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Yamaha GRIZZLY 350 YFM35FGDZ Owner's Manual
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Yamaha GRIZZLY 350 YFM35FGDZ Owner's Manual

Yamaha GRIZZLY 350 YFM35FGDZ Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
OWNER'S MANUAL
YFM35FGDZ
YFM35FWANZ
4S2-F8199-63

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Summary of Contents for Yamaha GRIZZLY 350 YFM35FGDZ

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM35FGDZ YFM35FWANZ 4S2-F8199-63...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2009.06-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35FGDZ YFM35FWANZ 4S2-F8199-63-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 98/37/EC, 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM350FWAN (YFM35FGD) (5Y4AH15W090502192–)
  • Page 5 Congratulations on your purchase of the Yamaha YFM35FGDZ/YFM35FWANZ. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting rac- ing 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 EBU17342 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: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 Please check your local riding laws and regulations before operating this ATV. EBU17410 YFM35FGDZ/YFM35FWANZ OWNER’S MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st edition, May 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel ............4-14 SPECIFICATION LABELS ......1-1 Fuel cock ..........4-15 Starter (choke) ..........4-17 SAFETY INFORMATION ......2-1 Seat ............4-17 Storage compartment .......4-18 DESCRIPTION ..........3-1 Front carrier ..........4-19 Left view ............3-1 Rear carrier ..........4-19 Right view............
  • Page 9 Operating the drive select lever and Periodic maintenance chart for driving in reverse ........6-3 the emission control system .....8-3 Engine break-in .......... 6-4 General maintenance and Parking ............6-5 lubrication chart ........8-5 Parking on a slope ........6-5 Removing and installing the panel ....8-9 Accessories and loading ......
  • Page 10 Adjusting the brake pedal and CLEANING AND STORAGE ......9-1 rear brake lever free play and Cleaning ............9-1 checking the brake pedal position ..8-32 Storage ............9-2 Axle boots ..........8-36 Brake light switches ......... 8-37 SPECIFICATIONS ........10-1 Checking and lubricating the cables ..8-37 Checking and lubricating the front and CONSUMER INFORMATION.......11-1 rear brake levers ........

  • Page 11: Location Of The Warning And Specification Labels

    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...
  • Page 12 < 40 kg ( 88 lbs) 37S-F817R-00 1P0-F816P-20 < 80 kg ( 176 lbs) 37S-F817R-10 25.0 kPa 25.0 kPa 0.25 kgf/cm² 0.25 kgf/cm² 3.6 psi 3.6 psi 5FU-F816M-M0...
  • Page 13 < 4900 N < 500 kgf < 1102 lbf < 147 N < 15 kgf < 33 lbf 4S2-F817S-00 1P0-F816R-00...
  • Page 14 37S-F816S-00 YEAR OF CONSTRUCTION : 2009 MODEL : YFM350FWAN YAMAHA MOTOR CO., LTD. MAX.POWER : 15.9 kW 2500 SHINGAI, IWATA, JAPAN MASS IN RUNNING ORDER : 275 kg 4S2-F155A-20 1P0-F816L-20...
  • Page 15 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
  • Page 16 NEVER use with drugs or alcohol. Adjust tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids. Turning 4WD-LOCK (“DIFF.LOCK”) takes more effort.
  • Page 17 This pictogram shows trailer Hitch Tow weight limit. (Combined weight of the trailer and all cargo in the trailer.) Overloading can cause loss of control. Loss of control can result in severe injury or death. This pictogram shows trailer Hitch Tongue weight limit.
  • Page 18 For Oceania...
  • Page 19 25 kPa, (3.6 psi) 25 kPa, (3.6 psi) 22 kPa, (3.2 psi) 22 kPa, (3.2 psi) MAXIMUM LOADING LIMIT PULLING LOAD: 4900 N (500 kgf) 1102 lbf TONGUE WEIGHT: 147 N ( 15 kgf) 33 lbf 5FU-F816M-20 5ND-F151K-00...
  • Page 20 1-10...

  • Page 21: Safety Information

    EBU17431 SAFETY INFORMATION EBU17563 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 22 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 23 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 24 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT.

  • Page 25: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 8 7 6 1. Fuel cock 1. Spark arrester 2. Throttle stop screw 2. Storage compartment and tool kit 3. Fuses 3. Air filter case 4. Battery 4. Spark plug 5. Rear shock absorber assembly spring preload adjusting 5.

  • Page 26: Controls And Instruments

    EBU17712 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 27: Instrument And Control Functions

    EBU17733 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 28: Indicator Lights And Warning Light

    EBU17814 Indicator lights and warning light If the indicator light flashes under any other circum- stances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. EBU17870 Neutral indicator light “NEUTRAL”...

  • Page 29: Speedometer

    ECB00010 NOTICE Due to the synchronizing mechanism in the differ- The engine may overheat if the ATV is over- ential gear case, the light may not come on until loaded. In this case, reduce the load to spec- the ATV starts moving. ification.

  • Page 30: Handlebar Switches

    EBU18061 Handlebar switches 1. Reset knob 2. Speedometer 3. Odometer 1. Light switch “ /OFF” 4. Tripmeter 2. Start switch “ ” 3. Engine stop switch “ ” 4. Override switch “OVERRIDE” 5. Horn switch “ ” EBU18080 Engine stop switch “ ”...
  • Page 31 EBU18101 EBU28510 Start switch “ ” Override switch “OVERRIDE” Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. EBU18161 Light switch “ /OFF” Set this switch to “ ”...
  • Page 32 EWB00150 handle differently. This could distract the oper- WARNING ator and increase the risk of losing control and of causing an accident. Always ride at a slow speed when the ATV is in four-wheel-drive differential gear lock, and al- This ATV is equipped with a switch to change from low extra time and distance for maneuvers.
  • Page 33 pectedly. This could distract the operator and increase the risk of losing control and causing an accident. EWB00140 WARNING Always ride at a slow speed when the ATV is in differential gear lock, and allow extra time and distance for maneuvers. All wheels turn at the same speed when the dif- ferential gear is locked, so it takes more effort to turn the ATV.
  • Page 34 “LOCK” (four-wheel drive with the differential gear locked): Power is supplied to the rear and front wheels and the differential gear is locked. Unlike in four-wheel drive, all wheels turn at the same speed. 1. Differential gear lock lever 2. On-Command four-wheel-drive switch “2WD”/“4WD” Stop the ATV, move the differential gear lock lever to position (a), and then push the differential gear lock switch in to the “LOCK”...

  • Page 35: Throttle Lever

    and hold the override switch to disable the differ- ential gear lock speed limiter. (See page 4-5 for a detailed explanation of this switch.) EBU18282 Throttle lever Once the engine is running, pushing the throttle le- ver will increase the engine speed. Regulate the speed of the ATV by varying the throttle position.

  • Page 36: Speed Limiter

    Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. EBU18323 Speed limiter Your ATV is equipped with an adjustable speed limiter.

  • Page 37: Brake Pedal And Rear Brake Lever

    1. Front brake lever 1. Brake pedal EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.

  • Page 38: Parking Brake

    EBU18460 Always be sure you have released the park- Parking brake ing brake before you begin to ride. The brake Use the parking brake before starting the engine or could overheat if you ride the ATV without re- parking the ATV, especially on a slope. Apply the leasing the parking brake.

  • Page 39: Recoil Starter

    1. Drive select lever 1. Recoil starter EWB00340 EBU18670 WARNING Recoil starter Shift the drive select lever into the neutral po- Firmly grasp the handle and pull slightly until en- sition and apply the parking brake before start- gagement can be felt. Then pull forcefully, being ing the engine, otherwise the ATV could start careful not to pull the rope all the way out.

  • Page 40: Fuel

    of sparks, open flames, or other sources of ig- nition such as the pilot lights of water heaters and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole.

  • Page 41: Fuel Cock

    3.3 L (0.87 US gal, 0.73 Imp.gal) rings, as well as to the exhaust system. 3. Wipe up any spilled fuel immediately. Your Yamaha engine has been designed to use NOTICE: Immediately wipe off spilled fuel regular unleaded gasoline with a research octane with a clean, dry, soft cloth, since fuel may number of 91 or higher.
  • Page 42 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 43: 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 44: Storage Compartment

    1. Seat 1. Projection 2. Seat lock lever 2. Seat holder To install the seat EBU18942 Storage compartment Insert the projections on the front of the seat into ECB00130 the seat holders and push down on the seat at the NOTICE rear.

  • Page 45: Front Carrier

    When storing any documents in the storage com- partment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartment. 1.

  • Page 46: Adjusting The Front And Rear Shock Absorber Assemblies

    2. Position indicator Adjust the spring preload as follows. Turn the spring preload adjusting ring in direction A special wrench can be obtained at a Yamaha (a) to increase the spring preload and thereby dealer to make this adjustment. harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension.
  • Page 47 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): 4-21...

  • Page 48: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 49 ITEM ROUTINE PAGE • Check operation, and correct if necessary. Rear brake • Lubricate cables if necessary. 5-3, 8-29, 8-32 • Check lever and pedal free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary.

  • Page 50: Fuel

    Front and rear brakes system should be checked by a Yamaha dealer. Brake levers and brake pedal Check that there is no free play in the front brake lever. If there is free play, have a Yamaha dealer check the brake system.

  • Page 51: Throttle Lever

    Check the operation of the throttle lever. It must 25.0 kPa (0.250 kgf/cm², 3.6 psi) open smoothly and spring back to the idle position Minimum tire pressure: when released. Have a Yamaha dealer correct if Front necessary. 22.0 kPa (0.220 kgf/cm², 3.2 psi)
  • Page 52 Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Manufacturing Corporation of America.

  • Page 53: Chassis Fasteners

    EBU19840 Front: Chassis fasteners Manufacturer/model: Make sure that all nuts, bolts and screws are prop- YFM35FGDZ MAXXIS/M979 erly tightened. YFM35FWANZ CHENG SHIN/C-828 Size: EBU19850 Instruments, lights and switches AT25 x 8-12 Type: Check that all instruments, lights and switches are Tubeless working properly.

  • Page 54: Operation

    Read the Owner’s Manual carefully before riding on. If the indicator light does not come on, the ATV. If there is a control or function you do not have a Yamaha dealer check the electrical cir- understand, ask your Yamaha dealer. cuit.
  • Page 55 Position (3): Cold engine start with ambient temperature If the engine fails to start, release the start above 25 °C (80 °F). switch, then push it again. Pause a few seconds Ambient temp./starter (choke) position before the next attempt. Each cranking should be as short as possible to preserve battery ener- gy.

  • Page 56: Starting A Warm Engine

    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. Instead, start the engine with the throttle slightly open. EBU20382 Operating the drive select lever and driving in reverse ECB00170...

  • Page 57: Engine Break-In

    If the indicator light does not come on, For ATVs equipped with an odometer or an hour have a Yamaha dealer check the electrical circuit. meter, follow the figures given in km (mi) or the figures given in hours.

  • Page 58: Parking

    If any engine trouble should occur during the EWB00831 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 EBU20701...

  • Page 59: Accessories And Loading

    Yamaha manufacture parts and acces- 4. Turn the fuel cock to “OFF”. sories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies pro- duce. Therefore, Yamaha can neither endorse nor...
  • Page 60 market products or having other modifications EBU21061 Loading performed to your ATV that change any of the ve- EWB00820 hicle’s design or operation characteristics can put WARNING you and others at greater risk of serious injury or Never exceed the stated load capacity for this death.
  • Page 61 Load cargo on the carriers as close to the center MAXIMUM LOADING LIMIT of the ATV as possible. Put cargo at the rear of ATV loading limit (total weight of rider, cargo, the front carrier, at the front of the rear carrier, accessories, and tongue): and center it.

  • Page 62: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 63: Getting To Know Your Atv

    EBU28505 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding Do not operate this ATV or allow anyone else instructions for recreational riding.
  • Page 64 Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
  • Page 65 Apparel Always wear the following to reduce risk of injury in an accident: Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 66 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 67 opening, even when the throttle lever is pushed to Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see box in this section or ve- the maximum engine power available and de- hicle labeling).
  • Page 68 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of cargo, rider, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 210.0 kg (463 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
  • Page 69 ATV should be during operation or after leaving the ATV, do not let genuine Yamaha or equivalent components de- brush, grass and other materials collect under the signed for use on this ATV and should be installed vehicle, near the muffler or exhaust pipe, or next to and used according to instructions.

  • Page 70: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 71 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do not ways be alert to changing terrain conditions ride on any paved public street, road or motorway. when operating the ATV.
  • Page 72 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 73: Turning Your Atv

    Select a large, flat, unpaved area to become famil- TURNING YOUR ATV iar with your ATV. Make sure that this area is free EWB01771 WARNING of obstacles and other riders. You should practice control of the throttle, brakes, and turning tech- Always follow proper procedures for turning niques in this area before trying more difficult ter- as described in this Owner’s Manual.

  • Page 74: 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 75 Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 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.
  • Page 76 Do not attempt to climb hills until you have mas- If you are climbing a hill and you find that you have tered basic maneuvers on flat ground. Always not properly judged your ability to make it to the check the terrain carefully before attempting any top, you should turn the ATV around while you still hill.

  • Page 77: Riding Downhill

    remount, following the procedure described in the Always check the terrain carefully before Owner’s Manual. WARNING! Stalling, rolling you start down any hill. backwards or improperly dismounting while Never operate the ATV on hills too steep for climbing a hill could result in ATV overturning. the ATV or for your abilities.

  • Page 78: Crossing A Slope

    Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this ATV is in “4WD”, all wheels (front and rear) are interconnected by the drive train.

  • Page 79: Crossing Through Shallow Water

    Shift your weight to the uphill side of the ATV. 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.
  • Page 80 The ATV can be used to cross slow moving, shal- ability. WARNING! Wet brakes may have re- low water of up to a maximum of 35 cm (14 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.
  • Page 81 1. Air filter case check hose 1. Drive select lever box check hose 1. V-belt cooling duct check hose (left front side of ATV) 1. Storage compartment check hose 7-20...

  • Page 82: Riding Over Rough Terrain

    cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may re- sult. SLIDING AND SKIDDING EWB01662 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 83: What To Do If

    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 84: What To Do

    WHAT TO DO... If your ATV is traversing a sloping surface: If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.

  • Page 85: Periodic Maintenance And Adjustment

    If you are not fa- EBU21731 miliar with vehicle service, have a Yamaha Owner’s manual and tool kit dealer perform the service. Be sure to put this owner’s manual in the plastic...
  • Page 86 However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

  • Page 87: Periodic Maintenance Chart For The Emission Control System

    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 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 89: General 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 90 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years •...
  • Page 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ 16 * Engine mount necessary. •...
  • Page 92 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. √ √ √ √ √ Lights and switches • Adjust headlight beams. EBU28391 Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle.

  • Page 93: 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 94 If the spark plug shows a distinctly different color, kit. the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-10...

  • Page 95: To Install The Spark Plug

    2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.

  • Page 96: Engine Oil And Oil Filter Cartridge

    EBU23318 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals spec- ified in the periodic maintenance and lubrication chart.
  • Page 97 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then re- move the engine oil drain bolt and the gasket to drain the oil from the crankcase.
  • Page 98 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. Make sure that the O-ring is properly seated. 1. Oil filter cartridge 1.
  • Page 99 9. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.20 L (2.33 US qt, 1.94 Imp.qt) With oil filter cartridge replacement: 2.30 L (2.43 US qt, 2.02 Imp.qt) 1.

  • Page 100: Final Gear Oil

    If any leakage is found, have 4. Correct oil level a Yamaha dealer check and repair the ATV. In ad- 3. If the oil is below the brim of the filler hole, add dition, the final gear oil level must be checked and...
  • Page 101 To change the final gear oil 1. Place the ATV on a level surface. 2. Remove the engine guard and the final gear case guard by removing the bolts. 1. Final gear oil drain bolt 2. O-ring 5. Install a new O-ring and the drain bolt, and then tighten the bolt to the specified torque.

  • Page 102: Differential Gear Oil

    If any leakage is found, However, when using this oil, noise from the final have a Yamaha dealer check and repair the ATV. gear case may occur when applying the rear In addition, the differential gear oil level must be brake.
  • Page 103 checked and the oil changed as follows at the in- 3. If the oil is below the brim of the filler hole, add tervals specified in the periodic maintenance and sufficient oil of the recommended type to raise lubrication chart. it to the correct level.
  • Page 104 1. Differential gear oil drain bolt 1. Differential gear oil filler bolt 2. Gasket 2. Gasket 3. Differential gear oil 4. Install a new gasket and the drain bolt, and 4. Correct oil level then tighten the bolt to the specified torque. Recommended differential gear oil: Tightening torque: See page 10-1.

  • Page 105: Cleaning The Air Filter Element

    8. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23646 Cleaning the air filter element The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart.
  • Page 106 1. Air filter case cover holder 1. Air filter element 2. Air filter case cover 5. Pull off the air filter element lock plate, and 4. Pull the air filter element out of the air filter then remove the sponge material from the air case.
  • Page 107 2. Sponge material damaged. 3. Air filter element lock plate 9. Apply Yamaha foam air filter oil or other qual- 6. Wash the sponge material gently but thor- ity foam air filter oil to the sponge material. oughly in solvent. WARNING! Always use...

  • Page 108: Cleaning The Spark Arrester

    case. Never operate the engine with the air filter element removed. This will allow un- filtered air to enter the engine, causing rap- id engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating.

  • Page 109: V-Belt Cooling Duct Check Hose

    EWB02340 WARNING Do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire. Always let the exhaust system cool prior to touching exhaust components.

  • Page 110: V-Belt Case Drain Plug

    If water drains from the V-belt case after removing most carburetor adjustments should be left to a the plug, have a Yamaha dealer check the ATV as Yamaha dealer, who has the necessary profes- the water may affect other engine parts.
  • Page 111 1450–1550 r/min tle stop screw in direction (a), and to decrease it, turn the screw in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 8-27...

  • Page 112: Adjusting The Throttle Cable Free Play

    (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.

  • Page 113: Adjusting The Drive Select Lever Safety System Cable

    Therefore, the safety system cable should be specified in the periodic maintenance and lubrica- checked and adjusted by a Yamaha dealer at the tion chart. intervals specified in the periodic maintenance and lubrication chart.

  • Page 114: Checking The Brake Fluid Level

    Yamaha dealer replace the brake friction plates as a set. 1. Brake pad 2. Lining thickness 1. Wear indicator The wheels need to be removed to check the 2. Wear limit mark brake pads.

  • Page 115: Changing The Brake Fluid

    Observe these precautions: Changing the brake fluid When checking the fluid level, make sure that Have a Yamaha dealer change the brake fluid at the top of the brake fluid reservoir is level. the intervals specified in the TIP after the periodic Use only the recommended quality brake fluid, maintenance and lubrication chart.

  • Page 116: Checking The Front Brake Lever Free Play

    The brake pedal and brake lever free play and the free play as shown. If there is free play, have a brake pedal position must be checked and, if nec- Yamaha dealer check the brake system. essary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 117 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 1. Brake pedal free play 1. Locknut 2. Brake lever free play adjusting bolt 2. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the final gear case.
  • Page 118 1. Brake lever free play adjusting nut 1. Brake pedal free play adjusting nut 2. Brake camshaft lever 3. Push the brake camshaft lever in direction (a) 3. Gap “A” until it stops [apply approximately 50 N (5.0 4. Push the brake camshaft lever in direction (a) kgf, 11.2 lbf) of force], and then turn the brake until it stops [apply approximately 50 N (5.0 pedal free play adjusting nut on the brake ca-...
  • Page 119 (a) to increase the free play, and in direction (b) to decrease it. Checking the brake pedal position The top of the brake pedal should be positioned 75.0–85.0 mm (2.95–3.35 in) above the footboard. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 8-35...

  • Page 120: Axle Boots

    The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart. Check the axle boots for tears or damage. If any damage is found, have them re- placed by a Yamaha dealer. 1. Rear axle boot (each side) 8-36...

  • Page 121: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. 1. Remove panel A. (See page 8-9.) 2. Turn the brake light switch adjusting nut while holding the brake light switch in place.

  • Page 122: Checking And Lubricating The Front And Rear Brake Levers

    EWB02581 Recommended lubricants: WARNING Front brake lever: Inspect cables frequently and replace if dam- Silicone grease aged. Corrosion can result when the cable Rear brake lever: sheaths become damaged, and cables can Lithium-soap-based grease also become frayed or kinked, which could restrict the operation of controls and lead to Front brake lever an accident or injury.

  • Page 123: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel hub bear- ings. To access the brake pedal pivot, remove panel A.

  • Page 124: Lubricating The Drive Shaft Universal Joint

    Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bush- es if necessary. EBU25051 Lubricating the rear knuckle pivots...

  • Page 125: Lubricating The Steering Shaft

    EBU25103 Lubricating the steering shaft Battery electrolyte is poisonous and danger- The steering shaft must be lubricated by a Yamaha ous, as it contains sulfuric acid, which can dealer at the intervals specified in the periodic cause severe burns. Avoid contact with skin, maintenance and lubrication chart.
  • Page 126 4. Pull the battery out of its compartment. [ECB01001] 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 127 If you do 2. Connect the positive battery lead first, then not have access to a constant-voltage battery connect the negative battery lead by installing charger, have a Yamaha dealer charge your their bolt. battery. To store the battery...

  • Page 128: Replacing A Fuse

    EBU25326 Replacing a fuse The main fuse and the fuse box are located under the seat. (See page 4-17.) 1. Headlight fuse 2. Ignition fuse 3. Auxiliary DC jack fuse (for optional auxiliary DC jack) 4. Four-wheel-drive motor fuse 5. Signaling system fuse 1.

  • Page 129: Replacing A Headlight Bulb

    Auxiliary DC jack fuse: 10.0 A 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. 8-45...
  • Page 130 4. Remove the burnt-out bulb by pulling it out. 5. Insert a new headlight bulb into the bulb hold- er by pushing it in. NOTICE: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.

  • Page 131: Adjusting A Headlight Beam

    8. Adjust the headlight beam if necessary. EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make 1. Headlight beam adjusting screw this adjustment. EBU25580 To raise a headlight beam, turn the headlight beam Replacing the tail/brake light bulb adjusting screw in direction (a).

  • Page 132: 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 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 1.

  • Page 133: 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 134: 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 135: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25881 tion of wheel bearings, brakes, transmis- Cleaning sion seals and electrical devices. Many Frequent, thorough cleaning of your ATV will not expensive repair bills have resulted from only enhance its appearance but will improve its improper high-pressure detergent applica- general performance and extend the useful life of tions such as those available in coin-oper-...

  • Page 136: Storage

    EBU25933 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inder, piston rings, etc.
  • Page 137 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.

  • Page 138: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 1995 mm (78.5 in) Air cooled 4-stroke, SOHC Overall width: Cylinder arrangement: 1095 mm (43.1 in) Forward-inclined single cylinder Overall height: Displacement: 1120 mm (44.1 in) 348 cm³ Bore × stroke: Seat height: 83.0 ×...
  • Page 139 SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- 0.50 L (0.53 US qt, 0.44 Imp.qt) Differential gear oil: Type: YFM35FGDZ Yamaha Friction Modified Shaft Drive Gear 50 ˚C Oil or SAE 80 API GL-4 Hypoid gear oil YFM35FWANZ Yamaha Friction Modified Shaft Drive SAE 5W-30 Gear Oil (Part No.: ACC-SHAFT-LU-00) or SAE 80 API...
  • Page 140 Clutch: Manufacturer/model: YFM35FGDZ MAXXIS/M979 Clutch type: YFM35FWANZ CHENG SHIN/C-828 Wet, centrifugal automatic Rear tire: Transmission: Type: Primary reduction system: Tubeless V-belt Size: Secondary reduction system: AT25 x 10-12 Shaft drive Manufacturer/model: Secondary reduction ratio: 41/21 × 24/18 × 33/9 (9.545) YFM35FGDZ MAXXIS/M980 YFM35FWANZ CHENG SHIN/C-828 Transmission type:...
  • Page 141 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: Right hand operation 12 V, 12.0 Ah Recommended fluid: Headlight: DOT 4...
  • Page 142 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: 10.0 A 10-5...

  • Page 143: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 144 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 145 1. Model label 11-3...
  • Page 146 INDEX Drive select lever ............4-12 Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-6 Drive select lever safety system cable, adjusting ..8-29 Air filter element, cleaning ..........8-21 Drive shaft universal joint, lubricating ......8-40 Axle boots ..............
  • Page 147 Seat ................4-17 Shock absorber assemblies, Key identification number ..........11-1 adjusting the front and rear ........4-20 Spark arrester, cleaning ..........8-24 Label locations ............... 1-1 Spark plug, checking ............. 8-9 Light switch ..............4-5 Specifications ............... 10-1 Speed limiter ..............4-10 Main switch ..............
  • Page 148 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2009.06-0.3×1 CR...

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