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Yamaha GRIZZLY 350 YFM35FGDY Owner's Manual - Owner’S Manual

Summary of GRIZZLY 350 YFM35FGDY

  • Page 1

    Yfm35fgy owner’s manual manuel du propriÉtaire manual del propietario 5uh-f8199-65 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 importantes a...

  • Page 2

    Printed in usa 2008.06-0.3 ×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 yfm35fgy 5uh-f8199-65-e0 u5uh65e0.Book page 1 monday, june 16, 2008 10:34 am.

  • Page 4

    Ebu17132 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. Ec declaration of conformity conforming to directive 98/37/ec (make, model) to which this declaration applies, conforms to the essential health and safety requirements of dir...

  • Page 5

    Ebu17170 introduction ebu17291 congratulations on your purchase of the yamaha yfm35fgy. 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 de...

  • 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 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

    Instruments, lights and switches ................ 5-6 operation .................................................. 6-1 starting a cold engine ................................ 6-1 starting a warm engine .............................. 6-3 operating the drive select lever and driving in reverse ..........

  • Page 10

    Adjusting the brake pedal and rear brake lever free play and checking the brake pedal position ......................................... 8-30 axle boots ................................................ 8-33 brake light switches ................................. 8-33 checking and lubricating the cabl...

  • 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 8 9 u5uh65e0.Book page 1 monday, june 16, 2008 10:34 am.

  • 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 u5uh65e0.Book page 3 monday, june 16, 2008 10:34 am.

  • Page 18

    2-4 2 for europe model: yfm350fwa max. Power: 15.9 kw mass in running order: 258 kg 5uh-f155a-10 9 8 7 6 u5uh65e0.Book page 4 monday, june 16, 2008 10:34 am.

  • Page 19

    2-5 2 for oceania 5fu-f816m-20 25 kpa, (3.6 psi) 25 kpa, (3.6 psi) 22 kpa, (3.2 psi) 22 kpa, (3.2 psi) 2 3 u5uh65e0.Book page 5 monday, june 16, 2008 10:34 am.

  • Page 20

    2-6 2 for oceania 6 7 u5uh65e0.Book page 6 monday, june 16, 2008 10:34 am.

  • Page 21

    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 1. Rear shock absorber assembly spring...

  • Page 22

    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 23

    4-1 4 ebu17732 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 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 25

    4-3 4 ebu17952 on-command four-wheel-drive indicator light “ ” this indicator light comes on when the on-com- mand four-wheel-drive switch is set to the “4wd” position. Tip due to the synchronizing mechanism in the differ- ential gear case, the light may not come on until the atv starts moving. Ebu1...

  • 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 ebu18170 horn switch “ ” press the switch to sound the horn. Ebu28431 on-command four-wheel-drive switch “2wd”/“4wd” this atv is equipped with a switch to change from two-wheel drive to four-wheel drive and vice versa. Select the appropriate drive according to the ter- rain and the conditions....

  • Page 28

    4-6 4 ebu18280 throttle lever once the engine is running, movement of the throt- tle lever will increase the engine speed. 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 t...

  • Page 29

    4-7 4 3. Tighten the locknut. Warning ewb00240 improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle...

  • Page 30

    4-8 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 31

    4-9 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 32

    4-10 4 warning ewb00340 shift the drive select lever into the neutral po- sition and apply the parking brake before start- ing the engine, otherwise the atv could start to move unexpectedly, which could cause an accident. Ebu18720 fuel tank cap remove the fuel tank cap by turning it counter- clockwi...

  • Page 33

    4-11 4 tip if knocking or pinging occurs, use a different brand of gasoline or higher octane grade. Notice 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. Warning...

  • Page 34

    4-12 4 ebu18820 fuel cock the fuel cock supplies fuel from the tank to the car- buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. Off with the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever...

  • Page 35

    4-13 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 36

    4-14 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. Tip make sure that the seat is securely fitted. Ebu18911 storage compartment notice ecb00130 do not store metal or sharply edged objects, like tools, in the storage...

  • Page 37

    4-15 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 38

    4-16 4 ebu18991 adjusting the front shock absorber as- semblies the spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspen- sion...

  • Page 39

    4-17 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. Ebu19021 adjusting the rear shock absorber as- sembly the spring preload can be adju...

  • Page 40

    4-18 4 1. Special wrench spring preload setting: minimum (soft): 1 standard: 2 maximum (hard): 5 u5uh65e0.Book page 18 monday, june 16, 2008 10:34 am.

  • Page 41

    5-1 5 ebu19200 pre-operation checks ebu19223 pre-operation check list before operating this atv, be sure to check the items listed in the following table. 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 ma...

  • Page 42

    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 recommended brake fluid to specified level if necessary. • check hydraulic system for leakage. C...

  • Page 43

    5-3 5 ebu19540 fuel make sure that there is sufficient fuel in the tank. (see page 4-10.) 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 44

    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 45

    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 (0.250 kgf/cm², 3.6 psi) rear: 25.0 kpa (0.250 kgf/cm², 3.6 psi) • che...

  • Page 46

    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). Ebu19840 chassis fasteners make sure that all nuts, bolts and screws are prop- erly tightened. Ebu1...

  • Page 47

    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 48

    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 49

    6-3 6 tip 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 the...

  • Page 50

    6-4 6 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 check the electrical circuit. 4. Check behind for people or obs...

  • Page 51

    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 52

    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 53

    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 54

    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 55

    7-1 7 ebu21141 riding your atv u5uh65e0.Book page 1 monday, june 16, 2008 10:34 am.

  • Page 56

    7-2 7 ebu21462 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 57

    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 58

    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 u5uh65e0.Book page 4 monday, june 16...

  • Page 59

    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 60

    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 61

    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 62

    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 63

    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 64

    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 65

    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 66

    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 67

    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 68

    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 69

    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 70

    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 71

    7-17 7 ground. The atv could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the atv immediately on the uphill side. Warning ewb01791 maintain a steady speed when climbing a hill. If you lose all forward speed: ● keep weight uphill. ● apply the brakes. ● apply ...

  • Page 72

    7-18 7 when this atv is in 4wd, 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 downhill side. A...

  • Page 73

    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 74

    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 75

    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 u5uh65e0.Book page 21 monda...

  • Page 76

    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 77

    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 78

    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 79

    8-1 8 ebu28782 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 80

    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 81

    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 82

    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 83

    8-5 8 ebu21864 general maintenance and lubrication chart no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 air filter element • clean and replace if necessary. Every 20–4...

  • Page 84

    8-6 8 9 * v-belt • check for wear, cracks or other damage, and re- place if necessary. √ √ √ √ 10 * chassis fasteners • make sure that all nuts, bolts, and screws are properly tightened. √ √ √ √ √ 11 * shock absorber as- semblies • check operation and correct if necessary. • check for oil leakage an...

  • Page 85

    8-7 8 ebu28390 tip ● 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. • every two years replace the internal components of the brake master cylinder and calipers...

  • Page 86

    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 87

    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 88

    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 89

    8-11 8 2. Check the engine oil level on a cold engine. Tip 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 d...

  • Page 90

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

  • Page 91

    8-13 8 tip an oil filter wrench is available at a nearby yamaha dealer. 5. 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. 6. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to the ...

  • Page 92

    8-14 8 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 the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “cd...

  • Page 93

    8-15 8 dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the final gear oil level 1. Place the atv on a level surface. Tip the final gear oil level must be checked on a cold engine. 2...

  • Page 94

    8-16 8 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 and the fi- nal gear oil drain bolt to drain the oil from the final gear case. 5. Install the drain bolt, and then tight...

  • Page 95

    8-17 8 notice 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 final gear case guard by installing the bol...

  • Page 96

    8-18 8 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case. 4. Install the drain bolt, and then tighten it to the specified torque. 5. Refill with the specified amount of the recom- mended differential gear oil. Ti...

  • Page 97

    8-19 8 ● the differential gear case capacity is greater than the recommended oil quantity, therefore the oil level cannot be accurately checked from the oil filler hole. Notice ecb00410 be sure no foreign material enters the differen- tial gear case. 6. Install the oil filler bolt, and then tighten ...

  • Page 98

    8-20 8 2. Remove the seat. (see page 4-13.) 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. 5. Pull off the air filter element lock plate, and then remove the sponge material from the air filter element fr...

  • Page 99

    8-21 8 6. 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 clean the sponge mate- rial because the engine could catch fire or ex- plode. 7. Squeeze the exces...

  • Page 100

    8-22 8 11. Insert the air filter element into the air filter case, and then install the air filter case cover by hooking the holders onto the air filter case. 12. Install the seat. Tip the air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ...

  • Page 101

    8-23 8 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. Install the bolts and tighten them to the speci- fied t...

  • Page 102

    8-24 8 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. Tip if water drains from the v-belt case after removing the plug, have a yamaha dealer check the atv as the water may affect other engin...

  • Page 103

    8-25 8 tip a diagnostic tachometer is needed to make this adjustment. 1. Start the engine and warm it up. Tip the engine is warm when it quickly responds to the throttle. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces- sary, adjust it to specification...

  • Page 104

    8-26 8 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 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 105

    8-27 8 ebu24071 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 by a yamaha dealer at the intervals specified in the periodic...

  • Page 106

    8-28 8 shoe has worn to the point that the wear indicator reaches the wear limit line or mark, have a yamaha dealer replace the brake shoes as a set. Ebu24251 checking the brake fluid level insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective....

  • Page 107

    8-29 8 ● 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 water does not enter the brake fluid reservoir when refilling. Water will signifi- cantly lower the boiling point of the fluid and may re...

  • Page 108

    8-30 8 ● make sure the brakes operate smoothly and that there is no free play. ● make sure the brakes do not drag. ● make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed ...

  • Page 109

    8-31 8 adjusting the brake lever free play the brake lever free play should measure 3.0–5.0 mm (0.12–0.20 in) as shown. If the free play is in- correct, adjust it as follows. 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 2. Turn the brake lever ...

  • Page 110

    8-32 8 3. Turn the brake lever free play adjusting bolt at the brake lever in direction (a) to increase the free play, and in direction (b) to decrease it. 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 s...

  • Page 111

    8-33 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 112

    8-34 8 the 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. 1. Remove panel a. (see page 8-8.) tip the brake light switch is properly adjusted when the brake light comes on just before braking takes effect. 2...

  • Page 113

    8-35 8 warning ewb02130 inspect cables frequently and replace if dam- aged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could re- strict the operation of controls and lead to an accident or injury. Ebu28711 checking and lubricating t...

  • Page 114

    8-36 8 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 8-8.) ebu24962 checking the wheel hub bearings the front...

  • Page 115

    8-37 8 notice ecb00620 never attempt to remove the battery cell seals, as this would permanently damage the battery. Warning ewb02160 battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing. Always shield...

  • Page 116

    8-38 8 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 ecb00930 to charge a vrla (valve regulated lead...

  • Page 117

    8-39 8 3. Install the battery holding plate by installing the bolts. 4. Install the seat. (see page 4-13.) ebu25325 replacing a fuse the main fuse and the fuse box are located under the seat. (see page 4-13.) 1. Positive battery lead (red) 2. Negative battery lead (black) 2 1 1. Main fuse 2. Spare m...

  • Page 118

    8-40 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

    8-41 8 4. If the fuse immediately blows again, have a yamaha dealer check the electrical system. Ebu25480 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 ...

  • Page 120

    8-42 8 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 can be burned or a fire could start if the bulb touch- es something flammable. 5. Inse...

  • Page 121

    8-43 8 to raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b). Ebu25580 replacing the tail/brake light bulb if the tail/brake light bulb burns out, have a yamaha dealer replace it. Ebu25651 removing a ...

  • Page 122

    8-44 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

    8-45 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

    8-46 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 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 126

    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 127

    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 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 engine oil: type: sae 5w-30 or sae 10w-30 or sae 10w-40 or sae 15w-40 or sae 20w-40 or sae 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 cart...

  • Page 130

    10-3 10 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 operation forward gear: 35/20 (1.750) reverse gear: 26/15 (1.733) chassis: frame type: steel...

  • Page 131

    10-4 10 rim size: 12 x 7.5at front brake: type: dual disc brake operation: right hand operation recommended 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:...

  • Page 132

    10-5 10 signaling system fuse: 10.0 a ignition fuse: 15.0 a auxiliary dc jack fuse: 10.0 a four-wheel-drive motor fuse: 3.0 a u5uh65e0.Book page 5 monday, june 16, 2008 10:34 am.

  • Page 133

    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 134

    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 135

    11-3 11 1. Model label u5uh65e0.Book page 3 monday, june 16, 2008 10:34 am.

  • Page 136

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning ............................................ 8-19 axle boots .................................................................... 8-33 b battery ............................................

  • Page 137

    K key identification number ............................................. 11-1 l label locations ............................................................... 2-1 light switch .................................................................... 4-4 m main switch ......................................

  • Page 138

    Yamaha motor co., ltd. Printed in usa 2008.06-0.3 ×1 cr (e) u5uh65e0.Book page 1 monday, june 16, 2008 10:34 am.