2003 YAMAHA WARRIOR 350 check oil

EBU00015
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ....................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION .................................... 3-1
Identification number records ............... 3-3
Key identification number ..................... 3-5
Vehicle identification number ............... 3-5
Model label ........................................... 3-7
CONTROL FUNCTIONS ......................... 4-1
Main switch........................................... 4-1
Indicator lights ...................................... 4-3
Handlebar switches .............................. 4-5
Throttle lever ........................................ 4-9
Speed limiter ...................................... 4-11
Clutch lever ........................................ 4-13
Brake lever ......................................... 4-13
Brake pedal ........................................ 4-15
Parking brake ..................................... 4-17
Shift pedal .......................................... 4-21
Drive select lever ................................ 4-21
1234
Fuel tank cap ..................................... 4-23
Fuel cock............................................ 4-23
Starter (choke) ................................... 4-25
Seat.................................................... 4-27
Front shock absorber adjustment ...... 4-29
Rear shock absorber adjustment ....... 4-31
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Chain.................................................. 5-15
Throttle lever ...................................... 5-17
Fittings and Fasteners ....................... 5-17
Lights ................................................. 5-17
Switches............................................. 5-17
Battery................................................ 5-19
Tires ................................................... 5-19
How to measure tire pressure ............ 5-23
Tire wear limit..................................... 5-25
5
U5NF61.book Page 1 Wednesday, June 13, 2001 5:18 PM

OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Warming up...........................................6-9
Drive select lever operation and
reverse driving ..................................6-11
Shifting ................................................6-15
To start out and accelerate .................6-17
To decelerate ......................................6-21
Engine break-in ...................................6-23
Parking ................................................6-27
Parking on a slope ..............................6-29
Accessories and loading .....................6-31
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good
judgement ...........................................7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-39
Climbing uphill.....................................7-45
Riding downhill ....................................7-55
Crossing a slope .................................7-59
Crossing through shallow water ..........7-63
Riding over rough terrain ....................7-67
Sliding and skidding ............................7-69
67
What to do if... .................................... 7-73
What to do... ....................................... 7-73
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Engine oil ............................................ 8-15
Spark plug inspection ......................... 8-25
Air filter cleaning ................................. 8-29
Carburetor adjustment ........................ 8-33
Idle speed adjustment ........................ 8-35
Throttle lever adjustment .................... 8-37
Valve clearance adjustment ............... 8-37
Front and rear brake pad
inspection ......................................... 8-39
Inspecting the brake fluid level ........... 8-41
Brake fluid replacement ...................... 8-45
Front brake adjustment....................... 8-47
Rear brake adjustment ....................... 8-49
Parking brake adjustment ................... 8-51
Adjusting the rear brake light .............. 8-55
Clutch lever free play adjustment ....... 8-57
Drive chain slack check ...................... 8-59
Drive chain slack adjustment .............. 8-61
Lubricating the drive chain.................. 8-63
8
U5NF61.book Page 2 Wednesday, June 13, 2001 5:18 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
BrakeCheck operation, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5 ~ 5-7,
8-39 ~ 8-49
ClutchCheck operation, condition and lever free play. 8-57
Parking brakeCheck operation, condition and cable free play. 8-51 ~ 8-53
FuelCheck fuel level.
Fill with fuel if necessary.5-9 ~ 5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13 ~ 5-15,
8-15 ~ 8-23
Drive chainCheck chain slack and condition.
Adjust if necessary.5-15, 8-59 ~ 8-63
ThrottleCheck for proper throttle cable operation and free play. 5-17, 8-37
Wheels and tiresCheck tire pressure, wear and damage.5-19 ~ 5-25,
8-71 ~ 8-73
Fittings and FastenersCheck all fittings and fasteners. 5-17
LightsCheck for proper operation. 5-17, 8-85 ~ 8-95
BatteryCheck fluid level.
Fill with distilled water if necessary.5-19, 8-75 ~ 8-81
U5NF61.book Page 1 Wednesday, June 13, 2001 5:18 PM

5-15
CAUTION:_ Be sure to use motor oils that do not contain
anti-friction modifiers. Passenger car motor
oils (often labeled “ENERGY CONSERVING II”)
contain anti-friction additives which will cause
clutch and/or starter clutch slippage, resulting
in reduced component life and poor engine
performance.
EBU00498
Chain
Check the general condition of the chain and check
the chain slack before every ride. Lubricate and ad-
just the chain as necessary. (See pages 8-59 ~ 8-63
for details.)Oil quantity:
Total amount:
3.2 L
Periodic oil change:
2.4 L
With oil filter replacement:
2.5 L
U5NF61.book Page 15 Wednesday, June 13, 2001 5:18 PM

8-7
EBU00262
3-PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*•Check valve clearance.
•Adjust if necessary.
Spark plug•Check condition.
•Adjust gap and clean.
•Replace if necessary.Air filter element•Clean.
•Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Carburetor*•Check idle speed/starter operation.
•Adjust if necessary.Crankcase breather
system*•Check breather hose for cracks or damage.
•Replace if necessary.Exhaust system*•Check for leakage.
•Tighten if necessary.
•Replace gasket(s) if necessary.Fuel line*•Check fuel hose for cracks or damage.
•Replace if necessary.Engine oil•Replace. (Warm engine before draining.)Engine oil filter element•Clean.
•Replace if necessary.Engine oil strainer•Clean.Drive chain•Check and adjust slack/alignment/clean/lube.Brakes*•Check operation/fluid leakage/See NOTE page 8-8.
•Correct if necessary.Clutch*•Check operation.
•Adjust if necessary.Wheels*•Check balance/damage/runout.
•Replace if necessary.U5NF61.book Page 7 Wednesday, June 13, 2001 5:18 PM

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
** Lithium-soap-based grease
NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
Wheel bearings*•Check bearing assembly for looseness/damage.
•Replace if damaged.Steering system*•Check operation.
•Repair if damaged.
•Check toe-in.
•Adjust if necessary.Upper and lower arm
pivot and steering
shaft*•Lubricate every 6 months.**Rear arm pivot*•Lubricate every 6 months.**Fittings and Fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.Battery*•Check specific gravity.
•Check breather hose for proper routing.
•Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5NF61.book Page 8 Wednesday, June 13, 2001 5:18 PM

8-15 1. Dipstick 2. Maximum level mark
3. Minimum level mark
1. Jauge 2. Repère de niveau maximum
3. Repère de niveau minimum
1. Varilla 2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU00949*
Engine oil
Engine oil level measurement
1. Place the machine on a level surface.
2. Warm up the engine for several minutes, and
then stop it.
3. Remove the dipstick, and then wipe it off with
a clean rag. Insert the dipstick in the filler hole
without screwing it in.NOTE:_ Wait a few minutes until the oil level settles before
checking. _4. Remove the dipstick, and then check the oil
level.
5. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
add oil to raise it to the proper level.CAUTION:_ Be sure no foreign material enters the crank-
case. _
U5NF61.book Page 15 Wednesday, June 13, 2001 5:18 PM

8-19 1. Oil filter cover 2. Bolt (× 3)
3. Oil filter 4. O-ring
1. Couvercle du filtre à huile 2. Boulon (× 3)
3. Filtre à huile 4. Joint torique
1. Tapa del filtro de aceite 2. Perno (× 3)
3. Filtro de aceite 4. Junta tórica
5. Remove the oil filter cover by removing the
bolts and then remove the oil filter element.
6. Clean the oil strainer and oil filter element
with solvent.
7. Check the O-ring for damage and replace it if
damaged.
8. Install the oil filter element, and O-ring.
9. Install the oil filter cover by installing the bolts.
10. Install the oil strainer, compression spring
and drain bolt. Tighten the drain bolt and oil
filter cover bolts to the specified torques.CAUTION:_ Before installing the drain bolt, be sure to in-
stall the O-ring, compression spring and oil
strainer. _11. Fill the engine with oil, and then install the
dipstick. Tightening torques:
Drain bolt (engine):
32 Nm (3.2 m·kgf)
Filter cover bolt:
10 Nm (1.0 m·kgf)
U5NF61.book Page 19 Wednesday, June 13, 2001 5:18 PM