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Yamaha GRIZZLY 350 YFM350AZ Owner's Manual - Owner’S Manual

Summary of GRIZZLY 350 YFM350AZ

  • Page 1

    Yfm35gz yfm350az owner’s manual manuel du propriÉtaire manual del propietario 5wh-f8199-66 read this manual carefully! It contains important safety information. Lire attentivement ce manuel! Il comprend d’importantes informations de sécurité. ¡lea este manual atentamente! Contiene indicaciones impor...

  • Page 2

    Printed in usa 2009.06-0.3 ×1 cr (e,f,s) yamaha motor co., ltd. Dic183.

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Owner’s manual yfm35gz yfm350az 5wh-f8199-66-e0 u5wh66e0.Book page 1 thursday, june 18, 2009 10:41 am.

  • Page 4

    Ebu17123 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. Ansi/svia 1-2007 general manager rv engineering division rv operations 19 february, 2009 yfm350a (yfm35g) (5y4ah10w090511001–) we, yamaha motor co., ltd. 2500 shingai, iwata,...

  • Page 5

    Ebu17170 introduction ebu17292 congratulations on your purchase of the yamaha yfm35gz/yfm350az. This atv represents the result of many years of yamaha experience in the production of fine sporting, touring, and pacesetting racing ma- chines. With the purchase of this yamaha, you can now appreciate t...

  • Page 6

    Ebu17330 important manual information ebu17342 failure to follow the warnings contained in this manual can result in serious in- jury or death. Particularly important information is distinguished in this manual by the following notations: * product and specifications are subject to change without no...

  • Page 7

    Ebu17350 important notice ebu17372 this atv is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this atv on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations before operating this atv. Ebu17410 yfm35gz/yfm3...

  • Page 8

    Ebu17420 table of contents location of the warning and specification labels ............................ 1-1 safety information .............................. 2-1 description .............................................. 3-1 left view ...................................................... 3-1 right...

  • Page 9

    Starting a warm engine .............................. 6-3 operating the drive select lever and driving in reverse ...................................... 6-3 engine break-in .......................................... 6-4 parking ....................................................... 6-5 parking on a...

  • Page 10

    Brake light switches ................................. 8-32 checking and lubricating the cables ........ 8-33 checking and lubricating the front and rear brake levers .................................... 8-33 checking and lubricating the brake pedal ...................................... 8-34 checki...

  • Page 11

    1-1 1 ebu29680 location of the warning and specification labels ebu27153 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a re...

  • Page 12

    1-2 1 37s-f817r-00 40 kg ( 88 lbs) 25.0 kpa 0.25 kgf/cm² 3.6 psi 25.0 kpa 0.25 kgf/cm² 3.6 psi 5fu-f816m-m0 37s-f817r-10 80 kg ( 176 lbs) 4900 n 500 kgf 1102 lbf 147 n 15 kgf 33 lbf 4s2-f817s-00 1p0-f816p-20 1 4 2 3 5 u5wh66e0.Book page 2 thursday, june 18, 2009 10:41 am.

  • Page 13

    1-3 1 1p0-f816r-00 1p0-f816l-20 year of construction : 2009 model : yfm350a max.Power : 15.9 kw mass in running order : 245 kg yamaha motor co., ltd. 2500 shingai, iwata, japan 5wh-f155a-20 6 7 8 9 u5wh66e0.Book page 3 thursday, june 18, 2009 10:41 am.

  • Page 14

    1-4 1 familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the owner’s manual. Always use an approved helmet and protective gear. Never permit children under age 6 to operate this atv. Operation of thi...

  • Page 15

    1-5 1 **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi never use with drugs or alcohol. Never store fuel or flammable liquids. This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do not incinerate, puncture or open. Use unleaded gasoline only. Measure tire pres...

  • Page 16

    1-6 1 this pictogram shows trailer hitch tow weight limit. (combined weight of the trailer and all cargo in the trailer.) overloading can cause loss of control. Loss of control can result in severe injury or death. This pictogram shows trailer hitch tongue weight limit. (weight on the trailer tongue...

  • Page 17

    1-7 1 for oceania u5wh66e0.Book page 7 thursday, june 18, 2009 10:41 am.

  • Page 18

    1-8 1 5fu-f816m-20 25 kpa, (3.6 psi) 25 kpa, (3.6 psi) 22 kpa, (3.2 psi) 22 kpa, (3.2 psi) load limit 40 kg{88 lbs} 5nd-f4877-20 load limit 80 kg{176 lbs} 5nd-f4897-20 maximum loading limit 5nd-f151k-00 pulling load: 4900 n (500 kgf) 1102 lbf tongue weight: 147 n ( 15 kgf) 33 lbf 1 3 2 4 5 u5wh66e0....

  • Page 19

    1-9 1 6 7 u5wh66e0.Book page 9 thursday, june 18, 2009 10:41 am.

  • Page 20

    2-1 2 ebu17431 safety information ebu17563 an atv is not a toy and can be hazard- ous to operate. An atv handles differently from other vehicles, in- cluding motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over o...

  • Page 21

    2-2 2 ● always inspect your atv each time you use it to make sure it is in safe operating condition. Al- ways follow the inspection and maintenance procedures and schedules described in this manual. ● always keep both hands on the handlebars and both feet on the footboards of the atv during operatio...

  • Page 22

    2-3 2 roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill. Turn the atv around and remount, following the procedure described in this manual. ● always check for obstacles before operating in a new ar...

  • Page 23

    2-4 2 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and seek medical ...

  • Page 24

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Fuel cock 2. Throttle stop screw 3. Air filter case 4. Fuses 5. Battery 6. Tail/brake light 7. Recoil starter 8. Engine oil filler cap 9. Oil filter cartridge 10.V-belt cooling duct check hose 3 4,5 1 2 6 10 9 7 8 1. Rear shock abs...

  • Page 25

    3-2 3 ebu17712 controls and instruments tip the atv you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Parking brake lock plate 5. Horn switch 6. Drive select lever 7. Speedometer 8. Main switch 9. Fuel tank c...

  • Page 26

    4-1 4 ebu17733 instrument and control functions ebu17770 main switch the positions of the main switch are as follows: on all electrical systems are supplied with power. The headlights, meter lighting and taillight come on when the light switch is on, and the engine can be started. The key cannot be ...

  • Page 27

    4-2 4 ebu17814 indicator lights and warning light ebu17850 reverse indicator light “reverse” this indicator light comes on when the transmis- sion is in the reverse position. Ebu17870 neutral indicator light “neutral” this indicator light comes on when the transmis- sion is in the neutral position. ...

  • Page 28

    4-3 4 ebu18022 speedometer this speedometer is equipped with an odometer and a tripmeter. The tripmeter can be reset to zero with the reset knob. Use the tripmeter to estimate how far you can ride on a tank of fuel before going to reserve. This information will enable you to plan fuel stops in the f...

  • Page 29

    4-4 4 ebu18101 start switch “ ” push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. Ebu18161 light switch “ / /off” set this switch to “ ” to turn on the low beams, the taillight and the meter lighting. Set the switch to “ ...

  • Page 30

    4-5 4 ebu18323 speed limiter your atv is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the ...

  • Page 31

    4-6 4 ebu18442 brake pedal and rear brake lever the brake pedal is located on the right side of the atv and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. 1. Front brake lever 1. Brake pe...

  • Page 32

    4-7 4 ebu18460 parking brake use the parking brake before starting the engine or parking the atv, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. Warning ewb00220 ● always set the pa...

  • Page 33

    4-8 4 ebu18670 recoil starter firmly grasp the handle and pull slightly until en- gagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out. Warning ewb00340 shift the drive select lever into the neutral po- sition and apply the parking brake before start- ing th...

  • Page 34

    4-9 4 ebu18754 fuel make sure there is sufficient gasoline in the tank. Warning ewb02521 gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, fol- low these instructions. 1. Before refueling, turn off the engine and be s...

  • Page 35

    4-10 4 3. Wipe up any spilled fuel immediately. Notice: immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. [ecb00981] 4. Turn the fuel tank cap fully clockwise to make sure it is securely closed. Warning ewb02531 gasoline is...

  • Page 36

    4-11 4 off with the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. On with the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine an...

  • Page 37

    4-12 4 res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to “on”! Ebu18850...

  • Page 38

    4-13 4 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. Make sure that the seat is securely fitted. Ebu18912 storage compartment notice ecb00130 do not store metal or sharply edged objects, like tools, in the storage com...

  • Page 39

    4-14 4 ● do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment. ● do not exceed the maximum load of 210.0 kg (463 lb) for the atv. Tip there is a check hose at the bottom of the storage compartment. If any water collects in this hose, re- move the hose, empty it, and then install...

  • Page 40

    4-15 4 ebu18992 adjusting the front shock absorber as- semblies the spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Warning ewb00400 always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor han...

  • Page 41

    4-16 4 ebu19023 adjusting the rear shock absorber as- sembly the spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Notice ecb01090 never turn the adjusting mechanism beyond the minimum and maximum settings. Adjust the spring preload as follows. Turn the spring pr...

  • Page 42

    4-17 4 tip a special wrench can be obtained at a yamaha dealer to make this adjustment. 1. Special wrench spring preload setting: minimum (soft): 1 standard: 2 maximum (hard): 5 u5wh66e0.Book page 17 thursday, june 18, 2009 10:41 am.

  • Page 43

    5-1 5 ebu19201 pre-operation checks ebu19224 inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual. Warning ewb00481 failure to inspect or maintain the v...

  • Page 44

    5-2 5 rear brake • check operation, and correct if necessary. • lubricate cables if necessary. • check lever and pedal free play, and adjust if necessary. 5-3, 8-26, 8-29 throttle lever • make sure that operation is smooth. Lubricate cable and lever hous- ing if necessary. • check cable free play, a...

  • Page 45

    5-3 5 ebu19541 fuel make sure that there is sufficient fuel in the tank. (see page 4-9.) ebu19560 engine oil make sure that the engine oil is at the specified lev- el. Add oil as necessary. (see page 8-12.) ebu19590 final gear oil make sure that the final gear oil is at the specified level. Add oil ...

  • Page 46

    5-4 5 ebu19761 throttle lever check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a yamaha dealer correct if necessary. Ebu19814 tires check tire pressure regularly to make sure it is at the recommended specifications. Also check ...

  • Page 47

    5-5 5 tire wear limit when the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. Tire information this atv is equipped with tubeless tires with valves. Warning ewb02551 use of improper tires on this atv may cause loss of control, increasing your risk of an acci- dent. After exte...

  • Page 48

    5-6 5 aftermarket tires and rims the tires and rims that came with your atv were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Ebu19840 chassis fasteners make su...

  • Page 49

    6-1 6 ebu19880 operation ebu19901 read the owner’s manual carefully before riding the atv. If there is a control or function you do not understand, ask your yamaha dealer. Warning ewb00631 read the owner’s manual carefully to become familiar with all controls in order to help pre- vent any loss of c...

  • Page 50

    6-2 6 position (3): cold engine start with ambient temperature above 25 °c (80 °f). Ambient temp./starter (choke) position 6. Completely close the throttle lever and start the engine by pushing the start switch. Notice: for maximum engine life, never accelerate hard when the engine is cold! [ecb0016...

  • Page 51

    6-3 6 ebu20291 starting a warm engine follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. Ebu20382 operating the drive select lever and driving in reve...

  • Page 52

    6-4 6 1. Bring the atv to a complete stop. 2. Apply the brake pedal. 3. Shift from neutral to reverse and vice versa by moving the drive select lever along the shift guide. Tip when in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a yamaha dealer ...

  • Page 53

    6-5 6 0–160 km (0–100 mi) or 0–10 hours avoid prolonged operation above 1/2 throttle. Vary the speed of the atv regularly. Do not operate it at one set throttle position. 160–320 km (100–200 mi) or 10–20 hours avoid prolonged operation above 3/4 throttle. Rev the engine freely, but do not use full t...

  • Page 54

    6-6 6 never park the atv on hills that are too steep to walk up easily. 1. With the transmission in the forward position, bring the atv to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake lever applied, apply the parking brake, and then slowly release the brake pedal. 4. Tur...

  • Page 55

    6-7 6 market products or having other modifications performed to your atv that change any of the ve- hicle’s design or operation characteristics can put you and others at greater risk of serious injury or death. You are responsible for injuries related to changes in the vehicle. Keep the following i...

  • Page 56

    6-8 6 ● do not exceed the maximum tongue weight. You can measure tongue weight with a bath- room scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Ad- just the load in the trailer, if necessary, to reduce the weight on the hitch. If you are carrying cargo and ...

  • Page 57

    7-1 7 ebu21141 riding your atv u5wh66e0.Book page 1 thursday, june 18, 2009 10:41 am.

  • Page 58

    7-2 7 ebu21634 getting to know your atv this atv is for recreation and utility use. This sec- tion, riding your atv, provides general atv riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your at...

  • Page 59

    7-3 7 riding your atv requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the atv’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more di...

  • Page 60

    7-4 7 apparel always wear the following to reduce risk of injury in an accident: ● approved motorcycle helmet that fits properly ● eye protection (goggles, helmet face shield, or protective eyewear) ● over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants an approved helmet and o...

  • Page 61

    7-5 7 do not operate after or while consuming alco- hol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. Consuming al- cohol or drugs could seriously affect your judg- ment, cause you to react more slowly, and affect your balance and perception. Warnin...

  • Page 62

    7-6 7 opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and de- creases the maximum speed of the atv. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (see page 4-5.) loa...

  • Page 63

    7-7 7 drive more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice to drive slowly (shift into first gear or low drive if avail- able on this model) whenever you are carrying heavier loads or when towing a trailer...

  • Page 64

    7-8 7 an overturn. Never attempt stunts, such as wheelies or jumps. Don’t try to show off. [ewb01481] modifications and accessories never modify this atv through improper installa- tion or use of accessories or other modification. All parts and accessories added to this atv should be genuine yamaha ...

  • Page 65

    7-9 7 to prevent burns, avoid touching the exhaust sys- tem. Park the atv in a place where pedestrians or children are not likely to touch it. Be careful where you ride this atv is designed for use on unpaved surfaces only. Warning! Paved surfaces may seriously affect handling and control of the atv...

  • Page 66

    7-10 7 know your country’s laws and regulations before you ride on unpaved public streets or roads. Do not ride on any paved public street, road or motorway. Warning! Never operate this atv on any paved street, paved road or motorway. You can collide with another vehicle. [ewb01521] know the terrain...

  • Page 67

    7-11 7 loose terrain could cause loss of traction or atv control, which could result in an accident, including an overturn. [ewb01541] 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 hit...

  • Page 68

    7-12 7 select a large, flat, unpaved area to become famil- iar with your atv. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, and turning tech- niques in this area before trying more difficult ter- rain. Set the parking brake and f...

  • Page 69

    7-13 7 this procedure should be practiced at slow speed many times in a large unpaved area with no obsta- cles. 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 proce- dure again. If the riding surface is slippery ...

  • Page 70

    7-14 7 ● never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. ● never attempt to turn the atv around on any hill until you have mastered the turning tech- nique as described in the owner’s manual on level gro...

  • Page 71

    7-15 7 do not attempt to climb hills until you have mas- tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. To climb a hill, you need trac...

  • Page 72

    7-16 7 riding downhill warning ewb01131 going down a hill improperly could cause overturns or loss of control. Always follow proper procedures for going down hills as de- scribed in this owner’s manual. ● always check the terrain carefully before you start down any hill. ● never operate the atv on h...

  • Page 73

    7-17 7 crossing a slope warning ewb01632 improperly crossing hills or turning on hills could cause loss of control or cause the atv to overturn. ● always follow proper procedures as de- scribed in the owner’s manual. ● avoid hills with excessively slippery or loose surfaces. ● avoid crossing the sid...

  • Page 74

    7-18 7 crossing through shallow water warning ewb01641 operating this vehicle through deep or fast- flowing water can lead to loss of control or an overturn. To reduce your risk of drowning or other injuries, use care when crossing through water. Never operate this atv water deeper than the depth sp...

  • Page 75

    7-19 7 ability. Warning! Wet brakes may have re- duced stopping ability, which could cause loss of control. [ewb02621] 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, the v-belt cooling duct check hose, the drive sel...

  • Page 76

    7-20 7 riding over rough terrain warning ewb01651 riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always fo...

  • Page 77

    7-21 7 cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the atv as loss of control and damage to the atv may re- sult. Sliding and skidding warning ewb01662 skidding or sliding improperly may cause you to lose control of this atv. You may also re- gain t...

  • Page 78

    7-22 7 with practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are re- duced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery sur...

  • Page 79

    7-23 7 ● if your atv is traversing a sloping surface: be sure to ride with your weight positioned to- wards the uphill side of the atv to maintain 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 discover that the atv is ...

  • Page 80

    8-1 8 ebu28783 periodic maintenance and adjustment ebu21671 periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most effi- cient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustmen...

  • Page 81

    8-2 8 the service information included in this manual and the tools provided in the owner’s tool kit are in- tended to assist you in the performance of preven- tive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work c...

  • Page 82

    8-3 8 ebu21743 periodic maintenance chart for the emission control system tip ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep i...

  • Page 83

    8-4 8 6 * exhaust system • check for leakage and replace gasket(s) if neces- sary. • check for looseness and tighten all screw clamps and joints if necessary. √ √ √ 7 spark arrester • clean. √ √ √ no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (2...

  • Page 84

    8-5 8 ebu21865 general maintenance and lubrication chart tip ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep in mind that if th...

  • Page 85

    8-6 8 4 * brake hoses • check for cracks or other damage, and replace if necessary. √ √ √ √ • replace. Every 4 years 5 * wheels • check runout and for damage, and replace if nec- essary. √ √ √ √ 6 * tires • check tread depth and for damage, and replace if necessary. • check air pressure and balance,...

  • Page 86

    8-7 8 15 engine oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ √ √ 16 engine oil filter car- tridge • replace. √ √ √ 17 final gear oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ 18 * moving parts and cables • lubricate. √ √ √ √ 19 * drive selec...

  • Page 87

    8-8 8 ebu28391 tip ● some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal components...

  • Page 88

    8-9 8 ebu23080 removing and installing the panel the panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. Ebu23112 panel a to remove the panel remove the bolt, and then take the...

  • Page 89

    8-10 8 dance with the periodic maintenance and lubrica- tion chart. In addition, the condition of the spark plug can reveal the condition of the engine. To remove the spark plug 1. Remove the spark plug cap. 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool k...

  • Page 90

    8-11 8 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. 3. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification. To install the spark plug 1. Clean the surface of the spark plug g...

  • Page 91

    8-12 8 ebu23319 engine oil and oil filter cartridge the engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals spec- ified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Pla...

  • Page 92

    8-13 8 5. If the engine oil is not between the tip of the dipstick and the maximum level mark, add sufficient oil of the recommended type to raise it to the correct level. Notice: be sure the engine oil is at the correct level, otherwise engine damage may result. [ecb00851] 6. Insert the dipstick in...

  • Page 93

    8-14 8 tip an oil filter wrench is available at a nearby yamaha dealer. 6. Apply a thin coat of engine oil to the o-ring of the new oil filter cartridge. Tip make sure that the o-ring is properly seated. 7. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to the ...

  • Page 94

    8-15 8 8. Install the engine oil drain bolt and its new gasket, and then tighten the bolt to the speci- fied torque. 9. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap. Tip be sure to wipe off spilled oil on any parts after t...

  • Page 95

    8-16 8 ● make sure that no foreign material enters the crankcase. 10. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 11. Turn the engine off, wait at least ten minutes, and then...

  • Page 96

    8-17 8 to change the final gear oil 1. Place the atv on a level surface. 2. Remove the final gear case guard by remov- ing the bolts. 3. Place an oil pan under the final gear case to collect the used oil. 4. Remove the final gear oil filler bolt, the final gear oil drain bolt, and their gasket to dr...

  • Page 97

    8-18 8 7. Check the oil filler bolt gasket for damage, and replace it if necessary. 8. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque. 9. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 10. Install the final gear case ...

  • Page 98

    8-19 8 1. Place the atv on a level surface. 2. Remove the seat. (see page 4-12.) 3. Remove the air filter case cover by unhooking the air filter case cover holders. 4. Pull the air filter element out of the air filter case. 1. Air filter case check hose 1. Air filter case cover holder 2. Air filter ...

  • Page 99

    8-20 8 5. Pull off the air filter element lock plate, and then remove the sponge material from the air filter element frame. 6. Wash the sponge material gently but thor- oughly in solvent. Warning! Always use parts cleaning solvent to clean the sponge material. Never use low-flash-point sol- vents o...

  • Page 100

    8-21 8 8. Check the sponge material and replace it if damaged. 9. Apply yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. Tip the sponge material should be wet but not drip- ping. 10. Pull the sponge material over the air filter ele- ment frame, and then insta...

  • Page 101

    8-22 8 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 arrester portion of the tailpipe and inside of the tailpipe housing. 4. Insert the tailpipe into the muffler and align the bolt holes. 5...

  • Page 102

    8-23 8 warning ewb02340 do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire. Always let the exhaust system cool prior to touching exhaust components. Ebu23920 v-belt coo...

  • Page 103

    8-24 8 ebu23940 adjusting the carburetor the carburetor should be checked and, if neces- sary, adjusted at the intervals specified in the peri- odic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carbur...

  • Page 104

    8-25 8 tip if the specified idling speed cannot be obtained as described above, have a yamaha dealer make the adjustment. Ebu24045 adjusting the throttle cable free play the throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in the periodic maintenanc...

  • Page 105

    8-26 8 4. Tighten the locknut. 5. Slide the rubber cover to its original position. Ebu24060 valve clearance the valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a yamaha dealer at the...

  • Page 106

    8-27 8 ebu24171 front brake pads check each front brake pad for damage and mea- sure the lining thickness. If a brake pad is dam- aged or if the lining thickness is less than 1.0 mm (0.04 in), have a yamaha dealer replace the brake pads as a set. Tip the wheels need to be removed to check the brake ...

  • Page 107

    8-28 8 ebu29840 checking the brake fluid level insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary. A low brake fluid level may indicate w...

  • Page 108

    8-29 8 have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are dam- aged or leaking. ● oil seals: replace every two years. ● brake hoses: replace every four years. Ebu24394 checking the front brake lever free...

  • Page 109

    8-30 8 1. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the rear wheel hub. 2. Turn the brake pedal free play adjusting nut on the brake cable at the rear wheel hub in di- rection (a) to increase the free play, and in di- rection (b) to decrease it. Adjusting the brake...

  • Page 110

    8-31 8 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 2. Turn the brake lever free play adjusting nut on the brake cable at the rear wheel hub so that gap “a” measures 0–1 mm (0–0.04 in). 3. Turn the brake lever free play adjusting bolt at the br...

  • Page 111

    8-32 8 4. Tighten the locknut at the brake lever. Tip when adjusting the rear brake lever free play: ● be sure not to step on the brake pedal. ● make sure the brake pedal does not move. Checking the brake pedal position the top of the brake pedal should be positioned 72.0–82.0 mm (2.83–3.23 in) abov...

  • Page 112

    8-33 8 3. Install the panel. Ebu24901 checking and lubricating the cables the operation and the condition of all control ca- bles should be checked before each ride, and the cables and cable ends should be lubricated if nec- essary. If a cable is damaged or does not move smoothly, have a yamaha deal...

  • Page 113

    8-34 8 front brake lever rear brake lever ebu28832 checking and lubricating the brake pedal the operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. Tip to access the brake pedal pivot, remove panel a. (see page 8-9.) recommended lub...

  • Page 114

    8-35 8 ebu24963 checking the wheel hub bearings the front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a yamaha dealer check the wheel hub bear- ing...

  • Page 115

    8-36 8 ebu29184 battery this model is equipped with a vrla (valve regu- lated lead acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened. Notice ecb00620 never attempt to remove the ba...

  • Page 116

    8-37 8 4. Pull the battery out of its compartment. To charge the battery have a yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the atv is equipped with optional electri- cal accessories. Notice ecb...

  • Page 117

    8-38 8 to install the battery tip be sure the battery is fully charged. 1. Place the battery in its compartment. 2. Connect the positive battery lead first, then connect the negative battery lead by installing their bolt. 3. Install the battery holding plate by installing the bolts. 4. Install the s...

  • Page 118

    8-39 8 if a fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Notice ecb00640 to prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified ...

  • Page 119

    8-40 8 ebu25481 replacing a headlight bulb if a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 2. Remove the headlight bulb holder cover by pulling it off. 3. Remove the headlight bulb holder by pushing it in and turning it counte...

  • Page 120

    8-41 8 4. Remove the burnt-out bulb by pulling it out. 5. Insert a new headlight bulb into the bulb hold- er by pushing it in. Notice: do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life wi...

  • Page 121

    8-42 8 ebu25580 replacing the tail/brake light bulb if the tail/brake light bulb burns out, have a yamaha dealer replace it. Ebu25651 removing a wheel 1. Place the atv on a level surface. 2. Loosen the wheel nuts. 3. Elevate the atv and place a suitable stand under the frame. 4. Remove the nuts from...

  • Page 122

    8-43 8 ● tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 3. Lower the atv to the ground. 4. Tighten the wheel nuts to the specified torques. 1. Arrow mark 1. Tapered nut tightening torques: front wheel nut: 55 nm (5.5 m·kgf, 40 ...

  • Page 123

    8-44 8 ebu25720 troubleshooting although yamaha atvs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshootin...

  • Page 124

    8-45 8 ebu25751 troubleshooting chart check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compression. Operate the electric starter. 2. Compression there is compression. There is no compressio...

  • Page 125

    9-1 9 ebu25860 cleaning and storage ebu25881 cleaning frequent, thorough cleaning of your atv will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the atv: a. Block off the end of the exhaust pipe to prevent w...

  • Page 126

    9-2 9 ebu25933 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a porous cover. Notice: storing the atv in a poorly ven- tilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust...

  • Page 127

    9-3 9 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. D...

  • Page 128

    10-1 10 ebu25960 specifications dimensions: overall length: 1984 mm (78.1 in) overall width: 1085 mm (42.7 in) overall height: 1120 mm (44.1 in) seat height: 827 mm (32.6 in) wheelbase: 1233 mm (48.5 in) ground clearance: 245 mm (9.6 in) minimum turning radius: 3000 mm (118 in) weight: with oil and ...

  • Page 129

    10-2 10 type: sae 5w-30, 10w-30, 10w-40, 15w-40, 20w-40 or 20w- 50 recommended engine oil grade: api service sg type or higher, jaso standard ma engine oil quantity: without oil filter cartridge replacement: 2.20 l (2.33 us qt, 1.94 imp.Qt) with oil filter cartridge replacement: 2.30 l (2.43 us qt, ...

  • Page 130

    10-3 10 forward gear: 35/20 (1.750) reverse gear: 26/15 (1.733) chassis: frame type: steel tube frame caster angle: 4.0 ° trail: 21.0 mm (0.83 in) front tire: type: tubeless size: at25 x 8-12 manufacturer/model: yfm350az cheng shin/c-828 yfm35gz maxxis/m979 rear tire: type: tubeless size: at25 x 10-...

  • Page 131

    10-4 10 operation: left hand and right foot operation front suspension: type: double wishbone spring/shock absorber type: coil spring/oil damper wheel travel: 160 mm (6.3 in) rear suspension: type: swingarm (monocross) spring/shock absorber type: coil spring/oil damper wheel travel: 180 mm (7.1 in) ...

  • Page 132

    11-1 11 ebu26000 consumer information ebu26012 identification numbers record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a yamaha dealer or for ref- erence in case the atv is s...

  • Page 133

    11-2 11 the year of manufacture is listed in the vehicle identification number as shown in the illustration. Tip the vehicle identification number is used to identify your atv. Ebu26050 model label the model label is affixed at the location in the il- lustration. Record the information on this label...

  • Page 134

    11-3 11 1. Model label u5wh66e0.Book page 3 thursday, june 18, 2009 10:41 am.

  • Page 135

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning ............................................ 8-18 b battery .......................................................................... 8-36 brake fluid, changing ...........................

  • Page 136

    Light switch .................................................................... 4-4 m main switch .................................................................... 4-1 maintenance and lubrication chart ................................. 8-5 maintenance chart, emission control system ...............

  • Page 137

    U5wh66e0.Book page 3 thursday, june 18, 2009 10:41 am.

  • Page 138

    Yamaha motor co., ltd. Printed in usa 2009.06-0.3 ×1 cr (e) u5wh66e0.Book page 1 thursday, june 18, 2009 10:41 am.