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  5. Owner's Manual

Yamaha GRIZZLY 350 YFM35FGDW Owner's Manual

Summary of GRIZZLY 350 YFM35FGDW

  • Page 1

    Yfm35fgdw owner’s manual manuel du propriÉtaire manual del propietario 4s2-f8199-60 dic183.

  • Page 2

    Printed in usa 2006.10-0.3 ×2 cr (e,f,s) yamaha motor co., ltd. Dic183.

  • Page 3: Owner’S Manual

    Owner’s manual yfm35fgdw 4s2-f8199-60-e0 u4s260e0.Book page 1 tuesday, october 3, 2006 1:53 pm.

  • Page 4

    Ebu27860 representing yamaha motor manufacturing corporation of america newnan, georgia u.S.A. Declare in sole responsibility, that the product ec declaration of conformity conforming to directive 98/37/ec yamaha motor co., ltd (name of supplier) 2500 shingai, iwata, shizuoka, japan (make, model) to...

  • Page 5

    Ebu17170 introduction ebu17290 congratulations on your purchase of the yamaha yfm35fgdw. This atv 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 d...

  • Page 6

    Ebu17330 important manual information ebu17341 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 ebu17370 welcome to the yamaha world of motor sports! 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 bef...

  • Page 8

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

  • Page 9

    Operation .................................................. 6-1 starting a cold engine ................................ 6-1 starting a warm engine .............................. 6-3 operating the drive select lever and driving in reverse ...................................... 6-3 engine break-in .....

  • Page 10

    Adjusting the brake pedal and rear brake lever free play and checking the brake pedal position ......................... 8-30 axle boots ................................................ 8-34 brake light switches ................................. 8-35 checking and lubricating the cables ........ 8-36...

  • Page 11

    1-1 1 ebu17430 safety information ebu17562 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 12

    1-2 1 ● 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 13

    1-3 1 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 14

    1-4 1 nition such as the pilot lights of water heat- ers and clothes dryers. Gasoline can catch fire and you could be burned. ● when transporting the atv in another vehi- cle, be sure it is kept upright and that the fuel cock is in the “off” position. Otherwise, fuel may leak out of the carburetor o...

  • Page 15

    2-1 2 ebu17660 location of the warning and specification labels u4s260e0.Book page 1 tuesday, october 3, 2006 1:53 pm.

  • Page 16

    2-2 2 ebu27150 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 replace- ment label from your yamaha dealer. For europe and ...

  • Page 17

    2-3 2 for europe u4s260e0.Book page 3 tuesday, october 3, 2006 1:53 pm.

  • Page 18

    2-4 2 for europe u4s260e0.Book page 4 tuesday, october 3, 2006 1:53 pm.

  • Page 19

    2-5 2 for oceania u4s260e0.Book page 5 tuesday, october 3, 2006 1:53 pm.

  • Page 20

    2-6 2 for oceania u4s260e0.Book page 6 tuesday, october 3, 2006 1:53 pm.

  • Page 21

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Front shock absorber assembly spring preload adjusting ring 2. Fuel cock 3. Throttle stop screw 4. Fuses 5. Battery 6. Rear shock absorber assembly spring preload adjusting ring 7. Recoil starter 8. Engine oil filler cap 9. Oil fil...

  • Page 22

    3-2 3 ebu17712 controls and instruments note: 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...

  • Page 23

    4-1 4 ebu17731 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 24

    4-2 4 ebu17813 indicator lights and warning light ebu28331 reverse indicator light “reverse” this indicator light comes on when the transmis- sion is in the reverse position. Furthermore, this indicator light flashes: ● when the override switch is being pushed, ● when the engine is being raced for 1...

  • Page 25

    4-3 4 if the warning light stays on, allow the engine to cool. If the warning light stays on when the engine is cool, have a yamaha dealer check the electrical circuit. Caution: ecb00010 ● the engine may overheat if the atv is over- loaded. In this case, reduce the load to spec- ification. ● start t...

  • Page 26

    4-4 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 27

    4-5 4 ebu18100 start switch “ ” push this switch to crank the engine with the start- er. Caution: ecb00050 see the starting instructions on page 6-1 prior to starting the engine. Ebu18160 light switch “ / /off” set this switch to “ ” to turn on the low beams, the taillight and the meter lighting. Se...

  • Page 28

    4-6 4 warning ewb00150 always ride at a slow speed when the atv is in four-wheel-drive differential gear lock, and al- low extra time and distance for maneuvers. All wheels turn at the same speed when the dif- ferential is locked, so it takes more effort to turn the atv. The effort needed to turn in...

  • Page 29

    4-7 4 drive to four-wheel drive or vice-versa while moving may cause the atv to unexpectedly handle differently. This could distract the oper- ator and increase the risk of losing control and of causing an accident. Ebu28370 on-command differential gear lock switch “4wd”/“lock” this atv is equipped ...

  • Page 30

    4-8 4 stop the atv, move the differential gear lock lever to position (a), and then push the differential gear lock switch in to the “lock” position. When the dif- ferential gear is locked, the differential gear lock in- dicator light “ ” comes on. To release the differential gear lock, stop the atv...

  • Page 31

    4-9 4 pectedly. This could distract the operator and increase the risk of losing control and causing an accident. Warning ewb00140 always ride at a slow speed when the atv is in differential gear lock, and allow extra time and distance for maneuvers. All wheels turn at the same speed when the dif- f...

  • Page 32

    4-10 4 before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. Warning ewb00250 malfunction of the throttle could make it diffi- cult to speed up or slow down when you need to. This could cause an...

  • Page 33

    4-11 4 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 brake lever is located...

  • Page 34

    4-12 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 p...

  • Page 35

    4-13 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 t...

  • Page 36

    4-14 4 ebu18750 fuel make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 1. Fuel tank cap 1. Fuel level 2. Fuel tank filler tube recommended fuel: unleaded gasoline only for europe: regular unleaded gasoline only with a research octane n...

  • Page 37

    4-15 4 note: if knocking or pinging occurs, use a different brand of gasoline or higher octane grade. Caution: ecb00070 use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. War...

  • Page 38

    4-16 4 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 and riding. Res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to thi...

  • Page 39

    4-17 4 move the starter (choke) in direction (b) to turn off the starter (choke). See the “starting a cold engine” section on page 6-1 for proper operation. Ebu18880 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 projections o...

  • Page 40

    4-18 4 ebu18941 storage compartment the storage compartment is located under the seat. (see page 4-17.) when storing any documents in the storage com- partment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the atv, be careful not to let any water enter the storag...

  • Page 41

    4-19 4 note: 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 it. Ebu18960 front carrier ● do not exceed the load limit of 40.0 kg (88 lb) for the front carrier. ● do not exceed the maximum load of 210.0...

  • Page 42

    4-20 4 note: a special wrench can be obtained at a yamaha dealer to make this adjustment. 1. Spring preload adjusting ring 2. Position indicator 1. Special wrench spring preload setting: minimum (soft): 1 standard: 2 maximum (hard): 5 u4s260e0.Book page 20 tuesday, october 3, 2006 1:53 pm.

  • Page 43

    4-21 4 warning ewb00400 always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. U4s260e0.Book page 21 tuesday, october 3, 2006 1:53 pm.

  • Page 44

    5-1 5 ebu19200 pre-operation checks ebu19220 pre-operation check list before operating this atv, be sure to check the items listed in the following table. Note: the maintenance of some items in the table has to be performed by a yamaha dealer. Refer to the “periodic maintenance and lubrication chart...

  • Page 45

    5-2 5 warning ewb00480 always inspect your atv each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual. Failure to inspect increases the possibility of an accident or equipment damage. ...

  • Page 46

    5-3 5 ebu19540 fuel make sure that there is sufficient fuel in the tank. (see page 4-14.) warning ewb00520 ● do not overfill the fuel tank. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the en- gine or the sun. ● be careful not to spill fuel, es...

  • Page 47

    5-4 5 brake fluid leakage (front brake) check to see if any brake fluid is leaking out of the hose, joint or brake fluid reservoir of the front brake. Apply the brake firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake ...

  • Page 48

    5-5 5 type: tubeless rear: manufacturer/model: cheng shin/c-828 (aus)(nzl) maxxis/m980 (eur)(gbr) size: at25 x 10-12 type: tubeless ● the tires should be set to the recommended pressure: recommended tire pressure: front: 25.0 kpa (3.6 psi) (0.250 kgf/cm²) rear: 25.0 kpa (3.6 psi) (0.250 kgf/cm²) • c...

  • Page 49

    5-6 5 set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: ebu19830 tire wear limit replace the tire when the tire groove decreases to 3 mm (0.12 in). 1. Low-pressure tire gauge recommended pressure: front 25.0 kpa (3.6 psi) (0.250 kgf/cm²) rear 25.0...

  • Page 50

    5-7 5 ebu19840 chassis fasteners make sure that all nuts, bolts and screws are prop- erly tightened. Ebu19850 instruments, lights and switches check that all instruments, lights and switches are working properly. Correct if necessary. 1. Tire wear limit u4s260e0.Book page 7 tuesday, october 3, 2006 ...

  • Page 51

    6-1 6 ebu19880 operation ebu19900 read the owner’s manual carefully before riding the atv. Warning ewb00630 read the owner’s manual carefully to become familiar with all controls in order to help pre- vent any loss of control, which could cause an accident or injury. If there is a control or func- t...

  • Page 52

    6-2 6 5. Use the starter (choke) in reference to the fig- ure: position (1): cold engine start with ambient temperature below 5 °c (40 °f). Position (2): cold engine start with ambient temperature between 0 °c (30 °f) and 30 °c (90 °f). Position (3): cold engine start with ambient temperature above ...

  • Page 53

    6-3 6 note: the engine is warm when it responds normally to the throttle with the starter (choke) turned off. 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 t...

  • Page 54

    6-4 6 3. Shift from neutral to reverse and vice versa by moving the drive select lever along the shift guide. Note: when in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a yamaha dealer check the electrical circuit. 4. Check behind for people or o...

  • Page 55

    6-5 6 polish themselves to the correct operating clear- ances. During this period, prolonged full-throttle operation or any condition that might result in en- gine overheating must be avoided. 0–160 km (0–100 mi) or 0–10 hours avoid prolonged operation above 1/2 throttle. Vary the speed of the atv r...

  • Page 56

    6-6 6 incline, place the atv transversely across the incline, shift the drive select lever to the for- ward position, stop the engine, apply the park- ing brake, and then block the front and rear wheels with rocks or other objects. Do not park the atv at all on hills that are so steep you could not ...

  • Page 57

    6-7 6 could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view. ● use extra caution when riding an atv with ac- cessories. The atv may handle differently than it does without accessories. Ebu21060 loading cargo or a trailer can cha...

  • Page 58

    6-8 6 ● load cargo on the carriers as close to the center of the atv as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it. ● tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an ac...

  • Page 59

    7-1 7 ebu21141 riding your atv u4s260e0.Book page 1 tuesday, october 3, 2006 1:53 pm.

  • Page 60

    7-2 7 ebu28500 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 61

    7-3 7 not recommended for children under 16 years of age. Warning ewb01390 a child under 16 should never operate an atv with engine size greater than 90 cc. Use by chil- dren of atvs that are not recommended for their age can lead to severe injury or death of the child. This atv is designed to carry...

  • Page 62

    7-4 7 apparel always wear an approved motorcycle helmet that fits properly. You should also wear: ● eye protection (goggles or face shield) ● gloves ● boots ● long-sleeved shirt or jacket ● long pants 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet u4s260e0.Book page 4 tuesday, octobe...

  • Page 63

    7-5 7 warning ewb01410 never operate this atv without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protecti...

  • Page 64

    7-6 7 in the owner’s manual. Failure to inspect the atv before operating or failure to properly maintain the atv increases the possibility of an accident or equipment damage. Warning ewb01440 always use the size and type tires specified in the owner’s manual for this atv on page 5-4. Always maintain...

  • Page 65

    7-7 7 loading and accessories use extra caution when riding the atv with addi- tional loads, such as accessories or cargo. The atv’s handling may be adversely affected. Re- duce your speed when adding additional loads. Warning ewb01460 ● never exceed the stated load capacity for this atv. ● cargo sh...

  • Page 66

    7-8 7 warning ewb01470 always keep both hands on the handlebars and both feet on the footboards of your atv during operation. Removing even one hand or foot can reduce your ability to control the atv or could cause you to lose your balance and fall off of the atv. If you remove a foot from a footboa...

  • Page 67

    7-9 7 installed and used according to instructions. Improper installation of accessories or modifi- cation of this atv may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized atv dealer. Exhaust system the exhaust system on t...

  • Page 68

    7-10 7 while riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles. Watch carefully for other vehicles. Make sure you know your country’s laws and regulations before you ride on unpaved public streets or roads. Do...

  • Page 69

    7-11 7 warning ewb01530 go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to chang- ing terrain conditions when operating the atv. Warning ewb01540 do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necess...

  • Page 70

    7-12 7 warning ewb01550 always mount a caution flag on the atv to make you more visible when operating in areas where you might not be seen by other vehicles. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- missio...

  • Page 71

    7-13 7 with the engine idling, return the starter (choke) to the closed position, shift the drive select lever into the forward position, and then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle i...

  • Page 72

    7-14 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 73

    7-15 7 warning ewb01580 never operate the atv on hills too steep for the atv or for your abilities. The atv can overturn more easily on extremely steep hills than on level surfaces or small hills. Practice on small- er hills before attempting large hills. It is important when climbing a hill to make...

  • Page 74

    7-16 7 warning ewb01600 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. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill...

  • Page 75

    7-17 7 could come off the ground. The atv could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the atv immediate- ly on the uphill side. Warning ewb02450 maintain a steady speed when climbing a hill. If you lose all forward speed: ● keep weight uphill. ● apply...

  • Page 76

    7-18 7 when this atv is in 4wd or 4wd-lock, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the down...

  • Page 77

    7-19 7 to cross a sloping surface. Avoid slopes with slip- pery surfaces or rough terrain that may upset your balance. As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly...

  • Page 78

    7-20 7 warning ewb01640 never operate this atv in fast flowing water or in water deeper than that specified in your owner’s manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the lin...

  • Page 79

    7-21 7 plug to drain any water that may have accumu- lated. Wash the atv in fresh water if it has been operated in salt water or muddy conditions. 1. Air filter case check hose 1. V-belt cooling duct check hose (left front side of atv) 1. Drive select lever box check hose u4s260e0.Book page 21 tuesd...

  • Page 80

    7-22 7 riding over rough terrain riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the atv or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the atv as loss of cont...

  • Page 81

    7-23 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 82

    7-24 7 on extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control. What to do if... This section is designed to be a reference guide only. Be sure to read each section on riding tech- niques completely. What to do...

  • Page 83

    8-1 8 ebu21654 periodic maintenance and minor repair ebu21670 safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your atv in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are expla...

  • Page 84

    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 85

    8-3 8 ebu22403 periodic maintenance and lubrication chart note: ● 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...

  • Page 86

    8-4 8 6 * rear brake • check operation and correct if necessary. • check brake lever and pedal free play, and adjust if necessary. √ √ √ √ √ • replace brake friction plates. Whenever worn to the limit 7 * brake hoses • check for cracks or other damage, and replace if necessary. √ √ √ √ • replace. Ev...

  • Page 87

    8-5 8 16 * knuckle pivots • lubricate with lithium-soap-based grease. √ √ √ 17 * steering shaft • lubricate with lithium-soap-based grease. √ √ √ 18 * steering system • check operation and repair or replace if damaged. • check toe-in and adjust if necessary. √ √ √ √ √ 19 * engine mount • check for c...

  • Page 88

    8-6 8 ebu28390 note: ● the air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. 27 * moving parts and cables • lubricate. √ √ √ √ 28 * drive select lever safety system c...

  • Page 89

    8-7 8 • every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid. • replace the brake hoses every four years and if cracked or damaged. U4s260e0.Book page 7 tuesday, october 3, 2006 1:53 pm.

  • Page 90

    8-8 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. Ebu23111 panel a to remove the panel remove the bolt, and then take the...

  • Page 91

    8-9 8 plug should be removed and checked in accor- 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 spar...

  • Page 92

    8-10 8 to install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification. 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug wi...

  • Page 93

    8-11 8 2. Check the engine oil level on a cold engine. Note: if the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. 3. Remove the engine oil filler cap, and then wipe the...

  • Page 94

    8-12 8 to change the engine oil (with or without oil fil- ter cartridge replacement) 1. Place the atv on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, an...

  • Page 95

    8-13 8 note: 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. Note: 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 ...

  • Page 96

    8-14 8 caution: ecb00300 ● in order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “cd” or oils of a higher quality than specified. In addition, do not use oils labeled “energy conserv- i...

  • Page 97

    8-15 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. Install the oil filler bolt, and then tighten it to the specified torque. To change the final gear oil 1. Remove the engine guard and the final gear case guard b...

  • Page 98

    8-16 8 5. Install the drain bolt, and then tighten it to the specified torque. 6. Add the recommended final gear oil to the brim of the filler hole as shown. Note: if the recommended oil is not available, sae80w- 90 api gl-5 hypoid gear oil may be used instead. However, when using this oil, noise fr...

  • Page 99

    8-17 8 caution: ecb00420 be sure no foreign material enters the final gear case. 7. Install the oil filler bolt, and then tighten it to the specified torque. 8. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 9. Install the engine guard and the final gear case guar...

  • Page 100

    8-18 8 note: the oil level should be at the brim of the filler hole. 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. Install the oil filler bolt, and then tighten it to the specified torque. To change the differentia...

  • Page 101

    8-19 8 5. Add the recommended differential gear oil to the brim of the filler hole as shown. Caution: ecb00410 be sure no foreign material enters the differen- tial gear case. 6. Install the oil filler bolt, and then tighten it to the specified torque. 7. Check the differential gear case for oil lea...

  • Page 102

    8-20 8 1. Remove the seat. (see page 4-17.) 2. Remove the air filter case cover by unhooking the holders. 3. 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 case cover u4s260e0.Book page 20 tuesday, october 3, 2006 1...

  • Page 103

    8-21 8 4. Pull off the lock plate, and then remove the sponge material from the air filter element frame. 5. Wash the sponge material gently but thor- oughly in solvent. Warning ewb01940 always use parts cleaning solvent to clean the sponge material. Never use low-flash-point solvents or gasoline to...

  • Page 104

    8-22 8 caution: ecb00440 do not twist the sponge material when squeez- ing it. 7. Check the sponge material and replace it if damaged. 8. Apply a quality foam air filter oil to the sponge material. Note: the sponge material should be wet but not drip- ping. 9. Pull the sponge material over the air f...

  • Page 105

    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 106

    8-24 8 ebu23920 v-belt cooling duct check hose if dust or water collects in the v-belt cooling duct check hose, remove the hose and clean it. Ebu23930 v-belt case drain plug after riding in water deep enough to allow it to en- ter the v-belt case, remove this plug to drain the water from the case. N...

  • Page 107

    8-25 8 caution: ecb00480 the carburetor has been set and extensively tested at the yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performance of or damage to the engine. Ebu24000 adjusting the engine idling speed the engine idling speed must be ch...

  • Page 108

    8-26 8 ebu24043 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 maintenance and lubrication chart. The throttle cable free play should measure 3.0– 5.0 mm (0.12–0.20 in) at the throttle lev...

  • Page 109

    8-27 8 ebu24070 adjusting the drive select lever safety system cable the drive select lever safety system cable stretch- es with use, which can result in improper function. Therefore, the safety system cable should be checked and adjusted at the intervals specified in the periodic maintenance and lu...

  • Page 110

    8-28 8 ebu28421 rear brake friction plates the rear brake is provided with a wear indicator, which allows you to check the brake friction plate wear without having to disassemble the brake. To check the brake friction plate wear, check the posi- tion of the wear indicator while applying the brake. I...

  • Page 111

    8-29 8 ● use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. ● refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. ● be careful that...

  • Page 112

    8-30 8 warning ewb02070 operating with improperly serviced or adjust- ed brakes could cause loss of braking ability, which could lead to an accident. After servicing: ● make sure the brakes operate smoothly and that the free play is correct. ● make sure the brakes do not drag. ● make sure the brakes...

  • Page 113

    8-31 8 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 2. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the final gear case. 1. Brake pedal free play 1. Brake lever free play 1. Locknut 2. Brake lever free play adjus...

  • Page 114

    8-32 8 3. Push the brake camshaft lever in direction (a) until it stops [apply approximately 47 n (10.6 lbf) (4.8 kgf) of force], and then turn the brake pedal free play adjusting nut on the brake ca- ble at the final gear case so that gap “a” mea- sures 2.5–3.0 mm (0.10–0.12 in). 4. Push the brake ...

  • Page 115

    8-33 8 5. Check the brake lever free play and, if neces- sary, adjust it by turning the brake lever free play adjusting bolt at the brake lever. Turn the brake lever free play adjusting bolt in direction (a) to increase the free play, and in direction (b) to decrease it. 6. Tighten the locknut at th...

  • Page 116

    8-34 8 warning ewb02080 operating with improperly serviced or adjust- ed brakes could cause loss of braking ability, which could lead to an accident. After servicing: ● make sure the brakes operate smoothly and that the free play is correct. ● make sure the brakes do not drag. Replacement of brake c...

  • Page 117

    8-35 8 ebu24751 brake light switches the operation of the brake light switches must be checked and, if necessary, adjusted at the inter- vals specified in the periodic maintenance and lu- brication chart. The brake light switch for the brake pedal can be adjusted as follows, but the other brake ligh...

  • Page 118

    8-36 8 ebu24900 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 dealer check or replace it...

  • Page 119

    8-37 8 rear brake lever ebu24950 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. Note: to access the brake pedal pivot, remove panel a. (see page 8-8.) ebu24961 checking the wheel bea...

  • Page 120

    8-38 8 ebu25021 checking the stabilizer bushes the stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a yamaha dealer replace the stabilizer bush- es if necessary. Ebu25050 lubricating the knuckle pivots the knuck...

  • Page 121

    8-39 8 ebu25222 battery this model is equipped with a sealed-type (mf) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections. Caution: ecb00620 never attempt to remove the ba...

  • Page 122

    8-40 8 2. Make sure to properly connect the battery leads to the battery terminals. Caution: ecb00630 ● always keep the battery charged. Storing a discharged battery can cause permanent battery damage. ● to charge a sealed-type (mf) battery, a spe- cial constant-voltage battery charger is re- quired...

  • Page 123

    8-41 8 the main fuse and the fuse box are located under the seat. (see page 4-17.) if a fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Caution: ecb00640 to prevent accidental short-circuiting, turn off the main switch when checking or replacing a...

  • Page 124

    8-42 8 warning ewb02171 always use a fuse of the specified rating, and never use a substitute object in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical sys- tem, which could lead to a fire. 3. Turn the key to “on” and turn on the electrical circui...

  • Page 125

    8-43 8 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 4. Remove the defective bulb by pulling it out. Warning ewb02220 a headlight bulb is hot when it is on and imme- diately after it is turned off. Wait for the bulb to cool before touching or removing it. You ...

  • Page 126

    8-44 8 caution: ecb00670 make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 8. Adjust the headlight beam if necessary. Ebu25550 adjusting a headlight beam caution: ecb00690 it is advisable to have a yamaha dealer make this adjustment. To raise a he...

  • Page 127

    8-45 8 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Ebu25700 installing a wheel 1. Install the wheel and the nuts. Note: ● the arrow mark on the tire must point toward the rotating direction of the wheel. ● tapered nuts are us...

  • Page 128

    8-46 8 2. Lower the atv to the ground. 3. 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 129

    8-47 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 130

    9-1 9 ebu25860 cleaning and storage ebu25880 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 131

    9-2 9 warning ewb02310 wet brakes may have reduced stopping ability, increasing the chance of an accident. Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. Ebu25932 storage short-term always store your atv in a cool, dry place and, if ...

  • Page 132

    9-3 9 c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (this will limit sparking during the next step.) d. Turn the engine over several times with the starter. (this will coat the cylinder wall with oil.) e. Re...

  • Page 133

    10-1 10 ebu25960 specifications dimensions: overall length: 1995 mm (78.5 in) overall width: 1095 mm (43.1 in) overall height: 1120 mm (44.1 in) seat height: 830 mm (32.7 in) wheelbase: 1235 mm (48.6 in) ground clearance: 245 mm (9.6 in) minimum turning radius: 3400 mm (134 in) weight: with oil and ...

  • Page 134

    10-2 10 engine oil: type: sae5w30 or sae10w30 or sae10w40 or sae15w40 or sae20w40 or sae20w50 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 repla...

  • Page 135

    10-3 10 spark plug gap: 0.6–0.7 mm (0.024–0.028 in) clutch: clutch type: wet, centrifugal automatic transmission: primary reduction system: v-belt secondary reduction system: shaft drive secondary reduction ratio: 41/21 × 24/18 × 33/9 (9.545) transmission type: v-belt automatic operation: left hand ...

  • Page 136

    10-4 10 rear: 28.0 kpa (4.1 psi) (0.280 kgf/cm²) front wheel: wheel type: panel wheel rim size: 12 x 6.0at rear wheel: wheel type: panel wheel rim size: 12 x 7.5at front brake: type: dual disc brake operation: right hand operation recommended fluid: dot 4 rear brake: type: wet multiple disc brake op...

  • Page 137

    10-5 10 oil temperature warning light: 12 v, 1.7 w × 1 on-command four-wheel-drive indicator light: 12 v, 1.7 w × 1 differential gear lock indicator light: 12 v, 1.7 w x 1 fuses: main fuse: 30.0 a headlight fuse: 15.0 a signaling system fuse: 10.0 a ignition fuse: 15.0 a auxiliary dc jack fuse: 10.0...

  • Page 138

    11-1 11 ebu26000 consumer information ebu26011 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 139

    11-2 11 the year of manufacture is listed in the vehicle identification number as shown in the illustration. Note: 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 lab...

  • Page 140

    11-3 11 1. Model label u4s260e0.Book page 3 tuesday, october 3, 2006 1:53 pm.

  • Page 141

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning ............................................ 8-19 axle boots .................................................................... 8-34 b battery ............................................

  • Page 142

    K key identification number ............................................. 11-1 knuckle pivots, lubricating ............................................ 8-38 l label locations ............................................................... 2-1 light switch ...............................................

  • Page 143

    U4s260e0.Book page 3 tuesday, october 3, 2006 1:53 pm.

  • Page 144

    Yamaha motor co., ltd. Printed in usa 2006.10-0.3 ×2 cr (e) u4s260e0.Book page 1 friday, october 20, 2006 11:30 am.