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Yamaha GRIZZLY 350 YFM35FGW Owner's Manual - Owner’S Manual

Summary of GRIZZLY 350 YFM35FGW

  • Page 1

    Yfm35fgw owner’s manual manuel du propriÉtaire manual del propietario 5uh-f8199-63.

  • Page 2

    Printed in usa 2006.05-0.3 ×1 cr (e,f,s) yamaha motor co., ltd..

  • Page 3: Owner’S Manual

    Owner’s manual yfm35fgw 5uh-f8199-63-e0 u5uh63e0.Book page 1 wednesday, april 26, 2006 9:21 am.

  • Page 4

    Ebu17131 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 europe n.V., (name of supplier) koolhovenlaan 101, 1119 nc schiphol-rijk, the ...

  • Page 5

    Ebu17170 introduction ebu17290 congratulations on your purchase of the yamaha yfm35fgw. 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...

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    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...

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    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 ................ 5-7 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 ............................... 8-29 axle boots ................................................ 8-32 brake light switches ................................. 8-32 checking and lubricating the cables ........ 8-33 checking and lubricating the fr...

  • 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...

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    2-1 2 ebu17660 location of the warning and specification labels u5uh63e0.Book page 1 wednesday, april 26, 2006 9:21 am.

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    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 u5uh63e0.Book page 3 wednesday, april 26, 2006 9:21 am.

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    2-4 2 for europe u5uh63e0.Book page 4 wednesday, april 26, 2006 9:21 am.

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    2-5 2 for oceania u5uh63e0.Book page 5 wednesday, april 26, 2006 9:21 am.

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    2-6 2 for oceania u5uh63e0.Book page 6 wednesday, april 26, 2006 9:21 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 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 ebu17730 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 ebu17812 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. Note: due to the synchronizing mechanism in the differ- ential gear case, the light may not come on until the atv starts moving. Eb...

  • Page 26

    4-4 4 ebu18060 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. Ebu18211 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 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 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. Note: make sure that the seat is securely fitted. Ebu18911 storage compartment caution: ecb00130 do not store metal or sharply edged objects, like tools, in the sto...

  • 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. 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 insta...

  • Page 38

    4-16 4 ebu18990 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. Ebu19020 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 u5uh63e0.Book page 18 wednesday, april 26, 2006 9:21 am.

  • Page 41

    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 42

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

  • 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). 1. Low-pressure tire gauge recommended pressure: front 25.0 kpa (3.6 psi) (0.250 kgf/cm²) rear 25.0...

  • Page 47

    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 u5uh63e0.Book page 7 wednesday, april 26, 2006...

  • Page 48

    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 49

    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 50

    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 51

    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 52

    6-5 6 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. 10–20 hours avoid prolonged operation above 3/4 throttle. Rev the engine freely, but do not use full throttle at any time. 20 hours and beyond the atv c...

  • Page 53

    6-6 6 do not park the atv at all on hills that are so steep you could not walk up them easily. 1. Bring the atv to a stop by applying the brakes in the forward position. 2. Stop the engine. 3. With the rear brake lever and pedal applied, apply the parking brake, and then slowly re- lease the brake p...

  • Page 54

    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 55

    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 56

    7-1 7 ebu21141 riding your atv u5uh63e0.Book page 1 wednesday, april 26, 2006 9:21 am.

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    7-2 7 ebu21461 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 58

    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 59

    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 u5uh63e0.Book page 4 wednesday, apri...

  • Page 60

    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 61

    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 62

    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 63

    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 64

    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 65

    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 66

    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 67

    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 68

    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 69

    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 70

    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 71

    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 72

    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 73

    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 74

    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 75

    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 76

    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 u5uh63e0.Book page 21 wedne...

  • Page 77

    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 78

    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 79

    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 80

    8-1 8 ebu21652 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 81

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

  • Page 82

    8-3 8 ebu22402 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 83

    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 shoes. Whenever worn to the limit 7 * brake hoses • check for cracks or other damage, and replace if necessary. √ √ √ √ • replace. Every 4 year...

  • Page 84

    8-5 8 16 * shock absorber as- semblies • check operation and correct if necessary. • check for oil leakage and replace if necessary. √ √ √ 17 * knuckle shafts • lubricate with lithium-soap-based grease. √ √ √ 18 * steering shaft • lubricate with lithium-soap-based grease. √ √ √ 19 * steering system ...

  • Page 85

    8-6 8 27 final gear oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ 28 * moving parts and cables • lubricate. √ √ √ √ 29 * drive select lever safety system cable • check operation and adjust or replace if neces- sary. √ √ √ 30 * throttle lever hous- ing and cable • check o...

  • Page 86

    8-7 8 ebu23070 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. • every two years replace the internal components of the brake master cylinders and calip...

  • Page 87

    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 88

    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 89

    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 90

    8-11 8 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Wait a few minutes until the oil settles before checking. 4. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. 5. Insert the dipstick into the filler hole (without screwing it in),...

  • Page 91

    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 92

    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 93

    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 94

    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 final gear case guard by remov- ing the bolt...

  • Page 95

    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. 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...

  • Page 96

    8-17 8 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 bolts and tightening them to the specified torque. Ebu23431 changing the differential gear oil the differential gear case must be checked for oil leakag...

  • Page 97

    8-18 8 4. Install the drain bolt, and then tighten it to the specified torque. 5. Add the specified amount of the recommend- ed differential gear oil. Note: ● do not exceed the specified differential gear oil quantity when filling. Overfilling will cause the oil to seep out of the breather hose duri...

  • Page 98

    8-19 8 ebu23640 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 the air filter element more frequently if you are riding in unusually wet or dusty areas. Note: there is a check hose at the ...

  • Page 99

    8-20 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 100

    8-21 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 101

    8-22 8 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Insert the tailpipe into the muffler and align the bolt holes. 5...

  • Page 102

    8-23 8 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 103

    8-24 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 104

    8-25 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 105

    8-26 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 106

    8-27 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

    8-28 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

    8-29 8 ● make sure the brakes operate smoothly and that the free play is correct. ● 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 perform...

  • Page 109

    8-30 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

    8-31 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. Note: when adjusting the rear brake lever free play: ● be sure not to step on the brake pedal. ● make...

  • Page 111

    8-32 8 ● make sure the brakes operate smoothly and that the free play is correct. ● make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a yamaha dealer. Ebu24230 axle boots the axle boots must be checked for damag...

  • Page 112

    8-33 8 3. Install the panel. 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 deal...

  • Page 113

    8-34 8 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 bearings the front a...

  • Page 114

    8-35 8 ebu25040 lubricating the upper and lower arm pivots the upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Ebu25080 lubricating the knuckle shafts the knuckle shafts must be lubricated at the inter- vals specified in t...

  • Page 115

    8-36 8 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 your eyes when working near batteries. Antidote: external: flush with water. Internal: drink large quantities...

  • Page 116

    8-37 8 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. Using a conventional battery charger will damage the battery. If you do not...

  • Page 117

    8-38 8 the main fuse and the fuse box are located under the seat. (see page 4-13.) 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 118

    8-39 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 119

    8-40 8 3. Remove the headlight bulb holder assembly by turning it counterclockwise. Note: the headlight bulb cannot be removed from the headlight bulb holder. To replace the headlight bulb, replace the headlight bulb holder assembly. Warning ewb02220 a headlight bulb is hot when it is on and imme- d...

  • Page 120

    8-41 8 6. Install the headlight bulb holder cover at the rear of the headlight. Caution: ecb00670 make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 7. Adjust the headlight beam if necessary. Ebu25550 adjusting a headlight beam caution: ecb00690 it...

  • Page 121

    8-42 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 122

    8-43 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 123

    8-44 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 124

    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 125

    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 126

    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 127

    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 128

    10-2 10 engine oil: type: sae5w30 or sae10w30 or sae10w40 or sae15w40 or sae20w40 or sae20w50 recommended engine oil grade: api service se, sf, sg type or higher 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....

  • Page 129

    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 130

    10-4 10 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: drum brake operation: left hand and right foot operation front suspension: type: double wishbone spring/...

  • Page 131

    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: 3.0 a u5uh63e0.Book page 5 wednesday, april 26, 2006 9:21 am.

  • Page 132

    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 133

    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 134

    11-3 11 1. Model label u5uh63e0.Book page 3 wednesday, april 26, 2006 9:21 am.

  • Page 135

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning ............................................ 8-19 axle boots .................................................................... 8-32 b battery ............................................

  • Page 136

    K key identification number ............................................. 11-1 knuckle shafts, lubricating ........................................... 8-35 l label locations ............................................................... 2-1 light switch ................................................

  • Page 137

    U5uh63e0.Book page 3 wednesday, april 26, 2006 9:21 am.

  • Page 138

    Yamaha motor co., ltd. Printed in usa 2006.05-0.3 ×1 cr (e) u5uh63e0.Book page 1 wednesday, april 26, 2006 9:21 am.