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

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OWNER'S MANUAL
YFM350FWA-W
YFM350A-W
38P-F8199-70

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Summary of Contents for Yamaha GRIZZLY 350

  • Page 1 OWNER’S MANUAL YFM350FWA-W YFM350A-W 38P-F8199-70...
  • Page 2 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 3 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 4: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Fuel tank cap ..........4-11 Fuel ............4-11 LOCATION OF THE WARNING AND Fuel cock ..........4-13 SPECIFICATION LABELS ......2-1 Starter (choke) ..........4-14 Steering lock ..........4-15 DESCRIPTION ..........3-1 Seat ............4-15 Left view ............3-1 Storage compartment .......4-16 Right view............
  • Page 5 Measuring the tire pressure ....... 5-5 SLIDING AND SKIDDING ......7-22 Tire wear limit ..........5-6 WHAT TO DO IF........7-24 Chassis fasteners ........5-7 WHAT TO DO..........7-24 Instruments, lights and switches ....5-7 PERIODIC MAINTENANCE AND MINOR OPERATION ..........6-1 REPAIR ............8-1 Starting a cold engine ........
  • Page 6 Checking the front brake pads and Troubleshooting ........8-40 rear brake shoes ........8-26 Troubleshooting chart .......8-41 Checking the brake fluid level ....8-27 Changing the brake fluid ......8-28 CLEANING AND STORAGE ......9-1 Checking the front brake lever free Cleaning ............9-1 play ............

  • Page 7: 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 8 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 9 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 10 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 11: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...

  • Page 12: Load Limit

    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. LOAD LIMIT 40 kg (88 lbs)
  • Page 13 LOAD LIMIT 80 kg (176 lbs) 5ND-F4897-20 Before you operate this vehicle, read the owner's manual. Lesen Sie die Bedlenungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario. < 16 Lire le manuel du propriétaire avant d'utiliser ce véhicule.

  • Page 14: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Fuel cock 1. Rear shock absorber assembly spring preload adjusting ring 2. Throttle stop screw 2. Storage compartment and tool kit 3. Air filter case 3. Spark plug 4. Fuses 4. Front shock absorber assembly spring preload adjusting 5.

  • Page 15: Controls And Instruments

    EBU17712 Controls and instruments 6 7 8 9 10 11 12 1. Rear brake lever 2. Left handlebar switches 3. Starter (choke) 4. Parking brake lock plate 5. Drive select lever 6. Speedometer 7. Main switch 8. Fuel tank cap 9.

  • Page 16: Instrument And Control Functions

    EBU17732 INSTRUMENT AND CONTROL FUNCTIONS EBUM0020 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The auxiliary light, meter lighting and taillight come on when the light switch is on, and the engine can be started.

  • Page 17: Indicator Lights And Warning Light

    If the warning light does not come on while the start switch is pushed to the left or right. switch is being pushed, then go off after the start switch is released, have a Yamaha dealer check the electrical circuit.

  • Page 18: Speedometer

    Speedometer cool. If the warning light stays on when the engine The speedometer shows the riding speed. This is cool, have a Yamaha dealer check the electrical speedometer is equipped with an odometer and a circuit. tripmeter. The tripmeter can be reset to “0” with the ECB00010 reset knob.

  • Page 19: Handlebar Switches

    EBU18061 Handlebar switches 1. Engine stop switch “ ” EBU18080 Engine stop switch “ ” Set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and 1. Light switch “ / ” 2. Hazard switch “ ”...
  • Page 20 EBU28061 EBU28000 Light switch “ / ” Hazard switch “ ” Set the switch to “ ” to turn on the high beam. With the key in the “ON” position, turn this switch Set this switch to “ ” to turn on the low beam. to “...

  • Page 21: Throttle Lever

    To change from two-wheel drive to four-wheel circumstances. Changing from two-wheel drive, stop the ATV and push the switch in to the drive to four-wheel drive or vice versa while “4WD” position. The four-wheel-drive indicator moving may cause the ATV to unexpectedly light “...

  • Page 22: 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 23: Front Brake Lever

    3. Tighten the locknut. EWB00240 WARNING Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be dam- aged.

  • Page 24: Brake Pedal

    1. Brake pedal 1. Rear brake lever EBU18460 EBUM0030 Parking brake Brake pedal Use the parking brake before starting the engine or The brake pedal is located on the right side of the parking the ATV, especially on a slope. Apply the ATV.

  • Page 25: Drive Select Lever

    EBU18581 Drive select lever The drive select lever is used to shift your ATV into the forward, neutral and reverse positions. See the “Operating the drive select lever and driving in re- verse” section on page 6-3 for the drive select lever operation.

  • Page 26: Fuel Tank Cap

    1. Recoil starter 1. Fuel tank cap EWB00340 EBU18752 WARNING Fuel Shift the drive select lever into the neutral po- Make sure that there is sufficient fuel in the tank. sition and apply the parking brake before start- Fill the fuel tank to the bottom of the filler tube as ing the engine, otherwise the ATV could start shown.
  • Page 27 NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade. ECB00070 CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

  • Page 28: Fuel Cock

    EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car- buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel flows to the carburetor.

  • Page 29: 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 30: Steering Lock

    EBU28010 To unlock the steering Steering lock 1. Open the steering lock cap, and then insert the key. 2. Turn the key 1/8 turn counterclockwise to re- lease the lock. 3. Remove the key, and then close the steering lock cap. EBU18880 Seat To remove the seat...

  • Page 31: Storage Compartment

    To install the seat EBU18911 Storage compartment Insert the projections on the front of the seat into ECB00130 the seat holders and push down on the seat at the CAUTION: rear. Do not store metal or sharply edged objects, NOTE: like tools, in the storage compartment.

  • Page 32: Front Carrier

    EBU18971 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 compartment. If any water collects in this hose, re- lb) for the rear carrier. move the hose, empty it, and then install it. Do not exceed the maximum load of 196.0 kg (432 lb) for the ATV.
  • Page 33 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 dealer to make this adjustment. Standard: Maximum (hard): 4-18...

  • Page 34: Adjusting The Rear Shock Absorber Assembly

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

  • Page 35: Catalytic Converter

    EWBM0010 WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. ECBM0010 CAUTION: The following precautions must be observed to prevent a fire hazard or other damages. Use only unleaded gasoline. The use of lead- ed gasoline will cause unrepairable damage 1.

  • Page 36: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 37 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. Hydraulic brake system 5-3, 8-26, 8-27, 8-29 • Check brake fluid level in reservoirs, and add recommended brake fluid to specified level if necessary.

  • Page 38: 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 39: Throttle Lever

    Apply the brake when released. Have a Yamaha dealer correct if firmly for one minute. If the lever moves slowly in- necessary.

  • Page 40: Measuring The Tire Pressure

    Size: Minimum tire pressure: AT25 x 8-12 31J Front: Type: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Tubeless Rear: Rear: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Manufacturer/model: • Use no more than the following pressures MAXXIS/M912Y when seating the tire beads. Size: Maximum tire seating pressure: AT25 x 10-12 38J...

  • Page 41: 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 42: 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 43: 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 44 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 45: 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 46: 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 47: 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 48: 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 49 could make steering difficult, an accessory that NOTE: limits your ability to move around on the seat, or Never exceed the maximum tongue weight (verti- one that limits your view. cal weight on trailer hitch point) of 147 N (33 lbf) Use extra caution when riding an ATV with ac- (15 kgf).
  • Page 50 Allow more braking distance. A heavier ATV takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. EWB00820 WARNING Never exceed the stated load capacity for this ATV.

  • Page 51: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 52: Getting To Know Your Atv

    EBUM0084 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 53 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 54 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 55 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 56 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 57 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 58 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 59: 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 60 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 61 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 62 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 63: Turning Your Atv

    With the engine idling, return the starter (choke) to EWB01570 WARNING the closed position, shift the drive select lever into the forward position, and then release the parking Always follow proper procedures for turning brake. Apply the throttle slowly and smoothly. The as described in this Owner’s Manual.

  • Page 64: 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 65 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 66 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 67: Riding Downhill

    hill side could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV imme- diately on the uphill side. EWB01791 WARNING Maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.

  • Page 68: Crossing A Slope

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

  • Page 69: 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 70 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 71 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 72: 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 73 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 74: 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 75: Periodic Maintenance And Minor Repair

    EBU28781 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 76 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 77: 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 78 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 79: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
  • Page 80 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for wear, cracks or other damage, and re- √ √ √ √ V-belt place if necessary. •...
  • Page 81 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Moving parts and √ √ √ √ 20 * • Lubricate. cables Drive select lever • Check operation and adjust or replace if neces- √...
  • Page 82 • Replace the brake hoses every four years and if cracked or damaged.

  • Page 83: 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 84 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 85: 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 86 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 87 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 88 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 89: 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- ECB00300 dition, the final gear oil level must be checked and...
  • Page 90 To change the final gear oil NOTE: 1. Place the ATV on a level surface. The oil level should be at the brim of the filler hole. 2. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil 2.
  • Page 91 1. Final gear oil drain bolt 1. Final gear oil 2. Final gear oil filler bolt 5. Install the drain bolt, and then tighten it to the 3. Correct oil level 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) ECB00420...

  • Page 92: Changing The Differential Gear Oil (4Wd Model)

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 93 The differential gear case capacity is greater than the recommended oil quantity, therefore the oil level cannot be accurately checked from the oil filler hole. Recommended differential gear oil: See page 10-1. Oil quantity: YFM350FWA 0.35 L (0.37 US qt) (0.31 Imp.qt) 1.

  • Page 94: Cleaning The Air Filter Element

    EBU23644 2. Remove the seat. (See page 4-15.) Cleaning the air filter element 3. Remove the air filter case cover by unhooking The air filter element should be cleaned at the in- the air filter case cover holders. tervals specified in the periodic maintenance and lubrication chart.
  • Page 95 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 96 ECB00440 11. Insert the air filter element into the air filter CAUTION: case, and then install the air filter case cover by hooking the holders onto the air filter case. Do not twist the sponge material when squeez- 12. Install the seat. ing it.

  • Page 97: V-Belt Cooling Duct Check Hose

    NOTE: poor performance and possible engine over- If water drains from the V-belt case after removing heating. 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 98: Adjusting The Engine Idling Speed

    (a), and to decrease The carburetor has been set and extensively it, turn the screw in direction (b). tested at the Yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performance of or damage to the engine.

  • Page 99: Adjusting The Throttle Cable Free Play

    1. Loosen the locknut. must be adjusted by a Yamaha dealer at the inter- 2. To increase the throttle cable free play, turn vals specified in the periodic maintenance and lu- the throttle cable free play adjusting bolt in di- brication chart.

  • Page 100: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm The rear brake is provided with a wear indicator, (0.04 in), have a Yamaha dealer replace the brake which allows you to check the brake shoe wear pads as a set.

  • Page 101: Checking The Brake Fluid Level

    Yamaha dealer replace the brake shoes as a set. pads for wear and the brake system for leakage. Front brake 1.

  • Page 102: Changing The Brake Fluid

    1. Minimum level mark EBUM0120 Changing the brake fluid 2. Maximum level mark Have a Yamaha dealer change the brake fluid at Observe these precautions: the intervals specified in the NOTE after the peri- When checking the fluid level, make sure that odic maintenance and lubrication chart.

  • Page 103: Checking The Front Brake Lever Free Play

    (zero in) as shown. If the free Replacement of brake components requires play is incorrect, have a Yamaha dealer check the professional knowledge. These procedures brake system. should be performed by a Yamaha dealer.
  • Page 104 1. Brake lever free play The brake pedal should have a free play of 0.0– 12.0 mm (0.00–0.47 in) as shown. If the free play is incorrect, have a Yamaha dealer check the brake system. 1. Distance between brake pedal and footboard bracket...

  • Page 105: Axle Boots

    The axle boots must be checked for damage at the adjusted as follows, but the other brake light intervals specified in the periodic maintenance and switches should be adjusted by a Yamaha dealer. lubrication chart. Check the axle boots for tears or 1. Remove panel A. (See page 8-9.) damage.

  • Page 106: Checking And Lubricating The Cables

    Silicone grease cables and cable ends should be lubricated if nec- Rear brake lever: essary. If a cable is damaged or does not move Lithium-soap-based grease smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil 8-32...

  • Page 107: Checking And Lubricating The Brake Pedal

    Front brake lever EBU24951 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. NOTE: To access the brake pedal pivot, remove panel A. (See page 8-9.) Recommended lubricant: Silicone grease...

  • Page 108: Checking The Wheel Hub Bearings

    If there is play EWB02160 in a wheel hub or if a wheel does not turn smoothly, WARNING have a Yamaha dealer check the wheel hub bear- Battery electrolyte is poisonous and danger- ings. ous, as it contains sulfuric acid, which can cause severe burns.
  • Page 109 To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.

  • Page 110: Replacing A Fuse

    EBU25324 Replacing a fuse 1. Headlight fuse 2. Ignition fuse 3. Auxiliary DC jack fuse (for optional auxiliary DC jack) 1. Main fuse 2. Spare main fuse 4. Four-wheel-drive motor fuse 5. Signaling system fuse 3. Fuse box 6. Spare fuse 4.

  • Page 111: Headlight Bulb

    30.0 A Yamaha dealer check the electrical system. Headlight fuse: EBU28160 15.0 A Headlight bulb Ignition fuse: If the headlight bulb burns out, have a Yamaha 15.0 A dealer replace it. Four-wheel-drive motor fuse: YFM350FWA 3.0 A EBU28170 Signaling system fuse: Headlight beam 10.0 A...

  • Page 112: Replacing A Turn Signal Light Bulb

    EBU28030 EBU28020 Replacing a turn signal light bulb Auxiliary light bulb 1. Remove the turn signal light lens by removing If the auxiliary light bulb burns out, have a Yamaha the screw. dealer replace it. EBU25651 Removing a wheel 1. Place the ATV on a level surface.

  • Page 113: Installing A Wheel

    EBU25701 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts. NOTE: The arrow mark on the tire must point toward the rotating direction of the wheel. Tapered nuts are used for both the front and rear wheels.

  • Page 114: 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 115: 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 116: 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 117: 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 118 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 8-34.

  • Page 119: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 1940 mm (76.4 in) Electric and recoil starter Overall width: Lubrication system: 1085 mm (42.7 in) Wet sump Overall height: Engine oil: 1120 mm (44.1 in) Seat height: Type: 827 mm (32.6 in) SAE 5W-30 or SAE 10W-30 or SAE 10W-40 or SAE Wheelbase:...
  • Page 120 Engine oil quantity: Spark plug (s): Without oil filter cartridge replacement: Manufacturer/model: 2.20 L (2.33 US qt) (1.94 Imp.qt) NGK/DR8EA With oil filter cartridge replacement: Spark plug gap: 2.30 L (2.43 US qt) (2.02 Imp.qt) 0.6–0.7 mm (0.024–0.028 in) Final gear oil: Clutch: Type: Clutch type:...
  • Page 121 Front tire: Maximum: Front: Type: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Tubeless Rear: Size: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) AT25 x 8-12 31J Front wheel: Manufacturer/model: MAXXIS/M911Y Wheel type: Rear tire: Panel wheel Rim size: Type: 12 x 6.0AT Tubeless Rear wheel: Size:...
  • Page 122 Bulb voltage, wattage × quantity: Operation: Right foot operation Headlight: 12 V, 35.0/35.0 W × 1 Front suspension: Type: Tail/brake light: 12 V, 5.0/21.0 W × 1 Double wishbone Spring/shock absorber type: Front turn signal light: 12 V, 10.0 W × 2 Coil spring/oil damper Wheel travel: Rear turn signal light:...
  • Page 123 Ignition fuse: 15.0 A Auxiliary DC jack fuse: 10.0 A Accessory fuse: 7.5 A Four-wheel-drive motor fuse: YFM350FWA 3.0 A 10-5...

  • Page 124: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 125 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 126 1. Model label 11-3...
  • Page 127 INDEX Accessories and loading ..........6-6 Differential gear oil (4WD model) ........5-3 Air filter element, cleaning ..........8-20 Differential gear oil, changing (4WD model) ....8-18 Auxiliary light bulb ............8-38 Drive select lever ............4-10 Axle boots ..............8-31 Drive select lever and driving in reverse ......
  • Page 128 Identification numbers ..........11-1 Safety information ............1-1 Indicator lights and warning light ........4-2 Seat ................4-15 Instruments, lights and switches ........5-7 Shock absorber assemblies, adjusting the front ..4-17 Shock absorber assembly, adjusting the rear ....4-19 Spark plug, checking ............
  • Page 129 Wheel hub bearings, checking ........8-34 Wheel, installing ............8-39 Wheel, removing ............8-38...
  • Page 130 YAMAHA MOTOR CO., LTD. PRINTED IN FRANCE 2008.01...

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