Yamaha GRIZZLY 350 YFM35GW Page 79 Owner'S Manual Download | Manualshive

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The service information included in this manual
and the tools provided in the owner’s tool kit are in-
tended to assist you in the performance of preven-
tive maintenance and minor repairs. However,
additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.

NOTE:

If you do not have the tools or experience 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
installed and used according to instructions. If
you have questions, consult an authorized
Yamaha ATV dealer.

U5WH63E0.book Page 2 Monday, May 8, 2006 1:25 PM

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Summary of Contents for GRIZZLY 350 YFM35GW

Page 1: ...YFM35GW OWNER S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO 5WH F8199 63 ...

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

Page 3: ...OWNER S MANUAL YFM35GW 5WH F8199 63 E0 U5WH63E0 book Page 1 Monday May 8 2006 1 25 PM ...

Page 4: ...pplicable 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...

Page 5: ...nd 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 OPERA...

Page 6: ...o change 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 o...

Page 7: ...rface paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17410 YFM35GW 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 U5WH63E0 book Page 1 Monday May 8 2006 1 25 PM ...

Page 8: ... 6 Parking brake 4 7 Drive select lever 4 7 Recoil starter 4 8 Fuel tank cap 4 8 Fuel 4 9 Fuel cock 4 10 Starter choke 4 11 Seat 4 12 Storage compartment 4 13 Front carrier 4 14 Rear carrier 4 14 Adjusting the front shock absorber assemblies 4 14 Adjusting the rear shock absorber assembly 4 15 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Front an...

Page 9: ...ual 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 Cleaning the air filter element 8 17 Cleaning the spark arrester 8 20 V belt cooling duct check hose 8 21 V belt case drain plug 8 21 Adjusting the carburetor 8 22 Adjusting the engine idling speed 8 22 Ad...

Page 10: ...rm pivots 8 33 Lubricating the knuckle shafts 8 33 Lubricating the steering shaft 8 33 Battery 8 33 Replacing a fuse 8 35 Replacing a headlight bulb 8 37 Adjusting a headlight beam 8 39 Replacing the tail brake light bulb 8 39 Removing a wheel 8 39 Installing a wheel 8 40 Troubleshooting 8 41 Troubleshooting chart 8 42 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER ...

Page 11: ... child 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...

Page 12: ...limbing 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 carefull...

Page 13: ...rakes 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 ...

Page 14: ...nous 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 po...

Page 15: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5WH63E0 book Page 1 Monday May 8 2006 1 25 PM ...

Page 16: ...bels 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 U5WH63E0 book Page 2 Monday May 8 2006 1 25 PM ...

Page 17: ...2 3 2 For Europe U5WH63E0 book Page 3 Monday May 8 2006 1 25 PM ...

Page 18: ...2 4 2 For Europe U5WH63E0 book Page 4 Monday May 8 2006 1 25 PM ...

Page 19: ...2 5 2 For Oceania U5WH63E0 book Page 5 Monday May 8 2006 1 25 PM ...

Page 20: ...2 6 2 For Oceania U5WH63E0 book Page 6 Monday May 8 2006 1 25 PM ...

Page 21: ...8 Engine oil dipstick 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 U5WH63E0 book Page 1 Monday May 8 2006 1 25 PM ...

Page 22: ...tly from the figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Starter choke 4 Parking brake lock plate 5 Horn switch 6 Drive select lever 7 Speedometer 8 Main switch 9 Fuel tank cap 10 Throttle lever 11 Front brake lever U5WH63E0 book Page 2 Monday May 8 2006 1 25 PM ...

Page 23: ...ollows 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 U5WH63E0 book Page 1 Monday May 8 2006 1 25 PM ...

Page 24: ...itch set to and then pushing 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 ...

Page 25: ... to plan fuel stops in the future EBU18060 Handlebar switches EBU18080 Engine stop switch Set this switch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to 1 Reset knob 2 Speedometer 3 Odometer 4 Tripmeter 1 Light ...

Page 26: ...oint that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU18170 Horn switch Press the switch to sound the horn EBU18280 Throttle lever Once the engine is running movement of the throt tle lever will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decel...

Page 27: ...2 To increase the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in direction b 3 Tighten the locknut WARNING EWB00240 Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operatio...

Page 28: ...ip EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar To apply the rear brake push down on the brake pedal or pull the brake lever toward the handlebar grip 1 Front brake lever 1 Brake pedal 1 Rear brake lever U5WH63E0 book Page 6 Monday May 8 2006 1 25 PM ...

Page 29: ...use loss of control or a collision 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 You could also wear out the brakes prematurely EBU18581 Drive select lever The drive select lever is used to shift your ATV into the forward ...

Page 30: ... WARNING EWB00340 Shift the drive select lever into the neutral po sition and apply the parking brake before start ing the engine otherwise the ATV could start to move unexpectedly which could cause an accident EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise 1 Drive select lever 1 Recoil starter U5WH63E0 book Page 8 Monday May 8 2006 1 25 PM ...

Page 31: ...n 1 Fuel tank cap 1 Fuel level 2 Fuel tank filler tube Recommended fuel UNLEADED GASOLINE ONLY For Europe Regular unleaded gasoline only with a research octane number of 91 or high er 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 U5WH63E0 book Page 9 Monday May 8 2006 1 25 PM ...

Page 32: ...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 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 expl...

Page 33: ...Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke 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 1 Arrow mark pointing to ON 1 Arrow mar...

Page 34: ...0 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely fitted 1 Starter choke 1 Seat 2 Seat lock lever U5WH63E0 book Page 12 Monday May 8 2006 1 25 PM ...

Page 35: ...damaging the stor age compartment Do not exceed the load limit of 2 0 kg 4 lb for the storage compartment Do not exceed the maximum load of 210 0 kg 463 lb for the ATV NOTE There is a check hose at the bottom of the storage compartment If any water collects in this hose re move the hose empty it and then install it 1 Projection 2 Seat holder 1 Storage compartment U5WH63E0 book Page 13 Monday May 8...

Page 36: ... ATV EBU18990 Adjusting the front shock absorber as semblies The spring preload 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 1 Storage compartment ch...

Page 37: ...BU19020 Adjusting the rear shock absorber as sembly The spring preload 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 1 Special wrench Spring preload s...

Page 38: ...e 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 U5WH63E0 book Page 16 Monday May 8 2006 1 25 PM ...

Page 39: ...e oil Check oil level in engine and add recommended 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 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 brake fluid level in reservoir and add...

Page 40: ...bles Make sure that operation is smooth Lubricate if necessary 8 31 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 32 Brake levers Make sure that operation is smooth Lubricate lever ...

Page 41: ...l is at the specified level Add oil as necessary See page 8 14 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 system Check for correct free play in the rear brake lever and brake pedal If the free play is incorrect ad just it See page 8 27 Check operation of the levers ...

Page 42: ... 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 EWB00591 Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pres sure may cause loss of control increasing you...

Page 43: ...20 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 the low pressure tire gauge NOTE The low press...

Page 44: ...tire 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 U5WH63E0 book Page 6 Monday May 8 2006 1 25 PM ...

Page 45: ...at 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 U5WH63E0 book Page 7 Monday May 8 2006 1 25 PM ...

Page 46: ...hich 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 co...

Page 47: ...e to 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 posit...

Page 48: ...ct 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 Re...

Page 49: ...erious 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 fi...

Page 50: ...ng 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...

Page 51: ...gned 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 accesso...

Page 52: ...e maximum 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 rid...

Page 53: ...you 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 c...

Page 54: ...7 1 7 EBU21141 RIDING YOUR ATV U5WH63E0 book Page 1 Monday May 8 2006 1 25 PM ...

Page 55: ...ty 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 ...

Page 56: ...e child 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 y...

Page 57: ...cle 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 U5WH63E0 book Page 4 Monday May 8 2006 1 25 PM ...

Page 58: ... chances 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 ens...

Page 59: ...WARNING 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 ite...

Page 60: ... brak 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 compar...

Page 61: ... into 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...

Page 62: ...bustible 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...

Page 63: ... roads 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 ...

Page 64: ...d practiced 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 bracke...

Page 65: ... You 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...

Page 66: ...one 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 t...

Page 67: ...rn 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...

Page 68: ...ow 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 c...

Page 69: ... weight to the uphill side of the ATV If your ATV has stalled or 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 ...

Page 70: ...ill 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 Improper braking may cause a loss of traction Use caution while descending a hill wit...

Page 71: ...ward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a ...

Page 72: ... 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 weight to the uphill side of the ATV CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shal low water of up t...

Page 73: ...es 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 c...

Page 74: ...ed 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 U5WH63E0 book Page 21 Monday May 8 2006 1 25 PM ...

Page 75: ...Never 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...

Page 76: ...eriod 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...

Page 77: ...have corrected 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 the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 14 If your ATV is t...

Page 78: ...DIVIDUAL 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 mainte...

Page 79: ...ience 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 insta...

Page 80: ...cal 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...

Page 81: ... 10 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 b...

Page 82: ...k starter choke operation and correct if nec essary Check engine idling speed and adjust if neces sary 22 Crankcase breather system Check breather hose for cracks or other damage and replace if necessary 23 Engine oil Change Check ATV for oil leakage and correct if neces sary 24 Engine oil filter car tridge Replace 25 Final gear oil Change Check ATV for oil leakage and correct if neces sary 26 Mov...

Page 83: ...nd adjust if neces sary Lubricate throttle lever housing and cable 29 Exhaust system Check for leakage and replace gasket s if neces sary Check for looseness and tighten all screw clamps and joints if necessary 30 Spark arrester Clean 31 Front and rear brake switches Check operation and correct if necessary 32 Lights and switches Check operation and correct if necessary Adjust headlight beams NO I...

Page 84: ...ars 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 U5WH63E0 book Page 7 Monday May 8 2006 1 25 PM ...

Page 85: ... Remove 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 ...

Page 86: ...ark 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 eros...

Page 87: ...ue 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 ...

Page 88: ...ng 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...

Page 89: ... pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt 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 U5WH63E0 book Page 12 Monday May 8 2006 1 2...

Page 90: ...nch 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...

Page 91: ... gear 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...

Page 92: ... guard 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...

Page 93: ...re 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 U5WH63E0 book Page 16 Monday May 8 2006 1 25 PM ...

Page 94: ...ir filter element more frequently if you are riding in unusually wet or dusty 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 12 2 Remove the air filter case cover by unhooking the holders Tightening torque Final gear oil filler bolt 23 Nm 2...

Page 95: ...ut of the air filter case 4 Pull off the lock plate and then remove the sponge material from the air filter element frame 1 Air filter case holder 2 Air filter case cover 1 Air filter element U5WH63E0 book Page 18 Monday May 8 2006 1 25 PM ...

Page 96: ...ut not drip ping 9 Pull the sponge material over the air filter ele ment frame and then install the lock plate 10 Insert the air filter element into the air filter case and then install the air filter case cover by hooking the holders onto the air filter case 11 Install the seat NOTE The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the AT...

Page 97: ... engine damage Addition ally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine over heating EBU27080 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the bolts 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use ...

Page 98: ...nts 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 EBU23930 V belt case drain plug After riding in water deep enough to allow it to en ter the V belt case remove this plug to drain the water from the case NOTE If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the w...

Page 99: ...xtensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart NOTE A diagnostic tachometer is needed t...

Page 100: ...ntenance and lubrication chart The throttle cable free play should measure 3 0 5 0 mm 0 12 0 20 in at the throttle lever Period ically check the throttle cable free play and if nec essary adjust it as follows NOTE The engine idling speed must be checked and ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the...

Page 101: ...safety system cable should be checked and adjusted at the intervals specified in the periodic maintenance and lubrication chart EBU24120 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart EBU24171 Front brake pads Check each front brake pad for damage ...

Page 102: ...e shoe has worn to the point that the wear indicator reaches the wear limit line or mark have a Yamaha dealer replace the brake shoes as a set EBU24251 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly causing it to become inef fective Before riding check that the brake fluid is above the minimum level mark and replenish if neces sary A low br...

Page 103: ...oiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid imme diately As the brake pads wear it is normal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24280 Changing the brake fluid Have a Yamaha dealer change the br...

Page 104: ...correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24511 Adjusting the brake pedal and rear brake lever free play The brake pedal and brake lever free play must be checked and if necessary adjusted at the int...

Page 105: ...urn the brake pedal free play adjusting nut on the brake cable at the rear wheel hub in di rection a to increase the free play and in di rection b to decrease it 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 Brake pedal free play 1 Brake pedal free play adjusting nut 2 Brake lever ...

Page 106: ...e at the rear wheel hub so that gap A measures 0 1 mm 0 0 04 in 3 Turn the brake lever free play adjusting bolt at the brake lever in direction a to increase the free play and in direction b to decrease it 1 Brake lever free play 2 Locknut 3 Brake lever free play adjusting bolt 1 Brake lever free play adjusting nut 2 Gap A U5WH63E0 book Page 29 Monday May 8 2006 1 25 PM ...

Page 107: ... switches The operation of the brake 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 ...

Page 108: ...osion 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 ...

Page 109: ...arings 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 Reco...

Page 110: ...ecified 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 bat...

Page 111: ...using 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 ...

Page 112: ... voltage 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 U5WH63E0 book Page 35 Monday May 8 2006 1 25 PM ...

Page 113: ...e a substitute object in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical sys tem which could lead to a fire 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Headlight fuse 2 Ignition fuse 3 Auxiliary DC jack fuse for op...

Page 114: ...ear of the headlight by pulling it off 2 Disconnect the headlight coupler by lifting the tab as shown and pulling out the coupler 3 Remove the headlight bulb holder assembly by turning it counterclockwise 1 Headlight bulb holder cover 1 Headlight coupler 1 Headlight bulb holder assembly U5WH63E0 book Page 37 Monday May 8 2006 1 25 PM ...

Page 115: ...light 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 on the headlight bulb using a cloth moistened with alc...

Page 116: ...isable 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 adjusting screw U5WH63E0 book Pag...

Page 117: ...0 Installing 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 U5WH63E0 book Page 40 Monday May 8 2006 1 25 PM ...

Page 118: ...t to 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...

Page 119: ...ug 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 le...

Page 120: ...terioration 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 place...

Page 121: ...and 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 stabil...

Page 122: ...d if 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 ...

Page 123: ...49 lb AUS 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 Bore stroke 83 0 64 5 mm 3 27 2 54 in Compression ratio 9 20 1 S...

Page 124: ...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 Manufacturer model NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automatic Transmiss...

Page 125: ...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 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...

Page 126: ...amper 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 7 W 1 Reverse indicator light 12 V 1 7 W 1 Oil temperature ...

Page 127: ...10 5 10 Auxiliary DC jack fuse 10 0 A U5WH63E0 book Page 5 Monday May 8 2006 1 25 PM ...

Page 128: ...f 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 i...

Page 129: ... 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 er 1 Vehicle identification number front left side 1 Vehicle identification number 2 Year of manufacture U5WH63E0 book Page 2 Friday April 6 2007 2 41 PM ...

Page 130: ...11 3 11 1 Model label U5WH63E0 book Page 3 Friday April 6 2007 2 41 PM ...

Page 131: ...is fasteners 5 7 Cleaning 9 1 D Drive select lever 4 7 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 24 Drive shaft universal joint lubricating 8 32 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 22 Engine oil 5 3 Engine oil and oil filter cartridge 8 10 Engine starting a warm 6 3 Engine stop switch 4 3 F Final gear oil 5 3 8 14...

Page 132: ...sting the rear 4 15 Spark arrester cleaning 8 20 Spark plug checking 8 8 Specifications 10 1 Speed limiter 4 5 Speedometer 4 3 Starter choke 4 11 Start switch 4 4 Steering shaft lubricating 8 33 Storage 9 2 Storage compartment 4 13 Suspension lubricating the upper and lower arm pivots 8 33 T Tail brake light bulb replacing 8 39 Throttle cable free play adjusting 8 23 Throttle lever 4 4 5 4 Tire pr...

Page 133: ...U5WH63E0 book Page 3 Friday April 6 2007 2 41 PM ...

Page 134: ...YAMAHA MOTOR CO LTD PRINTED IN USA 2006 05 0 3 2 CR E U5WH63E0 book Page 1 Friday April 6 2007 2 41 PM ...

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