OWNER’S MANUAL
READ THIS MANUAL CAREFULLY!
It contains important safety information.
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YFZ350T
LIT-11626-18-04 5FK-28199-17
This ATV should not be ridden by anyone under 16 years of age.
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INTRODUCTION
Congratulations on your purchase of the Yamaha YFZ350. It represents the result of many years
of Yamaha experience in the production of fine sporting, touring, and pacesetting racing
machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
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 spe-
cial 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:
8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND
COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
8 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 FOR
MORE INFORMATION.
8 THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE
UNDER 16 YEARS OF AGE.
8 THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT TYPE
RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.
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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:
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NOTE: A NOTE provides key information to make procedures easier or clearer.
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
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.
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IMPORTANT NOTICE
This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway.
This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
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YFZ350T
OWNER’S MANUAL
AFFIX DEALER
LABEL HERE
©2004 by Yamaha Motor Corporation,
U.S.A.
1st edition, March 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission
of Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-18-04
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Indicates a potential hazard that could
result in serious injury or death.
CONTENTS
LOCATION OF THE WARNING AND
1
SPECIFICATION LABELS....................1-1
SAFETY INFORMATION......................2-1
2
DESCRIPTION AND MACHINE
3
IDENTIFICATION .................................3-1
Identification number records............3-2
Key identification number..................3-2
Vehicle identification number ............3-3
Model label........................................3-3
CONTROL FUNCTIONS ......................4-1
4
Main switch........................................4-1
Handlebar switches...........................4-2
Throttle lever .....................................4-3
Throttle OverRide System.................4-4
Speed limiter .....................................4-4
Clutch lever .......................................4-6
Front brake lever ...............................4-6
Brake pedal .......................................4-7
Parking brake ....................................4-7
Shift pedal .........................................4-9
Kick starter ........................................4-9
Fuel tank cap...................................4-10
Fuel cock.........................................4-10
Starter (choke).................................4-11
Seat.................................................4-12
Front shock absorber
adjustment.....................................4-13
Rear shock absorber
adjustment.....................................4-14
PRE-OPERATION CHECKS ................5-1
5
Front and rear brakes........................5-3
Fuel ...................................................5-5
Engine mixing oil ...............................5-6
Transmission oil ................................5-7
Chain.................................................5-7
Throttle lever .....................................5-7
Fittings and fasteners........................5-8
Lights.................................................5-8
Switches............................................5-8
Tires ..................................................5-9
How to measure tire pressure .........5-10
Tire wear limit ..................................5-11
OPERATION .........................................6-1
6
Starting a cold engine........................6-1
Starting a warm engine .....................6-3
Warming up.......................................6-3
Shifting ..............................................6-4
To start out and accelerate ................6-5
To decelerate.....................................6-6
Engine break-in .................................6-7
Parking ..............................................6-8
Parking on a slope ............................6-9
Accessories and loading .................6-10
Riding Your ATV....................................7-1
7
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 ............................7-23
Climbing uphill.................................7-25
Riding downhill ................................7-30
Crossing a slope .............................7-32
Crossing through shallow water ......7-34
Riding over rough terrain.................7-36
Sliding and skidding ........................7-38
What to do if... ................................7-40
What to do... ...................................7-40
PERIODIC MAINTENANCE AND
8
ADJUSTMENT......................................8-1
Owner’s manual and tool kit..............8-1
Periodic maintenance/Lubrication .....8-3
Transmission oil ................................8-6
Cooling system..................................8-8
Spark plug inspection......................8-13
Air filter element cleaning................8-14
Spark arrester cleaning ...................8-17
Carburetor settings..........................8-19
Idle speed adjustment .....................8-26
Throttle lever adjustment.................8-28
Front and rear brake pad
inspection ......................................8-29
Brake fluid level check ....................8-30
Brake fluid replacement ..................8-31
Front brake lever free play ..............8-32
Brake pedal height adjustment........8-33
Parking brake adjustment ...............8-34
Adjusting the rear brake light
switch ............................................8-36
Clutch adjustment ...........................8-36
Drive chain slack check...................8-37
Drive chain slack adjustment ..........8-37
Lubricating the drive chain ..............8-38
Cable inspection and lubrication .....8-39
Brake and shift pedal/brake and
clutch lever lubrication...................8-40
Lubricating the front upper and
lower arm pivots ............................8-40
Rear arm pivot lubrication ...............8-41
Wheel removal ................................8-42
Wheel installation ............................8-42
Replacing the headlight bulb...........8-43
Headlight beam adjustment ............8-45
Tail/brake light bulb replacement.....8-46
Troubleshooting...............................8-47
Troubleshooting chart......................8-48
No spark..........................................8-51
CLEANING AND STORAGE ................9-1
9
A. Cleaning........................................9-1
B. Storage .........................................9-3
SPECIFICATIONS ..............................10-1
10
NOISE REGULATION.........................11-1
11
MAINTENANCE RECORD.................12-1
12
ATV LIMITED WARRANTY ................13-1
13
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LOCATION OF THE WARNING AND
SPECIFICATION LABELS
Read and understand all of the labels on your
machine. They contain important information
for safe and proper operation of your ATV.
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.
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WARNING
NEVER ride as a
passenger.
Passengers can cause
a loss of control,
resulting in SEVERE
INJURY or DEATH.
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5FE-2151H-01
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5FK-21696-01
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5FE-21568-01
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5FE-21697-01
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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:
8 Read this manual and all labels carefully and follow the operating procedures described.
8 Never operate an ATV without proper training or instruction. T
ake 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.
8 Always follow the age recommendation:
- A child under 16 years old should never operate an ATV with engine size greater than 90cc.
8 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.
8 Never carry a passenger on an ATV.
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8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking
lots and streets.
8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
8 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.
8 Never consume alcohol or drugs before or while operating this ATV.
8 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.
8 Never attempt wheelies, jumps, or other stunts.
8 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.
8 Always keep both hands on the handlebars and both feet on the footpegs of the ATV during
operation.
8 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
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8 Never operate on excessively rough, slippery or loose terrain until you have learned and prac-
ticed the skills necessary to control the ATV on such terrain. Always be especially cautious on
these kinds of terrain.
8 Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
8 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller
hills before attempting larger hills.
8 Always follow proper procedures for climbing hills as described in this manual. Check the ter-
rain carefully before you start up any hill. Never climb hills with excessively slippery or loose
surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear
changes. Never go over the top of a hill at high speed.
8 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.
8 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.
2-3
8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid
stalling, use the proper gear and maintain a steady speed when climbing a hill. If you stall or
roll backwards, follow the special procedure for braking described in this manual. Dismount on
the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following
the procedure described in this manual.
8 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.
8 Always be careful when skidding or sliding. Learn to safely control skidding or sliding by prac-
ticing 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.
8 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.
8 Always use the size and type of tires specified in this manual.
8 Always maintain proper tire pressure as described in this manual.
8 Never modify an ATV through improper installation or use of accessories.
2-4
8 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.
2-5
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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
lights of water heaters and clothes
dryers.
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.
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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.
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DESCRIPTION AND MACHINE IDENTIFICATION
1. Tail/brake light 12. Rear shock absorber
2. Seat 13. Spark arrester
3. Kick starter 14. Rear wheel
4. Fuel tank cap 15. Starter (choke)
5. Headlight 16. Shift pedal
6. Brake pedal 17. Clutch lever
7. Rear brake light switch 18. Parking brake
8. Front wheel 19. Main switch
9. Front shock absorber 20. Brake lever
10. Radiator 21. Throttle lever
11. Fuel cock 22. Handlebar switches
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
3-1
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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:
2. VEHICLE IDENTIFICATION NUMBER:
3. MODEL LABEL INFORMATION:
1
6
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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.
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1. Key identification number
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3-2
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Vehicle identification number
The vehicle identification number is stamped
into the frame.
NOTE:
The vehicle identification number is used to
identify your machine.
1. Vehicle identification number
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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.
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1. Model label
3-3
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OFF ON
CONTROL FUNCTIONS
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Indicates a potential hazard that could
result in serious injury or death.
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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.
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Handlebar switches
1. Light switch “LIGHTS”
2. Engine stop switch “ENG. STOP”
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Engine stop switch “ENG. STOP”
Make sure that the engine stop switch is in the
“RUN” position 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
turned to “OFF”.
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Light switch “LIGHTS”
Set the switch to the “LO” position to turn on
the low beam and the taillight.
Set the switch to the “HI” position to turn on
the high beam and the taillight.
Set the switch to the “OFF” position to turn off
all the lights.
NOTE:
The headlights and the taillight can be turned
on only when the engine is started.
4-2
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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.
1. 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.
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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
ATV. Consult a Yamaha dealer if you
can’t find or solve the problem yourself.
4-3
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Throttle OverRide System
If during operation, the carburetor or the throttle cable should malfunction and will not close
fully, take your thumb off the throttle lever.
The Throttle OverRide System immediately
cuts off the ignition.
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WARNING
POTENTIAL HAZARD
Continuing to ride the ATV after the
Throttle OverRide System (T.O.R.S.) has
stopped the engine.
WHAT CAN HAPPEN
Riding with a malfunction increases the
chance for an accident and injury.
HOW TO AVOID THE HAZARD
Make sure that the cause of the malfunction is corrected before restarting the
engine. You should have the ATV
inspected by a Yamaha dealer.
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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
a. No more than 12 mm (0.47 in)
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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
4–6 mm (0.16–0.24 in). See page 8-28.
4-5
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Clutch lever
The clutch lever is located on the left handlebar.
Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to
engage the clutch. The lever should be pulled
rapidly and released slowly for smooth clutch
operation.
1. Clutch lever
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Brake lever
The brake lever is located on the right handlebar. Pull it toward the handlebar to apply the
front brake.
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1. Brake lever
4-6
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Brake pedal
The brake pedal is located on the right side of
the machine. Push down on the pedal to apply
the rear brake.
1. Brake pedal
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Parking brake
Use the parking brake when you have to start
the engine or park the machine, especially on
a slope. Squeeze the clutch lever while pushing the button, then push in the lock plate to
apply the parking brake. Squeeze the clutch
lever to release the parking brake.
NOTE:
When the parking brake is used, engine
speed is limited to 2,300 r/min. Be sure the
parking brake is released before moving the
throttle lever. Otherwise, the engine will misfire, preventing normal operation.
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1. Button 2. Lock plate
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1. Locked position
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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 disc 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.
Always be sure you have released the
parking brake before you begin to ride.
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