2004 YAMAHA WARRIOR 350 battery

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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.................................................. 5-13
Throttle lever ...................................... 5-15
Fittings and fasteners......................... 5-15
Lights ................................................. 5-15
Switches............................................. 5-15
Battery................................................ 5-17
Tires ................................................... 5-17
How to measure tire pressure ............ 5-21
Tire wear limit..................................... 5-23
5
U5NF63.book Page 1 Wednesday, March 12, 2003 10:06 AM

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
91011U5NF63.book Page 3 Wednesday, March 12, 2003 10:06 AM

4-5 1. Light switch “LIGHTS”
2. Engine stop switch “ENG. STOP”
3. Start switch “START”
1. Contacteur d’éclairage “LIGHTS”
2. Coupe-circuit du moteur “ENG. STOP”
3. Contacteur du démarreur “START”
1. Interruptor de luces “LIGHTS”
2. Interruptor de paro del motor “ENG. STOP”
3. Interruptor de arranque “START”
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Handlebar switches
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Light switch “LIGHTS”
Set the switch to the “LO” position to turn on the
low beam and the taillight.
Set the switch to the “HI” position to turn on the
high beam and the taillight.
Set the switch to the “OFF” position to turn off all of
the lights.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 re-
charge it. _
U5NF63.book Page 5 Wednesday, March 12, 2003 10:06 AM

5-1
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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, 8-15–8-23
Drive chainCheck chain slack and condition.
Adjust if necessary.5-13, 8-61–8-65
ThrottleCheck for proper throttle cable operation and free play. 5-15, 8-39
Wheels and tiresCheck tire pressure, wear and damage.5-17–5-23,
8-73–8-75
Fittings and fastenersCheck all fittings and fasteners. 5-15
Lights and switchesCheck for proper operation. 5-15, 8-57, 8-87–8-97
BatteryCheck fluid level.
Fill with distilled water if necessary.5-17, 8-77–8-83
U5NF63.book Page 1 Wednesday, March 12, 2003 10:06 AM

5-17
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Battery
Check fluid level and fill if necessary. Use only dis-
tilled water if refilling is necessary. (See pages 8-77–
8-83.)
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Tires
Always use the recommended tires.
WARNING
Use of improper tires on this ATV, or operation
of this ATV with improper or uneven tire pres-
sure, may cause loss of control, increasing
your risk of accident.
Pay attention to the following.
1. The tires listed below have been approved
by Yamaha Motor Co., Ltd. for this model.
Other tire combinations are not recom-
mended.
Manufacturer Size Type
Front DUNLOP AT22
× 7-10 KT701
Rear DUNLOP AT22
× 10-9 KT775B
U5NF63.book Page 17 Wednesday, March 12, 2003 10:06 AM

6-7 a. Starter (choke) 1. Fully open
2. Half open 3. Closed
a. Starter (enrichisseur) 1. Complètement ouvert
2. Mi-ouvert 3. Fermé
a. Starter (choke) 1. Abre completamente
2. Semiabierto 3. Cerrado
6. Completely close the throttle lever and start
the engine by pushing the start switch.NOTE:_ If the engine fails to start, release the start switch,
then push it again. Pause a few seconds before
the next attempt. Each cranking should be as short
as possible to preserve battery energy. Do not
crank the engine more than 10 seconds on each
attempt. _7. If the engine is started with the starter (choke)
in position
1, the starter (choke) should be
returned to position
2 to warm up the en-
gine. If the engine is started with the starter
(choke) in position
2, keep the starter
(choke) in this position to warm up the en-
gine.
8. Continue warming up the engine until it idles
smoothly and return the starter (choke) to po-
sition
3 before riding.CAUTION:_ See the “Engine break-in” section prior to op-
erating engine for the first time. _
U5NF63.book Page 7 Wednesday, March 12, 2003 10:06 AM

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.
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
U5NF63.book Page 8 Wednesday, March 12, 2003 10:06 AM

8-77 1. Battery 2. Battery breather hose
3. Guide
1. Batterie 2. Reniflard de batterie
3. Bride
1. Batería 2. Manguera del respiradero de la batería
3. Guía
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Battery
Check the level of the battery fluid and see if the
terminals are tight. Add distilled water if the fluid
level is low.CAUTION:
Do not leave or store the battery on its side.
When inspecting the battery, be sure the
breather hose is routed correctly. If it touches
the frame or exists in such a way as to cause
battery electrolyte or gas to exit onto the
frame, structural and cosmetic damage to the
machine can occur.
U5NF63.book Page 77 Wednesday, March 12, 2003 10:06 AM