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  5. Owner's Manual

Yamaha BANSHEE Owner's Manual

Summary of BANSHEE

  • Page 1

    Owner’s manual read this manual carefully! It contains important safety information. W lit-11626-18-04 5fk-28199-17 this atv should not be ridden by anyone under 16 years of age. Yfz350t printed in japan 2004.3-1.1x1 ! (e) improper atv use can result in severe injury or death. Q warning always use a...

  • Page 2

    5fk-9-17 hyoshi 10/3/04 11:27 pm page 2.

  • Page 3: Introduction

    Ebu13320 introduction congratulations on your purchase of the yamaha yfz350. It represents the result of many years of yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this yamaha, you can now appreciate the high degree of crafts- m...

  • Page 4: Important Manual Information

    Ebu00801 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: q the safety alert symbol means attention! Become alert! Your safety is ...

  • Page 5: Important Notice

    Ebu15000 important notice this atv is designed and manufactured for off-road use only. It is illegal and unsafe to oper- ate this atv on any public street, road or highway. This atv complies with all applicable off-road noise level and spark arrester laws and regula- tions in effect at the time of m...

  • Page 6: Contents

    Location of the warning and specification labels....................1-1 safety information......................2-1 description and machine identification .................................3-1 identification number records ............3-2 key identification number ..................3-2 vehicle identi...

  • Page 7

    Seat .................................................4-12 front shock absorber adjustment.....................................4-13 rear shock absorber adjustment.....................................4-14 pre-operation checks ................5-1 front and rear brakes........................5-3 fuel ....

  • Page 8

    Crossing a slope .............................7-32 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 pe...

  • Page 9

    Tail/brake light bulb replacement.....8-46 troubleshooting...............................8-47 troubleshooting chart......................8-48 no spark ..........................................8-51 cleaning and storage ................9-1 a. Cleaning........................................9-1 b. Sto...

  • Page 10: Location of The Warning and

    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. 1-1 ebu00464 locati...

  • Page 11

    1-2 q w 1 e 5fe-21568-01 q warning never ride as a passenger. Passengers can cause a loss of control, resulting in severe injury or death. 5fe-2151h-40 5fe-2151h-01 5fk-21696-01 5fk-9-17-01 3/3/04 10:13 pm page 9.

  • Page 12

    1-3 r t y 5fe-21697-01 5fk-9-17-01 3/3/04 10:13 pm page 10

  • Page 13: Safety Information

    2-1 ebu13381 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 rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper ...

  • Page 14

    2-2 8 always avoid operating an atv on any paved surfaces, including sidewalks, driveways, parking lots and streets. 8 never operate an atv on any public street, road or highway, even a dirt or gravel one. 8 never operate an atv without wearing an approved motorcycle helmet that fits properly. You s...

  • Page 15

    2-3 8 never operate on excessively rough, slippery or loose terrain until you have learned and prac- ticed the skills necessary to control the atv on such terrain. Always be especially cautious on these kinds of terrain. 8 always follow proper procedures for turning as described in this manual. Prac...

  • Page 16

    2-4 8 always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use the 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 s...

  • Page 17

    8 never exceed the stated load capacity for an atv. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. For more information about atv safety, call the consumer pr...

  • Page 18: Qwarning

    2-6 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 immediately after the engine has been running and is still very hot. Do not spill gasoline on the en...

  • Page 19: Qwarning

    2-7 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. Qwarning 5fk-9-17-01 3/3/04 10:13...

  • Page 20

    3-1 1. Tail/brake light 12. Rear shock absorber 2. Seat 13. Spark arrester 3. Kick starter 14. Rear wheel 4. Fuel tank cap 15. Starter (choke) 5. Headlight 16. Shift pedal 6. Brake pedal 17. Clutch lever 7. Rear brake light switch 18. Parking brake 8. Front wheel 19. Main switch 9. Front shock absor...

  • Page 21

    Ebu00600 identification number records record the key identification number, vehicle identification number and model label informa- tion 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 number: ...

  • Page 22

    Ebu00036 vehicle identification number the vehicle identification number is stamped into the frame. Note: the vehicle identification number is used to identify your machine. 1. Vehicle identification number ebu00787 model label the model label is affixed to the location in the illustration. Record t...

  • Page 23: Control Functions

    Ebu00039 control functions w indicates a potential hazard that could result in serious injury or death. Ebu09420 main switch functions of the respective switch positions are as follows: on: the engine can be started only at this position and the headlights and taillight come on when the light switch...

  • Page 24

    Ebu00053 handlebar switches 1. Light switch “lights” 2. Engine stop switch “eng. Stop” ebu11580 engine stop switch “eng. Stop” make sure that the engine stop switch is in the “run” position before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the ...

  • Page 25: Qwarning

    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 time th...

  • Page 26: Qwarning

    Ebu00064 throttle override system if during operation, the carburetor or the throt- tle cable should malfunction and will not close fully, take your thumb off the throttle lever. The throttle override system immediately cuts off the ignition. Ebu11590 speed limiter the speed limiter keeps the thrott...

  • Page 27: Qwarning

    4-5 potential hazard improper adjustment of the speed limiter and throttle. What can happen the throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. How to avoid the hazard do not turn the adjusting screw out more than 12 ...

  • Page 28

    Ebu00068 clutch lever the clutch lever is located on the left handle- bar. Pull the clutch lever to the handlebar to disen- gage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. 1. Clutch lever ebu09880 brake ...

  • Page 29

    Ebu00989 brake pedal the brake pedal is located on the right side of the machine. Push down on the pedal to apply the rear brake. 1. Brake pedal ebu00080 parking brake use the parking brake when you have to start the engine or park the machine, especially on a slope. Squeeze the clutch lever while p...

  • Page 30: Qwarning

    1. Button 2. Lock plate 1. Locked position 4-8 q potential hazard improper use of the parking brake. What can happen the atv could start moving unexpected- ly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake disc could overhea...

  • Page 31

    Ebu00082 shift pedal this machine is equipped with a constant- mesh 6-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. 1. Shift pedal n. Neutral ebu00089 kick starter rotate the kick starter away from the engine. ...

  • Page 32

    Ebu00092 fuel tank cap remove the fuel tank cap by turning it coun- terclockwise. 1. Fuel tank cap 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...

  • Page 33

    Ebu00094 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 operation. (see ...

  • Page 34

    Ebu00566 seat to remove the seat, pull the seat lock lever upward and pull up the seat at the rear. To install the seat, insert the projection on the front of the seat into the seat holder and push down on the seat at the rear. Note: make sure that the seat is securely fitted. 1. Projection 2. Holde...

  • Page 35: Qwarning

    Ebu01104 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 adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direc...

  • Page 36: Qwarning

    Ebu15021 rear shock absorber adjustment the spring preload, rebound damping and compression damping forces of the rear shock absorber can be adjusted to suit the rider’s weight and the riding conditions. Adjust the spring preload as follows. 1. Loosen the locknut. 2. Turn the adjusting nut in direct...

  • Page 37

    Note: a special wrench can be obtained at a yamaha dealer to make this adjustment. 3. The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjusting nut. 4. Tighten the locknut to the specified torque. C c always tighten the locknut against the adjusting nut and tighten it t...

  • Page 38

    4-16 adjust the rebound damping force as follows. Turn the rebound damping force adjusting dial in direction a to increase the rebound damp- ing force and in direction b to decrease the rebound damping force. Adjust the compression damping force as fol- lows. Turn the compression damping force adjus...

  • Page 39: Qwarning

    C c never turn an adjusting mechanism beyond the minimum or maximum set- tings. Note: although the total number of clicks of a damp- ing force adjusting mechanism may not exact- ly match the above specifications due to small differences in production, the actual number of clicks always represents th...

  • Page 40: Pre-Operation Checks

    5-1 pre-operation checks before using this machine, check the following points: item routine page brakes 9 check operation, free play, fluid level and fluid leakage. 5-3–5-4 9 fill with dot 4 brake fluid if necessary. 8-29–8-33 clutch 9 check operation, condition and lever free play. 8-36 parking br...

  • Page 41: Qwarning

    5-2 potential hazard failure to inspect the atv before operat- ing. 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 operating condi...

  • Page 42

    Ebu11660 front and rear brakes brake lever and brake pedal 8 check that there is no free play in the brake lever. If there is free play, have a yamaha dealer inspect the brake system. 8 check for correct brake pedal height. (see page 8-33.) if the pedal height is incorrect, have a yamaha dealer adju...

  • Page 43: Qwarning

    5-4 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 cannot ...

  • Page 44

    Ebu13420 fuel make sure there is sufficient gasoline in the tank. 1. Filler tube 2. Fuel level your yamaha engine has been designed to use premium unleaded gasoline with a pump octane number ([r+m]/2) of 90 or higher, or research octane number of 95 or higher. If knocking or pinging occurs, use a di...

  • Page 45: Qwarning

    Ebu00132 engine mixing oil if yamalube “r” oil is not available, select an oil from the following list. C c never mix two types of oil in the same batch. Always use the same type of oil to ensure maximum engine performance. 5-6 potential hazard improper care when refueling. What can happen fuel can ...

  • Page 46

    Ebu12891 transmission oil make sure the transmission oil is at the speci- fied level. Add oil as necessary. (see pages 8-6–8-8.) c c 8 in order to prevent clutch slippage (since the transmission oil also lubri- cates the clutch), do not mix any chem- ical additives. Do not use oils with a diesel spe...

  • Page 47

    5-8 ebu11620 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. Ebu10030 lights check the headlights and tail/brake light to make sure they are in working...

  • Page 48: Qwarning

    5-9 ebu00157 tires potential hazard operating this atv with improper tires, or with improper or uneven tire pressure. What can happen use of improper tires on this atv, or operation of this atv with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. How to...

  • Page 49

    5-10 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 50

    Ebu00160 tire wear limit when the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. 5-11 a a. Tire wear limit 5fk-9-17-01 3/3/04 10:13 pm page 48.

  • Page 51: Operation

    Ebu00161 operation w indicates a potential hazard that could result in serious injury or death. Ebu00511 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 engine stop switch to “run”. 4. Shift the transmission into neutral. 5. Use...

  • Page 52

    Position 1: cold engine start- ambient temperature below 5°c (40°f). Position 2: cold engine start- ambient temperature at 0°c (30°f)–30°c (90°f) and warming up position. Position 3: cold engine start- ambient temperature above 25°c (80°f) and warm engine start position. 6. Completely close the thro...

  • Page 53

    Ebu00180 starting a warm engine to start a warm engine, refer to the “starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly. Ebu00538 warming up to get maximum engine life, always warm up the engine before starting off. Never acceler- ate har...

  • Page 54

    Ebu01981 shifting this model has a 6-speed forward transmis- sion. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to its original position, apply the c...

  • Page 55: Qwarning

    Ebu00203 to start out and accelerate 1. Release the throttle lever. C c always close the throttle while shifting gears. Otherwise, damage to the engine and drive train may result. 2. Pull the clutch lever to disengage the clutch. 3. Shift into first gear. 4. Open the throttle gradually and at the sa...

  • Page 56: Qwarning

    Ebu00207 to decelerate 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 before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lo...

  • Page 57

    6-7 ebu02092 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 58

    Ebu00212 parking when parking, stop the engine and shift into low gear. Turn the fuel cock to “off” and apply the parking brake. 1. Locked position 6-8 q 5fk-9-17-01 3/3/04 10:13 pm page 56.

  • Page 59: Qwarning

    Ebu11740 parking on a slope 1. Bring the machine to a stop by applying the brakes in low gear. 2. Stop the engine and release the clutch lever. 3. With the rear brake applied, apply the parking brake and slowly release the brake pedal. 6-9 potential hazard parking on a hill or other incline. What ca...

  • Page 60

    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. 8 choose only accessories designed for your atv. Your yamaha dealer has a variety o...

  • Page 61

    Ebu00584 loading as originally equipped, this atv is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: 8 never exceed the weight limits shown. An...

  • Page 62: Qwarning

    Potential hazard overloading this atv or carrying or tow- ing cargo improperly. What can happen could cause changes in vehicle han- dling which could lead to an accident. How to avoid the hazard never exceed the stated load capacity for this atv. Cargo should be properly distributed and securely att...

  • Page 63: Riding

    1 7-1 riding your atv ok ok ok ok 7-1 7 5fk-9-17-02 11/2/04 1:47 pm page 1.

  • Page 64

    7-3 getting to know your atv this atv is intended for recreational use by experienced operators only. Even though you are an experienced operator of all other all terrain vehicles or motorcycles, riding the atv requires special skills acquired through practice. Take your time to fully learn techniqu...

  • Page 65: Qwarning

    7-4 ride with care and good judge- ment get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this atv at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totall...

  • Page 66: Qwarning

    7-5 not recommended for children under 16 years of age. 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 severe injury or death of the child. How to avoid the hazard a child under 1...

  • Page 67: Qwarning

    7-6 this atv is designed to carry operator only - passengers prohibited. 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 avoid the hazard n...

  • Page 68: Qwarning

    Apparel 7-7 potential hazard operating this atv without wearing an approved motorcycle helmet, eye pro- tection and protective clothing. What can happen operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating with...

  • Page 69: Qwarning

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

  • Page 70: Qwarning

    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. Potential hazard failure to inspect the atv before operat- ing. Failure to properly maintain the atv. What can happen increases the possibility of an accident or...

  • Page 71: Qwarning

    W 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 inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limit...

  • Page 72: Qwarning

    7-11 loading and accessories as originally equipped, this atv is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Use extra caution when riding the atv with additional loads, such...

  • Page 73: Qwarning

    7-12 during operation always keep your feet on the footboards dur- ing operation. Otherwise your feet may con- tact the rear wheels. Potential hazard removing hands from handlebars or feet from footboards during operation. What can happen removing even one hand or foot can reduce your ability to con...

  • Page 74: Qwarning

    Avoid wheelies and jumping. You may lose control of the atv or overturn. 7-13 potential hazard attempting wheelies, jumps, and other stunts. What can happen increases the chance of an accident, including an overturn. How to avoid the hazard never attempt stunts, such as wheelies or jumps. Don’t try ...

  • Page 75: Qwarning

    7-14 modifications 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 this atv...

  • Page 76: Qwarning

    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. 7-15 potential hazard hot exhaust system. What can happen dry grass or brush...

  • Page 77: Qwarning

    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. 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 t...

  • Page 78: Qwarning

    7-17 do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles. 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 a...

  • Page 79: Qwarning

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

  • Page 80: Qwarning

    7-19 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, sl...

  • Page 81: Qwarning

    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. Potential hazard ope...

  • Page 82

    Select a large, flat area off-road to become familiar 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. Always avoid riding...

  • Page 83: Qwarning

    7-22 c c 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 before eng...

  • Page 84: Qwarning

    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 inside of the turn is allowed to slip or lose some traction, the atv will resist turning. A special tu...

  • Page 85

    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 86: Qwarning

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

  • Page 87: Qwarning

    7-26 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 owner’s manual. Always check the terrain carefully before you start up any hill. ...

  • Page 88: Qwarning

    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. Potential hazard improperly crossing hills or turning on h...

  • Page 89: Qwarning

    7-28 if your atv has stalled or stopped and you believe you can continue up the hill, restart carefully 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 aroun...

  • Page 90

    7-29 when fully stopped, apply the rear brake as well, and then lock the park- ing brake. 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 manual. 5fk-9-17-02 11/2/04 1:47 pm page 29.

  • Page 91: Qwarning

    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. Choose a low gear which will allow the engine compression to do most of the braking for you. Improper braking may cause a...

  • Page 92

    7-31 ok 5fk-9-17-02 11/2/04 1:47 pm page 31.

  • Page 93: Qwarning

    7-32 crossing a slope traversing a sloping surface on your atv requires 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 ter...

  • Page 94

    7-33 avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the atv. Ok 5fk-9-17-02 11/2/04 1:47 pm page 33.

  • Page 95: Qwarning

    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 water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or ups...

  • Page 96

    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. C c 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 in fre...

  • Page 97: Qwarning

    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 98

    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 99: Qwarning

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

  • Page 100

    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 ... 8 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 weight ...

  • Page 101

    8 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 going...

  • Page 102: Periodic Maintenance and

    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, adjustment and lubrication are exp...

  • Page 103: Qwarning

    The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the owner’s tool kit are suffi- cient for this purpose, except that a torque wrench is also ne...

  • Page 104

    8-3 initial every month 1 3 6 6 12 item routine whichever km 320 1200 2400 2400 4800 comes first (mi) (200) (750) (1500) (1500) (3000) hours 20 75 150 150 300 transmission 9 replace oil. 2 2 2 2 9 check coolant leakage. Cooling system 9 repair if necessary. 2 2 2 2 2 9 replace coolant every 24 month...

  • Page 105

    * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. 8-4 initial every month 1 3 6 6 12 item routine whichever km 320 1200 2400 2400 4800 comes first (mi) (200) (750) (1500) (1500) (3000) hours 20 75 150 150 300 throttle operation 9 inspect ...

  • Page 106

    8-5 note: 8 recommended brake fluid: dot 4 8 brake fluid replacement: 9 when disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required. 9 on the inner parts of the master cylinder and caliper cylinder, replace t...

  • Page 107

    8-6 ebu10981 transmission oil transmission oil measurement 1. Place the atv on a level surface. 2. Warm up the engine for several minutes, and then stop it. 3. Remove the oil filler cap and wipe off the dipstick with a clean rag. Insert the dip- stick in the filler hole without screwing it in. 1. Di...

  • Page 108

    1. Drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 6. Fill the engine with the recommended oil, and then install the oil filler cap. C c 8 in order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical addi- tives. Do...

  • Page 109

    8-8 7. Start the engine and warm up for a few minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately, and check for the cause. 8. Turn the engine off, and then check the oil level and correct it if necessary. Ebu01080 cooling system 1. Check the coolan...

  • Page 110

    3. Open the coolant reservoir cover. 1. Coolant reservoir cover 2. Coolant reservoir cap 4. Remove the coolant reservoir cap, and then add coolant or distilled water to raise it to the specified level. 5. Install the coolant reservoir cap. 6. Close the coolant reservoir cover. 7. Install the seat. C...

  • Page 111: Qwarning

    8-10 ebu00765 to change the coolant 1. Put the atv on a level place. 2. Remove the radiator cover bolts, and then remove the radiator cover. 1. Radiator cover 2. Radiator cover bolt ( ×3) 3. Place a container under the engine and remove the coolant drain bolts. 1. Drain bolt ( ×2) q q q w w potentia...

  • Page 112

    4. Remove the radiator cap. 1. Radiator cap 5. Remove the coolant reservoir cap. 1. Coolant reservoir cap 6. Disconnect the hose on the coolant reser- voir side and drain the coolant from the coolant reservoir. 1. Coolant reservoir hose 2. Coolant reservoir 7. After draining the coolant, thoroughly ...

  • Page 113

    9. Install the coolant reservoir hose. 10. Pour the recommended coolant into the radiator until it is full. C c hard water or salt water is harmful to the engine. You may use soft water if you can’t get distilled water. 11. Install the radiator cap. 12. Run the engine several minutes. Stop the engin...

  • Page 114

    8-13 ebu00287 spark plug inspection the spark plugs are important engine compo- nents and are easy to inspect. The condition of the spark plugs can indicate the condition of the engine. Normally, all spark plugs from the same engine should have the same color on the white porce- lain insulator aroun...

  • Page 115

    When installing a spark plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten to the specified torque. Ebu11334 air filter element cleaning note: there is a check hose at the bottom of the air fil- ter case. If dust or water collects in this hose...

  • Page 116: Qwarning

    8-15 1. Air filter element 2. Element frame 3. Lock plate 4. Wash the element gently but thoroughly in solvent. 5. Squeeze the excess solvent out of the air filter element and let it dry. C c do not twist the air filter element when squeezing it. 6. Inspect the air filter element and replace it if d...

  • Page 117

    8-16 7. Apply yamaha foam air filter oil or other quality foam air filter oil to the air filter ele- ment. Note: the air filter element should be wet but not drip- ping. 8. Pull the air filter element over its frame, and then install the lock plate by turning it. 9. Install the air filter element as...

  • Page 118

    Ebu13611 spark arrester cleaning be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screws. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrest...

  • Page 119: Qwarning

    8-18 potential hazard improper cleaning of the spark arrester. Hot exhaust system. What can happen could injure the eyes. Could cause burns. Could cause carbon monoxide poison- ing, possibly leading to death. Could start a fire. How to avoid the hazard when cleaning the spark arrester: always let th...

  • Page 120: Qwarning

    Ebu02994 carburetor settings in extremely cold weather, it is necessary to change the carburetor settings to maintain opti- mum engine performance and to prevent engine damage. 8-19 potential hazard improperly servicing or adjusting the carburetors. What can happen the carburetors could malfunction....

  • Page 121

    8-20 carburetor setting chart q 1st groove 2nd 3rd (standard) 4th 5th jet needle clip position 1. Main jet number altitude 0–1,500 m (5,000 ft) above 1,500 m (5,000 ft) temperature main jet jet needle pilot air screw main jet jet needle pilot air screw above 0°c #200 3rd groove 2.0 turns out #190 3r...

  • Page 122

    Changing the settings of the carburetors to change the settings of the carburetors, you need to disassemble and remove them. Follow the procedures for both carburetors. Disassembling and removing the carburetors 1. Turn the fuel cock to the “off” position. 2. Turn out the carburetor drain screw to d...

  • Page 123

    8-22 8. Remove the carburetor cap securing plate by removing the screw. 9. Loosen the carburetor joint screws. 10. Remove the carburetor cap. 11. Remove the throttle cable from the throttle valve, and then remove the throttle cable holder by removing the screws. 1 2 1 1 1 1 1 2 3 4 1. Carburetor cap...

  • Page 124

    8-23 12. Remove the carburetor, and then remove the float chamber by removing the screws. 1. Float chamber 2. Screw ( × 4) 13. Remove the float and needle valve. 1. Float 2. Needle valve 3. Main jet 14. Change the main jet and the jet needle clip position. (see page 8-20.) note: optional main jets c...

  • Page 125

    8-24 assembling and installing the carburetors assemble and install both carburetors by the fol- lowing steps. 1. Install the needle valve and float. 2. Install the float chamber by installing the screws. 3. Install the carburetor and tighten the joint screws. 4. Assemble the throttle valve. 5. Inst...

  • Page 126

    8-25 adjusting the throttle cables note: after the jet needle clip position is changed, the throttle cables may need to be adjusted. 1. Move the throttle lever a few times. 2. Push the throttle lever forward until it stops and hold it in this position. 3. Check through each carburetor window to see ...

  • Page 127

    Ebu03021 idle speed adjustment note: a diagnostic tachometer must be used for this procedure. Note: the throttle cables and carburetor synchro- nization must be set properly before adjusting the idle speed. 1. Adjust the pilot air screws. 8 turn in both pilot air screws until they lightly seat. 8 tu...

  • Page 128

    4. Connect the tachometer and set the idle to the specified idling speed by turning the idle adjust screws. Turn the adjusting screws in direction a to increase the engine speed, and in direction b to decrease the engine speed. 1. Idle speed adjust screw ( ×2) c c 8 idle speed adjust screws were pre...

  • Page 129

    Ebu00307 throttle lever adjustment note: adjust the engine idling speed before adjust- ing the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 4–6 mm (0.16–0.24 in). 3. Tighten the locknut. 1. Adjusting bolt 2. Locknut a. Free play 8-...

  • Page 130

    Ebu00309 front and rear brake pad inspection each brake pad is provided with a wear indi- cator. The indicators allow checking of brake pad wear without disassembling the brake. Apply the brake and inspect the wear indica- tors. If they are almost in contact with the disc plate, ask a yamaha dealer ...

  • Page 131

    8-30 ebu13040 brake fluid level check 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 minimum level mark and replenish if necessary. A low brake fluid level may indi- cate worn brak...

  • Page 132

    8 refill with the same type of brake fluid. Mixing fluids may result in a harmful chemi- cal reaction and lead to poor brake perfor- mance. 8 be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in...

  • Page 133: Qwarning

    8-32 ebu11870 front brake lever free play the front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a yamaha dealer check the brake sys- tem. Potential hazard operating with improperly serviced or adjusted brakes. What can happen you could lose braking ability...

  • Page 134: Qwarning

    8-33 ebu11910 brake pedal height adjustment the top of the brake pedal should be posi- tioned 10 mm (0.39 in) below the top of the footrest. If not, have a yamaha dealer adjust it. A. Brake pedal position potential hazard operating with improperly serviced or adjusted brakes. What can happen you cou...

  • Page 135

    Ebu11930 parking brake adjustment parking brake adjustment may be required if the parking brake does not hold properly. The cable length “a” should be adjusted to 46–50mm (1.81–1.97in). A. Cable length 1. Fully loosen the locknut and the adjusting bolt at the clutch lever. 1. Locknut 2. Adjusting bo...

  • Page 136: Qwarning

    5. Screw in the adjusting bolt at the rear brake caliper by hand until it feels tight, then screw it out 1/8 turn. Tighten the locknut to the specified torque. 1. Adjusting bolt 2. Locknut c c when tightening the locknut, hold the adjusting bolt with a wrench so that the adjusting bolt does not turn...

  • Page 137

    Ebu00833 adjusting the rear brake light switch the rear brake light switch, which is activated by the brake pedal and brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Rear brake light switch 2...

  • Page 138

    Ebu11440 drive chain slack check note: move the atv back and forth and find the tight- est position of the drive chain. Check and/or adjust the chain slack while it is in this tightest position. To check the drive chain slack, all tires must be touching the ground and there should be no weight on it...

  • Page 139

    3. After adjusting, be sure to tighten the lock- nuts and the wheel hub bolts. Ebu00805 lubricating the drive chain the drive chain must be cleaned and lubricat- ed at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when ridin...

  • Page 140: Qwarning

    1. O-rings 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special o-ring chain lubricant. C c do not use engine oil or any other lubri- cants for the drive chain, as they may con- tain substances that could damage the o- rings. Ebu00356 cable inspection and lubrication l...

  • Page 141

    Ebu00737 brake and shift pedal/brake and clutch lever lubrication lubricate the pivoting parts of each lever and pedal. Ebu15060 lubricating the front upper and lower arm pivots lubricate the upper and lower arm pivots with a grease gun. 8-40 recommended lubricant: lithium-soap-based grease (all-pur...

  • Page 142

    8-41 ebu00987 rear arm pivot lubrication lubricate the rear arm pivots. Recommended lubricant: lithium-soap-based grease 5fk-9-17-03 10/3/04 9:36 pm page 42.

  • Page 143

    8-42 ebu01112 wheel removal 1. Loosen the wheel nuts. 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Ebu00871 wheel installation when installing the wheel, reverse the removal procedure. Tighten the wheel nuts to the specified t...

  • Page 144

    8-43 ebu01139 replacing a headlight bulb if a headlight bulb burns out, replace the bulb as follows. 1. Remove the screw holding the headlight unit assembly to the headlight body. 1. Screw 2. Remove the bulb holder cover. 1. Bulb holder cover 3. Turn the bulb holder counterclockwise to remove the de...

  • Page 145: Qwarning

    4. Put a new headlight bulb into position and secure it in place with the bulb holder. 5. Install the bulb holder cover. 8-44 potential hazard a headlight bulb is hot when it is on and immediately after it is turned off. What can happen you can be burned, or a fire could start if the bulb touches so...

  • Page 146

    8-45 c c make sure the bulb holder cover is secure- ly fitted over the bulb holder and seated against the reflector. 6. Install the headlight unit assembly. 7. Adjust the headlight beam if necessary. Ebu01089 headlight beam adjustment c c it is advisable to have a yamaha dealer make this adjustment....

  • Page 147

    8-46 ebu00861 tail/brake light bulb replacement 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 1. Bulb holder 2. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 1. Bulb holder 2. Bulb 3. Install a new bulb in th...

  • Page 148: Qwarning

    Ebu00412 troubleshooting although yamaha machines receive a rigid inspection 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 quick, eas...

  • Page 149

    Ebu00440 troubleshooting chart starting problems or poor engine performance 8-48 check fuel flow 1. Fuel check if there is fuel in the fuel tank 2. Compression kick the kick starter to see if there is compression 3. Ignition remove plugs and check electrodes wet wipe clean with dry cloth dry attach ...

  • Page 150

    8-49 engine overheating wait until the engine has cooled. Check the coolant level in the reservoir tank and/or radiator. Level is ok. Level is low, check the cooling system for leakage. No leakage. Leakage. Ask a yamaha dealer to inspect and repair the cooling system. Add coolant. (see note.) restar...

  • Page 151: Qwarning

    8-50 potential hazard removing the radiator cap when the engine and radiator are still hot. What can happen you could be burned by hot fluid and steam blown out under pressure. How to avoid the hazard wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. ...

  • Page 152: Qwarning

    Ebu00414 no spark throttle override system (t.O.R.S.) is incor- porated in the ignition circuit, and if the sys- tem should fail, the spark plug will not spark. 8-51 potential hazard testing for an ignition system problem by disconnecting the throttle override system (t.O.R.S.). What can happen with...

  • Page 153: Cleaning and Storage

    Edu00415 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 prevent water...

  • Page 154: Qwarning

    7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 8. 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 finish. When finished, start the engi...

  • Page 155

    Ebu00529 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. Drain the fuel tank, fuel lines and carbure- tor float bowls. 2. Remove the spar...

  • Page 156: Specifications

    10-1 ebu00428 specifications model yfz350 dimension: overall length 1,855 mm (73.0 in) overall width 1,100 mm (43.3 in) overall height 1,080 mm (42.5 in) seat height 800 mm (31.5 in) wheel base 1,280 mm (50.4 in) ground clearance 135 mm (5.31 in) minimum turning radius: 3,600 mm (141.7 in) basic wei...

  • Page 157

    10-2 model yfz350 engine oil (2-cycle): type yamalube r, castrol r30, a545, a747 mixing ratio see page 5-6. Transmission oil: type yamalube 4 (10w30) or sae 10w30 recommended engine oil classification: api service se, sf, sg type or higher c c in order to prevent clutch slippage (since the engine oi...

  • Page 158

    10-3 model yfz350 fuel: type premium unleaded fuel only, premix tank capacity 12.0 l (2.6 imp gal, 3.2 us gal) reserve amount 2.5 l (0.6 imp gal, 0.7 us gal) carburetor: type/quantity vm26ss/2 manufacturer mikuni spark plug: type/manufacturer br8es/ngk spark plug gap 0.7–0.8 mm (0.028–0.031 in) clut...

  • Page 159

    10-4 model yfz350 gear ratio 1st 32/13 (2.461) 2nd 29/16 (1.812) 3rd 27/18 (1.500) 4th 25/20 (1.250) 5th 23/22 (1.045) 6th 21/24 (0.875) chassis: frame type steel tube frame caster angle 9° trail 40 mm (1.57 in) tire: type tubeless size front at21 × 7 - 10 rear at20 × 10 - 9 brake: front brake type ...

  • Page 160

    10-5 model yfz350 suspension: front suspension double wishbone rear suspension swingarm (link suspension) shock absorber: front shock absorber coil spring/oil damper rear shock absorber coil spring/gas-oil damper wheel travel: front wheel travel 230 mm (9.1 in) rear wheel travel 220 mm (8.7 in) elec...

  • Page 161: Noise Regulation

    11-1 ebu13640 noise regulation tampering with noise control system prohibited: federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inopera- tive by any person other than for purposes of maintenance, repair, or replacement of any device or element of design i...

  • Page 162: Maintenance Record

    12-1 ebu13670 maintenance record copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable pr...

  • Page 163

    13-1 ebu00433 5fk-9-17-03 10/3/04 9:36 pm page 64.

  • Page 164

    13-2 13 warranty questions and answers q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake s...

  • Page 165

    Ebu00436 w indicates a potential hazard that could result in serious injury or death. 5fk-9-17-03 10/3/04 9:36 pm page 66.

  • Page 166: Protect Your Investment

    Ebu00437 protect your investment 5fk-9-17-03 10/3/04 9:36 pm page 68.

  • Page 167: Owner’S Manual

    Owner’s manual read this manual carefully! It contains important safety information. W lit-11626-18-04 5fk-28199-17 this atv should not be ridden by anyone under 16 years of age. Yfz350t printed in japan 2004.3-1.1x1 ! (e) improper atv use can result in severe injury or death. Q warning always use a...

  • Page 168: Read    Carefull

    Dear new yamaha atv owner: congratulations on the purchase of your new yamaha atv. You have purchased a quality yamaha product that, with proper use and care, will provide hours of riding pleasure. Before you operate your new atv, yamaha recommends these important points: 8 read your owner’s manual ...

  • Page 169

    No postage necessary if mailed in the united states first class permit no. 4 cypress, ca postage will be paid by addressee yamaha motor corporation u.S.A. P.O. Box 6555 cypress, california 90630-9989 attn: sales administration atv card for us 4/2/03 9:06 am page 2.