Yamaha GRIZZLY 350 YFM35FGDW Owner's Manual
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Yamaha GRIZZLY 350 YFM35FGDW Owner's Manual

Yamaha GRIZZLY 350 YFM35FGDW Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM35FGDW
4S2-F8199-60
Table of Contents
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Summary of Contents for Yamaha GRIZZLY 350 YFM35FGDW

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM35FGDW 4S2-F8199-60...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2006.10-0.3×2 CR (E,F,S)
  • Page 3 OWNER’S MANUAL YFM35FGDW 4S2-F8199-60-E0...

  • Page 4: Ec Declaration Of Conformity

    EC Declaration of Conformity conforming to Directive 98/37/EC YAMAHA MOTOR CO., LTD (Name of supplier) 2500 Shingai, Iwata, Shizuoka, Japan Representing YAMAHA MOTOR MANUFACTURING CORPORATION of AMERICA Newnan, Georgia U.S.A. declare in sole responsibility, that the product YFM350AS(5Y4AH14W060500101~) YFM350FWAN(5Y4AH15W060500101~) (Make, model)
  • 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 EBU17341 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: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or...
  • 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 Starting a cold engine ........ 6-1 MINOR 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 and driving in reverse ........6-3 lubrication chart ........8-3 Engine break-in ..........
  • Page 10 Adjusting the brake pedal and rear brake CLEANING AND STORAGE ......9-1 lever free play and checking Cleaning ............9-1 the brake pedal position ......8-30 Storage ............9-2 Axle boots ..........8-34 Brake light switches ......... 8-35 SPECIFICATIONS ........10-1 Checking and lubricating the cables ..8-36 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. For Europe and Oceania...
  • Page 17 For Europe...
  • Page 18 For Europe...
  • Page 19 For Oceania...
  • Page 20 For Oceania...

  • Page 21: 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 22: Controls And Instruments

    EBU17712 NOTE: 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 23: Instrument And Control Functions

    EBU17731 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 24: Indicator Lights And Warning Light

    NOTE: 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 25: 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 26: 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 27 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” CAUTION: See the starting instructions on page 6-1 prior to starting the engine.
  • Page 28 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 29 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. EBU28370 On-Command differential gear lock switch “4WD”/“LOCK”...
  • Page 30 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 EWB00130 WARNING...

  • Page 31: 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 32: 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 33: 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 34: 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 35: 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 36: Fuel

    1. Fuel tank cap 1. Fuel level 2. Fuel tank filler tube EBU18750 Fuel Recommended fuel: Make sure that there is sufficient fuel in the tank. UNLEADED GASOLINE ONLY Fill the fuel tank to the bottom of the filler tube as For Europe: Regular unleaded gasoline only shown.

  • Page 37: Fuel Cock

    EBU18820 NOTE: Fuel cock If knocking or pinging occurs, use a different brand The fuel cock supplies fuel from the tank to the car- of gasoline or higher octane grade. buretor while also filtering it. The fuel cock lever positions are explained as fol- ECB00070 lows and shown in the illustrations.

  • 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

    ECB00130 CAUTION: 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 41: Front Carrier

    EBU18970 NOTE: Rear carrier There is a check hose at the bottom of the storage Do not exceed the load limit of 80.0 kg (176 lb) compartment. If any water collects in this hose, re- 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 42 1. Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): NOTE: A special wrench can be obtained at a Yamaha Standard: dealer to make this adjustment. Maximum (hard): 4-20...
  • Page 43 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 44: Pre-Operation Checks

    Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 45 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary. 5-4, 8-26 • Check cable free play, and adjust if necessary. Control cables • Make sure that operation is smooth. Lubricate if necessary. 8-36 •...

  • Page 46: 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 47: 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 48: Measuring The Tire Pressure

    Type: Minimum tire pressure: Tubeless Front: Rear: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Manufacturer/model: Rear: CHENG SHIN/C-828 (AUS)(NZL) 22.0 kPa (3.2 psi) (0.220 kgf/cm²) MAXXIS/M980 (EUR)(GBR) • Use no more than the following pressures Size: when seating the tire beads. AT25 x 10-12 Maximum tire seating pressure: Type:...

  • Page 49: Tire Wear Limit

    Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Low-pressure tire gauge Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Set the tire pressure when the tires are cold.

  • Page 50: Chassis Fasteners

    1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.

  • Page 51: 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 52 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): NOTE: Cold engine start with ambient temperature If the engine fails to start, release the start below 5 °C (40 °F).

  • Page 53: Starting A Warm Engine

    NOTE: NOTE: 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 54: 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 55: 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 56: 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 57 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 58 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 59: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 60: Getting To Know Your Atv

    EBU28500 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 61 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 62 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 63 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 64 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 65 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 66 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 67: 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 68 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 69 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 70 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 71: 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 72: 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 73 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 74 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 75: 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 76: 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 77: 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 78 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 79 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 80: 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 81 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 82: 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 83: Periodic Maintenance And Minor Repair

    EBU21654 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 84 NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING Never modify this ATV through improper in-...

  • Page 85: Periodic 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 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours • Check operation and correct if necessary. √ √ √ √ √ • Check brake lever and pedal free play, and adjust Rear brake if necessary.
  • Page 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours √ √ √ 16 * Knuckle pivots • Lubricate with lithium-soap-based grease. √ √ √ 17 * Steering shaft •...
  • Page 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Moving parts and √ √ √ √ • Lubricate. cables Drive select lever • Check operation and adjust or replace if neces- √...
  • Page 89 • 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 90: 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 91 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 92: 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 93 2. Check the engine oil level on a cold engine. NOTE: 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.
  • Page 94 To change the engine oil (with or without oil fil- 5. Remove the oil filter cartridge with an oil filter ter cartridge replacement) wrench. 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 95 NOTE: 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. NOTE: Make sure that the O-ring is properly seated. 1. Torque wrench...

  • Page 96: Final Gear Oil

    If any leakage is found, have Without oil filter cartridge replacement: a Yamaha dealer check and repair the ATV. In ad- 2.20 L (2.33 US qt) (1.94 Imp.qt) dition, the final gear oil level must be checked and...
  • Page 97 To change the final gear oil 1. Remove the engine guard and the final gear case guard by removing the bolts. 1. Final gear oil filler bolt 2. Correct oil level 3. Final gear oil 1. Engine guard 3. If the oil is below the brim of the filler hole, add 2.
  • Page 98 1. Final gear oil drain bolt 1. Final gear oil filler bolt 2. Correct oil level 5. Install the drain bolt, and then tighten it to the 3. Final gear oil specified torque. Recommended final gear oil: Tightening torque: See page 10-1. Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) NOTE:...

  • Page 99: Differential Gear Oil

    If any leakage is found, gear case. have a Yamaha dealer check and repair the ATV. 7. Install the oil filler bolt, and then tighten it to the In addition, the differential gear oil level must be specified torque.
  • Page 100 To change the differential gear oil 1. Place the ATV on a level surface. 2. Place an oil pan under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case.

  • Page 101: Cleaning The Air Filter Element

    5. Add the recommended differential gear oil to Tightening torque: the brim of the filler hole as shown. 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. EBU23640 Cleaning the air filter element The air filter element should be cleaned at the in-...
  • Page 102 1. Air filter case check hose 1. Air filter case cover holder 2. Air filter case cover 1. Remove the seat. (See page 4-17.) 3. Pull the air filter element out of the air filter 2. Remove the air filter case cover by unhooking case.
  • Page 103 1. Air filter element 1. Air filter element frame 2. Sponge material 4. Pull off the lock plate, and then remove the 3. Air filter element lock plate sponge material from the air filter element 5. Wash the sponge material gently but thor- frame.

  • Page 104: Cleaning The Spark Arrester

    ECB00440 manifold fittings for an air-tight seal. Tighten all fit- CAUTION: tings securely to avoid the possibility of unfiltered air entering the engine. Do not twist the sponge material when squeez- ing it. ECB00460 CAUTION: 7. Check the sponge material and replace it if damaged.
  • Page 105 1. Bolt 1. Tailpipe 2. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 4. Insert the tailpipe into the muffler and align the muffler. bolt holes. 3. Tap the tailpipe lightly, and then use a wire 5.

  • Page 106: V-Belt Cooling Duct Check Hose

    If water drains from the V-belt case after removing be performed by the owner as part of routine main- the plug, have a Yamaha dealer check the ATV as tenance. the water may affect other engine parts.

  • Page 107: Adjusting The Engine Idling Speed

    NOTE: NOTE: If the specified idling speed cannot be obtained as The engine is warm when it quickly responds to the described above, have a Yamaha dealer make the throttle. adjustment. 2. Attach the tachometer to the spark plug lead.

  • Page 108: Adjusting The Throttle Cable Free Play

    The valve clearance changes with use, resulting in bolt in direction (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. 8-26...

  • Page 109: 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 110: 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 111: Changing The Brake Fluid

    Water will signifi- free play of zero mm (zero in) as shown. If the free cantly lower the boiling point of the fluid and may play is incorrect, have a Yamaha dealer check the result in vapor lock. brake system.

  • Page 112: 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- EBU28632 ther free play is incorrect, adjust it as follows.
  • Page 113 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 114 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 47 N (10.6 4. Push the brake camshaft lever in direction (a) lbf) (4.8 kgf) of force], and then turn the brake until it stops [apply approximately 47 N (10.6 pedal free play adjusting nut on the brake ca-...
  • Page 115 (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. 8-33...

  • Page 116: 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. 8-34...

  • Page 117: 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. Brake light switch 1. Remove panel A. (See page 8-8.) 2. Brake light switch adjusting nut 3.

  • Page 118: Checking And Lubricating The Cables

    Front brake lever essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil EWB02130...

  • Page 119: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel bearings. NOTE: EBU24970 Lubricating the drive shaft universal To access the brake pedal pivot, remove panel A.

  • Page 120: 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 EBU25050...

  • Page 121: Battery

    Check and, if necessary, tighten the battery lead connections. To charge the battery ECB00620 Have a Yamaha dealer charge the battery as soon CAUTION: as possible if it seems to have discharged. Keep in Never attempt to remove the battery cell seals, mind that the battery tends to discharge more as this would permanently damage the battery.

  • Page 122: Replacing A Fuse

    2. Make sure to properly connect the battery access to a constant-voltage battery charg- leads to the battery terminals. er, have a Yamaha dealer charge your bat- tery. EBU25323 Replacing a fuse 1. Positive battery terminal 2. Negative battery terminal...
  • Page 123 ECB00640 CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A 1. Headlight fuse Headlight fuse: 2.

  • Page 124: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Cover at the rear of the headlight EBU25480 2.
  • Page 125 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 1. Do not touch the glass part of the bulb. ECB00650 1. Headlight bulb holder CAUTION: 4. Remove the defective bulb by pulling it out. Do not touch the glass part of the headlight EWB02220 bulb to keep it free from oil, otherwise the WARNING...

  • Page 126: Adjusting A Headlight Beam

    8. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make 1. Headlight beam adjusting screw this adjustment. EBU25580 Replacing the tail/brake light bulb To raise a headlight beam, turn the adjusting screw in direction (a).

  • Page 127: Installing A Wheel

    Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Wheel nut 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 1.

  • Page 128: Troubleshooting

    The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- 1. Tapered nut 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 8-39.

  • Page 133: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 1995 mm (78.5 in) Air cooled 4-stroke, SOHC Overall width: Cylinder arrangement: 1095 mm (43.1 in) Forward-inclined single cylinder Overall height: Displacement: 1120 mm (44.1 in) 348.0 cm³ Bore × stroke: Seat height: 83.0 ×...
  • Page 134 0.50 L (0.53 US qt) (0.44 Imp.qt) Type: Differential gear oil: SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Type: Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: ACC-SHAFT-LU-00) or SAE80 API GL-4 Hypoid gear oil -20˚ -10˚ 0˚ 20˚...
  • Page 135 Spark plug gap: Size: 0.6–0.7 mm (0.024–0.028 in) AT25 x 8-12 Clutch: Manufacturer/model: CHENG SHIN/C-828 (AUS)(NZL) Clutch type: MAXXIS/M979 (EUR)(GBR) Wet, centrifugal automatic Rear tire: Transmission: Type: Primary reduction system: Tubeless V-belt Size: Secondary reduction system: AT25 x 10-12 Shaft drive Manufacturer/model: Secondary reduction ratio: 41/21 ×...
  • Page 136 Rear: Rear suspension: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Type: Front wheel: Double wishbone Wheel type: Spring/shock absorber type: Panel wheel Coil spring/oil damper Rim size: Wheel travel: 12 x 6.0AT 180 mm (7.1 in) Rear wheel: Electrical system: Wheel type: Ignition system: Panel wheel DC.
  • Page 137 Oil temperature warning light: 12 V, 1.7 W × 1 On-command four-wheel-drive indicator light: 12 V, 1.7 W × 1 Differential gear lock indicator light: 12 V, 1.7 W x 1 Fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Ignition fuse:...

  • 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 ..8-27 Air filter element, cleaning ..........8-19 Drive shaft universal joint, lubricating ......8-37 Axle boots ..............
  • Page 142 Seat ................4-17 Shock absorber assemblies, Key identification number ..........11-1 adjusting the front and rear ........4-19 Knuckle pivots, lubricating ..........8-38 Spark arrester, cleaning ..........8-22 Spark plug, checking ............8-8 Label locations ............... 2-1 Specifications ............... 10-1 Light switch ..............
  • Page 144 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2006.10-0.3×2 CR...

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