Yamaha GRIZZLY 350 Owner'S Manual Download Page 110

Page: 110 / 166

8-20

TIP

The oil level should be at the brim of the filler hole.

3. If the oil is below the brim of the filler hole, add

sufficient oil of the recommended type to raise
it to the correct level.

4. Install the oil filler bolt, and then tighten it to the

specified torque.

To change the differential gear oil

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.

4. Install the drain bolt, and then tighten it to the

specified torque.

1. Differential gear oil
2. Differential gear oil filler bolt

3. Correct oil level

Tightening torque:

Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

1. Differential gear oil drain bolt

Tightening torque:

Differential gear oil drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

U4S212E0.book Page 20 Thursday, April 17, 2008 9:17 AM

Summary of Contents for GRIZZLY 350

Page 1: ...This ATV should not be ridden by anyone under 16 years of age WARNING OWNER S MANUAL 4S2 F8199 12 LIT 11626 22 18 YFM35FGIY READ THIS MANUAL CAREFULLY It contains important safety information DIC2342 ...

Page 2: ...EBU17092 Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold ...

Page 3: ...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 TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIO...

Page 4: ...safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key infor...

Page 5: ...nd spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17402 YFM35FGIY OWNER S MANUAL 2008 by Yamaha Motor Corporation U S A 1st edition April 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printe...

Page 6: ...lever 4 10 Speed limiter 4 10 Front brake lever 4 11 Brake pedal and rear brake lever 4 12 Parking brake 4 13 Drive select lever 4 13 Recoil starter 4 14 Fuel tank cap 4 15 Fuel 4 15 Fuel cock 4 16 Starter choke 4 18 Seat 4 18 Storage compartment 4 19 Front carrier 4 20 Rear carrier 4 21 Adjusting the front and rear shock absorber assemblies 4 21 PRE OPERATION CHECKS 5 1 Pre operation check list 5...

Page 7: ...7 32 WHAT TO DO 7 32 PERIODIC MAINTENANCE AND MINOR REPAIR 8 1 Owner s manual and tool kit 8 1 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing the panel 8 9 Checking the spark plug 8 10 Engine oil and oil filter cartridge 8 12 Final gear oil 8 16 Differential gear oil 8 19 Cleaning the air filter element 8 21 Clea...

Page 8: ...sal joint 8 41 Checking the stabilizer bushes 8 41 Lubricating the rear knuckle pivots 8 41 Lubricating the steering shaft 8 42 Battery 8 42 Replacing a fuse 8 44 Replacing a headlight bulb 8 46 Adjusting a headlight beam 8 48 Replacing the tail brake light bulb 8 48 Removing a wheel 8 48 Installing a wheel 8 49 Troubleshooting 8 50 Troubleshooting chart 8 52 CLEANING AND STORAGE 9 1 Cleaning 9 1 ...

Page 9: ...ould never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a 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 streets Never...

Page 10: ...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 11: ...water deeper than that recommended in this manual Remember that wet brakes 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 specifi...

Page 12: ...pilot lights of water heaters and clothes dryers When transporting the ATV in another vehi cle be sure it is kept upright and that the fuel cock is in the OFF position Other wise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause inju ries HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some gas...

Page 13: ...ust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad equate ventilation U4S212E0 book Page 5 Thursday April 17 2008 9 17 AM ...

Page 14: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U4S212E0 book Page 1 Thursday April 17 2008 9 17 AM ...

Page 15: ...abel from your Yamaha dealer Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an accident Never exceed the maximum front cargo limit of 88 lbs 40kg NEVER sit on the carrier Refer to instructions in the Owner s Manual 5ND F4877 30 WARNING 1 2 463 lbs 210 kg 5FU F816M 00 3 6 psi 25 kPa 3 6 psi 25 kPa 3 2 psi 22 kPa 3 2 psi 22 kPa...

Page 16: ...2 3 2 U4S212E0 book Page 3 Thursday April 17 2008 9 17 AM ...

Page 17: ...2 4 2 U4S212E0 book Page 4 Thursday April 17 2008 9 17 AM ...

Page 18: ...s 5 Battery 6 Rear shock absorber assembly spring preload adjusting ring 7 Recoil starter 8 Engine oil filler cap 9 Oil filter cartridge 10 V belt cooling duct check hose 1 Spark arrester 2 Storage compartment and tool kit 3 Air filter case 4 Spark plug 5 Rear brake light switch 6 Brake pedal 7 V belt case drain plug U4S212E0 book Page 1 Thursday April 17 2008 9 17 AM ...

Page 19: ... in this manual 1 Rear brake lever 2 Handlebar switches 3 Starter choke 4 Parking brake lock plate 5 Drive select lever 6 Speedometer 7 Main switch 8 Fuel tank cap 9 On Command four wheel drive differential gear lock switch 10 Throttle lever 11 Front brake lever U4S212E0 book Page 2 Thursday April 17 2008 9 17 AM ...

Page 20: ...h The positions of the main switch are as follows 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 U4S212E0 book Page 1 Thursday April 17 2008 9 17 AM ...

Page 21: ...in the neutral position EBU26931 Oil temperature warning light This warning light comes on when the engine over heats When this occurs stop the engine as soon as it is safe to do so and allow it to cool The electrical circuit of the warning light can be checked by turning the key to ON with the engine stop switch set to and then pushing the start switch If the warning light does not come on while ...

Page 22: ...set to the 4WD position TIP Due to the synchronizing mechanism in the differ ential gear case the light may not come on until the ATV starts moving EBU28341 On Command differential gear lock indicator light This indicator light and the On Command four wheel drive indicator light come on when the On Command differential gear lock switch is set to the LOCK position EBU18020 Speedometer The speedomet...

Page 23: ...tion 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 switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE U4S212E0 book Page 4 Thursday April 17 2008 9 17 AM ...

Page 24: ... for an extended period of time oth erwise the battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU28350 Override switch OVERRIDE Top speed is normally limited when operating in differential gear lock If conditions require more en gine power when riding forward push and hold this switch to override the diff...

Page 25: ...from four wheel drive to two wheel drive stop the ATV and push the switch in to the 2WD position POTENTIAL HAZARD Riding too fast while the ATV is in four wheel drive differential gear lock WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the ATV The effort needed to turn in creases with the riding speed You may lose control and have...

Page 26: ...Changing from two wheel drive to four wheel drive or from four wheel drive to two wheel drive while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in two wheel drive than in four wheel drive in some cir cumstances Changing from two wheel drive to four wheel drive or from four wheel drive to two wheel drive while moving may cause the ATV to unexpectedly handle differently This could ...

Page 27: ...the differential gear lock switch in to the LOCK position When the dif ferential gear is locked the differential gear lock in dicator light comes on To release the differential gear lock stop the ATV and push the switch to the 4WD position 1 Differential gear lock lever 2 On Command four wheel drive switch 2WD 4WD 1 On Command differential gear lock switch 4WD LOCK U4S212E0 book Page 8 Thursday Ap...

Page 28: ...wheel drive to differential gear lock or vice versa while moving may cause the ATV to handle differently unexpectedly This could distract the operator and increase the risk of losing control and causing an accident HOW TO AVOID THE HAZARD Always stop the ATV before changing from four wheel drive to four wheel drive differen tial gear lock or vice versa POTENTIAL HAZARD Riding too fast while the AT...

Page 29: ...le position as soon as the lever is released WARNING EWB00200 EBU18311 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum 1 Loosen the locknut 1 Throttle lever POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate mak ing it diffi...

Page 30: ...pply the front brake pull the brake lever toward the handlebar grip 1 Locknut 2 Adjusting screw 3 No more than 12 mm 0 47 in POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Im proper throttle operation could result You could lose control have an accident or be in jured HOW TO AVOID THE HAZARD Do not turn the adjusting screw...

Page 31: ...ght 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 U4S212E0 book Page 12 Thursday April 17 2008 9 17 AM ...

Page 32: ... for the drive select lever operation 1 Parking brake lock plate POTENTIAL HAZARD Improper use of the parking brake WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start ing the engine This could cause loss of con trol or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance...

Page 33: ... 1 Drive select lever 1 Recoil starter POTENTIAL HAZARD Starting the engine without shifting into the neutral position WHAT CAN HAPPEN The ATV could start to move unexpectedly which could cause an accident HOW TO AVOID THE HAZARD Shift the drive select lever into the neutral position and apply the parking brake before starting the engine U4S212E0 book Page 14 Thursday April 17 2008 9 17 AM ...

Page 34: ...cient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap 1 Fuel level 2 Fuel tank filler tube Recommended fuel UNLEADED GASOLINE ONLY 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 U4S212E0 book Page 15 Thursday April 17 2008 9 17 AM ...

Page 35: ...hol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ATV performance problems WARNING EWB00270 EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN F...

Page 36: ... 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 U4S212E0 book Page 17 Thursday April 17 2008 9 17 AM ...

Page 37: ...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 38: ...torage compartment The storage compartment is located under the seat See page 4 18 When storing any documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage compartment 1 Seat 2 Seat lock lever 1 Projection 2 Seat holder U4S212E0 book Page 19 Thursday April 17 2008 9 17 AM ...

Page 39: ...partment Do not exceed the maximum load of 210 0 kg 463 lb for the ATV TIP 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 EBU18961 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 1 Storage compartment 1 Stor...

Page 40: ...e rid er s weight and the riding conditions Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 P...

Page 41: ...1 Standard 2 Maximum hard 5 POTENTIAL HAZARD Improper shock absorber assembly adjust ment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorber assem blies on the left and right side to the same setting U4S212E0 book Page 22 Thursday April 17 2008 9 17 AM ...

Page 42: ... HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual ITEM ROUTINE PA...

Page 43: ... and adjust if necessary 5 3 8 30 8 33 Throttle lever Make sure that operation is smooth Lubricate cable and lever hous ing if necessary Check cable free play and adjust if necessary 5 4 8 29 Control cables Make sure that operation is smooth Lubricate if necessary 8 39 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air ...

Page 44: ...for correct free play in the rear brake lever and brake pedal If the free play is incorrect ad just it See page 8 33 Check operation of the levers and pedal They should move smoothly and there should be a firm feeling when the brake is applied If not have a Yamaha dealer check them POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injur...

Page 45: ...oper braking performance check the brake pads and friction plates for wear See page 8 30 WARNING EWB00540 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 Recommended brake fluid DOT 4 POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could ...

Page 46: ...been approved by Yamaha Motor Manufacturing Corpora tion of America for this model Other tire combinations are not recommended Front Manufacturer model MAXXIS M979 Size AT25 x 8 12 Type Tubeless Rear Manufacturer model MAXXIS M980 Size AT25 x 10 12 Type Tubeless The tires should be set to the recommend ed pressure Recommended tire pressure Front 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 kg...

Page 47: ...pecifications Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 22 0 kPa 0 220 kgf cm 3 2 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi Higher pres...

Page 48: ...ightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum Front 22 0 kPa 0 220 kgf cm 3 2 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi 1 Tire wear limit U4S212E0 book Page 7 Thursday April 17 2008 9 17 AM ...

Page 49: ...OTENTIAL HAZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an acci dent or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer POTENTIAL HAZARD Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which cou...

Page 50: ... the fig ure Position 1 Cold engine start with ambient temperature below 5 C 40 F Position 2 Cold engine start with ambient temperature between 0 C 30 F and 30 C 90 F Position 3 Cold engine start with ambient temperature above 25 C 80 F Ambient temp starter choke position 6 Completely close the throttle lever and start the engine by pushing the start switch TIP If the engine fails to start release...

Page 51: ...before riding TIP The engine is warm when it responds normally to the throttle with the starter choke turned off EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter choke is not required when the engine is warm Instead start the engine with the throttle slightly open EBU20370 Operating the drive select lever and driving in rev...

Page 52: ...verse indicator light should come on If the indicator light does not come on have a Yamaha dealer check the electrical circuit 4 Check behind for people or obstacles and then release the brake pedal 5 Open the throttle lever gradually and continue to watch to the rear while backing 1 Drive select lever 2 F Forward 3 N Neutral 4 R Reverse 1 Drive select lever 2 F Forward 3 N Neutral 4 R Reverse U4S...

Page 53: ...n that might result in en gine overheating must be avoided 0 160 km 0 100 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 160 320 km 100 200 mi or 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine freely but do not use full throttle at any time 320 km 200 mi or 20 hours and beyond...

Page 54: ... pedal 1 Parking brake lock plate POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the ATV transversely across the incline shift the drive select lever to the forward position stop the engine apply the parkin...

Page 55: ...ch can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits...

Page 56: ...fere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight 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 EW...

Page 57: ...nges in ATV handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing U4S212E0 book Page 9 Thursday April 17 2008 9 17 AM ...

Page 58: ...7 1 7 EBU21131 RIDING YOUR ATV U4S212E0 book Page 1 Thursday April 17 2008 9 17 AM ...

Page 59: ...over a period of time Take the time to learn the ba sic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable ac tivity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual...

Page 60: ...hildren under 16 years of age WARNING EWB00901 POTENTIAL HAZARD Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course ...

Page 61: ... that are not recom mended for their age can lead to severe inju ry or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc U4S212E0 book Page 4 Thursday April 17 2008 9 17 AM ...

Page 62: ... HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as need ed during operation It is not for carrying passengers U4S212E0 book Page 5 Thursday April 17 2008 9 17 AM ...

Page 63: ... protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or ja...

Page 64: ...uld cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always in...

Page 65: ...ss of control in creasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this ATV on page 5 5 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 6 POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of...

Page 66: ...See page 4 10 Loading and accessories Use extra caution when riding the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Re duce your speed when adding additional loads 1 Adjusting screw 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 l...

Page 67: ...cident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer U4S212E0 book Page 10 Thursday April 17 2008 9 17 AM ...

Page 68: ... could cause you to lose your balance and fall off of the ATV If you remove a foot from a foot board your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN...

Page 69: ...e situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nents designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer U4S212E0 book Page 12 Th...

Page 70: ...ccumulated around the engine area could catch fire Someone touching the exhaust system dur ing or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely ...

Page 71: ...alks driveways parking lots and streets POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways U4S212E0 book Page 14 Thursday April 17 200...

Page 72: ...n rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Coul...

Page 73: ...til you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be in jured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch c...

Page 74: ... the closed position shift the drive select lever into the forward position and then release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds un til you are thoroughly familiar wit...

Page 75: ...obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a colli sion ...

Page 76: ... practice riding first on gentle slopes Try more difficult climbs only after you have devel oped your skill In all cases avoid inclines with slip pery or loose surfaces or obstacles that might cause you to lose control WARNING EWB01090 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steeper incl...

Page 77: ... 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 could be on the other side of the hill U4S212E0 book Page 20 Thursday April 17 2008 9 17 AM ...

Page 78: ...e Physically turn the ATV around and then descend the hill POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turn ing on a...

Page 79: ...roperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Apply the parking brake after you are stopped If you begin rolling backwards Keep weight uphill 2WD Never apply the rear brake while roll ing backwards Apply the front brake ...

Page 80: ...wheels on the down hill side Avoid sudden application of either the front or rear brake because the wheels on the up hill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob s...

Page 81: ...7 24 7 U4S212E0 book Page 24 Thursday April 17 2008 9 17 AM ...

Page 82: ...ually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING EWB01141 POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ...

Page 83: ...7 26 7 U4S212E0 book Page 26 Thursday April 17 2008 9 17 AM ...

Page 84: ...e your ATV without verifying that you have regained proper braking ability POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that...

Page 85: ...e the drive select lever box check hose and the storage compartment check hose Also remove the V belt case drain plug to drain any water that may have accumu lated Wash the ATV in fresh water if it has been operated in salt water or muddy conditions 1 Air filter case check hose 1 V belt cooling duct check hose left front side of ATV U4S212E0 book Page 28 Thursday April 17 2008 9 17 AM ...

Page 86: ...r ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult WARNING EWB01160 1 Drive select lever box check hose 1 Storage compartment check hose 1 V belt case drain plug POTENTIAL HAZARD Improperly operating over obstacles U4S212E0 book Page 29 Thursday April 17 2008 9 17 AM ...

Page 87: ...OW TO AVOID THE HAZARD Before operating in a new area check for ob stacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual U4S212E0 book Page 30 Thursday April 17 2008 9 17 AM ...

Page 88: ...ained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide With practice over a period 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 ...

Page 89: ...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 19 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side o...

Page 90: ... ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See page 7 27 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death U4S212E0 book Page 33 Thursday April 17 2008 9 17 AM ...

Page 91: ...INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01820 EBU21720 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and always carry it on the bottom of the seat as shown Put the owner s tool kit and low pres sure tire gauge under the seat POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch cloth...

Page 92: ...er s tool kit 3 Low pressure tire gauge POTENTIAL HAZARD Operating this ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added t...

Page 93: ...re special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 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 i...

Page 94: ...ss and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U4S212E0 book Page 4 Thursday April 17 2008 9 17 AM ...

Page 95: ...ver worn to the limit 3 Rear brake Check operation and correct if necessary Check brake lever and pedal free play and adjust if necessary Replace brake friction plates Whenever worn to the limit 4 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years 5 Wheels Check runout and for damage and replace if nec essary 6 Tires Check tread depth and for damage and rep...

Page 96: ...sed grease 15 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 16 Engine mount Check for cracks or other damage and replace if necessary 17 Axle boots Check for cracks or other damage and replace if necessary 18 Engine oil Change Check ATV for oil leakage and correct if neces sary 19 Engine oil filter car tridge Replace 20 Differential gear oil ...

Page 97: ...st or replace if neces sary 24 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 25 Front and rear brake switches Check operation and correct if necessary 26 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB I...

Page 98: ...s replace the internal components of the brake master cylinder and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U4S212E0 book Page 8 Thursday April 17 2008 9 17 AM ...

Page 99: ...ibed in this chapter Refer to this section each time the panel needs to be removed and installed EBU23111 Panel A To remove the panel Remove the bolt and then take the panel off To install the panel Place the panel in the original position and install the bolt NOTICE ECB00380 When installing the panel be sure not to pinch the cables or wires 1 Panel A 1 Panel A 2 Bolt U4S212E0 book Page 9 Thursday...

Page 100: ...rk plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark 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 TIP If the spark plug shows a distinctly different color the engine could be operating imp...

Page 101: ...o specification 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in 1 Spark plug gap Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf U4S212E0 book P...

Page 102: ...the intervals spec ified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil set tles for an accurate reading 3 Remove the engine oil fille...

Page 103: ...nge the engine oil with or without oil fil ter cartridge replacement 1 Start the engine warm it up for several min utes and then turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase TIP Skip steps 4 6 if the oil filter cartridge is not being replaced 1 Dipstick 2 Max...

Page 104: ...oat of engine oil to the O ring of the new oil filter cartridge TIP Make sure that the O ring is properly seated 6 Install the new oil filter cartridge with an oil fil ter wrench and then tighten it to the specified torque with a torque wrench 1 Oil filter cartridge 1 Oil filter wrench 1 O ring U4S212E0 book Page 14 Thursday April 17 2008 9 17 AM ...

Page 105: ...x any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 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 m kgf 17 ft lbf Recommended...

Page 106: ...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 TIP The final gear oil level must be checked on a cold engine 2 Remove the final gear oil filler bolt and then check ...

Page 107: ...engine guard and the final gear case guard by removing the bolts 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 filler bolt 2 Correct oil level 3 Final gear oil Tightening torque Final gear oil filler bolt 24 Nm 2 4 m kgf 17 ft lbf 1 Engine gua...

Page 108: ...E80W 90 API GL 5 Hypoid gear oil may be used instead However when using this oil noise from the final gear case may occur when applying the rear brake 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 24 Nm 2 4 m kgf 17 ft lbf 1 Final gear oil filler bolt 2 Correct oil level 3 Final gear oil Recommended final gear oil See page 10 1 U4S212E0 book Page 18 Thursday April 17 2008...

Page 109: ... a Yamaha dealer check and repair the ATV In addition the differential gear oil level must be checked and the oil changed as follows at the in tervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface TIP The differential gear oil level must be checked on a cold engine 2 Remove the differential gear oil filler bo...

Page 110: ...erential 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 4 Install the drain bolt and then tighten it to the specified torque 1 Differential gear oil 2 Differential gear oil filler bolt 3 Correct oil level Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ...

Page 111: ...at the in tervals specified in the periodic maintenance and lubrication chart Clean or if necessary replace the air filter element more frequently if you are riding in unusually wet or dusty areas TIP 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 Differential gear oil 2 Differ...

Page 112: ...3 Remove the air filter case cover by unhooking the air filter case cover holders 4 Pull the air filter element out of the air filter case 1 Air filter case check hose 1 Air filter case cover holder 2 Air filter case cover U4S212E0 book Page 22 Thursday April 17 2008 9 17 AM ...

Page 113: ...e the sponge material from the air filter element frame 6 Wash the sponge material gently but thor oughly in solvent 1 Air filter element 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate U4S212E0 book Page 23 Thursday April 17 2008 9 17 AM ...

Page 114: ...ng 10 Pull the sponge material over the air filter ele ment frame and then install the lock plate 11 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 12 Install the seat POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or ...

Page 115: ...ated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine over heating EBU23882 Cleaning the spark arrester Be sure the exhau...

Page 116: ...Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust componen...

Page 117: ... 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 adjustment described in the following section however may be performed ...

Page 118: ... to make this adjustment 1 Start the engine and warm it up TIP 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 it...

Page 119: ... throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the throttle cable free play adjusting bolt in di rection 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 ...

Page 120: ...e friction plates must be checked for wear at the intervals specified in the periodic maintenance and lubrica tion chart TIP This ATV is equipped with a wet multiple disc type rear brake which is located inside of the final gear case 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...

Page 121: ...BU24251 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 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 wea...

Page 122: ...goes down suddenly have a Yamaha dealer check the cause EBU24281 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart In addition 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 dam aged or lea...

Page 123: ... plates for wear Adjusting the brake pedal and brake lever free play The brake pedal free play should measure 17 0 20 0 mm 0 67 0 79 in The brake lever free play should measure 8 0 10 5 mm 0 31 0 41 in If ei ther free play is incorrect adjust it as follows POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an a...

Page 124: ...ever free play adjusting bolt 2 Fully loosen the brake lever free play adjust ing nut on the brake cable at the final gear case 1 Brake pedal free play 1 Brake lever free play 1 Locknut 2 Brake lever free play adjusting bolt U4S212E0 book Page 34 Thursday April 17 2008 9 17 AM ...

Page 125: ... 2 5 3 0 mm 0 10 0 12 in 4 Push the brake camshaft lever in direction a until it stops apply approximately 50 N 5 0 kgf 11 0 lbf of force and then turn the brake lever free play adjusting nut on the brake ca ble at the final gear case so that gap B mea sures 4 0 6 0 mm 0 16 0 24 in 1 Brake lever free play adjusting nut 1 Brake pedal free play adjusting nut 2 Brake camshaft lever 3 Gap A U4S212E0 b...

Page 126: ...r TIP When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move Checking the brake pedal position The top of the brake pedal should be positioned 75 0 85 0 mm 2 95 3 35 in above the footboard If the brake pedal position is incorrect have a Yamaha dealer adjust it 1 Brake lever free play adjusting nut 2 Brake camshaft lever 3 Gap B ...

Page 127: ...e pedal and footboard POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures s...

Page 128: ...justed by a Yamaha dealer 1 Remove panel A See page 8 9 TIP The brake light switch is properly adjusted when the brake light comes on just before braking takes effect 2 Turn the brake light switch adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in d...

Page 129: ...s should be checked before each ride and the lever pivots should be lubricated if necessary 1 Brake light switch 2 Brake light switch adjusting nut Recommended lubricant Engine oil POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cables can also be come frayed or kinked which could restrict the operation of controls and lead to ...

Page 130: ...dal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel A See page 8 9 Recommended lubricant Lithium soap based grease U4S212E0 book Page 40 Thursday April 17 2008 9 17 AM ...

Page 131: ... chart Lubricate the universal joint using a grease gun EBU25021 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bush es if necessary EBU25051 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the interval...

Page 132: ...commended lubricant Lithium soap based grease POTENTIAL HAZARD Failure to handle batteries or battery electro lyte carefully WHAT CAN HAPPEN You could be poisoned You could be se verely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gas es HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of re...

Page 133: ...ttery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary To install the battery TIP Be sure the battery is fully charged 1 Place the battery in its compartment 2 Connect the positive battery lead first then ...

Page 134: ...e Regulated Lead Ac id battery a special constant voltage bat tery charger is required Using a conventional battery charger will damage the battery If you do not have access to a constant voltage battery charger have a Yamaha dealer charge your battery EBU25313 Replacing a fuse 1 Positive battery lead red 2 Negative battery lead black 2 1 1 Main fuse 2 Spare main fuse 3 Fuse box U4S212E0 book Page...

Page 135: ...ge WARNING EWB02151 1 Headlight fuse 2 Ignition fuse 3 Four wheel drive motor fuse 4 Signaling system fuse 5 Spare fuse Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 15 0 A Four wheel drive motor fuse 10 0 A Signaling system fuse 10 0 A POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fir...

Page 136: ...ht bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the headlight bulb holder cover by pulling it off 3 Remove the headlight bulb holder by pushing it in and turning it counterclockwise 1 Cover at the rear of the headlight 1 Headlight bulb holder cover 1 Headlight bulb holder U4S212E0 book Page 46 Thursday April 17 ...

Page 137: ...rints on the headlight bulb using a cloth moistened with alcohol or thinner 6 Install the bulb holder by pushing it in and turn ing it clockwise 7 Install the bulb holder cover and the cover at the rear of the headlight POTENTIAL HAZARD A headlight bulb is hot when it is on and im mediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something...

Page 138: ...er make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25580 Replacing the tail brake light bulb If the tail brake light bulb burns out have a Yamaha dealer replace it EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 1 Headlight beam adjusting s...

Page 139: ... 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP 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 U4S212E0 book Page 49 Thursday April 17 2008 9 17 AM ...

Page 140: ...TV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly 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 EWB02260 1 Tapered nut Tightening torques Front wheel nut...

Page 141: ...D THE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces U4S212E0 book Page 51 Thursday April 17 2008 9 17 AM ...

Page 142: ... 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 143: ...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 144: ...buretor 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 stabilizer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug POTENTIAL HAZARD Operation w...

Page 145: ...levers and pedals 7 Check and 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 c...

Page 146: ...ment 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 Starting system Electric and recoil starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 5W 30 or 10W 40 or 20W 50 SAE 5W 30 or SAE 10W 40 or SAE 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA 0 10 30 50 70 90 110 130 F YAMALUBE 4 ...

Page 147: ...t Wet element Fuel Recommended fuel Unleaded gasoline only 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 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 Transmission Primary reduction system V belt Secondary r...

Page 148: ...Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum Front 22 0 kPa 0 220 kgf cm 3 2 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi Front wheel Wheel type Panel wheel Rim size 12 x 6 0AT Rear wheel Wheel type Panel wheel Rim size 12 x 7 5AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Wet multiple disc brake Operation Left hand and right foot operation Fron...

Page 149: ...ty Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 Meter lighting 12 V 1 7 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Oil temperature warning light 12 V 1 7 W 1 On command four wheel drive indicator light 12 V 1 7 W 1 Differential gear lock indicator light 12 V 1 7 W x 1 Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ign...

Page 150: ...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 EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key ide...

Page 151: ...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 Model label U4S212E0 book Page 2 Thursday April 17 2008 9 17 AM ...

Page 152: ...ose of noise control prior to its sale or delivery to the ul timate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Mu...

Page 153: ...the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 U4S2...

Page 154: ...sequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also war...

Page 155: ... upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CUSTOMER SERVICE If your mac...

Page 156: ... to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodgi...

Page 157: ...osts less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 Indicates a potential hazard that could result in serious injury or death WARNING U4S2...

Page 158: ...11 9 11 EBU26132 U4S212E0 book Page 9 Thursday April 17 2008 9 17 AM ...

Page 159: ...ear 4 21 Chassis fasteners 5 7 Cleaning 9 1 D Differential gear lock indicator light 4 3 Differential gear oil 5 3 8 19 Drive select lever 4 13 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 30 Drive shaft universal joint lubricating 8 41 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 28 Engine oil 5 3 Engine oil and oil filter c...

Page 160: ... Recoil starter 4 14 Reverse indicator light 4 2 Riding your ATV 7 1 S Safety information 1 1 Seat 4 18 Shock absorber assemblies adjusting the front and rear 4 21 Spark arrester cleaning 8 25 Spark plug checking 8 10 Specifications 10 1 Speed limiter 4 10 Speedometer 4 3 Stabilizer bushes checking 8 41 Starter choke 4 18 Start switch 4 5 Steering shaft lubricating 8 42 Storage 9 2 Storage compart...

Page 161: ...Warranty limited 11 5 Wheel hub bearings checking 8 41 Wheel installing 8 49 Wheel removing 8 48 U4S212E0 book Page 3 Thursday April 17 2008 9 17 AM ...

Page 162: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 163: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 164: ... and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS ...

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