wheel YAMAHA WOLVERINE 400 2004 Owners Manual

Rear brake pedal and lever
adjustment........................................ 8-97
Adjusting the rear brake light
switch ............................................. 8-103
Cable inspection and lubrication ...... 8-105
Lubricating the brake levers and
brake pedal .................................... 8-107
Wheel removal ................................. 8-109
Wheel installation ............................. 8-111
Battery .............................................. 8-113
Battery maintenance ........................ 8-117
Fuse replacement............................. 8-119
Replacing a headlight bulb ............... 8-123
Headlight beam adjustment.............. 8-127
Tail/brake light bulb replacement ..... 8-127
Troubleshooting................................ 8-129
Troubleshooting chart....................... 8-131
CLEANING AND STORAGE .................. 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
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2-3

Never carry a passenger on an ATV.


Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, park-
ing lots and streets.


Never operate an ATV on any public street,
road or highway, even a dirt or gravel one.


Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly.
You should also wear eye protection (goggles
or face shield), gloves, boots, long-sleeved
shirt or jacket, and long pants.


Never consume alcohol or drugs before or
while operating this ATV.


Never operate at speeds too fast for your skills
or the conditions. Always go at a speed that is
proper for the terrain, visibility and operating
conditions, and your experience.


Never attempt wheelies, jumps, or other stunts.
U5TE61.book Page 3 Tuesday, May 6, 2003 4:40 PM

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”
EBU08020
Indicator and warning lights
EBU01223
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.
_
U5TE61.book Page 3 Tuesday, May 6, 2003 4:40 PM

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”
EBU12500
Reverse indicator light “R”
This indicator light comes on when the drive select
lever is in the “R” position.
EBU09720
Neutral indicator light “N”
This indicator light comes on when the drive select
lever is in the “N” position.
EBU00605
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. _
U5TE61.book Page 5 Tuesday, May 6, 2003 4:40 PM

4-15 1. Four-wheel drive switch “2WD/4WD”
1. Contacteur de commande du mode de traction “2WD”/“4WD”
1. Interruptor de modo de tracción “2WD/4WD”
EBU00061
On command four-wheel drive switch
“2WD/4WD”
To change from two-wheel drive (2WD) to four-
wheel drive (4WD), stop the ATV and set the
switch to the 4WD position.
To change from four-wheel drive (4WD) to two-
wheel drive (2WD), stop the ATV and set the
switch to the 2WD position.
WARNING
_ Always stop the ATV before changing from
2WD to 4WD or from 4WD to 2WD. The ATV
handles differently in 2WD than in 4WD in
some circumstances. Changing from 2WD to
4WD or vice-versa while moving may cause
the ATV to unexpectedly handle differently.
This could distract the operator and increase
the risk of losing control and an accident. _
U5TE61.book Page 15 Tuesday, May 6, 2003 4:40 PM

5-1
EBU00113
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
U5TE61.book Page 1 Tuesday, May 6, 2003 4:40 PM

6-21
EBU13760
Parking on a slope
WARNING
_ Avoid parking on hills or other inclines. Park-
ing on a hill or other incline could cause the
ATV to roll out of control, increasing the
chance of an accident. If you must park on an
incline, place the machine transversely across
the incline, apply the parking brake, and block
the front and rear wheels with rocks or other
objects. Do not park the ATV at all on hills that
are so steep you could not walk up them easi-
ly. _1. Bring the machine to a stop by applying the
brakes.
2. Stop the engine.
3. With the rear brake lever and pedal applied,
apply the parking brake, and then slowly re-
lease the brake pedal.
U5TE61.book Page 21 Tuesday, May 6, 2003 4:40 PM

7-21
During operation
Always keep your feet on the footboards during
operation. Otherwise your feet may contact the
rear wheels.
WARNING
_ Always keep both hands on the handlebars
and both feet on the footboards of your ATV
during operation. Removing even one hand or
foot can reduce your ability to control the ATV
or could cause you to lose your balance and
fall off of the ATV. If you remove a foot from a
footboard, your foot or leg may come into con-
tact with the rear wheels, which could injure
you or cause an accident. _Avoid wheelies and jumping. You may lose control
of the ATV or overturn.
WARNING
_ Never attempt stunts, such as wheelies or
jumps. Don’t try to show off. _
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7-37
With the engine idling, return the starter (choke) to
the closed position, shift the drive select lever into
the forward position, and then release the parking
brake. Apply the throttle slowly and smoothly. The
centrifugal clutch will engage and you will start to
accelerate. If the throttle is applied too abruptly,
the front wheels may lift off the ground resulting in
a loss of directional control. Avoid higher speeds
until you are thoroughly familiar with the operation
of your ATV.
When slowing down or stopping, release the throt-
tle and apply the brakes smoothly and evenly. Im-
proper use of the brakes can cause the tires to
lose traction, reducing control and increasing the
possibility of an accident.
U5TE61.book Page 37 Tuesday, May 6, 2003 4:40 PM

7-39
TURNING YOUR ATV
To achieve maximum traction while riding off-road,
the two rear wheels are mounted solidly on one
axle and turn together at the same speed. There-
fore, unless the wheel on the inside of the turn is
allowed to slip or lose some traction, the ATV will
resist turning. A special turning technique must be
used to allow the ATV to make turns quickly and
easily. It is essential that this skill be learned first at
low speed.
WARNING
_ Always follow proper procedures for turning
as described in this Owner’s Manual.
Practice turning at low speeds before attempt-
ing to turn at faster speeds. Do not turn at
speeds too fast for your skills or the condi-
tions. _
U5TE61.book Page 39 Tuesday, May 6, 2003 4:40 PM