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Yamaha GRIZZLY 350 YFM35FGIA Owner's Manual

Summary of GRIZZLY 350 YFM35FGIA

  • Page 1

    Yfm35fgia yfm35fwana owner’s manual manuel du propriÉtaire manual del propietario 4s2-f8199-64 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 i...

  • Page 2

    Printed in usa 2010.08-0.3 ×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 yfm35fgia yfm35fwana 4s2-f8199-64-e0 u4s264e0.Book page 1 thursday, august 5, 2010 1:24 pm.

  • Page 4

    Ebu27863 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. Ansi/svia 1-2007 general manager rv engineering division mc operations yamaha motor co., ltd. 9 march, 2010 yfm350fwan (yfm35fgi) (5y4ah15w0a0502501–) we, yamaha motor co., l...

  • Page 5

    Ebu17170 introduction ebu17292 congratulations on your purchase of the yamaha yfm35fgia/yfm35fwana. This atv represents the result of many years of yamaha experience in the production of fine sporting, touring, and pacesetting rac- ing machines. With the purchase of this yamaha, you can now apprecia...

  • 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 yfm35fgia/yf...

  • 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

    Operating the drive select lever and driving in reverse ...................................... 6-3 engine break-in .......................................... 6-4 parking ....................................................... 6-5 parking on a slope ..................................... 6-5 accessori...

  • Page 10

    Adjusting the brake pedal and rear brake lever free play and checking the brake pedal height ............ 8-32 axle boots ................................................ 8-36 brake light switches ................................. 8-37 checking and lubricating the cables ........ 8-37 checking and l...

  • Page 11

    1-1 1 ebu29680 location of the warning and specification labels ebu30290 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-10 80 kg ( 176 lbs) 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 1 2 3 4 1p0-f816p-20 u4s264e0.Book page 2 thursday, august 5, 2010 1:24 pm.

  • Page 13

    1-3 1 4900 n 500 kgf 1102 lbf 147 n 15 kgf 33 lbf 4s2-f817s-00 5 6 1p0-f816r-00 u4s264e0.Book page 3 thursday, august 5, 2010 1:24 pm.

  • Page 14

    1-4 1 37s-f816s-00 1p0-f816l-20 yamaha motor co., ltd. 2500 shingai, iwata, japan yfm350fwan 15.9 kw 275 kg 2010 4s2-f155a-30 7 8 10 9 u4s264e0.Book page 4 thursday, august 5, 2010 1:24 pm.

  • Page 15

    1-5 1 familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the owner’s manual. Always use an approved helmet and protective gear. Never permit children under age 6 to operate this atv. Operation of thi...

  • Page 16

    1-6 1 **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi never use with drugs or alcohol. Never store fuel or flammable liquids. This unit contains high-pressure nitrogen gas. Mishandling can cause an explosion. Do not incinerate, puncture or open. Use unleaded gasoline only. Measure the ti...

  • Page 17

    1-7 1 yamaha motor co., ltd. 2500 shingai, iwata, japan ****** *** kw *** kg **** 1 2 3 4 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. T...

  • Page 18

    1-8 1 for oceania 8 u4s264e0.Book page 8 thursday, august 5, 2010 1:24 pm.

  • Page 19

    1-9 1 1 3 4 5 2 5fu-f816m-20 25 kpa, (3.6 psi) 25 kpa, (3.6 psi) 22 kpa, (3.2 psi) 22 kpa, (3.2 psi) maximum loading limit 5nd-f151k-00 pulling load: 4900 n (500 kgf) 1102 lbf tongue weight: 147 n ( 15 kgf) 33 lbf u4s264e0.Book page 9 thursday, august 5, 2010 1:24 pm.

  • Page 20

    1-10 1 6 7 8 u4s264e0.Book page 10 thursday, august 5, 2010 1:24 pm.

  • Page 21

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

  • Page 22

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

  • Page 23

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

  • Page 24

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

  • Page 25

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Fuel cock 2. Throttle stop screw 3. Fuses 4. Battery 5. Rear shock absorber assembly spring preload adjusting ring 6. Engine oil filler cap 7. Oil filter cartridge 8. V-belt cooling duct check hose 1 2 6 7 8 5 3,4 1. Spark arrester...

  • Page 26

    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 27

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

  • Page 28

    4-2 4 ebu17815 indicator lights and warning light ebu17870 neutral indicator light “neutral” this indicator light comes on when the transmis- sion is in the neutral position. Ebu28331 reverse indicator light “reverse” this indicator light comes on when the transmis- sion is in the reverse position. ...

  • Page 29

    4-3 4 notice ecb00010 ● the engine may overheat if the atv is over- loaded. In this case, reduce the load to spec- ification. ● start the engine after making sure that the warning light is out. Continuous use while the warning light is on may cause damage to the engine. Ebu29611 on-command four-whee...

  • Page 30

    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 31

    4-5 4 ebu18101 start switch “ ” push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. Ebu18161 light switch “ / /off” set this switch to “ ” to turn on the low beams, the taillight and the meter lighting. Set the switch to “ ...

  • Page 32

    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 33

    4-7 4 ebu28372 on-command differential gear lock switch “4wd”/“lock” warning ewb00131 always stop the atv before changing from four-wheel drive to four-wheel-drive differen- tial gear lock or vice versa. The atv handles differently in four-wheel drive than in differential gear lock in some circum- s...

  • Page 34

    4-8 4 ● “lock” (four-wheel drive with the differential gear locked): power is supplied to the rear and front wheels and the differential gear is locked. Unlike in four-wheel drive, all wheels turn at the same speed. To lock the differential gear in four-wheel drive, make sure the on-command four-whe...

  • Page 35

    4-9 4 to release the differential gear lock, stop the atv and push the switch to the “4wd” position. Tip ● if the differential gear lock is not engaging prop- erly, turn the handlebar back and forth to help it engage. ● riding before the differential gear lock is proper- ly engaged will cause the ve...

  • Page 36

    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. Ebu18323 speed limiter your atv is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening...

  • Page 37

    4-11 4 ebu18442 brake pedal and rear brake lever the brake pedal is located on the right side of the atv and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. 1. Front brake lever 1. Brake p...

  • Page 38

    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 39

    4-13 4 ebu18720 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. Ebu18754 fuel make sure there is sufficient gasoline in the tank. Warning ewb02521 gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refuel...

  • Page 40

    4-14 4 of sparks, open flames, or other sources of ig- nition such as the pilot lights of water heaters and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole. Stop filling when the fuel reach- es the bottom of the fille...

  • Page 41

    4-15 4 doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. 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 ring...

  • Page 42

    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 43

    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. Ebu18881 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 44

    4-18 4 ebu18942 storage compartment notice ecb00130 do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartment. The storage compartment is located under the seat....

  • Page 45

    4-19 4 ebu18962 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 kg (463 lb) for the atv. Ebu18972 rear carrier ● do not exceed the load limit of 80.0 kg (176 lb) for the rear carrier. ● do not exceed the maximum load of...

  • Page 46

    4-20 4 tip 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 u4s264e0.Book page 20 thursday, august 5, 2010 1:24 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 recommended brake fluid to specified level if necessary. • check hydraulic system for leakage. C...

  • Page 49

    5-3 5 ebu19541 fuel make sure that there is sufficient fuel in the tank. (see page 4-13.) ebu19560 engine oil make sure that the engine oil is at the specified lev- el. Add oil as necessary. (see page 8-12.) ebu19590 final gear oil make sure that the final gear oil is at the specified level. Add oil...

  • Page 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 friction plates for wear. (see page 8-29.) ebu19761 throttle lever check the operation of the throttle leve...

  • 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 u4s264e0.Book page 1 thursday, august 5, 2010 1:24 pm.

  • Page 62

    7-2 7 ebu28506 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 4-10.) lo...

  • 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. Drive select lever box check hose 1. Storage compartment check hose 1 u4s264e0.Book page 20 thursday, august 5, 2010 1:24 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 what to do... ● if your atv doesn’t turn when you want it to: bring the atv to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (see page 7-12.) ● if...

  • Page 84

    8-1 8 ebu28783 periodic maintenance and adjustment ebu21673 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 13 * rear knuckle pivots • lubricate with lithium-soap-based grease. √ √ √ 14 * steering shaft • lubricate with lithium-soap-based grease. √ √ √ 15 * steering system • check operation and repair or replace if damaged. • check toe-in and adjust if necessary. √ √ √ √ √ 16 * engine mount • check ...

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

  • Page 93

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

  • Page 94

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

  • Page 95

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

  • Page 96

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

  • Page 97

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

  • Page 98

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

  • Page 99

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

  • Page 100

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

  • Page 101

    8-18 8 tip 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 from the final gear case may occur when applying the rear brake. 7. Install the oil filler bolt and its new o-ring, and then tighten the bolt to the specif...

  • Page 102

    8-19 8 checked and the oil changed as follows at the in- tervals specified in the periodic maintenance and lubrication chart. To check the differential gear oil level 1. Place the atv on a level surface. 2. Remove the differential gear oil filler bolt and its gasket, and then check the oil level in ...

  • Page 103

    8-20 8 4. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque. 5. Refill with the recommended differential gear oil to the brim of the filler hole as shown. Notice: be sure no foreign material en- ters the differential gear case. [ecb00411] 6. Check the oil f...

  • Page 104

    8-21 8 8. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. Ebu23646 cleaning the air filter element the air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart. Clean or, if necessary, replace the ...

  • Page 105

    8-22 8 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 frame. 1. Air filter case cover holder 2. Air filter case cover 1. Air filter element u4s264e0.Book page 22 thursday, augus...

  • Page 106

    8-23 8 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 or gasoline to clean the sponge ma- terial because the engine could catch fire or explode. [ewb01941] 7. Squeeze the ex...

  • Page 107

    8-24 8 case. Never operate the engine with the air filter element removed. This will allow un- filtered air to enter the engine, causing rap- id engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performa...

  • Page 108

    8-25 8 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the tailpipe bolts and tighten them to the specified torque. 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,...

  • Page 109

    8-26 8 ebu23931 v-belt case drain plug after riding in water deep enough to allow it to en- ter the v-belt case, remove the v-belt case drain 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 a...

  • Page 110

    8-27 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 111

    8-28 8 the throttle lever free play should measure 3.0– 5.0 mm (0.12–0.20 in) as shown. Periodically check the throttle lever free play and, if necessary, adjust it as follows. Tip the engine idling speed must be checked, and ad- justed if necessary, before adjusting the throttle le- ver free play. ...

  • Page 112

    8-29 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 113

    8-30 8 tip the wheels need to be removed to check the brake pads. (see page 8-47.) 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 ...

  • Page 114

    8-31 8 brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions: ● when checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● use only the recommen...

  • Page 115

    8-32 8 ebu24394 checking the front brake lever free play the brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake lever should have no free play as shown. If there is free play, have a yamaha dealer check the brake system. Ebu2...

  • Page 116

    8-33 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 1. Locknut 2. Brake lever free play adj...

  • Page 117

    8-34 8 3. Push the brake camshaft lever in direction (a) until it stops [apply approximately 50 n (5.0 kgf, 11.2 lbf) 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 c...

  • Page 118

    8-35 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 119

    8-36 8 ebu24230 axle boots the axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart. Check the axle boots for tears or damage. If any damage is found, have them re- placed by a yamaha dealer. 1. Distance between brake pedal and footboard ...

  • Page 120

    8-37 8 ebu24755 brake light switches the brake light, which is activated by the brake pedal and brake levers, should come on just be- fore braking takes effect. 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 yama...

  • Page 121

    8-38 8 warning ewb02581 ● 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 restrict the operation of controls and lead to an accident or injury. ● always make sure all control cabl...

  • Page 122

    8-39 8 rear brake lever ebu28832 checking and lubricating the brake pedal the operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. Tip to access the brake pedal pivot, remove panel a. (see page 8-9.) ebu24963 checking the wheel hub b...

  • Page 123

    8-40 8 ebu24972 lubricating the drive shaft universal joint the drive shaft universal joint must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Tip for parts equipped with a grease nipple, use a grease gun. Ebu25022 checking the stabilizer bushes the stab...

  • Page 124

    8-41 8 ebu25092 lubricating the steering shaft the steering shaft must be lubricated by a yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Tip for parts equipped with a grease nipple, use a grease gun. Ebu29187 battery the battery is located under the seat....

  • Page 125

    8-42 8 keep out of reach of children. Notice ecb00620 never attempt to remove the battery cell seals, as this would permanently damage the battery. To remove the battery 1. Remove the seat. (see page 4-17.) 2. Remove the battery holding plate by removing the bolts. 3. Disconnect the negative battery...

  • Page 126

    8-43 8 notice ecb00931 to charge a vrla (valve regulated lead acid) battery, a special (constant-voltage) battery charger is required. Using a conventional bat- tery charger will damage the battery. To store the battery ● if the atv will not be used for more than one month, remove the battery, fully...

  • Page 127

    8-44 8 ebu25326 replacing a fuse 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. Notice ecb00640 to prevent accidental short-circuiting, turn off the main switch when...

  • Page 128

    8-45 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 129

    8-46 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. Insert a new headlight bulb into the bulb hold- er by pushing it in. Notice: do not touch the glass part of the headlight bulb to keep it free from oil, oth...

  • Page 130

    8-47 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 131

    8-48 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 132

    8-49 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 133

    8-50 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 134

    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 135

    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 136

    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 137

    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: 3000 mm (118 in) weight: with oil and ...

  • Page 138

    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 139

    10-3 10 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 operation forward gear: 35/20 (1.750) revers...

  • Page 140

    10-4 10 rear wheel: wheel type: panel wheel rim size: 12 x 7.5at front brake: type: disc brake operation: right hand operation recommended fluid: dot 4 rear brake: type: wet multiple disc brake operation: left hand and right foot operation front suspension: type: double wishbone spring/shock absorbe...

  • Page 141

    10-5 10 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 a four-wheel-drive motor fuse: 10.0 a u4s264e0.Book page 5 thursday, august 5, 2010 1:24 pm.

  • Page 142

    11-1 11 ebu26000 consumer information ebu28200 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 143

    11-2 11 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 in the space provided. This information will be need- ed when ordering spare parts from a yamaha dea...

  • Page 144

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning ............................................ 8-21 axle boots .................................................................... 8-36 b battery ............................................

  • Page 145

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

  • Page 146

    Yamaha motor co., ltd. Printed in usa 2010.08-0.3 ×1 cr (e) u4s264e0.Book page 1 thursday, august 5, 2010 1:24 pm.