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Yamaha GRIZZLY 350 YFM35FGZ Owner's Manual

Yamaha GRIZZLY 350 YFM35FGZ Owner's Manual


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Table of Contents
It contains important safety information.
Il comprend d'importantes informations de sécurité.
Contiene indicaciones importantes acerca de la seguridad.


Table of Contents

Summary of Contents for Yamaha GRIZZLY 350 YFM35FGZ

  • 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 YFM35FGZ YFM350FAZ 1AB-F8199-60...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2009.04-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35FGZ YFM350FAZ 1AB-F8199-60-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, 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM350FWA (YFM35FG) (5Y4AH13W090513067–)
  • Page 5 Congratulations on your purchase of the Yamaha YFM35FGZ/YFM350FAZ. 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. EBU17410 YFM35FGZ/YFM350FAZ 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 ............4-10 SPECIFICATION LABELS ......1-1 Fuel cock ..........4-12 Starter (choke) ..........4-13 SAFETY INFORMATION ......2-1 Seat ............4-14 Storage compartment .......4-15 DESCRIPTION ..........3-1 Front carrier ..........4-16 Left view ............3-1 Rear carrier ..........4-16 Right view............
  • Page 9 OPERATION ..........6-1 PERIODIC MAINTENANCE AND Starting a cold engine ........ 6-1 ADJUSTMENT..........8-1 Starting a warm engine ......6-3 Owner’s manual and tool kit .......8-1 Operating the drive select lever and Periodic maintenance chart for the driving in reverse ........6-3 emission control system ......8-3 Engine break-in ..........
  • Page 10 Checking the front brake lever free SPECIFICATIONS ........10-1 play ............8-30 Adjusting the brake pedal and rear brake CONSUMER INFORMATION.......11-1 lever free play and checking the brake Identification numbers .......11-1 pedal position ......... 8-31 Axle boots ..........8-34 Brake light switches ......... 8-34 Checking and lubricating the cables ..
  • 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 < 40 kg ( 88 lbs) 37S-F817R-00 1P0-F816P-20 < 80 kg ( 176 lbs) 37S-F817R-10 25.0 kPa 25.0 kPa 0.25 kgf/cm² 0.25 kgf/cm² 3.6 psi 3.6 psi < 5FU-F816M-M0 4900 N < 500 kgf < 1102 lbf < 147 N <...
  • Page 13 1P0-F816L-20 YEAR OF CONSTRUCTION : 2009 MODEL : YFM350FWA YAMAHA MOTOR CO., LTD. MAX.POWER : 15.9 kW 1P0-F816R-00 2500 SHINGAI, IWATA, JAPAN MASS IN RUNNING ORDER : 258 kg 1AB-F155A-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 LOAD LIMIT 40 kg{88 lbs} 5ND-F4877-20 LOAD LIMIT 25 kPa, (3.6 psi) 80 kg{176 lbs} 25 kPa, (3.6 psi) 22 kPa, (3.2 psi) 22 kPa, (3.2 psi) 5ND-F4897-20 MAXIMUM LOADING LIMIT PULLING LOAD: 4900 N (500 kgf) 1102 lbf 5FU-F816M-20 TONGUE WEIGHT: 147 N ( 15 kgf) 33 lbf...
  • Page 20: Safety Information

    EBU17431 SAFETY INFORMATION EBU17563 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 21 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 22 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 23 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT.
  • Page 24: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 10 9 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.
  • Page 25: 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 26: Instrument And Control Functions

    EBU17733 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 27: Indicator Lights And Warning Light

    If the warning light stays on, allow the engine to 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 “ ” circuit.
  • Page 28: 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 29: Handlebar Switches

    EBU18061 EBU18101 Start switch “ ” Handlebar switches Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. EBU18161 Light switch “ /OFF” Set this switch to “ ”...
  • Page 30: Throttle Lever

    EBU28432 To change from two-wheel drive to four-wheel On-Command four-wheel-drive switch drive, stop the ATV and push the switch in to the “2WD”/“4WD” “4WD” position. The four-wheel-drive indicator EWB00163 light “ ” comes on. WARNING To change from four-wheel drive to two-wheel Always stop the ATV before changing from drive, stop the ATV and push the switch in to the two-wheel drive to four-wheel drive and vice...
  • Page 31: Speed Limiter

    Regulate the speed of the ATV by varying the EBU18323 Speed limiter throttle position. Because the throttle is spring- Your ATV is equipped with an adjustable speed loaded, the ATV will decelerate, and the engine will limiter. The speed limiter keeps the throttle from return to an idle any time the throttle lever is re- fully opening, even when the throttle lever is leased.
  • Page 32: Front Brake Lever

    1. Locknut 1. Front brake lever 2. Adjusting screw EBU18442 3. No more than 12 mm (0.47 in) Brake pedal and rear brake lever 3. Tighten the locknut. The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left EBU18391 handlebar.
  • Page 33: 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 34: 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 35: Fuel Tank Cap

    1. Recoil starter 1. Fuel tank cap EWB00340 EBU18753 WARNING Fuel Shift the drive select lever into the neutral po- Make sure there is sufficient gasoline in the tank. sition and apply the parking brake before start- EWB02521 ing the engine, otherwise the ATV could start WARNING to move unexpectedly, which could cause an Gasoline and gasoline vapors are extremely...
  • 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 91 or high- be sure to insert the pump nozzle into the fuel tank filler hole.
  • Page 37: Fuel Cock

    doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. 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 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 2. Seat lock lever To install the seat Insert the projections on the front of the seat into 1.
  • Page 40: Storage Compartment

    1. Projection 1. Storage compartment 2. Seat holder Do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment. EBU18912 Storage compartment Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. ECB00130 NOTICE Do not store metal or sharply edged objects,...
  • Page 41: Front Carrier

    EBU18992 Adjusting the front shock absorber as- semblies The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. EWB00400 WARNING Always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident.
  • Page 42: Adjusting The Rear Shock Absorber Assembly

    1. Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: Maximum (hard): EBU19023 Adjusting the rear shock absorber as-...
  • Page 43 ECB01090 NOTICE A special wrench can be obtained at a Yamaha Never turn the adjusting mechanism beyond dealer to make this adjustment. the minimum and maximum settings. Adjust the spring preload as follows. Turn the spring preload adjusting ring in direction...
  • 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, and correct if necessary. Rear brake • Lubricate cables if necessary. 5-3, 8-28, 8-31 • Check lever and pedal free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary.
  • Page 46: Fuel

    Front and rear brakes system should be checked by a Yamaha dealer. Brake levers and brake pedal Check that there is no free play in the front brake lever. If there is free play, have a Yamaha dealer check the brake system.
  • Page 47: Throttle Lever

    Check the operation of the throttle lever. It must 25.0 kPa (0.250 kgf/cm², 3.6 psi) open smoothly and spring back to the idle position Minimum tire pressure: when released. Have a Yamaha dealer correct if Front necessary. 22.0 kPa (0.220 kgf/cm², 3.2 psi)
  • Page 48 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 Manufacturing Corporation of America.
  • Page 49: Chassis Fasteners

    EBU19840 Front: Chassis fasteners Manufacturer/model: Make sure that all nuts, bolts and screws are prop- YFM350FAZ CHENG SHIN/C-828 erly tightened. YFM35FGZ MAXXIS/M979 Size: EBU19850 Instruments, lights and switches AT25 x 8-12 Type: Check that all instruments, lights and switches are Tubeless working properly.
  • Page 50: Operation

    Read the Owner’s Manual carefully before riding on. If the indicator light does not come on, the ATV. If there is a control or function you do not have a Yamaha dealer check the electrical cir- understand, ask your Yamaha dealer. cuit.
  • Page 51 Position (3): Cold engine start with ambient temperature If the engine fails to start, release the start above 25 °C (80 °F). switch, then push it again. Pause a few seconds Ambient temp./starter (choke) position before the next attempt. Each cranking should be as short as possible to preserve battery ener- gy.
  • 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. EBU20381 Operating the drive select lever and driving in reverse ECB00170...
  • Page 53: Engine Break-In

    If the indicator light does not come on, For ATVs equipped with an odometer or an hour have a Yamaha dealer check the electrical circuit. meter, follow the figures given in km (mi) or the figures given in hours.
  • Page 54: Parking

    If any engine trouble should occur during the EWB00830 engine break-in period, immediately have a WARNING Yamaha dealer check the ATV. Avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the EBU20700...
  • Page 55: Accessories And Loading

    ATV. Many companies with no con- nection to Yamaha manufacture parts and acces- sories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies pro- duce. Therefore, Yamaha can neither endorse nor...
  • Page 56 market products or having other modifications EBU21061 Loading performed to your ATV that change any of the ve- EWB00820 hicle’s design or operation characteristics can put WARNING you and others at greater risk of serious injury or Never exceed the stated load capacity for this death.
  • Page 57 Load cargo on the carriers as close to the center MAXIMUM LOADING LIMIT of the ATV as possible. Put cargo at the rear of ATV loading limit (total weight of rider, cargo, the front carrier, at the front of the rear carrier, accessories, and tongue): and center it.
  • Page 58: Riding Your Atv

  • Page 59: Getting To Know Your Atv

    EBU21465 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding Do not operate this ATV or allow anyone else instructions for recreational riding.
  • Page 60 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 61 Apparel Always wear the following to reduce risk of injury in an accident: Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 62 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 63 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 box in this section or ve- the maximum engine power available and de- hicle labeling).
  • Page 64 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of cargo, rider, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 210.0 kg (463 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
  • Page 65 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 66: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 67 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do not ways be alert to changing terrain conditions ride on any paved public street, road or motorway. when operating the ATV.
  • Page 68 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] 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.
  • Page 69: Turning Your Atv

    Select a large, flat, unpaved area to become famil- TURNING YOUR ATV iar with your ATV. Make sure that this area is free EWB01771 WARNING of obstacles and other riders. You should practice control of the throttle, brakes, and turning tech- Always follow proper procedures for turning niques in this area before trying more difficult ter- as described in this Owner’s Manual.
  • Page 70: 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 71 Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground.
  • Page 72 Do not attempt to climb hills until you have mas- If you are climbing a hill and you find that you have tered basic maneuvers on flat ground. Always not properly judged your ability to make it to the check the terrain carefully before attempting any top, you should turn the ATV around while you still hill.
  • Page 73: Riding Downhill

    remount, following the procedure described in the Always check the terrain carefully before Owner’s Manual. WARNING! Stalling, rolling you start down any hill. backwards or improperly dismounting while Never operate the ATV on hills too steep for climbing a hill could result in ATV overturning. the ATV or for your abilities.
  • Page 74: Crossing A Slope

    Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this ATV is in “4WD”, all wheels (front and rear) are interconnected by the drive train.
  • Page 75: Crossing Through Shallow Water

    Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill.
  • Page 76 The ATV can be used to cross slow moving, shal- ability. WARNING! Wet brakes may have re- low water of up to a maximum of 35 cm (14 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.
  • Page 77 1. Air filter case check hose 1. Drive select lever box check hose 1. V-belt cooling duct check hose (left front side of ATV) 1. Storage compartment check hose 7-20...
  • Page 78: Riding Over Rough Terrain

    cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may re- sult. SLIDING AND SKIDDING EWB01662 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.
  • Page 79: What To Do If

    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 80: What To Do

    WHAT TO DO... If your ATV is traversing a sloping surface: If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.
  • Page 81: Periodic Maintenance And Adjustment

    If you are not fa- EBU21731 miliar with vehicle service, have a Yamaha Owner’s manual and tool kit dealer perform the service. Be sure to put this owner’s manual in the plastic...
  • Page 82 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 it for you.
  • Page 83: 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 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 leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.
  • Page 85: 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 86 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 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Change. √ √ √ √ Engine oil • Check ATV for oil leakage, and correct if neces- sary.
  • Page 88 EBU28391 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 cylinder and calipers, and change the brake fluid.
  • Page 89: 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 90 If the spark plug shows a distinctly different color, kit. the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-10...
  • Page 91 2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.
  • Page 92: Engine Oil And Oil Filter Cartridge

    EBU23317 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals spec- ified in the periodic maintenance and lubrication chart.
  • Page 93 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then re- move the engine oil drain bolt to drain the oil from the crankcase.
  • Page 94 An oil filter wrench is available at a nearby Yamaha dealer. 6. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. Make sure that the O-ring is properly seated. 1. Oil filter cartridge 1.
  • Page 95 Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.20 L (2.33 US qt, 1.94 Imp.qt) With oil filter cartridge replacement: 2.30 L (2.43 US qt, 2.02 Imp.qt) Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down.
  • Page 96: Final Gear Oil

    If any leakage is found, have 1. Final gear oil a Yamaha dealer check and repair the ATV. In ad- 2. Final gear oil filler bolt dition, the final gear oil level must be checked and 3.
  • Page 97 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 98: Changing The Differential Gear Oil

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, 1. Final gear oil have a Yamaha dealer check and repair the ATV. 2. Final gear oil filler bolt 3. Correct oil level...
  • Page 99 Tightening torque: Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 5. Refill with the specified amount of the recom- mended differential gear oil. NOTICE: Be sure no foreign material enters the differ- ential gear case. [ECB00411] Do not exceed the specified differential gear oil quantity when filling.
  • Page 100: Cleaning The Air Filter Element

    Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23646 Cleaning the air filter element The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart.
  • Page 101 1. Air filter case cover holder 1. Air filter element 2. Air filter case cover 5. Pull off the air filter element lock plate, and 4. Pull the air filter element out of the air filter then remove the sponge material from the air case.
  • Page 102 2. Sponge material damaged. 3. Air filter element lock plate 9. Apply Yamaha foam air filter oil or other qual- 6. Wash the sponge material gently but thor- ity foam air filter oil to the sponge material. oughly in solvent. WARNING! Always use...
  • Page 103: Cleaning The Spark Arrester

    case. Never operate the engine with the air filter element removed. This will allow un- filtered air to enter the engine, causing rap- id engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating.
  • Page 104: V-Belt Cooling Duct Check Hose

    EWB02340 WARNING Do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire. Always let the exhaust system cool prior to touching exhaust components.
  • Page 105: 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 106 1450–1550 r/min tle stop screw in direction (a), and to decrease 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. 8-26...
  • Page 107: Adjusting The Throttle Cable Free Play

    (b). 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 108: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm es with use, which can result in improper function. (0.04 in), have a Yamaha dealer replace the brake Therefore, the safety system cable should be pads as a set.
  • Page 109: Checking The Brake Fluid Level

    If the Yamaha dealer replace the brake shoes as a set. brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.
  • Page 110: 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. No free play maintenance and lubrication chart. In addition,...
  • Page 111 EBU24514 Adjusting the brake pedal and rear brake lever free play and checking the brake pedal position The brake pedal and brake lever free play must be checked and, if necessary, adjusted at the inter- vals specified in the periodic maintenance and lu- brication chart.
  • Page 112 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 113 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. 8-33...
  • Page 114: Axle Boots

    Yamaha dealer. brication chart. 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 8-9.) 8-34...
  • Page 115: Checking And Lubricating The Cables

    If a cable is damaged or does not move 2. Turn the brake light switch adjusting nut while smoothly, have a Yamaha dealer check or replace holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a).
  • Page 116: Checking And Lubricating The Front And Rear Brake Levers

    EBU28711 Rear brake lever Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Recommended lubricants: Front brake lever: Silicone grease Rear brake lever: Lithium-soap-based grease...
  • Page 117: Checking The Wheel Hub Bearings

    EBU24963 Lubricating the steering shaft Checking the wheel hub bearings The steering shaft must be lubricated by a Yamaha The front and rear wheel hub bearings must be dealer at the intervals specified in the periodic checked at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 118: Battery

    EBU29184 Batteries produce explosive gases. Keep Battery sparks, flame, cigarettes or other sources of ig- This model is equipped with a VRLA (Valve Regu- nition away. Ventilate when charging or using lated Lead Acid) battery. There is no need to check in an enclosed space.
  • Page 119 To charge the battery ECB00940 Have a Yamaha dealer charge the battery as soon NOTICE as possible if it seems to have discharged. Keep in Always keep the battery charged. Storing a dis-...
  • Page 120: Replacing A Fuse

    To install the battery EBU25326 Replacing a fuse The main fuse and the fuse box are located under Be sure the battery is fully charged. the seat. (See page 4-14.) 1. Place the battery in its compartment. 2. Connect the positive battery lead first, then connect the negative battery lead by installing their bolt.
  • Page 121 3. Turn the key to “ON” and turn on the electrical the main switch when checking or replacing a circuits to check if the devices operate. fuse. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 8-41...
  • Page 122: Replacing A Headlight Bulb

    EBU25481 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. 1. Headlight bulb holder cover 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise.
  • Page 123: Adjusting A Headlight Beam

    ECB00690 moistened with alcohol or thinner. [ECB00651] NOTICE 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). To lower a headlight beam, turn the adjusting screw in direction (b).
  • Page 124: Replacing The Tail/Brake Light Bulb

    Replacing the tail/brake light bulb under the frame. 4. Remove the nuts from the wheel. If the tail/brake light bulb burns out, have a 5. Remove the wheel. Yamaha dealer replace it. EBU25701 EBU25651 Installing a wheel Removing a wheel 1.
  • Page 125 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 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 EBU25881 tion of wheel bearings, brakes, transmis- Cleaning sion seals and electrical devices. Many Frequent, thorough cleaning of your ATV will not expensive repair bills have resulted from only enhance its appearance but will improve its improper high-pressure detergent applica- general performance and extend the useful life of tions such as those available in coin-oper-...
  • 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 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 cm³ Bore × stroke: Seat height: 83.0 ×...
  • Page 132 Type: Differential gear oil: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- Type: SAE 80 API GL-4 Hypoid gear oil Quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt) 50 ˚C Air filter: Air filter element: SAE 5W-30 Wet element SAE 10W-30 Fuel: Recommended fuel: SAE 10W-40...
  • Page 133 Secondary reduction system: Manufacturer/model: Shaft drive YFM350FAZ CHENG SHIN/C-828 Secondary reduction ratio: YFM35FGZ MAXXIS/M980 41/21 × 24/18 × 33/9 (9.545) Loading: Transmission type: Maximum loading limit: V-belt automatic 210.0 kg (463 lb) Operation: (Total weight of rider, cargo, accessories, and tongue) Left hand operation Tire air pressure (measured on cold tires): Forward gear:...
  • Page 134 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: 12 V, 30/30 W × 2 Operation: Left hand and right foot operation Tail/brake light: 12 V, 5.0/21.0 W ×...
  • Page 135 Auxiliary DC jack fuse: 10.0 A Four-wheel-drive motor fuse: 3.0 A 10-5...
  • Page 136 Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 137 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 138 1. Model label 11-3...
  • Page 139 INDEX Differential gear oil, changing ........8-18 Drive select lever ............4-9 Accessories and loading ..........6-6 Drive select lever and driving in reverse ......6-3 Air filter element, cleaning ..........8-20 Drive select lever safety system cable, adjusting ..8-28 Axle boots ..............
  • Page 140 Spark arrester, cleaning ..........8-23 Spark plug, checking ............8-9 Key identification number ..........11-1 Specifications ............... 10-1 Speed limiter ..............4-6 Label locations ............... 1-1 Speedometer ..............4-3 Light switch ..............4-4 Starter (choke) ............. 4-13 Start switch ..............4-4 Main switch ..............
  • Page 142 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2009.04-0.3×1 CR...

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