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Yamaha WOLVERINE YFM350FXT, Owner'S Manual

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Yamaha WOLVERINE YFM350FXT Owner'S Manual Download Page 125

8-21

EBU13570

Spark arrester cleaning

Be sure the exhaust pipe and muffler are cool
before cleaning the spark arrester.

1. Remove the bolt.
2. Remove the tailpipe 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. Tailpipe

2. Spark arrester

5. Install and tighten the bolt. 

U2D410.book  Page 21  Thursday, April 1, 2004  1:59 PM

Summary of Contents for WOLVERINE YFM350FXT

Page 1: ......

Page 2: ......

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

Page 5: ...ise level and spark arrester laws and regu lations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU00981 AFFIX DEALER LABEL HERE YFM350FXT OWNER S MANUAL 2004 by Yamaha Motor Corporation U S A 1st edition March 2004 All rights reserved Any reprinting or unauthorized use without the written permission U2D410 book Page 2 Thursday ...

Page 6: ...ion number 3 2 Vehicle identification number 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator and warning lights 4 2 Handlebar switches 4 4 Throttle lever 4 5 Speed limiter 4 6 Front brake lever 4 7 Brake pedal and rear brake lever 4 7 Parking brake 4 8 Shift pedal 4 10 Reverse knob 4 10 Recoil starter 4 11 Fuel tank cap 4 12 Fuel cock 4 12 Starter choke 4 13 Seat 4 14 Storage box 4 15 Fr...

Page 7: ...old 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 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 23 Climbing uphill 7 25 Riding downhill 7 30 Crossing a slope 7 32 Crossing through shallow water 7 34 Riding over roug...

Page 8: ...justment 8 23 Reverse lock release cable adjustment 8 24 Front brake lever free play 8 27 Rear brake and parking brake adjustment 8 29 Adjusting the rear brake light switch 8 31 Clutch adjustment 8 32 Cable inspection and lubrication 8 32 Brake and shift pedal brake lever lubrication 8 33 Wheel removal 8 33 Wheel installation 8 34 Battery 8 35 Replenishing the battery fluid 8 37 Fuse replacement 8...

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 U2D410 book Page 4 Thursday April 1 2004 1 59 PM ...

Page 10: ...labels 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 U2D410 book Page 1 Thursday April 1 2004 1 59 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 U2D410 book Page 3 Thursday April 1 2004 1 59 PM ...

Page 13: ... 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 greate...

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

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

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

Page 17: ...ted load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Products Safety Com mission at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 U2D410 book Page 5 Thursd...

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

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 U2D410 book Page 7 Thursday April 1 2004 1 59 PM ...

Page 20: ...Brake pedal 6 Fuel cock 7 Starter choke 8 Seat lock lever 9 Storage box 10 Tail brake light 11 Recoil starter 12 Shift pedal 13 Rear brake lever 14 Parking brake 15 Main switch 16 Reverse knob 17 Speed limiter 18 Front brake lever 19 Throttle lever 20 Handlebar switches U2D410 book Page 1 Thursday April 1 2004 1 59 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 U2D410 book Page 2 Thursday Apr...

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 U2D410 book Page 3 Thursday April 1 2004 1 59 PM ...

Page 23: ...ath EBU09420 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position U2D410 book Page 1 Thursday April 1 2004 1 59 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 U2D410 book Page 3 Thursday April ...

Page 26: ...hen this switch is pushed CAUTION See the starting instructions on page 6 1 prior to starting the engine EBU11560 Light switch LIGHTS Set the switch to the LO position to turn on the low beam and the taillight Set the switch to the HI position to turn on the high beam and the taillight Set the switch to the OFF position to turn off all of the lights CAUTION _ Do not use the headlights with the eng...

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: ...rew a 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to 3 5 mm...

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 EBU00732 Brake pedal and rear brake lever 1 Brake pedal U2D410 book Page 7 Thursday April 1 2004 1 59 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 U2D410 book Page 8 Thursday April 1 2004 1 59 PM ...

Page 31: ...ng the engine 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 U2D410 book Page 9 Thursday April 1 2004 1 59 PM ...

Page 32: ...is at the bot tom position Neutral is one position above re verse 1 Shift pedal N Neutral position R Reverse position 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 U2D410 book Page 10 Thursday April 1 2004 1 59 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 U2D410 book Page 11 Thursday April 1 2004 1 59 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 U2D410 book Page 13 Thursday April 1 2004 1 59 PM ...

Page 36: ... at the rear 1 Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely fitted 1 Projection 2 2 Seat holder 2 U2D410 book Page 14 Thursday April 1 2004 1 59 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 U2D410 book Page 15 Thursday April 1 2004 1 59 PM ...

Page 38: ...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 2 Position indicator 1 Special wrench Standard position B A Minimum soft E Maximum hard U2D410 book Page 16 Thursday April 1 2004 1 59 PM ...

Page 39: ...T 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 U2D410 book Page 17 Thursday April 1 2004 1 59 PM ...

Page 40: ...g 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 2 Position indicator 1 Special wrench EBU00112 Standard position B A Minimum soft E Maximum hard U2D410 book Page 18 Thursday April 1 2004 1 59 PM ...

Page 41: ... 5 5 Engine oil Check oil level Fill with oil if necessary 5 6 8 6 8 10 Final gear oil Check for leakage 5 6 8 11 8 13 Differential gear oil Check for leakage 5 6 8 13 8 15 Throttle Check for proper throttle cable operation and free play 5 7 8 24 Wheels and tires Check tire pressure wear and damage 5 8 5 11 8 33 8 34 Fittings and fasteners Check all fittings and fasteners 5 7 Lights and switches C...

Page 42: ...er Brake fluid level Check the brake fluid level Add fluid if neces sary See pages 8 26 8 27 WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper ating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op erating condition A...

Page 43: ... provide proper braking per formance inspect the brake pads for wear See page 8 25 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected by th...

Page 44: ...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 45: ...HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to 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 th...

Page 46: ...ake sure that no foreign material en ters the crankcase _ EBU00493 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 11 8 13 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used EBU00494 Differential gear oil Make sure th...

Page 47: ...ine EBU10030 Lights Check the headlights and tail brake light to make sure they are in working condition Re pair as necessary for proper operation EBU11700 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for proper operation EBU00499 Battery Check fluid level and fill if necessary Use only distilled water if refilling is necessary See pages 8 35 8 38 Recommend...

Page 48: ...d for this model Other tire combina tions are not recommended ACE 01EACE 01E 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 25 kPa 0 25 kgf cm2 3 6 psi Rear 25 kPa 0 25 kgf cm2 3 6 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dislodge...

Page 49: ...e tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst U2D410 book Page 9 Thursday April 1 2004 1 59 PM ...

Page 50: ...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 Rear 25 kPa 0 25 kgf cm2 22 kPa 0 22 kgf cm2 28 kPa 0 28 kgf cm2 U2D410 book Page 10 Thursda...

Page 51: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit U2D410 book Page 11 Thursday April 1 2004 1 59 PM ...

Page 52: ... controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW TO AVOID TH...

Page 53: ...mmended to shift into neutral before starting the en gine 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warm 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...

Page 54: ...th the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it 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 slight...

Page 55: ...sion 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 ATV _ 4 Check behind you for people or obsta cles then release the brake 5 Open the throttle lever gradually and con tinue to watch to the rear while backing WARNING POTENTIAL HAZARD Improperly operating in reverse WH...

Page 56: ...n and repeatedly depress the shift pedal until it stops To shift into reverse first shift into neutral and then turn the reverse knob as explained on page 6 4 Depress the shift pedal and then release the reverse knob 1 Shift pedal N Neutral position R Reverse position CAUTION _ Do not coast for long periods with the en gine off and do not tow the ATV a long dis tance Even in the neutral position t...

Page 57: ...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 58: ...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 59: ... operation above half throt tle Allow a cooling off period of five to ten min utes after every hour of operation Vary the speed of the machine from time to time Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but EBU00211 Parking When parking stop the engine and shift into neutral Turn the fuel cock to...

Page 60: ...ill 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 ATV 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 them ea...

Page 61: ...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 62: ...riers Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with controls or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slow er you should go Although conditions vary it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or ...

Page 63: ...n vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking U2D410 book Page 12 Thursday April 1 2004 1 59 PM ...

Page 64: ...EBU13471 WARNING _ Indicates a potential hazard that could result in serious injury or death U2D410 book Page 13 Thursday April 1 2004 1 59 PM ...

Page 65: ...7 1 Riding Your ATV U2D410 book Page 1 Thursday April 1 2004 1 59 PM ...

Page 66: ...U2D410 book Page 2 Thursday April 1 2004 1 59 PM ...

Page 67: ... 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 68: ...time Take the time to learn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills lea...

Page 69: ...mmenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc U2D410 book Page 5 Thursday April 1 2004 1 59 PM ...

Page 70: ...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 U2D410 book Page 6 Thursday April 1 2004 1 59 PM ...

Page 71: ... 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 72: ...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 U2D410 book Page 8 Thursday April 1 2004 1 59 PM ...

Page 73: ...afe 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 74: ...op speed of the ATV Turning the adjusting screw in decreases the top speed and turning it out increases the top speed See page 4 6 for details 1 Locknut 2 Adjusting screw WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always ...

Page 75: ... 4 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 when carrying cargo or pulling a trailer Allow greater distance for brak...

Page 76: ...even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into 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 77: ...G POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off U2D410 book Page 13 Thursday April 1 2004 1 59 PM ...

Page 78: ...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 U2D410 book Page 14 Thursday April 1 2004 1 59 PM ...

Page 79: ...RNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine 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 U2D410 book Page 15 Thurs...

Page 80: ... this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets U2D410 book Page 16 Thursday April 1 2004 1 59 PM ...

Page 81: ...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 U2D410 book Page 17 Thursday April 1 2004 1 59 PM ...

Page 82: ... 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 U2D410 book Page 18 Thursday April 1 2004 1 59 PM ...

Page 83: ...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 U2D410 book Page 19 Thursday April 1 2004 1 59 PM ...

Page 84: ...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 U2D410 book Page 20 Thursday April 1 2004 1 59 PM ...

Page 85: ... 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 86: ...rop 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 ...

Page 87: ...s you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The ATV could go out of contr...

Page 88: ...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 89: ...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 90: ...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 U2D410 book Page 26 Thursday April 1 2004 1 59 PM ...

Page 91: ...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 92: ...he 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 the ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill...

Page 93: ...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 U2D410 book Page 29 Thursday April 1 2004 1 59 PM ...

Page 94: ...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 95: ...U2D410 book Page 31 Thursday April 1 2004 1 59 PM ...

Page 96: ...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 97: ...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 U2D410 book Page 33 Thursday April 1 2004 1 59 PM ...

Page 98: ...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 99: ...egained 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 _ U2D410 book Page 35 Thursday April 1 2004 1 59 PM ...

Page 100: ...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 101: ...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 U2D410 book Page 38 Thursday April 1 20...

Page 102: ...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 103: ...f necessary gradually let off the throttle and or steer to the outside of the turn See pag If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for war...

Page 104: ...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 105: ...er s tool kit under the seat The service in formation included in this manual is intended to provide you the owner with the necessary information for completing your own preven tive maintenance and minor repairs The tools provided in the owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and WARNING POTENTIAL HAZARD Servicing an ...

Page 106: ...th improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed...

Page 107: ... first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check idle speed starter operation Adjust if necessa...

Page 108: ...ble Check operation Adjust if necessary Wheels Check balance damage runout Replace if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Front and rear suspension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Drive shaft universal joint Lubricate with lithium soap based grease ITEM ROU...

Page 109: ...red On the inner parts of the master cylin ders or calipers replace the oil seals every two years Replace the brake hoses every four years or if cracked or damaged WARNING _ Indicates a potential hazard that could result in serious injury or death Lights and switches Check operation Adjust headlight beams ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 4...

Page 110: ...eck the engine oil level 1 Place the ATV on a level surface 2 Warm up the engine for several minutes and then turn it off 3 Wait a few minutes until the oil level set tles before checking 4 Remove the engine oil filler cap and then wipe the dipstick off with a clean rag In sert the dipstick in the filler hole without screwing it in and then remove it again to check the oil level 1 Engine oil fille...

Page 111: ... Insert the dipstick into the oil filler hole and then tighten the engine oil filler cap To change the engine oil with or without oil filter element cleaning 1 Place the ATV on a level surface 2 Warm up the engine for several minutes and then turn it off 3 Place a container under the engine to collect the used oil 4 Remove the engine oil filler cap and then remove the engine oil drain bolt to drai...

Page 112: ... ing cleaned _ 5 Remove the oil filter cover by removing the bolts and then remove the oil filter el ement 6 Clean the oil strainer and oil filter element with solvent 7 Check the O ring for damage and re place it if necessary 1 Engine oil filter element 2 O ring 8 Install the oil filter element and O ring NOTE _ Make sure the O ring is seated properly _ U2D410 book Page 8 Thursday April 1 2004 1 ...

Page 113: ...olt be sure to install the O ring compression spring and oil strainer _ 11 Add the specified amount of the recom mended engine oil and then install and tighten the engine oil filler cap Tightening torque Oil filter cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf Tightening torque Recommended oil See page 10 2 Oil quantity Without oil filter element replacement 2 9 L 2 6 Imp qt 3 1 US qt With oil filter elem...

Page 114: ...In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ 12 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 13 Turn the engine off and then check the oil level and correct it if necessary U2D410 book Page 10 Thurs...

Page 115: ...e final gear case NOTE _ 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 CAUTION _ Be sure no foreign material enters the final gear case _ 4 Install the oil filler bolt U2D410 book Page 11 Thursday April 1 2004 1 59 PM ...

Page 116: ...ace 3 Place a container under the final gear case to collect the used oil 4 Remove the oil filler bolt and the drain bolt to drain the oil 1 Final gear oil drain bolt 5 Install the drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 25 Nm 2 5 m kgf 18 ft lbf U2D410 book Page 12 Thursday April 1 2004 1 59 PM ...

Page 117: ... and then tighten them to the specified torque EBU07071 Differential gear oil replacement 1 Place the ATV on a level place 2 Remove the differential gear case cover by removing the bolts 1 Bolt 2 Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 19 L 0 17 Imp qt 0 20 US qt Tightening torque Final gear case cover bolt 25 Nm 2 5 m kgf 18 ft lbf U2D410 book Page 13 Thursday April 1 2004 ...

Page 118: ... Bolt 4 3 Place a container under the differential gear case 4 Remove the filler bolt and drain bolt to drain the oil 1 Differential case oil filler bolt U2D410 book Page 14 Thursday April 1 2004 1 59 PM ...

Page 119: ...er bolt and tighten to specifi cation 8 Check for oil leakage If oil leakage is Tightening torque Differential gear oil drain bolt 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 0 18 L 0 16 Imp qt 0 19 US qt Tightening torque Differential gear oil filler bolt 12 Nm 1 2 m kgf 8 7 ft lbf U2D410 book Page 15 Th...

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 U2D410 book Page 16 Thursday April 1 2004 1 59 PM ...

Page 121: ... periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes ex cessive you should replace the spark plug with one of the proper type Before installing the spark plug measure the electrode gap with a wire thickness gauge and adjust it to specification a Spark plug gap When installing the spark plug a...

Page 122: ...ase If dust or water collects in this hose empty the hose and clean the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seat See page 4 14 for 1 Air filter case cover 2 Screw 5 3 Remove the air filter element U2D410 book Page 18 Thursday April 1 2004 1 59 PM ...

Page 123: ...let it dry CAUTION _ Do not twist the air 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 U2D410 book Page 19 Thursday April 1 2004 1 59 PM ...

Page 124: ...0 hours It should be cleaned and lubri cated more often if the machine is operated in extremely dusty areas Each time air filter ele ment maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber joint to the carburetor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air e...

Page 125: ...lpipe 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 Tailpipe 2 Spark arrester 5 Install and tighten the bolt U2D410 book Page 21 Thursday April 1 2004 1 59 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: ... and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction a to increase the engine speed and in direc tion b to decrease the engine speed 1 Throttle stop screw EBU00303 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clear ance must be ...

Page 128: ...y This adjustment however should be left to a Yamaha dealer 1 Locknut 2 Adjusting nut 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 U2D410 book Page 24 Thursday April 1 2004 1 59 PM ...

Page 129: ...ickness is less than 1 mm 0 04 in have a Yamaha dealer re place the brake pads as a set Rear brake pads Each rear brake pad is provided with a wear indicator groove which allows you to check the brake pad wear without having to disas semble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disappeare...

Page 130: ... worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage 1 Minimum level mark Observe these precautions When checking the brake fluid level make sure the top of the brake fluid reservoir is level Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and po...

Page 131: ...ac es or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer check the cause if the brake fluid level goes down EBU11860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel Have a Yamaha dealer replace the following EBU11870 Front brake lever free play The front brake lever should have a free play of zero mm zero in at...

Page 132: ...ould 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 U2D410 book Page 28 Thursday April 1 2004 1 59 PM ...

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 U2D410 book Page 29 Thursday April 1 2004 1 59 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: ...oting parts of each lever and pedal EBU01112 Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil Recommended lubricant Lithium soap based grease all purpose grease U2D410 book Page 33 Thursday April 1 2004 1 59 PM ...

Page 138: ...pered side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel _ 1 Arrow mark 2 Lower the ATV so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf U2D410 book Page 34 Thursday April 1 2004 1 59 PM ...

Page 139: ... 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 U2D410 book Page 35...

Page 140: ...RNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flames cig arettes or other sources of ignition Ven tilate when charging or using in a closed space U2D410 book Page 36 Thursday April 1 2004 1 59 PM ...

Page 141: ...the upper and lower level marks Use only distilled water if refilling is necessary 1 Maximum level mark 2 Minimum level mark 1 Bolt 2 2 Negative lead 3 Positive lead 3 Disconnect the positive lead 4 Remove the battery bracket bolts brack et and battery CAUTION Normal tap water contains minerals which are harmful to a battery Therefore refill U2D410 book Page 37 Thursday April 1 2004 1 59 PM ...

Page 142: ...ery 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 and is not damaged or obstructed U2D410 book Page 38 Thursday April 1 2004 1 59 PM ...

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: ...emove 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 Headlight bulb holder cover 2 Headlight bulb holder 3 Reflector U2D410 book Page 40 Thursday April 1 2004 1 59 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: ...her with the wash ers 1 Storage box 2 Nut 2 3 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Tail brake light bulb holder 4 Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise U2D410 book Page 42 Thursday April 1 2004 1 59 PM ...

Page 147: ...el compression 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 ...

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 U2D410 book Page 44 Thursday April 1 2004 1 59 PM ...

Page 149: ...ere is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap or replace the spark plug No spark 4 Battery Engine turns over Check the fu...

Page 150: ... to the wheel axles 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 e...

Page 151: ...int or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings U2D410 ...

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 seve ral 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 U2D410 book Page 4 Thursday April 1 2004 1 59 PM ...

Page 154: ...50 mm 45 3 in 790 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 U2D410 book P...

Page 155: ... 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION In order to prevent clutch slippage since the 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 U2D410 book Page 2 Thursday ...

Page 156: ...nt 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 Type manufacturer Spark plug gap DR8EA NGK 0 6 0 7 mm 0 024 0 028 in Clutch type Wet centrifugal automatic MODEL YFM350FX U2D410 book Page 3 Thursday April 1 2004 1 59 PM ...

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 U2D410 book Page 4 Thursday April 1 2004 1 59 PM ...

Page 158: ...ar wheel travel 180 mm 7 1 in 180 mm 7 1 in Electrical Ignition system Generator system Battery type voltage capacity DC C D I A C magneto GM12CZ 4A 2 12V 12Ah Headlight type Krypton bulb Bulb voltage wattage quantity Headlight Tail brake light Indicator light Neutral Reverse Oil temparature 12V 30W 30W 2 12V 5W 21W 1 12V 1 7W 1 12V 1 7W 1 12V 1 7W 1 MODEL YFM350FX U2D410 book Page 5 Thursday Apri...

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: ...e minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 06E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 200 750 75 6 2 400 1 500 150 12 4 800 3 000 300 18 7 200 4 500 450 24 9 600 6 000 600 30 12 000 7 500 750 36 14 400 9 000 900 42 16 800 10 500 1 050 48 19 200 12 000 1 2...

Page 161: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U2D410 book Page 1 Thursday April 1 2004 1 59 PM ...

Page 162: ...1 2 3 4 5 6 7 8 9 10 9 9 13 E 13 fm Page 2 Thursday April 1 2004 2 49 PM ...

Page 163: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S U2D410 book Page 1 Thursday April 1 2004 1 59 PM ...

Page 164: ...1 2 3 4 5 6 7 8 9 10 9 9 9 U2D410 book Page 2 Thursday April 1 2004 1 59 PM ...

Page 165: ...EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death U2D410 book Page 3 Thursday April 1 2004 1 59 PM ...

Page 166: ...EBU00437 U2D410 book Page 5 Thursday April 1 2004 1 59 PM ...

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