2003 YAMAHA YFM350R brake fluid

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
What to do if ........................................7-73
67
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 ........................ 8-35
Idle speed adjustment ........................ 8-37
Throttle lever adjustment .................... 8-39
Valve clearance adjustment ............... 8-39
Front and rear brake pad
inspection ......................................... 8-41
Brake fluid level check ........................ 8-43
Brake fluid replacement ...................... 8-47
Front brake lever free play.................. 8-49
Brake pedal height adjustment ........... 8-51
Parking brake adjustment ................... 8-53
Adjusting the rear brake light switch ... 8-57
Clutch lever free play adjustment ....... 8-59
Drive chain slack check ...................... 8-61
Drive chain slack adjustment .............. 8-63
Lubricating the drive chain.................. 8-65
Cable inspection and lubrication......... 8-67
8
U5NF62.book Page 2 Wednesday, May 8, 2002 1:40 PM

Brake and shift pedal/brake and
clutch lever lubrication...................... 8-67
Front upper and lower arm pivot
lubrication ......................................... 8-69
Rear arm pivot lubrication .................. 8-71
Wheel removal ................................... 8-73
Wheel installation ............................... 8-75
Battery ................................................ 8-77
Replenishing the battery fluid ............. 8-81
Fuse replacement............................... 8-85
Replacing a headlight bulb ................. 8-87
Headlight beam adjustment................ 8-95
Tail/brake light bulb replacement ....... 8-97
Troubleshooting.................................. 8-99
Troubleshooting chart....................... 8-101
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................. 10-1
CONVERSION TABLE .......................... 11-1
91011U5NF62.book Page 3 Wednesday, May 8, 2002 1:40 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
BrakesCheck operation, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-41–8-51
ClutchCheck operation, condition and lever free play. 8-59
Parking brakeCheck operation, condition and cable length. 8-53–8-55
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, 8-61–8-65
ThrottleCheck for proper throttle cable operation and free play. 5-17, 8-39
Wheels and tiresCheck tire pressure, wear and damage.5-19–5-25,
8-73–8-75
Fittings and fastenersCheck all fittings and fasteners. 5-17
Lights and switchesCheck for proper operation. 5-17, 8-57, 8-87–8-97
BatteryCheck fluid level.
Fill with distilled water if necessary.5-19, 8-77–8-83
U5NF62.book Page 1 Wednesday, May 8, 2002 1:40 PM

5-5
EBU01167
Front and rear brakes
Brake lever and brake pedal

Check that there is no free play in the brake le-
ver. If there is free play, have a Yamaha dealer
inspect the brake system.


Check for correct brake pedal height. (See
page 8-51.) If the pedal height is incorrect,
have a Yamaha dealer adjust it.


Check the operation of the brake lever and
brake pedal. They should move smoothly and
there should be a firm feeling when the brakes
are applied. If not, have a Yamaha dealer in-
spect the brake system.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See pages 8-43–8-47.)
Recommended brake fluid: DOT 4
U5NF62.book Page 5 Wednesday, May 8, 2002 1:40 PM

5-7
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or brake fluid reservoirs. Apply the
brakes firmly for one minute. If there is any leak-
age, have a Yamaha dealer inspect the brake sys-
tem.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, in-
spect the brake pads for wear. (See page 8-41.)
WARNING
_ Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual,
have a Yamaha dealer check for the cause. _
U5NF62.book Page 7 Wednesday, May 8, 2002 1:40 PM

8-7
EBU00262
5-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.U5NF62.book Page 7 Wednesday, May 8, 2002 1:40 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 cylinders or calipers, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
2. On the inner parts of the master cylinders and calipers, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
Wheel bearings*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Steering system*•Check operation.
•Repair if damaged.
•Check toe-in.
•Adjust if necessary.Front and rear
suspension*•Check operation.
•Correct 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.Lights and switches*•Check operation.
•Adjust headlight beam.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5NF62.book Page 8 Wednesday, May 8, 2002 1:40 PM

8-43 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
Front
Avant
Delantero1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimoRear
Arrière
Trasero
EBU01185
Brake fluid level check
Insufficient brake fluid may let air enter the brake
system, possibly causing the brakes to become in-
effective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish if neces-
sary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
Observe these precautions:

When checking the fluid level, make sure the
top of the brake fluid reservoir is level by turn-
ing the handlebars.


Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake performance.
Recommended brake fluid: DOT 4
U5NF62.book Page 43 Wednesday, May 8, 2002 1:40 PM