2004 YAMAHA WOLVERINE 350 differential

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 ............... 3-7
Model label ........................................... 3-9
CONTROL FUNCTIONS ........................ 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-3
Speedometer ...................................... 4-11
Handlebar switches ............................ 4-13
Throttle lever ...................................... 4-19
Speed limiter ...................................... 4-21
Front brake lever ................................ 4-23
Brake pedal and rear brake lever ....... 4-25
Parking brake ..................................... 4-27
Drive select lever ................................ 4-29
Recoil starter ...................................... 4-31
1234
Fuel tank cap ..................................... 4-31
Fuel cock............................................ 4-33
Starter (choke) .................................. 4-35
Seat.................................................... 4-37
Storage box........................................ 4-39
Front carrier ....................................... 4-41
Rear carrier ........................................ 4-41
Front shock absorber adjustment ...... 4-43
Rear shock absorber adjustment ....... 4-45
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Final gear oil ...................................... 5-15
Differential gear oil ............................. 5-17
Throttle lever ...................................... 5-17
Fittings and fasteners......................... 5-19
Lights ................................................. 5-19
Switches............................................. 5-19
Tires ................................................... 5-21
How to measure tire pressure ............ 5-25
Tire wear limit..................................... 5-27
5
U5UH60.book Page 1 Wednesday, October 8, 2003 9:05 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
Engine break-in ...................................6-15
Parking ................................................6-17
Parking on a slope ..............................6-19
Accessories and loading .....................6-21
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 ....................7-69
Sliding and skidding ............................7-71
What to do if .......................................7-75
What to do ..........................................7-75
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ........................................ 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Panel removal and installation............ 8-15
Engine oil and oil filter cartridge ......... 8-19
Final gear oil ....................................... 8-29
Differential gear oil replacement ......... 8-35
Axle boots ........................................... 8-41
Spark plug inspection ......................... 8-43
Air filter element cleaning ................... 8-49
V-belt cooling duct check hose ........... 8-57
V-belt case drain plug ......................... 8-57
Carburetor adjustment ........................ 8-59
Idle speed adjustment ........................ 8-61
Valve clearance adjustment ............... 8-63
Throttle lever adjustment .................... 8-65
Front brake pad check ........................ 8-67
Rear brake shoe inspection ................ 8-67
Brake fluid level check ........................ 8-69
Brake fluid replacement ...................... 8-73
Front brake lever free play.................. 8-75
Rear brake pedal and lever
adjustment ........................................ 8-77
Adjusting the rear brake light
switch ............................................... 8-83
Cable inspection and lubrication......... 8-85
8
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5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-67–8-75
Rear brakeCheck operation, condition and free play.
Adjust if necessary.5-5–5-7,
8-67, 8-77–8-81
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-19–8-29
Final gear oil and
differential gear oilCheck for leakage.5-15–5-17,
8-29–8-39
ThrottleCheck for proper throttle cable operation. 5-17, 8-65
Wheels and tiresCheck tire pressure, wear and damage.5-21–5-27,
8-89–8-91
Fittings and fastenersCheck all fittings and fasteners. 5-19
Lights and switchesCheck for proper operation. 5-19, 8-103–8-107
Axle bootsCheck for damage. 8-41
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5-17
EBU00678
Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-35–
8-39 for details.)
EBU01083
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha
dealer repair as necessary for proper operation.Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
U5UH60.book Page 17 Wednesday, October 8, 2003 9:05 AM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*Check valve clearance.
Adjust if necessary.
Spark plugCheck 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 and adjust 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 cartridge
Replace.Engine oil strainer*
Clean.Final gear oil
Check oil level/oil leakage.
Replace every 12 months.Differential gear oil
Front brake*Check operation/fluid leakage. (See NOTE page 8-8.)
Correct if necessary.Rear brakeCheck operation.
Adjust if necessary.V-belt*Check operation.
Check for cracks or damage.U5UH60.book Page 7 Wednesday, October 8, 2003 9:05 AM

8-35 1. Differential oil filler bolt
1. Boulon de l’orifice de remplissage d’huile de différentiel
1. Perno de relleno de aceite del diferencial
1. Differential gear oil drain bolt
1. Boulon de vidange de l’huile de différentiel
1. Perno de drenaje de aceite de engranajes del diferencial
EBU01241
Differential gear oil replacement
1. Place the machine on a level surface.
2. Place a container under the differential gear
case to catch the oil.
3. Remove the oil filler bolt and oil drain bolt to
drain the oil.
4. Install the oil drain bolt, and then tighten it to
the specified torque.
Tightening torque:
Drain bolt:
10 Nm (1.0 m·kgf)
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8-37
5. Fill the differential gear case with the speci-
fied amount of the recommended oil.NOTE:_

Do not exceed the specified differential gear
oil quantity when filling. Overfilling will cause
the oil to seep out of the breather hose during
and after riding.


The differential gear oil level cannot be
checked. The differential gear case capacity
is greater than the recommended oil quantity,
therefore the oil level cannot be accurately
checked from the oil filler cap hole.
_
Recommended oil:
SAE 80 API “GL-4” Hypoid gear oil
Oil quantity:
0.35 L
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10-3
Final gear oil:
Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.23 L
Differential gear oil:
Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.35 L
Air filter: Wet element
Fuel:
Type Unleaded gasoline only
For Europe: Regular unleaded gasoline only with a
research octane number of 91 or higher
Fuel tank capacity 13.5 L
Fuel reserve amount 3.3 L
Carburetor:
Type/quantity BSR33/1
Manufacturer MIKUNI
Spark plug:
Type/manufacturer DR8EA / NGK
Spark plug gap 0.6–0.7 mm
Clutch type: Wet, centrifugal automaticModel YFM350FA
U5UH60.book Page 3 Wednesday, October 8, 2003 9:05 AM