Yamaha BANSHEE YFZ350Y, Owner'S Manual

Page 1: ... PROPRIÉTAIRE OWNER S MANUAL 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 ...

Page 2: ...PRINTED IN JAPAN 2008 06 0 6x2 E F S YAMAHA MOTOR CO LTD ...

Page 3: ...This A 3B5 28199 63 E0 YFZ350Y OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 4: ... of EEC If applicable If applicable To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted EN292 ANSI SVIA 1 2007 Title and or number and date of issue of standards and or specifications General Manager RV Engineering Division RV Company Signature Date of Issue Shinya Shima...

Page 5: ...des important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDER STAND AL...

Page 6: ...ithout notice This is the safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other propert...

Page 7: ... this ATV on any paved surface paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFZ350Y OWNER S MANUAL 2008 by Yamaha Motor Co Ltd 1st edition May 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 8: ... 5 Shift pedal 4 7 Kickstarter 4 7 Fuel tank cap 4 7 Fuel 4 8 Fuel cock 4 9 Starter choke 4 10 Seat 4 11 Adjusting the front shock absorber assemblies 4 12 Adjusting the rear shock absorber assembly 4 13 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel and 2 stroke engine oil mixing ratio 5 3 Transmission oil 5 3 Coolant 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Drive chain 5 4 Ti...

Page 9: ...the air filter element 8 17 Cleaning the spark arrester 8 21 Changing the carburetor settings 8 22 Adjusting the engine idling speed 8 30 Adjusting the throttle cable free play 8 32 Checking the front and rear brake pads 8 32 Checking the brake fluid level 8 33 Changing the brake fluid 8 35 Checking the front brake lever free play 8 35 Checking the brake pedal position 8 36 Adjusting the parking b...

Page 10: ... headlight beam 8 48 Replacing the tail brake light bulb 8 49 Removing a wheel 8 49 Installing a wheel 8 50 Troubleshooting 8 51 Troubleshooting charts 8 52 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 ...

Page 11: ...han 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road ...

Page 12: ...e ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly or make sudden gear chang...

Page 13: ... flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribed in this manual Never modify an ATV through im...

Page 14: ...inhale a lot of gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are poisonous and may cause loss of consciousness a...

Page 15: ...2 1 1 2 3 4 5 6 7 8 9 10 11 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 3 4 5 6 ...

Page 16: ...erstand 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 ...

Page 17: ...r tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death 3B5 2816M 00 30 0 kPa 4 4 psi 30 0 kPa 4 4 psi 27 0 kPa 4 0 psi 27 0 kPa 4 0 psi Front Rear Front Rear Maximum weight capacity ...

Page 18: ...2 4 1 2 3 4 5 6 7 8 9 10 11 ...

Page 19: ...2 5 1 2 3 4 5 6 7 8 9 10 11 4D3 2816L 00 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death ...

Page 20: ...2 6 1 2 3 4 5 6 7 8 9 10 11 ...

Page 21: ...0 Right view 1 Front shock absorber assembly 2 Radiator 3 Fuel cock 4 Rear shock absorber assembly 5 Spark arrester 6 Starter choke 7 Shift pedal 1 2 3 4 5 7 6 1 Tail brake light 2 Seat 3 Kickstarter 4 Fuel tank cap 5 Headlight 6 Brake pedal 7 Brake light switch 1 2 3 4 5 6 7 ...

Page 22: ...12 Controls and instruments TIP The ATV you have purchased may differ slightly from the figures shown in this manual 1 Clutch lever 2 Parking brake lock plate 3 Main switch 4 Brake lever 5 Throttle lever 6 Handlebar switches 1 2 3 4 6 5 ...

Page 23: ...positions of the main switch are as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch OFF ON 1 ...

Page 24: ...ight Set the switch to OFF to turn off all the lights NOTICE ECB00040 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU18280 Throttle lever Once the engine is running movement of the throt tle lever will in...

Page 25: ...or or the throttle ca ble should malfunction and will not close fully take your thumb off the throttle lever The throttle override system immediately cuts off the ignition WARNING EWB00260 Riding with a malfunction increases the chance for an accident and injury Make sure that the cause of the malfunction is corrected before restarting the engine or have the ATV in spected by a Yamaha dealer EBU18...

Page 26: ...g screw out more than 12 mm 0 47 in or the throttle cable could be dam aged Always make sure the throttle lever free play is adjusted to 4 0 6 0 mm 0 16 0 24 in See page 8 32 EBU18372 Clutch lever The clutch lever is located on the left handlebar To disengage the clutch pull the clutch lever toward the handlebar grip To engage the clutch release the clutch lever The clutch lever should be pulled r...

Page 27: ...sh down on the brake pedal EBU18500 Parking brake Use the parking brake before starting the engine or parking the ATV especially on a slope Squeeze the clutch lever while pushing the button then push in the lock plate to apply the parking brake Squeeze the clutch lever to release the parking brake TIP When the parking brake is used engine speed is limited to 2300 r min Be sure the parking brake is...

Page 28: ...f the parking brake is not ap plied This could cause loss of control or a collision 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 1 Button 2 Parking brake lock plate 1 2 1 Locked position...

Page 29: ...starter lever move it down lightly with your foot until the gears engage and then push it down smoothly but forcefully This model is equipped with a primary kickstarter allowing the engine to be started in any gear if the clutch is dis engaged However shifting the transmission into the neutral position before starting is recommend ed EBU18720 Fuel tank cap Remove the fuel tank cap by turning it co...

Page 30: ...as shown TIP If knocking or pinging occurs use a different brand 1 Fuel tank cap 1 1 Fuel level 2 Filler tube Recommended fuel PREMIUM UNLEADED GASOLINE ONLY For Europe PREMIUM UNLEADED GASO LINE ONLY with a research octane number of 95 or higher Fuel tank capacity 12 0 L 3 17 US gal 2 64 Imp gal Fuel reserve amount 2 5 L 0 66 US gal 0 55 Imp gal ...

Page 31: ...l fuel especially on the engine or exhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU18830 Fuel cock The fuel cock supplies fuel from the tank to the car buretors while also filtering it The fuel cock lever positions are explained as f...

Page 32: ... is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18840 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on 1 Arrow mark positioned over ON ON FUE...

Page 33: ...tion on page 6 1 for proper operation EBU18870 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear To install the seat Insert the projection on the front of the seat into the seat holder and push down on the seat at the rear TIP Make sure that the seat is securely fitted 1 Starter choke 1 a b 1 Seat lock lever 1 ...

Page 34: ...justing ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Projection 2 Seat holder 1 2 1 Spring preload adjusting ring 2 Position indicator Spring preload setting Minimum soft 1 Standard 3 Maximum h...

Page 35: ... stand the following information before han dling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock absorber assembly to an open flame or other high heat source This may cause the unit to explode due to ex cessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Do not...

Page 36: ... preload the longer distance A is the lower the spring preload With each complete turn of the adjusting nut distance A is changed by 1 5 mm 0 06 in 3 Tighten the locknut to the specified torque 1 Locknut 2 Spring preload adjusting nut 1 2 a b 1 Distance A Spring preload setting Minimum hard Distance A 213 5 mm 8 4 in Standard Distance A 220 5 mm 8 7 in Maximum soft Distance A 228 5 mm 9 0 in Tight...

Page 37: ...und damping force and thereby soften the damping Compression damping force Turn the adjusting knob in direction a to increase the compression damping force and thereby hard en the damping and in direction b to decrease the compression damping force and thereby soft en the damping 1 Rebound damping force adjusting dial 1 a b Rebound damping setting Minimum soft 20 click s in direction b Standard 12...

Page 38: ...o check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary WARNING EWB00460 Suspension components become hot during operation Never touch the compression damping force adjusting knob the rebound damping force adjusting dial or the oil reser voir with your bare hand or skin until suspen sion components have cooled 1 Compression damping force...

Page 39: ...maintenance of some items in the table has to be performed by a Yamaha dealer Refer to the periodic maintenance charts on page 8 3 to determine which service should be performed by a Yamaha dealer ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 8 5 3 Transmission oil Check oil level in transmission case ...

Page 40: ...lever free play and adjust if necessary 8 39 Throttle lever Make sure that operation is smooth Lubricate cable and lever hous ing if necessary Check cable free play and adjust if necessary 5 4 8 32 Control cables Make sure that operation is smooth Lubricate if necessary 8 43 Drive chain Check chain slack and adjust if necessary Check chain condition Lubricate if necessary 5 4 8 40 8 42 Wheels and ...

Page 41: ...st be checked on a cold en gine since the level varies with engine tempera ture WARNING EWB00510 Wait for the engine and radiator to cool before removing the radiator cap You could be burned by hot fluid and steam blown out under pressure Always put a thick rag over the cap when opening Allow any remaining pressure to escape before completely removing the cap EBU19710 Front and rear brakes Brake l...

Page 42: ... starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake pads for wear See page 8 32 WARNING EWB00580 Always check the brakes at the start of every ride Do not ride the ATV if you find any prob lem with the brakes or you could lose braking ability which could lead to an accident If a problem cannot be corrected by the adjust ment ...

Page 43: ...NLOP KT877A Size AT20 x 10 9 Type Tubeless The tires should be set to the recommended pressure Recommended tire pressure Front 30 0 kPa 0 300 kgf cm2 4 4 psi Rear 30 0 kPa 0 300 kgf cm2 4 4 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe ridin...

Page 44: ...re pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set the tire pressure when the tires are cold Set the tire pressures to the following specifications EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm 0 12 in 1 Low pressure tire gauge 1 Recommended pressure Front 30 0 kPa 0 300 kgf cm2 4 4 psi Rear 30 0 kPa...

Page 45: ...840 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 1 Tire wear limit ...

Page 46: ...ng in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an acci dent or collision NOTICE ECB00150 See the Engine break in section on page 6 4 prior to operating the engine for the first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the key to ON and the engine stop switch to 4 Shift the transmission int...

Page 47: ...old 8 Continue warming up the engine until it idles smoothly then return the starter choke to position 3 before riding TIP The engine is warm when it responds normally to the throttle with the starter choke turned off When the parking brake is applied engine speed is limited to 2300 r min Make sure the parking brake is released before moving the throttle lever otherwise the engine will misfire pre...

Page 48: ...e the parking brake NOTICE ECB00200 Always close the throttle before shifting gears otherwise damage to the engine and drive train may result 2 Pull the clutch lever to disengage the clutch 3 Shift into first gear 4 Open the throttle gradually and at the same time release the clutch lever slowly 5 Once the ATV has attained adequate speed release the throttle and at the same time quickly pull in th...

Page 49: ... train damage NOTICE ECB00180 Even with the transmission in the neutral po sition do not coast for long periods of time with the engine off and do not tow the ATV for long distances The transmission is prop erly lubricated only when the engine is run ning Inadequate lubrication may damage the transmission Always use the clutch when changing gears The engine transmission and drive train are not des...

Page 50: ...erate it at one set throttle position 160 320 km 100 200 mi or 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine through the gears freely but do not use full throttle at any time 320 km 200 mi or 20 hours and beyond The ATV can now be operated normally NOTICE ECB00220 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check t...

Page 51: ...block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the ATV to a stop by applying the brakes in first gear 2 Stop the engine and release the clutch lever 3 With the rear brake applied apply the parking brake and slowly release the brake pedal EBU20910 Accessories and loading EBU20920 Accessories...

Page 52: ...e that limits your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU20940 Loading As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add ac cessories so that you can carry cargo or tow a trail er you must use common sense and good judgment as the stability and handling of an ...

Page 53: ...e braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING EWB00820 Never exceed the stated load capacity for this ATV Overloading this ATV or carrying or tow ing cargo improperly could cause changes in ATV handling which could lea...

Page 54: ...7 1 1 2 3 4 5 6 7 8 9 10 11 EBU21141 RIDING YOUR ATV ...

Page 55: ...s on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics WARNING EWB01380 Never oper...

Page 56: ...ssenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or your passenger Apparel Always wear an approved motorcycle helmet that fits properly You should also wear eye protection...

Page 57: ...n accident and in creases your chances of a severe injury in the event of an accident Operating without protec tive clothing increases your chances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s performance capability is reduced by the influence of alcohol or drugs WARNING EWB01420 Never consume alcohol or drugs before or while driving t...

Page 58: ...his ATV with improper or uneven tire pres sure may cause loss of control increasing your risk of an accident Do not operate at speeds too fast for your skills or the conditions WARNING EWB01450 Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at speeds too fast for your skills or the conditions in creases your chances o...

Page 59: ... your speed when adding additional loads WARNING EWB01460 Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the...

Page 60: ...ootboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident Avoid wheelies and jumping You may lose control of the ATV or overturn WARNING EWB01480 Never attempt stunts such as wheelies or jumps Don t try to show off Modifications WARNING EWB01490 Never modify this ATV through improper in stallation or use of accessories All parts and accessori...

Page 61: ...round dry grass brush or other combustible materials to pre vent causing a fire hazard WARNING EWB01500 Do not touch the hot exhaust system Do not park the ATV during or after operation in a place where others might be likely to touch it Do not operate idle or park the ATV in dry grass dry ground cover or combustible ma terials BE CAREFUL WHERE YOU RIDE This ATV is designed for use on unpaved surf...

Page 62: ... any paved public street road or motorway WARNING EWB01520 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 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards which may cau...

Page 63: ...ls necessary to control the ATV on such terrain Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch...

Page 64: ... You should practice control of the throttle brakes shifting procedures and turning techniques in this area before trying more difficult terrain Always avoid riding on paved surfaces the ATV is designed for use on unpaved surfaces only and handling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruction on page 6 1 to start the engine Once it has warmed...

Page 65: ...NG EWB01720 Always open the throttle gradually and release the clutch lever slowly Otherwise the ATV could wheelie which would increase the chance of an accident NOTICE ECB00230 Do not shift gears without releasing the throt tle Damage to the engine or drive train may oc cur When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a low...

Page 66: ...the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly This procedure should be practiced at slow speed many times in a large unpaved area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop an...

Page 67: ...acles that might cause you to lose control WARNING EWB01580 Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Practice on small er hills before attempting large hills It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be...

Page 68: ...teep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose...

Page 69: ...e Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and re mount following the procedure described in the Owner s Manual RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Choose a low gear which will allow the en gine compression to do mos...

Page 70: ...angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slip pery surfaces or rough terrain ...

Page 71: ...as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV 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 whi...

Page 72: ...rol which could lead to an accident Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability NOTICE ECB00240 After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Wash the ATV in fresh water if it has been operated in salt water or muddy condi...

Page 73: ...large obsta cles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manu al SLIDING AND SKIDDING Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery condi...

Page 74: ...nce of skidding or sliding out of control WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding tech niques completely WHAT TO DO If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over t...

Page 75: ...eight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 17 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let ...

Page 76: ...EATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the ...

Page 77: ...you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for u...

Page 78: ... require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plugs Replace 3 Carburetors Check starter choke operation and correct if nec essary Check engine i...

Page 79: ...2 3 4 5 6 7 8 9 10 11 6 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 ...

Page 80: ...d level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 4 Rear brake Check operation and correct if necessary Check brake pedal free play and adjust if neces sary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or other damage and replace if necessary R...

Page 81: ...ation and correct if necessary Check for oil leakage and replace if necessary 15 Rear suspension relay arm and con necting arm pivot ing points Check operation and correct if necessary Lubricate with lithium soap based grease 16 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 17 Transmission oil Change Check ATV for oil leakage and correct if n...

Page 82: ...ur years and if cracked or damaged 19 Moving parts and cables Lubricate 20 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 21 Front and rear brake switches Check operation and correct if necessary 22 Lights and switches Check operation and correct if necessary Adjust headli...

Page 83: ...ine To remove a spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode of each spark plug is a medi um to light tan the ideal color when the ATV is ridden normally 2 Check that all spark plugs installed in the en gine have the same c...

Page 84: ...nd if necessary adjust the gap to specification 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque TIP If a torque wrench is not available when installing Specified spark plug NGK BR8ES Spark plug gap 0 7 0 8 mm 0 028 0 031 in 1 Sp...

Page 85: ...ATV on a level surface 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 remove the oil filler cap wipe the dipstick off with a clean rag insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level TIP The transmission oil should be between the mini mum and maximum level marks 4 If t...

Page 86: ...of the recom mended transmission oil and then install and tighten the oil filler cap NOTICE ECB00430 In order to prevent clutch slippage since the transmission oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In ad dition do not use oils labeled ENERGY CONSERVING II or higher Make sure that...

Page 87: ...he coolant level should be checked before each ride In addition the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart EBU23501 To check the coolant level 1 Place the ATV on a level surface TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser voir TIP ...

Page 88: ...oolant or dis tilled water to the maximum level mark and then install the reservoir cap NOTICE ECB00401 If coolant is not available use distilled water or soft tap water instead Do not use hard wa 1 Maximum level mark 2 Minimum level mark 1 2 1 Coolant reservoir cover 2 Coolant reservoir cap Coolant reservoir capacity up to the maximum level mark 0 28 L 0 30 US qt 0 25 Imp qt 1 2 ...

Page 89: ...Close the coolant reservoir cover 7 Install the seat TIP If the engine overheats see page 8 52 for further instructions EBU23521 To change the coolant WARNING EWB01890 Wait for the engine and radiator to cool before removing the radiator cap You could be burned by hot fluid and steam blown out under pressure Always place a thick rag over the cap when opening Allow any remaining pressure to escape ...

Page 90: ...8 15 1 2 3 4 5 6 7 8 9 10 11 4 Remove the radiator cap 5 Remove the coolant reservoir cap 1 Coolant drain bolt 1 1 1 Radiator cap 1 ...

Page 91: ...ooling system with clean tap water 8 Replace the coolant drain bolt washers if they are damaged and then tighten the coolant drain bolts to the specified torque 9 Connect the coolant reservoir hose 10 Pour the recommended coolant into the reser 1 Coolant reservoir cap 1 1 Coolant reservoir hose 2 Coolant reservoir Tightening torque Coolant drain bolt 14 Nm 1 4 m kgf 10 ft lbf 1 2 ...

Page 92: ...nd then turn it off 13 Remove the radiator cap to check the coolant level in the radiator If it is low add sufficient coolant until it reaches the top of the radiator and then install the radiator cap 14 Start the engine and then check for coolant leakage TIP If any leakage is found have a Yamaha dealer check the cooling system 15 Install the radiator cover by installing the bolts EBU23622 Cleanin...

Page 93: ...ty the hose and clean the air filter element and air fil ter case 1 Place the ATV on a level surface 2 Remove the seat See page 4 11 3 Remove the air filter case cover by unhooking the holders 4 Pull the air filter element out of the air filter case 1 Air filter case check hose 1 1 Air filter case cover 2 Air filter case cover holder 1 2 2 ...

Page 94: ...t WARNING EWB01940 Always use parts cleaning solvent to clean the sponge material Never use low flash point solvents or gasoline to clean the sponge mate rial because the engine could catch fire or ex plode 7 Squeeze the excess solvent out of the sponge material and let it dry 1 Air filter element lock plate 1 1 Sponge material 2 Air filter element frame 3 Air filter element lock plate 1 2 2 1 3 ...

Page 95: ...n install the lock plate by turning it 11 Insert the air filter element into the air filter case and then install the air filter case cover by hooking the holders onto the air filter case 12 Install the seat TIP The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element ...

Page 96: ...ed air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine over heating EBU28310 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the screws 2 Remove the tailpipe by pull...

Page 97: ...ge the carburetor settings to maintain opti mum engine performance and to prevent engine damage WARNING EWB01990 Improperly servicing or adjusting the carbu retors could cause them to malfunction with the possibility of an accident or the carbure tors could leak fuel which would be a fire hazard Carburetor adjustments should only be per formed by a Yamaha dealer Do not attempt to perform these pro...

Page 98: ... 6 7 8 9 10 11 erating the ATV to make sure it is working correctly Standard settings Main jet 200 Jet needle clip position 3rd groove Pilot air screw 2 0 turns out 1 Main jet number 1 1 Standard position Groove 3 1 ...

Page 99: ...l 3 Remove the seat 4 Remove the radiator cover and side cover by removing the screws 5 Disconnect the fuel hoses Temperature Altitude 0 1500 m 5000 ft Above 1500 m 5000 ft Main jet Jet needle Pilot air screw Main jet Jet needle Pilot air screw Above 0 C 32 F 200 3rd groove 2 0 turns out 190 3rd groove 2 1 2 turns out from 5 C 41 F to 15 C 5 F 220 3rd groove 1 1 2 turns out 200 3rd groove 2 0 turn...

Page 100: ...l tank by removing the bolts 7 Remove the air filter case cover by unhooking the holders 8 Remove the mixing chamber cap securing plate by removing the screw 1 Fuel tank 2 Bolt 1 2 2 2 2 1 Air filter case cover 2 Air filter case cover holder 1 2 2 ...

Page 101: ...arburetor joint screws 10 Remove the mixing chamber cap 11 Remove the throttle cable from the throttle valve and then remove the throttle cable hold er by removing the screws 1 Mixing chamber cap securing plate 2 Screw 2 1 1 Joint screw 1 1 1 1 ...

Page 102: ... 3 4 5 6 7 8 9 10 11 12 Remove the carburetor and then remove the float chamber by removing the screws 1 Throttle cable 2 Throttle valve 3 Throttle cable holder 4 Screw 1 2 3 4 1 Float chamber 2 Screw 1 2 2 2 2 ...

Page 103: ...at chamber by installing the screws 3 Install the carburetor and tighten the joint screws 4 Assemble the throttle valve 5 Install the mixing chamber cap and then tight en it securely to the specified torque 6 Install the mixing chamber cap securing plate by installing the screw NOTICE ECB00501 Be sure to match one of the projections on the carburetor cap with one of the slots on the se curing plat...

Page 104: ... it stops and hold it in this position 3 Check through each carburetor window to see if the punch mark on the throttle valve is at the specified position 4 If not loosen the locknut and turn the adjust ing nut until the specified position is obtained 1 Mixing chamber cap securing plate 2 Projection 3 Slot 4 Screw Tightening torque Mixing chamber cap securing plate screw 3 5 Nm 0 35 m kgf 2 5 ft lb...

Page 105: ...nance and lubrica tion chart TIP A diagnostic tachometer is needed to make this adjustment The carburetor synchronization and the throttle cable free play must be checked and adjusted if necessary before adjusting the engine idling speed 1 Start the engine and warm it up TIP The engine is warm when it quickly responds to the throttle 2 Attach the tachometer to the spark plug lead 3 Turn in both pi...

Page 106: ...a and to decrease it turn the screws in direction b NOTICE ECB00510 The throttle stop screws were preset at the factory When adjusting the idling speed turn both throttle stop screws the same amount otherwise the carburetor synchroni zation will be incorrect Adjusting the pilot air screws and the idling speed are separate procedures but they must be adjusted at the same time to achieve 1 Pilot air...

Page 107: ...check the throttle cable free play and if nec essary adjust it as follows TIP The engine idling speed must be checked and ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the throttle cable free play adjusting bolt in di rection a To decrease the throttle cable free play turn the adjusting bolt in direction b...

Page 108: ...ach brake pad is provided with a wear indicator which allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the position of the wear indicator while applying the brake If a brake pad has worn to the point that the wear indicator almost touches the brake disc have a Yamaha dealer re place the brake pads as a set EBU24251 Checking the brake ...

Page 109: ... precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking performance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance 1 Minimum level mark LOWER 1 ...

Page 110: ...ed in the TIP after the periodic maintenance and lubrication chart In addition have the oil seals of the master cylinders and cali pers as well as the brake hoses replaced at the in tervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EBU24393 Checking the front brake lever free play The brake lever free play must be ch...

Page 111: ...odic maintenance and lubrication chart The top of the brake pedal should be positioned 10 0 mm 0 39 in below the top of the footrest as shown If the brake pedal is not positioned as spec ified have a Yamaha dealer adjust it WARNING EWB02110 Operating with improperly serviced or adjust ed brakes could cause loss of braking ability which could lead to an accident After servicing Make sure the brakes...

Page 112: ...se the parking brake 2 Fully loosen the locknut and the adjusting bolt at the clutch lever 3 Loosen the locknut and the adjusting bolt at the rear brake caliper 4 Turn the adjusting bolt at the clutch lever in di rection a to increase the cable length and in direction b to decrease it TIP If the cable length cannot be adjusted to specifica tion consult a Yamaha dealer 5 Tighten the locknut at the ...

Page 113: ... of the ATV off the ground and spin the rear wheels Check to make sure there is no brake drag If brake drag is noticed perform the adjustment again EBU24740 Brake light switches The operation of the brake light switches must be checked and if necessary adjusted at the inter vals specified in the periodic maintenance and lu brication chart The brake light switch for the brake pedal can be adjusted ...

Page 114: ...d in the periodic maintenance and lubrication chart The clutch lever free play should measure as shown If the free play is incorrect adjust it as fol lows 1 Loosen the locknut at the clutch lever 2 To increase the clutch lever free play turn the adjusting bolt in direction a and to decrease it turn the bolt in direction b 3 Tighten the locknut TIP If the specified free play cannot be obtained as d...

Page 115: ...n checking and adjusting the drive chain slack there should be no weight on the ATV and all tires must be touching the ground 2 Move the ATV back and forth to locate the tightest portion of the drive chain and then measure the drive chain slack as shown 3 If the drive chain slack is incorrect adjust it as follows To adjust the drive chain slack 1 Place the ATV on a level surface 2 Loosen the axle ...

Page 116: ...t marks on each side of the swingarm and on the wheel hubs Use them to check for proper wheel axle alignment NOTICE ECB00541 Improper drive chain slack will overload the en gine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 4 Tighten the locknuts and the axle holding nut...

Page 117: ... must be lubricated after wash ing the ATV or riding in the rain 1 Clean the drive chain with kerosene and a small soft brush NOTICE ECB00570 To prevent damaging the O rings do not clean the drive chain with steam cleaners high pres sure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant Tightening torques Lockn...

Page 118: ...d and cables can also become frayed or kinked which could re strict the operation of controls and lead to an accident or injury EBU24922 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lubricated if necessary EBUM0170 Checking the shift pedal The operation of the shift pedal should b...

Page 119: ... have a Yamaha dealer check the wheel hub bear ings EBU25003 Lubricating the rear suspension relay arm and connecting arm pivoting points The rear suspension relay arm and connecting arm pivoting points must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart Lubricate the pivoting points using a grease gun Recommended lubricant Silicone grease Recommended ...

Page 120: ...ease gun Left side Right side EBU25102 Lubricating the steering shaft The steering shaft must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart EBU26881 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the headlight unit by removing the Recommended lubricant Lithium soap based grease 1 Grease nipple 1 1 Grease nipple...

Page 121: ...8 46 1 2 3 4 5 6 7 8 9 10 11 screw 2 Remove the headlight bulb holder cover 3 Remove the bulb holder by turning it counter clockwise 1 Screw 1 1 Headlight bulb holder cover 1 ...

Page 122: ...ew bulb into position and then install the bulb holder by turning it clockwise NOTICE ECB00650 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 affect ed Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth moistened with alcohol or thinner...

Page 123: ...e screw 8 Adjust the headlight beam if necessary EBU25551 Adjusting a headlight beam NOTICE ECB00690 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 1 Headlight bulb holder cover 2 Headlight bulb holder 3 Headlight unit 1 2 3 1 Headlight be...

Page 124: ...Remove the defective bulb by pushing it in and turning it counterclockwise 3 Insert a new bulb into the bulb holder push it in and then turn it clockwise until it stops 4 Install the bulb holder together with the bulb by turning it clockwise EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 1 Tail brake light bulb holder 1 1 Tail brake light bulb holder 2 Tail br...

Page 125: ...stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU25661 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Wheel nut 1 1 1 Wheel nut 1 1 ...

Page 126: ... it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or explode causi...

Page 127: ...ssion There is no compression Check the ignition Have a Yamaha dealer check the ATV Remove the spark plugs and check the electrodes 3 Ignition Wet Dry Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV Open the throttle halfway and operate the kickstarter Check the comp...

Page 128: ...If coolant is not available tap water can be temporarily used instead provided that it is changed to the rec ommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Star...

Page 129: ...heel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places 5 Rinse the AT...

Page 130: ...eaning section of this chapter 2 Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inders piston rings etc from ...

Page 131: ... all levers and pedals 7 Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative 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 TIP Make any necessary repairs before storing the A...

Page 132: ... on seat EN1032 ISO5008 Will not exceed 0 5 m s2 EUR Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s2 EUR Engine Engine type Liquid cooled 2 stroke Cylinder arrangement Forward inclined parallel 2 cylinder Displacement 347 0 cm3 Bore stroke 64 0 54 0 mm 2 52 2 13 in Compression ratio 6 50 1 Starting system Kickstarter Lubrication system Premix Type YAMALUBE 2 R Castrol R30 A545 A747 ...

Page 133: ...uretor Manufacturer MIKUNI Type quantity VM26SS x 2 Spark plug s Manufacturer model NGK BR8ES Spark plug gap 0 7 0 8 mm 0 028 0 031 in Clutch Clutch type Wet multiple disc Transmission Primary reduction system Helical gear Primary reduction ratio 66 23 2 869 Secondary reduction system Chain drive Secondary reduction ratio 41 14 2 929 Transmission type Constant mesh 6 speed Operation Left foot oper...

Page 134: ...inimum Front 27 0 kPa 0 270 kgf cm2 4 0 psi Rear 27 0 kPa 0 270 kgf cm2 4 0 psi Front wheel Wheel type Panel wheel Rim size 10 x 6 0AT Rear wheel Wheel type Panel wheel Rim size 9 x 8 5AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Double wishbo...

Page 135: ...10 11 Wheel travel 220 mm 8 7 in Electrical system Ignition system CDI Charging system AC magneto Headlight Bulb type Krypton bulb Bulb voltage wattage quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 ...

Page 136: ...rts from a Yamaha dealer or for ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26040 Vehicle identification number The vehicle identification number...

Page 137: ...ation number is used to identi fy your ATV 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 er 1 Vehicle identification number 1 1 Vehicle identification number 2 Year of manufacture ...

Page 138: ...11 3 1 2 3 4 5 6 7 8 9 10 11 1 Model label 1 ...

Page 139: ...ing 8 43 Carburetor settings changing 8 22 Chassis fasteners 5 7 Cleaning 9 1 Clutch lever 4 4 Clutch lever free play adjusting 8 39 Coolant 5 3 8 12 D Drive chain 5 4 Drive chain lubricating 8 42 Drive chain slack 8 40 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 30 Engine starting a warm 6 2 Engine stop switch 4 2 F Fuel 4 8 Fuel and 2 stroke engine oil mixing ratio 5 3 Fuel...

Page 140: ...ng the rear 4 13 Spark arrester cleaning 8 21 Spark plugs checking 8 8 Specifications 10 1 Speed limiter 4 3 Starter choke 4 10 Steering shaft lubricating 8 45 Storage 9 2 Suspension lubricating the upper and lower arm pivots 8 45 Suspension relay arm and connecting arm pivoting points lubricating the rear 8 44 T Tail brake light bulb replacing 8 49 Throttle cable free play adjusting 8 32 Throttle...

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Page 142: ...PRINTED IN JAPAN 2008 06 0 6x2 E YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER ...