2005 YAMAHA BRUIN 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 ............... 3-7
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
U5UH61.book Page 1 Tuesday, April 20, 2004 10:10 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
Differential gear oil replacement ......... 8-39
Axle boots ........................................... 8-45
Spark plug inspection ......................... 8-47
Air filter element cleaning ................... 8-53
V-belt cooling duct check hose ........... 8-61
V-belt case drain plug ......................... 8-61
Carburetor adjustment ........................ 8-63
Idle speed adjustment ........................ 8-65
Valve clearance adjustment ............... 8-67
Select lever safety system cable
adjustment ........................................ 8-67
Throttle lever adjustment .................... 8-69
Front brake pad check ........................ 8-71
Rear brake shoe inspection ................ 8-71
Brake fluid level check ........................ 8-73
Brake fluid replacement ...................... 8-77
Front brake lever free play.................. 8-79
Rear brake pedal and lever
adjustment ........................................ 8-81
8
U5UH61.book Page 2 Tuesday, April 20, 2004 10:10 AM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber
assembly spring preload
adjusting ring
2. Storage box and tool kit
3. Spark plug
4. Front shock absorber
assembly spring preload
adjusting ring
5. Brake pedal
6. V-belt case
7. Fuel cock
8. Air filter case
9. Fuses
10. Tail/brake light
11. Front shock absorber
assembly spring preload
adjusting ring
12. V-belt cooling duct check
hose
13. Oil filter cartridge14. Engine oil dipstick
15. Rear brake lever
16. Left handlebar switches
17. Starter (choke)
18. Horn switch
19. Drive select lever
20. Speedometer
21. Main switch
22. Fuel tank cap
23. Right handlebar
switch
24. Throttle lever
25. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5UH61.book Page 1 Tuesday, April 20, 2004 10:10 AM

4-7
EBU07330
Oil temperature warning light checking method
ACB-10E
Turn the main switch to “ON” and the
engine stop switch to “”.
Oil temperature warning
light does not come on.
Oil temperature warning
light comes on.
Check engine oil temperature.
Oil temperature warning
light does not come on.
Engine oil temperature and
electrical circuit are OK. Go
ahead with riding.
Push start switch with the
transmission in neutral.
Ask a Yamaha dealer to
inspect the electrical circuit.
Oil tempera-
ture is low.
Allow to cool.
Oil tempera-
ture is high.
Oil temperature
warning light comes
on momentarily.
U5UH61.book Page 7 Tuesday, April 20, 2004 10:10 AM

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,
8-71–8-79
Rear brakeCheck operation, condition and free play.
Adjust if necessary.5-5–5-7,
8-71, 8-81–8-85
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-21–8-31
Final gear oil and
differential gear oilCheck for leakage.5-15–5-17,
8-31–8-43
ThrottleCheck for proper throttle cable operation and free play. 5-17, 8-69
Wheels and tiresCheck tire pressure, wear and damage.5-21–5-27,
8-93–8-95
Fittings and fastenersCheck all fittings and fasteners. 5-19
Lights and switchesCheck for proper operation. 5-19, 8-107–8-111
Axle bootsCheck for damage. 8-45
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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 8-39–
8-43 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
U5UH61.book Page 17 Tuesday, April 20, 2004 10:10 AM

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.U5UH61.book Page 7 Tuesday, April 20, 2004 10:10 AM

8-8
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 8-9.)
Correct if necessary.Rear brakeCheck operation.
Adjust if necessary.Select lever safety system
cable*Check operation.
Adjust if necessary.V-belt*Check operation.
Check for cracks or damage.Wheels*Check balance/damage/runout.
Repair if necessary.Wheel bearing*Check bearing assemblies for looseness/damage.
Replace if damaged.Front and rear
suspension*Check operation.
Correct if necessary.Steering system*Check operation./Replace if damaged.
Check toe-in./Adjust if necessary.Drive shaft universal
joint*Lubricate with lithium-soap-based grease.Axle boots*Check operation.
Replace if damaged.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.
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
U5UH61.book Page 8 Tuesday, April 20, 2004 10:10 AM