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Yamaha GRIZZLY 350 YFM350DE Owner's Manual - Owner’S Manual

Summary of GRIZZLY 350 YFM350DE

  • Page 1

    Yfm35fgd yfm350fad owner’s manual manuel du propriÉtaire manual del propietario 1ns-f8199-61 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 imp...

  • Page 2

    Printed in usa 2012.05-0.3 ×1 cr (e,f,s) dic183.

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Warning owner’s manual yfm35fgd yfm350fad this atv should not be ridden by anyone under 16 years of age. 1ns-f8199-61-e0 u1ns61e0.Book page 1 tuesday, may 15, 2012 5:19 pm.

  • Page 4

    Ebu17136 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. En15997, ansi/svia 1-2010 29 february, 2012 yfm350fwa (yfm35fg) (5y4ah13w0c0515667–) we, yamaha motor co., ltd. 2500 shingai, iwata, japan, declare in sole responsibility, th...

  • Page 5

    Ebu17170 introduction ebu17292 congratulations on your purchase of the yamaha yfm35fgd/yfm350fad. This atv represents the re- sult 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...

  • 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 yfm35fgd/yfm...

  • 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 p...

  • Page 10

    Axle boots ................................................ 8-35 brake light switches ................................. 8-35 checking and lubricating the cables ........ 8-36 checking and lubricating the front and rear brake levers .................................... 8-37 checking and lubricating t...

  • Page 11

    1-1 1 ebu29680 location of the warning and specification labels ebu30291 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 u1ns61e0.Book page 2 tuesday, may 15, 2012 5:19 pm.

  • Page 13

    1-3 1 1p0-f816r-00 yamaha motor co., ltd. 2500 shingai, iwata, japan yfm350fwa 15.9 kw 255 kg 2012 1ns-f155a-10 yamaha 1hp-f811r-00 6 7 8 9 u1ns61e0.Book page 3 tuesday, may 15, 2012 5:19 pm.

  • 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. For atv type 1 category y12, use from 12 years old. Operation of this a...

  • Page 15

    1-5 1 **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi 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 unit contains high-p...

  • Page 16

    1-6 1 yamaha motor co., ltd. 2500 shingai, iwata, japan ****** *** kw *** kg **** 1 2 3 4 1 2 3 4 year of construction model name max. Power mass in running order u1ns61e0.Book page 6 tuesday, may 15, 2012 5:19 pm.

  • Page 17

    1-7 1 for oceania u1ns61e0.Book page 7 tuesday, may 15, 2012 5:19 pm.

  • 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 u1ns61e0....

  • Page 19

    1-9 1 6 7 u1ns61e0.Book page 9 tuesday, may 15, 2012 5:19 pm.

  • Page 20

    2-1 2 ebu17431 safety information ebu17565 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 ● never operate at speeds too fast for your skills or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. ● never attempt wheelies, jumps, or other stunts. ● always inspect your atv each time you use it to make sure...

  • Page 22

    2-3 2 ● always use proper procedures if you stall or roll backwards when climbing a hill. Maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- ...

  • Page 23

    2-4 2 in the event of an accident 1. If serious injuries are incurred, you may be safer staying next to your vehicle; it may shield you from oncoming riders. Depending on your injuries and position in the trail; you must make a judgment call as to whether you should move to a position off the trail....

  • Page 24

    2-5 2 4. Once immediate safety hazards are con- firmed not to exist, you may remove your hel- met to more closely inspect your vehicle. Check for external signs of wear, broken parts, fluid leaks, cracks in the frame, suspen- sion damage, wheel damage, and so on. Fuel, oil, and coolant usually give ...

  • Page 25

    2-6 2 warning ewb00072 avoid carbon monoxide poisoning all engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nau- sea, confusion, and eventually death. Carbon monoxide is a colorless, odorless, tasteless gas which may be pres...

  • Page 26

    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. Engine oil filler cap 8. Oil filter cartridge 9. V-belt cooling duct check hose 3 4,5 1 2 6 9 8 7 1. Rear shock absorber assembly spring...

  • Page 27

    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 28

    4-1 4 ebu17734 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 29

    4-2 4 ebu17816 indicator lights and warning light yfm35fgd yfm350fad ebu30820 neutral indicator light “ ” (for europe)/“neu- tral” (for oceania) this indicator light comes on when the transmis- sion is in the neutral position. Ebu30810 reverse indicator light “ ” (for europe)/“re- verse” (for oceani...

  • Page 30

    4-3 4 ebu26932 oil temperature warning light “ ” this warning light comes on when the engine over- heats. When this occurs, stop the engine as soon as it is safe to do so, and allow it to cool. The electrical circuit of the warning light can be checked by turning the key to “on”, with the engine sto...

  • Page 31

    4-4 4 yfm35fgd yfm350fad 1. Reset knob 2. Speedometer 3. Odometer 4. Tripmeter 2 3 4 1 1. Reset knob 2. Speedometer 3. Odometer 4. Tripmeter u1ns61e0.Book page 4 tuesday, may 15, 2012 5:19 pm.

  • Page 32

    4-5 4 ebu18061 handlebar switches ebu18080 engine stop switch “ / ” set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run ...

  • Page 33

    4-6 4 ebu28432 on-command four-wheel-drive switch “2wd”/“4wd” warning ewb00163 always stop the atv before changing from two-wheel drive to four-wheel drive and vice versa. The atv handles differently in two- wheel drive than in four-wheel drive in some circumstances. Changing from two-wheel drive to...

  • Page 34

    4-7 4 regulate the speed of the atv by varying the throttle position. Because the throttle is spring- loaded, the atv will decelerate, and the engine will return to an idle any time the throttle lever is re- leased. Before starting the engine, check the throttle to be sure it is operating smoothly. ...

  • Page 35

    4-8 4 3. Tighten the locknut. Ebu18391 front brake lever the front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip. Ebu18442 brake pedal and rear brake lever the brake pedal is located on the right side of the atv and the rear...

  • Page 36

    4-9 4 ebu18461 parking brake use the parking brake before starting the engine or after 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 ...

  • Page 37

    4-10 4 ● always be sure you have released the park- ing brake before you begin to ride. The brake could overheat if you ride the atv without re- leasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely. Ebu18581 drive...

  • Page 38

    4-11 4 ebu18755 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 ...

  • Page 39

    4-12 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 40

    4-13 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 41

    4-14 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 42

    4-15 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 43

    4-16 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 44

    4-17 4 ebu18993 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 45

    4-18 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 46

    4-19 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 u1ns61e0.Book page 19 tuesday, may 15, 2012 5:19 pm.

  • Page 47

    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 48

    5-2 5 front brake • check operation. If soft or spongy, have yamaha dealer bleed hy- draulic system. • check brake pads for wear, and replace if necessary. • check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary. • check hydraulic system for leakage. Cor...

  • Page 49

    5-3 5 ebu19541 fuel make sure that there is sufficient fuel in the tank. (see page 4-11.) ebu19560 engine oil make sure that the engine oil is at the specified lev- el. Add oil as necessary. (see page 8-11.) ebu19590 final gear oil make sure that the final gear oil is at the specified level. Add oil...

  • Page 50

    5-4 5 brake operation test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brake pads and shoes for wear. (see page 8-27.) ebu19761 throttle lever check the operation of the throttle lever. It must...

  • Page 51

    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 52

    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 53

    6-1 6 ebu19881 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 54

    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. Tip if the engine fails to start, release the start switch, then push it again. Pause a ...

  • Page 55

    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 56

    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 57

    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 58

    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 rear brake lever. 4...

  • Page 59

    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 60

    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 61

    7-1 7 ebu21141 riding your atv u1ns61e0.Book page 1 tuesday, may 15, 2012 5:19 pm.

  • Page 62

    7-2 7 ebu30651 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 63

    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 64

    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 65

    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 66

    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 4-7.) loa...

  • Page 67

    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 68

    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 69

    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 70

    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 71

    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 72

    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 73

    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 74

    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 75

    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 76

    7-16 7 remount, following the procedure described in the owner’s manual. Warning! Stalling, rolling backwards or improperly dismounting while climbing a hill could result in atv overturning. If you cannot control the atv, dismount imme- diately on the uphill side. [ewb01802] riding downhill warning ...

  • Page 77

    7-17 7 use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this atv is in “4wd”, all wheels (front and rear) are interconnected by the drive train. This...

  • Page 78

    7-18 7 ● shift your weight to the uphill side of the atv. ● 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 ground. Be very careful when turning on any hill. Traversing a sloping surface on your atv requires...

  • Page 79

    7-19 7 the atv can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) 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 upset the atv. Drive slowly and ca...

  • Page 80

    7-20 7 1. Air filter case check hose 1. V-belt cooling duct check hose (left front side of atv) 1. Storage compartment check hose 1. V-belt case drain plug u1ns61e0.Book page 20 tuesday, may 15, 2012 5:19 pm.

  • Page 81

    7-21 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 82

    7-22 7 if the rear wheels of your atv start to slide side- ways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide. With practice, over a period of time, ski...

  • Page 83

    7-23 7 the rear brake if the atv is in “2wd” – the atv may tip over on top of you. Dismount the atv on the uphill side. (see page 7-13.) ● 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 ...

  • Page 84

    8-1 8 ebu28783 periodic maintenance and adjustment ebu21674 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 85

    8-2 8 ebu21731 owner’s manual and tool kit be sure to put this owner’s manual in the plastic bag and always carry it on the bottom of the seat as shown. Put the owner’s tool kit and low-pres- sure tire gauge under the seat. The service information included in this manual and the tools provided in th...

  • Page 86

    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 87

    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 88

    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 89

    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 90

    8-7 8 14 * engine mount • check for cracks or other damage, and replace if necessary. √ √ √ 15 * axle boots • check for cracks or other damage, and replace if necessary. √ √ √ √ √ 16 engine oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ √ √ 17 engine oil filter car- tridg...

  • Page 91

    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 92

    8-9 8 ebu23213 checking the spark plug the spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart. In ad...

  • Page 93

    8-10 8 tip if the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a yamaha dealer check the atv. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and repla...

  • Page 94

    8-11 8 tip if a torque wrench is not available when installing the spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 3. Install the spark plug cap. Ebu23319 engine oil and oil ...

  • Page 95

    8-12 8 tip the engine oil should be between the tip of the dip- stick and the maximum level mark. 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 ...

  • Page 96

    8-13 8 tip skip steps 5–7 if the oil filter cartridge is not being replaced. 5. Remove the oil filter cartridge with an oil filter wrench. 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 ...

  • Page 97

    8-14 8 7. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to the specified torque with a torque wrench. 8. Install the engine oil drain bolt and its new gasket, and then tighten the bolt to the speci- fied torque. 1. O-ring 1. Torque wrench tightening torque: oi...

  • Page 98

    8-15 8 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 the engine and exhaust system have cooled down. Notice ecb00300 ● in order to prevent clutch slippage (since th...

  • Page 99

    8-16 8 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 4. Check the gasket for damage, and replace it if necessary. 5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque. To ch...

  • Page 100

    8-17 8 5. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque. 6. Refill with the recommended final gear oil to the brim of the filler hole as shown. Notice: be sure no foreign material enters the final gear case. [ecb00421] 7. Check the oil filler bolt gaske...

  • Page 101

    8-18 8 9. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 10. Install the final gear case guard by installing the bolts and tightening them to the specified torque. Ebu23436 changing the differential gear oil the differential gear case must be checked for oil leaka...

  • Page 102

    8-19 8 4. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque. 5. Refill with the specified amount of the recom- mended differential gear oil. Notice: be sure no foreign material enters the differ- ential gear case. [ecb00411] tip ● do not exceed the specifie...

  • Page 103

    8-20 8 1. Place the atv on a level surface. 2. Remove the seat. (see page 4-14.) 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 104

    8-21 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 105

    8-22 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 106

    8-23 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 107

    8-24 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 108

    8-25 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 109

    8-26 8 tip if the specified idling speed cannot be obtained as described above, have a yamaha dealer make the adjustment. Ebu24047 adjusting the throttle lever free play the throttle lever free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance ...

  • Page 110

    8-27 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 111

    8-28 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 112

    8-29 8 ebu29841 checking the brake fluid level before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid lev- el with the top of the reservoir level. Replenish the brake fluid if necessary. Warning ewb02720 improper maintenance can result in loss of braking abi...

  • Page 113

    8-30 8 brake pads for wear and the brake system for leak- age. If the brake fluid level goes down suddenly, have a yamaha dealer check the cause before fur- ther riding. Ebu24281 changing the brake fluid have a yamaha dealer change the brake fluid at the intervals specified in the tip after the peri...

  • Page 114

    8-31 8 ● before adjusting the brake pedal and brake lever free play, check the rear brake shoes for wear. Checking and adjusting the brake pedal height the top of the brake pedal should be positioned 72.0–82.0 mm (2.83–3.23 in) above the footboard bracket. Check and adjust the brake pedal height as ...

  • Page 115

    8-32 8 4. Turn the adjusting bolt in or out until the brake pedal height is within the specified limits. 5. Tighten the locknut. 6. Install the footboard by installing the bolts and nuts, and then tighten the bolts to the speci- fied torques. Adjusting the brake pedal free play the brake pedal free ...

  • Page 116

    8-33 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 117

    8-34 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 118

    8-35 8 4. Tighten the locknut at the brake lever. 5. Check gap “a” again and, if necessary, adjust it. 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. Ebu24230 axle boots the axle boots must be checked for damage...

  • Page 119

    8-36 8 the rear brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a yamaha dealer. Turn the rear brake light switch adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the...

  • Page 120

    8-37 8 ebu28711 checking and lubricating the front and rear brake levers the operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Front brake lever rear brake lever ebu28871 checking and lubricating the brake pedal t...

  • Page 121

    8-38 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 122

    8-39 8 ebu29189 battery the battery is located under the seat. (see page 4-14.) 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, t...

  • Page 123

    8-40 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 124

    8-41 8 2. Connect the positive battery lead first, then connect the negative battery lead by installing their bolt. Notice: when installing the bat- tery, the main switch must be off, and the positive lead must be connected before the negative lead. [ecb01110] 3. Install the battery holding plate by...

  • Page 125

    8-42 8 tip to access the main fuse, remove the battery lead cover by removing the screw. 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 replaci...

  • Page 126

    8-43 8 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Warning! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical system, which coul...

  • Page 127

    8-44 8 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 4. Remove the burnt-out bulb by pulling it out. 5. Place a new headlight bulb into position. Notice: do not touch the glass part of the headlight bulb to keep it free from oil, oth- erwise the transparency o...

  • Page 128

    8-45 8 7. Install the bulb holder cover and the cover at the rear of the headlight. Notice: make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. [ecb00671] 8. Adjust the headlight beam if necessary. Ebu25551 adjusting a headlight beam notice ecb00690...

  • Page 129

    8-46 8 3. Elevate the atv and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. Ebu25701 installing a wheel 1. Place the atv on a level surface. 2. Install the wheel and the nuts. Tip ● the arrow mark on the tire must point toward the rotating direction ...

  • Page 130

    8-47 8 3. Lower the atv to the ground. 4. Tighten the wheel nuts to the specified torques. 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, ...

  • Page 131

    8-48 8 ebu25752 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 132

    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 133

    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 134

    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 135

    10-1 10 ebu25961 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 136

    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 137

    10-3 10 secondary reduction system: shaft drive secondary reduction ratio: 41/21 × 24/18 × 33/9 (9.545) transmission type: v-belt automatic operation: left hand operation 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 ...

  • Page 138

    10-4 10 operation: right hand operation specified brake fluid: dot 4 rear brake: type: drum brake 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 spr...

  • Page 139

    10-5 10 four-wheel-drive motor fuse: 3.0 a ebu30401 for europe only the figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions...

  • Page 140

    11-1 11 ebu26000 consumer information ebu28201 identification numbers record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a yamaha dealer or for reference in case the atv is stolen. Vehicle identification n...

  • Page 141

    11-2 11 1. Model label u1ns61e0.Book page 2 tuesday, may 15, 2012 5:19 pm.

  • Page 142

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning ............................................ 8-19 axle boots .................................................................... 8-35 b battery ............................................

  • Page 143

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

  • Page 144

    Ebu26172 warning always : • use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. • avoid paved surfaces—pavement may seriously affect handling and control. Improper atv use can result in severe injury or death. Never use with drugs or alcohol always use an...