Yamaha YFM35FGZ, YFM350FAZ User Manual

READ THIS MANUAL CAREFULLY! It contains important safety information.

LIRE ATTENTIVEMENT CE MANUEL!

Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE!

Contiene indicaciones importantes acerca de la seguridad.

OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO

YFM35FGZ

YFM350FAZ

1AB-F8199-60

YAMAHA MOTOR CO., LTD.

PRINTED IN USA

2009.04-0.3×1 CR (E,F,S)

READ THIS MANUAL CAREFULLY! It contains important safety information.

OWNER’S MANUAL

YFM35FGZ

YFM350FAZ

1AB-F8199-60-E0

EBU17133

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.

EC Declaration of Conformity

conforming to Directive 98/37/EC, 2006/42/EC

We,YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product

YFM350FWA (YFM35FG)

(5Y4AH13W090513067–)

(Make, model)

to which this declaration applies, conforms to the essential health and safety requirements of Directive 98/37/EC, 2006/42/EC

(If applicable)

and to the other relevant Directives of EEC

2004/108/EC

(Title and/or number and date of issue of the other Directives of EEC)

(If applicable)

To effect correct application of the essential health and safety requirements stated in the Directives of EEC, the following-standards and/or technical specifications were consulted:

ANSI/SVIA 1-2007

(Title and/or number and date of issue of standards and/or specifications)

Manufacturer

YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA 1000 GA Highway 34 East, Newnan, Georgia 30265-1320, U.S.A.

Authorized Representative

YAMAHA MOTOR EUROPE N.V.

Koolhovenlaan 101, 1119 NC Schiphol-Rijk, The Netherlands

Signature

Shinya Shimada

General Manager

RV Engineering Division

RV Operations

Date of Issue

19 February, 2009

EBU17170

INTRODUCTION

EBU17292

Congratulations on your purchase of the Yamaha YFM35FGZ/YFM350FAZ. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

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 the 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 completely before operating your ATV. Make sure you understand all instructions.

●Pay close attention to the warning and notice labels on the ATV.

●This ATV should not be ridden by anyone under 16 years of age.

EBU17330

IMPORTANT MANUAL INFORMATION

EBU17342

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:

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

TIP	A TIP provides key information to make procedures easier or clearer.

* Product and specifications are subject to change without notice.

EBU17350

IMPORTANT NOTICE

EBU17372

This ATV is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

Please check your local riding laws and regulations before operating this ATV.

EBU17410

YFM35FGZ/YFM350FAZ

OWNER’S MANUAL ©2009 by Yamaha Motor Co., Ltd.

1st edition, April 2009 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

is expressly prohibited. Printed in U.S.A.

EBU17420

TABLE OF CONTENTS

LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................	1-1
SAFETY INFORMATION ..............................	2-1
DESCRIPTION ..............................................	3-1
Left view ......................................................	3-1
Right view....................................................	3-1
Controls and instruments ............................	3-2
INSTRUMENT AND CONTROL
FUNCTIONS ..................................................	4-1
Main switch ................................................	4-1
Indicator lights and warning light ................	4-2
Speedometer ..............................................	4-3
Handlebar switches ....................................	4-4
Throttle lever ..............................................	4-5
Speed limiter ..............................................	4-6
Front brake lever ........................................	4-7
Brake pedal and rear brake lever ...............	4-7
Parking brake .............................................	4-8
Drive select lever ........................................	4-9
Recoil starter ..............................................	4-9
Fuel tank cap ............................................	4-10

Fuel ...........................................................	4-10
Fuel cock ..................................................	4-12
Starter (choke) ..........................................	4-13
Seat ..........................................................	4-14
Storage compartment ...............................	4-15
Front carrier ..............................................	4-16
Rear carrier ...............................................	4-16
Adjusting the front shock absorber
assemblies ..............................................	4-16
Adjusting the rear shock absorber
assembly .................................................	4-17
PRE-OPERATION CHECKS ..........................	5-1
Fuel .............................................................	5-3
Engine oil ....................................................	5-3
Final gear oil ...............................................	5-3
Differential gear oil ......................................	5-3
Front and rear brakes .................................	5-3
Throttle lever ...............................................	5-4
Tires ............................................................	5-4
Chassis fasteners .......................................	5-6
Instruments, lights and switches .................	5-6

OPERATION ..................................................	6-1
Starting a cold engine ................................	6-1
Starting a warm engine ..............................	6-3
Operating the drive select lever and
driving in reverse ......................................	6-3
Engine break-in ..........................................	6-4
Parking .......................................................	6-5
Parking on a slope .....................................	6-5
Accessories and loading ............................	6-6
RIDING YOUR ATV ......................................	7-1
GETTING TO KNOW YOUR ATV...............	7-2
RIDE WITH CARE AND GOOD
JUDGMENT ..............................................	7-2
BE CAREFUL WHERE YOU RIDE.............	7-9
TURNING YOUR ATV ..............................	7-12
CLIMBING UPHILL ...................................	7-13
RIDING DOWNHILL..................................	7-16
CROSSING A SLOPE...............................	7-17
CROSSING THROUGH SHALLOW
WATER ...................................................	7-18
RIDING OVER ROUGH TERRAIN ...........	7-21
SLIDING AND SKIDDING.........................	7-21
WHAT TO DO IF... ....................................	7-22
WHAT TO DO... ........................................	7-23

PERIODIC MAINTENANCE AND
ADJUSTMENT................................................	8-1
Owner’s manual and tool kit .......................	8-1
Periodic maintenance chart for the
emission control system ...........................	8-3
General maintenance and lubrication
chart ..........................................................	8-5
Removing and installing the panel ..............	8-9
Checking the spark plug .............................	8-9
Engine oil and oil filter cartridge ................	8-12
Final gear oil .............................................	8-16
Changing the differential gear oil ..............	8-18
Cleaning the air filter element ...................	8-20
Cleaning the spark arrester ......................	8-23
V-belt cooling duct check hose .................	8-24
V-belt case drain plug ...............................	8-25
Adjusting the carburetor ............................	8-25
Adjusting the engine idling speed .............	8-25
Adjusting the throttle cable free play .........	8-27
Valve clearance ........................................	8-27
Adjusting the drive select lever safety
system cable ...........................................	8-28
Brakes .......................................................	8-28
Checking the front brake pads and
rear brake shoes .....................................	8-28
Checking the brake fluid level ...................	8-29
Changing the brake fluid ...........................	8-30

Checking the front brake lever free
play .........................................................	8-30
Adjusting the brake pedal and rear brake
lever free play and checking the brake
pedal position .........................................	8-31
Axle boots ................................................	8-34
Brake light switches .................................	8-34
Checking and lubricating the cables ........	8-35
Checking and lubricating the front and
rear brake levers ....................................	8-36
Checking and lubricating the brake
pedal ......................................................	8-36
Checking the wheel hub bearings ............	8-37
Lubricating the steering shaft ...................	8-37
Battery ......................................................	8-38
Replacing a fuse ......................................	8-40
Replacing a headlight bulb .......................	8-42
Adjusting a headlight beam ......................	8-43
Replacing the tail/brake light bulb ............	8-44
Removing a wheel ....................................	8-44
Installing a wheel ......................................	8-44
Troubleshooting .......................................	8-46
Troubleshooting chart ..............................	8-47
CLEANING AND STORAGE..........................	9-1
Cleaning .....................................................	9-1
Storage .......................................................	9-2

SPECIFICATIONS .......................................	10-1
CONSUMER INFORMATION.......................	11-1
Identification numbers ...............................	11-1

EBU29680

LOCATION OF THE WARNING AND SPECIFICATION LABELS

1

EBU27153

Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation.

Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer.

For Europe

8

9

1-1

			1	3
	1
			<	40 kg
			(	88 lbs)
				37S-F817R-00

2

4

25.0 kPa	25.0 kPa
0.25 kgf/cm²	0.25 kgf/cm²
3.6 psi	3.6 psi
	5FU-F816M-M0	5

1P0-F816P-20

< 80 kg ( 176 lbs)

37S-F817R-10

<4900 N

<500 kgf

<1102 lbf

<147 N

<15 kgf

<33 lbf

4S2-F817S-00

1-2

6

7

1

1P0-F816L-20

8

9

	YEAR OF CONSTRUCTION : 2009	MODEL : YFM350FWA
	YAMAHA MOTOR CO., LTD.	MAX.POWER : 15.9 kW
1P0-F816R-00	2500 SHINGAI, IWATA, JAPAN	MASS IN RUNNING ORDER : 258 kg

1AB-F155A-00

1-3

Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model.

1

Read the Owner’s manual.

ALWAYS use an approved helmet and protective gear.

NEVER permit children under age 6 to operate this ATV.

Operation of this ATV by children under the age of 6 increases the risk of severe injury or death.

Adult supervision required for children under age 16.

NEVER permit children under age 10 to operate this ATV.

Operation of this ATV by children under the age of 10 increases the risk of severe injury or death.

Adult supervision required for children under age 16.

NEVER permit children under age 12 to operate this ATV.

Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.

Adult supervision required for children under age 16.

NEVER operate this ATV if you are under age 16.

Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.

NEVER use on paved roads.

NEVER carry passengers.

1-4

NEVER use with drugs or alcohol.

NEVER store fuel or flammable liquids.

This unit contains high-pressure nitrogen gas.

Mishandling can cause explosion. Do not incinerate, puncture or open.

Use unleaded gasoline only.

Measure tire pressure when tires are cold.

		Adjust tire pressure.
		Improper tire pressure can cause loss of
						1
		control.
		Loss of control can result in severe injury or
**.* kPa	**.* kPa	death.
*.** kgf/cm² *.** kgf/cm²
*.* psi	*.* psi
		Turning the ATV in	4WD-LOCK
		(“DIFF.LOCK”) takes more effort.
		Operate at a slow speed and allow extra
		time and distance for maneuvers to avoid
		loss of control.
		This pictogram shows the loading limits
		and/or maximum load capacity for this ATV.
		Follow all load limits and other loading
		guidelines in this manual.
		Load may include the driver, passenger,
		human protective gear, accessories, goods,
		luggage, and all other load related items.
		Make sure you do not exceed the load limits.
		Overloading can cause loss of control.
		Loss of control can result in severe injury or
		death.

1-5

					This pictogram shows trailer Hitch Tow
					weight limit. (Combined weight of the trailer
	1
					and all cargo in the trailer.)
					Overloading can cause loss of control.
					Loss of control can result in severe injury or
					death.
					This pictogram shows trailer Hitch Tongue
					weight limit. (Weight on the trailer tongue.)
					Overloading can cause loss of control.
					Loss of control can result in severe injury or
					death.

1-6

For Oceania

1

1-7

			1
	1			LOAD LIMIT
				40 kg{88 lbs}
				5ND-F4877-20
			2

25 kPa, (3.6 psi)

25 kPa, (3.6 psi)

22 kPa, (3.2 psi)

22 kPa, (3.2 psi)

5FU-F816M-20

3

4

LOAD LIMIT

80 kg{176 lbs}

5ND-F4897-20

5

MAXIMUM LOADING LIMIT

PULLING	LOAD:	4900 N (500 kgf)
		1102 lbf
TONGUE	WEIGHT:	147 N ( 15 kgf)
		33 lbf
		5ND-F151K-00

1-8

6

7

1

1-9

EBU17431

SAFETY INFORMATION

2 EBU17563

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.

●Always follow the age recommendation:

– A child under 16 years old should never operate an ATV with engine size greater than 90 cc.

●Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

●Never carry a passenger on an ATV.

●Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and paved streets.

●Never operate an ATV on any paved street, paved road or motorway.

●Watch carefully for other vehicles when operating on unpaved public streets or roads. Make sure you know your country’s laws and regulations before you ride on unpaved public streets or roads.

●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 riding 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.

2-1

●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 speeds before attempting to turn at faster speeds and never turn at excessive speeds.

●Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

● Always follow proper procedures for climbing hills as described in this manual. 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 2 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

2-2

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

2the procedure described in this manual.

●Always check for obstacles before operating in a new area.

●Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

●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 brak-

ing.

EWB00071

WARNING

Avoid Carbon Monoxide Poisoning

All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death.

Carbon Monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust. Deadly levels of carbon monoxide can collect rapidly

2-3

and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas. If you experi-

ence any symptoms of carbon monoxide 2 poisoning, leave the area immediately, get

fresh air, and SEEK MEDICAL TREATMENT.

●Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels.

●Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports.

●Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors.

EWB02591

WARNING

When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.

2-4

EBU17680

EBU17690

Left view

1 2 3 4,5

3

10 9 8 7

1.Fuel cock

2.Throttle stop screw

3.Air filter case

4.Fuses

5.Battery

6.Tail/brake light

7.Recoil starter

8.Engine oil filler cap

9.Oil filter cartridge

10.V-belt cooling duct check hose

DESCRIPTION

EBU17700

Right view

6		1		2			3		4		5

8 7 6

1.Rear shock absorber assembly spring preload adjusting ring

2.Spark arrester

3.Storage compartment and tool kit

4.Spark plug

5.Front shock absorber assembly spring preload adjusting ring

6.Rear brake light switch

7.Brake pedal

8.V-belt case drain plug

3-1

EBU17712

Controls and instruments

1.Rear brake lever

2.Handlebar switches

3.Starter (choke)

4.Parking brake lock plate

5.Horn switch

6.Drive select lever

7.Speedometer

8.Main switch

9.Fuel tank cap

10.On-Command four-wheel-drive switch 11.Throttle lever

12.Front brake lever

TIP

The ATV you have purchased may differ slightly from the figures shown in this manual.

3

3-2

EBU17733

INSTRUMENT AND CONTROL FUNCTIONS

EBU17770

Main switch

The positions of the main switch are as follows:

ON

4All electrical systems are supplied with power. The headlights, meter lighting and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

OFF

All electrical systems are off. The key can be removed.

1. Main switch

4-1

EBU17814

Indicator lights and warning light

1.Reverse indicator light “REVERSE”

2.Neutral indicator light “NEUTRAL”

3.On-Command four-wheel-drive indicator light “ ”

4.Oil temperature warning light “ ”

EBU17850

Reverse indicator light “REVERSE”

This indicator light comes on when the transmission is in the reverse position.

EBU17870

Neutral indicator light “NEUTRAL”

This indicator light comes on when the transmission is in the neutral position.

EBU26931

Oil temperature warning light “ ”

This warning light comes on when the engine overheats. When this occurs, stop the engine as soon as it is safe to do so, and allow it to cool.

The electrical circuit of the warning light can be checked by turning the key to “ON”, with the engine stop switch set to “ ”, and then pushing the start switch. 4 If the warning light does not come on while the start switch is being pushed, then go off after the start switch is released, have a Yamaha dealer check

the electrical circuit.

If the warning light stays on, allow the engine to cool. If the warning light stays on when the engine is cool, have a Yamaha dealer check the electrical circuit.

ECB00010

NOTICE

●The engine may overheat if the ATV is overloaded. In this case, reduce the load to specification.

●Start the engine after making sure that the warning light is out. Continuous use while the warning light is on may cause damage to the engine.

4-2

EBU17952

On-Command four-wheel-drive indicator light “ ”

This indicator light comes on when the On-Com- mand four-wheel-drive switch is set to the “4WD” position.

TIP

4

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

EBU18021

Speedometer

The speedometer shows the riding speed. This speedometer is equipped with an odometer and a tripmeter. The tripmeter can be reset to zero with the reset knob. Use the tripmeter to estimate how far you can ride on a tank of fuel before going to reserve. This information will enable you to plan fuel stops in the future.

1.Reset knob

2.Speedometer

3.Odometer

4.Tripmeter

4-3

EBU18061

Handlebar switches

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

3.Start switch “ ”

4.Horn switch “ ”

EBU18080

Engine stop switch “ / ”

Set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run when this switch is set to “ ”.

EBU18101

Start switch “ ”

Push this switch to crank the engine with the starter. See the starting instructions on page 6-1 prior to starting the engine.

EBU18161
Light switch “		/	/OFF”
Set this switch to “			” to turn on the low beams,
					4
the taillight and the meter lighting. Set the switch
to “	” to turn on the high beams, the taillight and
the meter lighting. Set the switch to “OFF” to turn
off all the lights.
ECB00041

NOTICE

Do not use the headlights with the engine turned off for an extended period of time, otherwise 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. See page 8-38 for battery charging information.

EBU18170

Horn switch “ ”

Press the switch to sound the horn.

4-4

EBU28432

On-Command four-wheel-drive switch “2WD”/“4WD”

EWB00163

WARNING

Always stop the ATV before changing from two-wheel drive to four-wheel drive and vice versa. The ATV handles differently in two-

4wheel drive than in four-wheel drive in some circumstances. Changing from two-wheel drive to four-wheel drive or vice versa while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and increase the risk of losing control and of causing an accident.

This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice versa. Select the appropriate drive according to the terrain and the conditions.

●“2WD” (two-wheel drive): Power is supplied to the rear wheels.

●“4WD” (four-wheel drive): Power is supplied to the rear and front wheels.

To change from two-wheel drive to four-wheel drive, stop the ATV and push the switch in to the “4WD” position. The four-wheel-drive indicator light “ ” comes on.

To change from four-wheel drive to two-wheel drive, stop the ATV and push the switch in to the “2WD” position.

1. On-Command four-wheel-drive switch “2WD”/“4WD”

EBU18282

Throttle lever

Once the engine is running, pushing the throttle lever will increase the engine speed.

4-5