Yamaha RAPTOR 350 Owner'S Manual Download Page 105 | Manualshive

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8-1

EBU00515

PERIODIC MAINTENANCE AND

ADJUSTMENT

Periodic inspection, adjustment and lubrica-
tion will keep your machine in the safest and
most efficient condition possible. Safety is an
obligation of the machine owner. The most
important points of machine inspection, ad-
justment and lubrication are explained on the
following pages.

EBU01221

Owner’s manual and tool kit

You are recommended to put this owner’s
manual and low-pressure tire gauge in the vi-
nyl bag and always carry them along with the
owner’s tool kit under the seat.

1. Owner’s tool kit

2. Owner’s manual

3. Low-pressure tire gauge

WARNING

POTENTIAL HAZARD

Servicing an engine while it is running.

WHAT CAN HAPPEN

Moving parts can catch clothing or parts
of the body, causing injury.
Electrical components can cause
shocks or can start fires.

HOW TO AVOID THE HAZARD

Turn off the engine when performing
maintenance unless otherwise speci-
fied.

Have a Yamaha dealer perform service if
you are not familiar with machine ser-
vice.

U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM

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Summary of Contents for RAPTOR 350

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL ...

Page 2: ...EBU00776 ...

Page 3: ...ormation It provides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures 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 COMPLETELY BEFORE OPERATING YOUR ATV MA...

Page 4: ...bol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer U...

Page 5: ...oise level and spark arrester laws and regu lations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU13330 AFFIX DEALER LABEL HERE YFM350RV OWNER S MANUAL 2005 by Yamaha Motor Corporation U S A 1st edition June 2005 All rights reserved Any reprinting or unauthorized use without the written permission U5YT13 book Page 2 Wednesday ...

Page 6: ...Key identification number 3 2 Vehicle identification number 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator lights 4 2 Handlebar switches 4 2 Throttle lever 4 4 Speed limiter 4 5 Clutch lever 4 6 Brake lever 4 6 Brake pedal 4 7 Parking brake lever 4 8 Shift pedal 4 9 Drive select lever 4 10 Fuel tank cap 4 10 Fuel cock 4 11 Starter choke 4 12 Seat 4 13 Front shock absorber adjustment 4 1...

Page 7: ...3 Warming up 6 3 Drive select lever operation and Parking 6 9 Parking on a slope 6 10 Accessories and loading 6 11 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 23 Climbing uphill 7 25 Riding downhill 7 30 Crossing a slope 7 32 Crossing through shallow water 7 34 Riding over rough terrain 7 36 Sliding and sk...

Page 8: ...nt 8 19 Front brake pad inspection 8 19 Rear brake pad inspection 8 20 Brake fluid level check 8 21 Adjusting the rear brake light switch 8 27 Clutch lever free play adjustment 8 27 Drive chain slack check 8 29 Drive chain slack adjustment 8 30 Lubricating the drive chain 8 31 Cable inspection and lubrication 8 33 Brake and shift pedal brake and clutch lever lubrication 8 33 Lubricating the front ...

Page 9: ...ND STORAGE 9 1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 9 10 11 12 13 14 U5YT13 book Page 4 Wednesday June 29 2005 10 35 AM ...

Page 10: ...EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5YT13 book Page 1 Wednesday June 29 2005 10 35 AM ...

Page 11: ... remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 3 DRIVE SELECT LEVER Read owner s manual carefully before operating When shifting the drive select lever always be sure to stop the ATV and apply the rear brake 5YT 2151E 30 U5YT13 book Page 2 Wednesday June 29 2005 10 35 AM ...

Page 12: ...4 6 5 UNDER WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death U5YT13 book Page 3 Wednesday June 29 2005 10 35 AM ...

Page 13: ... operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater...

Page 14: ...s Always go at a speed that is proper for the terrain visibility operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Al ways follow the inspection and maintenance procedures and schedules described in this man ual Always keep both hands on the handlebars and both feet on th...

Page 15: ...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 before you start down any hill Shift your weight back ward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow ...

Page 16: ...op erating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by prac ticing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deep...

Page 17: ...ed load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Products Safety Com mission at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 U5YT13 book Page 5 Wednesd...

Page 18: ...ames or other sources of ignition such as the pilot When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gas...

Page 19: ... a closed area WHAT CAN HAPPEN Exhaust 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 adequate ventilation U5YT13 book Page 7 Wednesday June 29 2005 10 35 AM ...

Page 20: ...Drive select lever 4 Fuel tank cap 5 Main switch 6 Brake pedal 7 Headlights 8 Front wheel 9 Fuel cock 10 Rear wheel 11 Shift pedal 12 Clutch lever 13 Parking brake lever 14 Brake lever 15 Throttle lever 16 Handlebar switches U5YT13 book Page 1 Wednesday June 29 2005 10 35 AM ...

Page 21: ... spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number U5YT13 book Page 2 Wednesday Jun...

Page 22: ...icle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label U5YT13 book Page 3 Wednesday June 29 2005 10 35 AM ...

Page 23: ...h EBU00942 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position U5YT13 book Page 1 Wednesday June 29 2005 10 35 AM ...

Page 24: ...cator light R This indicator light comes on when the drive select lever is in reverse EBU00053 Handlebar switches 1 Light switch OFF 2 Engine stop switch 3 Start switch EBU12040 Light switch OFF Set the switch to to turn on the low beam and the taillight U5YT13 book Page 2 Wednesday June 29 2005 10 35 AM ...

Page 25: ...that the engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is set to EBU06070 Start switch The starter motor cranks the engine when this switch is pushed CAUTION _ See starting instructions prior to starting the engin...

Page 26: ...g the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle le...

Page 27: ...o more than 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to ...

Page 28: ... clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation Refer to Starting a cold engine for a de scription of the ignition circuit cut off system EBU00988 Brake lever The brake lever is located on the right handle bar Pull it toward the handlebar to apply the front brake 1 Brake lever U5YT13 book Page 6 Wednesday June 29...

Page 29: ...EBU00989 Brake pedal The brake pedal is located on the right side of the machine Push down on the pedal to apply the rear brake 1 Brake pedal U5YT13 book Page 7 Wednesday June 29 2005 10 35 AM ...

Page 30: ...chine especially on a slope To apply the parking brake move the parking brake lever in direction a To release the parking brake move the parking brake le ver in direction b 1 Parking brake lever Locked position 1 Parking brake lever Unlocked position U5YT13 book Page 8 Wednesday June 29 2005 10 35 AM ...

Page 31: ...APPEN The ATV could start moving unexpect edly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake disc could overheat if you ride the ATV without releasing the park ing brake You could lose braking per formance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the par...

Page 32: ...iving the machine either forward or in reverse Refer to page 6 4 for drive select lever operation 1 Drive select lever EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap U5YT13 book Page 10 Wednesday June 29 2005 10 35 AM ...

Page 33: ...unning ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON position 1 Arrow mark pointing to OFF OFF Position ON Position U5YT13 book Pa...

Page 34: ...ir fuel mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 RES Position U5YT13 book Page 12 Wednesday June 29 2005 10 35 AM ...

Page 35: ...at the rear 1 Seat lock lever 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 Projection 2 2 Seat holder 2 U5YT13 book Page 13 Wednesday June 29 2005 10 35 AM ...

Page 36: ...pring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring 2 Position indicator NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ 1 Special wrench Standard position C A Minimum soft E Maximum hard U5YT13 book Page 14 Wednesday June 29 2005 10 35 AM ...

Page 37: ... 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 absorbers on the left and right side to the same set ting U5YT13 book Page 15 Wednesday June 29 2005 10 35 AM ...

Page 38: ...2 To increase the spring preload turn the adjusting nut in direction a To decrease the spring preload turn the adjusting nut in direction b CAUTION _ Never attempt to turn the adjusting nut be yond the maximum or minimum setting _ NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ 1 Special wrench U5YT13 book Page 16 Wednesday June 29 2005 10 35 AM ...

Page 39: ..._ Always tighten the locknut against the ad justing nut and tighten it to the specified torque _ Measurement A Installed length Minimum hard 218 5 mm 8 6 in Standard 228 5 mm 9 0 in Maximum soft 233 5 mm 9 2 in A U5YT13 book Page 17 Wednesday June 29 2005 10 35 AM ...

Page 40: ...y or property damage Cyl inder damage could also result in poor handling which could cause an acci dent HOW TO AVOID THE HAZARD Do not tamper with or attempt to open the cylinder assembly Do not subject the shock absorber to an open flame or other high heat Do not deform or damage the cylin der in any way U5YT13 book Page 18 Wednesday June 29 2005 10 35 AM ...

Page 41: ...ble length 8 25 8 26 Fuel Check fuel level Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 6 8 6 8 9 Drive chain Check chain slack and condition Adjust if necessary 5 6 8 29 8 32 Throttle Check for proper throttle cable operation and free play 5 6 8 19 Wheels and tires Check tire pressure wear and damage 5 8 5 10 8 37 8 38 Fittings and fasteners Check al...

Page 42: ...not have a Yamaha dealer inspect the brake system Brake fluid level Check the brake fluid level Add fluid if neces sary See pages 8 21 8 22 WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper ating 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...

Page 43: ... provide proper braking per formance inspect the brake pads for wear See pages 8 19 8 20 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected...

Page 44: ...igned to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 9 0 L 1 98 Imp gal 2 38 US gal Reserv...

Page 45: ...AZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the...

Page 46: ...terial en ters the crankcase _ EBU00498 Chain Check the general condition of the chain and check the chain slack before every ride Lubri cate and adjust the chain as necessary See pages 8 29 8 32 for details EBU01083 Throttle lever Check to see that the throttle lever operates correctly It must open smoothly and spring back to the idle position when released Have a Yamaha dealer repair as necessar...

Page 47: ...ght to make sure they are in working condition Re pair as necessary for proper operation EBU01170 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for proper operation U5YT13 book Page 7 Wednesday June 29 2005 10 35 AM ...

Page 48: ...r Co Ltd for this model Other tire combina tions are not recommended 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 25 kPa 0 25 kgf cm2 3 6 psi Rear 25 kPa 0 25 kgf cm2 3 6 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dislodge from th...

Page 49: ...owing pressures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst Recommended pressure Minimum Maximum Front 25 kPa 0 25 kgf cm2 3 6 psi 22 kPa 0 22 kgf cm2 3 2 psi 28 kPa 0 28 kgf cm2 4 1 psi Rear 25 kPa 0 25 kgf cm2 3 6 p...

Page 50: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit U5YT13 book Page 10 Wednesday June 29 2005 10 35 AM ...

Page 51: ...ar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident 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 WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW ...

Page 52: ...ssion and the drive select lever in any position However it is recommend ed to shift into neutral before starting the engine _ 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 6 Completely...

Page 53: ...2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used The throttle should be opened slightly EBU01820 Warming up To get maximum engine life ...

Page 54: ...d return the throttle lever to the closed position 2 Pull in the clutch lever to disengage the clutch 3 Apply the brake pedal NOTE _ When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the machine _ 5 Check behind you for people or obsta cles and then release the brake pedal 6 Open the throttle lever gradually and re lease the clutc...

Page 55: ...ition apply the clutch and repeat edly depress the shift pedal until it stops When it stops it will be in first gear Raise the pedal slightly to neutral WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people beh...

Page 56: ...g without the clutch _ EBU14190 To start out and accelerate 1 Release the throttle lever and then re lease the parking brake CAUTION _ Always close the throttle while shifting gears Otherwise damage to the engine and drive train may result _ 2 Pull the clutch lever to disengage the clutch 3 Shift into first gear 4 Open the throttle gradually and at the same time release the clutch lever slow ly 5 ...

Page 57: ... the possibility of an accident WARNING POTENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever too quickly WHAT CAN HAPPEN The machine could wheelie This would increase the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too...

Page 58: ...2 3 seconds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this peri od consult a Yamaha dealer 0 10 hours Avoid continuous operation above half...

Page 59: ...EBU02111 Parking When parking stop the engine and shift into first gear Turn the fuel cock to OFF and ap ply the parking brake 1 Locked position U5YT13 book Page 9 Wednesday June 29 2005 10 35 AM ...

Page 60: ...es off _ 5 Turn the key to OFF WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline put the machine in low gear apply the parking brake and block the front and rear wheels with rocks or other objects Do not pa...

Page 61: ...a accesso ries nor have any control over the quality or suitability of them Choose a genuine Yamaha accessory or one that is equiva lent in design and quality Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object attached to the han dlebars which could make steering difficult an accessory that limits ...

Page 62: ...ers Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with controls or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slow er you should go Although conditions vary it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or wh...

Page 63: ... vehicle han dling 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 securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking U5YT13 book Page 13 Wednesday June 29 2005 10 35 AM ...

Page 64: ...EBU13552 WARNING _ Indicates a potential hazard that could result in serious injury or death U5YT13 book Page 14 Wednesday June 29 2005 10 35 AM ...

Page 65: ...7 1 Riding Your ATV U5YT13 book Page 1 Wednesday June 29 2005 10 35 AM ...

Page 66: ...skills acquired through practice Take your time to fully learn techniques be fore attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill operation of the controls Pay particular atten tion to the safety information on pages 2 1 2 7 Pl...

Page 67: ...ime Take the time to learn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills lear...

Page 68: ...menda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc U5YT13 book Page 5 Wednesday June 29 2005 10 35 AM ...

Page 69: ...atly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers U5YT13 book Page 6 Wednesday June 29 2005 10 35 AM ...

Page 70: ...accident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event Operating without protective clothing increases 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 slee...

Page 71: ...AZARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV U5YT13 book Page 8 Wednesday June 29 2005 10 35 AM ...

Page 72: ... is in safe op erating condition Always follow the inspection and main WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use the size a...

Page 73: ...p speed of the ATV Turning the adjusting screw in decreases the top speed and turning it out increases the top speed See page 4 5 for details 1 Locknut 2 Adjusting screw WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always g...

Page 74: ...LOADING LIMIT Vehicle loading limit total weight of rider cargo and accessories 100 kg 220 lb WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling 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 securely attach...

Page 75: ...ven one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation U5...

Page 76: ... POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off U5YT13 book Page 13 Wednesday June 29 2005 10 35 AM ...

Page 77: ...ause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed U5YT13 book Page 14 Wednesday June 29 2005 10 35 AM ...

Page 78: ...ING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during 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 U5YT13 book Page 15 Wednes...

Page 79: ...this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets U5YT13 book Page 16 Wednesday June 29 2005 10 35 AM ...

Page 80: ...ating 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 high ways U5YT13 book Page 17 Wednesday June 29 2005 10 35 AM ...

Page 81: ...to upset WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden 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 op U5YT13 book Page 18 Wednesday June 29 2005 10 35 AM ...

Page 82: ... vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain U5YT13 book Page 19 Wednesday June 29 2005 10 35 AM ...

Page 83: ...r hitch Do not ride in areas posted no trespassing Do not ride on private property without getting permission WARNING WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles U5YT13 book Page 20 Wednesday June 29 2005 10 35 AM ...

Page 84: ... and afterwards do not allow With the engine idling pull the clutch lever to disengage the clutch and shift into 1st gear and then release the parking brake Open the throttle gradually and at the same time re lease the clutch lever slowly Once the ATV has attained adequate speed release the throttle lever and at the same time quickly pull in the clutch lever and shift into 2nd gear Open the thrott...

Page 85: ...n creasing the possibility of an accident WARNING POTENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever too quickly WHAT CAN HAPPEN The ATV could wheelie This would in crease the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed...

Page 86: ... you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The ATV could go out of contro...

Page 87: ...proper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Av...

Page 88: ...ant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small hi...

Page 89: ...s as described in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes An obstacle a sharp drop or another vehicle or person could be on the other side of the hill U5YT13 book Page 26 Wednesday June 29 2005 10 35 AM ...

Page 90: ...r 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 technique as described in the 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 w...

Page 91: ...ld easily tip over backwards In stead apply the front brake gradually or dis mount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep wei...

Page 92: ...smount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu al U5YT13 book Page 29 Wednesday June 29 2005 10 35 AM ...

Page 93: ...n Whenever possible ride your ATV straight downhill Avoid sharp angles which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for go ing down hills as described in this O...

Page 94: ...U5YT13 book Page 31 Wednesday June 29 2005 10 35 AM ...

Page 95: ... up hill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no WARNING 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 unti...

Page 96: ...Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV U5YT13 book Page 33 Wednesday June 29 2005 10 35 AM ...

Page 97: ...ry or up set the ATV Drive slowly and carefully WARNING 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 accident HOW TO AVOID THE HAZARD Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to le...

Page 98: ...gained proper braking ability CAUTION _ 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 Wash the ATV in fresh water if it has been operated in salt water or muddy con ditions _ U5YT13 book Page 35 Wednesday June 29 2005 10 35 AM ...

Page 99: ...l and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper procedur...

Page 100: ...U5YT13 book Page 37 Wednesday June 29 2005 10 35 AM ...

Page 101: ...eels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide U5YT13 book Page 38 Wednesday June 29 20...

Page 102: ...trol may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious i...

Page 103: ... necessary gradually let off the throttle and or steer to the outside of the turn See pag If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for ward...

Page 104: ...ver that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water 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 un til you have regained adequate braking ability See ...

Page 105: ...21 Owner s manual and tool kit You are recommended to put this owner s manual and low pressure tire gauge in the vi nyl bag and always carry them along with the owner s tool kit under the seat WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires ...

Page 106: ...maha dealer to check the torque settings and adjust them as neces sary _ WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of ...

Page 107: ...tems marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills _ ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 300 800 2 500 1 600 2 500 1 600 5 000 3 200 hours 20 80 160 160 320 Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Carbur...

Page 108: ...re draining Engine oil filter element Clean Replace if necessary Engine oil strainer Clean Drive chain Check and adjust slack alignment clean lube Brakes Check operation fluid leakage See NOTE Page 8 5 Correct if necessary Clutch Check operation Adjust if necessary Wheels Check balance damage runout Replace if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damage...

Page 109: ... Replace the brake hoses every four years or if cracked or damaged WARNING Indicates a potential hazard that could result in serious injury or death Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check operation Adjust headlight beams ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 300 800 2 500 1 600 2 500...

Page 110: ...veral minutes and then turn it off 3 Wait a few minutes until the oil level set tles before checking 4 Remove the engine oil filler cap and then wipe the dipstick off with a clean rag In sert the dipstick in the filler hole without screwing it in and then remove it again to check the oil level 5 If the engine oil is at or below the mini mum level mark add sufficient oil of the recommended type to ...

Page 111: ...turn it off 3 Place a container under the engine to collect the used oil 4 Remove the engine oil filler cap and then remove the engine oil drain bolt to drain the oil from the crankcase CAUTION _ When removing the engine oil drain bolt the compression spring oil strainer and O ring will fall out Take care not to lose 1 Engine oil drain bolt 2 O ring 3 Compression spring 4 Engine oil strainer U5YT1...

Page 112: ...all the oil filter cover by installing the bolts and then tighten them to the speci fied torque 10 Install the oil strainer compression spring O ring and engine oil drain bolt Tighten the engine oil drain bolt to the specified torque CAUTION _ Before installing the engine oil drain bolt be sure to install the O ring compression spring and oil strainer _ Tightening torque Oil filter cover bolt 10 N...

Page 113: ...ed ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ 12 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 13 Turn the engine off and then check the oil level and correct it if necessary Recommended oil See page 10 2 Oil quantity Without oil fil...

Page 114: ...wn 1 Spark plug wrench Inspection The spark plug is an important engine compo nent and is easy to inspect The condition of the spark plug can indicate the condition of the engine The ideal color on the white insulator around the center electrode is a medium to light tan color for an ATV that is being ridden normally U5YT13 book Page 10 Wednesday June 29 2005 10 35 AM ...

Page 115: ...k plug with the specified plug Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification a Spark plug gap 2 Clean the surface of the spark plug gas ket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug and tighten it to the specified torque Specified spark plug DR8EA NGK Spark plug gap...

Page 116: ...pecified torque as soon as possible _ 4 Install the spark plug cap EBU14920 Air filter element cleaning 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 filter case _ 1 Air filter case check hose 1 Remove the seat See page 4 13 for U5YT13 book Page 12 Wednesday June 29 2005 10 35 AM ...

Page 117: ... filter case cover 2 Holder 4 3 Remove the air filter element assembly and then remove the air filter element from its frame 1 Air filter element assembly U5YT13 book Page 13 Wednesday June 29 2005 10 35 AM ...

Page 118: ...nd let it dry CAUTION _ Do not twist the air filter element when squeezing it _ WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element U5YT13 book Page 14 Wednesday June 29 2005 10 35 AM ...

Page 119: ...aned and lubri cated more often if the machine is operated in extremely dusty areas Each time the air filter element maintenance is performed check the air inlet to the filter case for obstructions Check the air filter case rubber joint to the car buretor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine _ CAUTIO...

Page 120: ... arrester 1 Remove the bolt 1 Bolt 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install and tighten the bolt U5YT13 book Page 16 Wednesday June 29 2005 10 35 AM ...

Page 121: ...ests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result WARNING 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 poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the sp...

Page 122: ...and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction a to increase the engine speed and in direc tion b to decrease the engine speed 1 Throttle stop screw EBU00303 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clear ance must be a...

Page 123: ...981 Front brake pad inspection Each brake pad is provided with a wear indi cator groove The indicator grooves allow checking of brake pad wear without disas sembling the brake Apply the brake and in spect the wear indicator grooves If a brake pad is worn to the point that the wear indicator groove is almost in contact with the disc plate ask a Yamaha dealer to replace the brake pads as a set Front...

Page 124: ... with a wear indi cator groove The indicator grooves allow checking of brake pad wear without disas sembling the brake Apply the brake and in spect the wear indicator grooves If a brake pad is worn to the point that the wear indicator groove is almost in contact with the disc plate ask a Yamaha dealer to replace the brake pads as a set Rear U5YT13 book Page 20 Wednesday June 29 2005 10 35 AM ...

Page 125: ...worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage 1 Minimum level mark Observe these precautions When checking the brake fluid level make sure the top of the brake fluid reservoir is level Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poo...

Page 126: ...teriorate painted surfac es or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer check the cause if the brake fluid level goes down EBU01186 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking Replace...

Page 127: ...ith improperly serviced or adjusted 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 Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re U5YT13 book Page 23...

Page 128: ...L HAZARD Operating with improperly serviced or adjusted 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 brake pedal position is 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 co...

Page 129: ...ing bolt A Cable length 1 Release the parking brake by moving the parking brake lever to the right 2 Fully loosen the locknut and the adjusting bolt at the rear brake caliper 3 Loosen the locknut on the brake cable 4 Turn the adjusting nut on the brake cable in direction a to increase the cable length or in direction b to decrease the cable length U5YT13 book Page 25 Wednesday June 29 2005 10 35 A...

Page 130: ...olt does not turn together with the locknut _ Tightening torque Locknut 16 Nm 1 6 m kgf 11 ft lbf WARNING POTENTIAL HAZARD Operating with improperly adjusted brakes WHAT CAN HAPPEN The brakes could malfunction causing reduced braking performance This could increase the chance of a collision or accident HOW TO AVOID THE HAZARD After adjusting the parking brake block the rear of the machine off the ...

Page 131: ...ier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EBU00741 Clutch lever free play adjustment The clutch lever free play should be adjusted to 5 10 mm 0 20 0 39 in 1 Loosen the locknut at the clutch lever 2 Turn the adjusting bolt at the clutch lever in direction a to increase the free play or in direction b to decrease the free pl...

Page 132: ...ing bolt c Clutch lever free play 6 Loosen the locknut at the crankcase side 7 Turn the adjusting nut at the crankcase in direction a to increase the free play or in direction b to decrease the free play 8 Tighten the locknut at the crankcase and the clutch lever 1 Locknut 2 Adjusting nut U5YT13 book Page 28 Wednesday June 29 2005 10 35 AM ...

Page 133: ...est position _ To check the drive chain slack all tires must be touching the ground and there should be no weight on it Check the drive chain slack at the position shown in the illustration Normal slack is approximately 25 0 35 0 mm 0 98 1 38 in If the slack exceeds 35 0 mm 1 38 in adjust it to specification a Drive chain slack U5YT13 book Page 29 Wednesday June 29 2005 10 35 AM ...

Page 134: ...drive chain turn the adjusting bolts in direction a To loosen the drive chain turn the adjusting NOTE _ There are alignment marks on each side of the swingarm and on the hub Use them to check for proper wheel axle alignment _ 1 Locknut 2 Adjusting bolt 3 Alignment marks 3 After adjusting tighten the locknuts and the wheel hub bolts to the specified U5YT13 book Page 30 Wednesday June 29 2005 10 35 ...

Page 135: ...UTION _ The drive chain must be lubricated after washing the ATV or riding in the rain _ 1 Clean the drive chain with kerosene and a small soft brush CAUTION _ To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate Tightening torques Locknut 16 Nm 1 6 m kgf 11 ft lbf Upper wheel hub bolt 120 Nm 12 0 m kgf 85 ft lbf Lower wheel hub bo...

Page 136: ...CAUTION _ Do not use engine oil or any other lubri cants for the drive chain as they may contain substances that could damage the O rings _ 1 O ring U5YT13 book Page 32 Wednesday June 29 2005 10 35 AM ...

Page 137: ... Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil Recommended ...

Page 138: ...U5YT13 book Page 34 Wednesday June 29 2005 10 35 AM ...

Page 139: ...ricate the upper and lower arm pivots with a grease gun 1 Upper grease nipple 2 2 Lower grease nipple 2 1 Upper grease nipple 2 2 Lower grease nipple 2 Recommended lubricant Lithium soap based grease Right Left U5YT13 book Page 35 Wednesday June 29 2005 10 35 AM ...

Page 140: ...EBU00987 Rear arm pivot lubrication Lubricate the rear arm pivots 1 Grease nipple 1 Grease nipple Recommended lubricant Lithium soap based grease U5YT13 book Page 36 Wednesday June 29 2005 10 35 AM ...

Page 141: ...oval 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 1 Nut 4 Front Rear U5YT13 book Page 37 Wednesday June 29 2005 10 35 AM ...

Page 142: ...alling the wheel reverse the remov al procedure Tighten the wheel nuts to the specified torques Tightening torques Wheel nut Front 45 Nm 4 5 m kgf 32 ft lbf Rear 45 Nm 4 5 m kgf 32 ft lbf U5YT13 book Page 38 Wednesday June 29 2005 10 35 AM ...

Page 143: ... distilled water in the bat tery If the battery seems to have discharged consult a Yamaha dealer CAUTION WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WHAT CAN HAPPEN You could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases U5YT13 book Page 39 Wednesday June 29 2005 10 35 AM ...

Page 144: ...re correct when putting the battery back in the machine HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15...

Page 145: ...er CAUTION _ To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse _ Specified fuse 15 0 A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse...

Page 146: ...ns out replace it as fol lows 1 Remove the headlight bulb holder cover at the rear of the headlight by pulling it off 1 Headlight bulb holder cover 2 Remove the headlight bulb holder by 1 Headlight bulb holder U5YT13 book Page 42 Wednesday June 29 2005 10 35 AM ...

Page 147: ... headlight unit 1 Do not touch the glass part of the bulb WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it U5YT13 book Page 43 Wednesday June 29 2005 10 35 AM ...

Page 148: ...Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner _ 5 Install the headlight bulb holder by align ing the projections with the holes in the headlight unit pushing it inward and turning it clockwise until it stops 6 Install the headlight bulb holder cover at the rear of the headlight U5YT13 book Page 44 Wednesday June 29 2005 10 35 A...

Page 149: ...m turn the adjusting bolt in di rection a To lower the beam turn the adjusting bolt in direction b EBU12170 Tail brake light bulb replacement 1 Screw 2 1 Remove the lens by removing the screws 2 Remove the defective bulb by pushing it inward and turning it counterclockwise U5YT13 book Page 45 Wednesday June 29 2005 10 35 AM ...

Page 150: ... a new bulb by pushing it inward and turning it clockwise 4 Install the lens by installing the screws CAUTION _ Do not overtighten the screws as the lens may break _ U5YT13 book Page 46 Wednesday June 29 2005 10 35 AM ...

Page 151: ...ence and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se vere ...

Page 152: ...ssion Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap or replace the spark plug No spark 4 Battery Engine turns over quickly Battery is good C...

Page 153: ... ets or wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash ers 4 Once the ...

Page 154: ...may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the l...

Page 155: ...oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil 3 Clean the drive chain thoroughly and lu bricate it See pages 8 31 8 32 4 Lubricate all control cables 5 Block up the frame to raise all wheels off the ground 6 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from enterin...

Page 156: ...ry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine U5YT13 book Page 4 Wednesday June 29 2005 10 35 AM ...

Page 157: ...820 mm 32 3 in 1 210 mm 47 6 in 115 mm 4 53 in 3 100 mm 122 0 in Basic weight With oil and full fuel tank 180 0 kg 397 lb Engine Type Cylinder arrangement Displacement Bore Stroke Compression ratio Starting system Lubrication system Air cooled 4 stroke SOHC Forward inclined single cylinder 349 0 cm3 83 0 64 5 mm 3 27 2 54 in 9 20 1 Electric starter Wet sump U5YT13 book Page 1 Wednesday June 29 200...

Page 158: ...30 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix 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 CONSERVING II or higher U5YT13 book Pa...

Page 159: ...turer Gap DR8EA NGK 0 6 0 7 mm 0 024 0 028 in Clutch Type Operation Wet multiple disc Left hand operation Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Spur gear 76 24 3 166 Chain drive 38 13 2 923 Constant mesh 6 speed forward 1 speed reverse Left foot operation MODEL YFM350R U5YT13 book Page 3 Wednes...

Page 160: ... 27 29 18 0 946 33 16 33 10 6 806 Chassis Frame type Caster angle Trail Steel tube 6 0 26 0 mm 1 02 in Tire Type Size Front Size Rear Tubeless AT21 7 10 AT20 10 9 Brake Front brake type Operation Rear brake type Operation Dual disc brake Right hand operation Single disc brake Right foot operation Suspension MODEL YFM350R U5YT13 book Page 4 Wednesday June 29 2005 10 35 AM ...

Page 161: ...ry type voltage capacity D C C D I A C magneto YTZ10S 12V 8 6Ah Headlight type Krypton bulb Bulb voltage wattage quantity Headlight Tail brake light Indicator light Neutral Reverse 12V 30W 30 0W 2 12V 5W 21 0W 1 12V 1 7W 1 12V 1 7W 1 Fuse 15 0A MODEL YFM350R U5YT13 book Page 5 Wednesday June 29 2005 10 35 AM ...

Page 162: ...se of noise control prior to its sale or delivery to the ultimate 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 Muff...

Page 163: ... minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 07E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 300 800 80 6 2 500 1 600 160 12 5 000 3 200 320 18 7 500 4 800 480 24 10 000 6 400 640 30 12 500 8 000 800 36 15 000 9 600 960 42 17 500 11 200 1 120 48 20 000 12 800 1 2...

Page 164: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U5YT13 book Page 1 Wednesday June 29 2005 10 35 AM ...

Page 165: ...1 2 3 4 5 6 7 8 9 10 9 9 13 U5YT13 book Page 2 Wednesday June 29 2005 10 35 AM ...

Page 166: ...EBU00435 1 YAMAHA EXTENDED SERVICE Y E S U5YT13 book Page 1 Wednesday June 29 2005 10 35 AM ...

Page 167: ...1 2 3 4 5 6 7 8 9 10 9 9 9 U5YT13 book Page 2 Wednesday June 29 2005 10 35 AM ...

Page 168: ...EBU00437 U5YT13 book Page 3 Wednesday June 29 2005 10 35 AM ...

Page 169: ...ct handling 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 PU...

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