2008 YAMAHA GRIZZLY 350 4WD ATV Repair Service Manual

This ATV should not be ridden by anyone under 16 years of age. WARNING OWNER’S MANUAL 5UH-F8199-16 LIT-11626-22-17 YFM35FGY READ THIS MANUAL CAREFULLY! It contains important safety information.

EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.

EBU17170 INTRODUCTION EBU17271 Congratulations on your purchase of the Yamaha YFM35FGY. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV. This manual includes important safety information. It provides information about special tech- niques 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 TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE- LY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. ● PAY CLOSE ATTENTION TO THE WARNING AND NOTICE LABELS ON THE ATV. ● NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMA- TION. ● THIS ATV, AND ANY OTHER ATV OVER 90 cc, 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 IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: * Product and specifications are subject to change without notice. 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 symbol to avoid possible injury or death. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. A TIP provides key information to make procedures easier or clearer. WARNING NOTICE TIP

EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! 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. EBU17402 YFM35FGY OWNER’S MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11626-22-17

WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU17420 TABLE OF CONTENTS SAFETY INFORMATION .............................. 1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 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 Handlebar switches .................................... 4-3 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 Pre-operation check list ..............................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 ............................................................5-5

Measuring the tire pressure ....................... 5-6 Tire wear limit ............................................. 5-7 Chassis fasteners ....................................... 5-7 Instruments, lights and switches ................ 5-7 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 .......................................... 6-5 Parking ....................................................... 6-6 Parking on a slope ..................................... 6-6 Accessories and loading ............................ 6-7 RIDING YOUR ATV ...................................... 7-1 GETTING TO KNOW YOUR ATV............... 7-2 RIDE WITH CARE AND GOOD JUDGEMENT ............................................ 7-3 BE CAREFUL WHERE YOU RIDE ........... 7-13 TURNING YOUR ATV .............................. 7-17 CLIMBING UPHILL ................................... 7-19 RIDING DOWNHILL.................................. 7-23 CROSSING A SLOPE............................... 7-25 CROSSING THROUGH SHALLOW WATER ................................................... 7-27 RIDING OVER ROUGH TERRAIN ........... 7-29 SLIDING AND SKIDDING .........................7-31 WHAT TO DO IF........................................7-32 WHAT TO DO............................................7-32 PERIODIC MAINTENANCE AND MINOR REPAIR ..........................................................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 ..............8-8 Checking the spark plug .............................8-9 Engine oil and oil filter cartridge ................8-11 Final gear oil .............................................8-15 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 .............8-26 Adjusting the throttle cable free play .........8-27 Valve clearance ........................................8-27 Adjusting the drive select lever safety system cable ...........................................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 ................................. 8-35 Checking and lubricating the cables ........ 8-36 Checking and lubricating the front and rear brake levers .................................... 8-36 Checking and lubricating the brake pedal ...................................................... 8-37 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 ...................... 8-44 Replacing the tail/brake light bulb ............ 8-44 Removing a wheel .................................... 8-44 Installing a wheel ...................................... 8-45 Troubleshooting ....................................... 8-46 Troubleshooting chart .............................. 8-48 CLEANING AND STORAGE ..........................9-1 Cleaning ......................................................9-1 Storage .......................................................9-2 SPECIFICATIONS .......................................10-1 CONSUMER INFORMATION.......................11-1 Identification numbers ...............................11-1 Noise regulation ........................................11-3 Maintenance record ..................................11-4 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY .........11-5 YAMAHA EXTENDED SERVICE (Y.E.S.) ...................................................11-7

1-1 1 EBU17430 SAFETY INFORMATION EBU17542 AN ATV IS NOT A TOY AND CAN BE HAZARD- OUS TO OPERATE. An ATV handles differently from other vehicles, including motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: ● Read this manual and all labels carefully and follow the operating procedures described. ● Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instruc- tor. Contact an authorized ATV dealer or call 1- 800-887-2887 to find out about the training courses nearest you. ● Always follow the age recommendation: – A child under 16 years old should never operate an ATV with engine size greater than 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 streets. ● Never operate an ATV on any public street, road or highway, even a dirt or gravel one. ● Never operate an ATV without wearing an ap- proved 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.

1-2 1 ● Always inspect your ATV each time you use it to make sure it is in safe operating condition. Al- ways 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 prac- ticed 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 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 tech- nique 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

2008 YAMAHA GRIZZLY 350 4WD ATV Repair Service Manual

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