2005 YAMAHA BRUIN 350 engine

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
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2-1
SAFETY INFORMATION
EBU13142
AN ATV IS NOT A TOY AND CAN BE HAZARD-OUS TO OPERATE.
An ATV handles differently
from other vehicles including motorcycles and
cars. A collision or rollover can occur quickly, even
during routine maneuvers such as turning and
riding on hills or over obstacles, if you fail to take
proper precautions.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:


Read this manual and all labels carefully and
follow the operating procedures described.


Never operate an ATV without proper training
or instruction.


Always follow the age recommendation:
– A child under 16 years old should never oper-
ate an ATV with engine size greater than 90cc.


Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she
does not have the abilities to operate it safely.
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2-15
WARNING
_

Always turn off the engine when refueling.


Do not refuel immediately after the engine
has been running and is still very hot.


Do not spill gasoline on the engine or ex-
haust pipe/muffler when refueling. Never
refuel while smoking, or in the vicinity of
sparks, open flames, or other sources of
ignition such as the pilot lights of water
heaters and clothes dryers. Gasoline can
catch fire and you could be burned.


When transporting the ATV in another ve-
hicle, be sure it is kept upright and that the
fuel cock is in the “OFF” position. Other-
wise, fuel may leak out of the carburetor or
fuel tank.


Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gaso-
line vapor, or get some gasoline in your
eyes, see your doctor immediately. If gaso-
line spills on your skin, wash with soap
and water. If gasoline spills on your cloth-
ing, change your clothes.
_
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2-17
WARNING
_ Always operate your ATV in an area with ade-
quate ventilation. Never start or run the engine
in a closed area. Exhaust fumes are poisonous
and may cause loss of consciousness and
death within a short time. _
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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

4-1 1. Main switch
1. Contacteur à clé
1. Interruptor principal
EBU00040
CONTROL FUNCTIONS
EBU12490
Main switch
Functions of the respective switch positions are as
follows:
ON:
The engine can be started only at this position and
the headlights, taillight and meter lighting come on
when the light switch is on.
OFF:
All electrical circuits are switched off. The key can
be removed in this position.
U5UH61.book Page 1 Tuesday, April 20, 2004 10:10 AM

4-5 1. Reverse indicator light “REVERSE”
2. Neutral indicator light “NEUTRAL”
3. Four-wheel-drive indicator light “”
4. Oil temperature warning light “”
1. Témoin de marche arrière “REVERSE”
2. Témoin de point mort “NEUTRAL”
3. Témoin 4x4 “”
4. Témoin d’avertissement de la température d’huile “”
1. Luz indicadora de marcha atrás “REVERSE”
2. Luz de control de punto muerto “NEUTRAL”
3. Luz de control del modo de tracción de cuatro ruedas “”
4. Luz de aviso de la temperatura del aceite “”
EBU11400
Oil temperature warning light “”
When the oil temperature reaches a specified lev-
el, this light comes on to warn that the engine oil
temperature is too hot. If the light comes on during
operation, stop the engine as soon as it is safe to
do so and allow the engine to cool down for about
10 minutes.CAUTION:_

The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.


Restart after making sure that the light is
out. Continuous use while the light is on
may cause damage to the engine.
_
U5UH61.book Page 5 Tuesday, April 20, 2004 10:10 AM