. READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM350FAS WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-17-32 5UH-F8199-10. Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines.

• Service Manual For 2004 Yamaha 350 Bruin

With the purchase of this Yamaha, you can now appreciate the high degree of crafts- manship and reliability that have made Yamaha a leader in these fields. EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SE- RIOUS 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! Failure to follow WARNING instructions could result in severe WARNING.

Please check your local riding laws and regulations before operating this machine. EBU01067 YFM350FAS OWNER’S MANUAL ©2003 by Yamaha Motor Corporation, AFFIX DEALER U.S.A.

1st edition, July 2003 LABEL HERE All rights reserved. Any reprinting. EBU00014 CONTROL FUNCTIONS.4-1 WARNING Main switch.4-1 Indicates a potential hazard that could Indicator and warning lights.4-2 result in serious injury or death. Handlebar switches.4-5 Throttle lever.4-8 Speed limiter.4-9 CONTENTS Front brake lever.4-10 Brake pedal and rear brake lever.4-10 LOCATION OF THE WARNING Parking brake.4-11. PRE-OPERATION CHECKS.

5-1 Accessories and loading.6-10 Front and rear brakes. 5-2 Fuel.5-4 RIDING YOUR ATV.7-1 Engine oil.5-6 Getting to know your ATV.7-3 Final gear oil.5-6 Ride with care and good Differential gear oil.

PERIODIC MAINTENANCE AND Front brake lever free play.8-30 ADJUSTMENT.8-1 Rear brake pedal and lever Owner’s manual and tool kit. 8-1 adjustment.8-31 Periodic maintenance/ Adjusting the rear brake light lubrication.8-3 switch.8-34 Panel removal and installation.8-5 Cable inspection and lubrication.8-35 Engine oil and oil filter cartridge. SPECIFICATIONS.10-1 NOISE REGULATION.11-1 MAINTENANCE RECORD. 12-1 ATV LIMITED WARRANTY.

13-1 YAMAHA EXTENDED SERVICE (Y.E.S.). EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS. 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. WARNING Overloading this ATV or carrying cargo improperly can change handling. Stability and braking performance and can lead to an accident. 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.

LOADING LIMIT MAXIMUM LOADING LIMIT ( 5 0 0 k g f ) PULLING LOAD: 4900 N 1102 l b f ( 1 5 k g f ) TONGUE WEIGHT: 147 N 33 l b f 5ND-F151K-00. 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. Never operate an ATV without wearing an approved motorcycle helmet that fits properly.

Service Manual For 2004 Yamaha 350 Bruin

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 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. Never go over the top of a hill at high speed. 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 con- trol. WARNING When transporting the ATV in another vehicle, be sure it is kept upright and POTENTIAL HAZARD that the fuel cock is in the “OFF” posi- Improper handling of gasoline. Otherwise, fuel may leak out of the WHAT CAN HAPPEN carburetor or fuel tank. 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. EBU00032 D ESCRIPTION AND MACHINE IDENTIFICATION 1. Rear shock absorber assembly 13.

V-belt cooling duct check hose spring preload adjusting ring 14. Oil filter cartridge 2. Spark arrester 15. Engine oil dipstick 3. Storage box and tool kit 16. Rear brake lever 4. This number can be used for ordering a new when ordering spare parts from a Yamaha key.

Dealer or for reference in case the vehicle is stolen. Record the information on this la- bel in the space provided. This information will be needed to order spare parts from your Yamaha dealer. Vehicle identification number (front left side) NOTE: The vehicle identification number is used to 1. EBU00039 C ONTROL FUNCTIONS WARNING Indicates a potential hazard that could result in serious injury or death.

EBU09420 Main switch Functions of the respective switch positions are as follows: 1. Main switch The engine can be started only at this position and the headlights and taillight come on when the light switch is on.

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.

EBU00605 EBU11400 Four-wheel-drive indicator light “ ” Oil temperature warning light “ ” This indicator light comes on when the 2WD/ When the oil temperature reaches a specified 4WD switch is in the 4WD position. Level, this light comes on to warn that the en- gine oil temperature is too hot.

Allow to cool. Engine oil temperature and Ask a Yamaha dealer to electrical circuit are OK. Go inspect the electrical circuit. Ahead with riding. 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 Engine stop switch “. 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”.

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 differ- ently. 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 1.

Throttle lever can’t find or solve the problem yourself. EBU01159 Speed limiter WARNING The speed limiter keeps the throttle from fully POTENTIAL HAZARD opening, even when the throttle lever is Improper adjustment of the speed limit- pushed to the maximum. Turning in the ad- er and throttle. Justing screw limits the maximum engine pow- WHAT CAN HAPPEN er available and decreases the maximum The throttle cable could be damaged. EBU00070 Front brake lever The front brake lever is located on the right handlebar.

Pull it toward the handlebar to ap- ply the front brake. Brake pedal 1. Front brake lever EBU00732 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. EBU00074 Parking brake WARNING Use the parking brake when you have to start POTENTIAL HAZARD the engine or park the machine, especially on Improper use of the parking brake. Apply the rear brake lever and push WHAT CAN HAPPEN down the lock plate to apply the parking The ATV could start moving unexpect- brake. EBU01106 EBU01107 Drive select lever Recoil starter The drive select lever is used to shift your ma- Firmly grasp the handle and pull slightly until chine into the forward, neutral and reverse po- engagement can be felt. Then pull forcefully, sitions.

EBU00092 Fuel tank cap WARNING Remove the fuel tank cap by turning it coun- POTENTIAL HAZARD terclockwise. Starting the engine without shifting into the neutral position.

WHAT CAN HAPPEN The ATV could start to move unexpect- edly, which could cause an accident. HOW TO AVOID THE HAZARD Shift the drive select lever into the neu- tral position and apply the parking brake.

EBU00093 Fuel cock OFF Position 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. EBU00095 Starter (choke) “ ” RES Position 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). EBU05670 Seat To install the seat, insert the projections on To remove the seat, pull the seat lock lever the front of the seat into the seat holders and upward and pull up the seat at the rear.

Push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. EBU14580 Storage box NOTE: There is a check hose at the bottom of the Maximum load limit: 2 kg (4.4 lb) storage box. If any water collects in this hose, remove the hose, empty it, and then install it.

CAUTION: To protect from damage, do not put metal products, like tools or sharply edged prod- ucts directly in the storage box. The spring preload can be adjusted to suit the A special wrench can be obtained at a rider’s weight and riding conditions.

Yamaha dealer to make this adjustment. Adjust the spring preload as follows. To increase the spring preload, turn the ad- Standard position: 2 justing ring in direction a. 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 ad- justing ring in direction a. To decrease the spring preload, turn the ad- justing ring in direction b. NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment.

Standard position: 2 1 - Minimum (soft) 5 - Maximum (hard) 1. Special wrench EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death. P RE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE. Check operation, free play, fluid level and fluid leakage.

5-2–5-3, Front brake. Fill with DOT 4 brake fluid if necessary. 8-27–8-30. Check operation, condition and free play. 5-2–5-3, Rear brake. Always inspect your ATV each time you should be a firm feeling when the brake is use it to make sure the ATV is in safe op- applied.

If not, have a Yamaha dealer in- erating condition. Always follow the inspection and main. Yamaha dealer check for for wear.

(See page 8-27.) the cause. EBU01085 Fuel Your Yamaha engine has been designed to Make sure there is sufficient gasoline in the use regular unleaded gasoline with a pump tank. Octane number (R+M/2) of 86 or higher, or research octane number of 91 or higher. Fuel can spill, which can cause a fire hol containing methanol is not recommended and severe injury.

Fuel expands when it by Yamaha because it may cause fuel system heats up. If the fuel tank is overfilled, damage or vehicle performance problems. EBU10842 EBU00493 Engine oil Final gear oil Make sure the engine oil is at the specified Make sure the final gear oil is at the specified level.

Add oil as necessary. (See pages 8-6– level. Add oil as necessary.

(See pages 8-11– 8-11.) 8-13 for details.) CAUTION. Add oil as necessary. (See and fasteners before a ride. Take the machine pages 8-14–8-15 for details.) to a Yamaha dealer or refer to the Service Manual for correct tightening torque. Recommended oil: SAE 80 API GL-4 Hypoid gear oil. The following are minimums: 1.

The tires listed below have been ap- Front 22 kPa (0.22 kgf/cm, 3.2 psi) proved by Yamaha Motor Co., Ltd. Rear 22 kPa (0.22 kgf/cm, 3.2 psi) for this model. Other tire combina- tions are not recommended. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm, 36 psi) Rear 250 kPa (2.5 kgf/cm, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully.

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 measure- ments of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. Tire wear limit 5-11. Turn the fuel cock to “ON”.

There is a control or function you do not 3. Turn the main switch to “ON” and the en- understand, ask your Yamaha dealer. Gine stop switch to “ ”. Shift the drive select lever into the neutral. 25 °C (80 °F) and warm engine should come on.

If it does not come on, start position. Ask a Yamaha dealer to inspect the elec- tric 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. NOTE: CAUTION: If the engine fails to start, release the See the “Engine break-in” section prior to start switch, then push the start switch operating the engine for the first time.

Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery en- EBU00180 ergy. EBU14600 Drive select lever operation and reverse driving CAUTION: Before shifting, stop the machine and re- turn the throttle lever to its closed posi- tion. Otherwise, the transmission may be damaged. Shifting: forward 1. Bring the machine to a complete stop 1.

Drive select lever should be on. If the light does not come on, 4. Check behind for people or obstacles, ask a Yamaha dealer to inspect the ATV. Then release the brake pedal.

Open the throttle lever gradually and con. WARNING POTENTIAL HAZARD Improper operation in reverse. WHAT CAN HAPPEN You could hit an obstacle or person be- hind 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. If any abnormality is noticed during this peri- brand new, you must not put an excessive od, consult a Yamaha dealer. Load on it for the first several hours of running. During the first 20 hours, the various parts in 0–10 hours. EBU00211 10–20 hours: Parking Avoid prolonged operation above 3/4 throttle.

When parking, stop the engine and shift into Rev the machine freely but do not use full neutral. Turn the fuel cock to “OFF” and apply throttle at any time. The parking brake.

EBU13750 Parking on a slope 1. Bring the machine to a stop by applying the brakes. Stop the engine. POTENTIAL HAZARD 3.

With the rear brake lever and pedal ap- Parking on a hill or other incline. Plied, apply the parking brake, and then WHAT CAN HAPPEN slowly release the brake pedal. Choose only accessories designed for your dlebars which could make steering difficult, ATV. Your Yamaha dealer has a variety of an accessory that limits your ability to move genuine Yamaha accessories. EBU12461 Loading Do not exceed the maximum tongue Cargo or a trailer can change the stability and weight. You can measure tongue weight handling of an ATV. With a bathroom scale.

Put the tongue of You must use common sense and good judg- the loaded trailer on the scale with the ment when carrying cargo or towing a trailer. Ride more slowly than you would without a WARNING load. The more weight you carry, the slow- POTENTIAL HAZARD er you should go.

Overloading this ATV or carrying or tow- Allow more braking distance. A heavier ve- ing cargo improperly. Hicle takes longer to stop. EBU14610 WARNING Indicates a potential hazard that could result in serious injury or death.

R iding Your. WARNING Indicates a potential hazard that could result in serious injury or death. Owner’s Manual completely and understand GETTING TO KNOW YOUR ATV the operation of the controls.

Pay particular at- This ATV is for recreation and utility use. This tention to the safety information on pages section, Riding your ATV, provides general 2-1–2-6. JUDGEMENT Beginning and inexperienced operators should complete the certified training Get training if you are inexperienced. Course offered by Yamaha. They should Beginners should get training from a certified then regularly practice the skills learned instructor.

In the course and the operating tech- Become familiar with this ATV at slow speeds niques described in this Owner’s Manu. Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommenda- tions for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended for their age can lead to se- vere injury or death of the child. 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.

Apparel Operating without protective clothing WARNING increases your chances of severe injury in the event of an accident. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an Always wear an approved motorcycle approved motorcycle helmet, eye pro- helmet that fits properly. Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator’s performance capability is reduced Operating this ATV after consuming al- by the influence of alcohol or drugs. Cohol or drugs.

WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Pre-operation checks WARNING Always perform the pre-operation checks list- POTENTIAL HAZARD ed on page 5-1 before riding for safety and Operating this ATV with improper tires, proper care of the ATV. Or with improper or uneven tire pres- WARNING sure. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before oper.

Speed limiter WARNING For riders less experienced with this model, Indicates a potential hazard that could this model is equipped with a speed limiter in result in serious injury or death. The throttle lever housing.

The speed limiter keeps the throttle from fully opening, even Do not operate at speeds too fast for your when the throttle lever is pushed to the maxi- skills or the conditions. Loading and accessories WARNING Use extra caution when riding the ATV with POTENTIAL HAZARD additional loads, such as accessories or car- Overloading this ATV or carrying or tow- go. The ATV’s handling may be adversely af- ing cargo improperly.

Reduce your speed when adding WHAT CAN HAPPEN additional loads. During operation WARNING Always keep your feet on the footboards dur- POTENTIAL HAZARD ing operation.

Otherwise your feet may con- Removing hands from handlebars or tact the rear wheels. Feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re- duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.

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, in- cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Never modify this ATV through improp- er installation or use of accessories. All parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions.

If you have questions, consult an autho- rized ATV dealer. Exhaust system Do not touch the hot exhaust system. The exhaust system on the ATV is very hot Do not park the ATV in a place where during and following operation. To prevent others might be likely to touch it. Burns, avoid touching the exhaust system. 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 con. Do not ride on any public road, street, or high- way. 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. Know the terrain where you ride. Ride cau- tiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and oth- er hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.

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 acci- dent, 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 neces.

When riding in an area where you might not WHAT CAN HAPPEN easily be seen, such as desert terrain, mount You could be in a collision. You could a caution flag on the ATV. DO NOT use the be injured. Flag pole bracket as a trailer hitch. Select a large, flat area off-road to become fa- With the engine idling, return the starter miliar with your ATV. Make sure that this area (choke) to the closed position, shift the drive is free of obstacles and other riders.

You select lever into the forward position, and then should practice control of the throttle, brakes, release the parking brake. TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for road, the two rear wheels are mounted solidly turning as described in this Owner’s on one axle and turn together at the same Manual. Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. CLIMBING UPHILL HOW TO AVOID THE HAZARD Use proper riding techniques to avoid vehicle Never operate the ATV on hills too steep overturns on hills. Be sure that you can ma- for the ATV or for your abilities.

Practice neuver your ATV well on flat ground before at- on smaller hills before attempting large tempting any incline and then practice riding hills. WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other POTENTIAL HAZARD side of the hill. 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 Own- er’s Manual. If you are climbing a hill and you find that you WARNING have not properly judged your ability to make POTENTIAL HAZARD it to the top, you should turn the ATV around Improperly crossing hills or turning on while you still have forward motion (provided hills. When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

If your ATV has stalled or stopped and you and rear brakes gradually, or dismount the believe you can continue up the hill, restart ATV immediately on the uphill side. Carefully to make sure you do not lift the front WARNING wheels which could cause you to lose control. If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards.

Apply the front brake. When fully stopped, ap- ply the rear brake as well, and then lock the parking brake. 4WD: Apply both front and rear brakes gradually. RIDING DOWNHILL When this ATV is in 4WD, all wheels (front When riding your ATV downhill, shift your and rear) are interconnected by the drive weight as far to the rear and uphill side of the train. This means that applying either the front ATV as possible.

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 go- ing down hills as described in this Own- er’s Manual. Note: a special technique is required when braking as you go down a hill.

CROSSING A SLOPE WARNING Traversing a sloping surface on your ATV re- POTENTIAL HAZARD quires you to properly position your weight to Improperly crossing hills or turning on maintain proper balance. Be sure that you hills. Have learned the basic riding skills on flat WHAT CAN HAPPEN ground before attempting to cross a sloping Could cause loss of control or cause the. CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have re- The ATV can be used to cross slow moving, duced stopping ability. Test your brakes shallow water of up to a maximum of 35 cm after leaving water. If necessary, apply (14 inches) in depth. Test your brakes after leaving the water.

Do CAUTION: not continue to ride your ATV without verifying After riding your ATV in water, be sure to that you have regained proper braking ability. 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. V-belt cooling duct check hose (left front side of ATV) 1. Storage box check hose 1. Drive select lever box check hose 1. V-belt case drain plug 7-36.

RIDING OVER ROUGH TERRAIN WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could Improperly operating over obstacles. Cause damage to the ATV or could lead to an WHAT CAN HAPPEN upset or accident. Be sure to keep your feet Could cause loss of control or a colli- firmly mounted on the footboards at all times. SLIDING AND SKIDDING If the rear wheels of your ATV start to slide Care should be used when riding on loose or sideways, control can usually be regained (if slippery surfaces since the ATV may slide.

If there is room to do so) by steering in the direc- unexpected and uncorrected, sliding could tion of the slide. With practice, over a period of time, skill at WARNING controlled sliding can be developed. The ter- POTENTIAL HAZARD rain should be chosen carefully before at- Skidding or sliding improperly. Tempting such maneuvers, since both stability WHAT CAN HAPPEN and control are reduced. Bear in mind that You may lose control of this ATV. WHAT TO DO IF. If your ATV starts to slide sideways: This section is designed to be a reference Steer in the direction of the slide if you have guide only.

Be sure to read each section on the room. Applying the brakes or accelerat- riding techniques completely. If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to main- tain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

EBU00515 P ERIODIC MAINTENANCE AND Have a Yamaha dealer perform service if ADJUSTMENT you are not familiar with machine ser- vice. Periodic inspection, adjustment and lubrica- tion will keep your machine in the safest and EBU14510 most efficient condition possible.

Safety is an Owner’s manual and tool kit. Yamaha or your machine to a Yamaha dealer to check equivalent components designed for the torque settings and adjust them as neces- use on this ATV and should be installed sary. EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY ITEM ROUTINE month months months months year. Check valve clearance.

Valves. Adjust if necessary. Check condition. Spark plug.

Adjust gap and clean. Replace if necessary. Every 20–40 hours Air filter element. Correct if necessary. Check operation. Lights and switches. 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:. EBU08070 EBU01147 Panel removal and installation Panel A The panel illustrated needs to be removed to To remove perform some of the maintenance described Remove the bolt, and then take the panel off. In this chapter.

To install Refer to this section each time the panel has Place the panel in the original position and in- to be removed or installed. EBU14540 Engine oil and oil filter cartridge 4. Remove the engine oil filler cap and wipe The engine oil level should be checked before off the dipstick with a clean rag.

In addition, the oil must be changed and the oil filter cartridge replaced at the inter- vals specified in the periodic maintenance and lubrication chart. Insert the dipstick in the oil filler hole 7. Insert the dipstick into the oil filler hole, (without screwing it in), and then remove and then tighten the oil filler cap.

It again to check the oil level. NOTE: The engine oil should be between the mini- mum and maximum level marks. To change the engine oil (with or without NOTE: oil filter cartridge replacement) Skip steps 4–6 if the oil filter cartridge is not 1. Start the engine, warm it up for several being replaced. Minutes, and then turn it off. Oil filter wrench 1.

O-ring NOTE: An oil filter wrench is available at a nearby Yamaha dealer. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge.

NOTE: Make sure the O-ring is seated properly. Install the new oil filter cartridge with an 7. Install the engine oil drain bolt, and then oil filter wrench, and then tighten it to the tighten it to the specified torque. Specified torque with a torque wrench. Tightening torque: Engine oil drain bolt: 23 Nm (2.3 mkgf, 16 ftlbf) 8. EBU11452 Final gear oil CAUTION: Final gear oil measurement In order to prevent clutch slippage 1.

Place the machine on a level surface. (since the engine oil also lubricates 2. Remove the oil filler bolt, and then check the clutch), do not mix any chemical the oil level in the final gear case. If the oil is below the brim of the filler hole, Final gear oil replacement add sufficient oil of the recommended 1. Remove the final gear case cover by re- type to raise it to the correct level. Moving the bolts.

CAUTION: Be sure no foreign material enters the final gear case. Remove the oil filler bolt and the drain Recommended oil: bolt to drain the 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. EBU01241 Differential gear oil replacement 1. Place the machine on a level surface. Place a container under the differential gear case to catch the oil.

Remove the oil filler bolt and oil drain bolt to drain the oil. Fill the differential gear case with the CAUTION: specified amount of the recommended Be sure no foreign material enters the dif- oil. Ferential gear case. Install the oil filler bolt.

Do not exceed the specified differential 7. Check for oil leakage. If oil leakage is gear oil quantity when filling. Spark plug inspection Removal Check the protective boots for holes or tears. If any damage is found, have them replaced 1. Remove the spark plug cap. By a Yamaha dealer.

Spark plug cap 1. Axle boot (× 2 each side) 8-16. Use the spark plug wrench in the owner’s Instead, take the ATV to a Yamaha dealer. Tool kit to remove the spark plug as shown.

You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. 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. 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. WARNING POTENTIAL HAZARD Using low flash point solvents or gaso- line 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 1.

Apply Yamaha foam air filter oil or other NOTE: The air filter element should be cleaned every quality foam air filter oil to the air filter el- 20–40 hours. It should be cleaned and lubri- ement.

If foam air filter oil is not available, cated more often if the machine is operated in engine oil may be used. NOTE: If water drains from the V-belt case after re- moving the plug, have a Yamaha dealer in- spect the ATV as the water may affect other engine parts. V-belt cooling duct check hose (Left front side of ATV) 1.

EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. Remove the bolts. Remove the tailpipe by pulling it out of the muffler. Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. The carburetor is a vital part of the engine and POTENTIAL HAZARD requires very sophisticated adjustment.

Most Improper cleaning of the spark arrester. Adjusting should be left to a Yamaha dealer Hot exhaust system who has the professional knowledge and ex- WHAT CAN HAPPEN perience to do so. To prevent this, the valve clear- tion b to decrease the engine speed. Ance must be adjusted regularly. This adjust- ment however, should be left to a professional Specified idle speed: Yamaha service technician. 1,450–1,550 r/min 8-25. EBU00307 Throttle lever adjustment NOTE: Adjust the engine idling speed before adjust- ing the throttle lever free play.

Loosen the locknut. Turn the adjusting bolt until the throttle le- ver free play is 3–5 mm (0.12–0.20 in). Tighten the locknut. Apply pads as a set. The rear brake and check the position of the in- dicator. If the indicator reaches the wear limit line, ask a Yamaha dealer to replace shoes as a set. Brake pad thickness NOTE: The wheels need to be removed to check the brake pads.

EBU13040 Brake fluid level check Observe these precautions: Insufficient brake fluid may let air enter the When checking the brake fluid level, make brake system, possibly causing the brakes to sure the top of the brake fluid reservoir is become ineffective. Complete fluid replacement should be done fluid immediately. Only by trained Yamaha service personnel. Have a Yamaha dealer check the cause if Have a Yamaha dealer replace the following the brake fluid level goes down. Components during periodic maintenance or when they are damaged or leaking.

The front brake lever should have a free play POTENTIAL HAZARD of zero mm (zero in) at the lever end. If not, Operating with improperly serviced or have a Yamaha dealer check the brake sys- adjusted brakes.

WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. EBU01239 Rear brake pedal and lever adjustment 2. Turn the adjusting nut on the brake pedal Brake pedal free play adjustment cable until the free play is 20–30 mm 1. Fully loosen the adjusting nut on the (0.79–1.18 in). Brake lever cable at the rear wheel. Brake lever free play adjustment 2. Turn in the adjusting nut on brake cable 1.

Loosen the locknut and fully turn in the to provide a gap of 0–1 mm (0–0.04 in) adjusting bolt at the brake lever. Between the brake camshaft lever and the pin. Make sure the brakes do not drag. Adjusting bolt a. Rear brake lever free play Replacement of brake components re- 4. Tighten the locknut.

Quires professional knowledge. These procedures should be performed by a Yamaha dealer. 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 neces- sary, adjust the brake light switch as follows. Inspect cables frequently. Replace dam- aged cables. Lubricate the inner cables and the cable ends.

If the cables do not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-35. EBU01112 Wheel removal 1. Loosen the wheel nuts. Elevate the ATV and place a suitable stand under the frame. Remove the nuts from the wheel. Remove the wheel.

Nut (× 4) 8-36. EBU01121 Wheel installation 2.

Lower the ATV so that the wheel is on the 1. Install the wheel and the nuts. NOTE: Tapered nuts are used for both the front and rear wheels. Install the nut with its ta- pered side towards the wheel.

Keep out of reach of chil- tery. If the battery seems to have discharged, dren. Consult a Yamaha dealer. Antidote: EXTERNAL: Flush with water. CAUTION: INTERNAL: Drink large quantities of wa- Do not try to remove the sealing caps of ter or milk. Then turn on the switches. If CAUTION: the fuse immediately blows again, con- A special battery charger (constant volt- sult a Yamaha dealer.

Age/ampere or constant voltage) is re- quired recharging sealed-type battery. Spare main fuse 1. Headlight fuse 3. Ignition fuse 3. Four-wheel drive fuse 4. Signaling system fuse 5. Spare fuse (× 3) Specified fuses: Main fuse: 30 A Headlight fuse: 15 A Ignition fuse: 15 A Four-wheel drive fuse: Signaling system fuse.

EBU14560 Replacing a headlight bulb WARNING If a headlight bulb burns out, replace it as fol- POTENTIAL HAZARD lows. Using an improper fuse.

Remove the bulb holder cover at the rear WHAT CAN HAPPEN of the headlight by pulling it off. An improper fuse can cause damage to the electrical system which could lead to a fire. Remove the headlight bulb holder by turning it counterclockwise. Headlight bulb holder tab (× 2) 1. Headlight bulb holder 3. Remove the defective bulb by unhooking the headlight bulb holder tabs. 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 flamma- ble. HOW TO AVOID THE HAZARD 1. Headlight beam adjustment ing it clockwise. Install the headlight bulb holder cover at It is advisable to have a Yamaha dealer the rear of the headlight. Make this adjustment. To raise the beam, turn the adjusting screw in direction a. EBU00412 Tail/brake light bulb replacement Troubleshooting If the tail/brake light bulb burns out, have a Although Yamaha machines receive a rigid in- Yamaha dealer replace it.

Spection before shipment from the factory, trouble may occur during operation. Any prob- lem in the fuel, compression, or ignition sys- tems can cause poor starting and loss of power. WARNING POTENTIAL HAZARD Checking the fuel system while smok- ing or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing se- vere injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Compression There is compression.

Compression normal. Use the electric starter to see if there is compression. Ask a Yamaha dealer to No compression. Ignition Wipe clean with dry cloth. Ignition system is Spark is good. EBU00419 C LEANING AND STORAGE CAUTION: Excessive water pressure may cause wa- A.

CLEANING ter seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend bills have resulted from improper high the useful life of many components. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after wash- 7.

Automotive type wax may be applied to ing. All painted and chrome plated surfaces. WHAT CAN HAPPEN Avoid combination cleaner-waxes.

Do not apply oil to fuel) any rubber parts or the seat cover. NOTE: Use of fuel stabilizer and conditioner elimi- nates the need to drain the fuel system. Con- sult a Yamaha dealer if the fuel system needs to be drained instead. 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 ex- cessively 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.

EBU00428 S PECIFICATIONS Model YFM350FA Dimensions: Overall length 1,984 mm (78.1 in) Overall width 1,085 mm (42.7 in) Overall height 1,120 mm (44.1 in) Seat height 827 mm (32.6 in) Wheelbase 1,233 mm (48.5 in) Minimum ground clearance 245 mm (9.65 in) Minimum turning radius 3,000 mm (118.1 in) Basic weight. Model YFM350FA Engine oil: Type 0˚ 90˚ 110˚ 130˚F 10˚ 30˚ 50˚ 70˚ YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20˚ -10˚ 0˚ 20˚ 30˚ 40˚ 50˚C 10˚ Recommended engine oil classification: API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the en- gine oil also lubricates the clutch), do not mix any. Model YFM350FA Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity: Periodic oil change 0.23 L (0.20 Imp qt, 0.24 US qt) Differential gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity: Periodic oil change 0.35 L (0.31 Imp qt, 0.37 US qt) Air filter: Wet element. Model YFM350FA Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive 41/21 × 24/18 × 33/9 (9.545) Secondary reduction ratio Transmission type V-belt automatic Operation Left hand operation Forward gear 35/20 (1.750) Reverse gear 26/15 (1.733) Chassis: Frame type Steel tube frame Caster angle 4°.

Model YFM350FA Suspension: Front suspension Double wishbone Rear suspension Swingarm (monocross) Shock absorber: Front shock absorber Coil spring / oil damper Rear shock absorber Coil spring / oil damper Wheel travel: Front wheel travel 160 mm (6.30 in) Rear wheel travel 180 mm (7.09 in) Electrical: Ignition system. Model YFM350FA Bulb voltage, wattage × quantity: 12 V, 30/30 W × 2 Headlight 12 V, 5/21 W × 1 Tail/brake light 12 V, 1.7 W × 1 Neutral indicator light 12 V, 1.7 W × 1 Reverse indicator light 12 V, 1.7 W ×. EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice 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. EBU13651 M AINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work is required. It is not acceptable proof of maintenance work. EBU00432 YAMAHA MOTOR CORPORATION, U.S.A.

ATV LIMITED WARRANTY 13-1. EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1. EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN USA 2003.08-5.4×1 CR.

Complete service repair workshop manual for the: Yamaha Bruin 350 YFM350 YFM35 This is the same manual dealerships use to repair your atv. Manual covers all the topics like: Engine Service, General Information, Transmission, Chassis, Lighting, Steering, Seats System, Clutch, Suspension, Locks, Brakes, Lubrication, Electrical, Frame Fuel System, Battery, etc. 2004 Yamaha YFM35AS-FAHS-FAS Bruin Auto 2WD 4WD HW 4×4. 2005 Yamaha YFM35BAT-FAT-FAHT BRUIN 2WD 4WD hunter.

2006 Yamaha YFM35BAV-FAV-FAHV Bruin 2WD 4WD PDF Manual. Instant Download. $9.95 Yamaha Bruin 350 Manual $14.99 OEM Parts & Online Schematics Diagram.FREE.