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Yamaha GRIZZLY 350 YFM35FGW, Owner'S Manual, Page: 109 / 138

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Yamaha GRIZZLY 350 YFM35FGW Owner'S Manual Download Page 109

8-30

8

Adjusting the brake lever free play

The brake lever free play should measure 3.0–5.0
mm (0.12–0.20 in) as shown. If the free play is in-
correct, adjust it as follows.

1. Loosen the locknut at the brake lever and fully

turn in the brake lever free play adjusting bolt.

2. Turn the brake lever free play adjusting nut on

the brake cable at the rear wheel hub so that
gap “A” measures 0–1 mm (0–0.04 in).

1. Brake pedal free play adjusting nut
2. Brake lever free play adjusting nut

1. Brake lever free play
2. Locknut

3. Brake lever free play adjusting bolt

U5UH63E0.book  Page 30  Wednesday, April 26, 2006  9:21 AM

Summary of Contents for GRIZZLY 350 YFM35FGW

Page 1: ...YFM35FGW OWNER S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO 5UH F8199 63 ...

Page 2: ...PRINTED IN USA 2006 05 0 3 1 CR E F S YAMAHA MOTOR CO LTD ...

Page 3: ...OWNER S MANUAL YFM35FGW 5UH F8199 63 E0 U5UH63E0 book Page 1 Wednesday April 26 2006 9 21 AM ...

Page 4: ...cable and to the other relevant EEC Directives 89 336 EEC Title and or number and date of issue of the other EEC Directives if applicable To effect correct application of the essential health and safety requirements stated in the EEC Directives the following standards and or technical specifications were consulted Title and or number and date of issue of standards and or specifications NL 1119 NC ...

Page 5: ...operation of this ATV This manual includes important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL COMPLETELY BEFORE OPERATIN...

Page 6: ...hange without notice 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 repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage to the ATV A NOTE provides key information to make procedures easier or c...

Page 7: ...ce paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17410 YFM35FGW OWNER S MANUAL 2006 by Yamaha Motor Co Ltd 1st edition April 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A U5UH63E0 book Page 1 Wednesday April 26 2006 9 21...

Page 8: ...4 7 Parking brake 4 8 Drive select lever 4 9 Recoil starter 4 9 Fuel tank cap 4 10 Fuel 4 10 Fuel cock 4 12 Starter choke 4 13 Seat 4 13 Storage compartment 4 14 Front carrier 4 15 Rear carrier 4 15 Adjusting the front shock absorber assemblies 4 16 Adjusting the rear shock absorber assembly 4 17 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Diffe...

Page 9: ...NOR REPAIR 8 1 Owner s manual and tool kit 8 1 Periodic maintenance and lubrication chart 8 3 Removing and installing the panel 8 8 Checking the spark plug 8 8 Engine oil and oil filter cartridge 8 10 Final gear oil 8 14 Changing the differential gear oil 8 17 Cleaning the air filter element 8 19 Cleaning the spark arrester 8 21 V belt cooling duct check hose 8 23 V belt case drain plug 8 23 Adjus...

Page 10: ...34 Lubricating the upper and lower arm pivots 8 35 Lubricating the knuckle shafts 8 35 Lubricating the steering shaft 8 35 Battery 8 35 Replacing a fuse 8 37 Replacing a headlight bulb 8 39 Adjusting a headlight beam 8 41 Replacing the tail brake light bulb 8 41 Removing a wheel 8 41 Installing a wheel 8 42 Troubleshooting 8 43 Troubleshooting chart 8 44 CLEANING AND STORAGE 9 1 Cleaning 9 1 Stora...

Page 11: ...ild if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Watch carefully for other vehicles when operat ing on unpaved public streets or roads Make sure you know your country s la...

Page 12: ...bing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully b...

Page 13: ...es may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribed in ...

Page 14: ...s If you should swal low some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are poiso...

Page 15: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5UH63E0 book Page 1 Wednesday April 26 2006 9 21 AM ...

Page 16: ...s contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer For Europe and Oceania U5UH63E0 book Page 2 Wednesday April 26 2006 9 21 AM ...

Page 17: ...2 3 2 For Europe U5UH63E0 book Page 3 Wednesday April 26 2006 9 21 AM ...

Page 18: ...2 4 2 For Europe U5UH63E0 book Page 4 Wednesday April 26 2006 9 21 AM ...

Page 19: ...2 5 2 For Oceania U5UH63E0 book Page 5 Wednesday April 26 2006 9 21 AM ...

Page 20: ...2 6 2 For Oceania U5UH63E0 book Page 6 Wednesday April 26 2006 9 21 AM ...

Page 21: ...gine oil filler cap 9 Oil filter cartridge 10 V belt cooling duct check hose 1 Rear shock absorber assembly spring preload adjusting ring 2 Spark arrester 3 Storage compartment and tool kit 4 Spark plug 5 Front shock absorber assembly spring preload adjusting ring 6 Brake light switch 7 Brake pedal 8 V belt case drain plug U5UH63E0 book Page 1 Wednesday April 26 2006 9 21 AM ...

Page 22: ...hown 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 Speedometer 8 Main switch 9 Fuel tank cap 10 On Command four wheel drive switch 11 Throttle lever 12 Front brake lever U5UH63E0 book Page 2 Wednesday April 26 2006 9 21 AM ...

Page 23: ...ows ON 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 The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U5UH63E0 book Page 1 Wednesday April 26 2006 9 21 AM ...

Page 24: ...ng the start switch If the warning light does not come on while the start switch is being pushed then go off after the start switch is released have a Yamaha dealer check the electrical circuit If the warning light stays on allow the engine to cool If the warning light stays on when the engine is cool have a Yamaha dealer check the electrical circuit CAUTION ECB00010 The engine may overheat if the...

Page 25: ...til the ATV starts moving EBU18020 Speedometer The speedometer shows the riding speed This speedometer is equipped with an odometer and a tripmeter The tripmeter can be reset to 0 with the reset knob Use the tripmeter to estimate how far you can ride on a tank of fuel before going to re serve This information will enable you to plan fuel stops in the future 1 Reset knob 2 Speedometer 3 Odometer 4 ...

Page 26: ...6 1 prior to starting the engine EBU18160 Light switch OFF Set this switch to to turn on the low beams the taillight and the meter lighting Set the switch to to turn on the high beams the taillight and the meter lighting Set the switch to OFF to turn off all the lights CAUTION ECB00040 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may di...

Page 27: ...nd push the switch in to the 4WD position To change from four wheel drive to two wheel drive stop the ATV and push the switch in to the 2WD position WARNING EWB00161 Always stop the ATV before changing from two wheel drive to four wheel drive and vice versa The ATV handles differently in two wheel drive than in four wheel drive in some circumstances Changing from two wheel drive to four wheel driv...

Page 28: ...slow down when you need to This could cause an accident Check the op eration of the throttle lever before you start the engine If the throttle does not work smoothly check for the cause Correct the problem be fore riding the ATV or consult a Yamaha dealer EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when...

Page 29: ... 0 5 0 mm 0 12 0 20 in See page 8 25 EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull the brake lever toward the handlebar grip 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 peda...

Page 30: ...he parking brake Squeeze the rear brake lever to release the parking brake WARNING EWB00220 Always set the parking brake before starting the engine The ATV could start moving un expectedly if the parking brake is not ap plied This could cause loss of control or a collision 1 Brake pedal 1 Rear brake lever 1 Parking brake lock plate U5UH63E0 book Page 8 Wednesday April 26 2006 9 21 AM ...

Page 31: ...8581 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 EBU18670 Recoil starter Firmly grasp the handle and pull slightly until en gagement can be felt Then pull forcefully being careful not to pull the rope all th...

Page 32: ...could start to move unexpectedly which could cause an accident EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise EBU18750 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Recoil starter 1 Fuel tank cap U5UH63E0 book Page 10 Wednesday April 26 2006 9 21 AM ...

Page 33: ...o heat from the en gine or the sun Be careful not to spill fuel especially on the engine or exhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely 1 Fuel level 2 Fuel tank filler tube Recommended fuel UNLEADED GASOLINE ONLY For Europe Regular ...

Page 34: ...With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this position when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark pointing to OFF 1 Arrow mark pointing to ON U5UH63E0 book Page 12 Wednesday April 26 2006 9 21...

Page 35: ...oke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the 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 EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at th...

Page 36: ...t is securely fitted EBU18911 Storage compartment CAUTION ECB00130 Do not store metal or sharply edged objects like tools in the storage compartment If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartment 1 Seat 2 Seat lock lever 1 Projection 2 Seat holder U5UH63E0 book Page 14 Wednesday April 26 2006 9 21 AM ...

Page 37: ... the hose empty it and then install it EBU18960 Front carrier Do not exceed the load limit of 40 0 kg 88 lb for the front carrier Do not exceed the maximum load of 210 0 kg 463 lb for the ATV EBU18970 Rear carrier Do not exceed the load limit of 80 0 kg 176 lb for the rear carrier Do not exceed the maximum load of 210 0 kg 463 lb for the ATV 1 Storage compartment 1 Storage compartment check hose U...

Page 38: ...ion a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 U5UH63E0 book Page 16 Wednesd...

Page 39: ... can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjus...

Page 40: ...4 18 4 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 U5UH63E0 book Page 18 Wednesday April 26 2006 9 21 AM ...

Page 41: ...commended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 10 Final gear oil Check ATV for oil leakage Correct if necessary 5 3 8 14 Differential gear oil Check ATV for oil leakage Correct if necessary 5 3 8 17 Front brake Check operation If soft or spongy have Yamaha dealer bleed hy draulic system Check brake pads for wear and replace if necessary Check br...

Page 42: ...th Lubricate if necessary 8 33 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 5 5 5 6 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 34 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 33 Axl...

Page 43: ...e that the final gear oil is at the specified level Add oil as necessary See page 8 14 EBU19600 Differential gear oil Make sure that the differential gear oil is at the specified level Add oil as necessary See page 8 17 EBU27670 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front brake lever If there is free play have a Yamaha dealer check the brake sys...

Page 44: ...ou could lose braking ability which could lead to an accident If a problem cannot be corrected by the adjust ment procedures provided in this manual have a Yamaha dealer check for the cause EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19811 Tires WARNING EWB005...

Page 45: ...inimum tire pressure Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm Rear 250 kPa 36 psi 2 5 kgf cm Higher pressures and fast inflation may cause a tire to burst Inflate the tires very slowly and carefully EBU19820 Measuring the tire pressure Use...

Page 46: ...e groove decreases to 3 mm 0 12 in 1 Low pressure tire gauge Recommended pressure Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm U5UH63E0 book Page 6 Wednesday April 26 2006 9 21 AM ...

Page 47: ...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 1 Tire wear limit U5UH63E0 book Page 7 Wednesday April 26 2006 9 21 AM ...

Page 48: ...h could lead to an acci dent or collision CAUTION ECB00150 See the Engine break in section on page 6 4 prior to operating the engine for the first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to 4 Shift the drive select lever into the neutral po sition The neutral indicator light should come on If the indicator light does not come ...

Page 49: ...o preserve battery ener gy Do not crank the engine more than 10 sec onds on each attempt If the battery is discharged pull the recoil starter to start the engine 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 engine If the engine is started with the starter choke in position 2 keep the starter choke in this position...

Page 50: ...lever and driving in reverse CAUTION ECB00170 Before shifting stop the ATV otherwise the transmission may be damaged Shifting Forward 1 Bring the ATV to a complete stop 2 Shift from neutral to forward and vice versa by moving the drive select lever along the shift guide NOTE Make sure that the drive select lever is completely shifted into position 3 Open the throttle lever gradually Shifting Rever...

Page 51: ...ous injury When you shift into reverse make sure there are no people or ob stacles behind you When it is safe to proceed go slowly EBU20681 Engine break in There is never a more important period in the life of your engine than the first 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first...

Page 52: ...When parking the ATV stop the engine shift the drive select lever into the forward position apply the parking brake and then turn the fuel cock to OFF EBU20760 Parking on a slope WARNING EWB00830 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 chance of an accident If you must park on an incline place the ATV tr...

Page 53: ...d for your ATV Your Yamaha dealer has a variety of gen uine Yamaha accessories Other accessories may also be available on the market However it is not possible for Yamaha to test all non Yamaha accessories nor control over their qual ity or suitability Choose a genuine Yamaha ac cessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory ...

Page 54: ...aximum tongue weight You can measure tongue weight with a bath room scale Put the tongue of the loaded trailer on the scale with the tongue at hitch height Ad just the load in the trailer if necessary to reduce the weight on the hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum ATV load limit MAXIMUM LOADING LIMIT ATV loading limit total weight of rider ...

Page 55: ... carry the slower you should go 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 WARNING EWB00820 Never exceed the stated load capacity for this ATV Overloading this ATV or carrying or tow ing cargo improperly could caus...

Page 56: ...7 1 7 EBU21141 RIDING YOUR ATV U5UH63E0 book Page 1 Wednesday April 26 2006 9 21 AM ...

Page 57: ...information on pages 1 1 1 4 Please also read all caution and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the...

Page 58: ...hild This ATV is designed to carry operator and car go only passengers prohibited WARNING EWB01400 Never carry a passenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or your...

Page 59: ... 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 U5UH63E0 book Page 4 Wednesday April 26 2006 9 21 AM ...

Page 60: ...ances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s performance capability is reduced by the influence of alcohol or drugs WARNING EWB01420 Never consume alcohol or drugs before or while driving this ATV Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding for proper care of the ATV and to ensure...

Page 61: ...NING EWB01450 Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at speeds too fast for your skills or the conditions in creases your chances of losing control of the ATV which can result in an accident Speed limiter For riders less experienced with this model the throttle lever housing is equipped with a speed lim iter T...

Page 62: ...ak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards during op eration otherwise they may contact the rear wheels MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 210 0 kg 463 lb Front carrier 40 0 kg 88 lb Rear carrier 80 0 kg 176 lb Storage compartme...

Page 63: ...to con tact with the rear wheels which could injure you or cause an accident Avoid wheelies and jumping You may lose control of the ATV or overturn WARNING EWB01480 Never attempt stunts such as wheelies or jumps Don t try to show off Modifications WARNING EWB01490 Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be gen ui...

Page 64: ...tible materials to pre vent causing a fire hazard WARNING EWB01500 Do not touch the hot exhaust system Do not park the ATV during or after operation in a place where others might be likely to touch it Do not operate idle or park the ATV in dry grass dry ground cover or combustible ma terials BE CAREFUL WHERE YOU RIDE This ATV is designed for use on unpaved surfaces only Riding on paved surfaces ca...

Page 65: ...ads Do not ride on any paved public street road or motorway WARNING EWB01520 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 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden haz...

Page 66: ...racticed the skills necessary to control the ATV on such terrain Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket a...

Page 67: ...u should practice control of the throttle brakes and turning tech niques in this area before trying more difficult ter rain Always avoid riding on paved surfaces the ATV is designed for use on unpaved surfaces only and handling maneuvers are more difficult to per form on pavement Set the parking brake and follow the instruction on page 6 1 to start the engine Once it has warmed up you are ready to...

Page 68: ... axle and turn together at the same speed There fore unless the wheel on the inside of the turn is al lowed to slip or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed WARNING EWB01570 Always follow proper procedures for turning as described in this...

Page 69: ...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 It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid ATV over tu...

Page 70: ...proper procedures for climb ing hills as described in this Owner s Manu al Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person coul...

Page 71: ... stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose control If you are unable to continue up the hill dismount the ATV on the up hill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply either brake abruptly If you are in 2WD apply only the front bra...

Page 72: ...d lock the parking brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and re mount following the procedure described in the Owner s Manual RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Engine compression will do most of the brakin...

Page 73: ...our path and ride no faster than you will be able to react to ob stacles which may appear WARNING EWB01620 Always follow proper procedures for going down hills as described in this Owner s Manu al Note a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avo...

Page 74: ...mpt 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 When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your we...

Page 75: ...may float causing loss of traction and loss of control which could lead to an accident Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability CAUTION ECB00280 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 chec...

Page 76: ...Wash the ATV in fresh water if it has been operated in salt water or muddy conditions 1 Air filter case check hose 1 V belt cooling duct check hose left front side of ATV 1 Drive select lever box check hose U5UH63E0 book Page 21 Wednesday April 26 2006 9 21 AM ...

Page 77: ...er attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manu al SLIDING AND SKIDDING Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in...

Page 78: ...od of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are re duced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost WARNING EWB01661 Learn to safely control skidding or sliding by practicing at low speeds an...

Page 79: ...d the slide See page 7 22 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT 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 14 If your ...

Page 80: ...IDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with maintenan...

Page 81: ...ce required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for use on this ATV and should be installe...

Page 82: ... skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1200 750 2400 1500 2400 1500 4800 3000 hours 20 75 150 150 300 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if necessary 4 Air filter element Cl...

Page 83: ... Wheel bearings Check for looseness or damage and replace if necessary 11 Swingarm Check for excessive play and correct if necessary 12 Upper and lower arm pivots Lubricate with lithium soap based grease 13 V belt Check for wear cracks or other damage and re place if necessary 14 Drive shaft univer sal joint Lubricate with lithium soap based grease 15 Chassis fasteners Make sure that all nuts bolt...

Page 84: ...mage and replace if necessary 22 Carburetor Check starter choke operation and correct if nec essary Check engine idling speed and adjust if neces sary 23 Crankcase breather system Check breather hose for cracks or other damage and replace if necessary 24 Engine oil Change Check ATV for oil leakage and correct if neces sary 25 Engine oil filter car tridge Replace 26 Differential gear oil Change Che...

Page 85: ...lever housing and cable 31 Exhaust system Check for leakage and replace gasket s if neces sary Check for looseness and tighten all screw clamps and joints if necessary 32 Spark arrester Clean 33 Front and rear brake switches Check operation and correct if necessary 34 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY ...

Page 86: ...ulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U5UH63E0 book Page 7 Wednesday April 26 2006 9 21 AM ...

Page 87: ...move the bolt and then take the panel off To install the panel Place the panel in the original position and install the bolt CAUTION ECB00380 When installing the panel be sure not to pinch the cables or wires EBU23211 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark 1 Panel A 1...

Page 88: ... plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally NOTE 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...

Page 89: ...is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap EBU23311 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 cha...

Page 90: ...it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 6 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level 7 Insert the dipstick into the oil filler hole and then tighten the engine oil filler cap 1 Engine oil filler cap 1 Dipstick 2 Maximum le...

Page 91: ...n under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase NOTE Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil drain bolt 1 Oil filter cartridge 1 Oil filter wrench U5UH63E0 book Page 12 Wednesday April 26 2006 ...

Page 92: ... and then tighten it to the specified torque with a torque wrench 8 Install the engine oil drain bolt and then tight en it to the specified torque 9 Add the specified amount of the recommend ed engine oil and then install and tighten the engine oil filler cap 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 23 Nm 2 3 ...

Page 93: ...ar oil The final gear case must be checked for oil leak age before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In ad dition the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oi...

Page 94: ...ard by remov ing the bolts 2 Place the ATV on a level surface 3 Place an oil pan under the final gear case to collect the used oil 4 Remove the final gear oil filler bolt and the fi nal gear oil drain bolt to drain the oil from the final gear case 1 Final gear oil 2 Final gear oil filler bolt 3 Correct oil level Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear ca...

Page 95: ...no foreign material enters the final gear case 7 Install the oil filler bolt and then tighten it to the specified torque 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil 2 Final gear oil filler bolt 3 Correct oil level Recommended final gear oil See page 10 1 U5UH63E0 book Page 16 Wednesday April 26 2006 9 21 AM ...

Page 96: ...fferential gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Place the ATV on a level surface 2 Place an oil pan under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case Tightening torque Final gear...

Page 97: ...e accurately checked from the oil filler hole CAUTION ECB00410 Be sure no foreign material enters the differen tial gear case 6 Install the oil filler bolt and then tighten it to the specified torque 7 Check the differential gear case for oil leak age If oil is leaking check for the cause 1 Differential gear oil drain bolt Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 2 ft l...

Page 98: ...areas NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air fil ter case 1 Remove the seat See page 4 13 2 Remove the air filter case cover by unhooking the holders 3 Pull the air filter element out of the air filter case 1 Air filter case check hose 1 Air filter case holder 2 Air filter case c...

Page 99: ...ts cleaning solvent to clean the sponge material Never use low flash point solvents or gasoline to clean the sponge mate rial because the engine could catch fire or ex plode 6 Squeeze the excess solvent out of the sponge material and let it dry 1 Air filter element 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate U5UH63E0 book Page 20 Wednesday April 26 2006 9 21 AM ...

Page 100: ...tenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine CAUTION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case ...

Page 101: ...lpipe into the muffler and align the bolt holes 5 Install and tighten the bolts WARNING EWB02340 Do not start the engine when cleaning the spark arrester otherwise it could cause injury to the eyes burns carbon monoxide poison ing possibly leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components 1 Bolt 2 Tailpipe 1 Tailpipe 2 Spark arrester U5UH63E0...

Page 102: ...40 Adjusting the carburetor The carburetor should be checked and if neces sary adjusted at the intervals specified in the peri odic maintenance and lubrication chart The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adju...

Page 103: ... to make this adjustment 1 Start the engine and warm it up NOTE The engine is warm when it quickly responds to the throttle 2 Attach the tachometer to the spark plug lead 3 Check the engine idling speed and if neces sary adjust it to specification by turning the throttle stop screw at the carburetor To in crease the engine idling speed turn the throt tle stop screw in direction a and to decrease i...

Page 104: ...adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle cable free play turn the adjusting bolt in direction b 3 Tighten the locknut EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the...

Page 105: ...intenance and lubrication chart EBU24171 Front brake pads Check each front brake pad for damage and mea sure the lining thickness If a brake pad is dam aged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set NOTE The wheels need to be removed to check the brake pads See page 8 41 EBU24180 Rear brake shoes The rear brake is provided with a we...

Page 106: ...neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriora...

Page 107: ...ervals specified in the NOTE after the peri odic maintenance and lubrication chart In addi tion have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EBU24390 Checking the front brake lever free play The brake lever ...

Page 108: ... lu brication chart NOTE Always perform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting the brake lever and brake pedal free play check the rear brake shoes for wear Adjusting the brake pedal free play The brake pedal free play should measure 20 0 30 0 mm 0 79 1 18 in as shown If the free play is incorrect adjust it as follows 1 Fully loosen th...

Page 109: ...rake lever and fully turn in the brake lever free play adjusting bolt 2 Turn the brake lever free play adjusting nut on the brake cable at the rear wheel hub so that gap A measures 0 1 mm 0 0 04 in 1 Brake pedal free play adjusting nut 2 Brake lever free play adjusting nut 1 Brake lever free play 2 Locknut 3 Brake lever free play adjusting bolt U5UH63E0 book Page 30 Wednesday April 26 2006 9 21 AM...

Page 110: ...he rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move WARNING EWB02080 Operating with improperly serviced or adjust ed brakes could cause loss of braking ability which could lead to an accident After servicing 1 Brake lever free play adjusting nut 2 Gap A 1 Locknut 2 Brake lever free play adjusting bolt U5UH63E0 book Page 31 Wednesday April 26...

Page 111: ...rake light switches must be checked and if necessary adjusted at the inter vals specified in the periodic maintenance and lu brication chart The brake light switch for the brake pedal can be adjusted as follows but the other brake light switches should be adjusted by a Yamaha dealer 1 Remove panel A See page 8 8 NOTE The brake light switch is properly adjusted when the brake light comes on just be...

Page 112: ...on can result when the cable sheaths become damaged and cables can also become frayed or kinked which could re strict the operation of controls and lead to an accident or injury EBU24911 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary 1 Brake light swi...

Page 113: ...ngs must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EBU24980 Lubricating the drive shaft universal joint The drive shaft universal joint must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recomme...

Page 114: ...fied in the periodic maintenance and lu brication chart EBU25222 Battery This model is equipped with a sealed type MF battery which does not require any maintenance There is no need to check the electrolyte or to add distilled water Check and if necessary tighten the battery lead connections CAUTION ECB00620 Never attempt to remove the battery cell seals as this would permanently damage the batter...

Page 115: ...ng in an enclosed space KEEP OUT OF REACH OF CHILDREN 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 To store the battery 1 If the ATV will not be used for more than one month remove the battery fully charge it ...

Page 116: ...ltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a constant voltage battery charg er have a Yamaha dealer charge your bat tery EBU25322 Replacing a fuse 1 Positive battery terminal 2 Negative battery terminal 1 Main fuse 2 Spare main fuse 3 Fuse box U5UH63E0 book Page 37 Wednesday April 26 2006 9 21 AM ...

Page 117: ...or replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage 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 6 Spare fuse Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 15 0 A Four wheel drive motor fuse 3 0 A Signaling system fuse 10 0 A Auxilia...

Page 118: ...circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU26902 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the bulb holder cover at the rear of the headlight by pulling it off 2 Disconnect the headlight coupler by lifting the tab as shown and pulling out the coupler 1 Headlight bul...

Page 119: ...ulb touch es something flammable 4 Install a new headlight bulb holder assembly by inserting it into the headlight unit and turn ing it clockwise CAUTION ECB00650 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affect ed Thoroughly clean off any dirt and finger prints o...

Page 120: ...t beam CAUTION ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25580 Replacing the tail brake light bulb If the tail brake light bulb burns out have a Yamaha dealer replace it EBU25650 Removing a wheel 1 Loosen the wheel nuts 1 Headlight beam ...

Page 121: ...nstalling a wheel 1 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 Install the nuts with their tapered side to wards the wheel 1 Wheel nut 1 Arrow mark U5UH63E0 book Page 42 Wednesday April 26 2006 9 21 AM ...

Page 122: ...o a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or explode causing se...

Page 123: ...and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the battery lead ...

Page 124: ...ioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places 5...

Page 125: ... areas where strong chemicals are stored Long term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilize...

Page 126: ...f necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative 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 onc...

Page 127: ... NZL Noise and vibration level Noise level 77 311 EEC 77 6 dB A EUR GBR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s EUR GBR Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s EUR GBR Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 348 0 cm 21 23 cu in Bore stroke 83 0 64 5 mm 3 27 2 54 in Compression ratio 9 20 ...

Page 128: ...ear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 35 L 0 37 US qt 0 31 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only EUR GBR Unleaded gasoline only AUS NZL Fuel tank capacity 13 5 L 3 57 US gal 2 97 Imp gal Fuel reserve amount 3 3 L 0 87 US gal 0 73 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BSR33 x 1 Spark plug s Manufacture...

Page 129: ... 828 AUS NZL MAXXIS M979 EUR GBR Rear tire Type Tubeless Size AT25 x 10 12 Manufacturer model CHENG SHIN C 828 AUS NZL MAXXIS M980 EUR GBR Loading Maximum loading limit 210 0 kg 463 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf...

Page 130: ...garm monocross Spring shock absorber type Coil spring oil damper Wheel travel 180 mm 7 1 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model YTX14AH Voltage capacity 12 V 12 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 Meter lighting 14 V 3 0 W 1 Neutral indicator light 12 V 1 ...

Page 131: ...uses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Auxiliary DC jack fuse 10 0 A Four wheel drive motor fuse 3 0 A U5UH63E0 book Page 5 Wednesday April 26 2006 9 21 AM ...

Page 132: ...erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26040 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key ide...

Page 133: ...BU26050 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 er 1 Vehicle identification number front left side 1 Vehicle identification number 2 Year of manufacture U5UH63E0 book Page 2 Wednesday April 26 2006 9 21 AM ...

Page 134: ...11 3 11 1 Model label U5UH63E0 book Page 3 Wednesday April 26 2006 9 21 AM ...

Page 135: ...5 7 Cleaning 9 1 D Differential gear oil 5 3 Differential gear oil changing 8 17 Drive select lever 4 9 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 26 Drive shaft universal joint lubricating 8 34 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 24 Engine oil 5 3 Engine oil and oil filter cartridge 8 10 Engine starting a warm 6 3...

Page 136: ...sting the front 4 16 Shock absorber assembly adjusting the rear 4 17 Spark arrester cleaning 8 21 Spark plug checking 8 8 Specifications 10 1 Speed limiter 4 6 Speedometer 4 3 Starter choke 4 13 Start switch 4 4 Steering shaft lubricating 8 35 Storage 9 2 Storage compartment 4 14 Suspension lubricating the upper and lower arm pivots 8 35 T Tail brake light bulb replacing 8 41 Throttle cable free p...

Page 137: ...U5UH63E0 book Page 3 Wednesday April 26 2006 9 21 AM ...

Page 138: ...YAMAHA MOTOR CO LTD PRINTED IN USA 2006 05 0 3 1 CR E U5UH63E0 book Page 1 Wednesday April 26 2006 9 21 AM ...

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