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Yamaha GRIZZLY 350 YFM350DF 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
YFM350DF
1NS-F8199-63

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Summary of Contents for Yamaha GRIZZLY 350 YFM350DF

  • 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 YFM350DF 1NS-F8199-63...
  • Page 2 Original instructions Notice originale Manual original PRINTED IN USA 2014.04-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM350DF WARNING This ATV should not be ridden by anyone under 16 years of age. 1NS-F8199-63-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 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM350FWA (YFM350DF) (5Y4AH13W0E0517767–)
  • 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 EBU17331 IMPORTANT MANUAL INFORMATION EBU17343 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. EBU17411 YFM350DF OWNER’S MANUAL ©2014 by Yamaha Motor Co., Ltd. 1st edition, January 2014 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 8: Table Of Contents

    EBU17421 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel cock ..........4-12 SPECIFICATION LABELS ......1-1 Starter (choke) ......... 4-14 Seat ............4-14 SAFETY INFORMATION ........2-1 Storage compartment....... 4-15 Front carrier ..........4-16 DESCRIPTION..........3-1 Rear carrier ..........4-16 Left view............3-1 Adjusting the front shock absorber Right view............3-1 assemblies..........
  • Page 9 Starting a warm engine ....... 6-3 Periodic maintenance chart for the Operating the drive select lever and driving emission control system......8-3 in reverse........... 6-3 General maintenance and lubrication Engine break-in ........... 6-4 chart............8-5 Parking ............6-5 Checking the spark plug......8-9 Parking on a slope ........
  • Page 10 Axle boots ..........8-36 INDEX ............12-1 Brake light switches ........8-36 Checking and lubricating the cables..8-36 Checking and lubricating the front and rear brake levers ........8-37 Checking and lubricating the brake pedal ............8-38 Checking the wheel hub bearings.....8-38 Lubricating the steering shaft ....8-39 Battery............8-39 Replacing a fuse ........8-42 Replacing a headlight bulb .......8-44...

  • 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 re- placement 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 YAMAHA 1HP-F811R-00 YFM350FWA 2014 15.9 kW YAMAHA MOTOR CO., LTD. 1P0-F816R-00 255 kg 2500 SHINGAI, IWATA, JAPAN 1NS-F155A-30...
  • 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 use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
  • Page 15 This unit contains high-pressure nitrogen Turning 4WD-LOCK gas. (“DIFF.LOCK”) takes more effort. Operate at a slow speed and allow extra Mishandling can cause an explosion. Do not incinerate, puncture or open. time and distance for maneuvers to avoid loss of control. This pictogram shows the loading limits and/or maximum load capacity for this ATV.
  • Page 16 Year of construction Model Name ****** **** *** kW YAMAHA MOTOR CO., LTD. Max. Power *** kg 2500 SHINGAI, IWATA, JAPAN Mass In Running Order...
  • 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

    EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Never allow a child under age 16 to operate an EBU17566 ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 21  Never operate at speeds too fast for your skills  Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 22  Never operate an ATV in fast flowing water or in technique described in this manual on level ground. Avoid crossing the side of a steep hill if water deeper than that recommended in this possible. manual. Remember that wet brakes may have ...
  • Page 23  Never maintain an ATV without proper knowl- vehicle. If the vehicle is in safe operating con- edge. Contact an authorized ATV dealer to in- dition and you can safely operate it, restart it form you on basic ATV maintenance. Certain and ride gently back to camp or other known maintenance can only be carried out by certified location where you can receive medical at-...
  • Page 24 While you may find aftermarket products similar in therefore, such accessories are not recom- design and quality to genuine Yamaha accesso- mended. ries, recognize that some aftermarket accessories  Use caution when adding electrical accesso- or modifications are not suitable because of po- ries.
  • Page 25  Do not run engine outdoors where engine EWB00073 WARNING exhaust can be drawn into a building through openings such as windows and doors. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, EWB02592 a deadly gas. Breathing carbon monoxide can WARNING cause headaches, dizziness, drowsiness, nau- When transporting the ATV in another vehicle,...

  • Page 26: Description

    EBU17681 DESCRIPTION EBU17691 EBU17701 Left view Right view 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. Spark plug 5.

  • Page 27: Controls And Instruments

    EBU17713 Controls and instruments The ATV you have purchased may differ slightly 2 3 4 5 6 7 8 9 11 12 from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Parking brake lock plate 5.

  • Page 28: Instrument And Control Functions

    EBU17735 INSTRUMENT AND CONTROL FUNCTIONS EBU17771 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 29: Indicator Lights And Warning Light

    For Oceania EBU17817 Indicator lights and warning light For Europe 1. Reverse indicator light “REVERSE” 2. Neutral indicator light “NEUTRAL” 3. On-Command four-wheel-drive indicator light “ ” 1. Reverse indicator light “R” 4. Oil temperature warning light “ ” 2. Neutral indicator light “N” 3.

  • Page 30: Speedometer

    Speedometer If the warning light stays on when the engine is This speedometer is equipped with an odometer cool, have a Yamaha dealer check the electrical and a tripmeter. The tripmeter can be reset to zero circuit. with the reset knob. Use the tripmeter to estimate...
  • Page 31 For Europe For Oceania 1. Reset knob 1. Reset knob 2. Speedometer 2. Speedometer 3. Odometer 3. Odometer 4. Tripmeter 4. Tripmeter...

  • Page 32: Handlebar Switches

    EBU18062 EBU18102 Start switch “ ” Handlebar switches Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. EBU18164 Light switch “ /OFF” Set this switch to “ ”...

  • Page 33: Throttle Lever

    To change from two-wheel drive to four-wheel EBU28433 On-Command four-wheel-drive switch drive, stop the ATV and push the switch in to the “2WD”/“4WD” “4WD” position. The four-wheel-drive indicator EWB00164 light “ ” comes on. WARNING To change from four-wheel drive to two-wheel Always stop the ATV before changing from drive, stop the ATV and push the switch in to the two-wheel drive to four-wheel drive and vice...

  • Page 34: Speed Limiter

    Regulate the speed of the ATV by varying the EBU18324 Speed limiter throttle position. Because the throttle is spring- Your ATV is equipped with an adjustable speed loaded, the ATV will decelerate, and the engine limiter. The speed limiter keeps the throttle from will return to an idle any time the throttle lever is re- fully opening, even when the throttle lever is leased.

  • Page 35: Front Brake Lever

    1. Locknut 1. Front brake lever 2. Adjusting screw EBU18443 3. No more than 12 mm (0.47 in) Brake pedal and rear brake lever 3. Tighten the locknut. The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left EBU18392 handlebar.

  • Page 36: Parking Brake

    EBU18462 Parking brake Use the parking brake before starting the engine or after parking the ATV, especially on a slope. Ap- ply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake.

  • Page 37: Drive Select Lever

     Always be sure you have released the park- ing brake before you begin to ride. The brake could overheat if you ride the ATV without re- leasing the parking brake. You could lose braking performance which could cause an accident.

  • Page 38: Fuel

    of sparks, open flames, or other sources of ignition such as the pilot lights of water heat- ers 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 39: 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 (95 or higher for Europe).
  • Page 40 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 posi- to the carburetor.

  • Page 41: 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 42: Storage Compartment

    1. Projection 1. Seat 2. Seat holder 2. Seat lock lever EBU18913 To install the seat Storage compartment Insert the projections on the front of the seat into ECB00131 the seat holders and push down on the seat at the NOTICE rear.

  • Page 43: Front Carrier

    1. Storage compartment 1. Storage compartment check hose  Do not exceed the load limit of 2.0 kg (4 lb) for EBU18963 Front carrier the storage compartment.  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 44: 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 45: Adjusting The Rear Shock Absorber Assembly

    ECB01091 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 46 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): 4-19...

  • Page 47: 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 48 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-28, 8-29, 8-30 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.

  • Page 49: Fuel

     Check that there is no free play in the front Test the brakes at slow speed after starting out to brake lever. If there is free play, have a Yamaha make sure they are working properly. If the brakes dealer check the brake system.

  • Page 50: Throttle Lever

    Check the operation of the throttle lever. It must Minimum tire pressure: open smoothly and spring back to the idle position Front when released. Have a Yamaha dealer correct if 22.0 kPa (0.220 kgf/cm², 3.2 psi) necessary. Rear 22.0 kPa (0.220 kgf/cm², 3.2 psi)
  • Page 51 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 52: Chassis Fasteners

    EBU19841 Front: Chassis fasteners Manufacturer/model: Make sure that all nuts, bolts and screws are CHENG SHIN/C-828 (AUS)(NZL) properly tightened. MAXXIS/MU13 (EUR)(FRA)(GBR) Size: EBU19851 Instruments, lights and switches AT25 x 8-12 Type: Check that all instruments, lights and switches are Tubeless working properly.

  • Page 53: 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 understand, ask your Yamaha dealer. circuit.
  • Page 54 Position (3): short as possible to preserve battery energy. Do Cold engine start with ambient temperature not crank the engine more than 10 seconds on above 25 °C (80 °F). each attempt. Ambient temp./starter (choke) position 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the en- gine.

  • Page 55: Starting A Warm Engine

    EBU20292 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. EBU20383 Operating the drive select lever and driving in reverse ECB00171...

  • Page 56: 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 57: Parking

    If any engine trouble should occur during the EWB00832 engine break-in period, immediately have a WARNING Yamaha dealer check the ATV. Avoid parking on hills or other inclines. Parking on a hill or other incline could cause the ATV to EBU20703...

  • Page 58: Accessories And Loading

    Yamaha manufacture parts 4. Turn the fuel cock to “OFF”. and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket compa- nies produce. Therefore, Yamaha can neither en-...
  • Page 59 aftermarket products or having other modifica- EBU21062 Loading tions performed to your ATV that change any of EWB00821 the vehicle’s design or operation characteristics WARNING can put you and others at greater risk of serious Never exceed the stated load capacity for this injury or death.
  • Page 60  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, car- the front carrier, at the front of the rear carrier, go, accessories, and tongue): and center it.

  • Page 61: Riding Your Atv

    EBU21142 RIDING YOUR ATV...

  • Page 62: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EBU30652 Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01382 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 63 the time to learn the basic techniques well before This ATV is designed to carry the operator and attempting more difficult maneuvers. Become fa- cargo only – passengers prohibited. miliar with this ATV at slow speeds first, even if you The long seat is to allow the operator to shift posi- are an experienced operator.
  • Page 64 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 65 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 mainte- Do not operate after or while consuming alco- nance procedures and schedules described in the hol or drugs.
  • Page 66  Do not exceed the maximum loading limits fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting for the vehicle (see “MAXIMUM LOADING screw limits the maximum engine power available LIMIT” in this section or vehicle labeling). ...
  • Page 67 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during ATV loading limit (total weight of cargo, rid- operation; otherwise, they may contact the rear er, accessories, and tongue): wheels. WARNING! Removing even one hand or 210.0 kg (463 lb) foot can reduce your ability to control the ATV Front carrier: or could cause you to lose your balance and...
  • Page 68 ATV should during operation or after leaving the ATV, do not be genuine Yamaha or equivalent components let brush, grass and other materials collect under designed for use on this ATV and should be in- the vehicle, near the muffler or exhaust pipe, or stalled and used according to instructions.

  • Page 69: 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 70 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do ways be alert to changing terrain conditions not ride on any paved public street, road or motor- when operating the ATV.
  • Page 71 terrain could cause loss of traction or ATV con- trol, which could result in an accident, includ- ing an overturn. [EWB01542] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 72: 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 EWB01772 WARNING of obstacles and other riders. You should practice control of the throttle, brakes, and turning techni- Always follow proper procedures for turning as ques in this area before trying more difficult ter- described in this Owner’s Manual.

  • Page 73: Climbing Uphill

    Improper riding procedures such as abrupt throt- tle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV be- gins to tip over to the outside while negotiating a turn, lean more to the inside.
  • Page 74  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 75 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 76: Riding Downhill

     Always check the terrain carefully before you around and remount, following the procedure de- scribed in the Owner’s Manual. WARNING! Stall- start down any hill.  Never operate the ATV on hills too steep for ing, rolling backwards improperly dismounting while climbing a hill could result in the ATV or for your abilities.

  • Page 77: Crossing A Slope

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

  • Page 78: Crossing Through Shallow Water

     Shift your weight to the uphill side of the ATV.  Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill.
  • Page 79 The ATV can be used to cross slow moving, shal- braking ability. WARNING! Wet brakes may have low water of up to a maximum of 35 cm (14 in) in reduced stopping ability, which could cause depth. Before entering the water, choose your loss of control.
  • Page 80 1. Air filter case check hose 1. Storage compartment check hose 1. V-belt cooling duct check hose (left front side of ATV) 1. V-belt case drain plug 7-20...

  • Page 81: Riding Over Rough Terrain

     Learn to safely control skidding or sliding by RIDING OVER ROUGH TERRAIN practicing at low speeds and on level, EWB01652 WARNING smooth terrain.  On extremely slippery surfaces, such as ice, Riding improperly over obstacles could cause loss of control or a collision. Before operating go slowly and be very cautious in order to re- in a new area, check for obstacles.

  • Page 82: What To Do If

    If the rear wheels of your ATV start to slide side- WHAT TO DO IF... ways, control can usually be regained (if there is This section is designed to be a reference guide room to do so) by steering in the direction of the only.
  • Page 83 USE THE REAR BRAKE IF THE ATV IS IN “2WD” – the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See page 7-13.)  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.

  • Page 84: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 85: Owner's Manual And Tool Kit

    Put the owner’s tool kit and low-pres- If you do not have the tools or experience required sure tire gauge under the seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s manual 2.

  • Page 86: 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 still be followed.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (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 88: 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 still be followed.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 89 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses •...
  • Page 90 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check operation and repair or replace if dam- √ √ √ √ √ Steering system aged. •...
  • Page 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check operation. • Check throttle lever free play, and adjust if neces- √ √ √ √ √...

  • Page 92: Checking The Spark Plug

    2. Remove the spark plug as shown, with the EBU23214 Checking the spark plug spark plug wrench included in the owner’s The spark plug is an important engine component, tool 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 ac- cordance with the periodic maintenance and lubri-...
  • Page 93 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 94: Engine Oil And Oil Filter Cartridge

    Tightening torque: Spark plug: If the engine was started before checking the oil 18 Nm (1.8 m·kgf, 13 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 95 To change the engine oil (with or without oil fil- ter cartridge replacement) The engine oil should be between the tip of the 1. Place the ATV on a level surface. dipstick and the maximum level mark. 2. Start the engine, warm it up for several minu- tes, and then turn it off.
  • Page 96 5. Remove the oil filter cartridge with an oil filter wrench. 1. Oil filter wrench An oil filter wrench is available at a nearby Yamaha dealer. 6. Apply a thin coat of engine oil to the O-ring of 1. Oil filter cartridge the new oil filter cartridge.
  • Page 97 1. O-ring 1. Torque wrench 7. Install the new oil filter cartridge with an oil fil- Tightening torque: ter wrench, and then tighten it to the specified Oil filter cartridge: torque with a torque wrench. 17 Nm (1.7 m·kgf, 12 ft·lbf) 8.

  • Page 98: Final Gear Oil

    Be sure to wipe off spilled oil on any parts after the age before each ride. If any leakage is found, have engine and exhaust system have cooled down. a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and ECB00301...
  • Page 99 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 filler bolt 2. Gasket 3. Final gear oil 4. Correct oil level 1.
  • Page 100 1. Final gear oil drain bolt 1. Final gear oil filler bolt 2. Gasket 2. Gasket 3. Final gear oil 5. Install the drain bolt and its new gasket, and 4. Correct oil level then tighten the bolt to the specified torque. Recommended final gear oil: Tightening torque: See page 10-1.

  • Page 101: Changing The Differential Gear Oil

    The differential gear case must be checked for oil 2. Gasket leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 102: Cleaning The Air Filter Element

    4. Install the drain bolt and its new gasket, and 6. Check the oil filler bolt gasket for damage, then tighten the bolt to the specified torque. and replace it if necessary. 7. Install the oil filler bolt and its gasket, and then Tightening torque: tighten the bolt to the specified torque.
  • Page 103 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 4-14.) case.
  • Page 104 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 105: Cleaning The Spark Arrester

    40 hours. It should be cleaned and lubricated damaged. more often if the ATV is operated in extremely 9. Apply Yamaha foam air filter oil or other qual- dusty areas. Each time the air filter element main- ity foam air filter oil to the sponge material.
  • Page 106 1. Tailpipe 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 muffler. the bolt holes. 3. Tap the tailpipe lightly, and then use a wire 5.

  • Page 107: 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. EBU23921 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 108: Adjusting The Carburetor

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

  • Page 109: Adjusting The Throttle Lever Free Play

    (a). To decrease the throttle lever free 1450–1550 r/min play, turn the adjusting bolt in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EBU24048 Adjusting the throttle lever free play...

  • Page 110: Valve Clearance

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

  • Page 111: Checking The Front Brake Pads And Rear Brake Shoes

    1. Brake pad aged or if the lining thickness is less than 1.0 mm 2. Lining thickness (0.04 in), have a Yamaha dealer replace the brake pads as a set. The wheels need to be removed to check the brake pads. (See page 8-46.)

  • Page 112: Checking The Brake Fluid Level

    Yamaha dealer replace the brake shoes as a set. 1. Minimum level mark Specified brake fluid: DOT 4 1. Wear limit line 2.

  • Page 113: Changing The Brake Fluid

     Use only the specified brake fluid; otherwise, EBU24283 Changing the brake fluid the rubber seals may deteriorate, causing Have a Yamaha dealer change the brake fluid at leakage.  Refill with the same type of brake fluid. Add- the intervals specified in the periodic maintenance and lubrication chart.

  • Page 114: Adjusting The Brake Pedal Height, And The Brake Pedal And Rear Brake Lever Free Play

     Before adjusting the brake pedal and brake le- ver free play, check the rear brake shoes for wear. Checking and adjusting the brake pedal height The top of the brake pedal should be positioned 72.0–82.0 mm (2.83–3.23 in) above the footboard bracket.
  • Page 115 1. Locknut 1. Footboard 2. Adjusting bolt 2. Bolt and nut 3. Bolt 4. Turn the adjusting bolt in or out until the brake pedal height is within the specified limits. 2. Check the brake pedal height. 5. Tighten the locknut. If the brake pedal height is correct, skip steps 3–5.
  • Page 116 1. Footboard bolt A 1. Brake pedal free play 2. Footboard bolt B 1. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the rear wheel Tightening torques: hub. Footboard bolt A: 2. Turn the brake pedal free play adjusting nut 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) on the brake cable at the rear wheel hub in di- Footboard bolt B:...
  • Page 117 1. Brake pedal free play adjusting nut 1. Brake lever free play 2. Brake lever free play adjusting nut 2. Locknut 3. Brake lever free play adjusting bolt Adjusting the brake lever free play 1. Loosen the locknut at the brake lever and fully The brake lever free play should measure 3.0–5.0 turn in the brake lever free play adjusting bolt.
  • Page 118 1. Brake lever free play adjusting nut 1. Locknut 2. Brake lever free play adjusting bolt 2. Gap “A” 4. Tighten the locknut at the brake lever. 3. Turn the brake lever free play adjusting bolt at 5. Check gap “A” again and, if necessary, adjust the brake lever in direction (a) to increase the free play, and in direction (b) to decrease it.

  • Page 119: Axle Boots

    The axle boots must be checked for damage at switches should be adjusted by a Yamaha dealer. the intervals specified in the periodic maintenance Turn the rear brake light switch adjusting nut while and lubrication chart.

  • Page 120: Checking And Lubricating The Front And Rear Brake Levers

    If a cable is damaged or does not move EBU28712 Checking and lubricating the front and smoothly, have a Yamaha dealer check or replace rear brake levers The operation of the front and rear brake levers Recommended lubricant: should be checked before each ride, and the lever Yamaha cable lubricant or other suitable pivots should be lubricated if necessary.

  • Page 121: Checking And Lubricating The Brake Pedal

    If there is play checked before each ride, and the pedal pivot in a wheel hub or if a wheel does not turn smooth- should be lubricated if necessary. ly, have a Yamaha dealer check the wheel hub bearings. Recommended lubricant: Lithium-soap-based grease...

  • Page 122: Lubricating The Steering Shaft

    Avoid contact with skin, eyes The steering shaft must be lubricated by a or clothing. Always shield your eyes when Yamaha dealer at the intervals specified in the pe- working near batteries. riodic maintenance and lubrication chart.
  • Page 123 [ECB01002] 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 elec- trical accessories.
  • Page 124 2. Connect the positive battery lead first, then ECB00932 NOTICE connect the negative battery lead by installing their bolt. NOTICE: When installing the bat- To charge a VRLA (Valve Regulated Lead Acid) tery, the main switch must be off, and the battery, a special (constant-voltage) battery charger is required.

  • Page 125: Replacing A Fuse

    EBU30671 Replacing a fuse The main fuse and the fuse box are located under the seat. (See page 4-14.) 1. Headlight fuse 2. Ignition fuse 3. Auxiliary DC jack fuse (for optional auxiliary DC jack) 4. Four-wheel-drive motor fuse 5. Signaling system fuse 1.
  • Page 126 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. 8-43...

  • Page 127: Replacing A Headlight Bulb

    EBU30661 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 128: Adjusting A Headlight Beam

    ECB00691 cohol or thinner. [ECB00652] 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 129: 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. EBU25702 EBU25652 Installing a wheel Removing a wheel 1.
  • Page 130  Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Tapered nut 3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified torques.

  • Page 131: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, ex- perience, and know-how to service the ATV prop- erly.

  • Page 132: Troubleshooting Chart

    Have a Yamaha dealer check the ATV. Check the compression. 4. Compression There is compression. The engine does not start. Have a Yamaha dealer check the ATV. Operate the electric starter. Have a Yamaha dealer check the ATV. There is no compression.

  • Page 133: Cleaning And Storage

    EBU25861 CLEANING AND STORAGE and deterioration of wheel bearings, EBU25882 Cleaning brakes, transmission seals and electrical Frequent, thorough cleaning of your ATV will not devices. Many expensive repair bills have only enhance its appearance but will improve its resulted from improper high-pressure de- general performance and extend the useful life of tergent applications such as those avail- many components.

  • Page 134: Storage

    EBU25934 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 135 tively, turn the wheels a little every month in order to prevent the tires from becoming de- graded 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 136: Specifications

    EBU25962 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) Single cylinder Overall height: Displacement: 1120 mm (44.1 in) 348 cm³ Bore × stroke: Seat height: 83.0 ×...
  • Page 137 Type: Quantity: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- 0.35 L (0.37 US qt, 0.31 Imp.qt) Air filter: Air filter element: 130 ˚F Wet element Fuel: SAE 5W-30 Recommended fuel: Regular unleaded gasoline only SAE 10W-30 Fuel tank capacity: SAE 10W-40 13.5 L (3.57 US gal, 2.97 Imp.gal) SAE 15W-40...
  • Page 138 Transmission type: Loading: V-belt automatic Maximum loading limit: Operation: 210.0 kg (463 lb) Left hand operation (Total weight of rider, cargo, accessories, and tongue) Forward gear: 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:...
  • Page 139 Specified brake fluid: Headlight: DOT 4 Bulb type: Rear brake: Krypton bulb Bulb voltage, wattage × quantity: Type: Drum brake Headlight: 12 V, 30.0/30.0 W × 2 Operation: Left hand and right foot operation Tail/brake light: 12 V, 5.0/21.0 W × 1 Front suspension: Type: Meter lighting:...
  • Page 140 EBU30402 For Europe only The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of work-force include the characteristics of the work room, the other sources of noise, etc.

  • Page 141: Consumer Information

    Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number (front left side)
  • Page 142 1. Model label 11-2...
  • Page 143 INDEX Drive select lever safety system cable, adjusting ..8-27 Accessories and loading ..........6-6 Air filter element, cleaning ........... 8-19 Engine break-in .............. 6-4 Axle boots ..............8-36 Engine, cold start ............6-1 Engine idling speed ............. 8-25 Engine oil ............... 5-3 Battery .................
  • Page 144 Starter (choke) .............. 4-14 Start switch ..............4-5 Main switch ..............4-1 Steering shaft, lubricating ..........8-39 Maintenance and lubrication chart ........8-5 Storage ................9-2 Maintenance chart, emission control system ....8-3 Storage compartment ..........4-15 Model label ..............11-1 Tail/brake light bulb, replacing ........8-46 Neutral indicator light .............4-2 Throttle lever ............
  • Page 146 EBU26173 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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