2005 YAMAHA BRUIN 350 2WD maintenance

EBU00946
1-INTRODUCTION
Congratulations on your purchase of the Yamaha
YFM350BA. It represents the result of many years
of Yamaha experience in the production of fine
sporting, touring, and pacesetting racing ma-
chines. With the purchase of this Yamaha, you can
now appreciate the high degree of craftsmanship
and reliability that have made Yamaha a leader in
these fields.
This manual will provide you with a good basic un-
derstanding of the features and operation of this
ATV.
This manual includes important safety in-
formation. It provides information about spe-
cial techniques and skills necessary to ride
your ATV. It also includes basic maintenance and
inspection procedures. If you have any questions
regarding the operation or maintenance of your
ATV, please consult a Yamaha dealer.
EE.book Page 4 Wednesday, April 21, 2004 8:59 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............ 8-17
Engine oil and oil filter cartridge ......... 8-21
Final gear oil ....................................... 8-31
Spark plug inspection ......................... 8-39
Air filter element cleaning ................... 8-45
V-belt cooling duct check hose ........... 8-53
V-belt case drain plug ......................... 8-53
Carburetor adjustment ........................ 8-55
Idle speed adjustment ........................ 8-57
Valve clearance adjustment ............... 8-59
Select lever safety system cable
adjustment ........................................ 8-59
Throttle lever adjustment .................... 8-61
Front brake pad check ........................ 8-63
Rear brake shoe inspection ................ 8-63
Brake fluid level check ........................ 8-65
Brake fluid replacement ...................... 8-69
Front brake lever free play.................. 8-71
Rear brake pedal and lever
adjustment ........................................ 8-73
Adjusting the rear brake light
switch ............................................... 8-79
Cable inspection and lubrication......... 8-81
8
EE.book Page 2 Wednesday, April 21, 2004 8:59 AM

Lubricating the brake levers and
brake pedal ...................................... 8-83
Wheel removal ................................... 8-85
Wheel installation ............................... 8-87
Battery ................................................ 8-89
Battery maintenance .......................... 8-93
Fuse replacement............................... 8-95
Replacing a headlight bulb ................. 8-99
Headlight beam adjustment.............. 8-103
Tail/brake light bulb replacement ..... 8-103
Troubleshooting................................ 8-105
Troubleshooting chart....................... 8-107
CLEANING AND STORAGE .................. 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
91011EE.book Page 3 Wednesday, April 21, 2004 8:59 AM

2-5

Always inspect your ATV each time you use it
to make sure it is in safe operating condition.
Always follow the inspection and maintenance
procedures and schedules described in this
manual.


Always keep both hands on the handlebars
and both feet on the footboards of the ATV dur-
ing operation.


Always go slowly and be extra careful when op-
erating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the
ATV.


Never operate on excessively rough, slippery
or loose terrain until you have learned and
practiced the skills necessary to control the
ATV on such terrain. Always be especially cau-
tious on these kinds of terrain.


Always follow proper procedures for turning as
described in this manual. Practice turning at
low speeds before attempting to turn at faster
speeds. Do not turn at excessive speed.
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5-4
WARNING
Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Own-
er’s Manual. Failure to inspect increases the possibility of an accident or equipment damage.
AVERTISSEMENT
_ Toujours effectuer ces contrôles avant chaque départ afin de s’assurer que le VTT peut être utilisé en toute sécu-
rité. Toujours respecter les procédés et intervalles de contrôle et d’entretien repris dans ce manuel. Omettre ces
contrôles accroît les risques d’accident ou d’endommagement du véhicule. _
ADVERTENCIA
_ Inspeccionar siempre el ATV cada vez que vaya a utilizarse, para asegurarse de que está en condicio-
nes de funcionar sin peligro. Seguir siempre los procedimientos y programas de inspección y mante-
nimiento descritos en el Manual del Propietario. Si no se inspecciona la máquina, aumenta el riesgo de
accidente o avería. _EE.book Page 4 Wednesday, April 21, 2004 8:59 AM

8-1
EBU00516
PERIODIC MAINTENANCE AND
ADJUSTMENTPeriodic inspection, adjustment and lubrication will
keep your machine in the safest and most efficient
condition possible. Safety is an obligation of the
machine owner. The most important points of ma-
chine inspection, adjustment and lubrication are
explained on the following pages.
WARNING
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or can start fires. Turn off
the engine when performing maintenance un-
less otherwise specified. Have a Yamaha deal-
er perform service if you are not familiar with
machine service.
EE.book Page 1 Wednesday, April 21, 2004 8:59 AM

8-3 1. Owner’s manual
2. Owner’s tool kit
3. Low-pressure tire gauge
1. Manuel du propriétaire
2. Trousse à outils du propriétaire
3. Manomètre basse pression pour pneus
1. Manual del propietario
2. Juego de herramientas del propietario
3. Manómetro de baja presión
EBU14520
Owner’s manual and tool kit
You are recommended to put this owner’s manual
in the vinyl bag and always carry it on the bottom
of the seat as shown. Put the owner’s tool kit and
low-pressure tire gauge under the seat.
The service information included in this manual is
intended to provide you, the owner, with the nec-
essary information for completing your own pre-
ventive maintenance and minor repairs. The tools
provided in the Owner’s tool kit are sufficient for
this purpose, except that a torque wrench is also
necessary to properly tighten nuts and bolts.NOTE:_ If you do not have a torque wrench available dur-
ing a service operation requiring one, take your
machine to a Yamaha dealer to check the torque
settings and adjust them as necessary. _
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8-7
EBU02621
PERIODIC MAINTENANCE/LUBRICATION
NOTE:_

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.


For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. How-
ever, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be
followed.
_
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
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.EE.book Page 7 Wednesday, April 21, 2004 8:59 AM