2004 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.................................................. 5-13
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

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
U5NF63.book Page 2 Wednesday, March 12, 2003 10:06 AM

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, 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

5-13
EBU10841
Engine oil
Make sure the engine oil is at the specified level.
Add oil as necessary. (See pages 8-15–8-23.)CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of
“CD” or oils of a higher quality than spec-
ified. In addition, do not use oils labeled
“ENERGY CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
EBU00498
Chain
Check the general condition of the chain and
check the chain slack before every ride. Lubricate
and adjust the chain as necessary. (See pages
8-61–8-65 for details.) Recommended engine oil and quantity:
See page 10-2.
U5NF63.book Page 13 Wednesday, March 12, 2003 10:06 AM

8-7
EBU00262
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 elementClean.
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 elementClean.
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.Wheel bearings*Check bearing assemblies for looseness/damage.
Replace if damaged.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

8-15 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
EBU01181
Engine oil
Engine oil level measurement
1. Place the ATV on a level surface.
2. Warm up the engine for several minutes, and
then stop it.
3. Remove the engine oil filler cap, and then
wipe the dipstick 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.NOTE:_ The oil level should be between the maximum and
minimum level marks. _
U5NF63.book Page 15 Wednesday, March 12, 2003 10:06 AM

8-19 1. Engine oil filter cover 2. Bolt (× 3)
3. Engine oil filter element 4. O-ring
1. Couvercle du filtre à huile de moteur 2. Boulon (× 3)
3.Élément du filtre à huile de moteur
4. Joint torique
1. Tapa del filtro de aceite de motor 2. Perno (× 3)
3. Elemento del filtro de aceite de motor
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
necessary.
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, O-
ring 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. _
U5NF63.book Page 19 Wednesday, March 12, 2003 10:06 AM