Yamaha GRIZZLY 350 YFM350AZ, Owner'S Manual

Page 1: ...L PROPIETARIO 5WH F8199 66 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 DIC183 ...

Page 2: ...PRINTED IN USA 2009 06 0 3 1 CR E F S YAMAHA MOTOR CO LTD DIC183 ...

Page 3: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL YFM35GZ YFM350AZ 5WH F8199 66 E0 U5WH66E0 book Page 1 Thursday June 18 2009 10 41 AM ...

Page 4: ...venlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Shinya Shimada Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 98 37 EC 2006 42 EC 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 Title ...

Page 5: ... of the features and operation of this ATV This manual includes 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 compl...

Page 6: ...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 property A TIP provides key infor...

Page 7: ...d or motorway Please check your local riding laws and regulations before operating this ATV EBU17410 YFM35GZ YFM350AZ OWNER S MANUAL 2009 by Yamaha Motor Co Ltd 1st edition June 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A U5WH66E0 book Page 1 Thursday June 18 2009 10 41 AM ...

Page 8: ...ear brake lever 4 6 Parking brake 4 7 Drive select lever 4 7 Recoil starter 4 8 Fuel tank cap 4 8 Fuel 4 9 Fuel cock 4 10 Starter choke 4 12 Seat 4 12 Storage compartment 4 13 Front carrier 4 14 Rear carrier 4 14 Adjusting the front shock absorber assemblies 4 15 Adjusting the rear shock absorber assembly 4 16 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Front and rear brake...

Page 9: ... 3 General maintenance and lubrication chart 8 5 Removing and installing the panel 8 9 Checking the spark plug 8 9 Engine oil and oil filter cartridge 8 12 Final gear oil 8 16 Cleaning the air filter element 8 18 Cleaning the spark arrester 8 21 V belt cooling duct check hose 8 23 V belt case drain plug 8 23 Adjusting the carburetor 8 24 Adjusting the engine idling speed 8 24 Adjusting the throttl...

Page 10: ...steering shaft 8 35 Battery 8 36 Replacing a fuse 8 38 Replacing a headlight bulb 8 40 Adjusting a headlight beam 8 41 Replacing the tail brake light bulb 8 42 Removing a wheel 8 42 Installing a wheel 8 42 Troubleshooting 8 44 Troubleshooting chart 8 45 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 U5WH66E0 book Page 3 T...

Page 11: ...he labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer For Europe 8 9 U5WH66E0 book Page 1 Thursday June 18 2009 10 41 AM ...

Page 12: ...s 25 0 kPa 0 25 kgf cm 3 6 psi 25 0 kPa 0 25 kgf cm 3 6 psi 5FU F816M M0 37S F817R 10 80 kg 176 lbs 4900 N 500 kgf 1102 lbf 147 N 15 kgf 33 lbf 4S2 F817S 00 1P0 F816P 20 1 4 2 3 5 U5WH66E0 book Page 2 Thursday June 18 2009 10 41 AM ...

Page 13: ...0 1P0 F816L 20 YEAR OF CONSTRUCTION 2009 MODEL YFM350A MAX POWER 15 9 kW MASS IN RUNNING ORDER 245 kg YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN 5WH F155A 20 6 7 8 9 U5WH66E0 book Page 3 Thursday June 18 2009 10 41 AM ...

Page 14: ...children under age 10 to operate this ATV Operation of this ATV by children under the age of 10 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 12 to operate this ATV Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 16...

Page 15: ...th Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all o...

Page 16: ... Overloading can cause loss of control Loss of control can result in severe injury or death This pictogram shows trailer Hitch Tongue weight limit Weight on the trailer tongue Overloading can cause loss of control Loss of control can result in severe injury or death U5WH66E0 book Page 6 Thursday June 18 2009 10 41 AM ...

Page 17: ...1 7 1 For Oceania U5WH66E0 book Page 7 Thursday June 18 2009 10 41 AM ...

Page 18: ...psi 22 kPa 3 2 psi LOAD LIMIT 40 kg 88 lbs 5ND F4877 20 LOAD LIMIT 80 kg 176 lbs 5ND F4897 20 MAXIMUM LOADING LIMIT 5ND F151K 00 PULLING LOAD 4900 N 500 kgf 1102 lbf TONGUE WEIGHT 147 N 15 kgf 33 lbf 1 3 2 4 5 U5WH66E0 book Page 8 Thursday June 18 2009 10 41 AM ...

Page 19: ...1 9 1 6 7 U5WH66E0 book Page 9 Thursday June 18 2009 10 41 AM ...

Page 20: ...hild 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 or motorway Watch carefully for other vehicles when operat ing on unpaved public streets or roads Make sure you know your country s l...

Page 21: ...bing 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 Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully b...

Page 22: ...our brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly 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 imp...

Page 23: ...e exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors WARNING EWB02591 When transporting the ATV in another vehicle be sure it is kept ...

Page 24: ...9 Oil filter cartridge 10 V belt cooling duct check hose 3 4 5 1 2 6 10 9 7 8 1 Rear shock absorber assembly spring preload adjusting ring 2 Spark arrester 3 Storage compartment and tool kit 4 Spark plug 5 Front shock absorber assembly spring preload adjusting ring 6 Rear brake light switch 7 Brake pedal 8 V belt case drain plug 1 2 3 4 5 6 7 8 U5WH66E0 book Page 1 Thursday June 18 2009 10 41 AM ...

Page 25: ... from the figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Starter choke 4 Parking brake lock plate 5 Horn switch 6 Drive select lever 7 Speedometer 8 Main switch 9 Fuel tank cap 10 Throttle lever 11 Front brake lever U5WH66E0 book Page 2 Thursday June 18 2009 10 41 AM ...

Page 26: ...ows ON 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 The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U5WH66E0 book Page 1 Thursday June 18 2009 10 41 AM ...

Page 27: ...ngine stop switch set to and then pushing the start switch If the warning light does not come on while the start switch is being pushed or if the warning light re mains on after the start switch is released have a Yamaha dealer check the electrical circuit If the warning light stays on when the engine is cool have a Yamaha dealer check the electrical circuit NOTICE ECB00010 The engine may overheat...

Page 28: ...n the future EBU18061 Handlebar switches EBU18080 Engine stop switch Set this switch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to 1 Reset knob 2 Speedometer 3 Odometer 4 Tripmeter 1 Light switch OFF 2 Engine s...

Page 29: ...t the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 36 for battery charging information EBU18170 Horn switch Press the switch to sound the horn EBU18282 Throttle lever Once the engine is running pushing the throttle le ver will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle ...

Page 30: ... turn the adjusting 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 3 0 5 0 mm 0 12 0 20 in See page 8 25 WARNING Improper ad justment of the speed limiter and throttle could cause throttle cable damage or im proper throttle operation You could lose control resulting in an accident EWB00241 3 Tighten the locknut...

Page 31: ...ght 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 1 Front brake lever 1 Brake pedal 1 Rear brake lever U5WH66E0 book Page 6 Thursday June 18 2009 10 41 AM ...

Page 32: ...e 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 prematurely EBU18581 Drive select lever The drive select lever is used to shift your ATV into the forward ne...

Page 33: ...RNING EWB00340 Shift the drive select lever into the neutral po sition and apply the parking brake before start ing the engine otherwise the ATV could start to move unexpectedly which could cause an accident EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise 1 Drive select lever 1 Recoil starter U5WH66E0 book Page 8 Thursday June 18 2009 10 41 AM ...

Page 34: ...e smoking or while in the vicinity of sparks open flames or other sources of ig nition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reach es the bottom of the filler tube Because fuel expands when it heats up heat from the en gine or the sun can...

Page 35: ... use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand Use of un leaded fuel will extend spark plug life and reduce maintenance c...

Page 36: ... this position when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark pointing to OFF 1 Arrow mark pointing to ON U5WH66E0 book Page 11 Thursday June 18 2009 10 41 AM ...

Page 37: ...oke 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 the starter choke Move the starter choke in direction b to turn off the starter choke See the Starting a cold engine section on page 6 1 for proper operation EBU18881 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at th...

Page 38: ...is securely fitted EBU18912 Storage compartment NOTICE ECB00130 Do not store metal or sharply edged objects like tools in the storage compartment If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartment 1 Seat 2 Seat lock lever 1 Projection 2 Seat holder U5WH66E0 book Page 13 Thursday June 18 2009 10 41 AM ...

Page 39: ... the hose empty it and then install it EBU18962 Front carrier Do not exceed the load limit of 40 0 kg 88 lb for the front carrier Do not exceed the maximum load of 210 0 kg 463 lb for the ATV EBU18972 Rear carrier Do not exceed the load limit of 80 0 kg 176 lb for the rear carrier Do not exceed the maximum load of 210 0 kg 463 lb for the ATV 1 Storage compartment 1 Storage compartment check hose U...

Page 40: ...r handling and loss of stability which could lead to an ac cident Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring prel...

Page 41: ...ttings Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 1 Spring preload adjusting ring 2 Position indicator U5WH66E0 book Page...

Page 42: ...P A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 U5WH66E0 book Page 17 Thursday June 18 2009 10 41 AM ...

Page 43: ...hicle check the following points 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 9 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 12 Final gear oil Check ATV for oil leakage Correct if necessary 5 3 8 ...

Page 44: ...Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 34 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 33 Chassis fasteners Make sure that all nuts ...

Page 45: ...nd pedal They should move smoothly and there should be a firm feeling when the brake is applied If not have a Yamaha dealer check them Brake fluid level front brake Check the brake fluid level Add fluid if necessary See page 8 28 Brake fluid leakage front brake Check to see if any brake fluid is leaking out of the hose joint or brake fluid reservoir of the front brake Apply the brake firmly for on...

Page 46: ...th from loss of control or rollover Tire pressure below the minimum specified could also cause the tire to dislodge from the rim un der severe riding conditions EWB02541 Set tire pressures to the following specifications The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the firs...

Page 47: ...with valves WARNING EWB02551 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 1 Low pressure tire gauge 1 Tire wear limit U5WH66E0 book Page 5 Thursday June 18 2009 10 41 AM ...

Page 48: ... 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 Front Manufacturer model YFM350AZ CHENG SHIN C 828 YFM35GZ MAXXIS M979 Size AT25 x 8 12 Type Tubeless Rear Manufacturer model YFM350AZ CHENG SHIN C 828 YFM35GZ MAXXIS M980 Size AT25 x 10...

Page 49: ...and the engine stop switch to 4 Shift the drive select lever into the neutral po sition The neutral indicator light should come on If the indicator light does not come on have a Yamaha dealer check the electrical cir cuit TIP The engine can be started under the following con ditions The drive select lever is in the neutral position The rear brake lever is applied with the drive se lect lever in an...

Page 50: ...e engine more than 10 sec onds on each attempt If the battery is discharged pull the recoil starter to start the engine 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 engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming ...

Page 51: ...top 2 Apply the brake pedal 3 Shift from neutral to forward and vice versa by moving the drive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted into position 4 Open the throttle lever gradually Shifting Reverse WARNING EWB00720 Improper operation in reverse could make you hit an obstacle or even a person behind you resulting in serious injury When ...

Page 52: ...igures given in km mi or the figures given in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first...

Page 53: ... check the ATV EBU20701 Parking When parking the ATV shift the drive select lever into the forward position stop the engine apply the parking brake and then turn the fuel cock to OFF EBU20763 Parking on a slope WARNING EWB00831 Avoid parking on hills or other inclines Park ing on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident If you must par...

Page 54: ...your ATV Many companies with no con nection to Yamaha manufacture parts and acces sories or offer other modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket companies pro duce Therefore Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recom mended by Yamaha even if sold and inst...

Page 55: ...s which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU21061 Loading WARNING EWB00820 Never exceed the stated load capacity for this ATV Overloading this ATV or carrying or tow ing cargo improperly cou...

Page 56: ...e an accident Make sure the load does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Allow more 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 t...

Page 57: ...7 1 7 EBU21141 RIDING YOUR ATV U5WH66E0 book Page 1 Thursday June 18 2009 10 41 AM ...

Page 58: ...and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 4 Also read all warning and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01381 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increased if the operato...

Page 59: ...90 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WARN...

Page 60: ... Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating wit...

Page 61: ...ch time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual WARNING Failure to inspect the ATV before operating it and to maintain it prop erly increases the possibility of an accident or equipment damage EWB01431 Speed limiter For ri...

Page 62: ...ide to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier vehicle takes longe...

Page 63: ...e your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident EWB01471 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and ...

Page 64: ...he engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine p...

Page 65: ...aces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01511 While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles Watch carefully for other vehicles Make sure you U5WH66E0 book...

Page 66: ...h may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01531 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary to...

Page 67: ...n flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where you cannot easily be seen Mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles EWB01551 Do not ride in areas posted no trespassing Do not ride on private property without getting per mission U5WH66E0 book Page 11 Thu...

Page 68: ...e traction reducing control and increasing the possi bility of an accident TURNING YOUR ATV WARNING EWB01771 Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions ATV could go out of control causing a collision or overturn To achieve m...

Page 69: ...egotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL WARNING EWB01671 Climbing hills improperly can cause overturns or loss of control Use proper riding tech niques described in t...

Page 70: ...t to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of a hill shift your weight to the uphill side of the ATV U5WH66E0 book Page 14 Thursday June 18 2009 10 41 AM ...

Page 71: ...are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill 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 72: ...raking can cause the wheels on the uphill side to come off the ground or cause loss of traction Gradually apply only the rear brake when going 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 Engine compression will do most of the braking for you Use caution while descending a h...

Page 73: ...equires 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 that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose...

Page 74: ... of an overturn 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 Drive slowly and care fully Test your brakes after leaving the water If neces sary apply them several times to let fric...

Page 75: ...heck hose the drive select lever box check hose and the storage compartment check hose Also remove the V belt case drain plug to drain any wa ter that may have accumulated NOTICE Und rained water can cause damage or improper operation ECB00841 Wash the ATV in fresh water if it has been operat ed in salt water or muddy conditions 1 Air filter case check hose 1 V belt cooling duct check hose left fr...

Page 76: ...such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac 1 Drive select lever box check hose 1 Storage compartment check hose 1 V belt case drain plug U5WH66E0 book Page 20 Thursday...

Page 77: ...slowly and be very cautious in order to re duce the chance of skidding or sliding out of control 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 conditions positioning your weight over the front wheels will sometimes help ...

Page 78: ...f the turn Position your weight over the front wheels for better control See page 7 12 If your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off the throttle and or steer to the outside of the turn See page 7 12 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is...

Page 79: ...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 wa ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability Se...

Page 80: ...inte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more information about carbon monoxide The intervals given in the periodic maintenance and lu...

Page 81: ...tenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s manual 2 Owner s tool kit 3 Low pressure tire gauge U5WH66E0 book Page 2 Thursday June 18 2009 10 41 AM ...

Page 82: ...re 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 plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust i...

Page 83: ...ss and tighten all screw clamps and joints if necessary 7 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 U5WH66E0 book Page 4 Thursday June 18 2009 10 41 AM ...

Page 84: ...ls 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 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check operation and correct if necessary Check fluid level and ATV for fluid leakage and c...

Page 85: ... place if necessary 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 11 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 12 Steering shaft Lubricate with lithium soap based grease 13 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 14 Engine mou...

Page 86: ...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 headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first mont...

Page 87: ... full throttle Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinder and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U5WH66E0 book Page 8 Thursday June 18 2009 10 41 AM ...

Page 88: ...n take the panel off To install the panel Place the panel in the original position and install the bolt NOTICE When installing the panel be sure not to pinch the cables or wires ECB00381 EBU23213 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checke...

Page 89: ...owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally TIP 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 1 Spark pl...

Page 90: ...ug threads 2 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 the spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 3 Install the spark plug cap Specified spark plug NGK DR8EA 1 S...

Page 91: ...engine TIP If the engine was started before checking the oil 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 3 Remove the engine oil filler cap and then wipe the engine oil dipstick off with a clean rag 4 Insert the dipstick into the filler hole without screwing it in and then remove it again to check the oil level ...

Page 92: ...ter cartridge replacement 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove ...

Page 93: ...g of the new oil filter cartridge TIP Make sure that the O ring is properly seated 7 Install the new oil filter cartridge with an oil fil ter wrench and then tighten it to the specified torque with a torque wrench 1 Oil filter cartridge 1 Oil filter wrench 1 O ring U5WH66E0 book Page 14 Thursday June 18 2009 10 41 AM ...

Page 94: ...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 addition do not use oils labeled ENERGY CONSERV ING II or higher 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf Recommended oil See page 10...

Page 95: ...the intervals specified in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface 2 Remove the final gear oil filler bolt and its gas ket and then check the oil level in the final gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type t...

Page 96: ...to drain the oil from the final gear case 5 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 6 Refill with the recommended final gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material enters the final gear case ECB00421 1 Final gear case guard 2 Bolt 1 Final gear oil drain bolt 2 Gasket Tightening torque Final gear oil drain b...

Page 97: ...ecified in the periodic maintenance and lubrication chart Clean or if necessary replace the air filter element more frequently if you are riding in unusually wet or dusty areas TIP There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air fil ter case 1 Final gear oil filler bolt 2 Gasket 3 Final gear o...

Page 98: ...3 Remove the air filter case cover by unhooking the air filter case cover holders 4 Pull the air filter element out of the air filter case 1 Air filter case check hose 1 Air filter case cover holder 2 Air filter case cover U5WH66E0 book Page 19 Thursday June 18 2009 10 41 AM ...

Page 99: ... sponge material Never use low flash point sol vents or gasoline to clean the sponge ma terial because the engine could catch fire or explode EWB01941 7 Squeeze the excess solvent out of the sponge material and let it dry NOTICE Do not twist the sponge material when squeezing it ECB00441 1 Air filter element 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate U5WH66E0 book...

Page 100: ...possible engine damage Additionally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating ECB00461 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 mainte...

Page 101: ...park arrester portion of the tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the bolts and tighten them to the speci fied torque 1 Bolt 2 Tailpipe 1 Tailpipe 2 Spark arrester Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf U5WH66E0 book Page 22 Thursday June 18 2009 10 41 AM ...

Page 102: ...ust or water collects in the V belt cooling duct check hose remove the hose and clean it EBU23930 V belt case drain plug After riding in water deep enough to allow it to en ter the V belt case remove this plug to drain the water from the case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the water may affect other engine parts 1 V belt cooli...

Page 103: ...se settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart TIP A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it...

Page 104: ...20 in at the throttle lever Period ically 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 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle cable free play turn the throttle cable free play adjusting bolt in di rection a To decr...

Page 105: ...cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EBU29601 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be per formed by a Yamaha dealer WARNING EWB02571 Operating with improperly serviced or adjust ed brakes could lead to a loss in braking ability and an accident EBU2...

Page 106: ... Rear brake shoes The rear brake is provided with a wear indicator which allows you to check the brake shoe wear without having to disassemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line or mark have a Yamaha dealer replace the brake shoes as a set ...

Page 107: ...ng performance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spi...

Page 108: ...rake system EBU24514 Adjusting the brake pedal and rear brake lever free play and checking the brake pedal position The brake pedal and brake lever free play must be checked and if necessary adjusted at the inter vals specified in the periodic maintenance and lu brication chart TIP Always perform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting ...

Page 109: ... in di rection a to increase the free play and in di rection b to decrease it Adjusting the brake lever free play The brake lever free play should measure 3 0 5 0 mm 0 12 0 20 in as shown If the free play is in correct adjust it as follows 1 Brake pedal free play 1 Brake pedal free play adjusting nut 2 Brake lever free play adjusting nut U5WH66E0 book Page 30 Thursday June 18 2009 10 41 AM ...

Page 110: ...he rear wheel hub so that gap A measures 0 1 mm 0 0 04 in 3 Turn the brake lever free play adjusting bolt at the brake lever in direction a to increase the free play and in direction b to decrease it 1 Brake lever free play 2 Locknut 3 Brake lever free play adjusting bolt 2 1 3 1 Brake lever free play adjusting nut 2 Gap A U5WH66E0 book Page 31 Thursday June 18 2009 10 41 AM ...

Page 111: ...rake pedal and brake levers should come on just be fore braking takes effect The brake light switch for the brake pedal can be adjusted as follows but the other brake light switches should be adjusted by a Yamaha dealer 1 Remove panel A See page 8 9 2 Turn the brake light switch adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting n...

Page 112: ...yed or kinked which could restrict the operation of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding 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 EBU28711 Checking and lubricating the front and rear brake levers The ope...

Page 113: ...cked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel A See page 8 9 Recommended lubricants Front brake lever Silicone grease Rear brake lever Lithium soap based grease Recommended lubricant Lithium soap based grease U5WH66E0 book Page 34 Thursday June 18 2009 10 41 AM ...

Page 114: ...e is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU25103 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease U5WH66E0 book Page 35 Thursday June 18 2009 10 41 AM ...

Page 115: ...h water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN To re...

Page 116: ...damage the battery If you do not have access to a constant voltage battery charger have a Yamaha dealer charge your battery To store the battery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB0...

Page 117: ...ttery lead by installing their bolt 3 Install the battery holding plate by installing the bolts 4 Install the seat See page 4 12 EBU25326 Replacing a fuse The main fuse and the fuse box are located under the seat See page 4 12 1 Positive battery lead red 2 Negative battery lead black 2 1 1 Main fuse 2 Spare main fuse 3 Fuse box U5WH66E0 book Page 38 Thursday June 18 2009 10 41 AM ...

Page 118: ...use An improper fuse or a substitute object can cause damage to the electrical system which could lead to a fire EWB02172 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Headlight fuse 2 Ignition fuse 3 Auxiliary DC jack fuse for optional auxiliary DC jack 4 Signaling s...

Page 119: ...ar of the headlight by pulling it off 2 Remove the headlight bulb holder cover by pulling it off 3 Remove the headlight bulb holder by pushing it in and turning it counterclockwise 1 Cover at the rear of the headlight 1 Headlight bulb holder cover 1 Headlight bulb holder U5WH66E0 book Page 40 Thursday June 18 2009 10 41 AM ...

Page 120: ...all the bulb holder by pushing it in and turn ing it clockwise 7 Install the bulb holder cover and the cover at the rear of the headlight NOTICE Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly ECB00671 8 Adjust the headlight beam if necessary EBU25551 Adjusting a headlight beam NOTICE ECB00690 It is advisable to have a Yamaha dealer make this a...

Page 121: ...eel nuts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU25701 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP The arrow mark on the tire must point toward the rotating direction of the wheel 1 Headlight beam adjusting screw 1 Wheel nut U5WH66E0 book Page 42 Thursday June 18 2009 10 41 AM...

Page 122: ...tapered side to wards the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U5WH66E0 book Page 43 Thursday June 18 2009 10 41 AM ...

Page 123: ...ny repair take 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...

Page 124: ... and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the battery lead...

Page 125: ...n dry out the linings EWB02311 NOTICE Excessive water pressure may cause water seepage and deteriora tion of wheel bearings brakes transmis sion seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applica tions such as those available in coin oper ated car washers ECB00711 4 Once most of the dirt has been hosed off wash all surfaces with war...

Page 126: ... available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparkin...

Page 127: ...om entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery see page 8 36 TIP Make any necessary repairs before storing the ATV U5WH66E0 book Page 3 Thursday June 18 2009 10 41 AM ...

Page 128: ...and vibration level Noise level 77 311 EEC YFM35GZ 77 6 dB A Vibration on seat EN1032 ISO5008 YFM35GZ Will not exceed 0 5 m s Vibration on handlebar EN1032 ISO5008 YFM35GZ Will not exceed 2 5 m s Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 348 cm Bore stroke 83 0 64 5 mm 3 27 2 54 in Compression ratio 9 20 1 Starting system Electri...

Page 129: ...e only YFM35GZ Regular unleaded gasoline only Fuel tank capacity 13 5 L 3 57 US gal 2 97 Imp gal Fuel reserve amount 3 3 L 0 87 US gal 0 73 Imp gal Carburetor Type quantity BSR33 x 1 Spark plug s Manufacturer model NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Shaft drive Secon...

Page 130: ...um loading limit 210 0 kg 463 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum Front 22 0 kPa 0 220 kgf cm 3 2 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi Front wheel Wheel type Panel wheel Rim size 12 x 6 0AT Rear wheel Wheel type Panel wheel Rim size 12 x 7 5AT Fron...

Page 131: ...I Charging system AC magneto Battery Model YTX14AH Voltage capacity 12 V 12 0 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage quantity Headlight 12 V 30 30 W 2 Tail brake light 12 V 5 0 21 0 W 1 Meter lighting 14 V 3 0 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Oil temperature warning light 12 V 1 7 W 1 Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signal...

Page 132: ...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 EBU26041 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key ide...

Page 133: ...el 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 front left side 1 Vehicle identification number 2 Year of manufacture 0 0 8 2008 9 2009 A 2010 B 2011 I O Q U Z not used 1 2 U5WH66E0 book Page 2 Thursday June 18 2009 10 ...

Page 134: ...11 3 11 1 Model label U5WH66E0 book Page 3 Thursday June 18 2009 10 41 AM ...

Page 135: ...ng 8 24 Carrier front 4 14 Carrier rear 4 14 Chassis fasteners 5 6 Cleaning 9 1 D Drive select lever 4 7 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 26 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 24 Engine oil 5 3 Engine oil and oil filter cartridge 8 12 Engine starting a warm 6 3 Engine stop switch 4 3 F Final gear oil 5 3...

Page 136: ...he front 4 15 Shock absorber assembly adjusting the rear 4 16 Spark arrester cleaning 8 21 Spark plug checking 8 9 Specifications 10 1 Speed limiter 4 5 Speedometer 4 3 Starter choke 4 12 Start switch 4 4 Steering shaft lubricating 8 35 Storage 9 2 Storage compartment 4 13 T Tail brake light bulb replacing 8 42 Throttle cable free play adjusting 8 25 Throttle lever 4 4 5 4 Tires 5 4 Troubleshootin...

Page 137: ...U5WH66E0 book Page 3 Thursday June 18 2009 10 41 AM ...

Page 138: ...YAMAHA MOTOR CO LTD PRINTED IN USA 2009 06 0 3 1 CR E U5WH66E0 book Page 1 Thursday June 18 2009 10 41 AM ...