brake YAMAHA YFM400F 2001 Owners Manual

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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 ........... 3-5
Model label ......................................... 3-7
CONTROL FUNCTIONS ......................... 4-1
Main switch......................................... 4-1
Indicator lights .................................... 4-3
Coolant temperature indicator light
checking method .............................. 4-7
Speedometer .................................... 4-11
Fuel gauge ........................................ 4-13
Handlebar switches .......................... 4-15
Throttle lever .................................... 4-21
Speed limiter .................................... 4-23
Front brake lever .............................. 4-25Rear brake pedal and lever.............. 4-27
Drive select lever .............................. 4-29
Recoil starter..................................... 4-29
Fuel tank cap..................................... 4-31
Fuel cock ........................................... 4-33
Starter (choke) “ ” ........................ 4-35
Seat ................................................... 4-37
Storage box ...................................... 4-39
Front carrier ...................................... 4-39
Rear carrier ....................................... 4-39
Front shock absorber
adjustment...................................... 4-41
Rear shock absorber
adjustment...................................... 4-45
Auxiliary DC jack .............................. 4-49
PRE-OPERATION CHECKS .................... 5-1
Front and rear brakes......................... 5-7
Fuel .................................................... 5-11
Engine oil .......................................... 5-15
Final gear oil ..................................... 5-19
Differential gear oil .......................... 5-21
Throttle lever .................................... 5-21
Fittings and Fasteners...................... 5-21
1234
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V-belt cooling duct check hose ....... 8-77
Carburetor adjustment..................... 8-81
Idle speed adjustment...................... 8-83
Valve clearance adjustment ............ 8-85
Throttle lever adjustment ................ 8-87
Front brake pad inspection .............. 8-89
Rear brake pad inspection ............... 8-89
Inspecting the brake fluid level ....... 8-91
Brake fluid replacement ................... 8-95
Front brake adjustment.................... 8-97
Rear brake lever adjustment ........... 8-99
Cable inspection and
lubrication ..................................... 8-103
Brake lever and brake pedal
lubrication ..................................... 8-105
Wheel removal ............................... 8-107
Wheel installation........................... 8-109
Battery ............................................. 8-111
Battery maintenance ...................... 8-115
Fuse replacement ........................... 8-117
Replacing the headlight bulb ........ 8-121
Headlight beam adjustment .......... 8-125
Taillight bulb replacement............. 8-127
Troubleshooting ............................. 8-129
Troubleshooting chart ................... 8-131CLEANING AND STORAGE................... 9-1
A. Cleaning ......................................... 9-1
B. Storage ........................................... 9-7
SPECIFICATIONS ................................. 10-1
HOW TO USE THE CONVERSION
TABLE ................................................... 11-1
91011

2-11
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Always check for obstacles before operat-
ing in a new area.
Never attempt to operate over large obsta-
cles, such as large rocks or fallen trees. Al-
ways follow proper procedures when
operating over obstacles as described in
this manual.
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Always be careful when skidding or sliding.
Learn to safely control skidding or sliding
by practicing at low speeds and on level,
smooth terrain. On extremely slippery sur-
faces, such as ice, go slowly and be very
cautious in order to reduce the chance of
skidding or sliding out of control.
l
Never operate an ATV in fast flowing water
or in water deeper than that recommended
in this manual. Remember that wet brakes
may have reduced stopping ability. Test
your brakes after leaving water. If neces-
sary, apply them several times to let friction
dry out the linings.

3-1
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DESCRIPTION AND MACHINE
IDENTIFICATION
1. Rear spring preload
adjusting ring
2. Storage box and tool kit
3. Spark plug
4. Rear brake fluid
reservoir
5. Radiator cap
6. Front spring preload
adjusting ring
7. V-belt case
8. Rear brake pedal
9. Front spring preload
adjusting ring
10. Fuel cock
11. Air filter case
12. Fuses13. V-belt cooling duct
check hose
14. 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 lever
NOTE:

The machine you have purchased may differ
slightly from those shown in the figures of this
manual.

4-25
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Front brake lever
The front brake lever is located on the right
handlebar. Pull it toward the handlebar to ap-
ply the front brake.
1. Front brake lever
1. Levier de frein avant
1. Palanca del freno delantero

4-27
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Rear brake pedal and lever
The brake pedal is located on the right side of
the machine and the brake lever is located on
the left handlebar. Push down on the pedal or
pull the lever toward the handlebar to apply
the rear brake.
1. Rear brake lever
1. Levier de frein arrière
1. Palanca del freno trasero1. Rear brake pedal
1. Pédale de frein arrière
1. Pedal del freno trasero

5-1
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PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Brakes
• Check operation, free play, fluid level and fluid leakage.
• Fill with DOT 4 brake fluid if necessary.5-7 ~ 5-9,
8-91 ~ 8-95
Fuel
• Check fuel level.
• Fill with fuel if necessary.5-11 ~ 5-13
Engine oil
• Check oil level.
• Fill with oil if necessary.5-15 ~ 5-17,
8-31 ~ 8-41
Coolant reservoir
• Check coolant level.
• Fill with coolant if necessary.8-53 ~ 8-63
Final gear oil/
Differential gear oil
• Check for leakage. 5-19, 8-41 ~ 8-51
Throttle
• Check for proper throttle cable operation. 5-21, 8-87
Wheels and tires
• Check tire pressure, wear and damage.5-25 ~ 5-31,
8-107 ~ 8-109
Fittings and Fasteners
• Check all fittings and fasteners. 5-21
Lights
• Check for proper operation. 5-23, 8-121 ~ 8-127
Front axle boots
• Check for damage. 8-63

5-7
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Front and rear brakes
1. Brake levers and brake pedal
Check for correct free play in the rear
brake lever and that there is no free play in
the front brake lever. If the free play is in-
correct, adjust it. (See pages 8-95 ~ 8-103.)
Check the operation of the levers and ped-
al. They should move smoothly and there
should be a firm feeling when the brakes
are applied. If not, have the machine in-
spected by a Yamaha dealer.
2. Brake fluid level
Check the brake fluid level.
Add fluid if necessary. (See pages 8-91 ~
8-95.)
3. Brake fluid leakage
Check to see if any brake fluid is leaking
out of the pipe joints or master cylinder.
Apply the brakes firmly for one minute. If
there is any leaking, have the machine in-
spected by a Yamaha dealer. Recommended brake fluid: DOT 4

5-9
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4. Brake operation
Test the brakes at slow speed after start-
ing out to make sure they are working
properly. If the brakes do not provide
proper braking performance, inspect the
brake pads for wear. (See page 8-89.)
WARNING

Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual,
have the ATV inspected by a Yamaha dealer.

6-3
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Starting a cold engine
WARNING

Always make sure all control cables work
smoothly before you begin riding in cold
weather. If the control cables are frozen or do
not work smoothly, you could be unable to
control the ATV, which could lead to an acci-
dent or collision.
1. Apply the rear brake lever.
2. Turn the fuel cock to “ON”.
3. Turn the main switch to “ON” and the en-
gine stop switch to “ ”.
4. Shift the drive select lever into the neutral
or park position.