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  4. BIG BEAR 4X4 YFM40FC
  5. Owner's Manual

Yamaha BIG BEAR 4X4 YFM40FC Owner's Manual

Summary of BIG BEAR 4X4 YFM40FC

  • Page 1

    5fu-f8199-12 lit-11626-15-22 read this manual carefully! It contains important safety information. This atv should not be ridden by anyone under 16 years of age. Warning yfm40fp(c) printed in usa 2001 · 5 - 2.9 × 1 cr (e) printed on recycled paper warning always : • use proper riding techniques to a...

  • Page 2: 5Fu-F8199-12

    5fu-f8199-12 lit-11626-15-22 read this manual carefully! It contains important safety information. This atv should not be ridden by anyone under 16 years of age. Warning yfm40fp(c) printed in usa 2001 · 5 - 2.9 × 1 cr (e) printed on recycled paper warning always : • use proper riding techniques to a...

  • Page 3: Introduction

    Ebu00941 1- introduction congratulations on your purchase of the yamaha yfm40f. It represents the result of many years of yamaha experience in the production of fine sporting, touring, and pace-setting racing atvs. With the purchase of this yamaha, you can now appreciate the high degree of craftsman...

  • Page 4: Important Manual Information

    Ebu00801 1- important manual information failure to follow the warnings contained in this manual can result in serious injury or death. Particularly important information is distinguished in this manual by the following notations: the safety alert symbol means attention! Become alert! Your safety is...

  • Page 5: Important Notice

    Ebu00011 important notice this machine is designed and manufactured for off-road use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with all applicable off-road noise level and spark arrester laws and regulations in effect at the t...

  • Page 6: Contents

    Ebu00014 warning indicates a potential hazard that could result in serious injury or death. Contents location of the warning and specification labels....... 1-1 safety information.................. 2-1 description and machine identification ............................. 3-1 identification number rec...

  • Page 7

    Front shock absorber adjustment................................... 4-18 rear shock absorber adjustment................................... 4-19 auxiliary dc jack ........................... 4-20 pre-operation checks ........... 5-1 front and rear brakes ..................... 5-3 fuel ...................

  • Page 8

    Crossing through shallow water.... 7-34 riding over rough terrain............... 7-36 sliding and skidding ...................... 7-38 what to do if ... .............................. 7-40 what to do ... ................................. 7-40 periodic maintenance and adjustment.........................

  • Page 9

    Cleaning and storage............ 9-1 a. Cleaning...................................... 9-1 b. Storage ....................................... 9-3 specifications.......................... 10-1 noise regulation.................... 11-1 maintenance record ............ 12-1 atv limited warranty............

  • Page 10: Location of The Warning and

    1-1 ebu00464 location of the warning and specification labels ee.Book page 1 tuesday, april 24, 2001 9:31 am.

  • Page 11

    1-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 read and understand all of the labels on your machine. They contain important information for safe and proper operation of your atv. Never remove any labels from your atv. If a label becomes difficult to read or comes off, a replacement label is available from yo...

  • Page 12: Maximum.Loading Limit

    1-3 3 4 5 6 pulling load: 4020 n ( 4 1 0 k g f ) 904 l b f tongue weight: 147 n ( 1 5 k g f ) 33 l b f 5fu-f151k-00 maximum.Loading limit maximum.Loading limit ee.Book page 3 tuesday, april 24, 2001 9:31 am.

  • Page 13

    1-4 7 8 ee.Book page 4 tuesday, april 24, 2001 9:31 am.

  • Page 14: Safety Information

    2-1 safety information ebu00924 an atv is not a toy and can be hazardous to operate. An atv handles differently from other vehicles including motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you...

  • Page 15

    2-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ● always avoid operating an atv on any paved surfaces, including sidewalks, driveways, parking 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 approved motorcycle...

  • Page 16

    2-3 ● always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. ● never operate the atv on hills too steep for the atv or for your abilities. Practice on smaller hills before att...

  • Page 17

    2-4 ● always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side ...

  • Page 18

    2-5 ● always use the size and type tires specified in this manual. Always maintain proper tire pres- sure as described in this manual. ● never modify an atv through improper installation or use of accessories. ● never exceed the stated load capacity for an atv. Cargo should be properly distributed a...

  • Page 19

    2-6 warning potential hazard improper handling of gasoline. What can happen gasoline can catch fire and you could be burned. How to avoid the hazard always turn off the engine when refuel- ing. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the ...

  • Page 20

    2-7 warning potential hazard starting or running the engine in a closed area. What can happen exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. How to avoid the hazard always operate your atv in an area with adequate ventilation. Ee.Book page 7 tuesday, a...

  • Page 21

    3-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ebu00032 description and machine identification 1. Rear carrier 2. Seat 3. Auxiliary dc jack 4. Front carrier 5. Rear brake pedal 6. Headlight 7. Fuel cock 8. Recoil starter 9. Tail/brake light 10. Rear wheel 11. Shift pedal 12. Front wheel 13. Rear brake lever 1...

  • Page 22

    3-2 ebu00600 identification number records record the key identification number, vehicle identification number and model label infor- mation in the spaces provided for assistance when ordering spare parts from a yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification numb...

  • Page 23

    3-3 ebu00036 vehicle identification number the vehicle identification number is stamped into the frame. 1. Vehicle identification number note: the vehicle identification number is used to identify your machine. Ebu00787 model label the model label is affixed to the location in the illustration. Reco...

  • Page 24: Control Functions

    4-1 ebu00039 control functions warning indicates a potential hazard that could result in serious injury or death. Ebu00041 main switch functions of the respective switch positions are as follows: on: engine can be started only at this position and the headlight and taillight come on when the light s...

  • Page 25

    4-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ebu00043 indicator lights 1. Reverse indicator light “reverse” 2. Neutral indicator light “neutral” 3. Oil temperature warning light “oil temp” 4. Four-wheel drive indicator light “ ” ebu00044 reverse indicator light “reverse” this indicator light comes on when t...

  • Page 26

    4-3 ebu00733 oil temperature warning light checking method acb-10e turn the main switch to “on” and the engine stop switch to “ ”. Oil temperature warning light does not come on. Oil temperature warning light comes on. Check engine oil temperature. Oil temperature warning light does not come on. Eng...

  • Page 27

    4-4 ebu00051 speedometer the speedometer shows riding speed. This speedometer is equipped with an odometer and trip odometer. The trip odometer can be reset to “0” with the reset knob. Use the trip odometer to estimate how far you can ride on a tank of fuel before going to reserve. This in- formatio...

  • Page 28

    4-5 ebu00053 handlebar switches 1. Lights switch “lights” 2. Engine stop switch “ ”/“ ” 3. Start switch “ ” ebu00849 engine stop switch “ ”/“ ” make sure that the engine stop switch is in the “ ” position. The engine stop switch controls ignition and can be used at all times to stop the engine, espe...

  • Page 29

    4-6 ebu00060 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. 1. On co...

  • Page 30

    4-7 ebu00062 throttle lever once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any tim...

  • Page 31

    4-8 ebu00066 speed limiter the speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the ad- juster limits the maximum engine power avail- able and decreases the maximum speed of the atv. 1. Locknut 2. Adjuster a. 12 mm (0.47 in) warn...

  • Page 32

    4-9 ebu00070 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 ebu00073 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 ...

  • Page 33

    4-10 ebu00074 parking brake use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to re- lease the parking brake. 1. Lock plate warning poten...

  • Page 34

    4-11 ebu00084 shift pedal this machine is equipped with a constant- mesh 5-speed forward and 1-speed reverse transmission. The shift pedal is located on the left side of the engine. Reverse is at the bot- tom position. Neutral is one position above re- verse. 1. Shift pedal n. Neutral r. Reverse ebu...

  • Page 35

    4-12 ebu00590 recoil starter firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out. 1. Recoil starter warning potential hazard starting the engine in gear and/or start- ing the engine without setting the park-...

  • Page 36

    4-13 ebu00092 fuel tank cap remove the fuel tank cap by turning it coun- terclockwise. 1. Fuel tank cap ee.Book page 13 tuesday, april 24, 2001 9:31 am.

  • Page 37

    4-14 ebu00093 fuel cock the fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. Off: with the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. On: with the lever in this position, fuel flows...

  • Page 38

    4-15 ebu00095 starter (choke) “ ” starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “starting a cold engine” for proper op- era...

  • Page 39

    4-16 ebu00567 seat to remove the seat, pull the seat lock lever upward and pull up the seat at the rear. 1. Seat lock lever to install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Note: make sure that the seat is securely fitt...

  • Page 40

    4-17 ebu00581 storage box caution: to protect from damage, do not put metal products, like tools or sharply edged prod- ucts directly in the storage box. If they must be stored, wrap them in appropriate cushion material. Ebu00582 front carrier ebu00583 rear carrier maximum load limit: 2 kg (4.4 lb) ...

  • Page 41

    4-18 ebu00635 front shock absorber adjustment the spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows: to increase the spring preload, turn the ad- juster in direction a . To decrease the spring preload, turn the ad- juster in directi...

  • Page 42

    4-19 ebu00634 rear shock absorber adjustment the spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows: to increase the spring preload, turn the ad- juster in direction a . To decrease the spring preload, turn the ad- juster in directio...

  • Page 43

    4-20 ebu00748 auxiliary dc jack the auxiliary dc jack is located at the front right side of the atv. The auxiliary dc jack can be used for suitable work lights, radios, etc. The auxiliary dc jack can only be used when the main switch is in the “on” position. 1. Turn the headlight switch to the “off”...

  • Page 44

    4-21 caution: _ ● do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. ● if accessories are used without the en- gine running or with the headlight turned on, the battery will lose its charge and engine starting may become d...

  • Page 45: Pre-Operation Checks

    5-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 pre-operation checks before using this machine, check the following points: item routine page front brake • check operation, free play, fluid level and fluid leakage. • fill with dot 4 brake fluid if necessary. 5-3 ~ 5-4, 8-21 ~ 8-28 rear brake • check operation,...

  • Page 46

    5-2 warning potential hazard failure to inspect the atv before oper- ating. Failure to properly maintain the atv. What can happen increases the possibility of an accident or equipment damage. How to avoid the hazard always inspect your atv each time you use it to make sure the atv is in safe op- era...

  • Page 47

    5-3 ebu00883 front and rear brakes brake levers and brake pedal check for correct free play in the brake levers and brake pedal. If the free play is incorrect, adjust it. (see pages 8-24 ~ 8-27.) check op- eration of the levers and pedal. They should move smoothly and there should be a firm feeling ...

  • Page 48

    5-4 warning potential hazard riding with improperly operating brakes. What can happen you could lose braking ability, which could lead to an accident. How to avoid the hazard always check the brakes at the start of every ride. Do not ride the atv if you find any problem with the brakes. If a problem...

  • Page 49

    5-5 ebu00886 fuel make sure there is sufficient gasoline in the tank. Caution: _ use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, exhaust system, etc. _ your yamaha engine has been designed to use regular unlea...

  • Page 50

    5-6 warning potential hazard improper care when refueling. What can happen fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. How to avoid the hazard do not overfill the...

  • Page 51

    5-7 ebu00484 engine oil make sure the engine oil is at the specified level. Add oil as necessary. (see pages 8-5 ~ 8-8.) caution: be sure to use motor oils that do not con- tain anti-friction modifiers. Passenger car motor oils (often labeled “energy conserving”) contain anti-friction additives whic...

  • Page 52

    5-8 ebu00493 final gear oil make sure the final gear oil is at the specified level. Add oil as necessary. (see pages 8-9 ~ 8-10 for details.) if desired, an sae 80w90 hypoid gear oil may be used for all conditions. Note: gl-4 is a quality and additive rating, gl-5 or gl-6 rated hypoid gear oils may ...

  • Page 53

    5-9 ebu00153 lights check the headlight and taillight to make sure they are in working condition. Repair as nec- essary for proper operation. Ebu00155 switches check the operation of the headlight switch, engine stop switch and any other switches. Repair as necessary for proper operation. Ebu00157 t...

  • Page 54

    5-10 2. The tires should be set to the recom- mended pressure: ● recommended tire pressure front 25 kpa (0.25 kgf/cm 2 , 3.6 psi) rear 25 kpa (0.25 kgf/cm 2 , 3.6 psi) ● check and adjust tire pressures when the tires are cold. ● tire pressures must be equal on both sides. 3. Tire pressure below the ...

  • Page 55

    5-11 ebu00159 how to measure tire pressure use the low-pressure tire gauge. Note: the low-pressure tire gauge is included as standard equipment. Make two measure- ments of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set press...

  • Page 56

    5-12 ebu00160 tire wear limit when the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. A. 3 mm (0.12 in) ee.Book page 12 tuesday, april 24, 2001 9:31 am.

  • Page 57: Operation

    6-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ebu00161 operation warning indicates a potential hazard that could result in serious injury or death. Ebu00749 starting a cold engine 1. Set the parking brake. 2. Turn the fuel cock to “on”. 3. Turn the main switch to “on” and the en- gine stop switch to “ ”. 4. ...

  • Page 58

    6-2 note: _ ● when the transmission is in neutral, the neutral indicator light should come on. If the light does not come on, ask a yamaha dealer to inspect it. ● the engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral before startin...

  • Page 59

    6-3 note: _ ● if the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next at- tempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. ● if the batte...

  • Page 60

    6-4 ebu00195 reverse knob operation and reverse driving caution: before shifting, stop the machine and re- turn the throttle lever to its closed posi- tion. Otherwise the transmission may be damaged. 1. Bring the machine to a complete stop and return the throttle lever to the closed position with th...

  • Page 61

    6-5 ebu00201 shifting this model has a 5-speed forward and 1-speed reverse transmission with centrifugal automatic clutch. The transmission allows you to control the amount of power you have available at a given speed or for starting accelerating, climb- ing, etc. To shift into neutral, return the t...

  • Page 62

    6-6 4. Once the machine has attained adequate speed, release the throttle lever. 5. Shift into second gear and release the shift pedal. 6. Open the throttle gradually. 7. Follow the same procedure when shifting to the next higher gear. Ebu00207 to decelerate: when slowing down or stopping, release t...

  • Page 63

    6-7 ebu00209 engine break-in there is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first s...

  • Page 64

    6-8 2. 10 ~ 20 hours: avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throttle at any time. 3. After break-in: avoid prolonged full throttle operation. Vary speeds occasionally. Ebu00211 parking when parking, stop the engine and shift into n...

  • Page 65

    6-9 ebu00219 parking on a slope 1. Bring the machine to a stop by applying the brakes in low gear. 2. Stop the engine. 3. With the rear brake lever and pedal ap- plied, apply the parking brake and slowly release the rear brake pedal. Warning potential hazard parking on a hill or other incline. What ...

  • Page 66

    6-10 ebu00221 accessories and loading ebu00222 accessories accessories can affect the handling and con- trol of your atv. Keep the following in mind when considering an accessory or operating an atv which has accessories. ● choose only accessories designed for your atv. Your yamaha dealer has a vari...

  • Page 67

    6-11 ebu00588 loading cargo or a trailer can change the stability and handling of an atv. You must use common sense and good judg- ment when carrying cargo or towing a trailer. Keep the following points in mind: ● never exceed the weight limits shown. An overloaded atv can be unstable. ● do not exce...

  • Page 68

    6-12 ● ride more slowly than you would without a load. The more weight you carry, the slow- er you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trailer. ● allow more braking distance. A heavier ve- hicle take...

  • Page 69

    6-13 ee.Book page 13 tuesday, april 24, 2001 9:31 am.

  • Page 70

    6-14 ebu00888 warning _ indicates a potential hazard that could result in serious injury or death. Ee.Book page 14 tuesday, april 24, 2001 9:31 am.

  • Page 71: Riding

    7-1 7 1- riding your atv ee.Book page 1 tuesday, april 24, 2001 9:31 am.

  • Page 72

    7-2 ee.Book page 2 tuesday, april 24, 2001 9:31 am.

  • Page 73

    7-3 warning _ indicates a potential hazard that could result in serious injury or death. Getting to know your atv this atv is mainly for utility use, but may also be used for recreation. This section, riding your atv, provides general atv riding in- structions for recreational riding. The skills and...

  • Page 74

    7-4 ride with care and good judgement get training if you are inexperienced. Beginners or inexperienced riders should get training from a certified instructor. Become fa- miliar with this atv at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum perfor...

  • Page 75

    7-5 not recommended for children under 16 years of age. Warning potential hazard failure to follow the age recommenda- tions for this atv. What can happen use by children of atvs that are not rec- ommended for their age can lead to se- vere injury or death of the child. How to avoid the hazard a chi...

  • Page 76

    7-6 this atv is designed to carry operator and cargo only – passengers prohibited. Warning potential hazard carrying a passenger on this atv. What can happen greatly reduces your ability to balance and control this atv. Could cause an accident, resulting in harm to you and/ or your passenger. How to...

  • Page 77

    7-7 apparel warning potential hazard operating this atv without wearing an approved motorcycle helmet, eye pro- tection and protective clothing. What can happen operating without an approved motor - cycle helmet in- creases your chances of a severe head injury or death in the event of an accident. O...

  • Page 78

    7-8 do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. Warning potential hazard operating this atv after consuming al- cohol or drugs. What can happen could seriously affect your judgment. Could cause you to react more ...

  • Page 79

    7-9 pre-operation checks always perform the pre-operation checks list- ed on page 5-1 before riding for safety and proper care of the atv. Warning potential hazard failure to inspect the atv before oper- ating. Failure to properly maintain the atv. What can happen increases the possibility of an acc...

  • Page 80

    7-10 warning _ indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. Speed limiter for riders less experienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The spe...

  • Page 81

    7-11 loading and accessories use extra caution when riding the atv with additional loads, such as accessories or car- go. The atv’s handling may be adversely af- fected. Reduce your speed when adding additional loads. Maximum loading limit ● vehicle loading limit (total weight of cargo, rider and ac...

  • Page 82

    7-12 during operation always keep your feet on the footboards dur- ing operation. Otherwise your feet may con- tact the rear wheels. Warning potential hazard removing hands from handlebars or feet from footboards during operation. What can happen removing even one hand or foot can re- duce your abil...

  • Page 83

    7-13 avoid wheelies and jumping. You may lose control of the atv or overturn. Warning potential hazard attempting wheelies, jumps, and other stunts. What can happen increases the chance of an accident, in- cluding an overturn. How to avoid the hazard never attempt stunts, such as wheelies or jumps. ...

  • Page 84

    7-14 modifications warning potential hazard operating this atv with improper modi- fications. What can happen improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident. How to avoid the hazard never modify ...

  • Page 85

    7-15 exhaust system the exhaust system on the atv is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the atv in a place where pedestrians or children are not likely to touch it. Warning potential hazard hot exhaust system. What can happen dry grass ...

  • Page 86

    7-16 be careful where you ride this atv is designed for off-road use only. Riding on paved surfaces can cause loss of control. Warning potential hazard operating this atv on paved surfaces. What can happen atvs are designed for off-road use only. Paved surfaces may seriously affect handling and cont...

  • Page 87

    7-17 do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles. Warning potential hazard operating this atv on public streets, roads or highways. What can happen you can collide with another vehicle. How to avoid the hazard never operat...

  • Page 88

    7-18 know the terrain where you ride. Ride cau- tiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and oth- er hidden hazards which may cause the atv to upset. Warning potential hazard failure to use extra care when operating this atv on unfamiliar terrain. What can h...

  • Page 89

    7-19 warning potential hazard failure to use extra care when operating on excessively rough, slippery or loose terrain. What can happen could cause loss of traction or vehicle control, which could result in an acci- dent, including an overturn. How to avoid the hazard do not operate on excessively r...

  • Page 90

    7-20 when riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the atv. Do not use the flag pole bracket as a trailer hitch. Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. Warning potential ha...

  • Page 91

    7-21 select a large, flat area off-road to become fa- miliar with your atv. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Al- ways avo...

  • Page 92

    7-22 caution: _ do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. _ when slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed b...

  • Page 93

    7-23 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. Therefore, unless the wheel on the in- side of the turn is allowed to slip or lose some traction, the atv will resist turning. A special ...

  • Page 94

    7-24 this procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your atv may continue to go straight. If the atv doesn’t turn, come to a stop and then practice the procedure again. If the riding sur- face is slippery or ...

  • Page 95

    7-25 climbing uphill use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can ma- neuver your atv well on flat ground before at- tempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In ...

  • Page 96

    7-26 warning potential hazard climbing hills improperly. What can happen could cause loss of control or cause the atv to overturn. How to avoid the hazard always follow proper procedures for climbing hills as described in this own- er’s manual. Always check the terrain carefully be- fore you start u...

  • Page 97

    7-27 if you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the atv around while you still have forward motion (provided you have the room to do so) and go down the hill. Warning potential hazard improperly crossing hills or turn...

  • Page 98

    7-28 if your atv has stalled or stopped and you be- lieve you can continue up the hill, restart care- fully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dis- mount the atv on the uphill side. Physically turn the atv a...

  • Page 99

    7-29 dismount on uphill side or to a side if pointed straight uphill. Turn the atv around and remount, following the pro- cedure described in the owner’s manu- al. Ee.Book page 29 tuesday, april 24, 2001 9:31 am.

  • Page 100

    7-30 riding downhill when riding your atv downhill, shift your weight as far to the rear and uphill side of the atv as possible. Move back on the seat and sit with your arms straight. Engine compres- sion will do most of the braking for you. For maximum engine compression braking effect, change to 4...

  • Page 101

    7-31 warning potential hazard going down a hill improperly. What can happen could cause loss of control or cause the atv to overturn. How to avoid the hazard always follow proper procedures for go- ing down hills as described in this own- er’s manual. Note: a special technique is required when braki...

  • Page 102

    7-32 crossing a slope traversing a sloping surface on your atv re- quires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough t...

  • Page 103

    7-33 when crossing the side of a hill: always follow proper procedures as de- scribed in the owner’s manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the atv. Ee.Book page 33 tuesday, april 24, 2001 9:31 am.

  • Page 104

    7-34 crossing through shallow water the atv can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the wa- ter, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or u...

  • Page 105

    7-35 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. Wash the atv...

  • Page 106

    7-36 riding over rough terrain riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the atv or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the atv as loss of control an...

  • Page 107

    7-37 ee.Book page 37 tuesday, april 24, 2001 9:31 am.

  • Page 108

    7-38 sliding and skidding care should be used when riding on loose or slippery surfaces since the atv may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, position- ing your weight over the ...

  • Page 109

    7-39 with practice, over a period of time, skill at controlled sliding can be developed. The ter- rain should be chosen carefully before at- tempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfa...

  • Page 110

    7-40 what to do if ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. What to do ... ● if your atv doesn’t turn when you want it to: bring the atv to a stop and practice the turning maneuvers again. Be sure you are putting your we...

  • Page 111

    7-41 ● if your atv is traversing a sloping surface: be sure to ride with your weight positioned towards the uphill side of the atv to main- tain proper balance. If the atv starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you dis- cover that the atv is ...

  • Page 112: Periodic Maintenance and

    8-1 ebu00515 periodic maintenance and adjustment periodic inspection, adjustment and lubrica- tion will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, ad- justment and lubrication a...

  • Page 113

    8-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1. Tool kit 2. Low-pressure tire gauge the service information included in this man- ual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor re- pairs. The tools provided in the owner’s to...

  • Page 114

    8-3 ebu00261 periodic maintenance/lubrication item routine initial every 1 month 3 months 6 months 6 months 1 year valves* • check valve clearance. • adjust if necessary. Spark plug • check condition. • adjust gap and clean. • replace if necessary. Air filter • clean. • replace if necessary. Every 2...

  • Page 115

    8-4 * it is recommended that these items be serviced by a yamaha dealer. Note: brake fluid replacement: 1. When disassembling the master cylinder or caliper cylin- der, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 2. On the inner parts of the master cylind...

  • Page 116

    8-5 ebu00949 engine oil engine oil level measurement 1. Place the machine on a level surface. 2. Warm up the engine for several minutes, and then stop it. 3. Remove the dipstick, and then wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in. 1. Dipstick note: _...

  • Page 117

    8-6 engine oil replacement and oil filter ele- ment cleaning 1. Place the machine on a level surface. 2. Warm up the engine for several minutes and stop it. 3. Place a container under the engine. 4. Remove the dipstick, and then remove the drain bolt to drain the oil. Caution: _ when removing the dr...

  • Page 118

    8-7 6. Clean the oil strainer and oil filter element with solvent. 7. Check the o-ring for damage and re- place it if damaged. 8. Install the oil filter element, and o-ring. 9. Install the oil filter cover by installing the bolts. 10. Install the oil strainer, compression spring and drain bolt. Tigh...

  • Page 119

    8-8 12. Warm up the engine for several minutes at idle speed. Check for oil leakage while warming up. Caution: _ if oil leakage is found, stop the engine im- mediately and check for the cause. _ oil pressure check 1. Put a cloth around the cylinder. 2. Slightly loosen the oil gallery bolt in the cyl...

  • Page 120

    8-9 ebu00825 final gear oil final gear oil measurement 1. Place the machine on a level place. 2. Remove the oil filler bolt and check the oil level. It should be up to the brim of the hole. If the level is low, add oil to raise it to the proper level. Caution: _ be sure no foreign material enters th...

  • Page 121

    8-10 2. Place the machine on a level place. 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. 1. Drain bolt 5. Install the drain bolt and tighten it to the specified torque. 6. Fill the final gear case with oil....

  • Page 122

    8-11 ebu00750 differential gear oil replacement 1. Place the machine on a level place. 2. Place a container under the differential gear case. 3. Remove the filler bolt and drain bolt to drain the oil. 1. Filler bolt 1. Drain bolt 4. Install the drain bolt and tighten to speci- fication. 5. Fill the ...

  • Page 123

    8-12 caution: be sure no foreign material enters the dif- ferential gear case. 6. Install the filler bolt and tighten to specifi- cation. 7. Check for oil leakage. If oil leakage is found, check for the cause. Recommended oil: sae 80 api “gl-4” hypoid gear oil oil quantity: periodic oil change: 0.35...

  • Page 124

    8-13 ebu00283 front axle boots check the protective boots for holes or tears. If any damage is found, have them replaced by a yamaha dealer. 1. Boot ( × 2) 1. Boot ( × 2) ebu00286 spark plug inspection the spark plug is an important engine compo- nent and is easy to inspect. The condition of the spa...

  • Page 125

    8-14 before installing the spark plug, measure the electrode gap with a feeler gauge and adjust to specification. A. Spark plug gap when installing the spark plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tight- en to the specified torque. Ebu0085...

  • Page 126

    8-15 1. Air filter case cover 3. Pull out the air filter element. 1. Air filter element 4. Separate the foam cover from the air filter element. 1. Air filter element 2. Foam cover ee.Book page 15 tuesday, april 24, 2001 9:31 am.

  • Page 127

    8-16 5. Tap the element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown. If the element is damaged, replace it. 6. Wash the foam cover gently but thor- oughly in water or solvent. 7. Squeeze the excess water or solvent out of the foam cover and l...

  • Page 128

    8-17 note: the air filter element should be cleaned every 20 ~ 40 hours. It should be cleaned more of- ten if the machine is operated in extremely dusty areas. Each time filter element mainte- nance is performed, check the air inlet to the filter case for obstructions. Check the air cleaner rubber j...

  • Page 129

    8-18 ebu00296 carburetor adjustment the carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a yamaha dealer who has the professional knowledge and ex- perience to do so. However, the idling speed may be performed by the owner as a par...

  • Page 130

    8-19 ebu00301 idle speed adjustment note: a diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throt...

  • Page 131

    8-20 ebu00303 valve clearance adjustment the correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clear- ance must be adjusted regularly. This adjust- ment however, should be left to a professional yamaha service technician. Ebu0...

  • Page 132

    8-21 ebu00439 front brake pad inspection apply the brake and inspect the wear indica- tor. If the wear indicator is almost in contact with the disc, ask a yamaha dealer to re- place the pads. 1. Wear indicator ( × 2) a. Wear limit: 1mm (0.04 in) ebu00313 rear brake shoe inspection a wear indicator i...

  • Page 133

    8-22 ebu00755 brake fluid level inspection insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the lower level and re- plenish when necessary. Observe these pre- cautions: 1. When checking ...

  • Page 134

    8-23 5. Brake fluid may deteriorate painted sur- faces or plastic parts. Always clean up spilled fluid immediately. 6. Have a yamaha dealer check the cause if the brake fluid level goes down. Ebu00752* brake fluid replacement 1. Complete fluid replacement should be done only by trained yamaha servic...

  • Page 135

    8-24 ebu00623 front brake adjustment the front brake lever should have a free play of zero mm (zero in) at the lever end. If not, ask a yamaha dealer to adjust it. A. Free play warning potential hazard operating with improperly serviced or adjusted brakes. What can happen you could lose braking abil...

  • Page 136

    8-25 ebu00329 rear brake pedal and lever adjustment 1. Brake pedal free play adjustment a. Fully loosen the adjusting nut on the brake cable. 1. Adjusting nut (brake cable) 2. Adjusting nut (brake rod) b. Turn the adjusting nut on the brake rod until free play is 20 ~ 30 mm (0.8 ~ 1.18 in). A. Free ...

  • Page 137

    8-26 2. Brake lever free play adjustment a. Loosen the locknut and fully turn in the adjusting bolt at the brake lever. 1. Locknut 2. Adjusting bolt b. Screw in the adjusting nut on brake cable to provide a gap of 0 ~ 1 mm (0 ~ 0.04 in) between the lever and the pin. 1. Adjusting nut (brake cable) a...

  • Page 138

    8-27 c. Turn the adjusting bolt until free play at the brake lever pivot is 5 ~ 7 mm (0.20 ~ 0.28 in). 1. Locknut 2. Adjusting bolt a. Free play: 5 ~ 7 mm (0.20 ~ 0.28 in) d. Tighten the locknut. Warning potential hazard operating with improperly serviced or adjusted brakes. What can happen you coul...

  • Page 139

    8-28 ebu00834 adjusting the rear brake light switch the rear brake light switch, which is activated by the brake pedal and brake levers, is prop- erly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting n...

  • Page 140

    8-29 3. Tighten the locknut to specification. Note: turn the adjusting bolt counterclockwise to decrease the clutch free play and turn it clock- wise to increase the free play. Ebu00356 cable inspection and lubrication tightening torque: 15 nm (1.5 m·kgf, 11 ft·lb) warning potential hazard damaged c...

  • Page 141

    8-30 lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a yamaha dealer to replace them. Ebu00727 brake and shift pedal/brake lever lubrication lubricate the pivoting parts of each lever and pedal. Ebu00373 wheel removal 1. Elevate the wheel by placing a suitab...

  • Page 142

    8-31 ebu00828 wheel installation when installing a wheel, reverse the removal procedure. Note: _ the arrow mark on the tire must point to- ward the rotating direction of the wheel. _ 1. Arrow mark 1. Tapered wheel nuts are used for both front and rear wheels. Install the nut with its tapered side to...

  • Page 143

    8-32 ebu00380 battery this machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the bat- tery. If the battery seems to have discharged, consult a yamaha dealer. Caution: do not try to remove the sealing caps of the battery c...

  • Page 144

    8-33 ebu00385 battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. Caution: a special battery charger (constant volt- age/ampere or constant voltage) is re- quired for ...

  • Page 145

    8-34 1. Main fuse 2. Four-wheel-drive fuse 3. Spare fuse 1. Headlight fuse 2. Ignition fuse 3. Auxiliary dc jack fuse 4. Carburetor warmer fuse 5. Spare fuse caution: _ to prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. _ warning potential hazard usin...

  • Page 146

    8-35 ebu00753 replacing the headlight bulb if the headlight bulb burns out, replace the bulb as follows: 1. Remove the headlight assembly by re- moving the screws. 2. Disconnect the coupler. 3. Remove the light unit assembly from the headlight assembly by removing the screw. 4. Remove the bulb holde...

  • Page 147

    8-36 6. Put a new bulb into position and secure it in place with the bulb holder. 7. Install the bulb holder cover. Caution: _ make sure the bulb holder cover is secure- ly fitted over the bulb holder and seated against the reflector. _ 8. Install the headlight assembly and con- nect the coupler. 9....

  • Page 148

    8-37 ebu00409 headlight beam adjustment caution: it is advisable to have a yamaha dealer make this adjustment. 1. Vertical adjustment: to raise the beam, turn the adjusting screw clockwise. To lower the beam, turn the screw coun- terclockwise. 1. Adjusting screw ( × 2) ebu00945 tail/brake light bulb...

  • Page 149

    8-38 1. Bulb holder 4. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 1. Bulb holder 2. Bulb 5. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 6. Install the bulb holder (together with the bulb). 7. Install t...

  • Page 150

    8-39 ebu00412 troubleshooting although yamaha machines receive a rigid in- spection before shipment from the factory, trouble may occur during operation. Any prob- lem in the fuel, compression, or ignition sys- tems can cause poor starting and loss of power. The troubleshooting chart describes a qui...

  • Page 151

    8-40 ebu00440 troubleshooting chart 1. Fuel check if there is fuel in the fuel tank. There is fuel. Turn the fuel cock to “off”. Remove the fuel pipe. Fuel cock clogged. Clean fuel cock. Some fuel. Turn the fuel cock to “res”. Restart engine. No fuel. Supply fuel 2. Compression use the electric star...

  • Page 152: Cleaning and Storage

    9-1 ebu00419 1- cleaning and storage a. Cleaning frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to preven...

  • Page 153

    9-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective ...

  • Page 154

    9-3 ebu00530 b. Storage long term storage (60 days or more) of your machine will require some preventive proce- dures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of yamaha fu...

  • Page 155

    9-4 7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an ex- cessively warm or cold place (less than 0 °c (30 °f) or more than 30 °c (90 °f)). Note: make any necessary repairs before storing the machine. Ee.Book page 4 tuesday, apr...

  • Page 156: Specifications

    10-1 ebu00428 specifications model yfm40f dimension: overall length overall width overall height seat height wheel base minimum ground clearance minimum turning radius 2,007 mm ( 79.0 in) 1,111 mm ( 43.7 in) 1,172 mm ( 46.1 in) 855 mm ( 33.7 in) 1,230 mm ( 48.4 in) 245 mm ( 9.65 in) 3,150 mm (124.0 ...

  • Page 157

    10-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 engine oil: type quantity: periodic oil change with oil filter replacement total amount see page 5-7 2.9 l (2.6 imp qt, 3.1 us qt) 3.0 l (2.6 imp qt, 3.2 us qt) 3.5 l (3.1 imp qt, 3.7 us qt) final gear oil: type quantity periodic oil change total amount sae 80 a...

  • Page 158

    10-3 spark plug: type/manufacturer gap dr8ea / ngk 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) clutch type wet, centrifugal automatic transmission: primary reduction system primary reduction ratio secondary reduction system secondary reduction ratio transmission type operation gear raito: 1st 2nd 3rd 4th 5th re...

  • Page 159

    10-4 brake: front brake type operation rear brake type operation dual disk brake right hand operation drum brake left hand and right foot operation suspension: front rear double wishbone swingarm (monocross) shock absorber: front rear coil spring / oil damper coil spring / oil damper wheel travel: f...

  • Page 160: Noise Regulation

    11-1 ebu00430 noise regulation tampering with noise control system prohibited: federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice or element of design...

  • Page 161: Maintenance Record

    12-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ebu00431 maintenance record copies of work orders and/or receipts for parts you purchase and install will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work...

  • Page 162

    13-1 ebu00432 yamaha motor corporation, u.S.A. Atv limited warranty ee.Book page 1 tuesday, april 24, 2001 9:31 am.

  • Page 163

    13-2 1 2 3 4 5 6 7 8 9 10 9 9 13 14 ee.Book page 2 tuesday, april 24, 2001 9:31 am.

  • Page 164

    14-1 ebu00435 yamaha extended service (y.E.S.) ee.Book page 1 tuesday, april 24, 2001 9:31 am.

  • Page 165

    14-2 1 2 3 4 5 6 7 8 9 10 9 9 9 14 ee.Book page 2 tuesday, april 24, 2001 9:31 am.

  • Page 166

    14-3 ebu00436 warning indicates a potential hazard that could result in serious injury or death. Ee.Book page 3 tuesday, april 24, 2001 9:31 am.

  • Page 167

    14-4 ee.Book page 4 tuesday, april 24, 2001 9:31 am.

  • Page 168

    14-5 ebu00437 ee.Book page 5 tuesday, april 24, 2001 9:31 am.