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Yamaha YFM350RZ 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
YFM35RZ
YFM350RZ
1BS-28199-60

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Summary of Contents for Yamaha YFM350RZ

  • 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 YFM35RZ YFM350RZ 1BS-28199-60...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2009.04-0.3×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35RZ YFM350RZ 1BS-28199-60-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 YFM350 (YFM35R) (JY4AH18W090004846–)
  • Page 5 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 YFM35RZ/YFM350RZ 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 .............4-8 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 ....8-34 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 ............8-37 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 4D3-2816L-20 43P-2816R-00...
  • Page 13 MAX. POWER : 20.0 kW MASS IN RUNNING ORDER : 180 kg 5YT-2156A-00 1AS-2816P-00 4AA-22259-40 25.0 kPa 25.0 kPa 0.25 kgf/cm² 0.25 kgf/cm² YEAR OF CONSTRUCTION : 2009 3.6 psi 3.6 psi YAMAHA MOTOR CO., LTD. 5YT-2816M-M0 2500 SHINGAI, IWATA, JAPAN 5PG-2817L-10...
  • Page 14 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
  • Page 15 NEVER use with drugs or alcohol. Adjust tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids. Turning 4WD-LOCK (“DIFF.LOCK”) takes more effort.
  • Page 16 This pictogram shows trailer Hitch Tow weight limit. (Combined weight of the trailer and all cargo in the trailer.) Overloading can cause loss of control. Loss of control can result in severe injury or death. This pictogram shows trailer Hitch Tongue weight limit.
  • Page 17 For Oceania...
  • Page 18 WARNING 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 NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE 4AA-22259-40 INJURY or DEATH. 5FE-2151H-01 WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.

  • Page 20: Safety Information

    EBU17431 SAFETY INFORMATION EBU17463 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 speed when climbing a hill. If you stall or roll Always be sure there are no obstacles or people backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on 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 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 25: 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 26: Instrument And Control Functions

    EBU17733 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 27: Indicator Lights

    EBU17792 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 “ ” EBU17830 Reverse indicator light “ ” EBU18080 Engine stop switch “ ”...

  • Page 28: Throttle Lever

    EBU18101 Regulate the speed of the ATV by varying the 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 29: 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 30: 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 31: 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 32: 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 33: Fuel Tank Cap

    1. Drive select lever 1. Fuel tank cap EBU18720 EBU18753 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 34 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 35: 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 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 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 38: Adjusting The Front Shock Absorber Assemblies

    2. Position indicator EWB00400 WARNING Always adjust the shock absorber assemblies A special wrench can be obtained at a Yamaha on the left and right side to the same setting. dealer to make this adjustment. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident.

  • Page 39: 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 40 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 41 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 42: 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 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. Rear brake 5-3, 8-22, 8-23, 8-25 • 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 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 8-22.) check the brake system.

  • Page 45: 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 8-29.) 25.0 kPa (0.250 kgf/cm², 3.6 psi) Minimum tire pressure: EBU19794 Tires...
  • Page 46 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 47: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are DUNLOP/KT851B working properly. Correct if necessary. Size: AT21 x 7-10 Type: Tubeless Rear: Manufacturer/model: DUNLOP/KT877A 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 48: 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 49 Position (3): Cold engine start with ambient temperature If the engine fails to start, release the start switch, above 25 °C (80 °F). then push it again. Pause a few seconds before Ambient temp./starter (choke) position the next attempt. Each cranking should be as short as possible to preserve battery energy.

  • Page 50: 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 51: Shifting

    When in reverse, the reverse indicator light should 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 52 EBU20591 8. Follow the same procedure when shifting to To start out and accelerate the next higher gear. 1. Release the throttle lever, and then release the parking brake. EBU20650 To decelerate ECB00200 NOTICE When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly.

  • Page 53: 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 54: Parking

    EBU20722 incline, shift into first gear, stop the engine, ap- 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 Do not park the ATV at all on hills that are so fuel cock to “OFF”.

  • Page 55: 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- Do not mount an accessory where it could inter- duce.
  • Page 56 EBU20941 If you are carrying cargo and towing a trailer, in- 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 57: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 58: Getting To Know Your Atv

    EBU21616 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is intended for recreational use by expe- WARNING rienced operators only. This section, Riding your Do not operate this ATV or allow anyone else ATV, provides general ATV riding instructions for to operate it without proper instruction.
  • Page 59 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 60 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 61 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 62 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 63 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 64 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 65: 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 66 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 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 control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.

  • Page 68: 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 69: 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 70 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 71 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 72: 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 73 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 74: 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 the front wheels slightly uphill. When riding on Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to slopes, be sure not to make sharp turns either up...

  • Page 75: 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 76: 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 77: 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 78: 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 79 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 80: Periodic Maintenance And Adjustment

    If you are not fa- EBU21691 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 and the low-...
  • Page 81 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 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

    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 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 cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years √...
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Shock absorber as- • Check operation and correct if necessary. √ √ √ semblies • Check for oil leakage and replace if necessary. Rear suspension re- lay arm and con- •...
  • Page 87 EBU23071 Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 88: Checking The Spark Plug

    EBU23212 2. Remove the spark plug as shown, with the 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 89 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 90: Engine Oil And Oil Filter Element

    Tightening torque: Spark plug: If the engine was started before checking the oil 17.5 Nm (1.75 m·kgf, 12.7 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 91 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 92 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 93 Tightening torque: Recommended oil: Oil filter element cover bolt: See page 10-1. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil quantity: Without oil filter element replacement: 10. Install the oil strainer, compression spring, O- 2.50 L (2.64 US qt, 2.20 Imp.qt) ring and engine oil drain bolt.

  • Page 94: Cleaning The Air Filter Element

    12. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 13. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary.
  • Page 95 1. Air filter case cover 1. Air filter element assembly 2. Air filter case cover holder 5. Remove the sponge material from the air filter 4. Pull the air filter element out of the air filter element frame. case. 1. Unlock. 8-16...
  • Page 96 2. Air filter element frame damaged. 3. Sponge material 9. Apply Yamaha foam air filter oil or other qual- 4. Air filter element seat ity foam air filter oil to the sponge material. 6. Wash the sponge material gently but thor- oughly in solvent.

  • Page 97: Cleaning The Spark Arrester

    NOTICE: Make sure that the air filter ele- EBU27701 Cleaning the spark arrester ment is properly seated in the air filter Select a well-ventilated area free of combustible case. Never operate the engine with the air materials and make sure the exhaust and muffler filter element removed.
  • Page 98 1. Tailpipe 1. Purging bolt 2. Spark arrester 7. Start the engine and rev it up approximately 4. Insert the tailpipe into the muffler and align the twenty times while momentarily creating ex- bolt holes. haust system back pressure by blocking the 5.

  • Page 99: Adjusting The Carburetor

    The carburetor has been set and extensively start a fire. tested at the Yamaha factory. Changing these Always let the exhaust system cool prior to settings without sufficient technical knowl- touching exhaust components.

  • Page 100: Adjusting The Throttle Cable Free Play

    3. Check the engine idling speed and, if neces- If the specified idling speed cannot be obtained as sary, adjust it to specification by turning the described above, have a Yamaha dealer make the throttle stop screw at the carburetor. To in- adjustment.

  • Page 101: Valve Clearance

    To must be adjusted by a Yamaha dealer at the inter- check the brake pad wear, check the wear indica- vals specified in the periodic maintenance and lu- tor grooves.

  • Page 102: Checking The Brake Fluid Level

    If a brake pad has worn to the point that a wear indicator groove almost appears, have a Yamaha dealer replace the brake pads as a set. 8-23...
  • Page 103 Always clean up spilled fluid imme- diately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause. 1. Minimum level mark 8-24...

  • Page 104: Changing The Brake Fluid

    EBU24291 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and cali- pers as well as the brake hoses replaced at the in- tervals listed below or whenever they are damaged or leaking.

  • Page 105: Adjusting The Parking Brake Free Play

    1. Locknut 1. Brake pedal position 2. Adjusting bolt EBU24711 3. Cable length “A” Adjusting the parking brake free play 1. Release the parking brake by moving the The parking brake free play must be checked and, parking brake lever to the right. if necessary, adjusted at the intervals specified in 2.

  • Page 106: 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 other brake light nut. [ECB00521] switches should be adjusted by a Yamaha dealer. 8-27...

  • Page 107: Adjusting The Clutch Lever Free Play

    EBU24820 Adjusting the clutch lever free play The brake light switch is properly adjusted when The clutch lever free play must be checked and, if the brake light comes on just before braking takes necessary, adjusted at the intervals specified in the effect.

  • Page 108: Drive Chain Slack

    3. Tighten the locknut at the clutch lever. scribed above or if the clutch does not operate cor- If the specified free play cannot be obtained, rectly, have a Yamaha dealer check the internal proceed with the following steps. clutch mechanism.
  • Page 109 1. Drive chain slack 1. Axle holding bolt (upper) 2. Axle holding bolt (lower) 3. If the drive chain slack is incorrect, adjust it as 3. Loosen the locknut on each side of the swing- follows. arm. To tighten the drive chain, turn the ad- To adjust the drive chain slack justing bolts in direction (a).

  • Page 110: Lubricating The Drive Chain

    Tightening torques: Locknut: There are alignment marks on both drive chain 16 Nm (1.6 m·kgf, 11 ft·lbf) pullers and an alignment mark on each side of the Axle holding bolt (upper): swingarm. Make sure to align the same alignment 120 Nm (12.0 m·kgf, 85 ft·lbf) mark on both drive chain pullers with the alignment Axle holding bolt (lower): mark on either side of the swingarm for proper...

  • Page 111: Checking And Lubricating The Cables

    If a cable is damaged or does not move pivots should be lubricated if necessary. smoothly, have a Yamaha dealer check or replace 8-32...

  • Page 112: Checking And Lubricating The Brake And Shift Pedals

    Clutch lever Recommended lubricants: Brake lever: Silicone grease Clutch lever: Lithium-soap-based grease Brake lever 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.

  • Page 113: Checking The Wheel Hub Bearings

    If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- ings. Shift pedal...

  • Page 114: Lubricating The Rear Suspension Relay Arm And Connecting Arm Pivoting Points

    Recommended lubricant: Lithium-soap-based grease EBU25003 Lubricating the rear suspension relay arm and connecting arm pivoting points The rear suspension relay arm and connecting arm pivoting points must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart.

  • Page 115: Lubricating The Upper And Lower Arm Pivots

    Left side 1. Grease nipple 1. Upper grease nipple 2. Lower grease nipple EBU25032 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun.

  • Page 116: Lubricating The Steering Shaft

    Lubricating the steering shaft cause severe burns. Avoid contact with skin, The steering shaft must be lubricated by a Yamaha eyes or clothing. Always shield your eyes dealer at the intervals specified in the periodic when working near batteries.
  • Page 117 [ECB01001] To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.
  • Page 118 If you do 2. Connect the positive battery lead first, then not have access to a constant-voltage battery connect the negative battery lead by installing charger, have a Yamaha dealer charge your their bolt. battery. To store the battery...

  • Page 119: Replacing The Fuse

    1. Fuse 4. If the fuse immediately blows again, have a 2. Spare fuse Yamaha dealer check the electrical system. The fuse holder is located under the seat. (See page 4-12.) EBU25542 If the fuse is blown, replace it as follows.
  • Page 120 3. Remove the burnt-out bulb from the headlight unit by pulling it out. 4. Install a new headlight bulb into the headlight unit by aligning the projection on the bulb with the groove in the headlight unit. NOTICE: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be ad-...

  • Page 121: Adjusting A Headlight Beam

    ECB00690 pushing it inward, and turning it clockwise until NOTICE it stops. It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting bolt in direction (a). To lower a headlight beam, turn the adjusting bolt in direction (b).

  • Page 122: Replacing The Tail/Brake Light Bulb

    EBU25601 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Remove the lens by removing the screws. 1. Tail/brake light bulb 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops.

  • Page 123: Installing A Wheel

    5. Remove the wheel. systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose EBU25661 skilled technicians have the necessary tools, expe- Installing a wheel rience, and know-how to service the ATV properly.
  • Page 124 EWB02280 WARNING Do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. 8-45...

  • Page 125: 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 126: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25902 may cause water seepage and deteriora- 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 127: 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 128 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 129: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Cylinder arrangement: Forward-inclined single cylinder Overall length: Displacement: 1780 mm (70.1 in) 349 cm³ Overall width: Bore × stroke: 1095 mm (43.1 in) 83.0 × 64.5 mm (3.27 × 2.54 in) Overall height: Compression ratio: 1080 mm (42.5 in) 9.20 :1 Seat height: Starting system:...
  • Page 130 2.60 L (2.75 US qt, 2.29 Imp.qt) Secondary reduction ratio: Air filter: 38/13 (2.923) Air filter element: Transmission type: Wet element Constant mesh 6-speed.forward, 1-speed.reverse Fuel: Operation: Recommended fuel: Left foot operation YFM350RZ Unleaded gasoline only YFM35RZ Regular unleaded gasoline only 10-2...
  • Page 131 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) DUNLOP/KT877A 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 132 Rim size: Electrical system: 9 x 8.5AT Ignition system: Front brake: DC. CDI Type: Charging system: Dual disc brake AC magneto Operation: Battery: Right hand operation Model: Recommended fluid: YTZ10S DOT 4 Voltage, capacity: Rear brake: 12 V, 8.6 Ah Type: Headlight: Single disc brake...

  • Page 133: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 134 EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 135 1. Model label 11-3...
  • Page 136 INDEX Drive select lever ............4-7 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 ................8-37 Engine idling speed ............8-20 Brake and clutch levers, checking and lubricating ..
  • Page 137 Storage ................9-2 Suspension, lubricating the upper and lower arm Main switch ..............4-1 pivots ................. 8-36 Maintenance and lubrication chart ......... 8-5 Suspension relay arm and connecting arm pivoting Maintenance chart, emission control system ....8-3 points, lubricating the rear ......... 8-35 Model label ..............
  • Page 138 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009.04-0.3×1 CR...

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