2006 YAMAHA BRUIN 350 4WD check 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
U5UH62.book Page 1 Tuesday, April 5, 2005 6:57 PM

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
U5UH62.book Page 2 Tuesday, April 5, 2005 6:57 PM

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. V-belt cooling duct check
hose12. Oil filter cartridge
13. Engine oil dipstick
14. Rear brake lever
15. Left handlebar switches
16. Starter (choke)
17. Horn switch
18. Drive select lever
19. Speedometer
20. Main switch
21. Fuel tank cap
22. On-Command four-wheel
drive switch
23. Throttle lever
24. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5UH62.book Page 1 Tuesday, April 5, 2005 6:57 PM

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.
U5UH62.book Page 7 Tuesday, April 5, 2005 6:57 PM

4-19 1. Throttle lever
1. Levier d’accélération
1. Palanca de aceleración
EBU00063
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.
U5UH62.book Page 19 Tuesday, April 5, 2005 6:57 PM

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, 8-107–8-113
Axle bootsCheck for damage. 8-45
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6-9
EBU00180
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.
EBU00182
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.
U5UH62.book Page 9 Tuesday, April 5, 2005 6:57 PM

8-7
EBU02622
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.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
_
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.Cylinder head cover
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.)U5UH62.book Page 7 Tuesday, April 5, 2005 6:57 PM