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 YFZ350Z This A 3B5-28199-64...
Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN 2009.05-0.4x1 ! (E,F,S)
Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFZ350Z This A 3B5-28199-64-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 confor ming to Directive 98 / 37 / EC, 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product ( JY43GG00090298220- )
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 Please check your local riding laws and regulations before operating this ATV. EBU17390 YFZ350Z OWNER’S MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st edition, April 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
Page 8: Table Of Contents
EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel cock ........... 4-9 Starter (choke) ......... 4-11 SPECIFICATION LABELS ......1-1 Seat ............4-11 Adjusting the front shock absorber SAFETY INFORMATION ......2-1 assemblies ..........4-12 Adjusting the rear shock absorber DESCRIPTION ..........
Page 9 Accessories and loading ......6-6 Cleaning the spark arrester ..... 8-21 Changing the carburetor settings ..... 8-23 RIDING YOUR ATV ........7-1 Adjusting the engine idling speed .... 8-31 Adjusting the throttle cable free play ..8-33 GETTING TO KNOW YOUR ATV....7-2 Brakes ............
Page 10 Replacing a headlight bulb ...... 8-47 Adjusting a headlight beam ..... 8-49 Replacing the tail/brake light bulb ... 8-50 Removing a wheel ........8-51 Installing a wheel ........8-52 Troubleshooting ........8-52 Troubleshooting charts ......8-54 CLEANING AND STORAGE......9-1 Cleaning ............
Page 11: Location Of The Warning And Specification Labels
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...
Page 12 4D3-2816L-20 43P-2816R-00...
Page 13 4AA-22259-40 30.0 30.0 0.30 kgf/cm 0.30 kgf/cm 3B5-2816M-M0 YEAR OF CONSTRUCTION : 2009 YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 5PG-2817L-10 MODEL : YFZ350 MAX. POWER : 36.2 kW MASS IN RUNNING ORDER : 187 kg 1AS-2816P-00 3B5-2156A-00...
Page 14 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. NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
Page 15 NEVER use with drugs or alcohol. Adjust tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids. Turning 4WD-LOCK (“DIFF.LOCK”) takes more effort.
Page 16 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. This pictogram shows trailer Hitch Tongue weight limit.
Page 17 For Oceania...
Page 18 WARNING WARNING Improper AT V use can result in SEVERE INJURY or DEATH. UNDER ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL Operating this ATV if you are under PROTECTIVE the age of 16 increases your GEAR...
Page 19 WA R N IN G Imprope r tire pressure or overloading can cause loss of cont rol. Loss of control can result in severe injury or death. OPERATING TIRE PRESSURE : Set with tires cold Re commended : Front : 30.0 k Pa ( 4.4 psi) Rear : 30.0 k Pa ( 4.4 psi) Minimum : Front : 27.0 k Pa ( 4.0 psi)
Page 20: Safety Information
EBU17431 SAFETY INFORMATION SAFETY INFORMATION EBU17593 does not have the abilities to operate it safely. Never carry a passenger on an ATV. AN ATV IS NOT A TOY AND CAN BE HAZARD- Always avoid operating an ATV on any paved OUS TO OPERATE.
Page 21 conditions, and your experience. Always follow proper procedures for climbing Never attempt wheelies, jumps, or other stunts. hills as described in this manual. Check the ter- Always inspect your ATV each time you use it to rain carefully before you start up any hill. Never make sure it is in safe operating condition.
Page 22 speed when climbing a hill. If you stall or roll this manual. backwards, follow the special procedure for Always maintain proper tire pressure as de- braking described in this manual. Dismount on scribed in this manual. the uphill side or to a side if pointed straight up- Never modify an ATV through improper installa- hill.
Page 23 ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT. Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels.
Page 24: Description
EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly 1. Tail/brake light 2. Radiator 2. Seat 3. Fuel cock 3. Kickstarter 4. Rear shock absorber assembly 4. Fuel tank cap 5. Spark arrester 5. Headlight 6. Starter (choke) 6.
Page 25: Controls And Instruments
EBU17712 Controls and instruments 1. Clutch lever 2. Parking brake lock plate 3. Main switch 4. Brake lever 5. Throttle lever 6. Handlebar switches The ATV you have purchased may differ slightly from the figures shown in this manual.
Page 26: Instrument And Control Functions
EBU17733 INSTRUMENT AND CONTROL FUNCTIONS EBU29810 Main switch The positions of the main switch are as follows: The engine can be started and the key cannot be removed. The headlights and taillight come on when the en- gine is started. All electrical systems are off.
Page 27: Handlebar Switches
EBU18061 EBU29780 Handlebar switches Light switch “ /OFF” Set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to turn on the high beams and the taillight. Set the switch to “OFF”...
Page 28: Throttle Lever
Make sure that the cause of the malfunction is corrected before restarting the engine or have the ATV in- spected by a Yamaha dealer. EBU18323 Speed limiter Your ATV is equipped with an adjustable speed limiter.
Page 29: Clutch Lever
justment of the speed limiter and throttle the clutch lever. The clutch lever should be pulled could cause throttle cable damage or im- rapidly and released slowly for smooth clutch oper- proper throttle operation. You could lose ation. control, resulting in an accident. [EWB00241] 1.
Page 30: Brake Pedal
1. Brake lever 1. Brake pedal EBU18432 EBU18500 Brake pedal Parking brake The brake pedal is located on the right side of the Use the parking brake before starting the engine or ATV. To apply the rear brake, push down on the parking the ATV, especially on a slope.
Page 31 wise, the engine will misfire, preventing normal op- eration. 1. Locked position EWB00220 1. Button WARNING 2. Parking brake lock plate Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied.
Page 32: Shift Pedal
prematurely. push it down smoothly but forcefully. This model is equipped with a primary kickstarter, allowing the engine to be started in any gear if the clutch is dis- EBU18530 Shift pedal engaged. However, shifting the transmission into the neutral position before starting is recommend- This ATV is equipped with a constant-mesh 6- speed transmission.
Page 33: Fuel
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 filler tube.
Page 34: Fuel Cock
spills on your clothing, change your clothes. Recommended fuel: PREMIUM UNLEADED GASOLINE ONLY ECB00060 NOTICE For Europe: PREMIUM UNLEADED GASO- LINE ONLY with a research octane number Use only unleaded gasoline. The use of leaded of 95 or higher. gasoline will cause severe damage to internal Fuel tank capacity: engine parts, such as the piston rings, as well 12.0 L (3.17 US gal, 2.64 Imp.gal)
Page 35 FUEL FUEL 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetors.
Page 36: Starter (Choke)
the 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. FUEL 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.
Page 37: Adjusting The Front Shock Absorber Assemblies
1. Seat lock lever 1. Projection 2. Seat holder To install the seat Insert the projection on the front of the seat into the EBU18992 Adjusting the front shock absorber seat holder and push down on the seat at the rear. assemblies Make sure that the seat is securely fitted.
Page 38: Adjusting The Rear Shock Absorber Assembly
2. Position indicator damping force adjusting dial or the oil reser- voir with your bare hand or skin until suspen- sion components have cooled. A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-13...
Page 39 ECB00090 NOTICE A special wrench can be obtained at a Yamaha Never turn an adjusting mechanism beyond dealer to make this adjustment. the minimum and maximum settings. The spring preload setting is determined by measuring distance A, shown in the illustration.
Page 40 Spring preload setting: Minimum (soft): Distance A = 213.5 mm (8.41 in) Standard: Distance A = 220.5 mm (8.68 in) Maximum (hard): Distance A = 228.5 mm (9.00 in) 3. Tighten the locknut to the specified torque. NOTICE: Always tighten the locknut against the adjusting nut, and then tighten it to the specified torque.
Page 41 knob in direction (a) to increase the compression Compression damping setting: damping force and thereby harden the damping, Minimum (soft): and in direction (b) to decrease the compression 1 click(s) in direction (a)* damping force and thereby soften the damping. Standard: 11 click(s) in direction (a)* Maximum (hard):...
Page 42 Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- er for any service. 4-17...
Page 43: Pre-Operation Checks
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
Page 44 ITEM ROUTINE PAGE Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Rear brake 5-3, 8-34, 8-35, 8-37 Check brake ﬂuid level in reservoir, and add recommended brake ﬂuid to speciﬁed level if necessary.
Page 45: Fuel And 2-Stroke Engine Oil Mixing Ratio
Brake lever and brake pedal Castrol A545 20:1 Check that there is no free play in the brake le- Castrol A747 ver. If there is free play, have a Yamaha dealer ECB00140 check the brake system. NOTICE Check for correct brake pedal height. (See Never mix two types of 2-stroke engine oil in page 8-37.) If the pedal height is incorrect, have...
Page 46: Throttle Lever
Check tire pressure regularly to make sure it is at brakes firmly for one minute. If there is any leak- the recommended specifications. Also check for age, have a Yamaha dealer check the brake sys- wear and damage. tem. Tire pressure...
Page 47 Recommended tire pressure: Front 30.0 kPa (0.300 kgf/cm , 4.4 psi) Rear 30.0 kPa (0.300 kgf/cm , 4.4 psi) Minimum tire pressure: Front 27.0 kPa (0.270 kgf/cm , 3.9 psi) Rear 27.0 kPa (0.270 kgf/cm , 3.9 psi) Maximum tire seating pressure: Front 1.
Page 48: Chassis Fasteners
After extensive tests, only the tires listed below EBU19840 Chassis fasteners have been approved for this model by Yamaha Motor Co., Ltd. Make sure that all nuts, bolts and screws are prop- erly tightened.
Page 49: Instruments, Lights And Switches
EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.
Page 50: Operation
Read the Owner’s Manual carefully before riding the ATV. If there is a control or function you do not Position (1): understand, ask your Yamaha dealer. Cold engine start with ambient temperature below EWB00631 5 °C (40 °F). WARNING Position (2): Read the Owner’s Manual carefully to become...
Page 51: Starting A Warm Engine
Ambient temp./starter (choke) position in position (2), keep the starter (choke) in this position to warm up the engine. °C 0° 10° 20° 30° 8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to 90°...
Page 52 starting, accelerating, climbing hills, etc. ECB00200 NOTICE To shift into neutral, release the throttle lever, ap- ply the clutch, and then repeatedly depress the Always close the throttle before shifting gears, shift pedal until it stops. otherwise damage to the engine and drive train When it stops, it will be in first gear.
Page 53: Engine Break-In
EBU20650 the transmission. To decelerate Always use the clutch when changing gears. When slowing down or stopping, release the throt- The engine, transmission and drive train are tle and apply the brakes smoothly and evenly. As not designed to withstand the shock of you slow down, shift to a lower gear.
Page 54: Parking
ECB00220 NOTICE If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. EBU20722 Parking When parking the ATV, shift into first gear, stop the engine, apply the parking brake, and then turn the...
Page 55: Parking On A Slope
Genuine Yamaha Accessories, which and rear wheels with rocks or other objects. are available only from a Yamaha dealer, have Do not park the ATV at all on hills that are so...
Page 56 An accessory which can shift position sories or offer other modifications for Yamaha or come off while you are riding could affect your vehicles. Yamaha is not in a position to test the ability to control the ATV. products that these aftermarket companies pro- Do not mount an accessory where it could inter- duce.
Page 57 tance for braking. Make sure the load does not interfere with con- trols or your ability to see where you are going. As originally equipped, this ATV is not designed to Ride more slowly than you would without a load. carry cargo or tow a trailer.
Page 58: Riding Your Atv
EBU21141 RIDING YOUR ATV...
Page 59: Getting To Know Your Atv
EBU21616 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is intended for recreational use by expe- WARNING rienced operators only. This section, Riding your Do not operate this ATV or allow anyone else ATV, provides general ATV riding instructions for to operate it without proper instruction.
Page 60 handling and performance characteristics. Take This ATV is designed to carry the operator the time to learn the basic techniques well before only – passengers prohibited. attempting more difficult maneuvers. Become fa- The long seat is to allow the operator to shift posi- miliar with this ATV at slow speeds first, even if you tion as needed during operation.
Page 61 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 other personal protective equipment can reduce the severity of injuries in an accident.
Page 62 accident. iter. The speed limiter keeps the throttle from fully [EWB01421] 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.
Page 63 Do not exceed the maximum loading limits During operation for the vehicle (see box in this section or ve- Always keep your feet on the footrests during op- hicle labeling). eration; otherwise, they may contact the rear Make sure the load does not interfere with wheels.
Page 64 ATV should be during operation or after leaving the ATV, do not let genuine Yamaha or equivalent components de- brush, grass and other materials collect under the signed for use on this ATV and should be installed vehicle, near the muffler or exhaust pipe, or next to and used according to instructions.
Page 65: Be Careful Where You Ride
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, and While riding on unpaved public streets or roads may cause the ATV to go out of control.
Page 66 Know the terrain where you ride. Ride cautiously in Do not operate on rough, slippery, or loose terrain unfamiliar areas. Stay alert for holes, rocks, or until you have learned and practiced the skills nec- roots in the terrain, and other hidden hazards essary to control the ATV on such terrain.
Page 67 Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. 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 hitch.
Page 68: Turning Your Atv
iar with your ATV. Make sure that this area is free Use this same procedure as you move into the of obstacles and other riders. You should practice higher gears. Be sure to coordinate the use of the control of the throttle, brakes, shifting procedures, throttle and shift pedal properly.
Page 69: Climbing Uphill
the ATV will resist turning. A special turning tech- This procedure should be practiced at slow speed nique must be used to allow the ATV to make turns many times in a large unpaved area with no obsta- quickly and easily. It is essential that this skill be cles.
Page 70 niques described in this Owner’s Manual. 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. Always check the terrain carefully before you start up any hill.
Page 71 hill. In all cases avoid inclines with slippery or loose make sure you do not lift the front wheels which surfaces, or obstacles that might cause you to lose could cause you to lose control. If you are unable control. to continue up the hill, dismount the ATV on the up- To climb a hill, you need traction, momentum, and hill side.
Page 72: Riding Downhill
Shift your weight backward and to the up side of the hill. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possi- ble.
Page 73: Crossing A Slope
stacles which may appear. 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 you to properly position your weight to maintain proper balance.
Page 74: Crossing Through Shallow Water
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 care- fully. CROSSING THROUGH SHALLOW WATER EWB01641 WARNING Operating this vehicle through deep or fast- flowing water can lead to loss of control or an overturn.
Page 75: Riding Over Rough Terrain
After riding your ATV in water, be sure to drain the 1. Air ﬁlter case check hose trapped water by removing the check hose at the bottom of the air filter case. NOTICE: Undrained RIDING OVER ROUGH TERRAIN water can cause damage or improper opera- EWB01651 tion.
Page 76: Sliding And Skidding
damage to the ATV or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footrests at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01662 WARNING...
Page 77: What To Do If
Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footrest to the outside of the turn. Position your weight over the front wheels for better control. (See page 7-11.) If your ATV begins to tip while turning: Lean more into the turn to regain balance.
Page 78 proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See page 7-16.) If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles.
Page 79: Periodic Maintenance And Adjustment
If you are not fa- EBU21691 Owner’s manual and tool kit miliar with vehicle service, have a Yamaha dealer perform the service. Be sure to put this owner’s manual and the low- pressure tire gauge in the plastic bag and always EWB02561 carry them along with the owner’s tool kit under the...
Page 80 However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform...
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 er comes ITEM 1300 2500 2500 5000 ﬁrst (mi) (200) (800) (1600) (1600) (3200) hours √ √ √ Spark arrester Clean.
Page 83: General Maintenance And Lubrication Chart
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 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 ﬁrst (mi) (200) (800) (1600) (1600) (3200) hours Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses Replace. Every 4 years √...
Page 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 ﬁrst (mi) (200) (800) (1600) (1600) (3200) hours Rear suspension relay arm and con- Check operation and correct if necessary. √ √ √ √ 15 * necting arm pivot- Lubricate with lithium-soap-based grease.
Page 86 EBU23071 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 of the brake master cylinders and calipers, and change the brake fluid.
Page 87: Checking The Spark Plugs
EBU28321 spark plug wrench included in the owner’s tool Checking the spark plugs kit. The spark plugs are important engine compo- nents, which are easy to check. Since heat and de- posits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lu- brication chart.
Page 88: Transmission Oil
In- Spark plug gap: stead, have a Yamaha dealer check the ATV. 0.7–0.8 mm (0.028–0.031 in) 3. Check each spark plug for electrode erosion To install a spark plug and excessive carbon or other deposits, and 1.
Page 89 fore each ride. In addition, the transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart. To check the transmission oil level 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off.
Page 90 To change the transmission oil Tightening torque: 1. Place the ATV on a level surface. Transmission oil drain bolt: 2. Start the engine, warm it up for several min- 20 Nm (2.0 m·kgf, 14 ft·lbf) utes, and then turn it off. 3.
Page 91: Coolant
crankcase. The coolant should be between the minimum and 7. Start the engine, and then let it idle for several maximum level marks. minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.
Page 92 Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. [ECB01011] Coolant reservoir capacity (up to the maximum level mark): 0.28 L (0.30 US qt, 0.25 Imp.qt) 6.
Page 93 2. Remove the radiator cover by removing the screws. 1. Coolant drain bolt 1. Radiator cover 4. Remove the radiator cap. 2. Screw 3. Place a container under the engine and re- move the coolant drain bolts. 8-15...
Page 94 1. Radiator cap 1. Coolant reservoir cap 5. Remove the coolant reservoir cap. 6. Disconnect the hose on the coolant reservoir side and drain the coolant from the coolant reservoir. 8-16...
Page 95 voir to the maximum level mark, and then in- stall the reservoir cap. NOTICE: Mix antifreeze with distilled water only. Howev- er, if distilled water is not available, soft water may be used for refilling. Do not use hard water or salt water since they are harmful to the engine.
Page 96: Cleaning The Air Filter Element
14. Start the engine, and then check for coolant leakage. If any leakage is found, have a Yamaha dealer check the cooling system. 15. Install the radiator cover by installing the screws.
Page 97 1. Air ﬁlter case cover 1. Air ﬁlter element lock plate 2. Air ﬁlter case cover holder 5. Remove the lock plate by turning it, and then 4. Pull the air filter element out of the air filter remove the sponge material from the air filter case.
Page 98 1. Sponge material damaged. 2. Air ﬁlter element frame 9. Apply Yamaha foam air filter oil or other qual- 3. Air ﬁlter element lock plate ity foam air filter oil to the sponge material. 6. Wash the sponge material gently but thor- oughly in solvent.
Page 99: Cleaning The Spark Arrester
and possible engine overheating. [ECB00461] 12. Install the seat. The air filter element should be cleaned every 20–40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas. Each time the air filter element main- tenance is performed, check the air inlet of the air filter case for obstructions.
Page 100 1. Screw 1. Screw 2. Tailpipe 2. Remove the tailpipe by pulling it out of the 3. Spark arrester muffler. 4. Gasket 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the 4.
Page 101: Changing The Carburetor Settings
Carburetor adjustments should only be per- formed by a Yamaha dealer. Do not attempt to perform these procedures unless you have mechanical knowledge and the neces- 1. Main jet number...
Page 102 1. Standard position: Groove 3 8-24...
Page 103 Carburetor setting chart Altitude Temperature 0–1500 m (5000 ft) Above 1500 m (5000 ft) Main jet Jet needle Pilot air screw Main jet Jet needle Pilot air screw Above 0 °C (32 °F) #200 3rd groove 2.0 turns out #190 3rd groove 2 1/2 turns out from +5 °C (41 °F) to...
Page 104 6. Remove the fuel tank by removing the bolts. 1. Air ﬁlter case cover 1. Fuel tank 2. Air ﬁlter case cover holder 2. Bolt 8. Remove the mixing chamber cap securing 7. Remove the air filter case cover by unhooking plate by removing the screw.
Page 105 1. Mixing chamber cap securing plate 1. Joint screw 2. Screw 10. Remove the mixing chamber cap. 9. Loosen the carburetor joint screws. 11. Remove the throttle cable from the throttle valve, and then remove the throttle cable hold- er by removing the screws. 8-27...
Page 106 12. Remove the carburetor, and then remove the 1. Throttle cable float chamber by removing the screws. 2. Throttle valve 3. Throttle cable holder 4. Screw 1. Float chamber 2. Screw 8-28...
Page 107 If the securing plate does not Optional main jets can be obtained at a Yamaha match a projection, tighten the carburetor dealer. cap until they align. Do not loosen the car- After the jet needle clip position is changed, the buretor cap.
Page 108 Adjusting the throttle cables 1. Move the throttle lever a few times. 2. Push the throttle lever forward until it stops and hold it in this position. 3. Check through each carburetor window to see if the punch mark on the throttle valve is at the specified position.
Page 109: Adjusting The Engine Idling Speed
tion chart. A diagnostic tachometer is needed to make this adjustment. The carburetor synchronization and the throttle cable free play must be checked, and adjusted if necessary, before adjusting the engine idling speed. 1. Start the engine and warm it up. 1.
Page 110 (b) (a) 1. Throttle stop screw 1. Pilot air screw 5. Remove the seat. (See page 4-11.) Engine idling speed: 6. Check the engine idling speed and, if neces- 1450–1550 r/min sary, adjust it to specification by turning the ECB00510 throttle stop screws at the carburetors.
Page 111: Adjusting The Throttle Cable Free Play
(a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 7. Install the seat. EBU24045...
Page 112: Checking The Front And Rear Brake Pads
If a brake pad has worn to the point that a wear indica- tor groove almost appears, have a Yamaha dealer replace the brake pads as a set. The wheels need to be removed to check the brake pads.
Page 113: Checking The Brake Fluid Level
Rear brake Front brake 1. Minimum level mark 1. Wear indicator groove EBU24252 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary.
Page 114 Rear brake LOWER LOWER 1. Brake ﬂuid reservoir cap 1. Minimum level mark 2. Brake ﬂuid reservoir cap 2. Refill with brake fluid. 3. Install the brake fluid reservoir cap. If the rear brake fluid level is low, replenish as fol- Observe these precautions: lows.
Page 115: Changing The Brake Fluid
Yamaha dealer check the cause. EBU24291 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition, 1. No free play...
Page 116: Adjusting The Parking Brake Free Play
10.0 mm (0.39 in) below the top of the footrest as shown. If the brake pedal is not positioned as spec- ified, have a Yamaha dealer adjust it. 1. Cable length “A” 1. Release the parking brake. 2. Fully loosen the locknut and the adjusting bolt 1.
Page 117 (a) to increase the cable length, and in direction (b) to decrease it. If the cable length cannot be adjusted to specifica- tion, consult a Yamaha dealer. 5. Tighten the locknut at the clutch lever. 6. Turn in the adjusting bolt at the rear brake cal-...
Page 118: Brake Light Switches
The brake light switch for the brake pedal can be so that it does not turn together with the adjusted as follows, but the other brake light locknut. switches should be adjusted by a Yamaha dealer. [ECB00521] Tightening torque: The brake light switch is properly adjusted when...
Page 119: Adjusting The Clutch Lever Free Play
If the specified free play cannot be obtained as de- shown. If the free play is incorrect, adjust it as fol- scribed above or if the clutch does not operate cor- lows. rectly, have a Yamaha dealer check the internal clutch mechanism. EBU24853 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary.
Page 120 Drive chain slack: 12.0–18.0 mm (0.47–0.71 in) 1. Axle holding nut (upper) 2. Axle holding nut (lower) 3. Loosen the locknut on each side of the swing- 1. Drive chain slack arm. To tighten the drive chain, turn the ad- justing bolts in direction (a).
Page 121: Lubricating The Drive Chain
specified limits. [ECB00542] Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) There are alignment marks on each side of the Axle holding nut (upper): swingarm and on the wheel hubs. Use them to 120 Nm (12.0 m·kgf, 85 ft·lbf) check for proper wheel axle alignment.
Page 122: Checking And Lubricating The Cables
If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace 8-44...
Page 123: Checking The Shift Pedal
Recommended lubricants: have a Yamaha dealer check the wheel hub bear- Brake lever: ings. Silicone grease Clutch lever: Lithium-soap-based grease EBUM0170 Checking the shift pedal The operation of the shift pedal should be checked before each ride.
Page 124: Lubricating The Upper And Lower Arm Pivots
EBU25032 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. Lubricate the pivoting points using a grease gun. Recommended lubricant: Lithium-soap-based grease Left side 1.
Page 125: Replacing A Headlight Bulb
Right side 1. Screw 1. Grease nipple 2. Remove the headlight bulb holder cover. EBU26882 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the screw. 8-47...
Page 126 1. Headlight bulb holder cover 1. Headlight bulb holder 3. Remove the bulb holder by turning it counter- 4. Remove the burnt-out bulb. clockwise. 5. Place a new bulb into position, and then install the bulb holder by turning it clockwise. NOTICE: Do not touch the glass part of the headlight bulb to keep it free from oil, oth- erwise the transparency of the glass, the...
Page 127: Adjusting A Headlight Beam
[ECB00681] 8. Adjust the headlight beam if necessary. EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam 8-49...
Page 128: Replacing The Tail/Brake Light Bulb
adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b). 1. Tail/brake light bulb holder 2. Remove the burnt-out bulb by pushing it in 1. Headlight beam adjusting screw and turning it counterclockwise. EBU25611 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as...
Page 129: Removing A Wheel
Front 1. Tail/brake light bulb holder 1. Wheel nut 2. Tail/brake light bulb 3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 4. Install the bulb holder (together with the bulb) by turning it clockwise.
Page 130: Installing A Wheel
3. Elevate the ATV and place a suitable stand systems yourself. However, should your ATV re- under the frame. quire any repair, take it to a Yamaha dealer, whose 4. Remove the nuts from the wheel. skilled technicians have the necessary tools, expe- 5.
Page 131 Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. 8-53...
Page 132: Troubleshooting Charts
Wipe off with a dry cloth and correct the the kickstarter. spark plug gaps, or replace the spark plugs. Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Have a Yamaha dealer check the ATV. 8-54...
Page 133: Engine Overheating
Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.
Page 134: Cleaning And Storage
EBU25860 CLEANING AND STORAGE EBU25921 sure may cause water seepage and Cleaning deterioration of wheel bearings, brakes, Frequent, thorough cleaning of your ATV will not transmission seals and electrical devices. only enhance its appearance but will improve its Many expensive repair bills have resulted general performance and extend the useful life of from improper high-pressure detergent many components.
Page 135: Storage
EBU25952 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inders, piston rings, etc.
Page 136 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. Make any necessary repairs before storing the ATV.
Page 137: Specifications
EBU25960 SPECIFICATIONS EBU2597F Engine: Engine type: Dimensions: Liquid cooled 2-stroke Overall length: Cylinder arrangement: 1855 mm (73.0 in) Forward-inclined parallel 2-cylinder Overall width: Displacement: 1100 mm (43.3 in) 347 cm Overall height: Bore × stroke: 1080 mm (42.5 in) 64.0 × 54.0 mm (2.52 × 2.13 in) Seat height: Compression ratio: 800 mm (31.5 in)
Page 138 Cooling system: Secondary reduction system: Chain drive Coolant reservoir capacity (up to the maximum level mark): Secondary reduction ratio: 0.28 L (0.30 US qt, 0.25 Imp.qt) 41/14 (2.929) Radiator capacity (including all routes): Transmission type: 1.50 L (1.59 US qt, 1.32 Imp.qt) Constant mesh 6-speed Air filter: Operation:...
Page 139 Manufacturer/model: Rear wheel: DUNLOP/KT851B Wheel type: Rear tire: Panel wheel Type: Rim size: Tubeless 9 x 8.5AT Size: Front brake: AT20 x 10-9 Type: Manufacturer/model: Dual disc brake DUNLOP/KT877A Operation: Loading: Right hand operation Maximum loading limit: Recommended fluid: 100.0 kg (220 lb) DOT 4 (Total weight of rider, cargo, accessories, and tongue) Rear brake:...
Page 140 Wheel travel: 220 mm (8.7 in) Electrical system: Ignition system: Charging system: AC magneto Headlight: Bulb type: Krypton bulb Bulb voltage, wattage × × × × quantity: Headlight: 12 V, 30/30 W × 2 Tail/brake light: 12 V, 5.0/21.0 W × 1 10-4...
Page 141: Consumer Information
Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
Page 142 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 143 1. Model label 11-3...
Page 144 INDEX Accessories and loading ..........6-6 Engine break-in .............. 6-4 Air filter element, cleaning..........8-18 Engine, cold start ............6-1 Engine idling speed............8-31 Engine, starting a warm ..........6-2 Brake and clutch levers, checking and lubricating ..8-44 Engine stop switch ............4-2 Brake fluid, changing............
Page 145 Model label..............11-2 Tail/brake light bulb, replacing ........8-50 Owner’s manual and tool kit..........8-1 Throttle cable free play, adjusting ........ 8-33 Throttle lever ............4-2 Throttle OverRide System..........4-3 Parking................6-5 Tires ................5-4 Parking brake..............4-5 Transmission oil ............5-3 8-10 Parking brake free play, adjusting.........8-38 Troubleshooting ............
Page 146 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2009.05-0.4x1 !

Yamaha BANSHEE 350 YFZ350Z Owner's Manual

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