2003 YAMAHA YFM350R clutch

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
U5NF62.book Page 1 Wednesday, May 8, 2002 1:40 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
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

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Seat
2. Drive select lever
3. Fuel tank cap
4. Main switch
5. Brake pedal
6. Headlights
7. Front wheel
8. Fuel cock9. Rear wheel
10. Shift pedal
11. Starter (choke)
12. Clutch lever
13. Parking brake
14. Brake lever
15. Throttle lever
16. Handlebar switchesNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5NF62.book Page 1 Wednesday, May 8, 2002 1:40 PM

4-13 1. Clutch lever
1. Levier d’embrayage
1. Palanca de embrague
1. Brake lever
1. Levier de frein
1. Palanca del freno
EBU00069
Clutch lever
The clutch lever is located on the left handlebar
and the ignition circuit cut-off system is incorporat-
ed in the clutch lever holder. 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. (Refer to “Starting a cold engine”
for a description of the ignition circuit cut-off sys-
tem.)
EBU00988
Brake lever
The brake lever is located on the right handlebar.
Pull it toward the handlebar to apply the front
brake.
U5NF62.book Page 13 Wednesday, May 8, 2002 1:40 PM

4-17 1. Button 2. Lock plate
1. Bouton 2. Verrou
1. Botón 2. Placa de bloqueo
1. Locked position
1. Position verrou bloqué
1. Posición bloqueada
EBU00081
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. Other-
wise, the engine will misfire, preventing normal op-
eration.
U5NF62.book Page 17 Wednesday, May 8, 2002 1:40 PM

4-21 1. Shift pedal
1. Pédale de sélection
1. Pedal del cambio
1. Drive select lever
1. Levier de présélection
1. Palanca de selección de gama
EBU00082
Shift pedal
This machine is equipped with a constant-mesh 6-
speed transmission. The shift pedal is located on
the left side of the engine and is used in combina-
tion with the clutch when shifting.
EBU00085
Drive select lever
The drive select lever is used for driving the machine
either forward or in reverse. Refer to page 6-11 for
drive select lever operation.
U5NF62.book Page 21 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