by unhook-
ing the holders.
U5TE61.book Page 69 Tuesday, May 6, 2003 4:40 PM

8-71 1. Air filter element
1.Élément de filtre à air
1. Elemento del filtro de aire
1. Air filter element frame
2. Air filter element
1. Armature d’élément de filtre à air
2.Élément de filtre à air
1. Bastidor del elemento del filtro de aire
2. Elemento del filtro de aire
3. Remove the air filter element, and then re-
move it from its frame.
4. Wash the element gently but thoroughly in
solvent.
WARNING
_ Always use parts cleaning solvent to clean the
air filter element. Never use low flash point sol-
vents or gasoline to clean the air filter element
because the engine could catch fire or ex-
plode. _
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8-73
5. Squeeze the excess solvent out of the air fil-
ter element and let it dry.CAUTION:_ Do not twist the air filter element when squeez-
ing it. _6. Inspect the air filter element and replace it if
damaged.
7. Apply foam air filter oil to the air filter element.
If foam air filter oil is not available, engine oil
may be used.NOTE:_ The air filter element should be wet but not drip-
ping. _8. Pull the air filter element over its frame.
9. Install the air filter element assembly.
10. Install the air filter case cover.
11. Install the seat.
U5TE61.book Page 73 Tuesday, May 6, 2003 4:40 PM

8-75
NOTE:_ The air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the machine is operated in extremely dusty
areas. Each time the air filter element mainte-
nance is performed, check the air inlet to the filter
case for obstructions. Check the air filter case rub-
ber joint to the carburetor and manifold fittings for
an airtight seal. Tighten all fittings securely to
avoid the possibility of unfiltered air entering the
engine. _CAUTION:_ Never operate the engine with the air filter ele-
ment removed. This will allow unfiltered air to
enter, causing rapid engine wear and possible
engine damage. Additionally, operation with-
out the air filter element will affect carburetor
jetting with subsequent poor performance and
possible engine overheating. _
U5TE61.book Page 75 Tuesday, May 6, 2003 4:40 PM

10-3
Final gear oil:
Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.23 L
Differential gear oil:
Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.35 L
Radiator capacity (including all routes): 1.32 L
Air filter: Wet element
Fuel:
Type Unleaded gasoline only
For Europe: Regular unleaded gasoline only with a
research octane number of 91 or higher
Fuel tank capacity 15 L
Fuel reserve amount 4.5 L
Carburetor:
Type/quantity BSR33/1
Manufacturer MIKUNI
Spark plug:
Type/manufacturer DR8EA / NGK
Spark plug gap 0.6–0.7 mm
Clutch type: Wet, centrifugal automaticModel YFM400FA
U5TE61.book Page 3 Tuesday, May 6, 2003 4:40 PM