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Yamaha GRIZZLY 350 YFM35GZ 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
YFM35GZ
YFM350AZ
5WH-F8199-66

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Summary of Contents for Yamaha GRIZZLY 350 YFM35GZ

  • 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 YFM35GZ YFM350AZ 5WH-F8199-66...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2009.06-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35GZ YFM350AZ 5WH-F8199-66-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 YFM350A (YFM35G) (5Y4AH10W090511001–)
  • 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. EBU17410 YFM35GZ/YFM350AZ OWNER’S MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st edition, June 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 .............4-9 SPECIFICATION LABELS ......1-1 Fuel cock ..........4-10 Starter (choke) ..........4-12 SAFETY INFORMATION ......2-1 Seat ............4-12 Storage compartment .......4-13 DESCRIPTION ..........3-1 Front carrier ..........4-14 Left view ............3-1 Rear carrier ..........4-14 Right view............
  • Page 9 Starting a warm engine ......6-3 Periodic maintenance chart for Operating the drive select lever and the emission control system .....8-3 driving in reverse ........6-3 General maintenance and Engine break-in .......... 6-4 lubrication chart ........8-5 Parking ............6-5 Removing and installing the panel ....8-9 Parking on a slope ........
  • Page 10 Brake light switches ......... 8-32 Checking and lubricating the cables ..8-33 Checking and lubricating the front and rear brake levers ........8-33 Checking and lubricating the brake pedal ........8-34 Checking the wheel hub bearings .... 8-35 Lubricating the steering shaft ....8-35 Battery ............

  • Page 11: Location Of The Warning And Specification Labels

    Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. For Europe...
  • Page 12 < 40 kg ( 88 lbs) 37S-F817R-00 1P0-F816P-20 < 80 kg ( 176 lbs) 37S-F817R-10 25.0 kPa 25.0 kPa 0.25 kgf/cm² 0.25 kgf/cm² 3.6 psi 3.6 psi < 5FU-F816M-M0 4900 N < 500 kgf < 1102 lbf < 147 N <...
  • Page 13 1P0-F816L-20 YEAR OF CONSTRUCTION : 2009 MODEL : YFM350A YAMAHA MOTOR CO., LTD. MAX.POWER : 15.9 kW 1P0-F816R-00 2500 SHINGAI, IWATA, JAPAN MASS IN RUNNING ORDER : 245 kg 5WH-F155A-20...
  • Page 14 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
  • Page 15 NEVER use with drugs or alcohol. Adjust tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids. Turning 4WD-LOCK (“DIFF.LOCK”) takes more effort.
  • Page 16 This pictogram shows trailer Hitch Tow weight limit. (Combined weight of the trailer and all cargo in the trailer.) Overloading can cause loss of control. Loss of control can result in severe injury or death. This pictogram shows trailer Hitch Tongue weight limit.
  • Page 17 For Oceania...
  • Page 18 LOAD LIMIT 40 kg{88 lbs} 5ND-F4877-20 LOAD LIMIT 25 kPa, (3.6 psi) 80 kg{176 lbs} 25 kPa, (3.6 psi) 22 kPa, (3.2 psi) 22 kPa, (3.2 psi) 5ND-F4897-20 MAXIMUM LOADING LIMIT PULLING LOAD: 4900 N (500 kgf) 1102 lbf 5FU-F816M-20 TONGUE WEIGHT: 147 N ( 15 kgf) 33 lbf...

  • Page 20: Safety Information

    EBU17431 SAFETY INFORMATION EBU17563 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 21 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 22 roll backwards, follow the special procedure for Always be sure there are no obstacles or people braking described in this manual. Dismount on behind you when you operate in reverse. When the uphill side or to a side if pointed straight up- it is safe to proceed in reverse, go slowly.
  • Page 23 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT.

  • Page 24: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 10 9 1. Fuel cock 1. Rear shock absorber assembly spring preload adjusting ring 2. Throttle stop screw 2. Spark arrester 3. Air filter case 3. Storage compartment and tool kit 4. Fuses 4.

  • Page 25: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Parking brake lock plate 5. Horn switch 6. Drive select lever 7.

  • Page 26: Instrument And Control Functions

    EBU17733 INSTRUMENT AND CONTROL FUNCTIONS EBU17770 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights, meter lighting and taillight come on when the light switch is on, and the engine can be started.

  • Page 27: Indicator Lights And Warning Light

    Yamaha dealer check the electrical circuit. If the warning light stays on when the engine is 1. Reverse indicator light “REVERSE” cool, have a Yamaha dealer check the electrical 2. Neutral indicator light “NEUTRAL” circuit. 3. Oil temperature warning light “...

  • Page 28: Speedometer

    EBU18022 EBU18061 Speedometer Handlebar switches This speedometer is equipped with an odometer and a tripmeter. The tripmeter can be reset to zero with the reset knob. Use the tripmeter to estimate how far you can ride on a tank of fuel before going to reserve.

  • Page 29: Throttle Lever

    EBU18101 EBU18282 Start switch “ ” Throttle lever Push this switch to crank the engine with the start- Once the engine is running, pushing the throttle le- er. See the starting instructions on page 6-1 prior ver will increase the engine speed. to starting the engine.

  • Page 30: Speed Limiter

    EBU18323 Speed limiter Your ATV is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 31: Brake Pedal And Rear Brake Lever

    1. Front brake lever 1. Brake pedal 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. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.

  • 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

    of sparks, open flames, or other sources of ig- nition such as the pilot lights of water heaters and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole.

  • Page 35: Fuel Cock

    3.3 L (0.87 US gal, 0.73 Imp.gal) rings, as well as to the exhaust system. 3. Wipe up any spilled fuel immediately. Your Yamaha engine has been designed to use NOTICE: Immediately wipe off spilled fuel regular unleaded gasoline with a research octane with a clean, dry, soft cloth, since fuel may number of 91 or higher.
  • Page 36 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 37: Starter (Choke)

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

  • Page 38: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18912 Storage compartment Insert the projections on the front of the seat into ECB00130 the seat holders and push down on the seat at the NOTICE rear.

  • Page 39: Front Carrier

    1. Storage compartment 1. Storage compartment check hose Do not exceed the load limit of 2.0 kg (4 lb) for EBU18962 the storage compartment. Front carrier Do not exceed the maximum load of 210.0 kg Do not exceed the load limit of 40.0 kg (88 lb) for (463 lb) for the ATV.

  • Page 40: Adjusting The Front Shock Absorber Assemblies

    Adjust the spring preload as follows. Turn the spring preload adjusting ring in direction (a) to increase the spring preload and thereby A special wrench can be obtained at a Yamaha harden the suspension, and in direction (b) to de- dealer to make this adjustment.

  • Page 41: Adjusting The Rear Shock Absorber Assembly

    ECB01090 NOTICE Never turn the adjusting mechanism beyond the minimum and maximum settings. Adjust the spring preload as follows. Turn the spring preload adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension.
  • Page 42 A special wrench can be obtained at a Yamaha dealer to make this adjustment. 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): 4-17...

  • Page 43: 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 44 ITEM ROUTINE PAGE • Check operation, and correct if necessary. Rear brake • Lubricate cables if necessary. 5-3, 8-26, 8-29 • Check lever and pedal free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary.

  • Page 45: Fuel

    If there is any leakage, the brake Check that there is no free play in the front brake system should be checked by a Yamaha dealer. lever. If there is free play, have a Yamaha dealer check the brake system. Brake operation...

  • Page 46: Throttle Lever

    Check the operation of the throttle lever. It must 25.0 kPa (0.250 kgf/cm², 3.6 psi) open smoothly and spring back to the idle position Rear when released. Have a Yamaha dealer correct if 25.0 kPa (0.250 kgf/cm², 3.6 psi) necessary. Minimum tire pressure:...
  • Page 47 Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Manufacturing Corporation of America.

  • Page 48: Chassis Fasteners

    EBU19840 Front: Chassis fasteners Manufacturer/model: Make sure that all nuts, bolts and screws are prop- YFM350AZ CHENG SHIN/C-828 erly tightened. YFM35GZ MAXXIS/M979 Size: EBU19850 Instruments, lights and switches AT25 x 8-12 Type: Check that all instruments, lights and switches are Tubeless working properly.

  • Page 49: Operation

    Read the Owner’s Manual carefully before riding on. If the indicator light does not come on, the ATV. If there is a control or function you do not have a Yamaha dealer check the electrical cir- understand, ask your Yamaha dealer. cuit.
  • Page 50 Position (3): Cold engine start with ambient temperature If the engine fails to start, release the start above 25 °C (80 °F). switch, then push it again. Pause a few seconds Ambient temp./starter (choke) position before the next attempt. Each cranking should be as short as possible to preserve battery ener- gy.

  • Page 51: 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. EBU20382 Operating the drive select lever and driving in reverse ECB00170...

  • Page 52: Engine Break-In

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

  • Page 53: Parking

    If any engine trouble should occur during the EWB00831 engine break-in period, immediately have a WARNING Yamaha dealer check the ATV. Avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the EBU20701...

  • Page 54: Accessories And Loading

    Yamaha manufacture parts and acces- 4. Turn the fuel cock to “OFF”. sories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies pro- duce. Therefore, Yamaha can neither endorse nor...
  • Page 55 market products or having other modifications EBU21061 Loading performed to your ATV that change any of the ve- EWB00820 hicle’s design or operation characteristics can put WARNING you and others at greater risk of serious injury or Never exceed the stated load capacity for this death.
  • Page 56 Load cargo on the carriers as close to the center MAXIMUM LOADING LIMIT of the ATV as possible. Put cargo at the rear of ATV loading limit (total weight of rider, cargo, the front carrier, at the front of the rear carrier, accessories, and tongue): and center it.

  • Page 57: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 58: Getting To Know Your Atv

    EBU21634 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding Do not operate this ATV or allow anyone else instructions for recreational riding.
  • Page 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 Apparel Always wear the following to reduce risk of injury in an accident: Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 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 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of cargo, rider, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 210.0 kg (463 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
  • Page 64 ATV should be during operation or after leaving the ATV, do not let genuine Yamaha or equivalent components de- brush, grass and other materials collect under the signed for use on this ATV and should be installed vehicle, near the muffler or exhaust pipe, or next to and used according to instructions.

  • Page 65: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 66 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do not ways be alert to changing terrain conditions ride on any paved public street, road or motorway. when operating the ATV.
  • Page 67 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 68: Turning Your Atv

    Select a large, flat, unpaved area to become famil- TURNING YOUR ATV iar with your ATV. Make sure that this area is free EWB01771 WARNING of obstacles and other riders. You should practice control of the throttle, brakes, and turning tech- Always follow proper procedures for turning niques in this area before trying more difficult ter- as described in this Owner’s Manual.

  • Page 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 Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground.
  • Page 71 Do not attempt to climb hills until you have mas- If you are climbing a hill and you find that you have tered basic maneuvers on flat ground. Always not properly judged your ability to make it to the check the terrain carefully before attempting any top, you should turn the ATV around while you still hill.

  • Page 72: Riding Downhill

    Shift your weight backward and to the up side of the hill. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possi- ble.

  • Page 73: Crossing A Slope

    Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill.

  • Page 74: Crossing Through Shallow Water

    The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
  • Page 75 ability. WARNING! Wet brakes may have re- duced stopping ability, which could cause loss of control. [EWB02621] 1. Air filter case check hose After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the storage compartment check hose.

  • Page 76: Riding Over Rough Terrain

    1. V-belt case drain plug 1. Drive select lever box check hose RIDING OVER ROUGH TERRAIN EWB01651 WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees.

  • Page 77: Sliding And Skidding

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

  • Page 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 footboard to the outside of the turn.
  • 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- EBU21731 miliar with vehicle service, have a Yamaha Owner’s manual and tool kit dealer perform the service. Be sure to put this owner’s manual in the plastic...
  • Page 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 • Change. √ √ √ √ Engine oil • Check ATV for oil leakage, and correct if neces- sary.
  • Page 87 EBU28391 Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid.

  • Page 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 If the spark plug shows a distinctly different color, kit. the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-10...
  • Page 90 2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.

  • Page 91: Engine Oil And Oil Filter Cartridge

    EBU23319 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals spec- ified in the periodic maintenance and lubrication chart.
  • Page 92 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then re- move the engine oil drain bolt and its gasket to drain the oil from the crankcase.
  • Page 93 An oil filter wrench is available at a nearby Yamaha dealer. 6. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. Make sure that the O-ring is properly seated. 1. Oil filter cartridge 1.
  • Page 94 9. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.20 L (2.33 US qt, 1.94 Imp.qt) With oil filter cartridge replacement: 2.30 L (2.43 US qt, 2.02 Imp.qt) 1.

  • Page 95: Final Gear Oil

    If any leakage is found, have 4. Correct oil level a Yamaha dealer check and repair the ATV. In ad- 3. If the oil is below the brim of the filler hole, add dition, the final gear oil level must be checked and...
  • Page 96 To change the final gear oil 1. Place the ATV on a level surface. 2. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil drain bolt 2. Gasket 5. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque.

  • Page 97: Cleaning The Air Filter Element

    9. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 10. Install the final gear case guard by installing the bolts and tightening them to the specified torque. Tightening torque: Final gear case guard bolt: 16 Nm (1.6 m·kgf, 11 ft·lbf) EBU23646 Cleaning the air filter element...
  • Page 98 1. Air filter case check hose 1. Air filter case cover holder 2. Air filter case cover 1. Place the ATV on a level surface. 4. Pull the air filter element out of the air filter 2. Remove the seat. (See page 4-12.) case.
  • Page 99 1. Air filter element 1. Air filter element frame 2. Sponge material 5. Pull off the air filter element lock plate, and 3. Air filter element lock plate then remove the sponge material from the air 6. Wash the sponge material gently but thor- filter element frame.

  • Page 100: Cleaning The Spark Arrester

    40 hours. It should be cleaned and lubricated more damaged. often if the ATV is operated in extremely dusty ar- 9. Apply Yamaha foam air filter oil or other qual- eas. Each time the air filter element maintenance ity foam air filter oil to the sponge material.
  • Page 101 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 102: V-Belt Cooling Duct Check Hose

    Always let the exhaust system cool prior to If water drains from the V-belt case after removing touching exhaust components. the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts. EBU23920 V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it.

  • Page 103: Adjusting The Carburetor

    Therefore, most carburetor adjustments should be left to a The engine is warm when it quickly responds to the Yamaha dealer, who has the necessary profes- throttle. sional knowledge and experience. The adjustment 2. Attach the tachometer to the spark plug lead.

  • Page 104: Adjusting The Throttle Cable Free Play

    3. To increase the throttle cable free play, turn If the specified idling speed cannot be obtained as the throttle cable free play adjusting bolt in di- described above, have a Yamaha dealer make the rection (a). To decrease the throttle cable free adjustment.

  • Page 105: Valve Clearance

    Checking the front brake pads and rear prevent this from occurring, the valve clearance brake shoes must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- The front brake pads and the rear brake shoes brication chart.
  • Page 106 1.0 mm without having to disassemble the brake. To check (0.04 in), have a Yamaha dealer replace the brake the brake shoe wear, check the position of the pads as a set.

  • Page 107: Checking The Brake Fluid Level

    1. Minimum level mark Changing the brake fluid Observe these precautions: Have a Yamaha dealer change the brake fluid at When checking the fluid level, make sure that the intervals specified in the TIP after the periodic the top of the brake fluid reservoir is level.

  • Page 108: Checking The Front Brake Lever Free Play

    If there is free play, have a brake. Yamaha dealer check the brake system. Before adjusting the brake lever and brake pedal free play, check the rear brake shoes for wear.
  • Page 109 1. Brake pedal free play adjusting nut 1. Brake pedal free play 2. Brake lever free play adjusting nut 1. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the rear wheel Adjusting the brake lever free play hub.
  • Page 110 1. Brake lever free play adjusting nut 1. Brake lever free play 2. Gap “A” 2. Locknut 3. Brake lever free play adjusting bolt 3. Turn the brake lever free play adjusting bolt at 1. Loosen the locknut at the brake lever and fully the brake lever in direction (a) to increase the turn in the brake lever free play adjusting bolt.

  • Page 111: Brake Light Switches

    Be sure not to step on the brake pedal. adjusted as follows, but the other brake light Make sure the brake pedal does not move. switches should be adjusted by a Yamaha dealer. 1. Remove panel A. (See page 8-9.) Checking the brake pedal position 2.

  • Page 112: 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 Recommended lubricant: Engine oil 8-33...

  • Page 113: Checking And Lubricating The Brake Pedal

    Rear brake lever Recommended lubricants: Front brake lever: Silicone grease Rear brake lever: Lithium-soap-based grease Front brake lever EBU28832 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.

  • Page 114: Checking The Wheel Hub Bearings

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

  • Page 115: Battery

    EBU29184 Batteries produce explosive gases. Keep Battery sparks, flame, cigarettes or other sources of ig- This model is equipped with a VRLA (Valve Regu- nition away. Ventilate when charging or using lated Lead Acid) battery. There is no need to check in an enclosed space.
  • Page 116 To charge the battery ECB00940 Have a Yamaha dealer charge the battery as soon NOTICE as possible if it seems to have discharged. Keep in Always keep the battery charged. Storing a dis-...

  • Page 117: Replacing A Fuse

    To install the battery EBU25326 Replacing a fuse The main fuse and the fuse box are located under Be sure the battery is fully charged. the seat. (See page 4-12.) 1. Place the battery in its compartment. 2. Connect the positive battery lead first, then connect the negative battery lead by installing their bolt.
  • Page 118 3. Turn the key to “ON” and turn on the electrical To prevent accidental short-circuiting, turn off circuits to check if the devices operate. the main switch when checking or replacing a 4. If the fuse immediately blows again, have a fuse. Yamaha dealer check the electrical system. 8-39...

  • Page 119: Replacing A Headlight Bulb

    EBU25481 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 1. Headlight bulb holder cover 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise.

  • Page 120: Adjusting A Headlight Beam

    ECB00690 moistened with alcohol or thinner. [ECB00651] NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).

  • Page 121: Replacing The Tail/Brake Light Bulb

    Replacing the tail/brake light bulb under the frame. 4. Remove the nuts from the wheel. If the tail/brake light bulb burns out, have a 5. Remove the wheel. Yamaha dealer replace it. EBU25701 EBU25651 Installing a wheel Removing a wheel 1.
  • Page 122 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 123: 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 124: 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 125: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25881 tion of wheel bearings, brakes, transmis- Cleaning sion seals and electrical devices. Many Frequent, thorough cleaning of your ATV will not expensive repair bills have resulted from only enhance its appearance but will improve its improper high-pressure detergent applica- general performance and extend the useful life of tions such as those available in coin-oper-...

  • Page 126: 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 127 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 128: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 1984 mm (78.1 in) Air cooled 4-stroke, SOHC Overall width: Cylinder arrangement: 1085 mm (42.7 in) Forward-inclined single cylinder Overall height: Displacement: 1120 mm (44.1 in) 348 cm³ Bore × stroke: Seat height: 83.0 ×...
  • Page 129 Type: Fuel: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- Recommended fuel: YFM350AZ Unleaded gasoline only YFM35GZ Regular unleaded gasoline only 130 ˚F Fuel tank capacity: 13.5 L (3.57 US gal, 2.97 Imp.gal) SAE 5W-30 Fuel reserve amount: 3.3 L (0.87 US gal, 0.73 Imp.gal) SAE 10W-30 Carburetor: SAE 10W-40...
  • Page 130 Forward gear: Tire air pressure (measured on cold tires): 35/20 (1.750) Recommended: Reverse gear: Front: 26/15 (1.733) 25.0 kPa (0.250 kgf/cm², 3.6 psi) Chassis: Rear: Frame type: 25.0 kPa (0.250 kgf/cm², 3.6 psi) Steel tube frame Minimum: Caster angle: Front: 4.0 °...
  • Page 131 Bulb voltage, wattage × quantity: Operation: Left hand and right foot operation Headlight: 12 V, 30/30 W × 2 Front suspension: Type: Tail/brake light: 12 V, 5.0/21.0 W × 1 Double wishbone Spring/shock absorber type: Meter lighting: 14 V, 3.0 W × 1 Coil spring/oil damper Wheel travel: Neutral indicator light:...

  • Page 132: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 133 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 134 1. Model label 11-3...
  • Page 135 INDEX Drive select lever safety system cable, adjusting ..8-26 Accessories and loading ..........6-6 Air filter element, cleaning ..........8-18 Engine break-in .............. 6-4 Engine, cold start ............6-1 Engine idling speed ............. 8-24 Battery ................8-36 Engine oil ............... 5-3 Brake fluid, changing ...........
  • Page 136 Light switch ..............4-4 Start switch ..............4-4 Steering shaft, lubricating ..........8-35 Storage ................9-2 Main switch ..............4-1 Storage compartment ........... 4-13 Maintenance and lubrication chart ......... 8-5 Maintenance chart, emission control system ....8-3 Model label ..............11-2 Tail/brake light bulb, replacing ........
  • Page 138 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2009.06-0.3×1 CR...

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Grizzly 350 yfm350az

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