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Yamaha GRIZZLY 350 2016 Installation Manual
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Yamaha GRIZZLY 350 2016 Installation 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
YFM35GTXH
B14-F8199-63

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Summary of Contents for Yamaha GRIZZLY 350 2016

  • 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 YFM35GTXH B14-F8199-63...
  • Page 2 Original instructions Notice originale Manual original PRINTED IN USA 2016.08-0.3×1 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35GTXH WARNING This ATV should not be ridden by anyone under 16 years of age. B14-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 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM350A (YFM35GTX) (5Y4AH10W0G0517001–)
  • 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 EBU17331 IMPORTANT MANUAL INFORMATION EBU17343 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. EBU17411 YFM35GTXH OWNER’S MANUAL ©2016 by Yamaha Motor Co., Ltd. 1st edition, June 2016 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 8: Table Of Contents

    EBU17421 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel cock ..........4-10 SPECIFICATION LABELS ......1-1 Starter (choke) ......... 4-11 Seat ............4-12 SAFETY INFORMATION ........2-1 Storage compartment....... 4-13 Front carrier ..........4-14 DESCRIPTION..........3-1 Rear carrier ..........4-14 Left view............3-1 Adjusting the front shock absorber Right view............3-1 assemblies..........
  • Page 9 Operating the drive select lever and Periodic maintenance chart for the driving in reverse........6-3 emission control system......8-3 Engine break-in ........... 6-4 General maintenance and lubrication Parking ............6-5 chart............8-5 Parking on a slope ........6-6 Checking the spark plug......8-9 Accessories and loading......
  • Page 10 Checking and lubricating the cables..8-35 Checking and lubricating the front and rear brake levers ........8-35 Checking and lubricating the brake pedal ............8-36 Checking the wheel hub bearings.....8-36 Lubricating the steering shaft ....8-37 Battery............8-37 Replacing a fuse ........8-40 Replacing a headlight bulb .......8-42 Adjusting a headlight beam ......8-43 Replacing the tail/brake light bulb ....8-44 Removing a wheel........8-44...

  • 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 re- placement 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 4900 N < 500 kgf < 1102 lbf < 147 N <...
  • Page 13 YAMAHA 1HP-F811R-00 YFM350A 2016 15.9 kW YAMAHA MOTOR CO., LTD. 1P0-F816R-00 238 kg 2500 SHINGAI, IWATA, JAPAN B14-F155A-30...
  • Page 14 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 use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
  • Page 15 This unit contains high-pressure nitrogen Turning 4WD-LOCK gas. (“DIFF.LOCK”) takes more effort. Operate at a slow speed and allow extra Mishandling can cause an explosion. Do not incinerate, puncture or open. time and distance for maneuvers to avoid loss of control. This pictogram shows the loading limits and/or maximum load capacity for this ATV.
  • Page 16 Year of construction Model Name ****** **** *** kW YAMAHA MOTOR CO., LTD. Max. Power *** kg 2500 SHINGAI, IWATA, JAPAN Mass In Running Order...
  • Page 17 For Oceania...
  • Page 18 LOAD LIMIT 40 kg{88 lbs} 5ND-F4877-20 LOAD LIMIT 25 kPa, (3.6 psi) 80 kg{176 lbs} 25 kPa, (3.6 psi) 22 kPa, (3.2 psi) 22 kPa, (3.2 psi) 5ND-F4897-20 MAXIMUM LOADING LIMIT PULLING LOAD: 4900 N (500 kgf) 1102 lbf 5FU-F816M-20 TONGUE WEIGHT: 147 N ( 15 kgf) 33 lbf...

  • Page 20: Safety Information

    EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Never allow a child under age 16 to operate an EBU17566 ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 21  Never operate at speeds too fast for your skills  Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 22  Never operate an ATV in fast flowing water or in technique described in this manual on level ground. Avoid crossing the side of a steep hill if water deeper than that recommended in this possible. manual. Remember that wet brakes may have ...
  • Page 23  Never maintain an ATV without proper knowl- vehicle. If the vehicle is in safe operating con- edge. Contact an authorized ATV dealer to in- dition and you can safely operate it, restart it form you on basic ATV maintenance. Certain and ride gently back to camp or other known maintenance can only be carried out by certified location where you can receive medical at-...
  • Page 24 While you may find aftermarket products similar in therefore, such accessories are not recom- design and quality to genuine Yamaha accesso- mended. ries, recognize that some aftermarket accessories  Use caution when adding electrical accesso- or modifications are not suitable because of po- ries.
  • Page 25  Do not run engine outdoors where engine EWB00073 WARNING exhaust can be drawn into a building through openings such as windows and doors. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, EWB02592 a deadly gas. Breathing carbon monoxide can WARNING cause headaches, dizziness, drowsiness, nau- When transporting the ATV in another vehicle,...

  • Page 26: Description

    EBU17681 DESCRIPTION EBU17691 EBU17701 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 3. Storage compartment and tool kit 4. Fuses 4. Fuel tank cap 5.

  • Page 27: Controls And Instruments

    EBU17714 Controls and instruments 2 3 4 5 6 9 10 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Parking brake lock plate 5. Horn switch 6. Drive select lever 7. Speedometer 8. Main switch 9. Throttle lever 10.Front brake lever The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 28: Instrument And Control Functions

    EBU17738 INSTRUMENT AND CONTROL FUNCTIONS EBU17771 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 29: Indicator Lights And Warning Light

    Yamaha dealer check the electrical circuit. If the warning light stays on when the engine is 1. Reverse indicator light “REVERSE” cool, have a Yamaha dealer check the electrical 2. Neutral indicator light “NEUTRAL” circuit. 3. Oil temperature warning light “...

  • Page 30: Speedometer

    EBU18024 EBU18066 Speedometer Handlebar switches This speedometer is equipped with an odometer and a tripmeter. The tripmeter can be reset to zero with the reset knob. Use the tripmeter to estimate how far you can ride on a tank of fuel before going to reserve.

  • Page 31: Throttle Lever

    EBU18102 EBU18283 Start switch “ ” Throttle lever Push this switch to crank the engine with the start- Once the engine is running, pushing the throttle le- er. See the starting instructions on page 6-1 prior ver will increase the engine speed. to starting the engine.

  • Page 32: Speed Limiter

    EBU18324 Speed limiter Your ATV is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 33: Brake Pedal And Rear Brake Lever

    1. Front brake lever 1. Brake pedal EBU18443 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 34: Parking Brake

     Always be sure you have released the park- EBU18462 Parking brake ing brake before you begin to ride. The brake Use the parking brake before starting the engine could overheat if you ride the ATV without re- or after parking the ATV, especially on a slope. Ap- leasing the parking brake.

  • Page 35: Fuel Tank Cap

    1. Drive select lever 1. Fuel tank cap EBU18721 EBU18757 Fuel tank cap Fuel Remove the fuel tank cap by turning it counter- Make sure there is sufficient gasoline in the tank. clockwise. EWB02522 WARNING Gasoline and gasoline vapors are extremely flammable.
  • Page 36 of sparks, open flames, or other sources of Recommended fuel: ignition such as the pilot lights of water heat- Regular unleaded gasoline only ers and clothes dryers. For Europe: Regular unleaded gasoline only 2. Do not overfill the fuel tank. When refueling, with a research octane number of 95 or be sure to insert the pump nozzle into the fuel higher...

  • Page 37: Fuel Cock

    Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane 1. Arrow mark pointing to “OFF”...

  • Page 38: Starter (Choke)

    1. Arrow mark pointing to “ON” 1. Arrow mark pointing to “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.

  • Page 39: Seat

    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. Seat 2. Seat lock lever To install the seat Insert the projections on the front of the seat into 1.

  • Page 40: Storage Compartment

    1. Projection 1. Storage compartment 2. Seat holder  Do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment. EBU18913 Storage compartment  Do not exceed the maximum load of 210.0 kg ECB00131 (463 lb) for the ATV. NOTICE Do not store metal or sharply edged objects, There is a check hose at the bottom of the storage...

  • Page 41: Front Carrier

    EBU18995 Adjusting the front shock absorber as- semblies The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. EWB00401 WARNING Always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident.

  • Page 42: Adjusting The Rear Shock Absorber Assembly

    1. Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: Maximum (hard): EBU19024 Adjusting the rear shock absorber as-...
  • Page 43 ECB01091 NOTICE A special wrench can be obtained at a Yamaha Never turn the adjusting mechanism beyond dealer to make this adjustment. the minimum and maximum settings. Adjust the spring preload as follows. Turn the spring preload adjusting ring in direction...

  • Page 44: 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 45 ITEM ROUTINE PAGE • Check operation, and correct if necessary. Rear brake • Lubricate cables if necessary. 5-3, 8-26, 8-29 • Check lever and pedal free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever Throttle lever housing if necessary.

  • Page 46: Fuel

    If there is any leakage, the brake  Check that there is no free play in the front system should be checked by a Yamaha dealer. brake lever. If there is free play, have a Yamaha dealer check the brake system. Brake operation ...

  • Page 47: 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 Rear when released. Have a Yamaha dealer correct if 25.0 kPa (0.250 kgf/cm², 3.6 psi) necessary. Minimum tire pressure:...
  • Page 48 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 49: Chassis Fasteners

    EBU19841 Front: Chassis fasteners Manufacturer/model: Make sure that all nuts, bolts and screws are CHENG SHIN/C828 (AUS, NZL) properly tightened. MAXXIS/MU13 (EUR, FRA, GBR) Size: EBU19851 Instruments, lights and switches AT25 x 8-12 Type: Check that all instruments, lights and switches are Tubeless working properly.

  • Page 50: 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 understand, ask your Yamaha dealer. circuit.
  • Page 51 Position (3): short as possible to preserve battery energy. Do Cold engine start with ambient temperature not crank the engine more than 10 seconds on above 25 °C (80 °F). each attempt. Ambient temp./starter (choke) position 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the en- gine.

  • Page 52: Starting A Warm Engine

    EBU20292 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. EBU20384 Operating the drive select lever and driving in reverse ECB00171...

  • Page 53: Engine Break-In

    When in reverse, the reverse indicator light should 1. Drive select lever come on. If the indicator light does not come on, 2. F (Forward) have a Yamaha dealer check the electrical circuit. 3. N (Neutral) 4. R (Reverse) 4. Check behind for people or obstacles, and then release the brake pedal.

  • Page 54: Parking

    There is never a more important period in the life engine break-in period, immediately have a of your engine than the first 320 km (200 mi) or 20 Yamaha dealer check the ATV. hours of riding. For this reason, you should read the following material carefully.

  • Page 55: Parking On A Slope

    4. Turn the fuel cock to “OFF”. Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket compa- nies produce. Therefore, Yamaha can neither en-...
  • Page 56 Yamaha or modifications not specifically bulky object attached to the handlebars which recommended by Yamaha, even if sold and in- could make steering difficult, an accessory that stalled by a Yamaha dealer. limits your ability to move around on the seat, or one that limits your view.
  • Page 57  Never exceed the weight limits shown. An over- the weight on the hitch. If you are carrying cargo loaded ATV can be unstable. and towing a trailer, include the tongue weight in the maximum ATV load limit.  Load cargo on the carriers as close to the center MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, car- of the ATV as possible.

  • Page 58: Riding Your Atv

    EBU21142 RIDING YOUR ATV...

  • Page 59: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EBU30902 Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01382 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 60 the time to learn the basic techniques well before This ATV is designed to carry the operator and attempting more difficult maneuvers. Become fa- cargo only – passengers prohibited. miliar with this ATV at slow speeds first, even if you The long seat is to allow the operator to shift posi- are an experienced operator.
  • Page 61 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 62 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 mainte- Do not operate after or while consuming alco- nance procedures and schedules described in the hol or drugs.
  • Page 63  Do not exceed the maximum loading limits fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting for the vehicle (see “MAXIMUM LOADING screw limits the maximum engine power available LIMIT” in this section or vehicle labeling). ...
  • Page 64 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during ATV loading limit (total weight of cargo, rid- operation; otherwise, they may contact the rear er, accessories, and tongue): wheels. WARNING! Removing even one hand or 210.0 kg (463 lb) foot can reduce your ability to control the ATV Front carrier: or could cause you to lose your balance and...
  • Page 65 ATV should during operation or after leaving the ATV, do not be genuine Yamaha or equivalent components let brush, grass and other materials collect under designed for use on this ATV and should be in- the vehicle, near the muffler or exhaust pipe, or stalled and used according to instructions.

  • Page 66: 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 67 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do ways be alert to changing terrain conditions not ride on any paved public street, road or motor- when operating the ATV.
  • Page 68 terrain could cause loss of traction or ATV con- trol, which could result in an accident, includ- ing an overturn. [EWB01542] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 69: 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 EWB01772 WARNING of obstacles and other riders. You should practice control of the throttle, brakes, and turning techni- Always follow proper procedures for turning as ques in this area before trying more difficult ter- described in this Owner’s Manual.

  • Page 70: Climbing Uphill

    Improper riding procedures such as abrupt throt- tle 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 be- gins to tip over to the outside while negotiating a turn, lean more to the inside.
  • Page 71  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 72 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 73: Riding Downhill

     Shift your weight backward and to the up side of the hill.  Never go down a hill at high speed.  Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side.

  • Page 74: Crossing A Slope

     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 75: Crossing Through Shallow Water

    The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
  • Page 76 braking ability. WARNING! Wet brakes may have reduced stopping ability, which could cause loss of control. [EWB02622] 1. Air filter case check hose 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, the V-belt cooling duct check hose and the storage compartment check hose.

  • Page 77: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN EWB01652 WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as lar- ge rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.
  • Page 78  Learn to safely control skidding or sliding by If the rear wheels of your ATV start to slide side- practicing at low speeds and on level, ways, control can usually be regained (if there is smooth terrain. room to do so) by steering in the direction of the ...

  • Page 79: What To Do If

    WHAT TO DO IF... USE THE REAR BRAKE – the ATV may tip over This section is designed to be a reference guide on top of you. Dismount the ATV on the uphill only. Be sure to read each section on riding tech- side.

  • Page 80: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 81: Owner's Manual And Tool Kit

    Put the owner’s tool kit and low-pres- If you do not have the tools or experience required sure tire gauge under the seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s manual 2.

  • Page 82: 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 still 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 1300 2500 2500 5000 km (mi) first (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 84: 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 still be followed.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses •...
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check operation and repair or replace if dam- √ √ √ √ √ Steering system aged. •...
  • Page 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. √ √ √ √ √ Lights and switches • Adjust headlight beams. EBU28392 ...

  • Page 88: Checking The Spark Plug

    2. Remove the spark plug as shown, with the EBU23214 Checking the spark plug spark plug wrench included in the owner’s The spark plug is an important engine component, tool kit. which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in ac- cordance with the periodic maintenance and lubri-...
  • Page 89 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 90: Engine Oil And Oil Filter Cartridge

    Tightening torque: Spark plug: If the engine was started before checking the oil 18 N·m (1.8 kgf·m, 13 lb·ft) level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. If a torque wrench is not available when installing 3.
  • Page 91 6. Check the O-ring for damage, and replace it if necessary. The engine oil should be between the tip of the 7. Insert the dipstick into the oil filler hole, and dipstick and the maximum level mark. then tighten the engine oil filler cap. To change the engine oil (with or without oil fil- ter cartridge replacement) 1.
  • Page 92 1. Engine oil drain bolt 1. Oil filter cartridge 2. Gasket Skip steps 5–7 if the oil filter cartridge is not being replaced. 5. Remove the oil filter cartridge with an oil filter wrench. 1. Oil filter wrench 8-13...
  • Page 93 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. Torque wrench Tightening torque: Oil filter cartridge: 17 N·m (1.7 kgf·m, 12 lb·ft)

  • Page 94: Final Gear Oil

    If any leakage is found, have NOTICE a Yamaha dealer check and repair the ATV. In ad-  In order to prevent clutch slippage (since the dition, the final gear oil level must be checked and...
  • Page 95 To change the final gear oil 1. Place the ATV on a level surface. 2. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil filler bolt 2. Gasket 3. Final gear oil 4. Correct oil level 1.
  • Page 96 1. Final gear oil drain bolt 1. Final gear oil filler bolt 2. Gasket 2. Gasket 3. Final gear oil 5. Install the drain bolt and its new gasket, and 4. Correct oil level then tighten the bolt to the specified torque. Recommended final gear oil: Tightening torque: See page 10-1.

  • Page 97: Cleaning The Air Filter Element

    9. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 10. Install the final gear case guard by installing the bolts and tightening them to the specified torque. Tightening torque: Final gear case guard bolt: 16 N·m (1.6 kgf·m, 12 lb·ft) EBU23647 Cleaning the air filter element...
  • Page 98 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 99 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 100: 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 rapid 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 101: V-Belt Cooling Duct Check Hose

    EWB02341 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 102: V-Belt Case Drain Plug

    If water drains from the V-belt case after removing fore, most carburetor adjustments should be left the plug, have a Yamaha dealer check the ATV as to a Yamaha dealer, who has the necessary pro- the water may affect other engine parts.

  • Page 103: Adjusting The Throttle Lever Free Play

    (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. EBU24048 Adjusting the throttle lever free play...

  • Page 104: Valve Clearance

    The valve clearance changes with use, resulting in 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 105: Adjusting The Drive Select Lever Safety System Cable

    Therefore, the safety system cable should be fied in the periodic maintenance and lubrication checked and adjusted by a Yamaha dealer at the chart. intervals specified in the periodic maintenance EBU24172 and lubrication chart.

  • Page 106: Checking The Brake Fluid Level

    Yamaha dealer replace the brake shoes as a set. 1. Brake pad 2. Lining thickness 1. Wear limit line The wheels need to be removed to check the 2.
  • Page 107 If the brake fluid level goes down sud- mance. denly, have a Yamaha dealer check the cause be-  Clean the filler cap before removing. Use fore further riding. only DOT 4 brake fluid from a sealed contain-...

  • Page 108: Changing The Brake Fluid

    EBU24283 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking.
  • Page 109  Before adjusting the brake pedal and brake le- ver free play, check the rear brake shoes for wear. Checking and adjusting the brake pedal height The top of the brake pedal should be positioned 72.0–82.0 mm (2.83–3.23 in) above the footboard bracket.
  • Page 110 1. Locknut 1. Footboard bolt A 2. Adjusting bolt 2. Footboard bolt B 4. Turn the adjusting bolt in or out until the brake Tightening torques: pedal height is within the specified limits. Footboard bolt A: 5. Tighten the locknut. 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) Footboard bolt B: Tightening torque:...
  • Page 111 1. Brake pedal free play 1. Brake pedal free play adjusting nut 2. Brake lever free play adjusting nut 1. Fully loosen the brake lever free play adjust- ing nut on the brake cable at the rear wheel Adjusting the brake lever free play hub.
  • Page 112 1. Brake lever free play 1. Brake lever free play adjusting nut 2. Locknut 2. Gap “A” 3. Brake lever free play adjusting bolt 3. Turn the brake lever free play adjusting bolt at 1. Loosen the locknut at the brake lever and fully the brake lever in direction (a) to increase the turn in the brake lever free play adjusting bolt.

  • Page 113: Brake Light Switches

    The rear 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. Turn the rear brake light switch adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a).

  • Page 114: Checking And Lubricating The Cables

    EBU28712 essary. If a cable is damaged or does not move Checking and lubricating the front and smoothly, have a Yamaha dealer check or replace rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever Recommended lubricant: pivots should be lubricated if necessary.

  • Page 115: Checking And Lubricating The Brake Pedal

    Front brake lever EBU28872 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease Rear brake lever EBU24964 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 116: Lubricating The Steering Shaft

    EBU2918A Battery ly, have a Yamaha dealer check the wheel hub The battery is located under the seat. (See page bearings. 4-12.) This model is equipped with a VRLA (Valve Regu- lated Lead Acid) battery.
  • Page 117 [ECB01002] 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 elec- trical accessories.
  • Page 118 2. Connect the positive battery lead first, then ECB00932 NOTICE connect the negative battery lead by installing their bolt. NOTICE: When installing the bat- To charge a VRLA (Valve Regulated Lead Acid) tery, the main switch must be off, and the battery, a special (constant-voltage) battery charger is required.

  • Page 119: Replacing A Fuse

    EBU30671 Replacing a fuse The main fuse and the fuse box are located under the seat. (See page 4-12.) 1. Headlight fuse 2. Ignition fuse 3. Signaling system fuse 4. Auxiliary DC jack fuse (for optional auxiliary DC jack) 5. Spare fuse 1.
  • Page 120 3. Turn the key to “ON” and turn on the electrical the main switch when checking or replacing a circuits to check if the devices operate. fuse. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 8-41...

  • Page 121: Replacing A Headlight Bulb

    EBU30662 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 1. Bulb cover 3. Remove the socket by pushing it in and turn- ing it counterclockwise.

  • Page 122: Adjusting A Headlight Beam

    ECB00691 cohol or thinner. [ECB00653] NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).

  • Page 123: Replacing The Tail/Brake Light Bulb

    Replacing the tail/brake light bulb under the frame. 4. Remove the nuts from the wheel. If the tail/brake light bulb burns out, have a 5. Remove the wheel. Yamaha dealer replace it. EBU25704 EBU25652 Installing a wheel Removing a wheel 1.
  • Page 124  Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Tapered nut 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques.

  • Page 125: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, ex- perience, and know-how to service the ATV prop- erly.

  • Page 126: Troubleshooting Chart

    Have a Yamaha dealer check the ATV. Check the compression. 4. Compression There is compression. The engine does not start. Have a Yamaha dealer check the ATV. Operate the electric starter. Have a Yamaha dealer check the ATV. There is no compression.

  • Page 127: Cleaning And Storage

    EBU25861 CLEANING AND STORAGE and deterioration of wheel bearings, EBU25882 Cleaning brakes, transmission seals and electrical Frequent, thorough cleaning of your ATV will not devices. Many expensive repair bills have only enhance its appearance but will improve its resulted from improper high-pressure de- general performance and extend the useful life of tergent applications such as those avail- many components.

  • Page 128: Storage

    EBU25934 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 129 tively, turn the wheels a little every month in order to prevent the tires from becoming de- graded 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 130: Specifications

    EBU25962 SPECIFICATIONS Dimensions: Vibration on handle (EN1032, ISO5008): 2.8 m/s² (EUR, FRA, GBR) Overall length: Uncertainty of measurement: 1984 mm (78.1 in) 0.7 m/s² (EUR, FRA, GBR) Overall width: Engine: 1085 mm (42.7 in) Overall height: Engine type: 1120 mm (44.1 in) Air cooled 4-stroke, SOHC Seat height: Cylinder arrangement:...
  • Page 131 2.30 L (2.43 US qt, 2.02 Imp.qt) Shaft drive Final gear oil: Secondary reduction ratio: Type: 41/21 × 24/18 × 33/9 (9.545) Yamaha Friction Modified Plus Shaft Drive Oil (Part No.: Transmission type: ACC-SHFTL-PL-32) or SAE 80 API GL-4 Hypoid gear oil V-belt automatic Quantity: Operation: 0.23 L (0.24 US qt, 0.20 Imp.qt)
  • Page 132 Forward gear: Tire air pressure (measured on cold tires): 35/20 (1.750) Recommended: Reverse gear: Front: 26/15 (1.733) 25.0 kPa (0.250 kgf/cm², 3.6 psi) Chassis: Rear: Frame type: 25.0 kPa (0.250 kgf/cm², 3.6 psi) Steel tube frame Minimum: Caster angle: Front: 4.00 °...
  • Page 133 Bulb voltage, wattage × quantity: Operation: Left hand and right foot operation Headlight: 12 V, 30.0/30.0 W × 2 Front suspension: Type: Tail/brake light: 12 V, 5.0/21.0 W × 1 Double wishbone Spring/shock absorber type: Meter lighting: 14 V, 3.0 W × 1 Coil spring/oil damper Wheel travel: Neutral indicator light:...
  • Page 134 levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of work-force include the characteristics of the work room, the other sources of noise, etc. i.e. the number of machines and other adjacent process- es, and the length of time for which an operator is exposed to the noise.

  • Page 135: Consumer Information

    Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number (front left side)
  • Page 136 1. Model label 11-2...

  • Page 137: Index

    INDEX Engine, cold start ............6-1 Engine idling speed ............. 8-23 Accessories and loading ..........6-6 Engine oil ............... 5-3 Air filter element, cleaning ........... 8-18 Engine oil and oil filter cartridge ........8-11 Engine, starting a warm ..........6-3 Battery .................
  • Page 138 Neutral indicator light .............4-2 Tail/brake light bulb, replacing ........8-44 Throttle lever ............4-4, 5-4 Throttle lever free play, adjusting .........8-24 Oil temperature warning light .........4-2 Tires ................5-4 Owner’s manual and tool kit ..........8-2 Troubleshooting ............8-46 Troubleshooting chart ..........8-47 Parking ................6-5 Parking brake ..............4-7 Valve clearance ............
  • Page 140 EBU26173 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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