Yamaha Warrior YFM350XRC Owner'S Manual Download Page 133

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8-26

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

to increase the free play or

in direction

to decrease the free play.

3. Tighten the locknut at the clutch lever.

NOTE:

If the specified free play cannot be obtained,
proceed with the following steps.

4. Loosen the locknut at the clutch lever.
5. Turn the adjusting bolt at the clutch lever

in direction

to loosen the cable.

1. Locknut

2. Adjusting bolt

c. Clutch lever free play

U5NF12.book Page 26 Wednesday, May 8, 2002 11:11 AM

Summary of Contents for Warrior YFM350XRC

Page 1: ...per 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 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 pas...

Page 2: ...EBU00776 ...

Page 3: ...ial 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 MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY...

Page 4: ...mbol 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 ...

Page 5: ...tions in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU00981 AFFIX DEALER LABEL HERE YFM350XR C OWNER S MANUAL 2002 by Yamaha Motor Corporation U S A 1st edition March 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in...

Page 6: ...ber 3 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 lever 4 6 Brake pedal 4 7 Parking brake 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 12 Front shock absorber adjustment 4 14 Rear shock...

Page 7: ...verse driving 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 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...

Page 8: ... brake adjustment 8 23 Adjusting the rear brake light switch 8 25 Clutch lever free play adjustment 8 26 Drive chain slack check 8 27 Drive chain slack adjustment 8 28 Lubricating the drive chain 8 30 Cable inspection and lubrication 8 31 Brake and shift pedal brake and clutch lever lubrication 8 31 Front upper and lower arm pivot lubrication 8 32 Rear arm pivot lubrication 8 33 Wheel removal 8 34...

Page 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 U5NF12 book Page 4 Wednesday May 8 2002 11 11 AM ...

Page 10: ...1 1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5NF12 book Page 1 Wednesday May 8 2002 11 11 AM ...

Page 11: ...machine They contain important information for safe and proper operation of your ATV Never 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 U5NF12 book Page 2 Wednesday May 8 2002 11 11 AM ...

Page 12: ...R 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 U5NF12 book Page 3 Wednesday May 8 2002 11 11 AM ...

Page 13: ...ow 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 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 g...

Page 14: ...ility 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 the inspection and maintenance procedures and schedules described in this man ual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slow...

Page 15: ...op 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 foll...

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 dee...

Page 17: ...ted 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 U5NF12 book Page 5 Wednes...

Page 18: ...s 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 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 gasoli...

Page 19: ... in 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 U5NF12 book Page 7 Wednesday May 8 2002 11 11 AM ...

Page 20: ...ke pedal 7 Headlights 8 Front wheel 9 Fuel cock 10 Rear wheel 11 Shift pedal 12 Starter choke 13 Clutch lever 14 Parking brake 15 Brake lever 16 Throttle lever 17 Handlebar switches NOTE The machine you have purchased may differ slightly from those shown in the figures of this manual U5NF12 book Page 1 Wednesday May 8 2002 11 11 AM ...

Page 21: ...ring 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 U5NF12 book Page 2 Wednesday...

Page 22: ...vehicle 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 U5NF12 book Page 3 Wednesday May 8 2002 11 11 AM ...

Page 23: ... death 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 U5NF12 book Page 1 Wednesday May 8 2002 11 11 AM ...

Page 24: ...ator light comes on when the trans mission is in neutral EBU00053 Handlebar switches 1 Light switch LIGHTS 2 Engine stop switch ENG STOP 3 Start switch START EBU01156 Light switch LIGHTS Set the switch to the LO position to turn on the low beam and the taillight Set the switch to the HI position to turn on the high beam and the taillight Set the switch to the OFF position to turn off all of the li...

Page 25: ... that the engine stop switch is in the RUN position 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 turned to OFF EBU00647 Start switch START The starter motor cranks the engine when this switch is pushed CAUTION See the starting instruction...

Page 26: ...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 lever before you start the engine If ...

Page 27: ...screw 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 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 3 5 ...

Page 28: ...ch 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 1 Clutch lever 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 U5NF12 book Page 6 Wednesd...

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 U5NF12 book Page 7 Wednesday May 8 2002 11 11 AM ...

Page 30: ...he lock plate to apply the parking brake Squeeze the clutch lever to release the parking brake NOTE When the parking brake is used engine speed is limited to 2 300 r min Be sure the parking brake is released before moving the throttle lever Otherwise the engine will mis fire preventing normal operation 1 Button 2 Lock plate 1 Locked position U5NF12 book Page 8 Wednesday May 8 2002 11 11 AM ...

Page 31: ...expect 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 parking brake before starting the engi...

Page 32: ...r 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 1 Fuel tank cap U5NF12 book Page 10 Wednesday May 8 2002 11 11 AM ...

Page 33: ...sition when the engine is not running 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 U5NF12 book Page 11 Wednesday May 8 2...

Page 34: ... 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 A Starter choke 1 Fully open 2 Half open 3 Closed EBU00567 Seat To remove the seat pull the seat lock lever upward and pull up the seat at the rear 1 Seat lock lever U5NF12 book Page 12 Wednesday May 8 2002 11 11 AM ...

Page 35: ...t 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 U5NF12 book Page 13 Wednesday May 8 2002 11 11 AM ...

Page 36: ...e 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 wrench can be obtained at a Yamaha dealer to make this adjustment _ 1 Special wrench Standard position A A Minimum soft E Maximum hard U5NF12 book Page 14 Wednesday May 8 2002 11 11 AM ...

Page 37: ...WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set ting U5NF12 book Page 15 Wednesday May 8 2002 11 11 AM ...

Page 38: ...ARNING POTENTIAL HAZARD This shock absorber contains highly pressurized nitrogen gas WHAT CAN HAPPEN The shock absorber could explode causing injury 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 ...

Page 39: ... _ 1 Special wrench 3 The length of the spring installed changes 1 mm 0 04 in per turn of the adjusting ring A Spring length Measurement A Installed length Standard 228 5 mm 9 0 in Minimum hard 220 5 mm 8 7 in Maximum soft 235 5 mm 9 3 in U5NF12 book Page 17 Wednesday May 8 2002 11 11 AM ...

Page 40: ...hten it to the specified torque _ Adjust the damping force as follows Turn the adjusting screw in direction a to in crease the damping force and in direction b to decrease the damping force 1 Damping force adjusting screw Tightening torque 51 Nm 5 1 m kgf 37 ft lbf Standard 15 clicks out Minimum soft 20 clicks out Maximum hard fully turned in position From the fully turned in position U5NF12 book ...

Page 41: ...ttempt to turn either adjusting mechanism beyond the maximum or mini mum settings _ EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death U5NF12 book Page 19 Wednesday May 8 2002 11 11 AM ...

Page 42: ... fuel if necessary 5 5 5 6 Engine oil Check oil level Fill with oil if necessary 5 7 8 5 8 8 Drive chain Check chain slack and condition Adjust if necessary 5 8 8 27 8 30 Throttle Check for proper throttle cable operation and free play 5 8 8 17 Wheels and tires Check tire pressure wear and damage 5 9 5 11 8 34 8 35 Fittings and fasteners Check all fittings and fasteners 5 8 Lights and switches Che...

Page 43: ...T CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op erating condition Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual U5NF12 book Page 2 Wednesday May 8 2002 11 11 AM ...

Page 44: ...a Yamaha dealer inspect the brake system Brake fluid level Check the brake fluid level Add fluid if neces sary See pages 8 18 8 19 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If there is any leakage have a Yamaha dealer inspect the brake system Brake operation Test the brakes at slow speed af...

Page 45: ...ead 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 by the ad justment procedures provided in this manual have a Yamaha dealer check for the cause U5NF12 book Page 4 Wednesday May 8 2002 11 11 AM ...

Page 46: ...n designed 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 2 0 Imp gal 2 4 US gal Res...

Page 47: ...L 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 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 ...

Page 48: ...ddition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ Recommended oil Recommended engine oil classification API Service SE SF SG type or higher 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 Oil quantity Periodic oil change 2 4 L 2 1 Imp qt 2 5 US qt With oi...

Page 49: ... fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque EBU01003 Lights Check the headlights and tail brake light 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...

Page 50: ...bina tions are not recommended Manufacturer Size Type Front DUNLOP AT22 7 10 KT701 Rear DUNLOP AT22 10 9 KT775B 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 specifi...

Page 51: ...ns 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 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...

Page 52: ...5 11 EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a 3 mm 0 12 in U5NF12 book Page 11 Wednesday May 8 2002 11 11 AM ...

Page 53: ... familiar 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 si...

Page 54: ...tion However it is recommended to shift into neutral before starting the en gine _ 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warm ing up position Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter ...

Page 55: ...oke to position 3 before riding CAUTION _ See the Engine break in section prior to operating engine for the first time _ 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 EBU00538 Warming up To get maximum engine life always warm up the engine before starting off Never accel...

Page 56: ...o 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 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 r...

Page 57: ...e 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 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 obst...

Page 58: ... _ EBU00203 To start out and accelerate 1 Release the throttle lever 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 Once the machine has attained adequate speed release the thr...

Page 59: ...L 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 high WHAT CAN HAPPEN The wheels could stop rota...

Page 60: ...le 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 1 0 10 hours Avoid continuous operation above half throttle Allow a cooling off ...

Page 61: ...00211 Parking When parking stop the engine and shift into neutral Turn the fuel cock to OFF and apply the parking brake 1 Button 2 Lock plate 1 Locked position U5NF12 book Page 9 Wednesday May 8 2002 11 11 AM ...

Page 62: ...g 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 park the ATV at all on hills that are so steep you could not wal...

Page 63: ...e 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 could affect your ability to control the ATV 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 at...

Page 64: ...e 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 when towing a trailer Allow...

Page 65: ...s 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 when carrying cargo or pulling a trailer Allow greater distance for braking U5NF12 book Page 13 Wednesday May 8 2002 11 11 AM ...

Page 66: ...6 14 EBU01176 WARNING _ Indicates a potential hazard that could result in serious injury or death U5NF12 book Page 14 Wednesday May 8 2002 11 11 AM ...

Page 67: ...7 1 7 1 Riding Your ATV U5NF12 book Page 1 Wednesday May 8 2002 11 11 AM ...

Page 68: ...7 2 U5NF12 book Page 2 Wednesday May 8 2002 11 11 AM ...

Page 69: ...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 necessary to enjoy riding safely Before you begin to ride be sure you have read this Own er s Manual completely and understand the operation of the controls Pay...

Page 70: ...ttempting 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 how to operate the ATV properly in dif ferent situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course o...

Page 71: ...commenda 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 U5NF12 book Page 5 Wednesday May 8 2002 11 11 AM ...

Page 72: ...Greatly 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 U5NF12 book Page 6 Wednesday May 8 2002 11 11 AM ...

Page 73: ...ent 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 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...

Page 74: ...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 U5NF12 book Page 8 Wednesday May 8 2002 11 11 AM ...

Page 75: ...ways follow the in spection and maintenance procedures and schedules described in the Owner s Manual 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 TH...

Page 76: ...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 go at a spee...

Page 77: ...TIAL 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 attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow t...

Page 78: ...g 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 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...

Page 79: ...ING 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 U5NF12 book Page 13 Wednesday May 8 2002 11 11 AM ...

Page 80: ...u 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 and used according to instructions If you have questions consult an autho rized ATV dealer U5NF12 book Page 14 Wed...

Page 81: ... 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 brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in...

Page 82: ...ng 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 U5NF12 book Page 16 Wednesday May 8 2002 11 11 AM ...

Page 83: ...Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and high ways U5NF12 book Page 17 Wednesday May 8 2002 11 11 AM ...

Page 84: ...e 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 erating on unfamiliar terrain Always be alert to changing terrain con ditions when operating the ATV U5NF12 book Page 18 Wednes...

Page 85: ...n 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 the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain U5NF12 book Page 19 Wednesday May 8 2002 11 11 AM ...

Page 86: ...spassing 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 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 U5NF12 book Page 20 Wednesday May 8 2002 11 ...

Page 87: ...me 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 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...

Page 88: ...ING POTENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever to 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 is too high WHAT CAN HAPPEN The wheels could s...

Page 89: ...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 properly WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The ATV could go out o...

Page 90: ...this 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 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 of...

Page 91: ...portant 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 smal...

Page 92: ...l 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 The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill U5NF12 b...

Page 93: ...rol 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 Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avo...

Page 94: ...n stead dismount 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 weight uphill Apply the brakes Lock the parking brake after you are s...

Page 95: ...9 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 U5NF12 book Page 29 Wednesday May 8 2002 11 11 AM ...

Page 96: ...s 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 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 Own er s Manual No...

Page 97: ...7 31 U5NF12 book Page 31 Wednesday May 8 2002 11 11 AM ...

Page 98: ...her 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 direction you wish to travel 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 att...

Page 99: ...7 33 Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV U5NF12 book Page 33 Wednesday May 8 2002 11 11 AM ...

Page 100: ...NING 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 Never operate this ATV in fast flowing water or in water deeper than that spec ified in your Owner s Manual Remember that wet brakes may have re duced stopping ability Test your brakes after ...

Page 101: ...ned 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 _ 1 Check hose U5NF12 book Page 35 Wednesday May 8 2002 11 11 AM ...

Page 102: ...ntrol 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 proc...

Page 103: ...7 37 U5NF12 book Page 37 Wednesday May 8 2002 11 11 AM ...

Page 104: ...t 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 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 U5NF12 book Page 38 Wednesday May 8 ...

Page 105: ... control 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 cautio...

Page 106: ...cessary 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 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 hav...

Page 107: ...is 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 pages 7 34 7 35 WARNING I_ Indicates a ...

Page 108: ...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 manual 2 Low pressure tire gauge 3 Owner s tool kit 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...

Page 109: ...aler 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 accesso...

Page 110: ...eather 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 damage Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter element Clean Replace if necessary Engine oil strainer Clean Drive chain Check and adjust slack alignment cl...

Page 111: ...t 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 necessary Front and rear suspension Check operation Correct if necessary Upper and lower arm pivot and steering shaft Lubricate every 6 months Rear arm pivot Lubricate every 6 months Fittings and fasteners Check all ch...

Page 112: ... NOTE _ Wait a few minutes until the oil level settles before checking _ 4 Remove the dipstick and then check the oil level NOTE _ The oil level should be between the maximum and minimum level marks _ 5 If the engine oil is below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct lev el CAUTION _ Be sure no foreign material enters the crankcase _ 1 Dipsti...

Page 113: ...veral minutes and stop it 3 Place a container under the engine to collect the used oil 4 Remove the engine oil filler cap and then remove the drain bolt to drain the oil CAUTION _ When removing the drain bolt the com pression spring oil strainer and O ring will fall out Take care not to lose these parts _ 1 Drain bolt 2 O ring 3 Compression spring 4 Oil strainer U5NF12 book Page 6 Wednesday May 8 ...

Page 114: ...ter cover by installing the bolts 10 Install the oil strainer compression spring O ring and drain bolt Tighten the drain bolt and oil filter cover bolts to the specified torques CAUTION _ Before installing the drain bolt be sure to install the O ring compression spring and oil strainer _ 11 Add the specified amount of the recom mended engine oil and then install the engine oil filler cap Tightenin...

Page 115: ...gn 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 Periodic oil change 2 4 L 2 1 Imp qt 2 5 US qt With oil filter replaceme...

Page 116: ...blems yourself Instead take the ATV to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes ex cessive you should replace the spark plug with one of the proper type Before installing the spark plug measure the electrode gap with a wire thickness gauge and adjust it t...

Page 117: ...lways clean the gasket surface and its mating surface Wipe off any grime from the threads and tight en it to the specified torque Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 5 ft lbf U5NF12 book Page 10 Wednesday May 8 2002 11 11 AM ...

Page 118: ...ean the air filter element and air filter case _ 1 Check hose 1 Remove the seat See page 4 12 for seat removal and installation proce dures 2 Remove the air filter case cover by re moving the screws 1 Air filter case cover 2 Screw 5 3 Remove the air filter element 4 Remove the air filter element from the frame U5NF12 book Page 11 Wednesday May 8 2002 11 11 AM ...

Page 119: ...et 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 U5NF12 book Page 12 Wednesday May 8 2002 11 11 AM ...

Page 120: ...should be cleaned and lubri cated more often if the machine is operated in extremely dusty areas Each time air filter ele ment maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber joint to the carburetor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the...

Page 121: ...e 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 arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install and tighten the bolt U5NF12 book Page 14 Wednesday May 8 2002 11 11 AM ...

Page 122: ...y 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 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...

Page 123: ...le 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 adjusted regularly T...

Page 124: ...ottle lever free play EBU01027 Front and rear brake pad inspection Each brake pad is provided with a wear indi cator groove The indicators allow checking of brake pad wear without disassembling the brake Apply the brake and inspect the wear indicator grooves If the pad is worn to the point that the wear indicator grooves are al most in contact with the disc plate ask a Yamaha dealer to replace the...

Page 125: ...e Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indi cate 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 Rear Front U5NF12 book Page 18 Wednesday May 8 2002 11 11 AM ...

Page 126: ...e fluid Mix 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 the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfac es or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer chec...

Page 127: ...y 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 the brake hoses every four years U5NF12 book Page 20 Wednesday May 8 2002 11 11 AM ...

Page 128: ...kes 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 quires professional knowledge These procedures should be p...

Page 129: ...T 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 components re quires professional knowledge These procedures should ...

Page 130: ...1 1 97 in A Cable length 1 Fully loosen the locknut and the adjusting bolt at the clutch lever 2 Loosen the locknut and the adjusting bolt at the rear brake caliper 3 Turn the adjusting bolt at the clutch lever in direction a to increase the cable length or in direction b to decrease the cable length 1 Locknut 2 Adjusting bolt U5NF12 book Page 23 Wednesday May 8 2002 11 11 AM ...

Page 131: ...liper by hand until it feels tight then screw it out 1 8 turn Tighten the locknut to the specified torque 1 Locknut 2 Adjusting bolt CAUTION _ When tightening the locknut hold the ad justing bolt with a wrench so that the ad justing bolt does not turn together with the locknut _ Tightening torque Locknut 16 Nm 1 6 m kgf 11 ft lbf U5NF12 book Page 24 Wednesday May 8 2002 11 11 AM ...

Page 132: ...in direction a To make the brake light come on later turn the adjusting nut in direction b 1 Rear brake light switch 2 Adjusting nut 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 blo...

Page 133: ... to increase the free play or in direction b to decrease the free play 3 Tighten the locknut at the clutch lever NOTE If the specified free play cannot be obtained proceed with the following steps 4 Loosen the locknut at the clutch lever 5 Turn the adjusting bolt at the clutch lever in direction a to loosen the cable 1 Locknut 2 Adjusting bolt c Clutch lever free play U5NF12 book Page 26 Wednesday...

Page 134: ...OTE _ Move the ATV back and forth and find the tightest position of the drive chain Check and or adjust the chain slack while it is in this tight 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 30 40 mm 1 2 1 6 in If the slack e...

Page 135: ...b nut 2 Loosen the locknuts on each side of the swingarm To tighten the drive chain turn the adjusting bolts in direction a To loosen the drive 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 U5NF12 book Page 28 Wednesday May 8 2002 11 11 AM ...

Page 136: ...t _ 1 Locknut 2 Adjusting bolt 3 Alignment marks 3 After adjusting tighten the locknuts and the wheel hub nuts to the specified torques Tightening torques Locknut 16 Nm 1 6 m kgf 12 ft lbf Upper wheel hub nut 120 Nm 12 0 m kgf 86 ft lbf Lower wheel hub nut 60 Nm 6 0 m kgf 43 ft lbf U5NF12 book Page 29 Wednesday May 8 2002 11 11 AM ...

Page 137: ...g 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 solvents _ 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION _ Do not use engine oil or any other lubri cants for...

Page 138: ...ZARD 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 Recommen...

Page 139: ...cation 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 U5NF12 book Page 32 Wednesday May 8 2002 11 11 AM ...

Page 140: ...8 33 EBU00987 Rear arm pivot lubrication Lubricate the rear arm pivots 1 Grease nipple 1 Grease nipple Recommended lubricant Lithium soap based grease U5NF12 book Page 33 Wednesday May 8 2002 11 11 AM ...

Page 141: ...2 Wheel removal 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 Front Rear U5NF12 book Page 34 Wednesday May 8 2002 11 11 AM ...

Page 142: ...edure NOTE _ The arrow mark on the tire must point to ward the rotating direction of the wheel _ 1 Arrow mark Tighten the wheel nuts to the specified torque Wheel nut torque Front 45 Nm 4 5 m kgf 33 ft lbf Rear 45 Nm 4 5 m kgf 33 ft lbf U5NF12 book Page 35 Wednesday May 8 2002 11 11 AM ...

Page 143: ...r store the battery on its side When inspecting the battery be sure the breather hose is routed correctly If it touches the frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cosmet ic damage to the machine can occur 1 Battery 2 Battery breather hose 3 Guide U5NF12 book Page 36 Wednesday May 8 2002 11 11 AM ...

Page 144: ... 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 minutes and get prompt medical attention Keep batteries away from sparks flames cig arettes or other sources of ignition...

Page 145: ... _ Normal tap water contains minerals which are harmful to a battery Therefore refill only with distilled water _ 4 When the machine is not to be used for a month or longer remove the battery and store it in a cool dark place Completely recharge the battery before using 5 If the battery is to be stored for a longer period than the above check the specific gravity at least once a month and re charg...

Page 146: ... 1 Fuse 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 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...

Page 147: ...t bulb If a headlight bulb burns out replace the bulb as follows 1 Remove the headlight assembly by re moving the bolts 1 Bolt 3 2 Disconnect the headlight couplers 1 Headlight coupler 2 U5NF12 book Page 40 Wednesday May 8 2002 11 11 AM ...

Page 148: ...oving the bolt 1 Headlight unit 2 Headlight assembly 3 Bolt 4 Remove the headlight unit cover by re moving the screw 1 Headlight unit cover 2 Screw 5 Remove the headlight bulb holder cover 1 Headlight bulb holder cover U5NF12 book Page 41 Wednesday May 8 2002 11 11 AM ...

Page 149: ...G 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 U5NF12 book Page 42 Wednesday May 8 2002 11 11 AM ...

Page 150: ... off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner _ 8 Install the headlight bulb holder cover 1 Headlight bulb holder cover 2 Headlight bulb holder CAUTION _ Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly _ 9 Install the headlight unit cover by install ing the screw 10 Install the headlight un...

Page 151: ...necessary EBU01089 Headlight beam adjustment CAUTION _ It is advisable to have a Yamaha dealer make this adjustment _ To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b 1 Adjusting screw 2 U5NF12 book Page 44 Wednesday May 8 2002 11 11 AM ...

Page 152: ...kwise 2 Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise 1 Tail brake light bulb holder 2 Bulb 3 Install a new bulb in the bulb holder by pushing it inward and turning it clockwise 4 Install the bulb holder together with the bulb by turning it clockwise U5NF12 book Page 45 Wednesday May 8 2002 11 11 AM ...

Page 153: ...perience 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 v...

Page 154: ...compression Ask a Yamaha dealer to inspect 3 Ignition Remove plug and check electrodes Wet Wipe clean with dry cloth Dry Attach plug cap and ground to chassis Use the electric starter Spark good Ignition system normal Spark weak Adjust plug gap or replace plug No spark Ask a Yamaha dealer to inspect 4 Battery Use the electric starter Engine turns over quickly Battery good Engine turns over slowly ...

Page 155: ...xles 3 Rinse the dirt 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 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 m...

Page 156: ...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 linings U5NF1...

Page 157: ... tablespoon 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 Clean the drive chain thoroughly and lu bricate it See page 8 30 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 outle...

Page 158: ...a 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 machine U5NF12 book Page 4 Wednesday May 8 2002 11 11 AM ...

Page 159: ... 5 in 1 080 mm 42 5 in 765 mm 30 1 in 1 200 mm 47 2 in 125 mm 4 92 in 3 500 mm 138 in Basic weight With oil and full fuel tank 191 kg 421 lb Engine Type Cylinder arrangement Displacement Bore Stroke Compression ratio Starting system Lubrication system Air cooled 4 stroke SOHC Forward inclined single cylinder 348 cm3 83 0 64 5 mm 3 27 2 54 in 9 2 1 Electric starter Wet sump U5NF12 book Page 1 Wedne...

Page 160: ...3 4 US qt MODEL YFM350X 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 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...

Page 161: ...rer Gap DR8EA NGK 0 6 0 7 mm 0 02 0 03 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 40 13 3 076 Constant mesh 6 speed forward 1 speed reverse Left foot operation MODEL YFM350X U5NF12 book Page 3 Wednesday ...

Page 162: ...r angle Trail Steel tube 7 30 mm 1 2 in Tire Type Size Front Size Rear Tubeless AT22 7 10 AT22 10 9 Brake Front brake type Operation Rear brake type Operation Dual disc brake Right hand operation Single disc brake Right foot operation Suspension Front Rear Double wishbone Swingarm link suspension Shock absorber Front Rear Coil spring oil damper Coil spring gas oil damper MODEL YFM350X U5NF12 book ...

Page 163: ...tery type voltage capacity D C C D I A C magneto GM12CZ 4A 2 12V 12Ah Headlight type Krypton bulb Bulb voltage wattage quantity Headlight Tail brake light Indicator light Neutral Reverse 12V 30W 30W 2 12V 5W 21W 1 12V 3 4W 1 12V 3 4W 1 Fuse 15A MODEL YFM350X U5NF12 book Page 5 Wednesday May 8 2002 11 11 AM ...

Page 164: ...rpose 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 M...

Page 165: ...arranty 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 02EACL 02E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months 54 Months 60 Months U5NF12 book Page 1 Wednesday May 8 ...

Page 166: ...13 1 EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U5NF12 book Page 1 Wednesday May 8 2002 11 11 AM ...

Page 167: ...13 2 1 2 3 4 5 6 7 8 9 10 9 9 13 14 U5NF12 book Page 2 Wednesday May 8 2002 11 11 AM ...

Page 168: ...14 1 EBU00435 YAMAHA EXTENDED SERVICE Y E S U5NF12 book Page 1 Wednesday May 8 2002 11 11 AM ...

Page 169: ...14 2 1 2 3 4 5 6 7 8 9 10 9 9 9 14 U5NF12 book Page 2 Wednesday May 8 2002 11 11 AM ...

Page 170: ...EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death U5NF12 book Page 3 Wednesday May 8 2002 11 11 AM ...

Page 171: ...EBU00437 U5NF12 book Page 5 Wednesday May 8 2002 11 11 AM ...

Page 172: ...per 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 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 pas...

Page 173: ...Card fm Page 1 Wednesday June 13 2001 9 35 AM ...

Page 174: ...Card fm Page 2 Wednesday June 13 2001 9 35 AM ...

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