Yamaha Bruin 350 Owners Manual ManualsLib Makes It Easy To Find Manuals Online! User 121920

2014-12-11

User Manual: Yamaha Bruin-350-Owners-Manual

Open the PDF directly: View PDF .
Page Count: 174

Download
Open PDF In Browser	View PDF

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00941

INTRODUCTION

Congratulations on your purchase of the Yamaha YFM350FA. It represents the result of many
years of Yamaha experience in the production of fine sporting, touring, and pace-setting 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.
This manual will provide you with a good basic understanding of the features and operation of this
ATV. This manual includes important safety information. It provides information about
special techniques and skills necessary to ride your ATV. It also includes basic maintenance
and inspection procedures. 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 TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND
COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
● NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE
TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887
N.

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00801

IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!

WARNING

CAUTION:
NOTE:

Failure to follow WARNING instructions could result in severe
injury or death to the machine operator, a bystander or a person
inspecting or repairing the machine.
A CAUTION indicates special precautions that must be taken to
avoid damage to the machine.
A NOTE provides key information to make procedures easier or clearer.

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

EBU00011

IMPORTANT NOTICE
This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to
operate this machine on any public street, road or highway.
This machine 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 machine.

EBU01067

AFFIX DEALER
LABEL HERE

YFM350FAS
OWNER’S MANUAL
©2003 by Yamaha Motor Corporation,
U.S.A.
1st edition, July 2003
All rights reserved. Any reprinting or
unauthorized use without the written
permission of

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

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

SAFETY INFORMATION.................. 2-1

DESCRIPTION AND MACHINE
IDENTIFICATION ............................. 3-1
Identification number records.......... 3-2
Key identification number................ 3-2
ber .......... 3-3

CONTROL FUNCTIONS...................4-1
Main switch ......................................4-1
Indicator and warning lights .............4-2
Handlebar switches .........................4-5
Throttle lever ....................................4-8
Speed limiter ....................................4-9
Front brake lever............................4-10
Brake pedal and rear brake
lever .............................................4-10
Parking brake.................................4-11
Drive select lever ...........................4-12
Recoil starter..................................4-12
Fuel tank cap .................................4-13
Fuel cock........................................4-14
Starter (choke) ...............................4-15
Seat................................................4-16
Storage box....................................4-17
Front carrier ...................................4-18

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

PRE-OPERATION CHECKS ........... 5-1
Front and rear brakes ..................... 5-2
Fuel ................................................. 5-4
Engine oil ........................................ 5-6
Final gear oil.................................... 5-6
Differential gear oil .......................... 5-7
Throttle lever ................................... 5-7
Fittings and fasteners...................... 5-7
Lights............................................... 5-7
Switches.......................................... 5-7
Tires ................................................ 5-8
How to measure tire pressure....... 5-10
Tire wear limit................................ 5-11
OPERATION..................................... 6-1
Starting a cold engine ..................... 6-1
Starting a warm engine................... 6-3
Warming up..................................... 6-3

Accessories and loading ............... 6-10
7

RIDING YOUR ATV .......................... 7-1
Getting to know your ATV ............... 7-3
Ride with care and good
judgement...................................... 7-4
Be careful where you ride.............. 7-16
Turning your ATV .......................... 7-22
Climbing uphill ............................... 7-24
Riding downhill .............................. 7-30
Crossing a slope............................ 7-32
Crossing through shallow water .... 7-34
Riding over rough terrain............... 7-37
Sliding and skidding....................... 7-38
What to do if................................... 7-40
What to do ..................................... 7-40

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

PERIODIC MAINTENANCE AND
ADJUSTMENT.................................. 8-1
Owner’s manual and tool kit............ 8-1
Periodic maintenance/
lubrication ...................................... 8-3
Panel removal and installation ........ 8-5
Engine oil and oil filter cartridge ...... 8-6
Final gear oil .................................. 8-11
Differential gear oil replacement ... 8-14
Axle boots...................................... 8-16
Spark plug inspection.................... 8-16
Air filter element cleaning.............. 8-19
V-belt cooling duct check hose ..... 8-22
V-belt case drain plug.................... 8-22
Spark arrester cleaning ................. 8-23
Carburetor adjustment................... 8-24
Idle speed adjustment ................... 8-25
Valve clearance adjustment .......... 8-25

Front brake lever free play.............8-30
Rear brake pedal and lever
adjustment ...................................8-31
Adjusting the rear brake light
switch ...........................................8-34
Cable inspection and lubrication....8-35
Lubricating the brake levers and
brake pedal ..................................8-35
Wheel removal...............................8-36
Wheel installation...........................8-37
Battery............................................8-38
Battery maintenance......................8-39
Fuse replacement ..........................8-39
Replacing a headlight bulb ............8-41
Headlight beam adjustment...........8-44
Tail/brake light bulb
replacement .................................8-45
Troubleshooting .............................8-45

U5UH10.book Page 4 Monday, July 28, 2003 5:15 PM

SPECIFICATIONS.......................... 10-1

NOISE REGULATION.................... 11-1

MAINTENANCE RECORD ............ 12-1

ATV LIMITED WARRANTY............ 13-1

YAMAHA EXTENDED SERVICE
(Y.E.S.) ........................................... 14-1

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00464

LOCATION OF THE WARNING AND
SPECIFICATION LABELS

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

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

WARNING

7
8

Overloading this ATV or carrying cargo improperly can change
handling. stability and braking performance and can lead to an
accident. Never exceed the maximum front cargo limit of
: 40kg (88 lbs)
NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.

9
10
11

5ND-F4877-00

12
13

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

WARNING
Overloading this ATV or carrying cargo improperly can change
handling. stability and braking performance and can lead to an
accident. Never exceed the maximum rear cargo limit of
: 80kg (176 lbs)
NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
5ND-F4897-00

U5UH10.book Page 4 Monday, July 28, 2003 5:15 PM

MAXIMUM .LOADING LIMIT
PULLING LOAD:
TONGUE WEIGHT:

4900
1102
147
33

(500kgf)
N
lbf
( 15kgf)
N
lbf
5ND-F151K-00

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU13401

SAFETY INFORMATION
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.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
● Read this manual and all labels carefully and follow the operating procedures described.
● Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call
1-800-887-2887 to find out about the training courses nearest you.
● Always follow the age recommendation:
- A child under 16 years old should never operate an ATV with engine size greater than 90cc.
● Never allow a child under age 16 to operate an ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she does not have the abilities to operate it safely.
● Never carry a passenger on an ATV.
TV on any paved surfaces, including sidewalks, driveways, park-

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

●

●
●
●
●

●
●
●

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
a jacket, and long pants.
Never consume alcohol or drugs before or while operating this ATV.
Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is
proper for the terrain, visibility, operating conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.
Always keep both hands on the handlebars and both feet on the footboards of the ATV during
operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on
these kinds of terrain.
Always follow proper procedures for turning as described in this manual. Practice turning at low

1
2
3
4
5
6
7
8
9
10
11
12
13

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

●

Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose
surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of
a hill at high speed.
Always follow proper procedures for going down hills and for braking on hills as described in
this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause
the vehicle to lean sharply to one side. Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the
ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning
technique described in this manual on level ground. Avoid crossing the side of a steep hill if
possible.
Always use proper procedures if you stall or roll backwards when climbing a hill. 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.
Always check for obstacles before operating in a new area. Never attempt to operate over

U5UH10.book Page 4 Monday, July 28, 2003 5:15 PM

●

●
●
●
●
●

Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice,
go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
Never operate an ATV in fast flowing water or in water deeper than that recommended in this
manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
Always 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 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.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.

U5UH10.book Page 5 Monday, July 28, 2003 5:15 PM

WARNING
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could
be burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refueling.
Do not refuel immediately after the engine has been running and is still very
hot.
Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or in the vicinity of sparks, open flames, or other
sources of ignition such as the pilot

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.
If gasoline spills on your skin, wash with
soap and water. If gasoline spills on
your clothing, change your clothes.

U5UH10.book Page 6 Monday, July 28, 2003 5:15 PM

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.

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00032

DESCRIPTION AND MACHINE IDENTIFICATION

1. Rear shock absorber assembly
spring preload adjusting ring
2. Spark arrester
3. Storage box and tool kit
4. Spark plug
5. Front shock absorber assembly
spring preload adjusting ring
6. Brake pedal
7. V-belt case
8. Fuel cock
9. Air filter case
10. Fuses
11. Tail/brake light
12. Front shock absorber assembly

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

V-belt cooling duct check hose
Oil filter cartridge
Engine oil dipstick
Rear brake lever
Left handlebar switches
Starter (choke)
Drive select lever
Main switch
Fuel tank cap
Right handlebar switch
Throttle lever
Front brake lever

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

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.
This number can be used for ordering a new
key.

1
2
3
4
5
6
7
8

2. VEHICLE IDENTIFICATION NUMBER:

9
10
1. Key identification number

3. MODEL LABEL INFORMATION:

11
12
13

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

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 (front left side)

NOTE:
The vehicle identification number is used to
identify your machine.

1. Model label

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00039

CONTROL FUNCTIONS

WARNING

Indicates a potential hazard that could
result in serious injury or death.

3
4

EBU09420

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.

5
6
1. Main switch

7
8
9
10
11
12
13

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

EBU08020

EBU09720

Indicator and warning lights

Neutral indicator light “N”
This indicator light comes on when the drive
select lever is in the “N” position.
EBU12500

Reverse indicator light “R”
This indicator light comes on when the drive
select lever is in the “R” position.

1.
2.
3.
4.

Neutral indicator light “N”
Reverse indicator light “R”
Four-wheel drive indicator light “ ”
Oil temperature warning light “ ”

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

EBU00605

EBU11400

Four-wheel-drive indicator light “ ”
This indicator light comes on when the 2WD/
4WD switch is in the 4WD position.

Oil temperature warning light “ ”
When the oil temperature reaches a specified
level, this light comes on to warn that the engine oil temperature is too hot. If the light
comes on during operation, stop the engine
as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.

NOTE:
Due to the synchronizing mechanism in the
differential gear case, the light may not come
on until the ATV starts moving.

CAUTION:
_

●

The engine may overheat if the ATV is
overloaded. If this happens, reduce
the load to specification.
Restart after making sure that the light
is out. Continuous use while the light
is on may cause damage to the engine.

U5UH10.book Page 4 Monday, July 28, 2003 5:15 PM

EBU00733

Oil temperature warning light checking method
ACB-10E

Turn the main switch to “ON” and the
engine stop switch to “ ”.

Oil temperature warning
light does not come on.

Oil temperature warning
light comes on.

Push start switch with the
transmission in neutral.

Check engine oil temperature.

Oil temperature
warning light comes
on momentarily.

Oil temperature warning
light does not come on.

Oil temperature is low.

Oil temperature is high.

Allow to cool.
Engine oil temperature and
electrical circuit are OK. Go

Ask a Yamaha dealer to
inspect the electrical circuit.

U5UH10.book Page 5 Monday, July 28, 2003 5:15 PM

EBU00053

Handlebar switches

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.
_

EBU12050

1. Light switch “
/
/OFF”
2. Engine stop switch “
/
”
3. Start switch “ ”

EBU01204

Light switch “
/
/OFF”
Set the switch to “
” to turn on the low beam

Engine stop switch “ / ”
Make sure that the engine stop switch is set to
“ ” before starting the engine. The engine
stop switch controls ignition and can be used
at all times to stop the engine, especially in an
emergency. The engine will not start or run
when the engine stop switch is set to “ ”.

U5UH10.book Page 6 Monday, July 28, 2003 5:15 PM

EBU00607

Start switch “ ”
The starter motor cranks the engine when this
switch is pushed.

CAUTION:
See starting instructions prior to starting
the engine. (See page 6-1 for details.)

1. Four-wheel drive switch “2WD/4WD”

EBU00601

On-Command four-wheel drive switch
“2WD/4WD”
To change from two-wheel drive (2WD) to
four-wheel drive (4WD), stop the ATV and set
the switch to the 4WD position.
To change from four-wheel drive (4WD) to

U5UH10.book Page 7 Monday, July 28, 2003 5:15 PM

WARNING
POTENTIAL HAZARD
Changing from 2WD to 4WD or from
4WD to 2WD while the ATV is moving.
WHAT CAN HAPPEN
The ATV handles differently in 2WD
than in 4WD in some circumstances.
Changing from 2WD to 4WD or from
4WD to 2WD while moving may cause
the ATV to unexpectedly handle differently. This could distract the operator
and increase the risk of losing control
and an accident.
HOW TO AVOID THE HAZARD
Always stop the ATV before changing
from 2WD to 4WD or vice-versa.

U5UH10.book Page 8 Monday, July 28, 2003 5:15 PM

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. Make sure
it returns to the idle position as soon as the lever is released.

WARNING
POTENTIAL HAZARD
Malfunction of throttle.
WHAT CAN HAPPEN
The throttle could be hard to operate,
making it difficult to speed up or slow
down when you need to. This could
cause an accident.
HOW TO AVOID THE HAZARD
Check the operation of the throttle lever
before you start the engine. If it does not
work smoothly, check for the cause.
Correct the problem before riding the

U5UH10.book Page 9 Monday, July 28, 2003 5:15 PM

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.

1. Locknut

2. Adjusting screw

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.
You could lose control, have an accident or be injured.
HOW TO AVOID THE HAZARD
Do not turn the adjusting screw out
more than 12 mm (0.47 in). Always make
sure the throttle lever free play is adjusted to 3–5 mm (0.12–0.20 in). See page
8-26.

U5UH10.book Page 10 Monday, July 28, 2003 5:15 PM

EBU00070

Front brake lever
The front brake lever is located on the right
handlebar. Pull it toward the handlebar to apply the front brake.

1. Brake pedal

1. Front brake lever

EBU00732

Brake pedal and rear brake lever

U5UH10.book Page 11 Monday, July 28, 2003 5:15 PM

EBU00074

Parking brake
Use the parking brake when you have to start
the engine or park the machine, especially on
a slope. Apply the rear brake lever and push
down the lock plate to apply the parking
brake. Squeeze the rear brake lever to release the parking brake.

1. Lock plate

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.
The brake could overheat if you ride the
ATV without releasing the parking
brake. You could lose braking performance which could cause an accident.
You could also wear out the brakes prematurely.
HOW TO AVOID THE HAZARD
Always set the parking brake before
starting the engine.

U5UH10.book Page 12 Monday, July 28, 2003 5:15 PM

EBU01106

EBU01107

Drive select lever
The drive select lever is used to shift your machine into the forward, neutral and reverse positions. (Refer to page 6-4 for the drive select
lever operation.)

Recoil starter
Firmly grasp the handle and pull slightly until
engagement can be felt. Then pull forcefully,
being careful not to pull the rope all the way
out.

1. Drive select lever

1. Recoil starter

U5UH10.book Page 13 Monday, July 28, 2003 5:15 PM

EBU00092

WARNING
POTENTIAL HAZARD
Starting the engine without shifting into
the neutral position.
WHAT CAN HAPPEN
The ATV could start to move unexpectedly, which could cause an accident.
HOW TO AVOID THE HAZARD
Shift the drive select lever into the neutral position and apply the parking brake
before starting the engine.

Fuel tank cap
Remove the fuel tank cap by turning it counterclockwise.

1. Fuel tank cap

U5UH10.book Page 14 Monday, July 28, 2003 5:15 PM

EBU00093

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. If you run out of
fuel while riding, turn the lever to this
position. THEN FILL THE FUEL TANK
AT THE FIRST OPPORTUNITY. After
refuelling, return the fuel cock lever to
the “ON” position.

OFF Position

1. Arrow mark pointing to “OFF”

ON Position

U5UH10.book Page 15 Monday, July 28, 2003 5:15 PM

EBU00095

RES Position

1. Arrow mark pointing to “RES”

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.)

U5UH10.book Page 16 Monday, July 28, 2003 5:15 PM

EBU05670

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

2. Seat lock lever

1. Projection (× 2)

2. Seat holder (× 2)

U5UH10.book Page 17 Monday, July 28, 2003 5:15 PM

EBU14580

Storage box
Maximum load limit: 2 kg (4.4 lb)

CAUTION:

NOTE:
There is a check hose at the bottom of the
storage box. If any water collects in this hose,
remove the hose, empty it, and then install it.
_

To protect from damage, do not put metal
products, like tools or sharply edged products directly in the storage box. If they
must be stored, wrap them in appropriate
cushion material.
_

1. Storage box check hose

U5UH10.book Page 18 Monday, July 28, 2003 5:15 PM

EBU00582

Front carrier
Maximum load limit: 40 kg (88 lb)

EBU00583

Rear carrier
Maximum load limit: 80 kg (176 lb)

EBU01104

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 ad-

1. Spring preload adjusting ring
2. Position indicator

NOTE:
A special wrench can be obtained at a
Yamaha dealer to make this adjustment.
_

Standard position: 2
1 - Minimum (soft)
5 - Maximum (hard)

U5UH10.book Page 19 Monday, July 28, 2003 5:15 PM

EBU01103

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:
To increase the spring preload, turn the adjusting ring in direction a.
To decrease the spring preload, turn the adjusting ring in direction b.
1. Special wrench

WARNING
POTENTIAL HAZARD
Improper shock absorber adjustment.
WHAT CAN HAPPEN
Uneven adjustment can cause poor
handling and loss of stability, which
1. Spring preload adjusting ring

U5UH10.book Page 20 Monday, July 28, 2003 5:15 PM

NOTE:
A special wrench can be obtained at a
Yamaha dealer to make this adjustment.
_

Standard position: 2
1 - Minimum (soft)
5 - Maximum (hard)

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

PRE-OPERATION CHECKS
1

Before using this machine, check the following points:

2
ITEM

ROUTINE

PAGE

Front brake

• Check operation, free play, fluid level and fluid leakage.
• Fill with DOT 4 brake fluid if necessary.

Rear brake

• Check operation, condition and free play.
• Adjust if necessary.

Fuel

• Check fuel level.
• Fill with fuel if necessary.

Engine oil

• Check oil level.
• Fill with oil if necessary.

Final gear oil/
differential gear oil

• Check for leakage.

5-6–5-7,
8-11–8-15

Throttle

• Check for proper throttle cable operation.

5-7, 8-26

Wheels and tires

• Check tire pressure, wear and damage.

5-8–5-11,
8-36–8-37

Fittings and fasteners

• Check all fittings and fasteners.

5-7

5-7, 8-34,
8-41–8-45

for proper operation.

5-2–5-3,
8-27–8-30

5-2–5-3,
8-27,8-31–8-33

5-4–5-5

6
7

5-6, 8-6–8-11

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

EBU12521

WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident
or equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you
use it to make sure the ATV is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.

Front and rear brakes
Brake levers and brake pedal
● Check for correct free play in the front
brake lever. If the free play is incorrect,
have a Yamaha dealer adjust it.
● Check for correct free play in the rear brake
lever and brake pedal. If the free play is incorrect, adjust it. (See pages 8-31–8-33.)
● Check operation of the levers and pedal.
They should move smoothly and there
should be a firm feeling when the brake is
applied. If not, have a Yamaha dealer inspect them.
Brake fluid level (front brake)
Check the brake fluid level. Add fluid if necessary. (See pages 8-28–8-29.)
Recommended brake fluid: DOT 4

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

Brake fluid leakage (front brake)
Check to see if any brake fluid is leaking out of
the hose, joint or brake fluid reservoir of the
front brake. Apply the brake firmly for one
minute. If the lever moves slowly inward,
there may be a leak in the brake system. If
there is any leakage, the brake system should
be inspected by a Yamaha dealer.
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 and shoes
for wear. (See page 8-27.)

WARNING
POTENTIAL HAZARD
Riding with improperly operating
brakes.
WHAT CAN HAPPEN
You could lose braking ability, which
could lead to an accident.
HOW TO AVOID THE HAZARD
Always check the brakes at the start of
every ride. Do not ride the ATV if you
find any problem with the brakes. If a
problem cannot be corrected by the adjustment procedures provided in this
manual, have a Yamaha dealer check for
the cause.

U5UH10.book Page 4 Monday, July 28, 2003 5:15 PM

EBU01085

Fuel
Make sure there is sufficient gasoline in the
tank.
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
Total:
13.5 L (2.97 Imp gal, 3.57 US gal)
Reserve:
3.3 L (0.73 Imp gal, 0.87 US gal)

CAUTION:
_

Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to internal engine parts, such as the valves
and piston rings, as well as to the exhaust
system.

Your Yamaha engine has been designed to
use regular unleaded gasoline with a 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.

U5UH10.book Page 5 Monday, July 28, 2003 5:15 PM

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.

nk filler tube

WARNING
POTENTIAL HAZARD
Improper care when refueling.
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire
and severe injury. Fuel expands when it
heats up. If the fuel tank is overfilled,
fuel could spill out due to heat from the
engine or the sun.
HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful
not to spill fuel, especially on the engine
or exhaust pipe. Wipe up any spilled fuel
immediately. Be sure the fuel tank cap is
closed securely. Do not refuel right after
the engine has been running and is still
very hot.

U5UH10.book Page 6 Monday, July 28, 2003 5:15 PM

EBU10842

EBU00493

Engine oil
Make sure the engine oil is at the specified
level. Add oil as necessary. (See pages 8-6–
8-11.)

Final gear oil
Make sure the final gear oil is at the specified
level. Add oil as necessary. (See pages 8-11–
8-13 for details.)

CAUTION:
_

●

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
CONSERVING II” or higher.
Make sure that no foreign material enters the crankcase.

Recommended engine oil type and

Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
If desired, an SAE 80W90 hypoid gear oil may
be used for all conditions.
NOTE:
GL-4 is a quality and additive rating, GL-5 or
GL-6 rated hypoid gear oils may also be used.

U5UH10.book Page 7 Monday, July 28, 2003 5:15 PM

EBU00678

EBU11620

Differential gear oil
Make sure the differential gear oil is at the
specified level. Add oil as necessary. (See
pages 8-14–8-15 for details.)

Fittings and fasteners
Always check the tightness of chassis fittings
and fasteners before a ride. Take the machine
to a Yamaha dealer or refer to the Service
Manual for correct tightening torque.

Recommended oil:
SAE 80 API GL-4 Hypoid gear oil

EBU01083

Throttle lever
Check to see that the throttle lever operates
correctly. It must open smoothly and spring
back to the idle position when released. Have
a Yamaha dealer repair as necessary for
proper operation.

EBU10030

Lights
Check the headlights and tail/brake light to
make sure they are in working condition. Repair as necessary for proper operation.
EBU11700

Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper
operation.

U5UH10.book Page 8 Monday, July 28, 2003 5:15 PM

EBU00157

Tires

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 accident.
HOW TO AVOID THE HAZARD
1. The tires listed below have been approved by Yamaha Motor Co., Ltd.
for this model. Other tire combinations are not recommended.

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 (0.22 kgf/cm2, 3.2 psi)
Rear 22 kPa (0.22 kgf/cm2, 3.2 psi)

U5UH10.book Page 9 Monday, July 28, 2003 5:15 PM

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.

U5UH10.book Page 10 Monday, July 28, 2003 5:15 PM

EBU00159

How to measure tire pressure
Use the low-pressure tire gauge.
NOTE:
The low-pressure tire gauge is included as
standard 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 be incorrect.
Set pressure with tires cold.
Set tire pressures to the following specifications:
ACE-02EACE-02E

Front

Recommended
pressure

Minimum

Maximum

25 kPa
(0.25 kgf/cm2,
3.6 psi)

22 kPa
(0.22 kgf/cm2,
3.2 psi)

28 kPa
(0.28 kgf/cm2,
4.0 psi)
28 kPa

1. Low-pressure tire gauge

U5UH10.book Page 11 Monday, July 28, 2003 5:15 PM

EBU00160

Tire wear limit
When the tire groove decreases to 3 mm
(0.12 in) due to wear, replace the tire.

a. Tire wear limit

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00161

EBU14590

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.

POTENTIAL HAZARD
Freezing control cables in cold weather.
WHAT CAN HAPPEN
You could be unable to control the ATV,
which could lead to an accident or collision.
HOW TO AVOID THE HAZARD
When riding in cold weather, always
make sure all control cables work
smoothly before you begin riding.
1. Apply the brake pedal.
2. Turn the fuel cock to “ON”.
3. Turn the main switch to “ON” and the engine stop switch to “ ”.
4. Shift the drive select lever into the neutral

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

NOTE:
● When the drive select lever is in the neutral position, the neutral indicator light
should come on. If it does not come on,
ask a Yamaha dealer to inspect the electric circuit.
● The engine can be started in any gear if
the brake pedal is applied. However, it is
recommended to shift into neutral before
starting the engine.
_

Position 3: Cold engine startambient temperature above
25 °C (80 °F) and warm engine
start position.

1
2
3
4
5
6
7

5. Use the starter (choke) in reference to
the figure:
Position 1: Cold engine startambient temperature below 5 °C
(40 °F).
Position 2: Cold engine startambient temperature at 0 °C
°F) and warm-

8
9
10
a. Starter (choke)
2. Half open

1. Fully open
3. Closed

6. Completely close the throttle lever and
start the engine by pushing the start

11
12
13

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

NOTE:
● If the engine fails to start, release the
start switch, then push the start switch
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.
● If the battery is discharged, pull the recoil
starter to start the engine.

CAUTION:

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.
engine until it

See the “Engine break-in” section prior to
operating the engine for the first time.
_

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.
EBU00182

Warming up
To get maximum engine life, always warm up
the engine before starting off. Never accelerate hard with a cold engine! To see whether or
not the engine is warm, check if it responds to

U5UH10.book Page 4 Monday, July 28, 2003 5:15 PM

EBU14600

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.
_

Shifting: forward
1. Bring the machine to a complete stop
and return the throttle lever to the closed
position.
2. Shift the gear from neutral to forward and
vice versa by moving the drive select lever along the shift guide.
NOTE:
Make sure that the drive select lever is com_

1. Drive select lever

3. Open the throttle lever gradually.

U5UH10.book Page 5 Monday, July 28, 2003 5:15 PM

Shifting: reverse
1. Bring the machine to a complete stop
and return the throttle lever to the closed
position.
2. Apply the brake pedal.
3. Shift the gear from neutral to reverse and
vice versa by moving the drive select lever along the shift guide.
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 ATV.
_

1. Drive select lever

4. Check behind for people or obstacles,
then release the brake pedal.
5. Open the throttle lever gradually and continue to watch to the rear while backing.

U5UH10.book Page 6 Monday, July 28, 2003 5:15 PM

WARNING
POTENTIAL HAZARD
Improper operation in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind you, resulting in serious injury.
HOW TO AVOID THE HAZARD
When you shift into reverse, make sure
there are no obstacles or people behind
you. When it is safe to proceed, go slowly.

U5UH10.book Page 7 Monday, July 28, 2003 5:15 PM

EBU02101

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.
During this period, prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided.
However, momentary (2–3 seconds maximum) full throttle operation under load does
not harm the engine.

Each full throttle acceleration sequence
should be followed with a substantial rest period for the engine by cruising at lower r/min
so the engine can rid itself of the temporary
build up of heat.
If any abnormality is noticed during this period, consult a Yamaha dealer.
0–10 hours:
Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the
speed of the machine from time to time. Do
not operate it at one set throttle position.

U5UH10.book Page 8 Monday, July 28, 2003 5:15 PM

EBU00211

10–20 hours:
Avoid prolonged operation above 3/4 throttle.
Rev the machine freely but do not use full
throttle at any time.
After break-in:
Avoid prolonged full throttle operation. Vary
speeds occasionally.

Parking
When parking, stop the engine and shift into
neutral. Turn the fuel cock to “OFF” and apply
the parking brake.

U5UH10.book Page 9 Monday, July 28, 2003 5:15 PM

EBU13750

Parking on a slope

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.
HOW TO AVOID THE HAZARD
Avoid parking on hills or other inclines.
If you must park on an incline, place the
machine transversely across the incline, apply the parking brake, and 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 machine to a stop by applying
the brakes.
2. Stop the engine.
3. With the rear brake lever and pedal applied, apply the parking brake, and then
slowly release the brake pedal.

U5UH10.book Page 10 Monday, July 28, 2003 5:15 PM

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. However, it is not possible for
Yamaha to test all non-Yamaha accessories, nor have any control over the quality or
suitability of them. Choose a genuine
Yamaha accessory, or one that is equivalent in design and quality.

●

Accessories should be rigidly and securely
mounted. An accessory which can shift position or come off while you are riding could
affect your ability to control the ATV.
Do not mount an accessory where it could
interfere with your ability to control the ATV.
Examples include (but are not limited to) a
heavy or bulky object attached to the handlebars which could make steering difficult,
an accessory that limits your ability to move
around on the seat, or one that limits your
view.
Use extra caution when riding an ATV with
accessories. The ATV may handle differently than it does without accessories.

U5UH10.book Page 11 Monday, July 28, 2003 5:15 PM

EBU12461

Loading
Cargo or a trailer can change the stability and
handling of an ATV.
You must use common sense and good judgment when carrying cargo or towing a trailer.
Keep the following points in mind:
● Never exceed the weight limits shown. An
overloaded ATV can be unstable.
MAXIMUM LOADING LIMIT
● Vehicle loading limit (total weight of
cargo, rider and accessories, and
tongue weight): 210 kg (463 lb)
● Front carrier: 40 kg (88 lb)
● Rear carrier: 80 kg (176 lb)
● Storage box: 2.0 kg (4.4 lb)
● Trailer hitch:
Pulling load (total weight of trailer
lbf)

●

Do not exceed the maximum tongue
weight. You can measure tongue weight
with a bathroom scale. Put the tongue of
the loaded trailer on the scale with the
tongue at hitch height. Adjust the load in the
trailer, if necessary, to reduce the weight on
hitch.
If you are carrying cargo and towing a trailer, include the tongue weight in the maximum vehicle load limit.
Load cargo on the carrier as close to the
center of the vehicle as possible. Put cargo
at the rear of the front carrier and at the
front of the rear carrier. Center the load
from side to side.
Tie down cargo securely to the carriers.
Make sure cargo in the trailer cannot move
around. A shifting load can cause an acci-

U5UH10.book Page 12 Monday, July 28, 2003 5:15 PM

●

●
●
●

Ride more slowly than you would without a
load. The more weight you carry, the slower you should go.
Allow more braking distance. A heavier vehicle takes longer to stop.
Avoid making sharp turns unless at very
slow speeds.
Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV.

WARNING
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.

U5UH10.book Page 13 Monday, July 28, 2003 5:15 PM

EBU14610

WARNING
_

Indicates a potential hazard that could
result in serious injury or death.

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

Riding

Your
ATV

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

WARNING
_

Indicates a potential hazard that could
result in serious injury or death.
GETTING TO KNOW YOUR ATV
This ATV is for recreation and utility use. This
section, Riding your ATV, provides general
ATV riding instructions for recreational riding.
The skills and techniques described in this
section, however, are appropriate for all types
of riding. Riding your ATV requires special
skills acquired through practice over a period
of time. Take the time to learn the basic techniques well before attempting more difficult
maneuvers.
Riding your new ATV can be a very enjoyable
rs of pleasure.

Owner’s Manual completely and understand
the operation of the controls. Pay particular attention to the safety information on pages
2-1–2-6. Please also read all caution and
warning labels on your ATV.

U5UH10.book Page 4 Monday, July 28, 2003 5:15 PM

RIDE WITH CARE AND GOOD
JUDGEMENT
Get training if you are inexperienced.
Beginners should get training from a certified
instructor.
Become familiar with this ATV at slow speeds
first, even if you are an experienced operator.
Do not attempt to operate at maximum performance until you are totally familiar with the
ATV’s handling and performance characteristics.

WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
greatly in-

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.
Riding your ATV requires skills acquired
through practice over a period of time.
Take the time to learn the basic techniques
well before attempting more difficult maneuvers.

U5UH10.book Page 5 Monday, July 28, 2003 5:15 PM

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
90 cc.

U5UH10.book Page 6 Monday, July 28, 2003 5:15 PM

This ATV is designed to carry operator and
cargo 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.

U5UH10.book Page 7 Monday, July 28, 2003 5:15 PM

Apparel

WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an
approved motorcycle helmet, eye protection and protective clothing.
WHAT CAN HAPPEN
Operating without
an approved motorcycle helmet increases
your
chances of a severe
head injury or death
in the event of an
accident.
Operating without eye protection can result in an accident and increases your
in the event

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

U5UH10.book Page 8 Monday, July 28, 2003 5:15 PM

Do not operate after consuming alcohol or
drugs.
Operator’s performance capability is reduced
by the influence of alcohol or drugs.

WARNING
POTENTIAL 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.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before
or while driving this ATV.

U5UH10.book Page 9 Monday, July 28, 2003 5:15 PM

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
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident
or equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you
use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures

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.
HOW TO AVOID THE HAZARD
Always use the size and type tires specified in the Owner’s Manual for this vehicle on pages 5-8–5-9. Always maintain
proper tire pressure as described in the
Owner’s Manual on page 5-10.

U5UH10.book Page 10 Monday, July 28, 2003 5:15 PM

WARNING
_

Indicates a potential hazard that could
result in serious injury or death.
Do not operate at speeds too fast for your
skills or the conditions.

WARNING
POTENTIAL HAZARD
Operating this ATV at speeds too fast
for your skills or the conditions.
WHAT CAN HAPPEN
Increases your chances of losing control of the ATV, which can result in an
accident.
HOW TO AVOID THE HAZARD
Always go at a speed that is proper for
erating con-

Speed limiter
For riders less experienced with this model,
this model is equipped with a speed limiter in
the throttle lever housing. The speed limiter
keeps the throttle from fully opening, even
when the throttle lever is pushed to the maximum. Turning the adjusting screw in limits the
maximum engine power available and decreases the maximum speed of the ATV.
Turning the adjusting screw in decreases top
speed and turning it out increases top speed.

U5UH10.book Page 11 Monday, July 28, 2003 5:15 PM

Loading and accessories
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.
MAXIMUM LOADING LIMIT
● Vehicle loading limit: 210 kg (463 lb)
* Total weight of cargo, rider and
accessories, and trailer hitch
vertical load.
● Front carrier: 40 kg (88 lb)
● Rear carrier: 80 kg (176 lb)
● Storage box: 2.0 kg (4.4 lb)
● Trailer hitch:
Pulling load: 500 kgf (1,102 lbf)
Total weight of trailer and cargo.
lbf)

U5UH10.book Page 12 Monday, July 28, 2003 5:15 PM

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. If you remove a
foot from a footboard, your foot or leg
may come into contact with the rear
wheels, which could injure you or cause
an accident.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet on the footboards of
your ATV during operation.

U5UH10.book Page 13 Monday, July 28, 2003 5:15 PM

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.

U5UH10.book Page 14 Monday, July 28, 2003 5:15 PM

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. All
parts and accessories added to this vehicle should be genuine Yamaha or
equivalent components designed for
use on this ATV and should be installed

U5UH10.book Page 15 Monday, July 28, 2003 5:15 PM

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.
Someone touching the exhaust system
during or after operation could be
burned.
HOW TO AVOID THE HAZARD

Do not touch the hot exhaust system.
Do not park the ATV in a place where
others might be likely to touch it.

U5UH10.book Page 16 Monday, July 28, 2003 5:15 PM

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.
HOW TO AVOID THE HAZARD
Always avoid paved surfaces, including
sidewalks, driveways, parking lots and
streets.

U5UH10.book Page 17 Monday, July 28, 2003 5:15 PM

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.

U5UH10.book Page 18 Monday, July 28, 2003 5:15 PM

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.
HOW TO AVOID THE HAZARD
Go slowly and be extra careful when operating on unfamiliar terrain. Always be

U5UH10.book Page 19 Monday, July 28, 2003 5:15 PM

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.
Always be especially cautious on these
kinds of terrain.

U5UH10.book Page 20 Monday, July 28, 2003 5:15 PM

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”.
Do not ride on private property without getting
permission.

WARNING

U5UH10.book Page 21 Monday, July 28, 2003 5:15 PM

Select a large, flat area off-road to become familiar with your ATV. Make sure that this area
is free of obstacles and other riders. You
should practice control of the throttle, brakes,
and turning techniques in this area before trying more difficult terrain.
Always avoid riding on paved surfaces: the
ATV is designed for off-road use only, and
handling maneuvers are more difficult to perform on pavement.
Set the parking brake and follow the instruction on page 6-1 to start the engine. Once it
has warmed up you are ready to begin riding
your ATV. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in
contact with these components.

With the engine idling, return the starter
(choke) to the closed position, shift the drive
select lever into the forward position, and then
release the parking brake. Apply the throttle
slowly and smoothly. The centrifugal clutch
will engage and you will start to accelerate. If
the throttle is applied too abruptly, the front
wheels may lift off the ground resulting in a
loss of directional control. Avoid higher
speeds until you are thoroughly familiar with
the operation of your ATV.
When slowing down or stopping, release the
throttle and apply the brakes smoothly and
evenly. Improper use of the brakes can cause
the tires to lose traction, reducing control and
increasing the possibility of an accident.

U5UH10.book Page 22 Monday, July 28, 2003 5:15 PM

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.

WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
ATV could go out of control, causing a
collision or overturn.

HOW TO AVOID THE HAZARD
Always follow proper procedures for
turning as described in this Owner’s
Manual.
Practice turning at low speeds before attempting to turn at faster speeds. Do not
turn at speeds too fast for your skills or
the conditions.
As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the
footboard to the outside of the turn (opposite
your desired direction) and lean your upper
body into the turn. Use the throttle to maintain
an even speed through the turn. This maneuver will let the wheel on the inside of the turn
slip slightly, allowing the ATV to make the turn

U5UH10.book Page 23 Monday, July 28, 2003 5:15 PM

Once you have learned this technique you
should be able to perform it at higher speeds
or in tighter curves.

This procedure should be practiced at slow
speed many times in a large off-road area
with no obstacles. If an incorrect technique is
used, your ATV may continue to go straight. If
the ATV doesn’t turn, come to a stop and then

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. It may also be necessary to gradually let
off on the throttle and steer to the outside of
the turn to avoid tipping over.
Remember: Avoid higher speeds until you are
thoroughly familiar with the operation of your
ATV.

U5UH10.book Page 24 Monday, July 28, 2003 5:15 PM

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.

WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on
extremely steep hills than on level surfaces or small hills.

HOW TO AVOID THE HAZARD
Never operate the ATV on hills too steep
for the ATV or for your abilities. Practice
on smaller hills before attempting large
hills.
It is important when climbing a hill to make
sure that your weight is transferred forward on
the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing
on the footboards and leaning forward over
the handlebars.

U5UH10.book Page 25 Monday, July 28, 2003 5:15 PM

WARNING
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.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly.
The ATV could flip over backwards.

An obstacle, a sharp drop, or another
vehicle or person could be on the other
side of the hill.

U5UH10.book Page 26 Monday, July 28, 2003 5:15 PM

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.

WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on
hills.
WHAT CAN HAPPEN
Could cause loss of control or cause the
ATV to overturn.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around
on any hill until you have mastered the
turning technique 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
possible.

U5UH10.book Page 27 Monday, July 28, 2003 5:15 PM

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.

U5UH10.book Page 28 Monday, July 28, 2003 5:15 PM

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.
If you start to roll backwards, DO NOT apply
either brake abruptly. If you are in 2WD, apply
only the front brake. When this ATV is in
4WD, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake
will brake all wheels. When descending hills,
using either brake lever or the brake pedal will
brake the wheels on the downhill side. Avoid

and rear brakes gradually, or dismount the
ATV immediately on the uphill side.

WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or improperly dismounting while climbing a hill.
WHAT CAN HAPPEN
Could result in ATV overturning.
HOW TO AVOID THE HAZARD
Maintain steady speed when climbing a
hill.
If you lose all forward speed:
Keep weight uphill.
Apply the brakes.
Apply the parking brake after you are
stopped.

U5UH10.book Page 29 Monday, July 28, 2003 5:15 PM

If you begin rolling backwards:
Keep weight uphill.
2WD: Never apply the rear brake
while rolling backwards. Apply the
front brake. When fully stopped, apply the rear brake as well, and then
lock the parking brake.
4WD: Apply both front and rear
brakes gradually. When fully stopped,
lock the parking brake.
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.

U5UH10.book Page 30 Monday, July 28, 2003 5:15 PM

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. Engine compression will do most of the braking for you. For
maximum engine compression braking effect,
change to 4WD before beginning to descend
the hill. Improper braking may cause a loss of
traction. Use caution while descending a hill
with loose or slippery surfaces. Braking ability
and traction may be adversely affected by
these surfaces. Improper braking may also
cause a loss of traction.

When this ATV is in 4WD, all wheels (front
and rear) are interconnected by the drive
train. This means that applying either the front
brake or the rear brake will brake all wheels.
When descending hills, using either brake lever or the brake pedal will brake the wheels
on the downhill side. Avoid sudden application of either the front or rear brake because
the wheels on the uphill side could come off
the ground. Apply both the front and rear
brakes gradually.
Whenever possible, ride your ATV straight
downhill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully
choose your path and ride no faster than you
will be able to react to obstacles which may
appear.

U5UH10.book Page 31 Monday, July 28, 2003 5:15 PM

WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the
ATV to overturn.
Always follow proper procedures for going down hills as described in this Owner’s Manual. Note: a special technique is
required when braking as you go down
a hill.
HOW TO AVOID THE HAZARD
Always check the terrain carefully before you start down any hill.
Shift your weight backward.
Never go down a hill at high speed.
Avoid going down a hill at an angle that

U5UH10.book Page 32 Monday, July 28, 2003 5:15 PM

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.
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 surfaces by pointing the front wheels slightly uphill. When riding on slopes be sure not to
make sharp turns either up or down hill.
If your ATV does begin to tip over, gradually
steer in the downhill direction if there are no

U5UH10.book Page 33 Monday, July 28, 2003 5:15 PM

U5UH10.book Page 34 Monday, July 28, 2003 5:15 PM

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.

WARNING
POTENTIAL HAZARD
Operating this ATV through deep or fast
flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction
and loss of control, which could lead to
an accident.
HOW TO AVOID THE HAZARD

Remember that wet brakes may have reduced stopping ability. Test your brakes
after leaving water. If necessary, apply
them several times to let friction dry out
the linings.

U5UH10.book Page 35 Monday, July 28, 2003 5:15 PM

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, the V-belt cooling duct check hose,
the drive select lever box check hose and
the storage box check hose. Also, remove
the V-belt case drain plug to drain any water that may have accumulated. Wash the
ATV in fresh water if it has been operated
in salt water or muddy conditions.
_

U5UH10.book Page 36 Monday, July 28, 2003 5:15 PM

1. V-belt cooling duct check hose (left front side of ATV)

1. Storage box check hose

U5UH10.book Page 37 Monday, July 28, 2003 5:15 PM

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. Could cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check
for obstacles.
Never attempt 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.

U5UH10.book Page 38 Monday, July 28, 2003 5:15 PM

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.
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.

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.

U5UH10.book Page 39 Monday, July 28, 2003 5:15 PM

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. You
may also regain traction unexpectedly,
which may cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Learn to safely control skidding or sliding by practicing at low speeds and on
level, smooth terrain.
On extremely slippery surfaces, such as
ice, go slowly and be very cautious in
order to reduce the chance of skidding
or sliding out of control.

U5UH10.book Page 40 Monday, July 28, 2003 5:15 PM

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 7-22–7-23.)
● If your ATV begins to tip while turning:
Lean more into the turn to regain balance. If
necessary, gradually let off the throttle and/
or steer to the outside of the turn. (See pag-

●

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 not recommended until you have corrected the slide. (See pages 7-38–7-39.)
If your ATV can’t make it up a hill you are
trying to climb:
Turn the ATV around if you still have forward speed. If not, stop, dismount on the
uphill side of the ATV and physically turn
the ATV around. If the ATV starts to slip
backwards, DO NOT USE THE REAR
BRAKE - the ATV may tip over on top of
you. Dismount the ATV on the uphill side.
(See pages 7-24–7-29.)

U5UH10.book Page 41 Monday, July 28, 2003 5:15 PM

●

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.)
If your ATV encounters shallow water:
Ride slowly and carefully through slow
moving water, watching for obstacles. Be
sure to let water 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. (See pages 7-34–7-36.)

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00515

PERIODIC MAINTENANCE AND
ADJUSTMENT

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.

WARNING
POTENTIAL HAZARD
Servicing an engine while it is running.
WHAT CAN HAPPEN
Moving parts can catch clothing or parts
of the body, causing injury.
Electrical components can cause

Have a Yamaha dealer perform service if
you are not familiar with machine service.
EBU14510

Owner’s manual and tool kit
You are recommended to put this owner’s
manual in the vinyl bag and always carry it on
the bottom of the seat as shown. Put the owner’s tool kit and low-pressure tire gauge under
the seat.
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

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

WARNING

1. Owner’s manual
2. Owner’s tool kit
3. Low-pressure tire gauge

NOTE:
If you do not have a torque wrench available
during a service operation requiring one, take
your machine to a Yamaha dealer to check
the torque settings and adjust them as necessary.
_

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. All
parts and accessories added to this vehicle should be genuine Yamaha or
equivalent components designed for
use on this ATV and should be installed
and used according to instructions. If

1
2
3
4
5
6
7
8
9
10
11
12
13

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

EBU00261

PERIODIC MAINTENANCE/LUBRICATION
ITEM
Valves*
Spark plug
Air filter element
Carburetor*
Crankcase breather
system*
Exhaust system*
Spark arrester
Fuel line*
Engine oil
Engine oil filter cartridge
Engine oil strainer*
Final gear oil
Differential gear oil
Front brake*

ROUTINE
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•

Check valve clearance.
Adjust if necessary.
Check condition.
Adjust gap and clean.
Replace if necessary.
Clean.
Replace if necessary.
Check and adjust idle speed/starter operation.
Adjust if necessary.
Check breather hose for cracks or damage.
Replace if necessary.
Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.
Clean.
Check fuel hose for cracks or damage.
Replace if necessary.
Replace. (Warm engine before draining.)
Replace.
Clean.
Check for oil leakage.
Replace every 12 months.
Check operation/fluid leakage. (See NOTE page 8-4.)
essary.
on.

1
month

INITIAL
EVERY
3
6
6
1
months months months
year

Every 20–40 hours
(More often in wet or dusty areas.)

U5UH10.book Page 4 Monday, July 28, 2003 5:15 PM

ITEM
V-belt*
Wheels*
Wheel bearing*
Front and rear
suspension*
Steering system*
Drive shaft universal joint*
Axle boots*
Fittings and fasteners*
Lights and switches*

ROUTINE
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•

1
month

INITIAL
EVERY
3
6
6
1
months months months
year

Check operation.
Check for cracks or damage.
Check balance/damage/runout.
Repair if necessary.
Check bearing assemblies for looseness/damage.
Replace if damaged.
Check operation.
Correct if necessary.
Check operation./Replace if damaged.
Check toe-in./Adjust if necessary.
Lubricate.
Check operation.
Replace if damaged.
Check all chassis fittings and fasteners.
Correct if necessary.
Check operation.
Adjust headlight beams.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

NOTE:
● Recommended brake fluid: DOT 4
● Brake fluid replacement:

• When disassembling the master cylinder or caliormally check the

U5UH10.book Page 5 Monday, July 28, 2003 5:15 PM

EBU08070

EBU01147

Panel removal and installation
The panel illustrated needs to be removed to
perform some of the maintenance described
in this chapter.
Refer to this section each time the panel has
to be removed or installed.

Panel A
To remove
Remove the bolt, and then take the panel off.
To install
Place the panel in the original position and install the bolt.

CAUTION:
_

When installing the panel, be sure not to
pinch the cables or wires.
_

1. Panel A

U5UH10.book Page 6 Monday, July 28, 2003 5:15 PM

EBU14540

Engine oil and oil filter cartridge
The engine oil level should be checked before
each ride. In addition, the oil must be changed
and the oil filter cartridge replaced at the intervals specified in the periodic maintenance
and lubrication chart.

4. Remove the engine oil filler cap and wipe
off the dipstick with a clean rag.

To check the engine oil level
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several
minutes, and then turn it off.
3. Wait a few minutes until the oil settles.
1. Engine oil filler cap

U5UH10.book Page 7 Monday, July 28, 2003 5:15 PM

5. Insert the dipstick in the oil filler hole
(without screwing it in), and then remove
it again to check the oil level.
NOTE:
The engine oil should be between the minimum and maximum level marks.
_

1. Maximum level mark

2. Minimum level mark

elow the mini-

7. Insert the dipstick into the oil filler hole,
and then tighten the oil filler cap.

U5UH10.book Page 8 Monday, July 28, 2003 5:15 PM

To change the engine oil (with or without
oil filter cartridge replacement)
1. Start the engine, warm it up for several
minutes, and then turn it off.
2. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap.
3. Remove the engine oil drain bolt to drain
the oil from the crankcase.

NOTE:
Skip steps 4–6 if the oil filter cartridge is not
being replaced.
_

4. Remove the oil filter cartridge with an oil
filter wrench.

1. Oil filter cartridge

U5UH10.book Page 9 Monday, July 28, 2003 5:15 PM

1. O-ring

1. Oil filter wrench

NOTE:
An oil filter wrench is available at a nearby
Yamaha dealer.
_

5. Apply a light coat of engine oil to the
O-ring of the new oil filter cartridge.
NOTE:
_

properly.
_

U5UH10.book Page 10 Monday, July 28, 2003 5:15 PM

6. Install the new oil filter cartridge with an
oil filter wrench, and then tighten it to the
specified torque with a torque wrench.

7. Install the engine oil drain bolt, and then
tighten it to the specified torque.
Tightening torque:
Engine oil drain bolt:
23 Nm (2.3 m·kgf, 16 ft·lbf)
8. Add the specified amount of recommended engine oil, and then install the engine
oil filler cap and tighten it.

1. Torque wrench

Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)

Recommended engine oil:
See page 10-2.
Oil quantity:
Without oil filter cartridge replacement:
2.2 L (1.94 Imp qt, 2.33 US qt)
With oil filter cartridge replacement:
2.3 L (2.02 Imp qt, 2.43 US qt)

U5UH10.book Page 11 Monday, July 28, 2003 5:15 PM

EBU11452

CAUTION:
_

●

9. Start the engine and warm it up for several minutes. While warming up, check for
oil leakage. If oil leakage is found, turn
the engine off immediately and check for
the cause.
hen check the

Final gear oil
Final gear oil measurement
1. Place the machine on a level surface.
2. Remove the oil filler bolt, and then check
the oil level in the final gear case.
NOTE:
The oil level should be at the brim of the filler
hole.
_

U5UH10.book Page 12 Monday, July 28, 2003 5:15 PM

3. If the oil is below the brim of the filler hole,
add sufficient oil of the recommended
type to raise it to the correct level.

Final gear oil replacement
1. Remove the final gear case cover by removing the bolts.

CAUTION:
_

Be sure no foreign material enters the final
gear case.
_

4. Install the oil filler bolt.

1. Final gear case cover

2. Bolt (× 2)

2. Place the machine on a level surface.
3. Place a container under the final gear
case to collect the used oil.

U5UH10.book Page 13 Monday, July 28, 2003 5:15 PM

4. Remove the oil filler bolt and the drain
bolt to drain the oil.

Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
Oil quantity:
0.23 L (0.20 Imp qt, 0.24 US qt)

CAUTION:
_

Be sure no foreign material enters the final
gear case.
_

1. Final gear oil drain bolt

5. Install the drain bolt, and then tighten it to
the specified torque.
Tightening torque:
Final gear oil drain bolt:
bf)

7. Install the oil filler bolt.
8. Check for oil leakage. If oil leakage is
found, check for the cause.
9. Install the final gear case cover bolts, and
then tighten them to the specified torque.
Tightening torque:
Final gear case cover bolt:
16 Nm (1.6 m·kgf, 11 ft·lbf)

U5UH10.book Page 14 Monday, July 28, 2003 5:15 PM

EBU01241

Differential gear oil replacement
1. Place the machine on a level surface.
2. Place a container under the differential
gear case to catch the oil.
3. Remove the oil filler bolt and oil drain bolt
to drain the oil.

1. Differential gear oil drain bolt

4. Install the oil drain bolt, and then tighten it
to the specified torque.

1. Differential gear oil filler bolt

Tightening torque:
Drain bolt:
10 Nm (1.0 m·kgf, 7 ft·lbf)

U5UH10.book Page 15 Monday, July 28, 2003 5:15 PM

5. Fill the differential gear case with the
specified amount of the recommended
oil.
NOTE:
● Do not exceed the specified differential
gear oil quantity when filling. Overfilling
will cause the oil to seep out of the
breather hose during and after riding.
● The differential gear oil level cannot be
checked. The differential gear case capacity is greater than the recommended
oil quantity, therefore the oil level cannot
be accurately checked from the oil filler
cap hole.

CAUTION:
_

Be sure no foreign material enters the differential gear case.
_

Recommended oil:
SAE 80 API “GL-4” Hypoid gear oil

6. Install the oil filler bolt.
7. Check for oil leakage. If oil leakage is
found, check for the cause.

U5UH10.book Page 16 Monday, July 28, 2003 5:15 PM

EBU00862

EBU14550

Axle boots
Check the protective boots for holes or tears.
If any damage is found, have them replaced
by a Yamaha dealer.

Spark plug inspection
Removal
1. Remove the spark plug cap.

1. Spark plug cap
1. Axle boot (× 2 each side)

U5UH10.book Page 17 Monday, July 28, 2003 5:15 PM

2. Use the spark plug wrench in the owner’s
tool kit to remove the spark plug as shown.

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)

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.

Installation
1. Measure the electrode gap with a wire
thickness gauge and, if necessary, adjust
the gap to specification.
Spark plug gap:
0.6–0.7 mm (0.02–0.03 in)

U5UH10.book Page 18 Monday, July 28, 2003 5:15 PM

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.
_

4. Install the spark plug cap.

a. Spark plug gap

2. Clean the surface of the spark plug gasket and its mating surface, and then wipe
off any grime from the spark plug
threads.
3. Install the spark plug and tighten it to the
specified torque.

U5UH10.book Page 19 Monday, July 28, 2003 5:15 PM

EBU11332

Air filter element cleaning
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.
_

1. Holder (× 4)

2. Air filter case cover

3. Remove the air filter element assembly,
and then remove the air filter element
from its frame.

1. Air filter case check hose

page 4-16 for

U5UH10.book Page 20 Monday, July 28, 2003 5:15 PM

WARNING

1. Air filter element frame

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. Air filter element

4. Wash the element gently but thoroughly
in solvent.

5. Squeeze the excess solvent out of the air
filter element and let it dry.

CAUTION:
_

Do not twist the air filter element when
squeezing it.
_

U5UH10.book Page 21 Monday, July 28, 2003 5:15 PM

7. Apply Yamaha foam air filter oil or other
quality foam air filter oil to the air filter element. If foam air filter oil is not available,
engine oil may be used.
NOTE:
The air filter element should be wet but not
dripping.
_

8. Pull the air filter element over its frame.
9. Install the air filter element assembly.
10. Install the air filter case cover by hooking
the holders.
11. Install the seat.

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.
Check the air filter case rubber joint to the carburetor and manifold fittings for an airtight
seal. Tighten all fittings securely to avoid the
possibility of unfiltered air entering the engine.
_

CAUTION:
_

Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid engine wear and
possible engine damage. Additionally, operation without the air filter element will af-

U5UH10.book Page 22 Monday, July 28, 2003 5:15 PM

EBU06411

EBU08741

V-belt cooling duct check hose
If dust or water collects in the V-belt cooling
duct check hose, remove the hose and clean
it.

V-belt case drain plug
After riding in water deep enough to allow it to
enter the V-belt case, remove this plug to
drain the water from the case.
NOTE:
If water drains from the V-belt case after removing the plug, have a Yamaha dealer inspect the ATV as the water may affect other
engine parts.
_

1. V-belt cooling duct check hose (Left front side of ATV)

U5UH10.book Page 23 Monday, July 28, 2003 5:15 PM

EBU01066

Spark arrester cleaning
Be sure the exhaust pipe and muffler are cool
before cleaning the spark arrester.
1. Remove the bolts.
2. Remove the tailpipe by pulling it out of
the muffler.

1. Spark arrester

4. Insert the tailpipe into the muffler and
align the bolt holes.
5. Install and tighten the bolts.

1. Bolt (× 3)

2. Tailpipe

3. Tap the tailpipe lightly, and then use a

U5UH10.book Page 24 Monday, July 28, 2003 5:15 PM

EBU00296

WARNING
POTENTIAL HAZARD
Improper cleaning of the spark arrester.
Hot exhaust system
WHAT CAN HAPPEN
Could injure the eyes.
Could cause burns.
Could cause carbon monoxide poisoning, possibly leading to death.
Could start a fire.
HOW TO AVOID THE HAZARD
When cleaning the spark arrester:
Always let the exhaust system cool prior to touching exhaust components.
Do not start the engine when cleaning
the exhaust system.

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.

CAUTION:
The carburetor was set at the Yamaha factory after many tests. If the settings are
disturbed by someone without sufficient
technical knowledge, poor engine performance and damage may result.

U5UH10.book Page 25 Monday, July 28, 2003 5:15 PM

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. Turn the screw in direction a to
increase the engine speed, and in direction b to decrease the engine speed.

1. Throttle stop screw

EBU00303

Valve clearance adjustment
The correct valve clearance changes with
use, resulting in improper fuel/air supply or
engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional

U5UH10.book Page 26 Monday, July 28, 2003 5:15 PM

EBU00307

Throttle lever adjustment
NOTE:
Adjust the engine idling speed before adjusting the throttle lever free play.
1. Loosen the locknut.
2. Turn the adjusting bolt until the throttle lever free play is 3–5 mm (0.12–0.20 in).
3. Tighten the locknut.
a. Throttle lever free play

U5UH10.book Page 27 Monday, July 28, 2003 5:15 PM

EBU13090

EBU00313

Front brake pad check
Check the brake pads for damage and wear.
If a brake pad thickness is less than 1 mm
(0.04 in), have a Yamaha dealer replace the
pads as a set.

Rear brake shoe inspection
A wear indicator is provided on the rear brake.
This indicator allows checking of brake shoe
wear without disassembling the brake. Apply
the rear brake and check the position of the indicator. If the indicator reaches the wear limit
line, ask a Yamaha dealer to replace shoes as
a set.

a. Brake pad thickness

NOTE:
The wheels need to be removed to check the
_

1. Wear limit line

2. Wear indicator

U5UH10.book Page 28 Monday, July 28, 2003 5:15 PM

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.

Observe these precautions:
● When checking the brake fluid level, make
sure the top of the brake fluid reservoir is
level.
● Use only the designated quality brake fluid,
otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
Recommended brake fluid: DOT 4
●

FRONT

●

Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical
reaction and lead to poor brake performance.
Be careful that water does not enter the
brake fluid reservoir when refilling. Water
will significantly lower the boiling point of
the fluid and may result in vapor lock.

U5UH10.book Page 29 Monday, July 28, 2003 5:15 PM

EBU11860

●

Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled
fluid immediately.
Have a Yamaha dealer check the cause if
the brake fluid level goes down.

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.

U5UH10.book Page 30 Monday, July 28, 2003 5:15 PM

EBU11870

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.

a. Front brake lever free play

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.
● Make sure the brakes do not drag.
● Make sure the brakes are not
spongy. All air must be bled from
the brake system.
Replacement of brake components re-

U5UH10.book Page 31 Monday, July 28, 2003 5:15 PM

EBU01239

Rear brake pedal and lever adjustment
Brake pedal free play adjustment
1. Fully loosen the adjusting nut on the
brake lever cable at the rear wheel.

2. Turn the adjusting nut on the brake pedal
cable until the free play is 20–30 mm
(0.79–1.18 in).

a. Brake pedal free play
1. Adjusting nut (brake pedal cable)
2. Adjusting nut (brake lever cable)

U5UH10.book Page 32 Monday, July 28, 2003 5:15 PM

Brake lever free play adjustment
1. Loosen the locknut and fully turn in the
adjusting bolt at the brake lever.

1. Locknut

2. Turn in the adjusting nut on brake cable
to provide a gap of 0–1 mm (0–0.04 in)
between the brake camshaft lever and
the pin.

2. Adjusting bolt
1. Adjusting nut (brake lever cable) a. Gap

U5UH10.book Page 33 Monday, July 28, 2003 5:15 PM

3. Turn the adjusting bolt at the brake lever
until the free play at the brake lever pivot
is 3–5 mm (0.12–0.20 in).

1. Locknut
2. Adjusting bolt
a. Rear brake lever free play

4. Tighten the locknut.

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.
● Make sure the brakes do not drag.
Replacement of brake components requires professional knowledge. These
procedures should be performed by a
Yamaha dealer.

U5UH10.book Page 34 Monday, July 28, 2003 5:15 PM

EBU12590

Adjusting the rear brake light switch
The rear brake light switch, which is activated
by the brake pedal and rear 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.
1. Remove panel A. (See page 8-5 for panel removal and installation procedures.)
2. 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. To make the
brake light come on later, turn the adjusting nut in direction b.
3. Install the panel.

1. Rear brake light switch

2. Adjusting nut

U5UH10.book Page 35 Monday, July 28, 2003 5:15 PM

EBU00356

EBU12600

Cable inspection and lubrication

Lubricating the brake levers and brake
pedal
Lubricate the pivoting parts.

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.
HOW TO AVOID THE HAZARD
Inspect cables frequently. Replace damaged cables.
Lubricate the inner cables and the cable ends.
If the cables do not operate smoothly, ask a
.

NOTE:
To access the brake pedal pivot, remove panel A. (See page 8-5 for panel removal and installation procedures.)
_

Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

U5UH10.book Page 36 Monday, July 28, 2003 5:15 PM

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.

1. Nut (× 4)

U5UH10.book Page 37 Monday, July 28, 2003 5:15 PM

EBU01121

Wheel installation
1. Install the wheel and the nuts.

2. Lower the ATV so that the wheel is on the
ground.

NOTE:
● Tapered nuts are used for both the front
and rear wheels. Install the nut with its tapered side towards the wheel.
● The arrow mark
on the tire must point
toward the rotating direction of the wheel.
_

1. Tapered nut

3. Tighten the wheel nuts to the specified
torque.
Wheel nut torque:
Front: 55 Nm (5.5 m·kgf, 40 ft·lbf)
Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf)

U5UH10.book Page 38 Monday, July 28, 2003 5:15 PM

EBU00380

Battery
This machine is equipped with a sealed-type
battery. Therefore it is not necessary to check
the electrolyte or add distilled water in the battery. If the battery seems to have discharged,
consult a Yamaha dealer.

CAUTION:
Do not try to remove the sealing caps of
the battery cells. You may damage the battery.

WARNING
POTENTIAL HAZARD
Failure to handle batteries or battery
electrolyte carefully.
WHAT CAN HAPPEN
ou could be

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. Follow with milk of magnesia, beaten egg or vegetable oil. Get
prompt medical attention.
EYES: Flush with water for 15 minutes
and get prompt medical attention. Keep
batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed
space.

U5UH10.book Page 39 Monday, July 28, 2003 5:15 PM

EBU00385

EBU08760*

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.

Fuse replacement
1. The main fuse case and the fuse box are
located under the seat.
2. If a 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.

CAUTION:
A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type
battery. Using a conventional battery
charger may shorten the battery life.
2. Always make sure the connections are
correct when putting the battery back in
the machine.

U5UH10.book Page 40 Monday, July 28, 2003 5:15 PM

1. Main fuse
3. Fuse box

2. Spare main fuse

1.
2.
3.
4.
5.

Headlight fuse
Ignition fuse
Four-wheel drive fuse
Signaling system fuse
Spare fuse (× 3)

Specified fuses:
Main fuse:
Headlight fuse:
Ignition fuse:

30 A
15 A
15 A

U5UH10.book Page 41 Monday, July 28, 2003 5:15 PM

EBU14560

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.
HOW TO AVOID THE HAZARD
Always use a fuse of the specified rating. Never use a material in place of the
proper fuse.

Replacing a headlight bulb
If a headlight bulb burns out, replace it as follows.
1. Remove the bulb holder cover at the rear
of the headlight by pulling it off.

CAUTION:
_

To prevent accidental short-circuiting,
turn off the main switch when checking or
replacing a fuse.
_

1. Headlight bulb holder cover

U5UH10.book Page 42 Monday, July 28, 2003 5:15 PM

2. Remove the headlight bulb holder by
turning it counterclockwise.

1. Headlight bulb holder tab (× 2)

1. Headlight bulb holder

3. Remove the defective bulb by unhooking
the headlight bulb holder tabs.

U5UH10.book Page 43 Monday, July 28, 2003 5:15 PM

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.
HOW TO AVOID THE HAZARD
Wait for the bulb to cool before touching
or removing it.

1. Do not touch the glass part of the bulb.

CAUTION:
_

4. Insert a new headlight bulb into the bulb
holder, and then secure the bulb by
hooking the tabs onto the bulb.

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

U5UH10.book Page 44 Monday, July 28, 2003 5:15 PM

EBU01089

5. Install the headlight bulb holder by turning it clockwise.
6. Install the headlight bulb holder cover at
the rear of the headlight.

Headlight beam adjustment

CAUTION:
_

It is advisable to have a Yamaha dealer
make this adjustment.
_

To raise the beam, turn the adjusting screw in
direction a.
To lower the beam, turn the adjusting screw in
direction b.

U5UH10.book Page 45 Monday, July 28, 2003 5:15 PM

EBU01105

EBU00412

Tail/brake light bulb replacement
If the tail/brake light bulb burns out, have a
Yamaha dealer replace it.

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.
The skilled technicians at a Yamaha dealership have the tools, experience, and knowhow to properly service your machine. Use
only genuine Yamaha parts on your machine.
Imitation parts may look like Yamaha parts,
but they are often inferior. Consequently, they
have a shorter service life and can lead to expensive repair bills.

U5UH10.book Page 46 Monday, July 28, 2003 5:15 PM

WARNING
POTENTIAL HAZARD
Checking the fuel system while smoking or near an open flame.
WHAT CAN HAPPEN
Fuel can ignite or explode, causing severe injury or property damage.
HOW TO AVOID THE HAZARD
Do not smoke when checking the fuel
system. Make sure there are no open
flames or sparks in the area, including
pilot lights from water heaters or furnaces.

U5UH10.book Page 47 Monday, July 28, 2003 5:15 PM

EBU04400

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.

Ask a Yamaha dealer to
inspect.

Wet

Check the
fuel flow.

Dry

Wipe clean with dry cloth.

Attach spark plug cap and
ground to chassis.

Use the
electric starter.

Ignition system is
normal.

Spark is weak.

No spark.
Battery is good.

Fuel cock is
clogged.

Clean the
fuel cock.

Spark is good.

Remove the
spark plug and
check electrodes.

No fuel.

Adjust the spark plug gap
or replace the spark plug.

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00419

CLEANING AND STORAGE

A. CLEANING
Frequent, thorough cleaning of your machine
will not only enhance its appearance but will
improve its general performance and extend
the useful life of many components.
1. Before cleaning the machine:
a. Block off the end of the exhaust pipe to
prevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plug and all filler
caps are properly installed.
2. If the engine case is excessively greasy,
apply degreaser with a paint brush. Do
not apply degreaser to the wheel axles.
3. Rinse the dirt and degreaser off with a
garden hose. Use only enough pressure

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.

1
2
3
4
5
6
7

4. Once the majority of the dirt has been
hosed off, wash all surfaces with warm
water and mild, detergent-type soap. An
old toothbrush or bottle brush is handy for
hard-to-get-at places.
5. Rinse the machine off immediately with
clean water and dry all surfaces with a
chamois, clean towel or soft absorbent

8
9
10
11
12
13

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

6. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.
7. 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.
WHAT CAN HAPPEN
Wet brakes may have reduced stopping
ability, increasing the chance of an accident.
HOW TO AVOID THE HAZARD
Test the brakes after washing. Apply the
brakes several times at slow speeds to
let friction dry out the linings.

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

EBU00530

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.
Specified amount:
1 oz of stabilizer to each gallon of fuel
(or 7.5 cc of stabilizer to each liter of
fuel)
NOTE:
Use of fuel stabilizer and conditioner elimil system. Con-

2. Remove the spark plug, pour about one
tablespoon of SAE 10W30 or 20W40
motor oil in the spark plug hole and reinstall the spark plug. Ground the spark
plug wire and turn the engine over several times to coat the cylinder wall with oil.
3. Lubricate all control cables.
4. Block up the frame to raise all wheels off
the ground.
5. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
6. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces
with a light film of oil. Do not apply oil to
any rubber parts or the seat cover.

U5UH10.book Page 4 Monday, July 28, 2003 5:15 PM

7. 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.

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00428

SPECIFICATIONS

1
2

Model
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Basic weight:
With oil and full fuel tank
Engine:
Engine type
Cylinder arrangement
Displacement

YFM350FA
3
1,984 mm (78.1 in)
1,085 mm (42.7 in)
1,120 mm (44.1 in)
827 mm (32.6 in)
1,233 mm (48.5 in)
245 mm (9.65 in)
3,000 mm (118.1 in)
258 kg (569 lb)

4
5
6
7
8
9
10

Air cooled 4-stroke, SOHC
Forward-inclined single cylinder
348.9 cm3
83.0 × 64.5 mm (3.27 × 2.54 in)

11
12
13

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

Model

YFM350FA

Engine oil:
Type
0˚

10˚

30˚

50˚

70˚

90˚

110˚

130˚F

YAMALUBE 4 (20W40) or SAE 20W40
YAMALUBE 4 (10W30) or SAE 10W30
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. 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 CONSERVING II” or higher.

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

Model
Final gear case oil:
Type
Quantity:
Periodic oil change
Differential gear case oil:
Type
Quantity:
Periodic oil change
Air filter:
Fuel:
Type
Fuel tank capacity
Fuel reserve amount
Carburetor:
Type/quantity
Manufacturer
Spark plug:

YFM350FA
SAE80 API GL-4 Hypoid gear oil
0.23 L (0.20 Imp qt, 0.24 US qt)
SAE80 API GL-4 Hypoid gear oil
0.35 L (0.31 Imp qt, 0.37 US qt)
Wet element
UNLEADED GASOLINE ONLY
13.5 L (2.97 lmp gal, 3.57 US gal)
3.3 L (0.73 lmp gal, 0.87 US gal)
BSR33 / 1
MIKUNI
DR8EA / NGK

U5UH10.book Page 4 Monday, July 28, 2003 5:15 PM

Model
Transmission:
Primary reduction system
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Forward gear
Reverse gear
Chassis:
Frame type
Caster angle
Trail
Tire:
Type
Size

YFM350FA
V-belt
Shaft drive
41/21 × 24/18 × 33/9 (9.545)
V-belt automatic
Left hand operation
35/20 (1.750)
26/15 (1.733)
Steel tube frame
4°
21 mm (0.83 in)

front
rear

Tubeless
AT25 × 8 - 12
AT25 × 10 - 12

type

Dual disc brake

Brake:

U5UH10.book Page 5 Monday, July 28, 2003 5:15 PM

Model
Suspension:
Front suspension
Rear suspension
Shock absorber:
Front shock absorber
Rear shock absorber
Wheel travel:
Front wheel travel
Rear wheel travel
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
Headlight type:

YFM350FA
Double wishbone
Swingarm (monocross)
Coil spring / oil damper
Coil spring / oil damper
160 mm (6.30 in)
180 mm (7.09 in)
DC-C.D.I.
A.C. magneto
YTX14AH
12 V, 12 Ah
Krypton bulb

U5UH10.book Page 6 Monday, July 28, 2003 5:15 PM

Model
Bulb voltage, wattage × quantity:
Headlight
Tail/brake light
Neutral indicator light
Reverse indicator light
Oil temperature warning light
Four-wheel drive indicator light
Fuses:
Main fuse
Headlight fuse
Ignition fuse
Four-wheel drive fuse
Signaling system fuse

YFM350FA
12 V, 30/30 W × 2
12 V, 5/21 W × 1
12 V, 1.7 W × 1
12 V, 1.7 W × 1
12 V, 1.7 W × 1
12 V, 1.7 W × 1
30 A
15 A
15 A
3A
10 A

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00430

NOISE REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior
to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after
such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED
BELOW.”
These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust
system

Muffler
Exhaust pipe
Silencer

Intake system

Air cleaner case
Air cleaner element
Intake duct

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU13651
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.
ACL-04E

MAINTENANCE
INTERVAL
1 Month

DATE OF
SERVICE

SERVICING DEALER
NAME AND ADDRESS

REMARKS

1
2
3
4
5
6

3 Months

6 Months

12 Months
18 Months

24 Months

30 Months

36 Months
42 Months

12
13

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00432

YAMAHA MOTOR CORPORATION, U.S.A.
ATV LIMITED WARRANTY

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

1
2
3
4
5
6
7
8
9
10
11
12
13

U5UH10.book Page 1 Monday, July 28, 2003 5:15 PM

EBU00435

YAMAHA EXTENDED SERVICE (Y.E.S.)

U5UH10.book Page 2 Monday, July 28, 2003 5:15 PM

1
2
3
4
5
6
7
8
9
10
11
12
13

U5UH10.book Page 3 Monday, July 28, 2003 5:15 PM

EBU00437

EBU00438

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.7
Linearized                      : No
Author                          : Provided By MANUALSLIB.COM - http://www.manualslib.com/
Create Date                     : 2014:04:14 11:51:50Z
Keywords                        : manuals, instruction manuals, user manuals, service manuals, user guides, pdf manuals, owners manuals, installation guides
Modify Date                     : 2014:12:07 12:42:56+08:00
Subject                         : Search through 700.000 manuals online & and download pdf manuals.
Has XFA                         : No
XMP Toolkit                     : Adobe XMP Core 5.4-c005 78.147326, 2012/08/23-13:03:03
Format                          : application/pdf
Creator                         : Provided By MANUALSLIB.COM - http://www.manualslib.com/
Description                     : Search through 700.000 manuals online & and download pdf manuals.
Title                           : ManualsLib - Makes it easy to find manuals online!
Creator Tool                    : pdftk 1.44 - www.pdftk.com
Metadata Date                   : 2014:12:07 12:42:56+08:00
Producer                        : itext-paulo-155 (itextpdf.sf.net-lowagie.com)
Document ID                     : uuid:09601b56-fcd6-764a-84a8-b11e1a6114d6
Instance ID                     : uuid:a8bc0213-0d83-e842-aa42-75be3b7b7f31
Page Count                      : 174

EXIF Metadata provided by EXIF.tools

Yamaha Bruin 350 Owners Manual ManualsLib Makes It Easy To Find Manuals Online! User 121920

Navigation menu

Versions of this User Manual:

Views

Navigation