Yamaha YFM350RZ, Owner'S Manual

Page 1: ...L PROPIETARIO 1BS 28199 60 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 JAPAN 2009 04 0 3 1 CR E F S PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO YAMAHA MOTOR CO LTD DIC183 ...

Page 3: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL YFM35RZ YFM350RZ 1BS 28199 60 E0 U1BS60E0 book Page 1 Thursday April 16 2009 4 11 PM ...

Page 4: ...ectives of EEC If applicable YAMAHA MOTOR EUROPE N V Koolhovenlaan 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 stan...

Page 5: ...mportant 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 understand all inst...

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: ... or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM35RZ YFM350RZ OWNER S MANUAL 2009 by Yamaha Motor Co Ltd 1st edition April 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1BS60E0 book Page 1 Thursday April 16 2009 4 11 PM ...

Page 8: ...lever 4 6 Shift pedal 4 7 Drive select lever 4 7 Fuel tank cap 4 8 Fuel 4 8 Fuel cock 4 10 Starter choke 4 11 Seat 4 12 Adjusting the front shock absorber assemblies 4 13 Adjusting the rear shock absorber assembly 4 14 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Front and rear brakes 5 3 Throttle lever 5 3 Drive chain 5 4 Tires 5 4 Chassis fasteners 5 6 Instruments lights and switches 5 6 OPE...

Page 9: ...nd oil filter element 8 11 Cleaning the air filter element 8 15 Cleaning the spark arrester 8 18 Adjusting the carburetor 8 20 Adjusting the engine idling speed 8 20 Adjusting the throttle cable free play 8 21 Valve clearance 8 22 Brakes 8 22 Checking the front and rear brake pads 8 22 Checking the brake fluid level 8 23 Changing the brake fluid 8 25 Checking the front brake lever free play 8 25 C...

Page 10: ...tery 8 37 Replacing the fuse 8 40 Replacing a headlight bulb 8 40 Adjusting a headlight beam 8 42 Replacing the tail brake light bulb 8 43 Removing a wheel 8 43 Installing a wheel 8 44 Troubleshooting 8 44 Troubleshooting chart 8 46 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 U1BS60E0 book Page 3 Thursday April 16 2009...

Page 11: ...els 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 1 2 3 4 5 6 7 8 U1BS60E0 book Page 1 Thursday April 16 2009 4 11 PM ...

Page 12: ...1 2 1 4D3 2816L 20 43P 2816R 00 1 2 3 U1BS60E0 book Page 2 Thursday April 16 2009 4 11 PM ...

Page 13: ... 6 psi 5YT 2816M M0 MODEL YFM350 MAX POWER 20 0 kW MASS IN RUNNING ORDER 180 kg 5YT 2156A 00 5PG 2817L 10 YEAROFCONSTRUCTION 2009 YAMAHAMOTORCO LTD 2500SHINGAI IWATA JAPAN 1AS 2816P 00 4AA 22259 40 5 7 8 6 4 U1BS60E0 book Page 3 Thursday April 16 2009 4 11 PM ...

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 U1BS60E0 book Page 6 Thursday April 16 2009 4 11 PM ...

Page 17: ...1 7 1 For Oceania 1 2 3 4 5 U1BS60E0 book Page 7 Thursday April 16 2009 4 11 PM ...

Page 18: ...lls or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIO...

Page 19: ...m weight capacity 100 kg 220 lbs Includes weight of operator cargo and accessories Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death 3 6 psi 3 6 psi 3 2 psi 3 2 psi 5YT 2816M 00 WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 5FE 2151H 01 4AA 22259 40 3 4 5 U1BS60E0 book ...

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: ...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 changes 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 terra...

Page 22: ...opping ability Test your 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 modi...

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: ... 4 Air filter case 5 Battery 6 Owner s tool kit 7 Oil filter element 8 Shift pedal 1 Spark arrester 2 Fuse 3 Rear shock absorber assembly spring preload adjusting nut 4 Drive select lever 5 Fuel tank cap 6 Spark plug 7 Engine oil filler cap 8 Brake pedal 9 Rear brake light switch 10 Rear brake fluid reservoir U1BS60E0 book Page 1 Thursday April 16 2009 4 11 PM ...

Page 25: ...have purchased may differ slightly from the figures shown in this manual 1 Clutch lever 2 Parking brake lever 3 Front brake fluid reservoir 4 Brake lever 5 Throttle lever 6 Main switch 7 Handlebar switches U1BS60E0 book Page 2 Thursday April 16 2009 4 11 PM ...

Page 26: ... 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 U1BS60E0 book Page 1 Thursday April 16 2009 4 11 PM ...

Page 27: ...061 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 Reverse indicator light R 2 Neutral indicator light N 1 Light switch OFF 2 Engine stop switch 3...

Page 28: ...arge it See page 8 37 for battery charging information 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 is spring loaded the ATV will decelerate and the engine will return to an idle any time the throttle lever is re leased Before starting the engine chec...

Page 29: ...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 EBU18382 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut off system is incorporat ed in the clutch lever holder To disengage the clutch pull the clutch lever toward the handlebar grip To engage the ...

Page 30: ... To apply the front brake pull the brake lever toward the handlebar grip EBU18432 Brake pedal The brake pedal is located on the right side of the ATV To apply the rear brake push down on the brake pedal 1 Clutch lever 1 Brake lever U1BS60E0 book Page 5 Thursday April 16 2009 4 11 PM ...

Page 31: ...pecially on a slope To apply the parking brake move the parking brake lever in direction a To release the parking brake move the parking brake lever in direction b 1 Brake pedal 1 Parking brake lever locked position 1 Parking brake lever unlocked position U1BS60E0 book Page 6 Thursday April 16 2009 4 11 PM ...

Page 32: ...ng performance which could cause an accident You could also wear out the brakes prematurely EBU18530 Shift pedal This ATV is equipped with a constant mesh 6 speed transmission The shift pedal is located on the left side of the engine and is used in combina tion with the clutch when shifting EBU18571 Drive select lever The drive select lever is used for driving the ATV either forward or in reverse ...

Page 33: ...and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling fol low these instructions 1 Before refueling turn off the engine and be sure that no one is sitting on the vehicle Nev er refuel while smoking or while in the vicinity 1 Drive select lever 1 Fuel tank cap U1BS60E0 book Page 8 Thursday April 16 2009 4 11 PM ...

Page 34: ...oft cloth since fuel may deteriorate painted surfaces or plastic parts ECB00981 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed WARNING EWB02531 Gasoline is poisonous and can cause injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your 1 Fue...

Page 35: ...inging occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce maintenance costs EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations OFF With the fuel cock lever in this position fuel will not flow Always turn the ...

Page 36: ...n 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 EBU18850 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 the starter choke 1 Arrow mark pointing to ON 1 Arrow mark p...

Page 37: ...18881 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 projections on the front of the seat into the seat holders and push down on the seat at the rear Make sure that the seat is securely fitted 1 Starter choke 1 Seat lock lever U1BS60E0 book Page 12 Thursday April 16 2009 4 11 PM ...

Page 38: ...d 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 Projection 2 Seat holder...

Page 39: ...s Adjust the spring preload as follows 1 Loosen the locknut 2 Turn the spring preload adjusting nut in direc tion a to increase the spring preload and thereby harden the suspension and in direc tion b to decrease the spring preload and thereby soften the suspension 1 Special wrench Spring preload setting Minimum soft 1 Standard 3 Maximum hard 5 1 Locknut 2 Spring preload adjusting nut U1BS60E0 boo...

Page 40: ...g 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 NOTICE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque ECB00081 1 Special wrench Spring preload setting Minimum soft Distance A 233 5 mm 9 19 in Standard Distance A 228 5 mm 9 00 in Maximum hard Distance A 218 ...

Page 41: ...ch could cause an accident 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 Do not deform or damage the cylinder in any way Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly to a Yamaha deal er for any service Tightening torque Locknut 42 Nm 4 2 m kgf 30...

Page 42: ... Yamaha dealer Before using this vehicle 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 8 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 11 Front brake Check operation If so...

Page 43: ...Control cables Make sure that operation is smooth Lubricate if necessary 8 32 Drive chain Check chain slack and adjust if necessary Check chain condition Lubricate if necessary 5 4 8 29 8 31 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 and shift pedals Make sure that operati...

Page 44: ... If not have a Yamaha dealer check the brake system Brake fluid level Check the brake fluid level Add fluid if necessary See page 8 23 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If there is any leak age have a Yamaha dealer check the brake sys tem Brake operation Test the brakes at slow spee...

Page 45: ...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 first reading to ...

Page 46: ...tubeless tires 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 Co Ltd 1 Low pressure tire gauge 1 Tire wear limit U1BS60E0 book Page 5 Thursday April 16 2009 4 11 PM ...

Page 47: ... may not be appropriate EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary Front Manufacturer model DUNLOP KT851B Size AT21 x 7 10 Type Tubeless Rear Manufacturer model DUNLOP KT877A Size AT20 x 10 9 Type Tubeless U1BS60E0 book P...

Page 48: ...ine stop switch to 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator light does not come on have a Yamaha deal er check the electrical circuit TIP This model is equipped with an ignition circuit cut off system The engine can be started under the following conditions The transmission is in neutral The clutch is disengaged with the shift pedal and the ...

Page 49: ...serve battery energy Do not crank the engine more than 10 seconds on each attempt 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 up the engine until it idles smoothly ...

Page 50: ...to a complete stop 2 Pull in the clutch lever to disengage the clutch 3 Apply the brake pedal 4 While pulling the drive select lever handle up ward move the drive select lever forward until it completely stops 5 Release the brake pedal 6 Open the throttle lever gradually and release the clutch lever slowly Shifting Forward to Reverse WARNING EWB00720 Improper operation in reverse could make you hi...

Page 51: ...e or obstacles and then release the brake pedal 6 Open the throttle lever gradually and release the clutch lever slowly Continue to watch to the rear while backing EBU29760 Shifting This ATV has a 6 speed forward and 1 speed re verse transmission The transmission allows you to control the amount of power you have available at a given speed or for starting accelerating climb ing hills etc To shift ...

Page 52: ...tle part way and gradually re lease the clutch lever 8 Follow the same procedure when shifting to the next higher gear EBU20650 To decelerate When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause ...

Page 53: ...llowing material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various parts in the engine wear and polish themselves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided 0 160 km 0 100 mi or 0 10 hours Avoid prolon...

Page 54: ...park on an incline place the ATV transversely across the incline shift into first gear stop the engine ap ply the parking brake and then 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 front brake shift into first gear and then stop the engine 2 With the fro...

Page 55: ...re not suitable because of poten tial safety hazards to you or others Installing after market products or having other modifications performed to your ATV that change any of the ve hicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following in mind when considerin...

Page 56: ...n the maximum ATV load limit Load cargo on the carriers as close to the center of the ATV as possible Put cargo at the rear of the front carrier at the front of the rear carrier and center it Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with con trols or your ability to see wher...

Page 57: ...7 1 7 EBU21141 RIDING YOUR ATV U1BS60E0 book Page 1 Thursday April 16 2009 4 11 PM ...

Page 58: ...ual completely 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...

Page 59: ...WB01390 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 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 WARNING N...

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: ...our control or ability to see where you are going Reduce speed and allow more room to stop A heavier vehicle takes longer to stop Avoid hills and rough terrain Choose terrain carefully Use extreme caution when towing or carrying a load on inclines Turn gradually and go slowly As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add ac cessories to carry ...

Page 63: ... wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off EWB01481 Modifications and accessories Never modify this ATV through improper installa tion or use of accessories or other modification All parts and accessories added to this ATV should be genuine ...

Page 64: ...tem Do not park the ATV in a place where others might be likely to touch it The muffler and other engine parts become ex tremely hot during operation and remain hot after the engine has stopped To reduce the risk of fire during operation or after leaving the ATV do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to other hot parts Check un...

Page 65: ...n with other vehicles Watch carefully for other vehicles Make sure you know your country s laws and regulations before you ride on unpaved public streets or roads Do not ride on any paved public street road or motorway WARNING Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle EWB01521 Know the terrain where you ride Ride cautiously in unfamiliar...

Page 66: ...NG Failure to use extra care when op erating on excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn EWB01541 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 WARNING You could collide with ano...

Page 67: ...not to accidentally move the shift pedal With the engine idling pull the clutch lever to disengage the clutch and shift into 1st gear and then release the parking brake Open the throttle gradually and at the same time re lease the clutch lever slowly Once the ATV has at tained adequate speed release the throttle lever and at the same time quickly pull in the clutch le ver and shift into 2nd gear O...

Page 68: ...ing 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 maximum traction on unpaved surfac es the two rear wheels turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resist...

Page 69: ...e ATV begins to tip over to the outside while negotiating 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 EWB01591 Climbing hills improperly can cause overturns or loss of contr...

Page 70: ...r person could be on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground 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 U1BS60E0 book Page 14 Thursday...

Page 71: ...er possible ride straight up hills Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side there could be another person an obstacle or a sharp drop off Use common sense and remember that some hills are too steep for you to climb or de scend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you sh...

Page 72: ...g the procedure described in the Owner s Manual WARNING Stalling rolling backwards or improperly dismounting while climbing a hill could result in ATV overturning If you cannot control the ATV dismount immediately on the uphill side EWB01802 RIDING DOWNHILL WARNING EWB01131 Going down a hill improperly could cause overturns or loss of control Always follow proper procedures for going down hills as...

Page 73: ...ll 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 most of the braking for you Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Im...

Page 74: ...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 75: ...ving 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 friction dry out the linings Do not continue to ride you...

Page 76: ...01651 Riding improperly over obstacles could cause loss of control or a collision Before operating in a new area check for obstacles Never at tempt to ride over large obstacles such as 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 cau...

Page 77: ...lowly 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 I...

Page 78: ... 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 18 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: ...rforming mainte 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 mainten...

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 tool kit 2 Owner s manual 3 Low pressure tire gauge U1BS60E0 book Page 2 Thursday April 16 2009 4 11 PM ...

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 U1BS60E0 book Page 4 Thursday April 16 2009 4 11 PM ...

Page 84: ... 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 Clutch Check operation and adjust if necessary 3 Front brake Check operation and correct if necessary Check fluid level and ATV fo...

Page 85: ...or excessive play and re place bearings if necessary Lubricate with lithium soap based grease 11 Upper and lower arm pivots Lubricate with lithium soap based grease 12 Drive chain Check chain slack and adjust if necessary Check rear wheel alignment and correct if neces sary Clean and lubricate 13 Drive chain rollers Check for wear and replace if necessary 14 Chassis fasteners Make sure that all nu...

Page 86: ...t if neces sary 20 Engine oil filter ele ment Clean or replace if necessary 21 Engine oil strainer Clean 22 Moving parts and cables Lubricate 23 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 24 Front and rear brake switches Check operation and correct if necessary 25 Ligh...

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 cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U1BS60E0 book Page 8 Thursday April 16 2009 4 11 PM ...

Page 88: ...ddition the condition of the spark plug can reveal the condition of the engine To remove the 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 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 nor...

Page 89: ...ecessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification To install the spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK DR8EA 1 Spark...

Page 90: ...ation chart To check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold 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 ra...

Page 91: ...ment cleaning 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 to drain the oil from the crankcase NOTICE When remov ing the engine oil drain bolt the compres sion spring oil strainer and O ring will fall...

Page 92: ...k the O rings for damage and replace them if necessary 8 Install the oil filter element and O ring TIP Make sure that the O ring is properly seated 9 Install the oil filter element cover by installing the bolts and then tighten them to the speci fied torque 1 Engine oil drain bolt 2 O ring 3 Compression spring 4 Oil strainer 1 Oil filter element cover 2 Bolt 3 Oil filter element 4 O ring U1BS60E0 ...

Page 93: ...300 In order to prevent clutch slippage since the engine 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 Make sure that no foreign material enters the crankcase Tightening torque Oil filter element cover bolt 10 Nm 1 0 m k...

Page 94: ...e in tervals specified 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 Place the ATV on a level surface 2 ...

Page 95: ... out of the air filter case 5 Remove the sponge material from the air filter element frame 1 Air filter case cover 2 Air filter case cover holder 1 Air filter element assembly 1 Unlock U1BS60E0 book Page 16 Thursday April 16 2009 4 11 PM ...

Page 96: ...ponge material and replace it if damaged 9 Apply Yamaha foam air filter oil or other qual ity foam air filter oil to the sponge material TIP The sponge material should be wet but not drip ping 10 Pull the sponge material over the air filter ele ment frame 11 Apply all purpose grease to the air filter ele ment seat 12 Insert the air filter element into the air filter case and then install the air f...

Page 97: ...ty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine EBU27701 Cleaning the spark arrester Select a well ...

Page 98: ...arily creating ex haust system back pressure by blocking the end of the muffler with a shop towel 8 Stop the engine and allow the exhaust pipe to cool 9 Install the purging bolt and tighten it to the specified torque 1 Tailpipe 2 Spark arrester Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 Purging bolt Tightening torque Purging bolt 27 Nm 2 7 m kgf 19 ft lbf U1BS60E0 book Page 19 Th...

Page 99: ...nt Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment described in the following section however may be performed by the owner as part of routine main tenance NOTICE ECB00480 The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical kn...

Page 100: ...sary adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The throttle cable free play should measure 2 0 4 0 mm 0 08 0 16 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 ...

Page 101: ...d brakes could lead to a loss in braking ability and an accident EBU24130 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EBU28790 Front brake pads Each brake pad is provided with two wear indicator grooves which allow you to check the brake pad wear without having to disasse...

Page 102: ... have a Yamaha dealer replace the brake pads as a set EBU24251 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly causing it to become inef fective Before riding check that the brake fluid is above the minimum level mark and replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake flu...

Page 103: ... 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 spilled fluid imme diately As the brake pads wear it is normal for the brake fluid level to gradually go down However if the brake ...

Page 104: ...y The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart The brake lever should have no free play as shown If there is free play have a Yamaha dealer check the brake system EBU24592 Checking the brake pedal position The brake pedal position must be checked and if necessary adjusted at the intervals specified in the periodic maintenanc...

Page 105: ...arking brake free play as follows 1 Release the parking brake by moving the parking brake lever to the right 2 Fully loosen the locknut and the adjusting bolt at the rear brake caliper 3 Loosen the locknut on the brake cable 4 Turn the adjusting nut on the brake cable in di rection a to increase the cable length and in direction b to decrease it 1 Brake pedal position 1 Locknut 2 Adjusting bolt 3 ...

Page 106: ...erformance This could increase the chance of a collision or accident After adjusting the parking brake free play block the rear 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 inte...

Page 107: ...EBU24820 Adjusting the clutch lever free play The clutch lever free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The clutch lever free play should measure 5 0 10 0 mm 0 20 0 39 in as shown If the free play is incorrect adjust it as follows 1 Loosen the locknut at the clutch lever 1 Brake light switch 2 Brake light switc...

Page 108: ...ocknut at the crankcase and the clutch lever TIP If the specified free play cannot be obtained as de scribed above or if the clutch does not operate cor rectly have a Yamaha dealer check the internal clutch mechanism EBU24844 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the ATV on a level surface TIP Whe...

Page 109: ... the adjusting bolts in direction b and push the wheels forward Turn each adjusting bolt exactly the same amount to maintain correct axle alignment NOTICE Im proper drive chain slack will overload the engine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage To prevent this from occur ring keep the drive chain slack within the specified limits ECB00542 1 Drive...

Page 110: ...rt otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECB00561 The drive chain must be lubricated after wash ing the ATV or riding in the rain or wet areas 1 Clean the drive chain with kerosene and a small soft brush NOTICE To prevent dam aging the O rings do not clean the drive chain with steam cleaners high pressure washers o...

Page 111: ...1 Inspect cables frequently and replace if dam aged Corrosion can result when the cable sheaths become damaged and cables can also become frayed 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 unab...

Page 112: ...f the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease Recommended lubricant Lithium soap based grease U1BS60E0 book Page 33 Thursday April 16 2009 4 11 PM ...

Page 113: ...nance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU24995 Lubricating the swingarm pivots The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the pe riodic maintenance and lubrication chart U1BS60E0 book Page 34 Thursday April 16 2009 4 11 PM ...

Page 114: ...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 Lithium soap based grease Recommended lubricant Lithium soap based grease 1 Grease nipple 1 Grease nipple U1BS60E0 book Page 35 Thursday April 16 2009 4 11 PM ...

Page 115: ...icated at the intervals specified in the periodic mainte nance and lubrication chart Lubricate the pivoting points using a grease gun Left side 1 Grease nipple Recommended lubricant Lithium soap based grease 1 Upper grease nipple 2 Lower grease nipple U1BS60E0 book Page 36 Thursday April 16 2009 4 11 PM ...

Page 116: ...e the battery cell seals as this would permanently damage the battery WARNING EWB02160 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia b...

Page 117: ...ositive battery lead by removing their bolt NOTICE When removing the bat tery the main switch must be off and the negative lead must be disconnected be fore the positive lead ECB01001 4 Pull the battery out of its compartment To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly...

Page 118: ...d for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00940 Always keep the battery charged Storing a dis charged battery can cause permanent battery damage To install the battery TIP Be sure the battery is fully charged 1 Place the battery in its compartment 2 Connect the positive battery lead first then connect the negative battery lead by installin...

Page 119: ...ting and never use a substitute ob ject in place of the proper fuse 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 EBU25542 Replacing a headlight bulb If...

Page 120: ...headlight unit NOTICE Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner ECB00651 1 Headlight bulb holder cover 1 Headlight bulb holder 1 Do not t...

Page 121: ...ulb holder cover is securely fit ted over the bulb holder and seated prop erly ECB00671 7 Adjust the headlight beam if necessary EBU25561 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 bolt in direction a To lower a headlight beam turn the adjusting bolt in direction b 1 Headlight b...

Page 122: ...turning it counterclockwise 3 Insert a new bulb into the socket push it in and then turn it clockwise until it stops 4 Install the lens by installing the screws NOTICE Do not overtighten the screws otherwise the lens may break ECB00701 EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 1 Screw 1 Tail brake light bulb U1BS60E0 book Page 43 Thursday April 16 2009 4 ...

Page 123: ...ems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself However should your ATV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itatio...

Page 124: ...g the fuel system Fuel can ignite or explode causing severe inju ry or property damage Make sure there are no open flames or sparks in the area including pi lot lights from water heaters or furnaces U1BS60E0 book Page 45 Thursday April 16 2009 4 11 PM ...

Page 125: ... 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 126: ...s 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 warm water and mild det...

Page 127: ... 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 128: ...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 37 TIP Make any necessary repairs before storing the ATV U1BS60E0 book Page 3 Thursday April 16 2009 4 11 PM ...

Page 129: ...on level Noise level 77 311 EEC YFM35RZ 84 3 dB A Vibration on seat EN1032 ISO5008 YFM35RZ Will not exceed 0 5 m s Vibration on handlebar EN1032 ISO5008 YFM35RZ Will not exceed 2 5 m s Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 349 cm Bore stroke 83 0 64 5 mm 3 27 2 54 in Compression ratio 9 20 1 Starting system Electric starter L...

Page 130: ...8 Imp gal Fuel reserve amount 2 7 L 0 71 US gal 0 59 Imp gal Carburetor Type quantity BSR36 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 multiple disc Operation Left hand operation Transmission Primary reduction system Spur gear Primary reduction ratio 76 24 3 166 Secondary reduction system Chain drive Secondary reduction ratio 38 13...

Page 131: ...51B Rear tire Type Tubeless Size AT20 x 10 9 Manufacturer model DUNLOP KT877A Loading Maximum loading limit 100 0 kg 220 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...

Page 132: ...9 in Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper Wheel travel 210 mm 8 3 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model YTZ10S Voltage capacity 12 V 8 6 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 Neutral indicator light 12 ...

Page 133: ...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 134: ... 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 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 U1BS60E0 book Page 2 Thursday April 16 2009 4 11 PM ...

Page 135: ...11 3 11 1 Model label U1BS60E0 book Page 3 Thursday April 16 2009 4 11 PM ...

Page 136: ...ers 5 6 Cleaning 9 1 Clutch lever 4 4 Clutch lever free play adjusting 8 28 D Drive chain 5 4 Drive chain lubricating 8 31 Drive chain slack 8 29 Drive select lever 4 7 Drive select lever and driving in reverse 6 3 E Engine break in 6 6 Engine cold start 6 1 Engine idling speed 8 20 Engine oil 5 3 Engine oil and oil filter element 8 11 Engine starting a warm 6 3 Engine stop switch 4 2 F Fuel 4 8 5...

Page 137: ...he rear 4 14 Spark arrester cleaning 8 18 Spark plug checking 8 9 Specifications 10 1 Speed limiter 4 3 Starter choke 4 11 Start switch 4 3 Steering shaft lubricating 8 37 Storage 9 2 Suspension lubricating the upper and lower arm pivots 8 36 Suspension relay arm and connecting arm pivoting points lubricating the rear 8 35 Swingarm pivots lubricating 8 34 T Tail brake light bulb replacing 8 43 Thr...

Page 138: ...YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009 04 0 3 1 CR E U1BS60E0 book Page 1 Thursday April 16 2009 4 11 PM ...