Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM40FP(C) WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-15-22 5FU-F8199-12...
Page 2 LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN USA 2001 · 5 - 2.9 1 CR...
Page 3 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 craftsmanship and reliability that have made Yamaha a leader in these fields.
Page 4: Warning
EBU00801 I MPORTANT 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 INVOLVED! Failure to follow WARNING instructions could result in severe WARNING...
Page 5 Please check your local riding laws and regulations before operating this machine. EBU00531 YFM40FP (C) OWNER’S MANUAL © 2001 by Yamaha Motor Corporation, AFFIX DEALER U.S.A. 1st Edition, April 2001 LABEL HERE All rights reserved.
Page 6: Table Of Contents
EBU00014 CONTROL FUNCTIONS....4-1 WARNING Main switch ........4-1 Indicates a potential hazard that could Indicator lights........4-2 result in serious injury or death. Oil temperature warning light checking method......4-3 Speedometer ........4-4 CONTENTS Fuel gauge ........4-4 Handlebar switches ......4-5 Throttle lever ........4-7 LOCATION OF THE WARNING Speed limiter ........4-8 AND SPECIFICATION LABELS..
Page 7 Front shock absorber OPERATION ........6-1 adjustment........4-18 Starting a cold engine...... 6-1 Rear shock absorber Starting a warm engine ....6-3 adjustment........4-19 Warming up ........6-3 Auxiliary DC jack......4-20 Reverse knob operation and reverse driving ....... 6-4 PRE-OPERATION CHECKS ...
Page 8 Crossing through shallow water..7-34 Rear brake shoe inspection...8-21 Riding over rough terrain....7-36 Brake fluid level inspection ....8-22 Sliding and skidding ...... 7-38 Brake fluid replacement ....8-23 What to do if ......... 7-40 Front brake adjustment....8-24 What to do ........7-40 Rear brake pedal and lever adjustment ........8-25 PERIODIC MAINTENANCE AND...
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.... 13-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ........... 14-1...
Page 10: Location Of The Warning And Specification Labels
EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
Page 11 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 your Yamaha dealer.
Page 12 MAXIMUM . LOADING LIMIT MAXIMUM . LOADING LIMIT ( 4 1 0 k g f ) PULLING LOAD: 4020 N 904 l b f ( 1 5 k g f ) TONGUE WEIGHT: 147 N 33 l b f 5FU-F151K-00...
Page 14: Safety Information
EBU00924 SAFETY INFORMATION 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 fail to take proper precautions.
Page 15 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 helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
Page 16 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 attempting larger hills.
Page 17 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 or to a side if pointed straight uphill.
Page 18 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 and securely attached.
Page 19 WARNING When transporting the ATV in another vehicle, be sure it is kept upright and POTENTIAL HAZARD that the fuel cock is in the “OFF” posi- Improper handling of gasoline. tion. Otherwise, fuel may leak out of the WHAT CAN HAPPEN carburetor or fuel tank.
Page 20 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.
Page 21: Description And Machine Identification
EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Rear carrier 12. Front wheel 2. Seat 13. Rear brake lever 3. Auxiliary DC jack 14. Parking brake lock plate 4. Front carrier 15. Starter (choke) 5. Rear brake pedal 16. Speedometer 6. Headlight 17.
Page 22: Identification Number Records
This number can be used for ordering a new when ordering spare parts from a Yamaha key. dealer or for reference in case the vehicle is stolen.
Page 23: Model Label
Record the information on this la- bel in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine.
Page 24: Control Functions
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: Engine can be started only at this position and the headlight and taillight come on when the light switch is on.
Page 25: Indicator Lights
EBU00043 EBU00732 Indicator lights Oil temperature warning light “OIL TEMP” When the oil temperature reaches a specified level, this light comes on to warn that the en- gine oil temperature is too hot. If the warning light comes on during operation, stop the en- gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.
Page 26: Oil Temperature Warning Light Checking Method
Allow to cool. Engine oil temperature and Ask a Yamaha dealer to electrical circuit are OK. Go inspect the electrical circuit. ahead with riding.
Page 27: Speedometer
EBU00051 EBU00052 Speedometer Fuel gauge The speedometer shows riding speed. This The fuel gauge indicates the amount of fuel in speedometer is equipped with an odometer the fuel tank. When the needle reaches the and trip odometer. The trip odometer can be red line, refill the tank at the first opportunity.
Page 28: Handlebar Switches
EBU00053 EBU00607 Handlebar switches Start switch “ ” The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine. (See page 6-1 for details.) EBU00735 Light switch Turn the switch to the “ ”...
Page 29 EBU00060 On command four-wheel drive switch WARNING “2WD/4WD” POTENTIAL HAZARD To change from two-wheel drive (2WD) to Changing from 2WD to 4WD or from four-wheel drive (4WD), stop the ATV and set 4WD to 2WD while the ATV is moving. the switch to the 4WD position.
Page 30: Throttle Lever
Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you 1. Throttle lever can’t find or solve the problem yourself.
Page 31: Speed Limiter
EBU00066 Speed limiter WARNING The speed limiter keeps the throttle from fully POTENTIAL HAZARD opening, even when the throttle lever is Improper adjustment of the speed limit- pushed to the maximum. Screwing in the ad- er and throttle. juster limits the maximum engine power avail- WHAT CAN HAPPEN able and decreases the maximum speed of The throttle cable could be damaged.
Page 32: Front Brake Lever
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. Rear brake pedal 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 left handlebar.
Page 33: Parking Brake
EBU00074 Parking brake WARNING Use the parking brake when you have to start POTENTIAL HAZARD the engine or park the machine, especially on Improper use of the parking brake. a slope. Apply the rear brake lever and push WHAT CAN HAPPEN down the lock plate to apply the parking The ATV could start moving unexpect- brake.
Page 34: Shift Pedal
EBU00084 EBU00747 Shift pedal Reverse knob This machine is equipped with a constant- The reverse knob is used to shift into reverse mesh 5-speed forward and 1-speed reverse gear. transmission. The shift pedal is located on the Refer to the “Reverse knob operation and re- left side of the engine.
Page 35: Recoil Starter
EBU00590 Recoil starter WARNING Firmly grasp the handle and pull slightly until POTENTIAL HAZARD engagement can be felt. Then pull forcefully, Starting the engine in gear and/or start- being careful not to pull the rope all the way ing the engine without setting the park- out.
Page 36: Fuel Tank Cap
EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun- terclockwise. 1. Fuel tank cap 4-13...
Page 37: Fuel Cock
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 to the carburetor.
Page 38: Starter (Choke)
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).
Page 39: Seat
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.
Page 40: Storage Box
EBU00581 EBU00582 Storage box Front carrier Maximum load limit: 2 kg (4.4 lb) Maximum load limit: 40 kg (88 lb) CAUTION: EBU00583 To protect from damage, do not put metal Rear carrier products, like tools or sharply edged prod- Maximum load limit: 80 kg (176 lb) ucts directly in the storage box.
Page 41: Front Shock Absorber Adjustment
EBU00635 Front shock absorber adjustment Standard position: B The spring preload can be adjusted to suit the A - Minimum (Soft) rider’s weight and riding conditions. E - Maximum (Hard) Adjust the spring preload as follows: To increase the spring preload, turn the ad- WARNING juster in direction a.
Page 42: Rear Shock Absorber Adjustment
EBU00634 Rear shock absorber adjustment Standard position: B The spring preload can be adjusted to suit the A - Minimum (Soft) rider’s weight and riding conditions. E - Maximum (Hard) Adjust the spring preload as follows: To increase the spring preload, turn the ad- juster in direction a.
Page 43: Auxiliary Dc Jack
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”...
Page 44 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 difficult.
Page 45: Pre-Operation Checks
PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE • Check operation, free play, fluid level and fluid leakage. Front brake 5-3 ~ 5-4, • Fill with DOT 4 brake fluid if necessary. 8-21 ~ 8-28 Rear brake •...
Page 46 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- erating condition.
Page 47: Front And Rear Brakes
If not, have a Yamaha dealer. the ATV inspected by a Yamaha dealer. Brake operation Test the brakes at slow speed after starting Brake fluid level (Front brake) out to make sure they are working properly.
Page 48 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 cannot be corrected by the ad- justment procedures provided in this manual, have the ATV inspected by a Yamaha dealer.
Page 49: Fuel
UNLEADED GASOLINE ONLY Fuel tank capacity: hol containing methanol is not recommended Total: by Yamaha because it may cause fuel system 15 L (3.3 Imp gal, 4.0 US gal) damage or vehicle performance problems. Reserve: 4.0 L (0.9 Imp gal, 1.1 US gal) CAUTION: Use only unleaded gasoline.
Page 50 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.
Page 51: Engine Oil
EBU00484 Engine oil CAUTION: Make sure the engine oil is at the specified Be sure to use motor oils that do not con- level. Add oil as necessary. (See pages 8-5 ~ tain anti-friction modifiers. 8-8.) Passenger car motor oils (often labeled “Energy Conserving”) contain anti-friction Recommended oil: additives which will cause clutch and/or...
Page 52: Final Gear Oil
Repair as necessary for proper operation. EBU00152 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.
Page 53: Lights
HOW TO AVOID THE HAZARD 1. The tires listed below have been ap- proved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recommended. Manufacturer Size...
Page 54 2. The tires should be set to the recom- 4. Use no more than the following pres- mended pressure: sures when seating the tire beads. Recommended tire pressure Front 250 kPa (2.5 kgf/cm , 36 psi) Front 25 kPa (0.25 kgf/cm , 3.6 psi) Rear 250 kPa (2.5 kgf/cm , 36 psi)
Page 55: How To Measure Tire Pressure
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.
Page 56: Tire Wear Limit
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) 5-12...
Page 57: Operation
2. Turn the fuel cock to “ON”. there is a control or function you do not 3. Turn the main switch to “ON” and the en- understand, ask your Yamaha dealer. gine stop switch to “ ”. 4. Shift the transmission into neutral.
Page 58 25 °C (80 °F) neutral indicator light should come on. If the and warm engine start position. 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.
Page 59: Starting A Warm Engine
NOTE: CAUTION: If the engine fails to start, release the start See the “Engine break-in” section prior to switch, then push the start switch again. operating the engine for the first time. Pause a few seconds before the next at- tempt.
Page 60: Reverse Knob Operation And Reverse Driving
If the light does not come on, CAUTION: ask a Yamaha dealer to inspect the machine. Before shifting, stop the machine and re- 4. Check behind you for people or obsta- turn the throttle lever to its closed posi- cles, then release the rear brake lever.
Page 61: Shifting
EBU00201 Shifting CAUTION: This model has a 5-speed forward and 1-speed Do not coast for long periods with the en- reverse transmission with centrifugal automatic gine off, and do not tow the machine a clutch. The transmission allows you to control long distance.
Page 62: To Decelerate
EBU00207 4. Once the machine has attained adequate To decelerate: speed, release the throttle lever. When slowing down or stopping, release the 5. Shift into second gear and release the throttle and apply the brakes smoothly and shift pedal. evenly. As you slow down, shift to a lower 6.
Page 63: Engine Break-In
Because the engine is If any abnormality is noticed during this peri- brand new, you must not put an excessive od, consult a Yamaha dealer. load on it for the first several hours of running. 1. 0 ~ 10 hours:...
Page 64: Parking
EBU00211 2. 10 ~ 20 hours: Parking Avoid prolonged operation above When parking, stop the engine and shift into 3/4 throttle. Rev the machine freely neutral. Turn the fuel cock to “OFF” and apply through the gears but do not use full the parking brake.
Page 65: Parking On A Slope
EBU00219 Parking on a slope 1. Bring the machine to a stop by applying the brakes in low gear. WARNING 2. Stop the engine. POTENTIAL HAZARD 3. With the rear brake lever and pedal ap- Parking on a hill or other incline. plied, apply the parking brake and slowly WHAT CAN HAPPEN release the rear brake pedal.
Page 66: Accessories And Loading
Choose only accessories designed for your dlebars which could make steering difficult, ATV. Your Yamaha dealer has a variety of an accessory that limits your ability to move genuine Yamaha accessories. Other ac-...
Page 67 EBU00588 Loading Do not exceed the maximum tongue Cargo or a trailer can change the stability and weight. You can measure tongue weight handling of an ATV. with a bathroom scale. Put the tongue of You must use common sense and good judg- the loaded trailer on the scale with the ment when carrying cargo or towing a trailer.
Page 68 Ride more slowly than you would without a WARNING load. The more weight you carry, the slow- POTENTIAL HAZARD er you should go. Although conditions vary, Overloading this ATV or carrying or tow- it is good practice not to exceed 2nd gear ing cargo improperly.
Page 69 6-13...
Page 70 EBU00888 WARNING Indicates a potential hazard that could result in serious injury or death. 6-14...
Page 71 R iding Your...
Page 73: Riding Your Atv
WARNING Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV ride, be sure you have read this Owner’s Man- This ATV is mainly for utility use, but may also ual completely and understand the operation be used for recreation.
Page 74: Ride With Care And Good Judgement
Beginning and inexperienced operators should complete the certified training Get training if you are inexperienced. course offered by Yamaha. They should Beginners or inexperienced riders should get then regularly practice the skills learned training from a certified instructor. Become fa-...
Page 75 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.
Page 76 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.
Page 77 Apparel Operating without protective clothing WARNING increases your chances of severe injury in the event of an accident. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an Always wear an approved motorcycle approved motorcycle helmet, eye pro- helmet that fits properly.
Page 78 Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator’s performance capability is reduced Operating this ATV after consuming al- by the influence of alcohol or drugs. cohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly.
Page 79 Pre-operation checks WARNING Always perform the pre-operation checks list- POTENTIAL HAZARD ed on page 5-1 before riding for safety and Operating this ATV with improper tires, proper care of the ATV. or with improper or uneven tire pres- WARNING sure. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before oper-...
Page 80 Speed limiter WARNING For riders less experienced with this model, Indicates a potential hazard that could this model is equipped with a speed limiter in result in serious injury or death. the throttle lever housing. The speed limiter keeps the throttle from fully opening, even Do not operate at speeds too fast for your when the throttle lever is pushed to the maxi- skills or the conditions.
Page 81 Loading and accessories WARNING Use extra caution when riding the ATV with POTENTIAL HAZARD additional loads, such as accessories or car- Overloading this ATV or carrying or tow- go. The ATV’s handling may be adversely af- ing cargo improperly. fected. Reduce your speed when adding WHAT CAN HAPPEN additional loads.
Page 82 During operation WARNING Always keep your feet on the footboards dur- POTENTIAL HAZARD ing operation. Otherwise your feet may con- Removing hands from handlebars or tact the rear wheels. feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re- duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
Page 83 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 Never modify this ATV through improp- er installation or use of accessories. All parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized ATV dealer.
Page 85 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.
Page 86: Be Careful Where You Ride
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 control of the ATV, and may cause the vehicle to go out of con-...
Page 87 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 operate this ATV on any public street, road or highway, even a dirt or...
Page 88 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.
Page 89 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 rough, slippery or loose terrain until you have learned and practiced the skills neces-...
Page 90 When riding in an area where you might not WHAT CAN HAPPEN easily be seen, such as desert terrain, mount You could be in a collision. You could a caution flag on the ATV. DO NOT use the be injured. flag pole bracket as a trailer hitch.
Page 91 Select a large, flat area off-road to become fa- With the engine idling, lift the shift pedal to the miliar with your ATV. Make sure that this area 1st gear position and then release the parking is free of obstacles and other riders. You brake.
Page 92 WARNING CAUTION: POTENTIAL HAZARD Do not shift gears without releasing the Engaging a lower gear when the engine throttle. Damage to the engine or drive speed is too high. train may occur. WHAT CAN HAPPEN When slowing down or stopping, release the The wheels could stop rotating.
Page 93: Turning Your Atv
TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for road, the two rear wheels are mounted solidly turning as described in this Owner’s on one axle and turn together at the same Manual.
Page 94 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip.
Page 95: Climbing Uphill
CLIMBING UPHILL HOW TO AVOID THE HAZARD Use proper riding techniques to avoid vehicle Never operate the ATV on hills too steep overturns on hills. Be sure that you can ma- for the ATV or for your abilities. Practice neuver your ATV well on flat ground before at- on smaller hills before attempting large tempting any incline and then practice riding hills.
Page 96 WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other POTENTIAL HAZARD side of the hill. 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.
Page 97 If you are climbing a hill and you find that you When crossing the side of a hill: have not properly judged your ability to make Always follow proper procedures as de- it to the top, you should turn the ATV around scribed in the Owner’s Manual.
Page 98 If your ATV has stalled or stopped and you be- WARNING lieve you can continue up the hill, restart care- POTENTIAL HAZARD fully to make sure you do not lift the front Stalling, rolling backwards or improper- wheels which could cause you to lose control. ly dismounting while climbing a hill.
Page 99 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- 7-29...
Page 100: Riding Downhill
RIDING DOWNHILL When this ATV is in 4WD, all wheels (front When riding your ATV downhill, shift your and rear) are interconnected by the drive weight as far to the rear and uphill side of the train. This means that applying either the front ATV as possible.
Page 101 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.
Page 102: Crossing A Slope
CROSSING A SLOPE If your ATV does begin to tip over, gradually Traversing a sloping surface on your ATV re- steer in the downhill direction if there are no quires you to properly position your weight to obstacles in your path. As you regain proper maintain proper balance.
Page 103 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. 7-33...
Page 104: Crossing Through Shallow Water
CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have re- The ATV can be used to cross slow moving, duced stopping ability. Test your brakes shallow water of up to a maximum of 35 cm after leaving water. If necessary, apply (14 inches) in depth.
Page 105 Test your brakes after leaving the water. Do CAUTION: not continue to ride your ATV without verifying After riding your ATV in water, be sure to that you have regained proper braking ability. drain the trapped water by removing the check hose at the bottom of the air filter case.
Page 106: Riding Over Rough Terrain
RIDING OVER ROUGH TERRAIN WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could Improperly operating over obstacles. cause damage to the ATV or could lead to an WHAT CAN HAPPEN upset or accident. Be sure to keep your feet Could cause loss of control or a colli- firmly mounted on the footboards at all times.
Page 107 7-37...
Page 108: Sliding And Skidding
SLIDING AND SKIDDING If the rear wheels of your ATV start to slide Care should be used when riding on loose or sideways, control can usually be regained (if slippery surfaces since the ATV may slide. If there is room to do so) by steering in the direc- unexpected and uncorrected, sliding could tion of the slide.
Page 109 With practice, over a period of time, skill at WARNING controlled sliding can be developed. The ter- POTENTIAL HAZARD rain should be chosen carefully before at- Skidding or sliding improperly. tempting such maneuvers, since both stability WHAT CAN HAPPEN and control are reduced. Bear in mind that You may lose control of this ATV.
Page 110: What To Do If
WHAT TO DO IF ... If your ATV starts to slide sideways: This section is designed to be a reference Steer in the direction of the slide if you have guide only. Be sure to read each section on the room. riding techniques completely.
Page 111 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.
Page 112: Periodic Maintenance And Adjustment
EBU00515 PERIODIC MAINTENANCE AND Have a Yamaha dealer perform service if ADJUSTMENT you are not familiar with machine ser- vice. Periodic inspection, adjustment and lubrica- tion will keep your machine in the safest and most efficient condition possible. Safety is an EBU00535 obligation of the machine owner.
Page 113 If during a service operation requiring one, take you have questions, consult an autho- your machine to a Yamaha dealer to check rized Yamaha ATV dealer. the torque settings and adjust them as neces- sary.
Page 114: Periodic Maintenance/Lubrication
EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY ITEM ROUTINE month months months months year • Check valve clearance. Valves* • Adjust if necessary. • Check condition. Spark plug • Adjust gap and clean. • Replace if necessary. • Clean. Every 20~40 hours Air filter •...
Page 115 • Replace if damaged. • Check all chassis fittings and fasteners. Fittings and Fasteners* • Correct if necessary. * It is recommended that these items be serviced by a Yamaha dealer. NOTE: NOTE: Recommended brake fluid: DOT4 Brake fluid replacement: 1.
Page 116: Engine Oil
EBU00949 Engine oil 4. Remove the dipstick, and then check the Engine oil level measurement oil level. 1. Place the machine on a level surface. 5. The oil level should be between the max- 2. Warm up the engine for several minutes, imum and minimum marks.
Page 117 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.
Page 118 6. Clean the oil strainer and oil filter element Tightening torque: with solvent. 7. Check the O-ring for damage and re- Drain bolt (engine): place it if damaged. 32 Nm (3.2 m·kgf, 23 ft·lb) 8. Install the oil filter element, and O-ring. Filter cover bolt: 9.
Page 119 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.
Page 120: Final Gear Oil
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.
Page 121 2. Place the machine on a level place. 6. Fill the final gear case with oil. 3. Place a container under the final gear Recommended oil: See page 10-2. case to collect the used oil. Oil quantity: 4. Remove the oil filler bolt and the drain Periodic oil change: bolt to drain the oil.
Page 122: Differential Gear Oil Replacement
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. Drain bolt 4. Install the drain bolt and tighten to speci- fication.
Page 123 Recommended oil: SAE 80 API “GL-4” Hypoid gear oil Oil quantity: Periodic oil change: 0.35 L (0.31 Imp qt, 0.37 US qt) Total amount: 0.4 L (0.35 Imp qt, 0.42 US qt) CAUTION: Be sure no foreign material enters the dif- ferential gear case.
Page 124: Front Axle Boots
Do not attempt to diagnose such problems yourself. Instead, take the machine to a Yamaha deal- er. You should periodically remove and in- spect the spark plug because heat and 1. Boot ( 2) deposits will cause the spark plug to slowly break down and erode.
Page 125: Air Filter Cleaning
EBU00851 Before installing the spark plug, measure the Air filter cleaning electrode gap with a feeler gauge and adjust NOTE: to specification. There is a check hose at the bottom of the air filter case. If dust or water collects in this Spark plug gap: hose, empty the hose and clean the air filter 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Page 126 4. Separate the foam cover from the air filter element. 1. Air filter case cover 3. Pull out the air filter element. 1. Air filter element 2. Foam cover 1. Air filter element 8-15...
Page 127 WARNING 5. Tap the element lightly to remove most of the dust and dirt. Blow out the remaining POTENTIAL HAZARD dirt with compressed air as shown. If the Using low flash point solvents or gaso- element is damaged, replace it. line to clean the foam cover.
Page 128: Spark Arrester Cleaning
EBU00754 NOTE: Spark arrester cleaning The air filter element should be cleaned every Select a well-ventilated area free of combusti- 20 ~ 40 hours. It should be cleaned more of- ble materials and make sure the exhaust pipe ten if the machine is operated in extremely and muffler are cool.
Page 129: Carburetor Adjustment
The carburetor is a vital part of the engine and POTENTIAL HAZARD requires very sophisticated adjustment. Most Improperly purging the exhaust system. adjusting should be left to a Yamaha dealer Hot exhaust system. who has the professional knowledge and ex- WHAT CAN HAPPEN perience to do so.
Page 130: Idle Speed Adjustment
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 throttle.
Page 131: Valve Clearance Adjustment
1. Loosen the locknut. ment however, should be left to a professional 2. Turn the adjusting bolt until the throttle le- Yamaha service technician. ver free play is 3 ~ 5 mm (0.12 ~ 0.20 in). 3. Tighten the locknut.
Page 132: Front Brake Pad Inspection
A wear indicator is provided on the rear brake. tor. If the wear indicator is ALMOST in contact This indicator allows checking of brake shoe with the disc, ask a YAMAHA dealer to re- wear without disassembling the brake. place the pads.
Page 133: Brake Fluid Level Inspection
EBU00755 Brake fluid level inspection FRONT 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.
Page 134: Brake Fluid Replacement
Always clean up 1. Complete fluid replacement should be spilled fluid immediately. done only by trained Yamaha service 6. Have a Yamaha dealer check the cause personnel. if the brake fluid level goes down. 2. Have a Yamaha dealer replace the fol-...
Page 135: Front Brake Adjustment
The front brake lever should have a free play POTENTIAL HAZARD of zero mm (zero in) at the lever end. If not, Operating with improperly serviced or ask a Yamaha dealer to adjust it. adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.
Page 136: Rear Brake Pedal And Lever Adjustment
EBU00329 Rear brake pedal and lever adjustment b. Turn the adjusting nut on the brake rod 1. Brake pedal free play adjustment until free play is 20 ~ 30 mm (0.8 ~ a. Fully loosen the adjusting nut on the 1.18 in).
Page 137 2. Brake lever free play adjustment b. Screw in the adjusting nut on brake cable a. Loosen the locknut and fully turn in the to provide a gap of 0 ~ 1 mm (0 ~ 0.04 in) adjusting bolt at the brake lever. between the lever and the pin.
Page 138 Make sure the brakes do not drag. a. Free play: 5 ~ 7 mm (0.20 ~ 0.28 in) Replacement of brake components re- d. Tighten the locknut. quires professional knowledge. These procedures should be performed by a Yamaha dealer. 8-27...
Page 139: Adjusting The Rear Brake Light Switch
EBU00834 EBU00346 Adjusting the rear brake light switch Clutch adjustment The rear brake light switch, which is activated 1. Loosen the locknut. by the brake pedal and brake levers, is prop- 2. Slowly turn the adjusting bolt counter- erly adjusted when the brake light comes on clockwise until resistance is felt.
Page 140: Cable Inspection And Lubrication
EBU00356 3. Tighten the locknut to specification. Cable inspection and lubrication WARNING Tightening torque: POTENTIAL HAZARD 15 Nm (1.5 m·kgf, 11 ft·lb) Damaged control cables. NOTE: WHAT CAN HAPPEN Turn the adjusting bolt counterclockwise to Corrosion can result when the outer decrease the clutch free play and turn it clock- covering of control cables becomes wise to increase the free play.
Page 141: Brake And Shift Pedal/Brake Lever Lubrication
Yamaha dealer to replace them. stand under the frame. 2. Remove the nuts from the wheel. Recommended lubricant: 3. Remove the wheel assembly. Yamaha chain and cable lube or SAE 10W30 motor oil EBU00727 Brake and shift pedal/brake lever lubrication Lubricate the pivoting parts of each lever and pedal.
Page 142: Wheel Installation
EBU00828 Wheel installation 1. Tapered wheel nuts are used for both When installing a wheel, reverse the removal front and rear wheels. Install the nut with procedure. its tapered side towards the wheel. NOTE: The arrow mark on the tire must point to- ward the rotating direction of the wheel.
Page 143: Battery
Keep out of reach of chil- tery. If the battery seems to have discharged, dren. consult a Yamaha dealer. Antidote: EXTERNAL: Flush with water. CAUTION: INTERNAL: Drink large quantities of wa- Do not try to remove the sealing caps of ter or milk.
Page 144: Battery Maintenance
Then turn on the switches. If CAUTION: the fuse immediately blows again, con- A special battery charger (constant volt- sult a Yamaha dealer. age/ampere or constant voltage) is re- Specified fuses: quired recharging...
Page 145 WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rat- 1. Main fuse 2.
Page 146: Replacing The Headlight Bulb
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.
Page 147 8. Install the headlight assembly and con- WARNING nect the coupler. POTENTIAL HAZARD 9. Adjust the headlight beam. (See page The headlight bulb is hot when it is on 8-37.) and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flamma- ble.
Page 148: Headlight Beam Adjustment
Tail/brake light bulb replacement 1. Open the storage box. (See page 4-17.) CAUTION: 2. Remove the nuts together with washers. It is advisable to have a Yamaha dealer make this adjustment. 1. Vertical adjustment: To raise the beam, turn the adjusting screw clockwise.
Page 149 1. Bulb holder 1. Bulb holder 2. Bulb 4. Remove the defective bulb from the bulb 5. Install a new bulb in the bulb holder by holder by pushing it inward and turning it pushing it inward and turning it clockwise. counterclockwise.
Page 150: Troubleshooting
EBU00412 Troubleshooting WARNING Although Yamaha machines receive a rigid in- POTENTIAL HAZARD spection before shipment from the factory, Checking the fuel system while smok- trouble may occur during operation. Any prob- ing or near an open flame. lem in the fuel, compression, or ignition sys-...
Page 151: Troubleshooting Chart
2. Compression There is compression. Compression normal. Use the electric starter to see if there is compression. No compression. Ask a Yamaha dealer to inspect. Wipe clean with 3. Ignition Ignition system dry cloth. Spark good. normal. Remove the plug and check the electrodes.
Page 152: Cleaning And Storage
EBU00419 C LEANING AND STORAGE CAUTION: A. CLEANING Excessive water pressure may cause wa- Frequent, thorough cleaning of your machine ter seepage and deterioration of wheel will not only enhance its appearance but will bearings, brakes, transmission seals and improve its general performance and extend electrical devices.
Page 153 6. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after wash- 7. Automotive type wax may be applied to ing. all painted and chrome plated surfaces. WHAT CAN HAPPEN Avoid combination cleaner-waxes.
Page 154: Storage
Do not apply oil to fuel) any rubber parts or the seat cover. NOTE: Use of fuel stabilizer and conditioner elimi- nates the need to drain the fuel system. Con- sult a Yamaha dealer if the fuel system needs to be drained instead.
Page 155 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.
Page 156: Specifications
EBU00428 SPECIFICATIONS MODEL YFM40F Dimension: Overall length 2,007 mm ( 79.0 in) Overall width 1,111 mm ( 43.7 in) Overall height 1,172 mm ( 46.1 in) Seat height 855 mm ( 33.7 in) Wheel base 1,230 mm ( 48.4 in) Minimum ground clearance 245 mm ( 9.65 in) Minimum turning radius...
Page 157 MODEL YFM40F Engine oil: Type See page 5-7 Quantity: Periodic oil change 2.9 L (2.6 Imp qt, 3.1 US qt) With oil filter replacement 3.0 L (2.6 Imp qt, 3.2 US qt) Total amount 3.5 L (3.1 Imp qt, 3.7 US qt) Final gear oil: Type SAE 80 API “GL-4”...
Page 158 MODEL YFM40F Spark plug: Type/manufacturer DR8EA / NGK 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Clutch type Wet, centrifugal automatic Transmission: Primary reduction system Spur gear Primary reduction ratio 76/24 (3.166) Secondary reduction system Shaft drive Secondary reduction ratio 28/24 24/18 33/09 (5.703)
Page 159 MODEL YFM40F Brake: Front brake type Dual disk brake Operation Right hand operation Rear brake type Drum brake Operation Left hand and right foot operation Suspension: Front Double wishbone Rear Swingarm (monocross) Shock absorber: Front Coil spring / oil damper Rear Coil spring / oil damper Wheel travel:...
Page 160: Noise Regulation
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 incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Page 161: Maintenance Record
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 is required. It is not acceptable proof of maintenance work.
Page 162: Atv Limited Warranty
EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1...
Page 163 13-2...
Page 164: Yamaha Extended Service (Y.e.s.)
EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1...
Page 165 14-2...
Page 166 EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death. 14-3...
Page 167 14-4...
Page 168 EBU00437 14-5...

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