coolant YAMAHA WOLVERINE 400 2004 Owners Manual

EBU00015
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ...................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION ................................... 3-1
Identification number records ............... 3-3
Key identification number ..................... 3-5
Vehicle identification number ............... 3-7
Model label ........................................... 3-9
CONTROL FUNCTIONS ........................ 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-3
Speedometer ........................................ 4-7
Fuel gauge ........................................... 4-9
Handlebar switches ............................ 4-11
Throttle lever ...................................... 4-17
Speed limiter ...................................... 4-19
Front brake lever ................................ 4-21
Brake pedal and rear brake lever ....... 4-23
Parking brake ..................................... 4-25
Drive select lever ................................ 4-27
1234
Recoil starter ...................................... 4-29
Fuel tank cap ..................................... 4-29
Fuel cock............................................ 4-31
Starter (choke) ................................... 4-33
Seat.................................................... 4-35
Storage box........................................ 4-37
Front carrier ....................................... 4-39
Rear carrier ........................................ 4-39
Front shock absorber adjustment ...... 4-41
Rear shock absorber adjustment ....... 4-43
Auxiliary DC jack ................................ 4-45
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Final gear oil ...................................... 5-15
Differential gear oil ............................. 5-17
Coolant............................................... 5-17
Throttle lever ...................................... 5-19
Fittings and fasteners......................... 5-21
Lights ................................................. 5-21
Switches............................................. 5-21
Tires ................................................... 5-23
5
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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.
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4-3 1. Coolant temperature warning light “”
2. Reverse indicator light “R”
3. Four-wheel-drive indicator light “”
4. Neutral indicator light “N”
1. Témoin d’avertissement de la température du liquide de
refroidissement “”
2. Témoin de marche arrière “R”
3. Témoin 4x4 “”
4. Témoin de point mort “N”
1. Luz de aviso de la temperatura del refrigerante “”
2. Luz de control de marcha atrás “R”
3. Luz de control del modo de tracción de cuatro ruedas “”
4. Luz de control de punto muerto “N”
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Indicator and warning lights
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Coolant temperature warning light “”
When the coolant temperature reaches a specified
level, this light comes on to warn that the coolant
temperature is too hot. If the 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.
To check the coolant temperature warning light,
shift the drive select lever into neutral, turn the key
to “ON”, and then press the start switch. If the light
does not come on, have a Yamaha dealer inspect
the electrical circuit.CAUTION:_

The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.


Restart after making sure that the light is
out. Continuous use while the light is on
may cause damage to the engine.
_
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4-5 1. Coolant temperature warning light “”
2. Reverse indicator light “R”
3. Four-wheel-drive indicator light “”
4. Neutral indicator light “N”
1. Témoin d’avertissement de la température du liquide de
refroidissement “”
2. Témoin de marche arrière “R”
3. Témoin 4x4 “”
4. Témoin de point mort “N”
1. Luz de aviso de la temperatura del refrigerante “”
2. Luz de control de marcha atrás “R”
3. Luz de control del modo de tracción de cuatro ruedas “”
4. Luz de control de punto muerto “N”
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Reverse indicator light “R”
This indicator light comes on when the drive select
lever is in the “R” position.
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Neutral indicator light “N”
This indicator light comes on when the drive select
lever is in the “N” position.
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Four-wheel-drive indicator light “”
This indicator light comes on when the 2WD/4WD
switch is in the 4WD position.NOTE:_ Due to the synchronizing mechanism in the differ-
ential gear case, the light may not come on until
the ATV starts moving. _
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5-1
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PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-87–8-95
Rear brakeCheck operation, condition and free play.
Adjust if necessary.5-5–5-7,
8-87, 8-97–8-101
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-29–8-39
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.8-51–8-61
Final gear oil and
differential gear oilCheck for leakage.5-15–5-17,
8-39–8-49
ThrottleCheck for proper throttle cable operation. 5-19, 8-85
Wheels and tiresCheck tire pressure, wear and damage.5-23–5-29,
8-109–8-111
Fittings and fastenersCheck all fittings and fasteners. 5-21
Lights and switchesCheck for proper operation. 5-21, 8-123–8-127
Axle bootsCheck for damage. 8-61
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5-17
EBU00678
Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-45–
8-49 for details.)
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Coolant
Check the coolant level in the coolant reservoir
when the engine is cold. (The coolant level will
vary with engine temperature.) The coolant level is
satisfactory if it is between the minimum and max-
imum level marks on the coolant reservoir. If the
coolant level is at or below the minimum level
mark, add distilled water to bring the level up to the
maximum level mark. Change the coolant every
two years. (See pages 8-51–8-61 for details.) Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
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5-19
CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you cannot get
distilled water. _
WARNING
_ Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always put a thick rag over the cap
when opening. Allow any remaining pressure
to escape before completely removing the cap. _
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Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha
dealer repair as necessary for proper operation.Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
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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

8-51 1. Coolant reservoir cap
2. Maximum level mark
3. Minimum level mark
1. Bouchon du vase d’expansion
2. Repère de niveau maximum
3. Repère de niveau minimum
1. Tapa del depósito de refrigerante
2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU13210
Cooling system
1. Place the ATV on a level surface.
2. Check the coolant level in the coolant reser-
voir when the engine is cold as the coolant
level will vary with engine temperature.NOTE:_ The coolant level should be between the minimum
and maximum level marks. _3. If the coolant is at or below the minimum level
mark, remove panel D. (See pages 8-17–
8-19 for panel removal and installation proce-
dures.)
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