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Yamaha GRIZZLY 350 YFM35FGY Owner's Manual

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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 acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
OWNER'S MANUAL
YFM35FGY
5UH-F8199-65

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Summary of Contents for Yamaha GRIZZLY 350 YFM35FGY

  • Page 1 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 acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM35FGY 5UH-F8199-65...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2008.06-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35FGY 5UH-F8199-65-E0...
  • Page 4 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 We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM350FWA (5Y4AH13W080511701~)
  • Page 5 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 degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • 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: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 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.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Fuel ............4-10 Fuel cock ..........4-12 LOCATION OF THE WARNING AND Starter (choke) ..........4-13 SPECIFICATION LABELS ......2-1 Seat ............4-13 Storage compartment .......4-14 DESCRIPTION ..........3-1 Front carrier ..........4-15 Left view ............3-1 Rear carrier ..........4-15 Right view............
  • Page 9 Instruments, lights and switches ....5-6 PERIODIC MAINTENANCE AND MINOR REPAIR ............8-1 OPERATION ..........6-1 Owner’s manual and tool kit .......8-1 Starting a cold engine ........ 6-1 Periodic maintenance chart for the Starting a warm engine ......6-3 emission control system ......8-3 Operating the drive select lever and General maintenance and lubrication driving in reverse ........
  • Page 10 Adjusting the brake pedal and rear brake SPECIFICATIONS ........10-1 lever free play and checking the brake pedal position ......... 8-30 CONSUMER INFORMATION.......11-1 Axle boots ..........8-33 Identification numbers .......11-1 Brake light switches ......... 8-33 Checking and lubricating the cables ..8-34 Checking and lubricating the front and rear brake levers ........

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION EBU17562 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 12 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 13 roll backwards, follow the special procedure for Always be sure there are no obstacles or people braking described in this manual. Dismount on behind you when you operate in reverse. When the uphill side or to a side if pointed straight up- it is safe to proceed in reverse, go slowly.
  • Page 14 nition such as the pilot lights of water heat- EWB00070 WARNING ers and clothes dryers. Gasoline can catch fire and you could be burned. Always operate your ATV in an area with ade- When transporting the ATV in another vehi- quate ventilation.

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 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 Oceania...
  • Page 17 For Europe...
  • Page 18 For Europe MODEL: YFM350FWA MAX. POWER: 15.9 kW MASS IN RUNNING ORDER: 258 kg 5UH-F155A-10...
  • Page 19 For Oceania 25 kPa, (3.6 psi) 25 kPa, (3.6 psi) 22 kPa, (3.2 psi) 22 kPa, (3.2 psi) 5FU-F816M-20...
  • Page 20 For Oceania...

  • Page 21: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Fuel cock 1. Rear shock absorber assembly spring preload adjusting ring 2. Throttle stop screw 2. Spark arrester 3. Air filter case 3. Storage compartment and tool kit 4. Fuses 4. Spark plug 5.

  • Page 22: Controls And Instruments

    EBU17712 Controls and instruments 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.

  • Page 23: Instrument And Control Functions

    EBU17732 INSTRUMENT AND CONTROL FUNCTIONS EBU17770 Main switch The positions of the main switch are as follows: 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.

  • Page 24: Indicator Lights And Warning Light

    1. Reverse indicator light “REVERSE” cool. If the warning light stays on when the engine 2. Neutral indicator light “NEUTRAL” is cool, have a Yamaha dealer check the electrical 3. On-Command four-wheel-drive indicator light “ ” 4. Oil temperature warning light “...

  • Page 25: Speedometer

    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. Due to the synchronizing mechanism in the differ- ential gear case, the light may not come on until the ATV starts moving.

  • Page 26: Handlebar Switches

    EBU18061 EBU18100 Handlebar switches Start switch “ ” Push this switch to crank the engine with the start- ECB00050 NOTICE See the starting instructions on page 6-1 prior to starting the engine. EBU18160 Light switch “ /OFF” Set this switch to “ ”...
  • Page 27 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: Throttle Lever

    Correct the problem be- the throttle lever. fore riding the ATV or consult a Yamaha dealer. EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 29: Front Brake Lever

    EBU18391 Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip. 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in) 3.

  • Page 30: Parking Brake

    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. 1.

  • Page 31: Drive Select Lever

    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.

  • Page 32: Fuel Tank Cap

    1. Recoil starter 1. Fuel tank cap EWB00340 EBU18752 WARNING Fuel Shift the drive select lever into the neutral po- Make sure that there is sufficient fuel in the tank. sition and apply the parking brake before start- Fill the fuel tank to the bottom of the filler tube as ing the engine, otherwise the ATV could start shown.
  • Page 33 If knocking or pinging occurs, use a different brand of gasoline or higher octane grade. ECB00070 NOTICE 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.

  • Page 34: Fuel Cock

    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. 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel flows to the carburetor.

  • Page 35: Starter (Choke)

    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. 1. Arrow mark pointing to “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 36: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18911 Storage compartment Insert the projections on the front of the seat into ECB00130 the seat holders and push down on the seat at the NOTICE rear.

  • Page 37: Front Carrier

    1. Storage compartment 1. Storage compartment check hose Do not exceed the load limit of 2.0 kg (4 lb) EBU18961 Front carrier for the storage compartment. Do not exceed the maximum load of 210.0 kg Do not exceed the load limit of 40.0 kg (88 lb) (463 lb) for the ATV.

  • Page 38: Adjusting The Front Shock Absorber Assemblies

    EBU18991 Adjusting the front shock absorber as- A special wrench can be obtained at a Yamaha semblies dealer to make this adjustment. The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Adjust the spring preload as follows.

  • Page 39: Adjusting The Rear Shock Absorber Assembly

    Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase A special wrench can be obtained at a Yamaha the spring preload and thereby harden the suspen- dealer to make this adjustment.
  • Page 40 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): 4-18...

  • Page 41: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 42 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-27, 8-28, 8-29 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 43: Fuel

    Check that there is no free play in the front brake Be careful not to spill fuel, especially on the lever. If there is free play, have a Yamaha dealer engine or exhaust pipe which can cause a check the brake system.

  • Page 44: Throttle Lever

    Apply the brake firmly for one minute. If the when released. Have a Yamaha dealer correct if lever moves slowly inward, there may be a leak in necessary.

  • Page 45: Measuring The Tire Pressure

    Type: Minimum tire pressure: Tubeless Front: Rear: 22.0 kPa (0.220 kgf/cm², 3.2 psi) Manufacturer/model: Rear: CHENG SHIN/C-828 (AUS)(NZL) 22.0 kPa (0.220 kgf/cm², 3.2 psi) MAXXIS/M980 (EUR)(GBR) • Use no more than the following pressures Size: when seating the tire beads. AT25 x 10-12 Maximum tire seating pressure: Type:...

  • Page 46: Tire Wear Limit

    EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). 1. Low-pressure tire gauge Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: 1. Tire wear limit Recommended pressure: EBU19840 Front...

  • Page 47: Operation

    4. Shift the drive select lever into the neutral po- accident or injury. If there is a control or func- sition. The neutral indicator light should come tion you do not understand, ask your Yamaha on. If the indicator light does not come on, dealer.
  • Page 48 5. Use the starter (choke) in reference to the fig- 6. Completely close the throttle lever and start ure: the engine by pushing the start switch. Position (1): Cold engine start with ambient temperature If the engine fails to start, release the start below 5 °C (40 °F).

  • Page 49: Starting A Warm Engine

    The engine is warm when it responds normally to Make sure that the drive select lever is completely the throttle with the starter (choke) turned off. shifted into position. 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.

  • Page 50: Engine Break-In

    If the indicator light does not come on, resulting in serious injury. When you shift into have a Yamaha dealer check the electrical circuit. reverse, make sure there are no people or ob- stacles behind you. When it is safe to proceed, go slowly.

  • Page 51: Parking

    EBU20760 Parking on a slope engine break-in period, immediately have a EWB00830 Yamaha dealer check the ATV. WARNING Avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the ATV to roll out of control, increasing the...

  • Page 52: Accessories And Loading

    3. With the rear brake lever and pedal applied, may also be available on the market. However, apply the parking brake, and then slowly re- it is not possible for Yamaha to test all non- lease the brake pedal. Yamaha accessories, nor control over their qual- ity or suitability.
  • Page 53 could make steering difficult, an accessory that MAXIMUM LOADING LIMIT limits your ability to move around on the seat, or ATV loading limit (total weight of rider, cargo, one that limits your view. accessories, and tongue): Use extra caution when riding an ATV with ac- 210.0 kg (463 lb) cessories.
  • Page 54 Load cargo on the carriers as close to the center curely attached. Reduce speed when carrying of the ATV as possible. Put cargo at the rear of cargo or pulling a trailer. Allow greater dis- the front carrier, at the front of the rear carrier, tance for braking.

  • Page 55: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 56: Getting To Know Your Atv

    EBU21462 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV Beginners should get training from a certified in- This ATV is for recreation and utility use. This sec- structor. tion, Riding your ATV, provides general ATV riding Become familiar with this ATV at slow speeds first, instructions for recreational riding.
  • Page 57 Not recommended for children under 16 years This ATV is designed to carry operator and car- of age. go only – passengers prohibited. EWB01390 EWB01400 WARNING WARNING A child under 16 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 90 cc.
  • Page 58 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...
  • Page 59 EWB01410 WARNING 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 protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 60 in the Owner’s Manual. Failure to inspect the Speed limiter ATV before operating or failure to properly For riders less experienced with this model, the maintain the ATV increases the possibility of throttle lever housing is equipped with a speed lim- an accident or equipment damage.
  • Page 61 Loading and accessories EWB01460 WARNING Use extra caution when riding the ATV with addi- tional loads, such as accessories or cargo. The Never exceed the stated load capacity for ATV’s handling may be adversely affected. Re- this ATV. duce your speed when adding additional loads. Cargo should be properly distributed and se- curely attached.
  • Page 62 All parts and tact with the rear wheels, which could injure accessories added to this ATV should be gen- you or cause an accident. uine Yamaha or equivalent components de- signed for use on this ATV and should be...

  • Page 63: Be Careful Where You Ride

    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 the ATV is very hot during and following operation.
  • Page 64 EWB01520 WARNING Never operate this ATV on any paved street, paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. 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.
  • Page 65 EWB01530 ATV on such terrain. Failure to use extra care WARNING when operating on excessively rough, slippery or loose terrain could cause loss of traction or Go slowly and be extra careful when operating ATV control, which could result in an accident, on unfamiliar terrain.
  • Page 66 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 EWB01550 control of the throttle, brakes, and turning tech- WARNING niques in this area before trying more difficult ter- Always mount a caution flag on the ATV to rain.

  • Page 67: Turning Your Atv

    With the engine idling, return the starter (choke) to EWB01570 WARNING the closed position, shift the drive select lever into the forward position, and then release the parking Always follow proper procedures for turning brake. Apply the throttle slowly and smoothly. The as described in this Owner’s Manual.

  • Page 68: Climbing Uphill

    Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.
  • Page 69 EWB01580 Never go over the top of any hill at high WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never operate the ATV on hills too steep for the of the hill. ATV or for your abilities.
  • Page 70 EWB01600 WARNING 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.

  • Page 71: Riding Downhill

    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. EWB01791 WARNING Maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.

  • Page 72: Crossing A Slope

    When this ATV is in 4WD, all wheels (front and Avoid going down a hill at an angle that rear) are interconnected by the drive train. This would cause the ATV to lean sharply to one means that applying either the front brake or the side.

  • Page 73: Crossing Through Shallow Water

    to cross a sloping surface. Avoid slopes with slip- Shift your weight to the uphill side of the pery surfaces or rough terrain that may upset your ATV. balance. As you travel across a slope, lean your body in the uphill direction.
  • Page 74 EWB01640 Test your brakes after leaving the water. Do not WARNING continue to ride your ATV without verifying that you have regained proper braking ability. Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual.
  • Page 75 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. V-belt cooling duct check hose (left front side of ATV) 1. Air filter case check hose 1.

  • Page 76: Riding Over Rough Terrain

    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.
  • Page 77 If the rear wheels of your ATV start to slide side- ways, control can usually be regained (if there is With practice, over a period of time, skill at con- room to do so) by steering in the direction of the trolled sliding can be developed.

  • Page 78: What To Do If

    On extremely slippery surfaces, such as ice, If your ATV can’t make it up a hill you are trying go slowly and be very cautious in order to re- to climb: duce the chance of skidding or sliding out of Turn the ATV around if you still have forward control.

  • Page 79: Periodic Maintenance And Minor Repair

    EBU28782 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21670 otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with Safety is an obligation of the owner. Periodic in- maintenance work. spection, adjustment and lubrication will keep your...
  • Page 80 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING...

  • Page 81: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 82 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 83: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
  • Page 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for wear, cracks or other damage, and re- √ √ √ √ V-belt place if necessary. •...
  • Page 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Moving parts and √ √ √ √ 20 * • Lubricate. cables Drive select lever • Check operation and adjust or replace if neces- √...

  • Page 86: Removing And Installing The Panel

    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. 1. Panel A 2.
  • Page 87 Do not kit. attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 88: Engine Oil And Oil Filter Cartridge

    3. Install the spark plug with the spark plug Specified spark plug: wrench, and then tighten it to the specified NGK/DR8EA torque. To install the spark plug Tightening torque: 1. Measure the spark plug gap with a wire thick- Spark plug: ness gauge and, if necessary, adjust the gap 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) to specification.
  • Page 89 2. Check the engine oil level on a cold engine. 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.
  • Page 90 To change the engine oil (with or without oil fil- 4. Remove the oil filter cartridge with an oil filter ter cartridge replacement) wrench. 1. Start the engine, warm it up for several min- utes, and then turn it off. 2.
  • Page 91 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. Make sure that the O-ring is properly seated. 1. Torque wrench Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf)

  • Page 92: Final Gear Oil

    Make sure that no foreign material enters the Final gear oil crankcase. The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- 8-14...
  • Page 93 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. The final gear oil level must be checked on a cold engine.
  • Page 94 2. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the 1. Final gear case guard specified torque. 2. Bolt 3. Place an oil pan under the final gear case to Tightening torque: collect the used oil.

  • Page 95: Changing The Differential Gear Oil

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, ECB00420 have a Yamaha dealer check and repair the ATV. NOTICE In addition, the differential gear oil must be Be sure no foreign material enters the final changed as follows at the intervals specified in the gear case.
  • Page 96 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case. 1. Differential gear oil drain bolt 4. Install the drain bolt, and then tighten it to the specified torque.

  • Page 97: Cleaning The Air Filter Element

    The differential gear case capacity is greater EBU23645 Cleaning the air filter element than the recommended oil quantity, therefore The air filter element should be cleaned at the in- the oil level cannot be accurately checked from tervals specified in the periodic maintenance and the oil filler hole.
  • Page 98 2. Remove the seat. (See page 4-13.) 3. Remove the air filter case cover by unhooking the air filter case cover holders. 1. Air filter element 5. Pull off the air filter element lock plate, and then remove the sponge material from the air 1.
  • Page 99 ECB00440 NOTICE Do not twist the sponge material when squeez- ing it. 1. Air filter element frame 2. Sponge material 3. Air filter element lock plate 6. Wash the sponge material gently but thor- oughly in solvent. 8. Check the sponge material and replace it if EWB01940 damaged.

  • Page 100: Cleaning The Spark Arrester

    11. Insert the air filter element into the air filter will affect carburetor jetting with subsequent case, and then install the air filter case cover poor performance and possible engine over- by hooking the holders onto the air filter case. heating.

  • Page 101: V-Belt Cooling Duct Check Hose

    3. Tap the tailpipe lightly, and then use a wire EWB02340 WARNING brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside Do not start the engine when cleaning the of the tailpipe housing. spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire.

  • Page 102: V-Belt Case Drain Plug

    If water drains from the V-belt case after removing most carburetor adjustments should be left to a the plug, have a Yamaha dealer check the ATV as Yamaha dealer, who has the necessary profes- the water may affect other engine parts.
  • Page 103 Engine idling speed: tle stop screw in direction (a), and to decrease 1450–1550 r/min it, turn the screw in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 8-25...

  • Page 104: Adjusting The Throttle Cable Free Play

    The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.

  • Page 105: 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 maintenance and lubrication chart.

  • Page 106: Checking The Brake Fluid Level

    Yamaha dealer replace the brake shoes as a set. pads for wear and the brake system for leakage. 1. Wear limit line 1.

  • Page 107: Changing The Brake Fluid

    Yamaha dealer check the cause. EBU24281 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic 1. Brake lever free play maintenance and lubrication chart. In addition,...

  • Page 108: Adjusting The Brake Pedal And Rear Brake Lever Free Play And Checking The Brake Pedal Position

    Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24513 Adjusting the brake pedal and rear brake lever free play and checking the...
  • Page 109 1. Brake pedal free play adjusting nut 1. Brake lever free play 2. Brake lever free play adjusting nut 2. Locknut 3. Brake lever free play adjusting bolt Adjusting the brake lever free play 1. Loosen the locknut at the brake lever and fully The brake lever free play should measure 3.0–5.0 turn in the brake lever free play adjusting bolt.
  • Page 110 Make sure the brake pedal does not move. Checking the brake pedal position The top of the brake pedal should be positioned 72.0–82.0 mm (2.83–3.23 in) above the footboard bracket. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 8-32...

  • Page 111: Axle Boots

    Replacement of brake components requires professional knowledge. These procedures The operation of the brake light switches must be should be performed by a Yamaha dealer. checked and, if necessary, adjusted at the inter- vals specified in the periodic maintenance and lu- brication chart.

  • Page 112: Checking And Lubricating The Cables

    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.) The brake light switch is properly adjusted when the brake light comes on just before braking takes effect.

  • Page 113: Checking And Lubricating The Front And Rear Brake Levers

    EWB02130 Front brake lever WARNING 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.

  • Page 114: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel hub bear- ings. To access the brake pedal pivot, remove panel A.
  • Page 115 ECB00620 2. Remove the battery holding plate by removing NOTICE the bolts. 3. Disconnect the negative battery lead first, Never attempt to remove the battery cell seals, then the positive battery lead by removing as this would permanently damage the battery. their bolt.
  • Page 116 To charge the battery ECB00940 NOTICE Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in Always keep the battery charged. Storing a dis- mind that the battery tends to discharge more...

  • Page 117: Replacing A Fuse

    1. Main fuse 1. Positive battery lead (red) 2. Spare main fuse 2. Negative battery lead (black) 3. Fuse box 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.
  • Page 118 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Ignition fuse: 15.0 A Four-wheel-drive motor fuse: 3.0 A 1. Headlight fuse Signaling system fuse: 2.

  • Page 119: Replacing A Headlight Bulb

    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.

  • Page 120: Adjusting A Headlight Beam

    8. Adjust the headlight beam if necessary. EBU25551 Adjusting a headlight beam 1. Do not touch the glass part of the bulb. ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. 8-42...

  • Page 121: Replacing The Tail/Brake Light Bulb

    Replacing the tail/brake light bulb Installing a wheel If the tail/brake light bulb burns out, have a 1. Place the ATV on a level surface. Yamaha dealer replace it. 2. Install the wheel and the nuts. EBU25651 Removing a wheel...
  • Page 122 Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Tapered nut 3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified torques.

  • Page 123: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 124: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 125: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25880 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 126: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the brakes after washing. Apply the brakes several 2.
  • Page 127 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-36.

  • Page 128: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 1984 mm (78.1 in) Air cooled 4-stroke, SOHC Overall width: Cylinder arrangement: 1085 mm (42.7 in) Forward-inclined single cylinder Overall height: Displacement: 1120 mm (44.1 in) 348.0 cm³ Bore × stroke: Seat height: 83.0 ×...
  • Page 129 Engine oil: Differential gear oil: Type: Type: SAE 5W-30 or SAE 10W-30 or SAE 10W-40 or SAE SAE 80 API GL-4 Hypoid gear oil 15W-40 or SAE 20W-40 or SAE 20W-50 Quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt) Air filter: 50 ˚C Air filter element: Wet element...
  • Page 130 Transmission: Rear tire: Primary reduction system: Type: V-belt Tubeless Secondary reduction system: Size: Shaft drive AT25 x 10-12 Secondary reduction ratio: Manufacturer/model: 41/21 × 24/18 × 33/9 (9.545) CHENG SHIN/C-828 (AUS)(NZL) Transmission type: MAXXIS/M980 (EUR)(GBR) Loading: V-belt automatic Operation: Maximum loading limit: Left hand operation 210.0 kg (463 lb) Forward gear:...
  • Page 131 Rim size: Charging system: 12 x 7.5AT AC magneto Front brake: Battery: Type: Model: Dual disc brake YTX14AH Operation: Voltage, capacity: Right hand operation 12 V, 12.0 Ah Recommended fluid: Headlight: DOT 4 Bulb type: Rear brake: Krypton bulb Bulb voltage, wattage × quantity: Type: Drum brake Headlight:...
  • Page 132 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 10-5...

  • Page 133: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 134 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 deal- 11-2...
  • Page 135 1. Model label 11-3...
  • Page 136 INDEX Drive select lever ............4-9 Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-6 Drive select lever safety system cable, adjusting ..8-27 Air filter element, cleaning ..........8-19 Axle boots ..............8-33 Engine break-in .............. 6-4 Engine, cold start ............
  • Page 137 Shock absorber assembly, adjusting the rear ....4-17 Spark arrester, cleaning ..........8-22 Key identification number ..........11-1 Spark plug, checking ............. 8-8 Specifications ............... 10-1 Label locations ............... 2-1 Speed limiter ..............4-6 Light switch ..............4-4 Speedometer ..............4-3 Starter (choke) .............
  • Page 138 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2008.06-0.3×1 CR...

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