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Yamaha YFM350R 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
YFM35RD
YFM350RD
1BS-28199-63

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Summary of Contents for Yamaha YFM350R

  • 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 YFM35RD YFM350RD 1BS-28199-63...
  • Page 2 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2012.03-0.3×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35RD YFM350RD WARNING This ATV should not be ridden by anyone under 16 years of age. 1BS-28199-63-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 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM350 (YFM35R) (JY4AH18W0C0007613–)
  • Page 5 Congratulations on your purchase of the Yamaha YFM35RD/YFM350RD. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing ma- chines. 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 YFM35RD/YFM350RD OWNER’S MANUAL ©2012 by Yamaha Motor Co., Ltd. 1st edition, February 2012 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 .............4-8 SPECIFICATION LABELS ......1-1 Fuel cock ..........4-10 Starter (choke) ..........4-11 SAFETY INFORMATION ......2-1 Seat ............4-12 Adjusting the front shock absorber DESCRIPTION ..........3-1 assemblies ..........4-13 Left view ............3-1 Adjusting the rear shock absorber Right view............
  • Page 9 Shifting ............6-4 General maintenance and lubrication Engine break-in .......... 6-6 chart ............8-5 Parking ............6-7 Checking the spark plug ......8-9 Parking on a slope ........6-7 Engine oil and oil filter element ....8-11 Accessories and loading ......6-8 Cleaning the air filter element ....8-15 Cleaning the spark arrester ......8-18 RIDING YOUR ATV ........
  • Page 10 Lubricating the swingarm pivots ....8-35 Lubricating the rear suspension relay arm and connecting arm pivoting points ..8-35 Lubricating the upper and lower arm pivots ............8-36 Lubricating the steering shaft ....8-37 Battery ............8-38 Replacing the fuse ........8-40 Replacing a headlight bulb .......

  • 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 1PD-2811R-00 43P-2816R-01...
  • Page 13 YFM350 20.0 kW 180 kg 5YT-2156A-10 1AS-2816P-00 4AA-22259-40 25.0 kPa 25.0 kPa 2012 0.25 kgf/cm² 0.25 kgf/cm² 3.6 psi 3.6 psi YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 5YT-2816M-M0 8AC-2817L-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 use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
  • Page 15 This unit contains high-pressure nitrogen Turning 4WD-LOCK gas. (“DIFF.LOCK”) takes more effort. Mishandling can cause an explosion. Do not Operate at a slow speed and allow extra incinerate, puncture or open. time and distance for maneuvers to avoid loss of control. This pictogram shows the loading limits and/or maximum load capacity for this ATV.
  • Page 16 Model Name ****** Max. Power *** kW *** kg Mass In Running Order 1 Year of construction **** YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN...
  • Page 17 For Oceania...
  • Page 18 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate : • without proper training or instruction. •...
  • Page 19 WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. OPERATING TIRE PRESSURE: Set with tires cold • Recommended : Front : 25.0 kPa, 3.6 psi Rear : 25.0 kPa, 3.6 psi •...

  • Page 20: Safety Information

    EBU17431 SAFETY INFORMATION ● EBU17465 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 21 ● Never operate at speeds too fast for your skills ● Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 22 ● Always use proper procedures if you stall or roll reduced stopping ability. Test your brakes after backwards when climbing a hill. To avoid stall- leaving water. If necessary, apply them several ing, use the proper gear and maintain a steady times to let friction dry out the linings.
  • Page 23 In the event of an accident tion. If necessary, contact your riding party or 1. If serious injuries are incurred, you may be local authorities to let them know where you safer staying next to your vehicle; it may are and what has happened. shield you from oncoming riders.
  • Page 24 This im- While you may find aftermarket products similar in proper position limits the freedom of movement design and quality to genuine Yamaha accesso- of the operator and may limit control ability, ries, recognize that some aftermarket accessories...
  • Page 25 ● Do not run engine outdoors where engine EWB00072 WARNING exhaust can be drawn into a building through openings such as windows and Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, doors. a deadly gas. Breathing carbon monoxide can EWB02591 cause headaches, dizziness, drowsiness, nau- WARNING...

  • Page 26: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly spring preload adjusting 1. Spark arrester ring 2. Fuse 2. Fuel cock 3. Rear shock absorber assembly spring preload adjusting 3. Throttle stop screw 4. Air filter case 4.

  • Page 27: Controls And Instruments

    EBU17712 Controls and instruments 1. Clutch lever 2. Parking brake lever 3. Front brake fluid reservoir 4. Brake lever 5. Throttle lever 6. Main switch 7. Handlebar switches The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 28: Instrument And Control Functions

    EBU17734 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

  • Page 29: Indicator Lights

    EBU17793 EBU18061 Indicator lights Handlebar switches 1. Reverse indicator light “R” 1. Light switch “ /OFF” 2. Neutral indicator light “N” 2. Engine stop switch “ ” 3. Start switch “ ” EBU17860 Neutral indicator light “ ” EBU18080 Engine stop switch “ ”...

  • Page 30: Throttle Lever

    Regulate the speed of the ATV by varying the EBU18101 Start switch “ ” throttle position. Because the throttle is spring- Push this switch to crank the engine with the start- loaded, the ATV will decelerate, and the engine will er.

  • Page 31: Clutch Lever

    2. To increase the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (a). To de- crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b).

  • Page 32: Brake Lever

    1. Clutch lever 1. Brake lever EBU18411 EBU18432 Brake lever Brake pedal The brake lever is located at the right handlebar The brake pedal is located on the right side of the grip. To apply the front brake, pull the brake lever ATV.

  • Page 33: Parking Brake Lever

    1. Brake pedal 1. Parking brake lever (locked position) EBU18520 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a).

  • Page 34: Shift Pedal

    EWB00220 WARNING ● Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. ● Always be sure you have released the park- ing brake before you begin to ride.

  • Page 35: Fuel Tank Cap

    1. Drive select lever 1. Fuel tank cap EBU18720 EBU18755 Fuel tank cap Fuel Remove the fuel tank cap by turning it counter- Make sure there is sufficient gasoline in the tank. clockwise. EWB02521 WARNING Gasoline and gasoline vapors are extremely flammable.
  • Page 36 of sparks, open flames, or other sources of ig- Recommended fuel: nition such as the pilot lights of water heaters UNLEADED GASOLINE ONLY and clothes dryers. For Europe: Regular unleaded gasoline only 2. Do not overfill the fuel tank. When refueling, with a research octane number of 95 or be sure to insert the pump nozzle into the fuel higher...

  • Page 37: Fuel Cock

    Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane 1. Arrow mark pointing to “OFF”...

  • Page 38: Starter (Choke)

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

  • Page 39: Seat

    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. Seat lock lever 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 1.

  • Page 40: Adjusting The Front Shock Absorber Assemblies

    Uneven adjustment can cause poor handling A special wrench can be obtained at a Yamaha and loss of stability, which could lead to an ac- dealer to make this adjustment.

  • Page 41: Adjusting The Rear Shock Absorber Assembly

    ECB01090 NOTICE Never turn the adjusting mechanism beyond the minimum and maximum settings. Adjust the spring preload as follows. 1. Loosen the locknut. 2. Turn the spring preload adjusting nut in direc- tion (a) to increase the spring preload and thereby harden the suspension, and in direc- tion (b) to decrease the spring preload and thereby soften the suspension.
  • Page 42 Spring preload setting: Minimum (soft): ● A special wrench can be obtained at a Yamaha Distance A = 233.5 mm (9.19 in) dealer to make this adjustment. Standard: ● The spring preload setting is determined by Distance A = 228.5 mm (9.00 in) measuring distance A, shown in the illustration.
  • Page 43 ● Do not deform or damage the cylinder in any way. ● 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. 4-16...

  • Page 44: 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 45 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. Rear brake 5-3, 8-23, 8-24, 8-26 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.

  • Page 46: Fuel

    Check that there is no free play in the brake le- do not provide proper braking performance, check ver. If there is free play, have a Yamaha dealer the brake pads for wear. (See page 8-23.) check the brake system.

  • Page 47: Drive Chain

    EBU19770 Recommended tire pressure: Drive chain Front Check the condition of the drive chain and check 25.0 kPa (0.250 kgf/cm², 3.6 psi) the drive chain slack. Lubricate and adjust the Rear drive chain as necessary. (See page 8-30.) 25.0 kPa (0.250 kgf/cm², 3.6 psi) Minimum tire pressure: EBU19794 Tires...
  • Page 48 EWB02551 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

  • Page 49: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are DURO/DI-K158B working properly. Correct if necessary. Size: AT21 x 7-10 Type: Tubeless Rear: Manufacturer/model: DURO/DI-K778A Size: AT20 x 10-9 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling,...

  • Page 50: Operation

    If the indicator Read the Owner’s Manual carefully before riding light does not come on, have a Yamaha deal- the ATV. If there is a control or function you do not er check the electrical circuit.
  • Page 51 Position (3): as possible to preserve battery energy. Do not Cold engine start with ambient temperature crank the engine more than 10 seconds on each above 25 °C (80 °F). attempt. Ambient temp./starter (choke) position 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine.

  • Page 52: Starting A Warm Engine

    EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. EBU20341 Operating the drive select lever and driving in reverse ECB00170...

  • Page 53: Shifting

    When in reverse, the reverse indicator light should lease the clutch. be on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 5. Check behind you for people or obstacles, and then release the brake pedal.
  • Page 54 8. Follow the same procedure when shifting to EBU20593 To start out and accelerate the next higher gear. 1. Release the throttle lever, apply the front or rear brake, and then release the parking EBU20650 To decelerate brake. When slowing down or stopping, release the throt- 2.

  • Page 55: Engine Break-In

    There is never a more important period in the life of engine break-in period, immediately have a your engine than the first 320 km (200 mi) or 20 Yamaha dealer check the ATV. hours of riding. For this reason, you should read the following material carefully.

  • Page 56: Parking

    incline, shift into first gear, stop the engine, ap- EBU20722 Parking ply the parking brake, and then block the front When parking the ATV, shift into first gear, stop the and rear wheels with rocks or other objects. engine, apply the parking brake, and then turn the Never park the ATV on hills that are too steep fuel cock to “OFF”.

  • Page 57: Accessories And Loading

    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- ●...
  • Page 58 ● If you are carrying cargo and towing a trailer, in- EBU20941 Loading clude the tongue weight in the maximum ATV EWB00820 load limit. WARNING ● Load cargo on the carriers as close to the center Never exceed the stated load capacity for this of the ATV as possible.

  • Page 59: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 60: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EBU21617 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 61 Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
  • Page 62 proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. [EWB01411] Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision.
  • Page 63 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 64 opening, even when the throttle lever is pushed to ● Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see “MAXIMUM LOADING the maximum engine power available and de- LIMIT” below or vehicle labeling). ●...
  • Page 65 All parts and accessories added to this ATV should be genuine Yamaha or equivalent components de- signed for use on this ATV and should be installed and used according to instructions. If you have...
  • Page 66 WARNING! Operating this ATV with improper erating in areas where combustible materials may modifications may cause changes in handling have collected. Do not idle or park the vehicle in which in some situations could lead to an acci- long dry grass or other dry ground cover. dent.

  • Page 67: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE Watch carefully for other vehicles. Make sure you This ATV is designed for use on unpaved surfaces know your country’s laws and regulations before only. WARNING! Paved surfaces may seriously you ride on unpaved public streets or roads. Do not affect handling and control of the ATV, and ride on any paved public street, road or motorway.
  • Page 68 have enough time to react to hidden rocks, loose terrain could cause loss of traction or bumps, or holes. Go slowly and be extra care- ATV control, which could result in an accident, ful when operating on unfamiliar terrain. Al- including an overturn.
  • Page 69 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.

  • Page 70: Turning Your Atv

    trol. NOTICE: Do not shift gears without To achieve maximum traction on unpaved surfac- [EWB02631] releasing the throttle. Damage to the engine or es, the two rear wheels turn together at the same drive train may occur. speed. Therefore, unless the wheel on the inside [ECB01071] Use this same procedure as you move into the of the turn is allowed to slip or lose some traction,...

  • Page 71: Climbing Uphill

    Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. 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.
  • Page 72 ● Shift your weight forward. ● Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards. ● Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
  • Page 73 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footrests and leaning forward over the handlebars. Whenever possible, ride straight up hills.

  • Page 74: Riding Downhill

    If you start to roll backwards, DO NOT apply the rear brake, and apply the front brake gradually. The ATV could easily tip over backwards. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount the ATV im- mediately on the uphill side or to a side if pointed straight uphill.
  • Page 75 ● Never operate the ATV on hills too steep for Whenever possible, ride your ATV straight down- the ATV or for your abilities. The ATV can hill. Avoid sharp angles which could allow the ATV overturn more easily on extremely steep hills to tip or roll over.

  • Page 76: Crossing A Slope

    CROSSING A SLOPE As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the EWB01632 WARNING steering when riding on loose surfaces by pointing Improperly crossing hills or turning on hills the front wheels slightly uphill.

  • Page 77: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER EWB01641 WARNING Operating this vehicle through deep or fast- flowing water can lead to loss of control or an overturn. To reduce your risk of drowning or other injuries, use care when crossing through water. Never operate this ATV water deeper than the depth specified in your Owner’s Man- ual, as tires may float, increasing the risk of an overturn.

  • Page 78: Riding Over Rough Terrain

    1. Air filter case check hose RIDING OVER ROUGH TERRAIN EWB01651 After riding your ATV in water, be sure to drain the WARNING trapped water by removing the check hose at the Riding improperly over obstacles could cause bottom of the air filter case. NOTICE: Undrained loss of control or a collision.

  • Page 79: Sliding And Skidding

    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 Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 80: What To Do If

    WHAT TO DO... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footrest to the outside of the turn. Position your weight over the front wheels for better control.
  • Page 81 ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 82: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 83: Owner's Manual And Tool Kit

    If you do not have the tools or experience required seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s tool kit 2. Owner’s manual 3.

  • Page 84: 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. INITIAL...
  • Page 85 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 86: 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. INITIAL...
  • Page 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 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 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Make sure that all nuts, bolts, and screws are √ √ √ √ √ Chassis fasteners properly tightened. Shock absorber as- •...
  • Page 89 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation. • Check throttle lever free play, and adjust if neces- √ √ √ √ √ 23 * Throttle lever sary.

  • Page 90: Checking The Spark Plug

    2. Remove the spark plug as shown, with the EBU23213 Checking the spark plug spark plug wrench included in the owner’s tool The spark plug is an important engine component, kit. which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica-...
  • Page 91 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not 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 92: Engine Oil And Oil Filter Element

    Tightening torque: Spark plug: If the engine was started before checking the oil 18 Nm (1.8 m·kgf, 13 ft·lbf) 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. If a torque wrench is not available when installing 3.
  • Page 93 To change the engine oil (with or without oil fil- ter element cleaning) 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.
  • Page 94 1. Oil filter element cover 1. Engine oil drain bolt 2. Bolt 2. O-ring 3. Oil filter element 3. Compression spring 4. O-ring 4. Oil strainer 6. Clean the oil strainer and oil filter element with solvent. Skip steps 5–9 if the oil filter element is not being 7.
  • Page 95 engine oil drain bolt, be sure to install the Tightening torque: O-ring, compression spring and oil strain- Oil filter element cover bolt: [ECB00321] 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tightening torque: 10. Apply a thin coat of clean engine oil to a new Engine oil drain bolt: O-ring.

  • Page 96: Cleaning The Air Filter Element

    ECB00300 NOTICE There is a check hose at the bottom of the air filter ● In order to prevent clutch slippage (since the case. If dust or water collects in this hose, empty engine oil also lubricates the clutch), do not the hose and clean the air filter element and air fil- mix any chemical additives.
  • Page 97 1. Air filter case cover 1. Air filter element 2. Air filter case cover holder 5. Turn the air filter element retaining plate 1/4 4. Pull the air filter element out of the air filter turn, and then remove the plate from the air fil- case.
  • Page 98 4. Air filter element seat damaged. 7. Wash the sponge material gently but thor- 10. Apply Yamaha foam air filter oil or other qual- oughly in solvent. WARNING! Always use ity foam air filter oil to the sponge material. parts cleaning solvent to clean the sponge material.

  • Page 99: Cleaning The Spark Arrester

    12. Install the air filter element retaining plate onto the air filter element will affect carburetor the air filter element frame, and then turn the jetting with subsequent poor performance plate 1/4 turn to align the arrow marks on the and possible engine overheating.
  • Page 100 1. Tailpipe 1. Tailpipe bolt 2. Spark arrester 2. Tailpipe 4. Insert the tailpipe into the muffler and align the 2. Remove the tailpipe by pulling it out of the bolt holes. muffler. 5. Install the bolt and tighten it to the specified 3.

  • Page 101: Adjusting The Carburetor

    Tightening torque: Purging bolt: 27 Nm (2.7 m·kgf, 20 ft·lbf) EWB02380 WARNING Never run the engine in an enclosed area when purging the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monox- ide poisoning, possibly leading to death, and start a fire.

  • Page 102: Adjusting The Engine Idling Speed

    Yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment The engine is warm when it quickly responds to the described in the following section, however, may throttle. be performed by the owner as part of routine main- tenance.

  • Page 103: Adjusting The Throttle Lever Free Play

    To prevent this from occurring, the valve clearance 1. Slide the rubber cover back. must be adjusted by a Yamaha dealer at the inter- 2. Loosen the locknut. vals specified in the periodic maintenance and lu- 3.

  • Page 104: Brakes

    If a brake pad has worn to the point that a wear indicator groove almost appears, have that a wear indicator groove almost appears, have a Yamaha dealer replace the brake pads as a set. a Yamaha dealer replace the brake pads as a set. 8-23...

  • Page 105: Checking The Brake Fluid Level

    Front brake 1. Wear indicator groove 1. Minimum level mark EBU29841 Rear brake Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid lev- el with the top of the reservoir level. Replenish the brake fluid if necessary.

  • Page 106: Changing The Brake Fluid

    Clean the filler cap before removing. Use age. If the brake fluid level goes down suddenly, only DOT 4 brake fluid from a sealed contain- have a Yamaha dealer check the cause before fur- ther riding. ● Use only the specified brake fluid; otherwise,...

  • Page 107: Checking The Front Brake Lever Free Play

    If the brake pedal is not positioned as spec- intervals specified in the periodic maintenance and ified, have a Yamaha dealer adjust it. lubrication chart. The brake lever should have no free play as shown. If there is free play, have a Yamaha dealer check the brake system.
  • Page 108 If the cable length cannot be adjusted to specifica- 2. Fully loosen the locknut and the adjusting bolt tion, consult a Yamaha dealer. at the rear brake caliper. 3. Slide the rubber cover back at the brake ca- 6.

  • Page 109: Brake Light Switches

    The brake light switch for the brake pedal can be that it does not turn together with the lock- adjusted as follows, but the front brake light switch nut. should be adjusted by a Yamaha dealer. [ECB00521] Turn the rear brake light switch adjusting nut while Tightening torque: holding the brake light switch in place.
  • Page 110 The clutch lever free play should measure 5.0– 10.0 mm (0.20–0.39 in) as shown. If the free play If the specified clutch lever free play could be ob- is incorrect, adjust it as follows. tained as described above, skip steps 4–8. 1.

  • Page 111: Drive Chain Slack

    If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal clutch mechanism. EBU24845 Drive chain slack The drive chain slack should be checked before 1.
  • Page 112 There are alignment marks on both drive chain pullers and an alignment mark on each side of the swingarm. Make sure to align the same alignment mark on both drive chain pullers with the alignment mark on either side of the swingarm for proper wheel alignment.

  • Page 113: Lubricating The Drive Chain

    Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf) Axle holding bolt (upper): 120 Nm (12 m·kgf, 87 ft·lbf) Axle holding bolt (lower): 73 Nm (7.3 m·kgf, 53 ft·lbf) EBU24882 Lubricating the drive chain The drive chain must be cleaned and lubricated at 1.

  • Page 114: Checking And Lubricating The Brake And Clutch Levers

    If a cable is damaged or does not move EBU24922 Checking and lubricating the brake and smoothly, have a Yamaha dealer check or replace clutch levers The operation of the brake and clutch levers Recommended lubricant: should be checked before each ride, and the lever Yamaha Chain and Cable Lube or engine oil pivots should be lubricated if necessary.

  • Page 115: Checking And Lubricating The Brake And Shift Pedals

    Clutch lever Brake pedal Shift pedal EBU28841 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease 8-34...

  • Page 116: Checking The Wheel Hub Bearings

    Lubricating the rear suspension relay in a wheel hub or if a wheel does not turn smoothly, arm and connecting arm pivoting have a Yamaha dealer check the wheel hub bear- points ings. The rear suspension relay arm and connecting...

  • Page 117: Lubricating The Upper And Lower Arm Pivots

    1. Grease nipple 1. Grease nipple EBU25033 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. For parts equipped with a grease nipple, use a grease gun.

  • Page 118: Lubricating The Steering Shaft

    2. Lower grease nipple 2. Lower grease nipple EBU25092 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. For parts equipped with a grease nipple, use a grease gun.

  • Page 119: Battery

    KEEP OUT OF REACH OF CHILDREN. EBU2522E Battery ECB00620 The battery is located under the seat. (See page NOTICE 4-12.) Never attempt to remove the battery cell seals, This model is equipped with a VRLA (Valve Regu- as this would permanently damage the battery. lated Lead Acid) battery.
  • Page 120 To charge the battery damage. Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in To install the battery mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.

  • Page 121: Replacing The Fuse

    2. Connect the positive battery lead first, then EBU25243 Replacing the fuse connect the negative battery lead by installing their bolt. NOTICE: When installing the bat- tery, the main switch must be off, and the positive lead must be connected before the negative lead.

  • Page 122: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25542 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 123 3. Remove the burnt-out bulb from the headlight 5. Install the headlight bulb holder by aligning the unit by pulling it out. projections with the holes in the headlight unit, pushing it inward, and turning it clockwise until 4. Install a new headlight bulb into the headlight unit by aligning the projection on the bulb with it stops.

  • Page 124: Adjusting A Headlight Beam

    If the tail/brake light bulb burns out, replace it as NOTICE follows. 1. Remove the lens by removing the screws. It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a).

  • Page 125: Removing A Wheel

    1. Wheel nut 1. Tail/brake light bulb 3. Elevate the ATV and place a suitable stand 3. Insert a new bulb into the socket, push it in, under the frame. and then turn it clockwise until it stops. 4. Remove the nuts from the wheel. 4.

  • Page 126: 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 127: 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 128: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE may cause water seepage and deteriora- EBU25902 Cleaning tion of wheel bearings, brakes, transmis- Frequent, thorough cleaning of your ATV will not sion seals and electrical devices. Many only enhance its appearance but will improve its expensive repair bills have resulted from general performance and extend the useful life of improper high-pressure detergent applica-...

  • Page 129: Storage

    EBU25933 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 inder, piston rings, etc.
  • Page 130 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.

  • Page 131: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 1780 mm (70.1 in) Air cooled 4-stroke, SOHC Overall width: Cylinder arrangement: 1095 mm (43.1 in) Single cylinder Overall height: Displacement: 1080 mm (42.5 in) 349 cm³ Bore × stroke: Seat height: 83.0 ×...
  • Page 132 Type: Fuel tank capacity: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- 9.0 L (2.38 US gal, 1.98 Imp.gal) Fuel reserve amount: 2.7 L (0.71 US gal, 0.59 Imp.gal) Carburetor: 130 ˚F Type × quantity: BSR36 x 1 SAE 5W-30 Spark plug (s): SAE 10W-30 Manufacturer/model:...
  • Page 133 Gear ratio: Rear tire: 1st: Type: 36/16 (2.685) Tubeless 2nd: Size: 33/20 (1.969) AT20 x 10-9 3rd: Manufacturer/model: 29/23 (1.504) DURO/DI-K778A 4th: Loading: 27/26 (1.239) Maximum loading limit: 5th: 100.0 kg (220 lb) 25/28 (1.065) (Total weight of rider, cargo, accessories, and tongue) 6th: Tire air pressure (measured on cold tires): 23/29 (0.946)
  • Page 134 Rim size: Electrical system: 9 x 8.0AT Ignition system: Front brake: DC CDI Type: Charging system: Disc brake AC magneto Battery: Operation: Right hand operation Model: Specified brake fluid: YTZ10S DOT 4 Voltage, capacity: Rear brake: 12 V, 8.6 Ah Headlight: Type: Disc brake...
  • Page 135 EBU30401 For Europe only The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of work-force include the characteristics of the work room, the other sources of noise, etc.

  • Page 136: Consumer Information

    Record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 137 1. Model label 11-2...
  • Page 138 INDEX Drive select lever ............4-7 Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-8 Air filter element, cleaning ..........8-15 Engine break-in .............. 6-6 Engine, cold start ............6-1 Battery ................8-38 Engine idling speed ............8-21 Brake and clutch levers, checking and lubricating ..
  • Page 139 Maintenance and lubrication chart ......... 8-5 Suspension, lubricating the upper and Maintenance chart, emission control system ....8-3 lower arm pivots ............8-36 Model label ..............11-1 Suspension relay arm and connecting arm pivoting points, lubricating the rear ......... 8-35 Swingarm pivots, lubricating ........
  • Page 140 EBU26162 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER CARRY NEVER USE NEVER USE AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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