Yamaha GRIZZLY 350 YFM35FGDY Owner's Manual
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Yamaha GRIZZLY 350 YFM35FGDY 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
YFM35FGDY
4S2-F8199-62

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Summary of Contents for Yamaha GRIZZLY 350 YFM35FGDY

  • 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 YFM35FGDY 4S2-F8199-62...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2008.06-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35FGDY 4S2-F8199-62-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 98 / 37 /EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM350FWAN (5Y4AH15W080501601~)
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Fuel ............4-14 Fuel cock ..........4-15 LOCATION OF THE WARNING AND Starter (choke) ..........4-16 SPECIFICATION LABELS ......2-1 Seat ............4-17 Storage compartment .......4-18 DESCRIPTION ..........3-1 Front carrier ..........4-19 Left view ............3-1 Rear carrier ..........4-19 Right view............
  • Page 9 OPERATION ..........6-1 PERIODIC MAINTENANCE AND MINOR Starting a cold engine ........ 6-1 REPAIR ............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 Adjusting the brake pedal and rear brake CLEANING AND STORAGE ......9-1 lever free play and checking the brake Cleaning ............9-1 pedal position ......... 8-32 Storage ............9-2 Axle boots ..........8-36 Brake light switches ......... 8-37 SPECIFICATIONS ........10-1 Checking and lubricating the cables ..8-38 Checking and lubricating the front and CONSUMER INFORMATION.......11-1 rear brake levers ........

  • Page 11: Safety Information

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

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.
  • Page 18 MODEL: YFM350FWAN MAX. POWER: 15.9 kW MASS IN RUNNING ORDER: 275 kg 4S2-F155A-10...

  • Page 19: Description

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

  • Page 20: 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 21: Instrument And Control Functions

    EBU17732 INSTRUMENT AND CONTROL FUNCTIONS EBU17770 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights, meter lighting and taillight come on when the light switch is on, and the engine can be started.

  • Page 22: Indicator Lights And Warning Light

    EBU17813 Indicator lights and warning light If the indicator light flashes under any other circum- stances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. EBU17870 Neutral indicator light “NEUTRAL”...

  • Page 23: Speedometer

    On-Command differential gear lock indicator cool. If the warning light stays on when the engine light “ ” is cool, have a Yamaha dealer check the electrical This indicator light and the On-Command four- circuit. wheel-drive indicator light “ ” come on when the...

  • Page 24: Handlebar Switches

    EBU18061 Handlebar switches 1. Reset knob 2. Speedometer 3. Odometer 1. Light switch “ /OFF” 4. Tripmeter 2. Start switch “ ” 3. Engine stop switch “ ” 4. Override switch “OVERRIDE” 5. Horn switch “ ” EBU18080 Engine stop switch “ ”...
  • Page 25 EBU18100 EBU18170 Start switch “ ” Horn switch “ ” Push this switch to crank the engine with the start- Press the switch to sound the horn. EBU28510 ECB00050 Override switch “OVERRIDE” NOTICE See the starting instructions on page 6-1 prior to starting the engine.
  • Page 26 EWB00150 To change from two-wheel drive to four-wheel WARNING drive, stop the ATV and push the switch in to the “4WD” position. The four-wheel-drive indicator Always ride at a slow speed when the ATV is in light “ ” comes on. four-wheel-drive differential gear lock, and al- low extra time and distance for maneuvers.
  • Page 27 drive to four-wheel drive or vice versa while moving may cause the ATV to unexpectedly handle differently. This could distract the oper- ator and increase the risk of losing control and of causing an accident. EBU28371 On-Command differential gear lock switch “4WD”/“LOCK”...
  • Page 28 1. Differential gear lock lever 1. On-Command differential gear lock switch “4WD”/“LOCK” 2. On-Command four-wheel-drive switch “2WD”/“4WD” To release the differential gear lock, stop the ATV Stop the ATV, move the differential gear lock lever and push the switch to the “4WD” position. to position (a), and then push the differential gear EWB00131 WARNING...

  • Page 29: Throttle Lever

    pectedly. This could distract the operator and require full engine power to be available, push increase the risk of losing control and causing and hold the override switch to disable the differ- an accident. ential gear lock speed limiter. (See page 4-5 for a detailed explanation of this switch.) EWB00140 WARNING...

  • Page 30: Speed Limiter

    If the throttle does not work smoothly, check for the cause. Correct the problem be- fore riding the ATV or consult a Yamaha dealer. 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in)

  • Page 31: Front Brake Lever

    EBU18391 Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip. 1. Brake pedal 1. Front brake lever EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar.

  • Page 32: Parking Brake

    EBU18460 Always be sure you have released the park- Parking brake ing brake before you begin to ride. The brake Use the parking brake before starting the engine or could overheat if you ride the ATV without re- parking the ATV, especially on a slope. Apply the leasing the parking brake.

  • Page 33: Recoil Starter

    1. Drive select lever 1. Recoil starter EWB00340 EBU18670 WARNING Recoil starter Shift the drive select lever into the neutral po- Firmly grasp the handle and pull slightly until en- sition and apply the parking brake before start- gagement can be felt. Then pull forcefully, being ing the engine, otherwise the ATV could start careful not to pull the rope all the way out.

  • Page 34: Fuel

    1. Fuel tank cap 1. Fuel level 2. Fuel tank filler tube EBU28940 Fuel Recommended fuel: Make sure that there is sufficient fuel in the tank. Regular unleaded gasoline only with a re- Fill the fuel tank to the bottom of the filler tube as search octane number of 91 or higher shown.

  • Page 35: Fuel Cock

    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. EWB00310 WARNING Do not overfill the fuel tank. Fuel expands when it heats up.

  • Page 36: 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 37: 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 38: Storage Compartment

    ECB00130 NOTICE Do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartment. 1. Projection 2. Seat holder EBU18941 Storage compartment The storage compartment is located under the seat.

  • Page 39: Front Carrier

    EBU18971 Rear carrier There is a check hose at the bottom of the storage Do not exceed the load limit of 80.0 kg (176 compartment. If any water collects in this hose, re- lb) for the rear carrier. move the hose, empty it, and then install it. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV.
  • Page 40 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 Standard: dealer to make this adjustment. Maximum (hard): 4-20...
  • Page 41 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. 4-21...

  • Page 42: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 43 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-29, 8-30, 8-31 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 44: Fuel

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

  • Page 45: Throttle Lever

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

  • Page 46: Measuring The Tire Pressure

    Rear: • Use no more than the following pressures Manufacturer/model: when seating the tire beads. MAXXIS/M980 Maximum tire seating pressure: Size: Front: AT25 x 10-12 250 kPa (2.5 kgf/cm², 36 psi) Type: Rear: Tubeless 250 kPa (2.5 kgf/cm², 36 psi) The tires should be set to the recommended Higher pressures and fast inflation may pressure:...

  • Page 47: Tire Wear Limit

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

  • Page 48: Operation

    4. Shift the drive select lever into the neutral po- accident or injury. If there is a control or func- sition. The neutral indicator light should come tion you do not understand, ask your Yamaha on. If the indicator light does not come on, dealer.
  • Page 49 5. Use the starter (choke) in reference to the fig- 6. Completely close the throttle lever and start ure: the engine by pushing the start switch. Position (1): Cold engine start with ambient temperature If the engine fails to start, release the start below 5 °C (40 °F).

  • Page 50: Starting A Warm Engine

    The engine is warm when it responds normally to Make sure that the drive select lever is completely the throttle with the starter (choke) turned off. shifted into position. EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm.

  • Page 51: Engine Break-In

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

  • Page 52: Parking

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

  • Page 53: Accessories And Loading

    3. With the rear brake lever and pedal applied, may also be available on the market. However, apply the parking brake, and then slowly re- it is not possible for Yamaha to test all non- lease the brake pedal. Yamaha accessories, nor control over their qual- ity or suitability.
  • Page 54 could make steering difficult, an accessory that MAXIMUM LOADING LIMIT limits your ability to move around on the seat, or ATV loading limit (total weight of rider, cargo, one that limits your view. accessories, and tongue): Use extra caution when riding an ATV with ac- 210.0 kg (463 lb) cessories.
  • Page 55 Load cargo on the carriers as close to the center curely attached. Reduce speed when carrying of the ATV as possible. Put cargo at the rear of cargo or pulling a trailer. Allow greater dis- the front carrier, at the front of the rear carrier, tance for braking.

  • Page 56: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 57: Getting To Know Your Atv

    EBU28502 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV Beginners should get training from a certified in- This ATV is for recreation and utility use. This sec- structor. tion, Riding your ATV, provides general ATV riding Become familiar with this ATV at slow speeds first, instructions for recreational riding.
  • Page 58 Not recommended for children under 16 years This ATV is designed to carry operator and car- of age. go only – passengers prohibited. EWB01390 EWB01400 WARNING WARNING A child under 16 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 90 cc.
  • Page 59 Apparel Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet...
  • Page 60 EWB01410 WARNING Never operate this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 61 in the Owner’s Manual. Failure to inspect the Speed limiter ATV before operating or failure to properly For riders less experienced with this model, the maintain the ATV increases the possibility of throttle lever housing is equipped with a speed lim- an accident or equipment damage.
  • Page 62 Loading and accessories EWB01460 WARNING Use extra caution when riding the ATV with addi- tional loads, such as accessories or cargo. The Never exceed the stated load capacity for ATV’s handling may be adversely affected. Re- this ATV. duce your speed when adding additional loads. Cargo should be properly distributed and se- curely attached.
  • Page 63 All parts and tact with the rear wheels, which could injure accessories added to this ATV should be gen- you or cause an accident. uine Yamaha or equivalent components de- signed for use on this ATV and should be...

  • Page 64: Be Careful Where You Ride

    installed and used according to instructions. Improper installation of accessories or modifi- cation of this ATV may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized ATV dealer. Exhaust system The exhaust system on the ATV is very hot during and following operation.
  • Page 65 EWB01520 WARNING Never operate this ATV on any paved street, paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. While riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles.
  • Page 66 EWB01530 ATV on such terrain. Failure to use extra care WARNING when operating on excessively rough, slippery or loose terrain could cause loss of traction or Go slowly and be extra careful when operating ATV control, which could result in an accident, on unfamiliar terrain.
  • Page 67 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice EWB01550 control of the throttle, brakes, and turning tech- WARNING niques in this area before trying more difficult ter- Always mount a caution flag on the ATV to rain.

  • Page 68: Turning Your Atv

    With the engine idling, return the starter (choke) to must be used to allow the ATV to make turns the closed position, shift the drive select lever into quickly and easily. It is essential that this skill be the forward position, and then release the parking learned first at low speed.

  • Page 69: 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 70 EWB01580 Never go over the top of any hill at high WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never operate the ATV on hills too steep for the of the hill. ATV or for your abilities.
  • Page 71 EWB01600 WARNING Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.

  • Page 72: Riding Downhill

    could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediate- ly on the uphill side. EWB02450 WARNING Maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.

  • Page 73: Crossing A Slope

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

  • Page 74: Crossing Through Shallow Water

    to cross a sloping surface. Avoid slopes with slip- Shift your weight to the uphill side of the pery surfaces or rough terrain that may upset your ATV. balance. As you travel across a slope, lean your body in the uphill direction.
  • Page 75 EWB01640 Test your brakes after leaving the water. Do not WARNING continue to ride your ATV without verifying that you have regained proper braking ability. Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual.
  • Page 76 plug to drain any water that may have accumu- lated. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. 1. V-belt cooling duct check hose (left front side of ATV) 1. Air filter case check hose 1.

  • Page 77: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times.
  • Page 78 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 79: What To Do If

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

  • Page 80: Periodic Maintenance And Minor Repair

    EBU28782 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21670 otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with Safety is an obligation of the owner. Periodic in- maintenance work. spection, adjustment and lubrication will keep your...
  • Page 81 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING...

  • Page 82: 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 83 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 84: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
  • Page 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Drive shaft univer- √ √ √ • Lubricate with lithium-soap-based grease. sal joint • Make sure that all nuts, bolts, and screws are √...
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Change. √ √ √ Final gear oil • Check ATV for oil leakage, and correct if neces- sary.
  • Page 87 • Every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.

  • Page 88: 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 89 Do not kit. attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 90: Engine Oil And Oil Filter Cartridge

    3. Install the spark plug with the spark plug Specified spark plug: wrench, and then tighten it to the specified NGK/DR8EA torque. To install the spark plug Tightening torque: 1. Measure the spark plug gap with a wire thick- Spark plug: ness gauge and, if necessary, adjust the gap 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) to specification.
  • Page 91 2. Check the engine oil level on a cold engine. If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. 3.
  • Page 92 To change the engine oil (with or without oil fil- 4. Remove the oil filter cartridge with an oil filter ter cartridge replacement) wrench. 1. Start the engine, warm it up for several min- utes, and then turn it off. 2.
  • Page 93 An oil filter wrench is available at a nearby Yamaha dealer. 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. Make sure that the O-ring is properly seated. 1. Torque wrench Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf)

  • Page 94: Final Gear Oil

    Make sure that no foreign material enters the Final gear oil crankcase. The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- 8-15...
  • Page 95 dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the final gear oil level 1. Place the ATV on a level surface. The final gear oil level must be checked on a cold engine.
  • Page 96 2. Remove the engine guard and the final gear case guard by removing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the 1. Engine guard specified torque. 2. Final gear case guard 3.
  • Page 97 ECB00420 NOTICE Be sure no foreign material enters the final gear case. 7. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 24 Nm (2.4 m·kgf, 17 ft·lbf) 1. Final gear oil filler bolt 8.

  • Page 98: Differential Gear Oil

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil level must be checked and the oil changed as follows at the in- tervals specified in the periodic maintenance and lubrication chart.
  • Page 99 To change the differential gear oil 5. Refill with the recommended differential gear 1. Place the ATV on a level surface. oil to the brim of the filler hole as shown. 2. Place an oil pan under the differential gear case to collect the used oil.

  • 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. EBU23645 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 ECB00440 NOTICE Do not twist the sponge material when squeez- ing it. 1. Air filter element frame 2. Sponge material 3. Air filter element lock plate 6. Wash the sponge material gently but thor- oughly in solvent. 8. Check the sponge material and replace it if EWB01940 damaged.

  • Page 103: Cleaning The Spark Arrester

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

  • Page 104: V-Belt Cooling Duct Check Hose

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

  • Page 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 Engine idling speed: tle stop screw in direction (a), and to decrease 1450–1550 r/min it, turn the screw in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 8-27...

  • Page 107: Adjusting The Throttle Cable Free Play

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

  • Page 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

    A low brake fluid level may indicate worn the wear indicator reaches the wear limit mark, brake pads and/or brake system leakage. If the have a Yamaha dealer replace the brake friction brake fluid level is low, be sure to check the brake plates as a set.

  • 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. Brake lever free play maintenance and lubrication chart. In addition,...

  • Page 111: Adjusting The Brake Pedal And Rear Brake Lever Free Play And Checking The Brake Pedal Position

    Replacement of brake components requires play professional knowledge. These procedures The brake pedal free play should measure 17.0– should be performed by a Yamaha dealer. 20.0 mm (0.67–0.79 in). The brake lever free play should measure 8.0–10.5 mm (0.31–0.41 in). If ei- EBU28635 ther free play is incorrect, adjust it as follows.
  • Page 112 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 1. Brake pedal free play 1. Locknut 2. Brake lever free play adjusting bolt 2. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the final gear case.
  • Page 113 1. Brake lever free play adjusting nut 1. Brake pedal free play adjusting nut 2. Brake camshaft lever 3. Push the brake camshaft lever in direction (a) 3. Gap “A” until it stops [apply approximately 50 N (5.0 4. Push the brake camshaft lever in direction (a) kgf, 11.0 lbf) of force], and then turn the brake until it stops [apply approximately 50 N (5.0 pedal free play adjusting nut on the brake ca-...
  • Page 114 (a) to increase the free play, and in direction (b) to decrease it. Checking the brake pedal position The top of the brake pedal should be positioned 75.0–85.0 mm (2.95–3.35 in) above the footboard. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 8-35...

  • Page 115: Axle Boots

    1. Front axle boot (each side) Make sure the brakes operate smoothly and that the free play is correct. Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 8-36...

  • Page 116: Brake Light Switches

    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.) 1. Brake light switch 2. Brake light switch adjusting nut 3.

  • Page 117: Checking And Lubricating The Cables

    Rear brake lever: cables and cable ends should be lubricated if nec- Lithium-soap-based grease essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Front brake lever Recommended lubricant: Engine oil EWB02130...

  • Page 118: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel hub bear- ings. To access the brake pedal pivot, remove panel A.

  • Page 119: Checking The Stabilizer Bushes

    Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bush- es if necessary. 1. Grease nipple EBU25051...

  • Page 120: Battery

    EBU29182 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 121 To charge the battery Have a Yamaha dealer charge the battery as soon To install the battery as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more Be sure the battery is fully charged.

  • Page 122: Replacing A Fuse

    1. Main fuse 1. Positive battery lead (red) 2. Spare main fuse 2. Negative battery lead (black) 3. Fuse box 3. Install the battery holding plate by installing the bolts. 4. Install the seat. (See page 4-17.) ECB00940 NOTICE Always keep the battery charged. Storing a dis- charged battery can cause permanent battery damage.
  • Page 123 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Ignition fuse: 15.0 A Four-wheel-drive motor fuse: 10.0 A 1. Headlight fuse Signaling system fuse: 2.

  • Page 124: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25480 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off.

  • Page 125: Adjusting A Headlight Beam

    8. Adjust the headlight beam if necessary. EBU25551 Adjusting a headlight beam 1. Do not touch the glass part of the bulb. ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. 8-46...

  • Page 126: Replacing The Tail/Brake Light Bulb

    Replacing the tail/brake light bulb Installing a wheel If the tail/brake light bulb burns out, have a 1. Place the ATV on a level surface. Yamaha dealer replace it. 2. Install the wheel and the nuts. EBU25651 Removing a wheel...
  • Page 127 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 128: 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 129: 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 130: Cleaning And Storage

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

  • Page 131: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the brakes after washing. Apply the brakes several 2.
  • Page 132 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-41.

  • Page 133: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Cylinder arrangement: Forward-inclined single cylinder Overall length: Displacement: 1995 mm (78.5 in) 348.0 cm³ Overall width: Bore × stroke: 1095 mm (43.1 in) 83.0 × 64.5 mm (3.27 × 2.54 in) Overall height: Compression ratio: 1120 mm (44.1 in) 9.20 :1 Seat height: Starting system:...
  • Page 134 Differential gear oil: Type: Type: SAE 5W-30 or SAE 10W-30 or SAE 10W-40 or SAE Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 15W-40 or SAE 20W-40 or SAE 20W-50 API GL-4 Hypoid gear oil Quantity: 0.23 L (0.24 US qt, 0.20 Imp.qt) 50 ˚C...
  • Page 135 Transmission: Rear tire: Primary reduction system: Type: V-belt Tubeless Secondary reduction system: Size: Shaft drive AT25 x 10-12 Secondary reduction ratio: Manufacturer/model: 41/21 × 24/18 × 33/9 (9.545) MAXXIS/M980 Transmission type: Loading: V-belt automatic Maximum loading limit: Operation: 210.0 kg (463 lb) Left hand operation (Total weight of rider, cargo, accessories, and tongue) Forward gear:...
  • Page 136 Rim size: Charging system: 12 x 7.5AT AC magneto Front brake: Battery: Type: Model: Dual disc brake YTX14AH Operation: Voltage, capacity: Right hand operation 12 V, 12.0 Ah Recommended fluid: Headlight: DOT 4 Bulb type: Rear brake: Krypton bulb Bulb voltage, wattage × quantity: Type: Wet multiple disc brake Headlight:...
  • Page 137 Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Ignition fuse: 15.0 A Auxiliary DC jack fuse: 10.0 A Four-wheel-drive motor fuse: 10.0 A 10-5...

  • Page 138: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 139 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 140 1. Model label 11-3...
  • Page 141 INDEX Drive select lever ............4-12 Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-6 Drive select lever safety system cable, adjusting ..8-29 Air filter element, cleaning ..........8-21 Drive shaft universal joint, lubricating ......8-39 Axle boots ..............
  • Page 142 Key identification number ..........11-1 Safety information ............1-1 Seat ................4-17 Shock absorber assemblies, adjusting the front and Label locations ............... 2-1 rear ................4-19 Light switch ..............4-5 Spark arrester, cleaning ..........8-24 Spark plug, checking ............8-9 Main switch ..............
  • Page 143 Wheel, installing ............8-47 Wheel, removing ............8-47...
  • Page 144 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2008.06-0.3×1 CR...

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