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Yamaha GRIZZLY 350 YFM35FGW Owner's Manual
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Yamaha GRIZZLY 350 YFM35FGW Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM35FGW
5UH-F8199-63

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Summary of Contents for Yamaha GRIZZLY 350 YFM35FGW

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM35FGW 5UH-F8199-63...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2006.05-0.3×1 CR (E,F,S)
  • Page 3 OWNER’S MANUAL YFM35FGW 5UH-F8199-63-E0...

  • Page 4: Ec Declaration Of Conformity

    EC Declaration of Conformity conforming to Directive 98/37/EC YAMAHA MOTOR EUROPE N.V., (Name of supplier) Koolhovenlaan 101, 1119 NC Schiphol-Rijk, The Netherlands, representing YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA, Newnan, Georgia, U.S.A., declare in sole responsibility, that the product YFM350FWA (5Y4AH13W050500001~) (Make, model)
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or...
  • Page 7 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Fuel ............4-10 Fuel cock ..........4-12 LOCATION OF THE WARNING AND Starter (choke) ..........4-13 SPECIFICATION LABELS ......2-1 Seat ............4-13 Storage compartment .......4-14 DESCRIPTION ..........3-1 Front carrier ..........4-15 Left view ............3-1 Rear carrier ..........4-15 Right view............
  • Page 9 Instruments, lights and switches ....5-7 PERIODIC MAINTENANCE AND MINOR REPAIR ............8-1 OPERATION ..........6-1 Owner’s manual and tool kit .......8-1 Starting a cold engine ........ 6-1 Periodic maintenance and lubrication Starting a warm engine ......6-3 chart ............8-3 Operating the drive select lever and Removing and installing the panel ....8-8 driving in reverse ........
  • Page 10 Adjusting the brake pedal and rear CLEANING AND STORAGE ......9-1 brake lever free play ....... 8-29 Cleaning ............9-1 Axle boots ..........8-32 Storage ............9-2 Brake light switches ......... 8-32 Checking and lubricating the cables ..8-33 SPECIFICATIONS ........10-1 Checking and lubricating the front and rear brake levers ........

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION EBU17562 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 12 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 13 roll backwards, follow the special procedure for Always be sure there are no obstacles or people braking described in this manual. Dismount on behind you when you operate in reverse. When the uphill side or to a side if pointed straight up- it is safe to proceed in reverse, go slowly.
  • Page 14 nition such as the pilot lights of water heat- EWB00070 WARNING ers and clothes dryers. Gasoline can catch fire and you could be burned. Always operate your ATV in an area with ade- When transporting the ATV in another vehi- quate ventilation.

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. For Europe and Oceania...
  • Page 17 For Europe...
  • Page 18 For Europe...
  • Page 19 For Oceania...
  • Page 20 For Oceania...

  • Page 21: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Fuel cock 1. Rear shock absorber assembly spring preload adjusting ring 2. Throttle stop screw 2. Spark arrester 3. Air filter case 3. Storage compartment and tool kit 4. Fuses 4. Spark plug 5.

  • Page 22: Controls And Instruments

    EBU17712 NOTE: Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Parking brake lock plate 5. Horn switch 6. Drive select lever 7.

  • Page 23: Instrument And Control Functions

    EBU17730 INSTRUMENT AND CONTROL FUNCTIONS EBU17770 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights, meter lighting and taillight come on when the light switch is on, and the engine can be started.

  • Page 24: Indicator Lights And Warning Light

    1. Reverse indicator light “REVERSE” cool. If the warning light stays on when the engine 2. Neutral indicator light “NEUTRAL” is cool, have a Yamaha dealer check the electrical 3. On-Command four-wheel-drive indicator light “ ” 4. Oil temperature warning light “...

  • Page 25: Speedometer

    EBU17952 On-Command four-wheel-drive indicator light “ ” This indicator light comes on when the On-Com- mand four-wheel-drive switch is set to the “4WD” position. NOTE: Due to the synchronizing mechanism in the differ- ential gear case, the light may not come on until the ATV starts moving.

  • Page 26: Handlebar Switches

    EBU18060 EBU18100 Handlebar switches Start switch “ ” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18160 Light switch “ /OFF” Set this switch to “ ”...
  • Page 27 EBU18170 Horn switch “ ” Press the switch to sound the horn. EBU18211 On-Command four-wheel-drive switch “2WD”/“4WD” This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice-versa. Select the appropriate drive according to the ter- rain and the conditions.

  • Page 28: Throttle Lever

    Correct the problem be- the throttle lever. fore riding the ATV or consult a Yamaha dealer. EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 29: Front Brake Lever

    EBU18391 Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip. 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in) 3.

  • Page 30: Parking Brake

    EBU18460 Parking brake Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. 1.

  • Page 31: Drive Select Lever

    Always be sure you have released the park- ing brake before you begin to ride. The brake could overheat if you ride the ATV without re- leasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely.

  • Page 32: Fuel Tank Cap

    1. Recoil starter 1. Fuel tank cap EWB00340 EBU18750 WARNING Fuel Shift the drive select lever into the neutral po- Make sure that there is sufficient fuel in the tank. sition and apply the parking brake before start- Fill the fuel tank to the bottom of the filler tube as ing the engine, otherwise the ATV could start shown.
  • Page 33 NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade. ECB00070 CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

  • Page 34: Fuel Cock

    EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car- buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel flows to the carburetor.

  • Page 35: Starter (Choke)

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Arrow mark pointing to “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 36: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18911 Storage compartment Insert the projections on the front of the seat into ECB00130 the seat holders and push down on the seat at the CAUTION: rear.

  • Page 37: Front Carrier

    1. Storage compartment 1. Storage compartment check hose Do not exceed the load limit of 2.0 kg (4 lb) EBU18960 Front carrier for the storage compartment. Do not exceed the maximum load of 210.0 kg Do not exceed the load limit of 40.0 kg (88 lb) for (463 lb) for the ATV.

  • Page 38: Adjusting The Front Shock Absorber Assemblies

    EBU18990 NOTE: Adjusting the front shock absorber as- A special wrench can be obtained at a Yamaha semblies dealer to make this adjustment. The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Adjust the spring preload as follows.

  • Page 39: Adjusting The Rear Shock Absorber Assembly

    Adjust the spring preload as follows. NOTE: Turn the adjusting ring in direction (a) to increase A special wrench can be obtained at a Yamaha the spring preload and thereby harden the suspen- dealer to make this adjustment. sion, and in direction (b) to decrease the spring preload and thereby soften the suspension.
  • Page 40 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): 4-18...

  • Page 41: Pre-Operation Checks

    Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 42 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary. 5-4, 8-25 • Check cable free play, and adjust if necessary. Control cables • Make sure that operation is smooth. Lubricate if necessary. 8-33 •...

  • Page 43: Fuel

    Check that there is no free play in the front brake Be careful not to spill fuel, especially on the lever. If there is free play, have a Yamaha dealer engine or exhaust pipe which can cause a check the brake system.

  • Page 44: Throttle Lever

    Apply the brake firmly for one minute. If the when released. Have a Yamaha dealer correct if lever moves slowly inward, there may be a leak in necessary.

  • Page 45: Measuring The Tire Pressure

    Type: Minimum tire pressure: Tubeless Front: Rear: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Manufacturer/model: Rear: CHENG SHIN/C-828 (AUS)(NZL) 22.0 kPa (3.2 psi) (0.220 kgf/cm²) MAXXIS/M980 (EUR)(GBR) • Use no more than the following pressures Size: when seating the tire beads. AT25 x 10-12 Maximum tire seating pressure: Type:...

  • Page 46: Tire Wear Limit

    Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Low-pressure tire gauge Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Set the tire pressure when the tires are cold.

  • Page 47: Chassis Fasteners

    1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.

  • Page 48: Operation

    4. Shift the drive select lever into the neutral po- accident or injury. If there is a control or func- sition. The neutral indicator light should come tion you do not understand, ask your Yamaha on. If the indicator light does not come on, dealer.
  • Page 49 5. Use the starter (choke) in reference to the fig- 6. Completely close the throttle lever and start ure: the engine by pushing the start switch. Position (1): NOTE: Cold engine start with ambient temperature If the engine fails to start, release the start below 5 °C (40 °F).

  • Page 50: Starting A Warm Engine

    NOTE: NOTE: The engine is warm when it responds normally to Make sure that the drive select lever is completely the throttle with the starter (choke) turned off. shifted into position. EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm.

  • Page 51: Engine Break-In

    If the indicator light does not come on, resulting in serious injury. When you shift into have a Yamaha dealer check the electrical circuit. reverse, make sure there are no people or ob- stacles behind you. When it is safe to proceed, go slowly.

  • Page 52: Parking

    If any engine trouble should occur during the EWB00830 engine break-in period, immediately have a WARNING Yamaha dealer check the ATV. Avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the EBU20700...

  • Page 53: Accessories And Loading

    ATV. Your Yamaha dealer has a variety of gen- uine Yamaha accessories. Other accessories may also be available on the market. However, it is not possible for Yamaha to test all non- Yamaha accessories, nor control over their qual- ity or suitability. Choose a genuine Yamaha ac- cessory, or one that is equivalent in design and quality.
  • Page 54 could make steering difficult, an accessory that MAXIMUM LOADING LIMIT limits your ability to move around on the seat, or ATV loading limit (total weight of rider, cargo, one that limits your view. accessories, and tongue): Use extra caution when riding an ATV with ac- 210.0 kg (463 lb) cessories.
  • Page 55 Load cargo on the carriers as close to the center curely attached. Reduce speed when carrying of the ATV as possible. Put cargo at the rear of cargo or pulling a trailer. Allow greater dis- the front carrier, at the front of the rear carrier, tance for braking.

  • Page 56: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 57: Getting To Know Your Atv

    EBU21461 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV Beginners should get training from a certified in- This ATV is for recreation and utility use. This sec- structor. tion, Riding your ATV, provides general ATV riding Become familiar with this ATV at slow speeds first, instructions for recreational riding.
  • Page 58 Not recommended for children under 16 years This ATV is designed to carry operator and car- of age. go only – passengers prohibited. EWB01390 EWB01400 WARNING WARNING A child under 16 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 90 cc.
  • Page 59 Apparel Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet...
  • Page 60 EWB01410 WARNING Never operate this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 61 in the Owner’s Manual. Failure to inspect the Speed limiter ATV before operating or failure to properly For riders less experienced with this model, the maintain the ATV increases the possibility of throttle lever housing is equipped with a speed lim- an accident or equipment damage.
  • Page 62 Loading and accessories EWB01460 WARNING Use extra caution when riding the ATV with addi- tional loads, such as accessories or cargo. The Never exceed the stated load capacity for ATV’s handling may be adversely affected. Re- this ATV. duce your speed when adding additional loads. Cargo should be properly distributed and se- curely attached.
  • Page 63 All parts and tact with the rear wheels, which could injure accessories added to this ATV should be gen- you or cause an accident. uine Yamaha or equivalent components de- signed for use on this ATV and should be...

  • Page 64: Be Careful Where You Ride

    installed and used according to instructions. Improper installation of accessories or modifi- cation of this ATV may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized ATV dealer. Exhaust system The exhaust system on the ATV is very hot during and following operation.
  • Page 65 EWB01520 WARNING Never operate this ATV on any paved street, paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. While riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles.
  • Page 66 EWB01530 ATV on such terrain. Failure to use extra care WARNING when operating on excessively rough, slippery or loose terrain could cause loss of traction or Go slowly and be extra careful when operating ATV control, which could result in an accident, on unfamiliar terrain.
  • Page 67 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice EWB01550 control of the throttle, brakes, and turning tech- WARNING niques in this area before trying more difficult ter- Always mount a caution flag on the ATV to rain.

  • Page 68: Turning Your Atv

    With the engine idling, return the starter (choke) to EWB01570 WARNING the closed position, shift the drive select lever into the forward position, and then release the parking Always follow proper procedures for turning brake. Apply the throttle slowly and smoothly. The as described in this Owner’s Manual.

  • Page 69: Climbing Uphill

    Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, 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 inside.
  • Page 70 EWB01580 Never go over the top of any hill at high WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never operate the ATV on hills too steep for the of the hill. ATV or for your abilities.
  • Page 71 EWB01600 WARNING Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.

  • Page 72: Riding Downhill

    ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediately on the uphill side. EWB01791 WARNING Maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.

  • Page 73: Crossing A Slope

    When this ATV is in 4WD, all wheels (front and Avoid going down a hill at an angle that rear) are interconnected by the drive train. This would cause the ATV to lean sharply to one means that applying either the front brake or the side.

  • Page 74: Crossing Through Shallow Water

    to cross a sloping surface. Avoid slopes with slip- Shift your weight to the uphill side of the pery surfaces or rough terrain that may upset your ATV. balance. As you travel across a slope, lean your body in the uphill direction.
  • Page 75 EWB01640 Test your brakes after leaving the water. Do not WARNING continue to ride your ATV without verifying that you have regained proper braking ability. Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual.
  • Page 76 plug to drain any water that may have accumu- lated. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. 1. V-belt cooling duct check hose (left front side of ATV) 1. Air filter case check hose 1.

  • Page 77: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times.
  • Page 78 If the rear wheels of your ATV start to slide side- ways, control can usually be regained (if there is With practice, over a period of time, skill at con- room to do so) by steering in the direction of the trolled sliding can be developed.

  • Page 79: What To Do If

    On extremely slippery surfaces, such as ice, If your ATV can’t make it up a hill you are trying go slowly and be very cautious in order to re- to climb: duce the chance of skidding or sliding out of Turn the ATV around if you still have forward control.

  • Page 80: Periodic Maintenance And Minor Repair

    EBU21652 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21670 otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with Safety is an obligation of the owner. Periodic in- maintenance work. spection, adjustment and lubrication will keep your...
  • Page 81 NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING Never modify this ATV through improper in-...

  • Page 82: Periodic Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 83 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours • Check operation and correct if necessary. √ √ √ √ √ • Check brake lever and pedal free play, and adjust Rear brake if necessary.
  • Page 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Shock absorber as- • Check operation and correct if necessary. √ √ √ semblies • Check for oil leakage and replace if necessary. √...
  • Page 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours • Change. √ √ Final gear oil • Check ATV for oil leakage, and correct if neces- sary. Moving parts and √...
  • Page 86 EBU23070 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 87: Removing And Installing The Panel

    EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 1. Panel A 2.
  • Page 88 Do not kit. attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 89: Engine Oil And Oil Filter Cartridge

    3. Install the spark plug with the spark plug Specified spark plug: wrench, and then tighten it to the specified NGK/DR8EA torque. To install the spark plug Tightening torque: 1. Measure the spark plug gap with a wire thick- Spark plug: ness gauge and, if necessary, adjust the gap 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) to specification.
  • Page 90 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Wait a few minutes until the oil settles before checking. 4. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. 1.
  • Page 91 To change the engine oil (with or without oil fil- 5. Remove the oil filter cartridge with an oil filter ter cartridge replacement) wrench. 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 92 NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 6. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure that the O-ring is properly seated. 1. Torque wrench...

  • Page 93: Final Gear Oil

    If any leakage is found, have Without oil filter cartridge replacement: a Yamaha dealer check and repair the ATV. In ad- 2.20 L (2.33 US qt) (1.94 Imp.qt) dition, the final gear oil level must be checked and...
  • Page 94 To change the final gear oil 1. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil 2. Final gear oil filler bolt 3. Correct oil level 1. Final gear case guard 3. If the oil is below the brim of the filler hole, add 2.
  • Page 95 1. Final gear oil drain bolt 1. Final gear oil 2. Final gear oil filler bolt 5. Install the drain bolt, and then tighten it to the 3. Correct oil level specified torque. Recommended final gear oil: Tightening torque: See page 10-1. Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) ECB00420...

  • Page 96: Changing The Differential Gear Oil

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 97 The differential gear case capacity is greater than the recommended oil quantity, therefore the oil level cannot be accurately checked from the oil filler hole. Recommended differential gear oil: See page 10-1. Oil quantity: 0.35 L (0.37 US qt) (0.31 Imp.qt) ECB00410 CAUTION: 1.

  • Page 98: Cleaning The Air Filter Element

    EBU23640 2. Remove the air filter case cover by unhooking Cleaning the air filter element the holders. The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas.
  • Page 99 1. Air filter element 1. Air filter element frame 2. Sponge material 4. Pull off the lock plate, and then remove the 3. Air filter element lock plate sponge material from the air filter element 5. Wash the sponge material gently but thor- frame.

  • Page 100: Cleaning The Spark Arrester

    ECB00440 manifold fittings for an air-tight seal. Tighten all fit- CAUTION: tings securely to avoid the possibility of unfiltered air entering the engine. Do not twist the sponge material when squeez- ing it. ECB00460 CAUTION: 7. Check the sponge material and replace it if damaged.
  • Page 101 1. Bolt 1. Tailpipe 2. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 4. Insert the tailpipe into the muffler and align the muffler. bolt holes. 3. Tap the tailpipe lightly, and then use a wire 5.

  • Page 102: V-Belt Cooling Duct Check Hose

    If water drains from the V-belt case after removing be performed by the owner as part of routine main- the plug, have a Yamaha dealer check the ATV as tenance. the water may affect other engine parts.

  • Page 103: Adjusting The Engine Idling Speed

    NOTE: NOTE: If the specified idling speed cannot be obtained as The engine is warm when it quickly responds to the described above, have a Yamaha dealer make the throttle. adjustment. 2. Attach the tachometer to the spark plug lead.

  • Page 104: Adjusting The Throttle Cable Free Play

    The valve clearance changes with use, resulting in bolt in direction (b). improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. 8-25...

  • Page 105: Adjusting The Drive Select Lever Safety System Cable

    1.0 mm The rear brake is provided with a wear indicator, (0.04 in), have a Yamaha dealer replace the brake which allows you to check the brake shoe wear pads as a set.

  • Page 106: Checking The Brake Fluid Level

    Yamaha dealer replace the brake shoes as a set. pads for wear and the brake system for leakage. 1. Wear limit line 1.

  • Page 107: Changing The Brake Fluid

    Water will signifi- free play of zero mm (zero in) as shown. If the free cantly lower the boiling point of the fluid and may play is incorrect, have a Yamaha dealer check the result in vapor lock. brake system.

  • Page 108: Adjusting The Brake Pedal And Rear Brake Lever Free Play

    Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24511 Adjusting the brake pedal and rear brake lever free play...
  • Page 109 1. Brake pedal free play adjusting nut 1. Brake lever free play 2. Brake lever free play adjusting nut 2. Locknut 3. Brake lever free play adjusting bolt Adjusting the brake lever free play 1. Loosen the locknut at the brake lever and fully The brake lever free play should measure 3.0–5.0 turn in the brake lever free play adjusting bolt.
  • Page 110 1. Brake lever free play adjusting nut 1. Locknut 2. Gap “A” 2. Brake lever free play adjusting bolt 3. Turn the brake lever free play adjusting bolt at 4. Tighten the locknut at the brake lever. the brake lever in direction (a) to increase the NOTE: free play, and in direction (b) to decrease it.

  • Page 111: Axle Boots

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light EBU24230 switches should be adjusted by a Yamaha dealer. Axle boots 1. Remove panel A. (See page 8-8.) The axle boots must be checked for damage at the...

  • Page 112: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil 8-33...

  • Page 113: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel bearings. NOTE: To access the brake pedal pivot, remove panel A.

  • Page 114: Lubricating The Upper And Lower Arm Pivots

    EBU25100 Recommended lubricant: Lubricating the steering shaft Lithium-soap-based grease The steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- EBU25040 brication chart. Lubricating the upper and lower arm pivots Recommended lubricant: The upper and lower arm pivots must be lubricated Lithium-soap-based grease at the intervals specified in the periodic mainte- nance and lubrication chart.
  • Page 115 KEEP OUT OF REACH OF CHILDREN. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.

  • Page 116: Replacing A Fuse

    To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat- tery. 8-37...
  • Page 117 ECB00640 CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A 1. Headlight fuse Headlight fuse: 2.

  • Page 118: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Headlight bulb holder cover EBU26902 2. Disconnect the headlight coupler by lifting the Replacing a headlight bulb tab as shown and pulling out the coupler.
  • Page 119 3. Remove the headlight bulb holder assembly 4. Install a new headlight bulb holder assembly by turning it counterclockwise. by inserting it into the headlight unit and turn- ing it clockwise. 1. Headlight bulb holder assembly 1. Do not touch the glass part of the bulb. NOTE: ECB00650 The headlight bulb cannot be removed from the...

  • Page 120: Adjusting A Headlight Beam

    ECB00690 1. Headlight beam adjusting screw CAUTION: EBU25580 It is advisable to have a Yamaha dealer make Replacing the tail/brake light bulb this adjustment. If the tail/brake light bulb burns out, have a To raise a headlight beam, turn the adjusting Yamaha dealer replace it.

  • Page 121: Installing A Wheel

    Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Wheel nut 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 1.

  • Page 122: Troubleshooting

    The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- 1. Tapered nut rience, and know-how to service the ATV properly.

  • Page 123: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 124: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25880 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 125: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the brakes after washing. Apply the brakes several 2.
  • Page 126 c. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F)]. For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-35.

  • Page 127: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 1984 mm (78.1 in) Air cooled 4-stroke, SOHC Overall width: Cylinder arrangement: 1085 mm (42.7 in) Forward-inclined single cylinder Overall height: Displacement: 1120 mm (44.1 in) 348.0 cm³ (21.23 cu.in) Bore × stroke: Seat height: 83.0 ×...
  • Page 128 Engine oil: Differential gear oil: Type: Type: SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 SAE80 API GL-4 Hypoid gear oil or SAE20W40 or SAE20W50 Quantity: 0.35 L (0.37 US qt) (0.31 Imp.qt) Air filter: -20˚ -10˚ 0˚ 20˚ 30˚ 40˚ 50˚C 10˚...
  • Page 129 Transmission: Rear tire: Primary reduction system: Type: V-belt Tubeless Secondary reduction system: Size: Shaft drive AT25 x 10-12 Secondary reduction ratio: Manufacturer/model: 41/21 × 24/18 × 33/9 (9.545) CHENG SHIN/C-828 (AUS)(NZL) Transmission type: MAXXIS/M980 (EUR)(GBR) Loading: V-belt automatic Operation: Maximum loading limit: Left hand operation 210.0 kg (463 lb) Forward gear:...
  • Page 130 Rim size: Wheel travel: 12 x 6.0AT 180 mm (7.1 in) Rear wheel: Electrical system: Wheel type: Ignition system: Panel wheel DC. CDI Rim size: Charging system: 12 x 7.5AT AC magneto Front brake: Battery: Type: Model: Dual disc brake YTX14AH Operation: Voltage, capacity:...
  • Page 131 Fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Ignition fuse: 15.0 A Auxiliary DC jack fuse: 10.0 A Four-wheel-drive motor fuse: 3.0 A 10-5...

  • Page 132: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 133 EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 134 1. Model label 11-3...
  • Page 135 INDEX Drive select lever ............4-9 Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-6 Drive select lever safety system cable, adjusting ..8-26 Air filter element, cleaning ..........8-19 Drive shaft universal joint, lubricating ......8-34 Axle boots ..............
  • Page 136 Shock absorber assembly, adjusting the rear ....4-17 Spark arrester, cleaning ..........8-21 Key identification number ..........11-1 Spark plug, checking ............8-8 Knuckle shafts, lubricating ........... 8-35 Specifications ............... 10-1 Speed limiter ..............4-6 Label locations ............... 2-1 Speedometer ..............4-3 Light switch ..............
  • Page 138 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2006.05-0.3×1 CR...

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