2005 YAMAHA YFM350R check engine

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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
Start switch .......................................... 4-7
Throttle lever ........................................ 4-9
Speed limiter ...................................... 4-11
Clutch lever ........................................ 4-13
Brake lever ......................................... 4-13
Brake pedal ........................................ 4-15
Parking brake lever ............................ 4-17
Shift pedal .......................................... 4-21
1234
Drive select lever ............................... 4-21
Fuel tank cap ..................................... 4-23
Fuel cock............................................ 4-23
Starter (choke) .................................. 4-27
Seat.................................................... 4-29
Front shock absorber adjustment ...... 4-31
Rear shock absorber adjustment ....... 4-33
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
Tires ................................................... 5-17
How to measure tire pressure ............ 5-21
Tire wear limit..................................... 5-23
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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 ..............................6-27
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 ................................7-41
Climbing uphill.....................................7-47
Riding downhill ....................................7-57
Crossing a slope .................................7-61
Crossing through shallow water ..........7-65
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
Engine oil and oil filter element........... 8-17
Spark plug inspection ......................... 8-29
Air filter element cleaning ................... 8-33
Carburetor adjustment ........................ 8-41
Idle speed adjustment ........................ 8-43
Throttle lever adjustment .................... 8-45
Valve clearance adjustment ............... 8-45
Front brake pad inspection ................. 8-47
Rear brake pad inspection.................. 8-47
Brake fluid level check ........................ 8-49
Brake fluid replacement ...................... 8-53
Front brake lever free play.................. 8-55
Brake pedal height adjustment ........... 8-57
Parking brake adjustment ................... 8-59
Adjusting the rear brake light switch ... 8-65
Clutch lever free play adjustment ....... 8-67
Drive chain slack check ...................... 8-69
Drive chain slack adjustment .............. 8-71
Lubricating the drive chain.................. 8-73
Cable inspection and lubrication......... 8-75
Brake and shift pedal/brake and
clutch lever lubrication ...................... 8-75
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4-9 1. Throttle lever
1. Levier d’accélération
1. Palanca de aceleración
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Throttle lever
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying the
throttle position. Because the throttle is spring-
loaded, the machine will decelerate, and the en-
gine will return to an idle any time the hand is re-
moved from the throttle lever.
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
WARNING
Malfunction of the throttle could make it diffi-
cult to speed up or slow down when you need
to. This could cause an accident. Check the
operation of the throttle lever before you start
the engine. If the throttle does not work
smoothly, check for the cause. Correct the
problem before riding the ATV or consult a
Yamaha dealer.
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5-1
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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,
8-47–8-57
ClutchCheck operation, condition and lever free play. 8-67
Parking brakeCheck operation, condition and cable length. 8-59–8-63
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-17–8-27
Drive chainCheck chain slack and condition.
Adjust if necessary.5-13, 8-69–8-73
ThrottleCheck for proper throttle cable operation and free play. 5-15, 8-45
Wheels and tiresCheck tire pressure, wear and damage.5-17–5-23,
8-85–8-87
Fittings and fastenersCheck all fittings and fasteners. 5-15
Lights and switchesCheck for proper operation.5-15, 8-65,
8-97–8-105
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5-13
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Engine oil
Make sure the engine oil is at the specified level.
Add oil as necessary. (See pages 8-17–8-27.)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 specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
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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
8-69–8-73 for details.) Recommended engine oil type and quantity:
See page 10-2.
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6-9
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Starting a warm engine
To start a warm engine, refer to the “Starting a cold
engine” section. The starter (choke) should not be
used. The throttle should be opened slightly.
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Warming up
To get maximum engine life, always warm up the
engine before starting off. Never accelerate hard
with a cold engine! To see whether or not the en-
gine is warm, check if it responds to the throttle
normally with the starter (choke) turned off.
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8-7
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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 starter (choke) operation.
Adjust engine idling speed.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.U5YT61.book Page 7 Wednesday, April 7, 2004 3:59 PM

8-8 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Engine oil strainer
Clean.Drive chain
Check and adjust slack/alignment/clean/lube.Brakes*Check operation/fluid leakage/See NOTE page 8-9.
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.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 with lithium-soap-based grease.Rear arm pivot*
Lubricate every 6 months with lithium-soap-based grease.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
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
U5YT61.book Page 8 Wednesday, April 7, 2004 3:59 PM