READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM350RV WARNING LIT-11626-19-68 This ATV should not be ridden by anyone under 16 years of age.
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U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU13320 INTRODUCTION 1- Congratulations on your purchase of the Yamaha YFM350R. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU00801 IMPORTANT MANUAL INFORMATION 1- FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM EBU15000 IMPORTANT NOTICE 2- This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1 2 SAFETY INFORMATION.................. 2-1 3 DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2 Key identification number................ 3-2 Vehicle identification number .......... 3-3 Model label .......................
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM 5 6 PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-2 Fuel ................................................. 5-4 Engine oil ........................................ 5-6 Chain............................................... 5-6 Throttle lever ................................... 5-6 Fittings and fasteners...................... 5-6 Lights............................................... 5-7 Switches.........................
U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM 8 PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1 Owner’s manual and tool kit............ 8-1 Periodic maintenance chart for the emission control system.......... 8-3 General maintenance and lubrication chart ............................. 8-4 Engine oil and oil filter element ....... 8-6 Spark plug inspection.................... 8-10 Air filter element cleaning.............. 8-12 Spark arrester cleaning .................
U5YT13.book Page 4 Wednesday, June 29, 2005 10:35 AM Troubleshooting chart ................... 8-48 9 CLEANING AND STORAGE............ 9-1 A. Cleaning...................................... 9-1 B. Storage ....................................... 9-3 10 SPECIFICATIONS.......................... 10-1 11 NOISE REGULATION.................... 11-1 12 MAINTENANCE RECORD ............ 12-1 13 ATV LIMITED WARRANTY............ 13-1 14 YAMAHA EXTENDED SERVICE (Y.E.S.) .........................................
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U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM 2 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 1 2 3 Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 4 5 6 7 1 3 DRIVE SELECT LEVER 8 9 Read owner’s manual carefully before operating.
U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM 4 6 5 WARNING UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU13351 SAFETY INFORMATION 1 2 AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM ● ● ● ● ● ● ● ● ● ● Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate an ATV on any public street, road or highway, even a dirt or gravel one. Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.
U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM ● ● ● ● ● Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. Always follow proper procedures for climbing hills as described in this manual.
U5YT13.book Page 4 Wednesday, June 29, 2005 10:35 AM ● ● ● ● ● Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.
U5YT13.book Page 5 Wednesday, June 29, 2005 10:35 AM ● ● ● ● Always use the size and type of tires specified in this manual. Always maintain proper tire pressure as described in this manual. Never modify an ATV through improper installation or use of accessories. Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.
U5YT13.book Page 6 Wednesday, June 29, 2005 10:35 AM WARNING When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately.
U5YT13.book Page 7 Wednesday, June 29, 2005 10:35 AM WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. 2. 3. 4. 5. 6. 7. 8. Spark arrester Seat Drive select lever Fuel tank cap Main switch Brake pedal Headlights Front wheel 9. 10. 11. 12. 13. 14. 15. 16. Fuel cock Rear wheel Shift pedal Clutch lever Parking brake lever Brake lever Throttle lever Handlebar switches NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual.
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: Key identification number The key identification number is stamped on the key as shown in the following illustration.
U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 1.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU00039 CONTROL FUNCTIONS 1 WARNING 2 Indicates a potential hazard that could result in serious injury or death. 3 4 EBU00942 5 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM EBU00043 EBU00053 Indicator lights Handlebar switches 1. Reverse indicator light “R” 2. Neutral indicator light “N” 1. Light switch “ / /OFF” 2. Engine stop switch “ / ” 3. Start switch “ ” EBU14930 Reverse indicator light “R” This indicator light comes on when the drive select lever is in reverse. EBU12040 Light switch “ / /OFF” Set the switch to “ ” to turn on the low beam and the taillight.
U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM EBU06070 Start switch “ ” The starter motor cranks the engine when this switch is pushed. CAUTION: _ Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. CAUTION: _ See starting instructions prior to starting the engine. (See page 6-1 for details.
U5YT13.book Page 4 Wednesday, June 29, 2005 10:35 AM EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly.
U5YT13.book Page 5 Wednesday, June 29, 2005 10:35 AM EBU01159 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result.
U5YT13.book Page 6 Wednesday, June 29, 2005 10:35 AM EBU00069 EBU00988 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. (Refer to “Starting a cold engine” for a description of the ignition circuit cut-off system.
U5YT13.book Page 7 Wednesday, June 29, 2005 10:35 AM EBU00989 Brake pedal The brake pedal is located on the right side of the machine. Push down on the pedal to apply the rear brake. 1.
U5YT13.book Page 8 Wednesday, June 29, 2005 10:35 AM EBU13870 Parking brake lever Use the parking brake when you have to start the engine or park the machine, especially 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. Parking brake lever (Unlocked position) 1.
U5YT13.book Page 9 Wednesday, June 29, 2005 10:35 AM EBU00082 Shift pedal This machine is equipped with a constantmesh 6-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision.
U5YT13.book Page 10 Wednesday, June 29, 2005 10:35 AM EBU00085 EBU00092 Drive select lever The drive select lever is used for driving the machine either forward or in reverse. Refer to page 6-4 for drive select lever operation. Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Fuel tank cap 1.
U5YT13.book Page 11 Wednesday, June 29, 2005 10:35 AM EBU00930 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position, fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve.
U5YT13.book Page 12 Wednesday, June 29, 2005 10:35 AM EBU00950 Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “Starting a cold engine” for proper operation. (See page 6-1.) RES Position 1. Arrow mark pointing to “RES” 1.
U5YT13.book Page 13 Wednesday, June 29, 2005 10:35 AM EBU00567 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. NOTE: Make sure that the seat is securely fitted. 1. Seat lock lever 1. Projection (× 2) 4-13 2.
U5YT13.book Page 14 Wednesday, June 29, 2005 10:35 AM EBU01104 NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Front shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b.
U5YT13.book Page 15 Wednesday, June 29, 2005 10:35 AM WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting.
U5YT13.book Page 16 Wednesday, June 29, 2005 10:35 AM EBU12871 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows. 1. Loosen the locknut. 2. To increase the spring preload, turn the adjusting nut in direction a. To decrease the spring preload, turn the adjusting nut in direction b. CAUTION: _ Never attempt to turn the adjusting nut beyond the maximum or minimum setting.
U5YT13.book Page 17 Wednesday, June 29, 2005 10:35 AM Measurement A: Installed length: Minimum (hard): 218.5 mm (8.6 in) Standard: 228.5 mm (9.0 in) Maximum (soft): 233.5 mm (9.2 in) CAUTION: _ Always tighten the locknut against the adjusting nut and tighten it to the specified torque. _ A A. Spring length 4. Tighten the locknut to the specified torque. Tightening torque: 42 Nm (4.
U5YT13.book Page 18 Wednesday, June 29, 2005 10:35 AM WARNING POTENTIAL HAZARD This shock absorber contains highly pressurized nitrogen gas. WHAT CAN HAPPEN The shock absorber could explode, causing injury or property damage. Cylinder damage could also result in poor handling which could cause an accident. HOW TO AVOID THE HAZARD ● Do not tamper with or attempt to open the cylinder assembly. ● Do not subject the shock absorber to an open flame or other high heat.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM PRE-OPERATION CHECKS 1 Before using this machine, check the following points: ITEM ROUTINE PAGE 2 3 Brakes • Check operation, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. 5-2–5-3, 8-19–8-24 Clutch • Check operation, condition and lever free play. 8-27–8-28 Parking brake • Check operation, condition and cable length. 8-25–8-26 5 Fuel • Check fuel level. • Fill with fuel if necessary.
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM EBU01166 Front and rear brakes Brake lever and brake pedal ● Check that there is no free play in the brake lever. If there is free play, have a Yamaha dealer inspect the brake system. ● Check for correct brake pedal height. (See page 8-24.) If the pedal height is incorrect, have a Yamaha dealer adjust it. ● Check the operation of the lever and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied.
U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM 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 leakage, have a Yamaha dealer inspect the brake system. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brake pads for wear. (See pages 8-19–8-20.
U5YT13.book Page 4 Wednesday, June 29, 2005 10:35 AM EBU01085 Fuel Make sure there is sufficient gasoline in the tank. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.
U5YT13.book Page 5 Wednesday, June 29, 2005 10:35 AM Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. 1. Fuel tank filler tube WARNING POTENTIAL HAZARD Improper care when refueling.
U5YT13.book Page 6 Wednesday, June 29, 2005 10:35 AM EBU10842 EBU00498 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-6– 8-9.) Chain Check the general condition of the chain and check the chain slack before every ride. Lubricate and adjust the chain as necessary. (See pages 8-29–8-32 for details.) CAUTION: _ ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
U5YT13.book Page 7 Wednesday, June 29, 2005 10:35 AM EBU01003 Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation. EBU01170 Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation.
U5YT13.book Page 8 Wednesday, June 29, 2005 10:35 AM EBU00157 Tires 2. The tires should be set to the recommended pressure: ● Recommended tire pressure Front 25 kPa (0.25 kgf/cm2, 3.6 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) ● Check and adjust tire pressures when the tires are cold. ● Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 22 kPa (0.
U5YT13.book Page 9 Wednesday, June 29, 2005 10:35 AM Set pressure with tires cold. Set tire pressures to the following specifications: 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. Recommended pressure Minimum Maximum Front 25 kPa (0.25 kgf/cm2, 3.6 psi) 22 kPa (0.
U5YT13.book Page 10 Wednesday, June 29, 2005 10:35 AM EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU00161 EBU14940 OPERATION Starting a cold engine WARNING WARNING Indicates a potential hazard that could result in serious injury or death. WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM Position 3: Cold engine startambient temperature above 25 °C (80 °F) and warm engine start position. NOTE: This model is equipped with an ignition circuit cut-off system. The engine can be started under the following conditions. ● When the transmission is in neutral. The neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it.
U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM EBU00180 Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly. NOTE: If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt.
U5YT13.book Page 4 Wednesday, June 29, 2005 10:35 AM EBU01172 NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the machine. Drive select lever operation and reverse driving _ CAUTION: _ _ Before shifting, stop the machine and return the throttle lever to its closed position, otherwise the transmission may be damaged. 5. Check behind you for people or obstacles, and then release the brake pedal. 6.
U5YT13.book Page 5 Wednesday, June 29, 2005 10:35 AM EBU01173 Shifting This model has a 6-speed forward and 1-speed reverse transmission. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to the closed position, apply the clutch and repeatedly depress the shift pedal until it stops. When it stops, it will be in first gear. Raise the pedal slightly to neutral.
U5YT13.book Page 6 Wednesday, June 29, 2005 10:35 AM EBU14190 To start out and accelerate: 1. Release the throttle lever, and then release the parking brake. CAUTION: _ ● ● Do not coast for long periods with the engine off, and do not tow the machine a long distance. Even in neutral position, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may cause damage. Always use the clutch when changing gears.
U5YT13.book Page 7 Wednesday, June 29, 2005 10:35 AM EBU00207 To decelerate: When slowing down or stopping, release the throttle 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 the tires to lose traction, reducing control and increasing the possibility of an accident. 8. Follow the same procedure when shifting to the next higher gear.
U5YT13.book Page 8 Wednesday, June 29, 2005 10:35 AM EBU02092 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances.
U5YT13.book Page 9 Wednesday, June 29, 2005 10:35 AM EBU02111 Parking When parking, stop the engine and shift into first gear. Turn the fuel cock to “OFF” and apply the parking brake. 1.
U5YT13.book Page 10 Wednesday, June 29, 2005 10:35 AM EBU14730 Parking on a slope 3. Stop the engine by setting the engine stop switch to “ ”. 4. With the front and rear brakes applied, pull the clutch lever, shift into 1st gear, and then slowly release the clutch lever, brake lever and brake pedal. WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident.
U5YT13.book Page 11 Wednesday, June 29, 2005 10:35 AM EBU00221 Accessories and loading ● EBU00222 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market.
U5YT13.book Page 12 Wednesday, June 29, 2005 10:35 AM EBU00584 Loading As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable.
U5YT13.book Page 13 Wednesday, June 29, 2005 10:35 AM WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
U5YT13.book Page 14 Wednesday, June 29, 2005 10:35 AM EBU13552 WARNING _ Indicates a potential hazard that could result in serious injury or death.
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U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM WARNING _ Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by experienced operators only. Even though you are an experienced operator of all other all terrain vehicles or motorcycles, riding the ATV requires special skills acquired through practice. Take your time to fully learn techniques before attempting more difficult maneuvers. operation of the controls.
U5YT13.book Page 4 Wednesday, June 29, 2005 10:35 AM RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Get training if you are inexperienced.
U5YT13.book Page 5 Wednesday, June 29, 2005 10:35 AM Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc.
U5YT13.book Page 6 Wednesday, June 29, 2005 10:35 AM This ATV is designed to carry operator only – passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
U5YT13.book Page 7 Wednesday, June 29, 2005 10:35 AM Apparel Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
U5YT13.book Page 8 Wednesday, June 29, 2005 10:35 AM Do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIPOTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.
U5YT13.book Page 9 Wednesday, June 29, 2005 10:35 AM Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident.
U5YT13.book Page 10 Wednesday, June 29, 2005 10:35 AM Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits the power and top speed of the ATV. Turning the adjusting screw in decreases the top speed, and turning it out increases the top speed. (See page 4-5 for details.) WARNING _ Indicates a potential hazard that could result in serious injury or death.
U5YT13.book Page 11 Wednesday, June 29, 2005 10:35 AM Loading and accessories As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads.
U5YT13.book Page 12 Wednesday, June 29, 2005 10:35 AM During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
U5YT13.book Page 13 Wednesday, June 29, 2005 10:35 AM Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
U5YT13.book Page 14 Wednesday, June 29, 2005 10:35 AM Modifications WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
U5YT13.book Page 15 Wednesday, June 29, 2005 10:35 AM Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire.
U5YT13.book Page 16 Wednesday, June 29, 2005 10:35 AM BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
U5YT13.book Page 17 Wednesday, June 29, 2005 10:35 AM Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
U5YT13.book Page 18 Wednesday, June 29, 2005 10:35 AM Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.
U5YT13.book Page 19 Wednesday, June 29, 2005 10:35 AM WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
U5YT13.book Page 20 Wednesday, June 29, 2005 10:35 AM 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. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”.
U5YT13.book Page 21 Wednesday, June 29, 2005 10:35 AM 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, release the clutch lever slowly. Once the ATV has attained adequate speed, release the throttle lever and at the same time, quickly pull in the clutch lever and shift into 2nd gear. Open the throttle part way and gradually release the clutch.
U5YT13.book Page 22 Wednesday, June 29, 2005 10:35 AM When slowing down or stopping, release the throttle 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 the tires to lose traction, reducing control and increasing the possibility of an accident. WARNING POTENTIAL HAZARD Opening the throttle abruptly or releasing the clutch lever too quickly.
U5YT13.book Page 23 Wednesday, June 29, 2005 10:35 AM TURNING YOUR ATV To achieve maximum traction while riding offroad, the two rear wheels are mounted solidly on one axle and 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 turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed.
U5YT13.book Page 24 Wednesday, June 29, 2005 10:35 AM Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.
U5YT13.book Page 25 Wednesday, June 29, 2005 10:35 AM CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
U5YT13.book Page 26 Wednesday, June 29, 2005 10:35 AM WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill.
U5YT13.book Page 27 Wednesday, June 29, 2005 10:35 AM If you 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. When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
U5YT13.book Page 28 Wednesday, June 29, 2005 10:35 AM 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 control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill.
U5YT13.book Page 29 Wednesday, June 29, 2005 10:35 AM Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s Manual.
U5YT13.book Page 30 Wednesday, June 29, 2005 10:35 AM RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces.
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U5YT13.book Page 32 Wednesday, June 29, 2005 10:35 AM CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills.
U5YT13.book Page 33 Wednesday, June 29, 2005 10:35 AM Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
U5YT13.book Page 34 Wednesday, June 29, 2005 10:35 AM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) 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 carefully. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
U5YT13.book Page 35 Wednesday, June 29, 2005 10:35 AM Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. _ 1.
U5YT13.book Page 36 Wednesday, June 29, 2005 10:35 AM RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision.
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U5YT13.book Page 38 Wednesday, June 29, 2005 10:35 AM SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.
U5YT13.book Page 39 Wednesday, June 29, 2005 10:35 AM With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
U5YT13.book Page 40 Wednesday, June 29, 2005 10:35 AM WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. ● WHAT TO DO ... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-23–7-24.
U5YT13.book Page 41 Wednesday, June 29, 2005 10:35 AM ● ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32– 7-33.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Have a Yamaha dealer perform service if you are not familiar with machine service. Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM EBU15731 Periodic maintenance chart for the emission control system NOTE: _ ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
U5YT13.book Page 4 Wednesday, June 29, 2005 10:35 AM EBU15720 General maintenance and lubrication chart ITEM Air filter element Engine oil Engine oil filter element Engine oil strainer Drive chain Brakes* Clutch* Wheels* Wheel bearings* Steering system* Front and rear suspension* Upper and lower arm pivot and steering shaft* Rear arm pivot* Whichever month comes first km (mi) hours ROUTINE • • • • • • • • • • • • • • • • • • • • • Clean. Replace if necessary. Replace (Warm engine before draining.
U5YT13.book Page 5 Wednesday, June 29, 2005 10:35 AM ITEM Fittings and fasteners* Lights and switches* Whichever month comes first km (mi) hours ROUTINE • • • • 1 320 (200) 20 INITIAL 3 1,300 (800) 80 6 2,500 (1,600) 160 EVERY 6 12 2,500 5,000 (1,600) (3,200) 160 320 Check all chassis fittings and fasteners. Correct if necessary. Check operation. Adjust headlight beams.
U5YT13.book Page 6 Wednesday, June 29, 2005 10:35 AM EBU11812 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals specified in the periodic maintenance and lubrication chart. 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. CAUTION: _ Be sure no foreign material enters the crankcase.
U5YT13.book Page 7 Wednesday, June 29, 2005 10:35 AM 6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. To change the engine oil (with or without oil filter element cleaning) 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes, and then turn it off. 3. Place a container under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase. 1.
U5YT13.book Page 8 Wednesday, June 29, 2005 10:35 AM 5. Remove the oil filter cover by removing the bolts, and then remove the oil filter element. 6. Clean the oil strainer and oil filter element with solvent. 9. Install the oil filter cover by installing the bolts, and then tighten them to the specified torque. Tightening torque: Oil filter cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 10. Install the oil strainer, compression spring, O-ring and engine oil drain bolt.
U5YT13.book Page 9 Wednesday, June 29, 2005 10:35 AM 11. Add the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap. CAUTION: _ ● Recommended oil: See page 10-2. Oil quantity: Without oil filter element replacement: 2.50 L (2.20 Imp qt, 2.64 US qt) With oil filter element replacement: 2.60 L (2.29 Imp qt, 2.75 US qt) ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
U5YT13.book Page 10 Wednesday, June 29, 2005 10:35 AM EBU14550 Spark plug inspection Removal 1. Remove the spark plug cap. 1. Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator around the center electrode is a medium-to-light tan color for an ATV that is being ridden normally. Do not attempt to diagnose such problems yourself. 1.
U5YT13.book Page 11 Wednesday, June 29, 2005 10:35 AM Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. Specified spark plug: DR8EA (NGK) a. Spark plug gap 2.
U5YT13.book Page 12 Wednesday, June 29, 2005 10:35 AM EBU14920 Air filter element cleaning NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. _ NOTE: 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 filter case.
U5YT13.book Page 13 Wednesday, June 29, 2005 10:35 AM 1. Air filter case cover 1. Air filter element assembly 2. Holder (× 4) 3. Remove the air filter element assembly, and then remove the air filter element from its frame.
U5YT13.book Page 14 Wednesday, June 29, 2005 10:35 AM WARNING 1. Element retaining plate 3. Air filter element POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. 2. Frame 4. Air filter element seat 4. Wash the element gently but thoroughly in solvent. 5.
U5YT13.book Page 15 Wednesday, June 29, 2005 10:35 AM 7. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element. NOTE: The air filter element should be cleaned every 20–40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet to the filter case for obstructions.
U5YT13.book Page 16 Wednesday, June 29, 2005 10:35 AM EBU13571 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolt. 1. Tailpipe 2. Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install and tighten the bolt. 1. Bolt 2. Remove the tailpipe by pulling it out of the muffler. 3.
U5YT13.book Page 17 Wednesday, June 29, 2005 10:35 AM EBU00296 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine. WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes.
U5YT13.book Page 18 Wednesday, June 29, 2005 10:35 AM EBU13020 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. _ _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw.
U5YT13.book Page 19 Wednesday, June 29, 2005 10:35 AM EBU00307 EBU13981 Throttle lever adjustment Front brake pad inspection Each brake pad is provided with a wear indicator groove. The indicator grooves allow checking of brake pad wear without disassembling the brake. Apply the brake and inspect the wear indicator grooves. If a brake pad is worn to the point that the wear indicator groove is almost in contact with the disc plate, ask a Yamaha dealer to replace the brake pads as a set.
U5YT13.book Page 20 Wednesday, June 29, 2005 10:35 AM EBU13990 Rear brake pad inspection Each brake pad is provided with a wear indicator groove. The indicator grooves allow checking of brake pad wear without disassembling the brake. Apply the brake and inspect the wear indicator grooves. If a brake pad is worn to the point that the wear indicator groove is almost in contact with the disc plate, ask a Yamaha dealer to replace the brake pads as a set.
U5YT13.book Page 21 Wednesday, June 29, 2005 10:35 AM EBU13040 Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Rear 1.
U5YT13.book Page 22 Wednesday, June 29, 2005 10:35 AM EBU01186 ● ● ● ● Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. ● Replace the oil seals every two years. ● Replace the brake hoses every four years. Refill with the same type of brake fluid.
U5YT13.book Page 23 Wednesday, June 29, 2005 10:35 AM EBU01187 Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer check the brake system. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct.
U5YT13.book Page 24 Wednesday, June 29, 2005 10:35 AM EBU14951 Brake pedal height adjustment The top of the brake pedal should be positioned 50.2 mm (1.98 in) above the top of the frame as shown. If the brake pedal is not positioned as specified, have a Yamaha dealer adjust it. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.
U5YT13.book Page 25 Wednesday, June 29, 2005 10:35 AM EBU14711 Parking brake adjustment Parking brake adjustment may be required if the parking brake does not hold properly. The cable length A should be adjusted to 64– 68 mm (2.52–2.68 in). 1. Locknut A. Cable length 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.
U5YT13.book Page 26 Wednesday, June 29, 2005 10:35 AM NOTE: If the cable cannot be adjusted to specification, consult a Yamaha dealer. _ WARNING POTENTIAL HAZARD Operating with improperly adjusted brakes. WHAT CAN HAPPEN The brakes could malfunction, causing reduced braking performance. This could increase the chance of a collision or accident. HOW TO AVOID THE HAZARD After adjusting the parking brake, block the rear of the machine off the ground and spin the rear wheels.
U5YT13.book Page 27 Wednesday, June 29, 2005 10:35 AM EBU00833 EBU00741 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction a.
U5YT13.book Page 28 Wednesday, June 29, 2005 10:35 AM 4. Loosen the locknut at the clutch lever. 5. Turn the adjusting bolt at the clutch lever in direction a to loosen the cable. 1. Locknut c. Clutch lever free play 6. Loosen the locknut at the crankcase side. 7. Turn the adjusting nut at the crankcase in direction a to increase the free play or in direction b to decrease the free play. 8. Tighten the locknut at the crankcase and the clutch lever. 2. Adjusting bolt 1. Locknut 8-28 2.
U5YT13.book Page 29 Wednesday, June 29, 2005 10:35 AM EBU01144 Drive chain slack check NOTE: Move the ATV back and forth and find the tightest position of the drive chain. Check and/ or adjust the chain slack while it is in this tightest position. _ _ To check the drive chain slack, all tires must be touching the ground and there should be no weight on it. Check the drive chain slack at the position shown in the illustration Normal slack is approximately 25.0–35.0 mm (0.98– 1.38 in).
U5YT13.book Page 30 Wednesday, June 29, 2005 10:35 AM EBU14990 Drive chain slack adjustment 1. Loosen the rear wheel hub upper and lower bolts. NOTE: There are alignment marks on each side of the swingarm and on the hub. Use them to check for proper wheel axle alignment. _ _ 1. Upper wheel hub bolt 2. Lower wheel hub bolt 2. Loosen the locknuts on each side of the swingarm. To tighten the drive chain, turn the adjusting bolts in direction a.
U5YT13.book Page 31 Wednesday, June 29, 2005 10:35 AM EBU00805 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) Upper wheel hub bolt: 120 Nm (12.0 m·kgf, 85 ft·lbf) Lower wheel hub bolt: 73 Nm (7.
U5YT13.book Page 32 Wednesday, June 29, 2005 10:35 AM CAUTION: _ Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. _ 1.
U5YT13.book Page 33 Wednesday, June 29, 2005 10:35 AM EBU00356 Cable inspection and lubrication Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury.
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U5YT13.book Page 35 Wednesday, June 29, 2005 10:35 AM EBU15060 Lubricating the front upper and lower arm pivots Lubricate the upper and lower arm pivots with a grease gun. Left Recommended lubricant: Lithium-soap-based grease Right 1. Upper grease nipple (× 2) 2. Lower grease nipple (× 2) 1. Upper grease nipple (× 2) 2.
U5YT13.book Page 36 Wednesday, June 29, 2005 10:35 AM EBU00987 Rear arm pivot lubrication Lubricate the rear arm pivots. Recommended lubricant: Lithium-soap-based grease 1. Grease nipple 1. Grease nipple 1.
U5YT13.book Page 37 Wednesday, June 29, 2005 10:35 AM EBU01112 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Rear Front 1. Nut (× 4) 1.
U5YT13.book Page 38 Wednesday, June 29, 2005 10:35 AM EBU08710 Wheel installation When installing the wheel, reverse the removal procedure. Tighten the wheel nuts to the specified torques. Tightening torques: Wheel nut: Front: 45 Nm (4.5 m·kgf, 32 ft·lbf) Rear: 45 Nm (4.
U5YT13.book Page 39 Wednesday, June 29, 2005 10:35 AM EBU03800 Battery WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases. 1. Positive battery terminal 2. Negative battery terminal This machine is equipped with a sealed-type battery.
U5YT13.book Page 40 Wednesday, June 29, 2005 10:35 AM EBU03850 Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk.
U5YT13.book Page 41 Wednesday, June 29, 2005 10:35 AM EBU03900 Fuse replacement 1. The fuse case is located under the seat. 2. If the fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches. If the fuse immediately blows again, consult a Yamaha dealer. WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire.
U5YT13.book Page 42 Wednesday, June 29, 2005 10:35 AM EBU14721 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the headlight bulb holder cover at the rear of the headlight by pulling it off. 1. Headlight bulb holder 1. Headlight bulb holder cover 2. Remove the headlight bulb holder by pushing it inward and turning it counterclockwise.
U5YT13.book Page 43 Wednesday, June 29, 2005 10:35 AM 3. Remove the defective bulb from the headlight unit by pulling it out. 4. Install a new headlight bulb into the headlight unit by aligning the projection on the bulb with the groove in the headlight unit. WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable.
U5YT13.book Page 44 Wednesday, June 29, 2005 10:35 AM CAUTION: _ Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. _ 5.
U5YT13.book Page 45 Wednesday, June 29, 2005 10:35 AM EBU14050 EBU12170 Headlight beam adjustment Tail/brake light bulb replacement CAUTION: _ It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting bolt in direction a. To lower the beam, turn the adjusting bolt in direction b. 1. Screw (× 2) 1. Remove the lens by removing the screws. 2. Remove the defective bulb by pushing it inward and turning it counterclockwise. 1.
U5YT13.book Page 46 Wednesday, June 29, 2005 10:35 AM 1. Bulb 3. Install a new bulb by pushing it inward and turning it clockwise. 4. Install the lens by installing the screws. CAUTION: _ Do not overtighten the screws as the lens may break.
U5YT13.book Page 47 Wednesday, June 29, 2005 10:35 AM EBU00412 Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer.
U5YT13.book Page 48 Wednesday, June 29, 2005 10:35 AM EBU00440 Troubleshooting chart Turn the fuel cock lever to “ON”. There is fuel. Turn the fuel cock lever to “OFF”. Remove the fuel hose from the fuel cock. Some fuel. Turn the fuel cock lever to “RES”. Restart the engine. No fuel. Supply fuel. 1. Fuel Check if there is fuel in the fuel tank. 2. Compression Use the electric starter to see if there is compression. 3. Ignition There is compression. Compression normal. No compression.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU00417 CLEANING AND STORAGE CAUTION: Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A.
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM 7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. WARNING POTENTIAL HAZARD Operation with wet brakes after washing.
U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM EBU00525 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product. 2.
U5YT13.book Page 4 Wednesday, June 29, 2005 10:35 AM 8. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU00428 SPECIFICATIONS 1- MODEL YFM350R Dimension: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turning radius 1,770 mm ( 69.7 in) 1,095 mm ( 43.1 in) 1,080 mm ( 42.5 in) 820 mm ( 32.3 in) 1,210 mm ( 47.6 in) 115 mm ( 4.53 in) 3,100 mm (122.0 in) Basic weight: With oil and full fuel tank 180.
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM MODEL YFM350R Engine oil: Type 0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F 1 2 YAMALUBE 4 (20W40) or SAE 20W40 3 YAMALUBE 4 (10W30) or SAE 10W30 4 SAE 5W30 -20˚ Recommended engine oil classification: -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
U5YT13.book Page 3 Wednesday, June 29, 2005 10:35 AM MODEL YFM350R Air filter: Wet element Fuel: Type Tank capacity Reserve amount UNLEADED GASOLINE ONLY 9.0 L (1.98 Imp gal, 2.38 US gal) 2.7 L (0.59 Imp gal, 0.71 US gal) Carburetor: Type × quantity Manufacturer BSR36 × 1 MIKUNI Spark plug: Type/manufacturer Gap DR8EA / NGK 0.6–0.7 mm (0.024–0.
U5YT13.book Page 4 Wednesday, June 29, 2005 10:35 AM MODEL YFM350R Gear ratio: 36/16 × 20/27 × 29/18 (2.685) 33/20 × 20/27 × 29/18 (1.969) 29/23 × 20/27 × 29/18 (1.504) 27/26 × 20/27 × 29/18 (1.239) 25/28 × 20/27 × 29/18 (1.065) 23/29 × 20/27 × 29/18 (0.946) 33/16 × 33/10 (6.806) 1st 2nd 3rd 4th 5th 6th Reverse Chassis: Frame type Caster angle Trail Steel tube 6.0° 26.0 mm (1.
U5YT13.book Page 5 Wednesday, June 29, 2005 10:35 AM MODEL YFM350R Wheel travel: Front Rear 200.0 mm (7.87 in) 210.0 mm (8.27 in) Electrical: Ignition system Generator system Battery type/voltage capacity D.C. C.D.I. A.C. magneto YTZ10S/12V, 8.6Ah Headlight type: Krypton bulb Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator light: Neutral Reverse 12V, 30W/30.0W × 2 12V, 5W/21.0W × 1 12V, 1.7W × 1 12V, 1.7W × 1 Fuse: 15.
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U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU15740 1- MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU00432 YAMAHA MOTOR CORPORATION, U.S.A.
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U5YT13.book Page 1 Wednesday, June 29, 2005 10:35 AM EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.
U5YT13.book Page 2 Wednesday, June 29, 2005 10:35 AM 1 2 3 4 5 6 7 8 9 10 9 9 9 EBU00436 14 WARNING Indicates a potential hazard that could result in serious injury or death.
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EBU00438 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.
