Yamaha Raptor YFM350S Ower'S Manual Download

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3-1

EBU00032

DESCRIPTION AND MACHINE IDENTIFICATION

1. Spark arrester
2. Seat
3. 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

NOTE:

The machine you have purchased may differ
slightly from those shown in the figures of this
manual.

U5YT10.book Page 1 Friday, December 12, 2003 2:32 PM

Summary of Contents for Raptor YFM350S

Page 1: ...r riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJ...

Page 2: ...EBU00776...

Page 3: ...s 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 T...

Page 4: ...ol 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...

Page 5: ...ons in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU13340 AFFIX DEALER LABEL HERE YFM350S OWNER S MANUAL 2003 by Yamaha Motor...

Page 6: ...2 Vehicle identification number 3 3 Model label 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...

Page 7: ...ving 6 4 Shifting 6 5 To start out and accelerate 6 6 To decelerate 6 7 Engine break in 6 8 Parking 6 9 Parking on a slope 6 10 Accessories and loading 6 11 RIDING YOUR ATV 7 1 Getting to know your AT...

Page 8: ...height adjustment 8 24 Parking brake adjustment 8 25 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 Lu...

Page 9: ...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 U5YT10 book Page 4 Friday...

Page 10: ...1 1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5YT10 book Page 1 Friday December 12 2003 2 32 PM...

Page 11: ...y 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 operatin...

Page 12: ...WARNING 5FE 21697 01 NEVER operate this ATV if you are under age 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death U5YT10 book Page 3 Friday December...

Page 13: ...the 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 authoriz...

Page 14: ...ity and 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...

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...

Page 16: ...p 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...

Page 17: ...d 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...

Page 18: ...of ignition such as the pi lot lights of water heaters and clothes dryers When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwi...

Page 19: ...n 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 v...

Page 20: ...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 NOTE The machine you have...

Page 21: ...ng 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 num...

Page 22: ...hicle 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 prov...

Page 23: ...eath 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...

Page 24: ...dicator light N This indicator light comes on when the trans mission is in neutral EBU00053 Handlebar switches 1 Light switch OFF 2 Engine stop switch 3 Start switch EBU12040 Light switch OFF Set the...

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 no...

Page 26: ...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 t...

Page 27: ...rew a 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 cou...

Page 28: ...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 circui...

Page 29: ...4 7 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 U5YT10 book Page 7 Friday December 12 2003 2 32 PM...

Page 30: ...achine 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 Lock...

Page 31: ...pect 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 in...

Page 32: ...driving 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...

Page 33: ...th 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 p...

Page 34: ...l 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...

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...

Page 36: ...spring 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 wren...

Page 37: ...AT 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 th...

Page 38: ...direction a To decrease the spring preload turn the adjusting nut in direction b 1 Spring preload adjusting nut 2 Locknut CAUTION _ Never attempt to turn the adjusting nut be yond the maximum or mini...

Page 39: ...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 Tighte...

Page 40: ...roperty 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...

Page 41: ...cable 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 5 8 8 Drive chain Check chain slack and condition Adjust if...

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 20 8 21 WARNING POTENTIAL HAZARD Failure to inspect the ATV before...

Page 43: ...t 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 abilit...

Page 44: ...signed 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 pre...

Page 45: ...HAZARD 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 hea...

Page 46: ...he 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...

Page 47: ...ight 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 oper...

Page 48: ...na tions are not recommended Manufacturer Size Type Front DUNLOP AT21 7 10 KT851B Rear DUNLOP AT20 10 9 KT877A 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 25...

Page 49: ...1 Low pressure tire gauge 4 Use no more than the following 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 t...

Page 50: ...5 10 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 U5YT10 book Page 10 Friday December 12 2003 2 32 PM...

Page 51: ...iliar 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 u...

Page 52: ...owever 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...

Page 53: ...warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding CAUTION _ See the Engine break in section prior to operating engin...

Page 54: ...disengage the clutch 3 Apply the brake pedal 4 While pulling the knob move the drive select lever toward the rear until it com pletely stops NOTE _ When in reverse the reverse indicator light should b...

Page 55: ...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 1 Shift pedal N Neutral position WARNING POTENTIAL HAZARD Impro...

Page 56: ...ut 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 _...

Page 57: ...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...

Page 58: ...tle 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 ca...

Page 59: ...6 9 EBU00211 Parking When parking stop the engine and shift into neutral Turn the fuel cock to OFF and apply the parking brake 1 Locked position U5YT10 book Page 9 Friday December 12 2003 2 32 PM...

Page 60: ...lever and brake pedal NOTE _ Make sure that the neutral indicator light goes off _ 5 Turn the key to OFF WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll...

Page 61: ...a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding c...

Page 62: ...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...

Page 63: ...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 attached Reduce speed...

Page 64: ...6 14 EBU13552 WARNING _ Indicates a potential hazard that could result in serious injury or death U5YT10 book Page 14 Friday December 12 2003 2 32 PM...

Page 65: ...7 1 7 1 Riding Your ATV U5YT10 book Page 1 Friday December 12 2003 2 32 PM...

Page 66: ...7 2 U5YT10 book Page 2 Friday December 12 2003 2 32 PM...

Page 67: ...chniques 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 oper...

Page 68: ...empting 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 creased if the operator does not know ho...

Page 69: ...mmenda 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 shou...

Page 70: ...eatly 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 al...

Page 71: ...t Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of...

Page 72: ...HAZARD 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 re...

Page 73: ...ays follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pre...

Page 74: ...e 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...

Page 75: ...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...

Page 76: ...even 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 c...

Page 77: ...G 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 o...

Page 78: ...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 Y...

Page 79: ...rush 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 ope...

Page 80: ...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...

Page 81: ...erating 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 dir...

Page 82: ...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...

Page 83: ...or 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 t...

Page 84: ...assing Do not ride on private property without getting permission WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a c...

Page 85: ...in contact with these components 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...

Page 86: ...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...

Page 87: ...u 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 T...

Page 88: ...is technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much sp...

Page 89: ...rtant 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 f...

Page 90: ...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 sudde...

Page 91: ...l 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 Owner s Manual on level ground...

Page 92: ...ont 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 resul...

Page 93: ...Dismount 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 U5YT10 book Page 29 Friday December 12 2003 2...

Page 94: ...which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear WARNING POTENTIAL HAZARD Going down a hill imp...

Page 95: ...7 31 U5YT10 book Page 31 Friday December 12 2003 2 32 PM...

Page 96: ...r up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the directio...

Page 97: ...7 33 Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV U5YT10 book Page 33 Friday December 12 2003 2 32 PM...

Page 98: ...NG 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...

Page 99: ...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...

Page 100: ...rol 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 AVO...

Page 101: ...7 37 U5YT10 book Page 37 Friday December 12 2003 2 32 PM...

Page 102: ...wheels 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 regaine...

Page 103: ...ontrol 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 overtur...

Page 104: ...ssary gradually let off the throttle and or steer to the outside of the turn See pag es 7 23 7 24 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying...

Page 105: ...s 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 a...

Page 106: ...d 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...

Page 107: ...er 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 modific...

Page 108: ...ather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or da...

Page 109: ...that could result in serious injury or death Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Steering system Check operation Repair if damaged Check toe in Adjust if ne...

Page 110: ...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 c...

Page 111: ...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 co...

Page 112: ...seated properly _ 9 Install 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...

Page 113: ...led 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 l...

Page 114: ...nspection 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...

Page 115: ...ified 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...

Page 116: ...e 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 e...

Page 117: ...ir 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 U5YT10 book Page 12 Friday December 12 2003...

Page 118: ...ot twist the air filter element when squeezing it _ 6 Inspect the air filter element and replace it if damaged WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air fil...

Page 119: ...ne 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...

Page 120: ...the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe 1 Tailpipe 2 Spark arr...

Page 121: ...tests 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 Ho...

Page 122: ...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 EB...

Page 123: ...fore adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle le ver free play is 2 4 mm 0 08 0 16 in 3 Tighten the locknut 1 Locknut 2 Adjusting bolt...

Page 124: ...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 1 We...

Page 125: ...replace the brake pads as a set 1 Wear indicator groove EBU13040 Brake fluid level check Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective...

Page 126: ...ing fluids may result in a harmful chemical reaction and lead to poor brake perfor mance Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower th...

Page 127: ...by trained Yamaha service personnel Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace...

Page 128: ...s 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 su...

Page 129: ...d 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 ped...

Page 130: ...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 ca...

Page 131: ...bolt 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 m...

Page 132: ...irection a To make the brake light come on later turn the adjusting nut in direction b 1 Rear brake light switch 2 Rear brake light switch adjusting nut EBU00741 Clutch lever free play adjustment The...

Page 133: ...sting 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...

Page 134: ...ight 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 Norma...

Page 135: ...ve chain turn the adjusting bolts in direction b and push the wheels forward Turn each adjusting bolt exactly the same amount to maintain correct axle alignment NOTE _ There are alignment marks on eac...

Page 136: ...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 w...

Page 137: ...2 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 rings U5YT10 book Page 32 Friday December 12 2003 2 32...

Page 138: ...RD 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 restrict...

Page 139: ...8 34 U5YT10 book Page 34 Friday December 12 2003 2 32 PM...

Page 140: ...tion Lubricate the upper and lower arm pivots 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...

Page 141: ...0987 Rear arm pivot lubrication Lubricate the rear arm pivots 1 Grease nipple 1 Grease nipple 1 Grease nipple Recommended lubricant Lithium soap based grease U5YT10 book Page 36 Friday December 12 200...

Page 142: ...moval 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 U5YT10 book Page 37 Friday Dec...

Page 143: ...talling 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 33 ft lbf Rear 45 Nm 4 5 m kgf 33 ft lbf U5YT10 book...

Page 144: ...ery seems to have discharged consult a Yamaha dealer CAUTION _ Do not try to remove the sealing caps of the battery cells You may damage the bat tery _ WARNING POTENTIAL HAZARD Failure to handle batte...

Page 145: ...are 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 dre...

Page 146: ...e 2 Spare fuse CAUTION _ To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse _ Specified fuse 15 A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CA...

Page 147: ...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 pushing it inward and turning it count...

Page 148: ...e 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...

Page 149: ...d 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...

Page 150: ...the adjusting bolt in di rection a To lower the beam turn the adjusting bolt in direction b 1 Adjusting bolt EBU12170 Tail brake light bulb replacement 1 Screw 2 1 Remove the lens by removing the scre...

Page 151: ...ll 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 _ U5YT10 book Page 46 Friday Decem...

Page 152: ...rience 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 short...

Page 153: ...nition 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 Spa...

Page 154: ...irt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals...

Page 155: ...ch 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 brake...

Page 156: ...espoon of SAE 10W30 or 20W40 motor 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 Clea...

Page 157: ...dry 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 machi...

Page 158: ...n 820 mm 32 3 in 1 210 mm 47 6 in 115 mm 4 53 in 3 100 mm 122 in Basic weight With oil and full fuel tank 180 0 kg 397 lb Engine Type Cylinder arrangement Displacement Bore Stroke Compression ratio St...

Page 159: ...MODEL YFM350 0 10 30 50 70 90 110 130 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...

Page 160: ...acturer 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 Sec...

Page 161: ...ngle Trail Steel tube 6 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 Sing...

Page 162: ...Battery 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 30W 2...

Page 163: ...ose 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 inope...

Page 164: ...the warranty The chart below is printed only as a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 04E MAINTENANCE INTERVAL DATE OF SERVICE SE...

Page 165: ...13 1 EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U5YT10 book Page 1 Friday December 12 2003 2 32 PM...

Page 166: ...13 2 1 2 3 4 5 6 7 8 9 10 9 9 13 14 U5YT10 book Page 2 Friday December 12 2003 2 32 PM...

Page 167: ...14 1 EBU00435 1 YAMAHA EXTENDED SERVICE Y E S U5YT10 book Page 1 Friday December 12 2003 2 32 PM...

Page 168: ...14 2 1 2 3 4 5 6 7 8 9 10 9 9 9 14 U5YT10 book Page 2 Friday December 12 2003 2 32 PM...

Page 169: ...14 3 EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death U5YT10 book Page 3 Friday December 12 2003 2 32 PM...

Page 170: ...14 5 EBU00437 U5YT10 book Page 5 Friday December 12 2003 2 32 PM...

Page 171: ...r riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJ...

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