Yamaha WOLVERINE YFM350FXR Owner'S Manual Download Page 108 | Manualshive

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8-1

EBU00515

PERIODIC MAINTENANCE AND

ADJUSTMENT

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

EBU00257

Owner’s manual and tool kit

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

1. Tool kit

2. Low-pressure tire gauge

3. Owner’s manual

WARNING

POTENTIAL HAZARD

Servicing an engine while it is running.

WHAT CAN HAPPEN

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

HOW TO AVOID THE HAZARD

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

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

U4KB1D.book Page 1 Tuesday, April 9, 2002 12:05 PM

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Summary of Contents for WOLVERINE YFM350FXR

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Page 3: ...nformation It provides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV ...

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 re pairing 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: ...noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU00981 AFFIX DEALER LABEL HERE YFM350FXR OWNER S MANUAL 2002 by Yamaha Motor Corporation U S A 1st edition February 2002 All rights reserved Any reprinting or unauthorized use without the written permission U4KB1D book Page 2 T...

Page 6: ...umber 3 2 Vehicle identification number 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator and warning lights 4 2 Oil temperature warning light checking method 4 3 Handlebar switches 4 4 Throttle lever 4 5 Speed limiter 4 6 Front brake lever 4 7 Rear brake pedal and lever 4 7 Parking brake 4 8 Shift pedal 4 10 Reverse knob REV 4 10 Recoil starter 4 11 Fuel tank cap 4 12 Fuel cock 4 12 Start...

Page 7: ... cold engine 6 1 Starting a warm engine 6 3 To decelerate 6 7 Engine break in 6 7 Parking 6 8 Parking on a slope 6 9 Accessories and loading 6 10 RIDING YOUR ATV Getting to know your atv 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your atv 7 23 Climbing uphill 7 25 Riding downhill 7 30 Crossing a slope 7 32 Crossing through shallow water 7 34 Riding over rough ...

Page 8: ...k release cable adjustment 8 21 Throttle lever adjustment 8 21 Rear brake and parking brake adjustment 8 26 Adjusting the rear brake light switch 8 28 Clutch adjustment 8 29 Cable inspection and lubrication 8 29 Brake and shift pedal brake lever lubrication 8 30 Wheel removal 8 31 Wheel installation 8 31 Battery 8 33 Replenishing the battery fluid 8 34 Fuse replacement 8 36 Replacing a headlight b...

Page 9: ...SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 10 11 12 13 14 U4KB1D book Page 4 Tuesday April 9 2002 12 05 PM ...

Page 10: ...abels on your 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 U4KB1D book Page 1 Tuesday April 9 2002 12 05 PM ...

Page 11: ...d rough terrain Maximum Vehicle Load 180 kg 397 lbs Includes weight of operator cargo and accessories and if applicable trailer tongue weight WARNING NEVER ride as a passenger WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper tr...

Page 12: ...RNING 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 U4KB1D book Page 3 Tuesday April 9 2002 12 05 PM ...

Page 13: ...he operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Begin ners 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 grea...

Page 14: ...Always go at a speed that is proper for the terrain visibility 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 ...

Page 15: ... of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight back ward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow...

Page 16: ...p erating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by prac ticing at low speeds and on level smooth terrain On 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 deepe...

Page 17: ...d load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance 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 U4KB1D book Page 5 Tuesday ...

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

Page 19: ...n a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation U4KB1D book Page 7 Tuesday April 9 2002 12 05 PM ...

Page 20: ...l 5 Fuel cock 6 Starter choke 7 Seat lock lever 8 Storage box 9 Tail brake light 10 Recoil starter 11 Shift pedal 12 Rear brake lever 13 Parking brake 14 Main switch 15 Reverse knob 16 Speed limiter 17 Front brake lever 18 Throttle lever 19 Handlebar switch U4KB1D book Page 1 Tuesday April 9 2002 12 05 PM ...

Page 21: ...g 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 U4KB1D book Page 2 Tuesday Apri...

Page 22: ...hicle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label U4KB1D book Page 3 Tuesday April 9 2002 12 05 PM ...

Page 23: ...EBU01057 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 tail brake light come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position U4KB1D book Page 1 Tuesday April 9 2002 12 05 PM ...

Page 24: ...pecified level this light comes on to warn that the en gine oil temperature is too hot If the light comes on during operation stop the engine as soon as it is safe to do so and allow the en gine to cool down for about 10 minutes CAUTION _ The engine may overheat if the ATV is overloaded If this happens reduce the load to specification Restart after making sure that the light is out Continuous use ...

Page 25: ...ck engine oil temperature Oil temperature warning light does not come on Engine oil temperature and electrical circuit are OK Go ahead with riding Push start switch with the transmission in neutral Ask a Yamaha dealer to inspect the electrical circuit Oil tempera ture is low Allow to cool Oil tempera ture is high Oil temperature warning light comes on momentarily U4KB1D book Page 3 Tuesday April 9...

Page 26: ...n this switch is pushed CAUTION See the starting instructions on page 6 1 prior to starting the engine EBU01076 Light switch LIGHTS Turn the switch to the LO position to switch on the low beam and the tail brake light Turn the switch to the HI position to switch on the high beam and the tail brake light Turn the switch to the OFF position to switch off the headlights and the tail brake light CAUTI...

Page 27: ...ng the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle l...

Page 28: ... 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 speed adjuster out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjusted to 3 5 mm 0 12 0...

Page 29: ... front brake lever is located on the right handlebar Pull it toward the handlebar to ap ply the front brake 1 Front brake lever EBU00073 Rear brake pedal and lever 1 Rear brake pedal U4KB1D book Page 7 Tuesday April 9 2002 12 05 PM ...

Page 30: ... in the lock plate to apply the parking brake Squeeze the rear brake 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 U4KB1D book Page 8 Tuesday April 9 2002 12 05 PM ...

Page 31: ...gine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking perfor mance which could cause an accident You could also wear out the brakes pre maturely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine U4KB1D book Page 9 Tuesday April 9 2002 12 05 PM ...

Page 32: ... Reverse is at the bot tom position Neutral is one position above re verse 1 Shift pedal N Neutral R Reverse EBU01028 Reverse knob REV The reverse knob is used to shift into reverse gear Refer to the Reverse knob operation and reverse driving section page 6 4 before operating this machine in reverse gear 1 Reverse knob REV U4KB1D book Page 10 Tuesday April 9 2002 12 05 PM ...

Page 33: ...il starter WARNING POTENTIAL HAZARD Starting the engine in gear and or start ing the engine without setting the park ing brake WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Put the transmission in neutral and set the parking brake before starting the en gine U4KB1D book Page 11 Tuesday April 9 2002 12 05 PM ...

Page 34: ...ill not flow Always turn the lever to this position 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 p...

Page 35: ... mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 U4KB1D book Page 13 Tuesday April 9 2002 12 05 PM ...

Page 36: ...ull up the seat at the rear 1 Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely fitted U4KB1D book Page 14 Tuesday April 9 2002 12 05 PM ...

Page 37: ... damage do not put metal products like tools or sharply edged prod ucts directly in the storage box If they must be stored wrap them in appropriate cushion material Maximum load limit 2 kg 4 4 lb U4KB1D book Page 15 Tuesday April 9 2002 12 05 PM ...

Page 38: ...Adjust the spring preload as follows To increase the 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 1 Special wrench Standard position B A Minimum soft E Maximum hard U4KB1D book Page 16 Tuesday April 9 2002 12 05 PM ...

Page 39: ...a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring WARNING POTENTIAL HAZARD Improper shock absorber adjustment 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 U4KB1D book Page ...

Page 40: ...1 Special wrench EBU00112 Standard position B A Minimum soft E Maximum hard U4KB1D book Page 18 Tuesday April 9 2002 12 05 PM ...

Page 41: ...f necessary 5 5 5 6 Engine oil Check oil level Fill with oil if necessary 5 7 8 5 8 8 Final gear oil Check for leakage 5 8 8 9 8 10 Differential gear oil Check for leakage 5 8 8 11 8 12 Throttle Check for proper throttle cable operation 5 8 8 21 Wheels and tires Check tire pressure wear and damage 5 9 5 12 8 31 8 32 Fittings and Fasteners Check all fittings and fasteners 5 8 Lights Check for prope...

Page 42: ...ases 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 U4KB1D book Page 2 Tuesday April 9 2002 12 05 PM ...

Page 43: ...ke fluid level Check the brake fluid level Add fluid if neces sary See pages 8 23 8 24 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or master cylinder Apply the brakes firmly for one minute If there is any leaking have the machine inspected by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working prop...

Page 44: ...d 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 the ATV inspected by a Yamaha dealer U4KB1D book Page 4 Tuesday April 9 2002 12 05 PM ...

Page 45: ...esigned 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 13 L 2 9 Imp gal 3 4 US gal Reserve...

Page 46: ...D Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fue...

Page 47: ...han specified In addition do not use oils labeled ENERGY CON SERVING 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 9 L 2 6 Imp q...

Page 48: ... specified level Add oil as necessary See EBU01083 Throttle lever Check to see that the throttle lever operates correctly It must open smoothly and spring back to the idle position when released Have a Yamaha dealer repair as necessary for proper operation EBU00152 Fittings and Fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine Recommended oil SAE...

Page 49: ...cessary See pages 8 33 8 35 EBU00157 Tires 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 acci dent HOW TO AVOID THE HAZARD 1 The tires listed below have been ap proved by Yama...

Page 50: ... could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 22 kPa 0 22 kgf cm2 3 2 psi Rear 22 kPa 0 22 kgf cm2 3 2 psi 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 Fas...

Page 51: ...ading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifica tions ACE 02EACE 02E 1 Low pressure tire gauge Recommended pressure Minimum Maximum Front 25 kPa 0 25 kgf cm2 3 6 psi 22 kPa 0 22 kgf cm2 3 2 psi 28 kPa 0 28 kgf cm2 4 0 psi 25 kPa 2 22 kPa 2 28 kPa 2 U4KB1D book Page 11 Tuesday April 9 2002 12 05...

Page 52: ...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 U4KB1D book Page 12 Tuesday April 9 2002 12 05 PM ...

Page 53: ...iliar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion H...

Page 54: ...engine 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 1 Fully open 2 Half open 3 Closed a Starter choke 6 Completely close the throttle leve...

Page 55: ... engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 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...

Page 56: ...transmission into reverse by pressing down on the shift pedal NOTE When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the machine 4 Check behind you for people or obsta cles then release the rear brake lever 5 Open the throttle lever gradually and con tinue to watch to the rear while backing WARNING POTENTIAL HAZARD Improperly oper...

Page 57: ...g climbing etc To shift into neutral return the throttle lever to its original position and re peatedly depress the shift pedal until it stops CAUTION Do not coast for long periods with the en gine off and do not tow the machine a long distance Even with gears in neutral the transmission is only properly lubricat ed when the engine is running Inadequate lubrication may damage the transmission U4KB...

Page 58: ...ease the throttle lever 5 Shift into second gear and release the shift pedal 6 Open the throttle gradually 7 Follow the same procedure when shifting to the next higher gear WARNING POTENTIAL HAZARD Opening the throttle before releasing the shift pedal WHAT CAN HAPPEN The machine could wheelie This would increase the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Release the shif...

Page 59: ...owing material Because the engine is brand new you must not put an excessive load on it for the first several hours of running During the first 20 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition which might result in ex cessive engine heating must be avoided However momentary...

Page 60: ...ration above half throttle Allow a cooling off period of five to ten minutes after every hour of opera tion Vary the speed of the machine from time to time Do not operate it at one set throttle position 2 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at EBU00211 Parking When parking stop the engine and shift into neut...

Page 61: ...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 walk up ...

Page 62: ...ha accesso ries nor have any control over the quality or suitability of them Choose a genuine Yamaha accessory or one that is equiva lent in design and quality Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object attached to the han dlebars which could make steering difficult an accessory that limits...

Page 63: ...f you are carrying cargo and towing a trail er include the tongue weight in the maxi mum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent MAXIMUM LO...

Page 64: ...d hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed a...

Page 65: ...U4KB1D book Page 13 Tuesday April 9 2002 12 05 PM ...

Page 66: ...EBU01114 WARNING _ Indicates a potential hazard that could result in serious injury or death U4KB1D book Page 14 Tuesday April 9 2002 12 05 PM ...

Page 67: ...7 1 Riding Your ATV U4KB1D book Page 1 Tuesday April 9 2002 12 05 PM ...

Page 68: ...U4KB1D book Page 2 Tuesday April 9 2002 12 05 PM ...

Page 69: ... riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable 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 partic...

Page 70: ... to learn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in creased if the operator does not know HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly pra...

Page 71: ...mmenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc U4KB1D book Page 5 Tuesday April 9 2002 12 05 PM ...

Page 72: ...EN 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 U4KB1D book Page 6 Tuesday April 9 2002 12 05 PM ...

Page 73: ... accident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sle...

Page 74: ...ARD 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 U4KB1D book Page 8 Tuesday April 9 2002 12 05 PM ...

Page 75: ...fe op erating condition Always follow the in spection and maintenance procedures WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use ...

Page 76: ...r limits the power and top speed of the ATV Turning the screw in decreases top speed and turning it out increases top speed 1 Locknut 2 Adjuster 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 speed that is prop...

Page 77: ... kg 728 lb Tongue weight vertical weight on trailer hitch point 15 kg 33 lb WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed wh...

Page 78: ...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 U...

Page 79: ...G POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off U4KB1D book Page 13 Tuesday April 9 2002 12 05 PM ...

Page 80: ...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 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 U4KB1D book Page 14 Tuesday April 9 2002 12 05 PM ...

Page 81: ...NING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass U4KB1D book Page 15 Tuesd...

Page 82: ... 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 U4KB1D book Page 16 Tuesday April 9 2002 12 05 PM ...

Page 83: ...rating 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 U4KB1D book Page 17 Tuesday April 9 2002 12 05 PM ...

Page 84: ... to upset WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op U4KB1D book Page 18 Tuesday April 9 2002 12 05 PM ...

Page 85: ...r 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 U4KB1D book Page 19 Tuesday April 9 2002 12 05 PM ...

Page 86: ...s posted no trespassing Do not ride on private property without getting permission WARNING POTENTIAL HAZARD Operating in areas where you might not 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 U4KB1D book Page 20 Tuesday April 9 2002 12 05 PM ...

Page 87: ... skin or clothing to come in contact with these With the engine idling lift the shift pedal to the 1st gear position and then release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate Once the ATV has at tained adequate speed release the throttle and lift the shift pedal to the 2nd gear position Release the shift pedal and ...

Page 88: ...p er use of the brakes or shifting can cause the tires to lose traction reducing control and in creasing the possibility of an accident WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make su...

Page 89: ... As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control...

Page 90: ...mproper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember A...

Page 91: ...tant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small h...

Page 92: ...ls as described in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes An obstacle a sharp drop or another vehicle or person could be on the other side of the hill U4KB1D book Page 26 Tuesday April 9 2002 12 05 PM ...

Page 93: ...or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your ...

Page 94: ... the ATV in gear The ATV could easily tip over backwards In 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 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 A...

Page 95: ...ismount 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 U4KB1D book Page 29 Tuesday April 9 2002 12 05 PM ...

Page 96: ...on Whenever possible ride your ATV straight downhill Avoid sharp angles which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for go ing down hills as described in this ...

Page 97: ...U4KB1D book Page 31 Tuesday April 9 2002 12 05 PM ...

Page 98: ...g the front wheels slightly up hill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no 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 HAPP...

Page 99: ...a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV U4KB1D book Page 33 Tuesday April 9 2002 12 05 PM ...

Page 100: ...ery or up set the ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to l...

Page 101: ... regained 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 U4KB1D book Page 35 Tuesday April 9 2002 12 05 PM ...

Page 102: ...ol 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 procedu...

Page 103: ...U4KB1D book Page 37 Tuesday April 9 2002 12 05 PM ...

Page 104: ...heels 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 U4KB1D book Page 38 Tuesday April 9 200...

Page 105: ...ntrol may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious ...

Page 106: ...essary gradually let off the throttle and or steer to the outside of the turn See pages 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 have ...

Page 107: ...over that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV un til you have regained adequate braking ability See...

Page 108: ...257 Owner s manual and tool kit You are recommended to put this owner s manual and low pressure tire gauge in the vi nyl bag and always carry them along with the owner s tool kit under the seat WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires...

Page 109: ...our machine to a Yamaha dealer to check the torque settings and adjust them as neces sary WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er instal...

Page 110: ...peed starter operation Adjust if necessary Cylinderhead cover breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check leakage Retighten if necessary Replace gasket 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 Clean Engine oil strainer ...

Page 111: ...looseness damage Replace if damaged Steering system Check operation Replace if damaged Check toe in Adjust if necessary Drive shaft universal joint Lubricate every 6 months Axle boots Replace if damaged Fittings and Fasteners Check all chassis fittings and fasteners Correct if necessary Battery Check specific gravity Check that the breather hose is positioned properly Correct if necessary ITEM ROU...

Page 112: ...n wipe the dipstick off with a clean rag In sert the dipstick in the filler hole without screwing it in 4 Remove the dipstick and then check the oil level NOTE The oil level should be between the maximum and minimum marks If the level is low add oil to raise it to the proper level _ CAUTION Be sure no foreign material enters the crankcase U4KB1D book Page 5 Tuesday April 9 2002 12 05 PM ...

Page 113: ... 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 5 Remove the oil filter cover by removing the bolts and then remove the oil filter element U4KB1D book Page 6 Tuesday April 9 2...

Page 114: ...e 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 Fill the engine with oil and then install the Tightening torques Drain bolt engine 32 Nm 3 2 m kgf 23 ft lbf Filter cover bolt 8 Nm 0 8 m kgf 6 0 ft lbf U4KB1D...

Page 115: ...he crankcase Recommended oil See page 5 7 Oil quantity Periodic oil change 2 9 L 2 6 lmp qt 3 1 US qt With oil filter replacement 3 0 L 2 6 lmp qt 3 2 US qt Total amount 3 5 L 3 1 lmp qt 3 7 US qt U4KB1D book Page 8 Tuesday April 9 2002 12 05 PM ...

Page 116: ... low add oil to raise it to the proper level CAUTION Be sure no foreign material enters the final gear case 3 Install the oil filler bolt and tighten it to the specified torque 1 Filler bolt 2 Final gear oil 3 Correct oil level Final gear oil replacement 1 Remove the final gear case cover Tightening torque Oil filler bolt 25 Nm 2 5 m kgf 18 ft lbf U4KB1D book Page 9 Tuesday April 9 2002 12 05 PM ...

Page 117: ...n it to the specified torque 6 Fill the final gear case with oil CAUTION Be sure no foreign material enters the final gear case 7 Install the filler bolt and tighten to the specified torque Recommended oil See page 10 3 Oil quantity Periodic oil change 0 19 L 0 17 Imp qt 0 20 US qt Total amount 0 25 L 0 22 Imp qt 0 26 US qt Tightening torque Filler bolt final gear case U4KB1D book Page 10 Tuesday ...

Page 118: ...ace the machine on a level place 2 Remove the differential gear case cover 3 Place a container under the differential gear case 4 Remove the filler bolt and drain bolt to drain the oil 1 Filler bolt U4KB1D book Page 11 Tuesday April 9 2002 12 05 PM ...

Page 119: ...he filler bolt and tighten to specifi cation Tightening torque Drain bolt differential gear case 12 Nm 1 2 m kgf 8 7 ft lbf Recommended oil SAE 80 or SAE 80W 90 API GL 5 Hypoid gear oil for L S D Limited Slip Differential Oil quantity Periodic oil change 0 18 L 0 16 Imp qt 0 19 US qt Total amount 0 2 L 0 18 Imp qt 0 21 US qt Tightening torque U4KB1D book Page 12 Tuesday April 9 2002 12 05 PM ...

Page 120: ...EBU00862 Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by a Yamaha dealer 1 Boot 2 1 Boot 2 U4KB1D book Page 13 Tuesday April 9 2002 12 05 PM ...

Page 121: ... 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 feeler gauge and adjust to specification a Spark plug gap When installing the spark plug alway...

Page 122: ...he air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Check hose 1 Air filter case cover 3 Remove the air filter element and sepa rate it from the guide U4KB1D book Page 15 Tuesday April 9 2002 12 05 PM ...

Page 123: ... the filter element when 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 U4KB1D book Page 16 Tuesday April 9 2002 12 05 PM ...

Page 124: ...i cated more often if the machine is operated in extremely dusty areas Each time filter ele ment maintenance is performed check the air inlet to the filter case for obstructions Check the air cleaner rubber joint to the carburetor and manifold fittings for an airtight seal Tight en all fittings securely to avoid the possibility of unfiltered air entering the engine CAUTION Never operate the engine...

Page 125: ...pipe by pulling it out of the muffler 1 Bolt 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 4 Insert the tailpipe into the muffler and align the bolt holes 1 Tail pipe 2 Spark arrester 5 Install and tighten the bolt U4KB1D book Page 18 Tuesday April 9 2002 12 05 PM ...

Page 126: ...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 s...

Page 127: ...eter and set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in to increase engine speed and out to de crease 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 This adjust m...

Page 128: ...rly This adjustment however should be left to a Yamaha dealer 1 Locknut 2 Adjuster EBU00307 Throttle lever adjustment NOTE Adjust the engine idling speed before adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle le ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut U4KB1D book Page 21 Tuesday April 9 2002 12 05 PM ...

Page 129: ...ke pad wear without disassembling the brake Apply the brake and inspect the wear indica tors If they are ALMOST in contact with the disc plate ask a Yamaha dealer to replace the pads 1 Wear indicator 2 a Wear limit 1 mm 0 04 in 1 Wear indicator 2 a Wear limit 1 mm 0 04 in Front Rear U4KB1D book Page 22 Tuesday April 9 2002 12 05 PM ...

Page 130: ...the lower level and replenish when necessary Observe these precautions 1 Minimum level mark LOWER 1 When checking the fluid level make sure the top of the master cylinder is level by turning the handlebars 2 Use only the designated quality brake flu id Otherwise the rubber seals may dete riorate causing leakage and poor brake performance Front Rear U4KB1D book Page 23 Tuesday April 9 2002 12 05 PM...

Page 131: ...iorate painted sur faces or plastic parts Always clean up spilled fluid immediately 6 Have a Yamaha dealer check the cause if the brake fluid level goes down EBU01118 Brake fluid replacement 1 Complete fluid replacement should be done only by trained Yamaha service personnel 2 Have a Yamaha dealer replace the fol lowing components during periodic main tenance or when they are damaged or leaking Re...

Page 132: ...mproperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is cor rect 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 U4KB1D book Page 25 Tue...

Page 133: ... cable and parking brake cable locknuts 1 Rear brake cable locknut 2 Parking brake cable locknut 3 Parking brake cable adjusting bolt 4 Rear brake cable adjusting bolt 3 Loosen the rear caliper adjusting bolt 1 Caliper adjusting bolt locknut 2 Caliper adjusting bolt U4KB1D book Page 26 Tuesday April 9 2002 12 05 PM ...

Page 134: ... so that there is no free play in the ca ble Then tighten the parking brake cable locknut 1 Rear brake cable locknut 2 Parking brake cable locknut 3 Parking brake cable adjusting bolt 4 Rear brake cable adjusting bolt 7 Turn the rear brake cable adjusting bolt so that there is no free play in the brake lever Then tighten the rear brake cable locknut 8 Turn the rear wheel to make sure there is no b...

Page 135: ...Turn the adjusting nut while holding the rear WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is cor rect Make sure the brakes do not drag Make sure the brakes are not spongy All air must b...

Page 136: ...ckwise to decrease the clutch free play and turn it clock wise to increase the free play EBU00356 Cable inspection and lubrication Tightening torque WARNING POTENTIAL HAZARD 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 accid...

Page 137: ...eplace them EBU00727 Brake and shift pedal brake lever lubrication Lubricate the pivoting parts of each lever and pedal Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil Recommended lubricant Lithium soap based grease all purpose grease U4KB1D book Page 30 Tuesday April 9 2002 12 05 PM ...

Page 138: ...heel 4 Remove the wheel EBU01121 Wheel installation 1 Install the wheel and the nuts NOTE _ Tapered nuts are used for both the front and rear wheels Install the nut with its ta pered side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel _ U4KB1D book Page 31 Tuesday April 9 2002 12 05 PM ...

Page 139: ... the ATV so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 64 Nm 6 4 m kgf 46 ft lbf Rear 64 Nm 6 4 m kgf 46 ft lbf U4KB1D book Page 32 Tuesday April 9 2002 12 05 PM ...

Page 140: ... 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 WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WHAT CAN HAPPEN You could be poisoned You could be U4KB1D book Page 33...

Page 141: ...THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sp...

Page 142: ...ove the battery and store it in a cool dark place Completely recharge the battery before reusing 6 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 charge the battery when it is too low 7 Always make sure the connections are correct when putting the battery back in the machine Make sure the breather hose is properly connected...

Page 143: ...dealer CAUTION To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse Specified fuse 20 A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse U...

Page 144: ...ollows 1 Remove the screws holding the headlight unit assembly to the headlight body 1 Screw 2 Remove the bulb holder cover 3 Turn the bulb holder counterclockwise to remove the defective bulb 1 Bulb holder cover 2 Bulb holder 3 Reflector U4KB1D book Page 37 Tuesday April 9 2002 12 05 PM ...

Page 145: ...ustment To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b WARNING POTENTIAL HAZARD The 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 removi...

Page 146: ... nuts together with washers 1 Storage box 2 Nut 2 3 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Bulb holder 4 Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise U4KB1D book Page 39 Tuesday April 9 2002 12 05 PM ...

Page 147: ...ession or ignition sys tems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it to a Yamaha dealer The skilled technicians at a Yamaha dealer ship have the tools experience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look...

Page 148: ...PEN Fuel can ignite or explode causing se vere injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnac es U4KB1D book Page 41 Tuesday April 9 2002 12 05 PM ...

Page 149: ...there is compression There is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the plug and check the 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 4 Battery Engine turns over Check fuel flow Turn the fuel ...

Page 150: ...les 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 ma...

Page 151: ... may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the ...

Page 152: ...ablespoon 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 sever al times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing in a humid or salt a...

Page 153: ...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 U4KB1D book Page 4 Tuesday April 9 2002 12 05 PM ...

Page 154: ...0 mm 31 1 in 1 230 mm 48 4 in 220 mm 8 66 in 3 500 mm 138 in Basic weight With oil and full fuel tank 234 5 kg 517 lb Engine 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 and recoil starter Wet sump U4KB1D book Page 1 Tuesday Ap...

Page 155: ... 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 engine oil also lubricates the clutch do not mix any chemical addi tives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or high er U4KB1D book Page 2 Tuesday April 9 20...

Page 156: ...AE80 or SAE80W 90 API GL 5 Hypoid gear oil for L S D Limited Slip Differential 0 18 L 0 16 Imp qt 0 19 US qt 0 2 L 0 18 Imp qt 0 21 US qt Air filter Wet type element Fuel Type Fuel tank capacity Fuel reserve amount UNLEADED GASOLINE ONLY 13 L 2 9 Imp gal 3 4 US gal 1 7 L 0 37 Imp gal 0 45 US gal Carburetor Type quantity Manufacturer BST34 1 MIKUNI Spark plug MODEL YFM350FX U4KB1D book Page 3 Tuesd...

Page 157: ...erse gear Spur gear 76 24 3 167 Shaft drive 24 28 24 18 33 09 4 190 Constant mesh 5 speed Left foot operation 38 13 2 923 34 18 1 889 30 22 1 364 26 25 1 040 24 29 0 828 22 17 35 15 3 020 Chassis Frame type Caster angle Trail Steel tube 4 19 mm 0 75 in Tire Type Size front rear Tubeless AT23 8 12 AT23 10 12 Brake MODEL YFM350FX U4KB1D book Page 4 Tuesday April 9 2002 12 05 PM ...

Page 158: ...Rear wheel travel 180 mm 7 1 in 180 mm 7 1 in Electrical Ignition system Generator system Battery type voltage capacity C D I AC magneto GM12CZ 4A 2 12V 12AH Headlight type Krypton bulb Bulb voltage wattage quantity Headlight Tail brake light Indicator light Neutral Reverse Oil temparature 12V 30W 30W 2 12V 5W 21W 1 12V 1 7W 1 12V 1 7W 1 12V 1 7W 1 MODEL YFM350FX U4KB1D book Page 5 Tuesday April 9...

Page 159: ...se of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muff...

Page 160: ...the warranty The chart below is printed only as a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 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 U4KB1D book Page 1 Tuesday April 9 2002 12 05 PM ...

Page 161: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U4KB1D book Page 1 Tuesday April 9 2002 12 05 PM ...

Page 162: ...1 2 3 4 5 6 7 8 9 10 9 9 13 U4KB1D book Page 2 Tuesday April 9 2002 12 05 PM ...

Page 163: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S U4KB1D book Page 1 Tuesday April 9 2002 12 05 PM ...

Page 164: ...1 2 3 4 5 6 7 8 9 10 9 9 9 U4KB1D book Page 2 Tuesday April 9 2002 12 05 PM ...

Page 165: ...EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death U4KB1D book Page 3 Tuesday April 9 2002 12 05 PM ...

Page 166: ...EBU00437 U4KB1D book Page 5 Tuesday April 9 2002 12 05 PM ...

Page 167: ...EBU00438 ...

Page 168: ...Card fm Page 1 Monday April 8 2002 3 23 PM ...

Page 169: ...Card fm Page 2 Monday April 8 2002 3 23 PM ...

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