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Yamaha WOLVERINE 350 YFM35XY, Owner'S Manual, Page: 16 / 128

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Yamaha WOLVERINE 350 YFM35XY Owner'S Manual Download Page 16

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EBU17670

Read and understand all of the labels on your ATV. These labels contain important information for safe and
proper operation.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace-
ment label from your Yamaha dealer.

U3D563E0.book  Page 2  Monday, May 12, 2008  11:12 AM

Summary of Contents for WOLVERINE 350 YFM35XY

Page 1: ...PIETARIO 3D5 F8199 63 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad DIC183 ...

Page 2: ...PRINTED IN USA 2008 05 0 3 1 CR E F S YAMAHA MOTOR CO LTD DIC183 ...

Page 3: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL YFM35XY 3D5 F8199 63 E0 U3D563E0 book Page 1 Monday May 12 2008 11 12 AM ...

Page 4: ...essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted EN292 ANSI SVIA 1 2007 Title and or number and date of issue of standards and or specifications General Manager RV Engineering Division RV Company Signature Date of Issue Shinya Shimada 26 March 2008 YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119NC Schipho...

Page 5: ...ormation It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDER STAND ALL INSTRUCTIONS PAY CLOSE...

Page 6: ... safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key info...

Page 7: ...face paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17410 YFM35XY OWNER S MANUAL 2008 by Yamaha Motor Co Ltd 1st edition April 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A U3D563E0 book Page 1 Monday May 12 2008 11 12 AM...

Page 8: ...e 4 6 Drive select lever 4 7 Fuel tank cap 4 7 Fuel 4 8 Fuel cock 4 9 Starter choke 4 10 Seat 4 11 Storage compartment 4 12 Adjusting the front shock absorber assemblies 4 13 Adjusting the rear shock absorber assembly 4 14 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Tires 5 4 Measuring the tire pressu...

Page 9: ...aintenance and lubrication chart 8 5 Removing and installing the panel 8 8 Checking the spark plug 8 8 Engine oil and oil filter cartridge 8 10 Final gear oil 8 14 Cleaning the air filter element 8 17 Cleaning the spark arrester 8 21 V belt cooling duct check hose 8 22 V belt case drain plug 8 22 Adjusting the carburetor 8 23 Adjusting the engine idling speed 8 23 Adjusting the throttle cable free...

Page 10: ...e steering shaft 8 34 Battery 8 34 Replacing a fuse 8 37 Replacing a headlight bulb 8 38 Adjusting a headlight beam 8 40 Replacing the tail brake light bulb 8 40 Removing a wheel 8 41 Installing a wheel 8 42 Troubleshooting 8 43 Troubleshooting chart 8 44 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 U3D563E0 book Page 3...

Page 11: ...child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Watch carefully for other vehicles when operat ing on unpaved public streets or roads Make sure you know your country s ...

Page 12: ...limbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefull...

Page 13: ...y Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribed in this manual Never modify an ATV thr...

Page 14: ... gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are poisonous and may cause loss of consciousness and death within...

Page 15: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U3D563E0 book Page 1 Monday May 12 2008 11 12 AM ...

Page 16: ...V These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer U3D563E0 book Page 2 Monday May 12 2008 11 12 AM ...

Page 17: ...2 3 2 U3D563E0 book Page 3 Monday May 12 2008 11 12 AM ...

Page 18: ...t and tool kit 6 Seat lock lever 7 Rear shock absorber assembly spring preload adjusting ring 8 Engine oil filler cap 9 Oil filter cartridge 10 V belt cooling duct check hose 1 Spark arrester 2 Tail brake light 3 Spark plug 4 Front shock absorber assembly spring preload adjusting ring 5 Rear brake light switch 6 Brake pedal 7 V belt case U3D563E0 book Page 1 Monday May 12 2008 11 12 AM ...

Page 19: ... purchased may differ slightly from the figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Starter choke 4 Drive select lever 5 Main switch 6 Fuel tank cap 7 Front brake lever 8 Throttle lever U3D563E0 book Page 2 Monday May 12 2008 11 12 AM ...

Page 20: ...e as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U3D563E0 book Page 1 Monday May 12 2008 11 12 AM ...

Page 21: ...h set to and then pushing the start switch If the warning light does not come on while the start switch is being pushed then go off after the start switch is released have a Yamaha dealer check the electrical circuit If the warning light stays on allow the engine to cool If the warning light stays on when the engine is cool have a Yamaha dealer check the electrical circuit NOTICE ECB00010 The engi...

Page 22: ...arting instructions on page 6 1 prior to starting the engine EBU18151 Light switch OFF Set this switch to to turn on the low beams and the taillight Set the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00040 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to ...

Page 23: ...r slow down when you need to This could cause an accident Check the op eration of the throttle lever before you start the engine If the throttle does not work smoothly check for the cause Correct the problem be fore riding the ATV or consult a Yamaha dealer EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even wh...

Page 24: ... 3 0 5 0 mm 0 12 0 20 in See page 8 24 EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull the brake lever toward the handlebar grip EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar To apply the rear brake push down on the brake pe...

Page 25: ... the parking brake Squeeze the rear brake lever to release the parking brake WARNING EWB00220 Always set the parking brake before starting the engine The ATV could start moving un expectedly if the parking brake is not ap plied This could cause loss of control or a collision 1 Brake pedal 1 Rear brake lever 1 Parking brake lock plate U3D563E0 book Page 6 Monday May 12 2008 11 12 AM ...

Page 26: ...ould also wear out the brakes prematurely EBU18581 Drive select lever The drive select lever is used to shift your ATV into the forward neutral and reverse positions See the Operating the drive select lever and driving in re verse section on page 6 3 for the drive select lever operation EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise 1 Drive select lever U3D563E0 bo...

Page 27: ... 1 Fuel tank cap 1 Fuel level 2 Fuel tank filler tube Recommended fuel UNLEADED GASOLINE ONLY For Europe Regular unleaded gasoline only with a research octane number of 91 or high er Fuel tank capacity 14 5 L 3 83 US gal 3 19 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal U3D563E0 book Page 8 Monday May 12 2008 11 12 AM ...

Page 28: ...to spill fuel especially on the engine or exhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explaine...

Page 29: ...the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke 1 Arrow mark positioned over ON 1 Arrow mark...

Page 30: ... choke See the Starting a cold engine section on page 6 1 for proper operation EBU26981 Seat To remove the seat Push the seat lock lever backward and pull up the seat at the rear 1 Starter choke 1 Seat 1 Seat lock lever U3D563E0 book Page 11 Monday May 12 2008 11 12 AM ...

Page 31: ...ts in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage compartment NOTICE ECB00130 Do not store metal or sharply edged objects like tools in the storage compartment If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartment Do not exc...

Page 32: ...ing preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Storage co...

Page 33: ... as sembly The spring preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum ...

Page 34: ... obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 U3D563E0 book Page 15 Monday May 12 2008 11 12 AM ...

Page 35: ...mine which service should be performed by a Yamaha dealer ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 8 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 10 Final gear oil Check ATV for oil leakage Co...

Page 36: ...on and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 5 5 5 6 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 33 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 33 Axle boots Check for cracks or damage and replace if necessary 8 32 Ch...

Page 37: ... is at the specified level Add oil as necessary See page 8 14 EBU27670 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front brake lever If there is free play have a Yamaha dealer check the brake system Check for correct free play in the rear brake lever and brake pedal If the free play is incorrect ad just it See page 8 28 Check operation of the levers a...

Page 38: ...ocedures provided in this manual have a Yamaha dealer check for the cause EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19812 Tires WARNING EWB00592 Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pres sure may cause loss ...

Page 39: ...Pa 0 220 kgf cm 3 2 psi Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi Higher pressures and fast inflation may cause a tire to burst Inflate the tires very slowly and carefully EBU19821 Measuring the tire pressure Use the low pressure tire gauge TIP The low pressure tire gauge is incl...

Page 40: ... sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum Front 22 0 kPa 0 220 kgf cm 3 2 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi 1 Tire wear limit U3D563E0 book Page 6...

Page 41: ...hich could lead to an acci dent or collision NOTICE ECB00150 See the Engine break in section on page 6 4 prior to operating the engine for the first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to 4 Shift the drive select lever into the neutral po sition The neutral indicator light should come on If the indicator light does not com...

Page 42: ...ranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt 7 If the engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine NOTICE ECB00...

Page 43: ...t lever and driving in reverse NOTICE ECB00170 Before shifting stop the ATV otherwise the transmission may be damaged Shifting Forward 1 Bring the ATV to a complete stop 2 Shift from neutral to forward and vice versa by moving the drive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted into position 3 Open the throttle lever gradually Shifting Rever...

Page 44: ...to reverse make sure there are no people or ob stacles behind you When it is safe to proceed go slowly EBU20682 Engine break in TIP For ATVs equipped with an odometer or an hour meter follow the figures given in km mi or the figures given in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine...

Page 45: ... a Yamaha dealer check the ATV EBU20700 Parking When parking the ATV stop the engine shift the drive select lever into the forward position apply the parking brake and then turn the fuel cock to OFF EBU20760 Parking on a slope WARNING EWB00830 Avoid parking on hills or other inclines Park ing on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident...

Page 46: ...n design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering diffi...

Page 47: ...e you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING EWB00820 Never exceed the stated load capacity fo...

Page 48: ...7 1 7 EBU21141 RIDING YOUR ATV U3D563E0 book Page 1 Monday May 12 2008 11 12 AM ...

Page 49: ...ice and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics WARNIN...

Page 50: ... child This ATV is designed to carry operator and car go only passengers prohibited WARNING EWB01400 Never carry a passenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or yo...

Page 51: ...le helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet U3D563E0 book Page 4 Monday May 12 2008 11 12 AM ...

Page 52: ...chances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s performance capability is reduced by the influence of alcohol or drugs WARNING EWB01420 Never consume alcohol or drugs before or while driving this ATV Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding for proper care of the ATV and to ensu...

Page 53: ...ARNING EWB01450 Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at speeds too fast for your skills or the conditions in creases your chances of losing control of the ATV which can result in an accident Speed limiter For riders less experienced with this model the throttle lever housing is equipped with a speed lim iter...

Page 54: ... should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards during op eration otherwise they may contact the rear wheels WARNING EWB01470 Always keep both hands o...

Page 55: ...ld be gen uine Yamaha or equivalent components de signed for use on this ATV and should be installed and used according to instructions Improper installation of accessories or modifi cation of this ATV may cause changes in han dling which in some situations could lead to an accident If you have questions consult an au thorized ATV dealer Exhaust system The exhaust system on the ATV is very hot dur...

Page 56: ...DE This ATV is designed for use on unpaved surfaces only Riding on paved surfaces can cause loss of control WARNING EWB01510 Always avoid paved surfaces including side walks driveways parking lots and streets ATVs are designed for use on unpaved surfac es only Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control U3D563E0 book Page 9 Monday ...

Page 57: ... Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle In many areas it is illegal to operate ATVs on public streets roads and highways Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards which may cause the ATV to upset WARNING EWB01530 Go slowly and be extr...

Page 58: ...n accident including an overturn When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING EWB01550 Always mount a caution flag on the ATV to make you more visible when operating in areas where you might not be seen by other vehicles Watch carefully for other vehicles Do not ride in a...

Page 59: ...hen release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds un til you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the throt tle a...

Page 60: ... This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly This procedure should be practiced at slow speed many times in a large unpaved area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippe...

Page 61: ...skill In all cases avoid inclines with slip pery or loose surfaces or obstacles that might cause you to lose control WARNING EWB01580 Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Practice on small er hills before attempting large hills It is important when climbing a hill t...

Page 62: ... room to do so and go down the hill WARNING EWB01600 Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid ...

Page 63: ...ead ap ply the front brake gradually or dismount the ATV immediately on the uphill side WARNING EWB01741 Maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Apply the parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply the rear brake while rolling backwards Apply the front brake When fully stop...

Page 64: ...n hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear WARNING EWB01620 Always follow proper procedures for going down hills as described in this Owner s Manu al Note a special technique is required when braking as you go down a hill Always check the terrain carefully before...

Page 65: ...to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING EWB01631 Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on lev...

Page 66: ...y and care fully WARNING EWB01640 Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the lin ings If the ATV is operated through deep or fast flowing water the tires may float causing lo...

Page 67: ... by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hose and the storage compartment drain plugs Also remove the V belt case drain plug to drain any water that may have accumu lated Wash the ATV in fresh water if it has been operated in salt water or muddy conditions 1 Air filter case check hose U3D563E0 book Page 20 ...

Page 68: ...21 7 1 V belt cooling duct check hose left front side of ATV 1 Drive select lever box check hose 1 Storage compartment drain plug 1 V belt case drain plug U3D563E0 book Page 21 Monday May 12 2008 11 12 AM ...

Page 69: ...r obstacles always follow proper procedures as described in the Owner s Manu al SLIDING AND SKIDDING Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes h...

Page 70: ...is section is designed to be a reference guide only Be sure to read each section on riding tech niques completely WHAT TO DO If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See page 7 12 If your A...

Page 71: ...tioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 18 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter dra...

Page 72: ...IVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with mainten...

Page 73: ...ence required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for use on this ATV and should be instal...

Page 74: ...ire special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust ...

Page 75: ...ness and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U3D563E0 book Page 4 Monday May 12 2008 11 12 AM ...

Page 76: ...e pads Whenever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake lever and pedal free play and adjust if necessary Replace brake shoes Whenever worn to the limit 4 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years 5 Wheels Check runout and for damage and replace if nec essary 6 Tires Check tread depth and for damage and r...

Page 77: ...ust if necessary 14 Engine mount Check for cracks or other damage and replace if necessary 15 Axle boots Check for cracks or other damage and replace if necessary 16 Engine oil Change Check ATV for oil leakage and correct if neces sary 17 Engine oil filter car tridge Replace 18 Engine oil strainer Clean 19 Final gear oil Change Check ATV for oil leakage and correct if neces sary 20 Moving parts an...

Page 78: ...ystem cable Check operation and adjust or replace if neces sary 22 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 23 Front and rear brake switches Check operation and correct if necessary 24 Lights and switches Check operation and correct if necessary Adjust headlight beam...

Page 79: ...Remove the bolt and then take the panel off To install the panel Place the panel in the original position and install the bolt NOTICE ECB00380 When installing the panel be sure not to pinch the cables or wires EBU23211 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark 1 Panel A ...

Page 80: ...ark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally TIP If the spark plug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 2 Check the spark plug for electrode erosi...

Page 81: ... is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap EBU23315 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the intervals spec ified in the periodic maintenance and lubrication ch...

Page 82: ... the dipstick into the filler hole without screwing it in and then remove it again to check the oil level TIP The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level 6 Insert the dipstick into the oil filler hole and then tighten the engine oil filler ...

Page 83: ...ine to collect the used oil 3 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase TIP Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil drain bolt 1 Oil filter cartridge 1 Oil filter wrench U3D563E0 book Page 12 Monday May 12 2008 11 12 AM ...

Page 84: ... then tighten it to the specified torque with a torque wrench 7 Install the engine oil drain bolt and then tight en it to the specified torque 8 Refill with the specified amount of the recom mended engine oil and then install and tight en the engine oil filler cap 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 23 Nm...

Page 85: ...t 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 10 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary EBU23383 Final gear oil The final gear case must be checked for oil leak age before each ride If any leakage is found have a Yamaha dealer check and repair ...

Page 86: ...k the oil level in the final gear case TIP The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 4 Install the oil filler bolt and then tighten it to the specified torque To change the final gear oil 1 Place the ATV on a level surface 1 Final gear oil 2 Final gear oil fill...

Page 87: ...ar oil drain bolt to drain the oil from the final gear case 5 Install the drain bolt and then tighten it to the specified torque 6 Refill with the recommended final gear oil to the brim of the filler hole as shown 1 Final gear case guard 2 Bolt 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf U3D563E0 book Page 16 Monday May 12 2008 11 12 AM ...

Page 88: ...he air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean or if necessary replace the air filter element more frequently if you are riding in unusually wet or dusty areas 1 Final gear oil 2 Final gear oil filler bolt 3 Correct oil level Recommended final gear oil See page 10 1 Tightening torque Final gear oil ...

Page 89: ...nd air fil ter case 1 Place the ATV on a level surface 2 Remove the seat See page 4 11 3 Remove the air filter case cover by unhooking the air filter case cover holders 4 Pull the air filter element out of the air filter case 1 Air filter case check hose 1 Air filter case cover holder 2 Air filter case cover U3D563E0 book Page 18 Monday May 12 2008 11 12 AM ...

Page 90: ...ways use parts cleaning solvent to clean the sponge material Never use low flash point solvents or gasoline to clean the sponge mate rial because the engine could catch fire or ex plode 7 Squeeze the excess solvent out of the sponge material and let it dry 1 Air filter element 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate U3D563E0 book Page 19 Monday May 12 2008 11 1...

Page 91: ...leaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air...

Page 92: ... out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the tailpipe cover by installing the bolts and then tighten them to the specified torque 1 Bolt 2 Tailpipe cover 1 Tailpipe 2 Spark arrester...

Page 93: ...dust or water collects in the V belt cooling duct check hose remove the hose and clean it EBU23930 V belt case drain plug After riding in water deep enough to allow it to en ter the V belt case remove this plug to drain the water from the case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the water may affect other engine parts 1 V belt cool...

Page 94: ...ese settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart TIP A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm i...

Page 95: ...0 5 0 mm 0 12 0 20 in at the throttle lever Period ically check the throttle cable free play and if nec essary adjust it as follows TIP The engine idling speed must be checked and ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the throttle cable free play adjusting bolt in di rection a To decrease the throt...

Page 96: ...em cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EBU24120 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart EBU24171 Front brake pads Check each front brake pad for...

Page 97: ...r limit line or mark have a Yamaha dealer replace the brake shoes as a set EBU24251 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly causing it to become inef fective Before riding check that the brake fluid is above the minimum level mark and replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system lea...

Page 98: ...teriorate painted surfaces or plastic parts Always clean up spilled fluid imme diately As the brake pads wear it is normal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24281 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic mainte...

Page 99: ...t drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24513 Adjusting the brake pedal and rear brake lever free play and checking the brake pedal position The brake pedal and brake lever free play must be checked and if necessary adjusted at the...

Page 100: ...rn the brake pedal free play adjusting nut on the brake cable at the rear wheel hub in di rection a to increase the free play and in di rection b to decrease it Adjusting the brake lever free play The brake lever free play should measure 3 0 5 0 mm 0 12 0 20 in as shown If the free play is in correct adjust it as follows 1 Brake pedal free play 1 Brake pedal free play adjusting nut 2 Brake lever f...

Page 101: ... at the rear wheel hub so that gap A measures 0 1 mm 0 0 04 in 3 Turn the brake lever free play adjusting bolt at the brake lever in direction a to increase the free play and in direction b to decrease it 1 Brake lever free play 2 Locknut 3 Brake lever free play adjusting bolt 1 Brake lever free play adjusting nut 2 Gap A U3D563E0 book Page 30 Monday May 12 2008 11 12 AM ...

Page 102: ... Yamaha dealer adjust it WARNING EWB02080 Operating with improperly serviced or adjust ed brakes could cause loss of braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha d...

Page 103: ...ve panel A See page 8 8 TIP The brake light switch is properly adjusted when the brake light comes on just before braking takes effect 2 Turn the brake light switch adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b 3 Install the panel E...

Page 104: ...ke levers should be checked before each ride and the lever pivots should be lubricated if necessary EBU28832 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel A See page 8 8 Recommended lubricant Engine oil Recommended lubricants Front br...

Page 105: ... There is no need to check the electrolyte or to add distilled water However the battery lead connections need to be checked and if necessary tightened NOTICE ECB00620 Never attempt to remove the battery cell seals as this would permanently damage the battery WARNING EWB02160 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cause severe burns Avoid contact wit...

Page 106: ...e by removing the bolts 3 Disconnect the negative battery lead first then the positive battery lead by removing their bolt 4 Pull the battery out of its compartment To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri cal accessories...

Page 107: ... 2 Connect the positive battery lead first then connect the negative battery lead by installing their bolt 3 Install the battery holding plate by installing the bolts 4 Install the seat See page 4 11 NOTICE ECB00632 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a VRLA Valve Regulated Lead Ac id battery a special constant voltage bat tery ...

Page 108: ...r the seat See page 4 11 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits NOTICE ECB00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 1 Main fuse 2 Spare main fuse 3 Fuse box 1 Headlight fuse 2 Ignition fuse 3 Signaling system fuse 4 Spare fuse U3D563E0 book Page 37 Monday May 12 2008 11 12 AM ...

Page 109: ...its to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25541 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the headlight bulb holder cover at the rear of the headlight by pulling it off 2 Remove the headlight bulb holder by pushing it inward and turning it counterclockwise Specified fus...

Page 110: ...e in the headlight unit NOTICE ECB00650 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affect ed Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth moistened with alcohol or thinner 5 Install the headlight bulb holder by aligning the pr...

Page 111: ...ng a headlight beam NOTICE ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the adjusting bolt in direction a To lower a headlight beam turn the adjusting bolt in direction b EBU25600 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the lens by removing the screws 1 Headlight beam adjusting...

Page 112: ...t stops 4 Install the lens by installing the screws NOTICE ECB00700 Do not overtighten the screws otherwise the lens may break EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 3 Elevate the ATV and place a suitable stand under the frame 1 Screw 1 Tail brake light bulb 1 Wheel nut U3D563E0 book Page 41 Monday May 12 2008 11 12 AM ...

Page 113: ... rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side to wards the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U3D563E0 book Page 42 Monday May 12 2008 ...

Page 114: ...any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite o...

Page 115: ...g and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the battery lea...

Page 116: ...erioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places...

Page 117: ...nd areas where strong chemicals are stored Long term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabili...

Page 118: ...d if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it ...

Page 119: ...29 0 kg 505 lb Noise and vibration level Noise level 77 311 EEC 79 4 dB A Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 348 0 cm Bore stroke 83 0 64 5 mm 3 27 2 54 in Compression ratio 9 20 1 Starting system Electric...

Page 120: ... Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 14 5 L 3 83 US gal 3 19 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal Carburetor Manufacturer MIKUNI Type quantity BSR33 x 1 Spark plug s Manufacturer model NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction...

Page 121: ...MAXXIS M938 Loading Maximum loading limit 100 0 kg 220 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum Front 22 0 kPa 0 220 kgf cm 3 2 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi Front wheel Wheel type Panel wheel Rim size 12 x 6 0AT Rear wheel Wheel type Panel wheel...

Page 122: ... 180 mm 7 1 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model YTX14AH Voltage capacity 12 V 12 0 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Oil temperature warning light 12 V 1 7 W 1 Fuses Main fuse 20 0 ...

Page 123: ...f erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26040 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key i...

Page 124: ...your ATV EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number 1 Vehicle identification number 2 Year of manufacture U3D563E0 book Page 2 Monday May 12 2008 11 12 AM ...

Page 125: ...11 3 11 1 Model label U3D563E0 book Page 3 Monday May 12 2008 11 12 AM ...

Page 126: ... 32 Carburetor adjusting 8 23 Chassis fasteners 5 6 Cleaning 9 1 D Drive select lever 4 7 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 25 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 23 Engine oil 5 3 Engine oil and oil filter cartridge 8 10 Engine starting a warm 6 3 Engine stop switch 4 3 F Final gear oil 5 3 8 14 Fuel 4 8 ...

Page 127: ...k absorber assembly adjusting the rear 4 14 Spark arrester cleaning 8 21 Spark plug checking 8 8 Specifications 10 1 Speed limiter 4 4 Starter choke 4 10 Start switch 4 3 Steering shaft lubricating 8 34 Storage 9 2 Storage compartment 4 12 T Tail brake light bulb replacing 8 40 Throttle cable free play adjusting 8 24 Throttle lever 4 4 5 4 Tire pressure measuring 5 5 Tires 5 4 Tire wear limit 5 6 ...

Page 128: ...YAMAHA MOTOR CO LTD PRINTED IN USA 2008 05 0 3 1 CR E U3D563E0 book Page 1 Monday May 12 2008 11 12 AM ...

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