torque YAMAHA WOLVERINE 400 2004 Owners Manual

5-21
EBU01162
Fittings and fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.
EBU01003
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
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Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper op-
eration.
U5TE61.book Page 21 Tuesday, May 6, 2003 4:40 PM

8-3 1. Owner’s manual
2. Owner’s tool kit
3. Low-pressure tire gauge
1. Manuel du propriétaire
2. Trousse à outils du propriétaire
3. Manomètre basse pression pour pneus
1. Manual del propietario
2. Juego de herramientas del propietario
3. Manómetro de baja presión
EBU13200
Owner’s manual and tool kit
You are recommended to put this owner’s manual
in the vinyl bag and always carry it on the bottom
of the seat as shown. Put the owner’s tool kit and
low-pressure tire gauge in the storage box.
The service information included in this manual is
intended to provide you, the owner, with the nec-
essary information for completing your own pre-
ventive maintenance and minor repairs. The tools
provided in the Owner’s tool kit are sufficient for
this purpose, except that a torque wrench is also
necessary to properly tighten nuts and bolts.NOTE:_ If you do not have a torque wrench available dur-
ing a service operation requiring one, take your
machine to a Yamaha dealer to check the torque
settings and adjust them as necessary. _
U5TE61.book Page 3 Tuesday, May 6, 2003 4:40 PM

8-25 1. Quick fastener (× 2) 2. Panel C
1. Fixation rapide (× 2) 2. Cache C
1. Fijador rápido (× 2) 2. Panel C
1. Panel E 2. Bolt (× 3)
1. Cache E 2. Boulon (× 3)
1. Panel E 2. Perno (× 3)
To install1. Place the panel in the original position and in-
stall the quick fasteners.
2. Place the carrier in the original position and
install the carrier bolts under the fenders.
3. Install the top carrier bolts, and then tighten
all bolts to the specified torques.
EBU01013
Panel E
To removeRemove the bolts, and then take the panel off.
To installPlace the panel in the original position, and then
install the bolts.Tightening torque:
Carrier bolt (top):
34 Nm (3.4 m·kgf)
Carrier bolt (under fenders):
7 Nm (0.7 m·kgf)
U5TE61.book Page 25 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

8-41 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

8-57 1. Radiator cap
1. Bouchon du radiateur
1. Tapa del radiador
1. Coolant reservoir hose
1. Flexible du vase d’expansion
1. Manguera del depósito de refrigerante
5. Remove the radiator cap.
6. Remove panel D. (See page 8-17 for panel
removal and installation procedures.)
7. Remove the coolant reservoir cap.
8. Disconnect the hose on the coolant reservoir
side, and then drain the coolant from the
coolant reservoir.
9. After draining the coolant, thoroughly flush
the cooling system with clean tap water.
10. Replace the coolant drain bolt washer if it is
damaged, install the coolant drain bolt, and
then tighten it to the specified torque.
11. Connect the coolant reservoir hose.Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf)
U5TE61.book Page 57 Tuesday, May 6, 2003 4:40 PM

8-67 a. Spark plug gap
a.Écartement des électrodes
a. Huelgo de la bujía
Installation
1. Measure the electrode gap with a wire thick-
ness gauge and, if necessary, adjust the gap
to specification.
2. Clean the gasket surface. Wipe off any grime
from the threads.
3. Install the spark plug and tighten it to the
specified torque.NOTE:_ If a torque wrench is not available when you are in-
stalling a spark plug, a good estimate of the correct
torque is 1/4 to 1/2 turn past finger tight. Have the
spark plug tightened to the specified torque as
soon as possible. _4. Install the spark plug cap.
5. Install the panel. Spark plug gap:
0.6–0.7 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf)
U5TE61.book Page 67 Tuesday, May 6, 2003 4:40 PM

8-111 1. Arrow mark
1. Flèche
1. Marca en forma
1. Tapered nut
1.Écrou conique
1. Tuerca cónica
EBU01121
Wheel installation
1. Install the wheel and the nuts.NOTE:_

Tapered nuts are used for both the front and
rear wheels. Install the nut with its tapered
side towards the wheel.


The arrow mark on the tire must point to-
ward the rotating direction of the wheel.
_2. Lower the ATV so that the wheel is on the
ground.
3. Tighten the wheel nuts to the specified
torque.
Wheel nut torque:
Front: 55 Nm (5.5 m·kgf)
Rear: 55 Nm (5.5 m·kgf)
U5TE61.book Page 111 Tuesday, May 6, 2003 4:40 PM