warning YAMAHA WARRIOR 350 2003 Workshop Manual

8-29 1. Check hose
1. Flexible de contrôle
1. Manguito de comprobación
1. Air filter case cover
2. Screw (× 5)
1. Couvercle du boîtier de filtre à air
2. Vis (× 5)
1. Tapa de la caja del filtro de aire
2. Tornillo (× 5)
EBU00950
Air filter cleaningNOTE:_ There is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-
ter case. _1. Remove the seat.
2. Remove the air filter case cover by removing
the screws.
3. Remove the air filter element, and separate it
from the guide.
4. Wash the element gently but thoroughly in
solvent.
WARNING
_ Always use parts cleaning solvent to clean the
air filter element. Never use low flash point sol-
vents or gasoline to clean the air filter element
because the engine could catch fire or explode. _5. Squeeze the excess solvent out of the air fil-
ter element and let it dry.CAUTION:_ Do not twist the air filter element when squeez-
ing it. _
U5NF61.book Page 29 Wednesday, June 13, 2001 5:18 PM

8-47 a. Zero mm
a.Zéro mm
a. Cero mm
EBU00951
Front brake adjustment
The front brake lever should have a free play of
zero mm at the lever end. If not, ask a Yamaha
dealer to adjust it.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
U5NF61.book Page 47 Wednesday, June 13, 2001 5:18 PM

8-49 a. 10 mm
EBU00952*
Rear brake adjustment
Pedal height adjustment
The top of the brake pedal should be positioned
10 mm below the top of the footboard. If not, ask a
Yamaha dealer to adjust it.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident. After servic-
ing:

Make sure the brakes operate smoothly
and that the brake pedal position is cor-
rect.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U5NF61.book Page 49 Wednesday, June 13, 2001 5:18 PM

8-53 a. Cable length (46 ~ 50 mm)
a. Longueur de câble (46 à 50 mm)
a. Longitud del cable (46 ~ 50 mm)
4. Tighten the adjusting bolt locknut on the
clutch lever.
5. Screw in the adjusting bolt on the brake cali-
per by hand until it feels tight, then screw it
out 1/8 turn. Tighten the adjusting bolt locknut
to the specified torque.CAUTION:_ When tightening the locknut, hold the adjust-
ing bolt with a wrench so that the adjusting
bolt does not turn together with the locknut. _
WARNING
_ Operating with improperly adjusted brakes
could cause the brakes to malfunction, result-
ing in reduced braking performance. This
could increase the chance of a collision or ac-
cident. After adjusting the parking brake, block
the rear of the machine off the ground and spin
the rear wheels. Check to make sure there is
no brake drag. If brake drag is noticed, perform
the adjustment again. _
Tightening torque:
Locknut:
16 Nm (1.6 m·kgf)
U5NF61.book Page 53 Wednesday, June 13, 2001 5:18 PM

8-65
EBU00570
Cable inspection and lubrication
WARNING
Inspect cables frequently and replace if dam-
aged. Corrosion can result when the outer cov-
ering of control cables becomes damaged.
Cables can also become frayed or kinked. Op-
eration of controls could be restricted, which
could cause an accident or injury.Lubricate the inner cables and the cable ends. If
the cables do not operate smoothly, ask a Yamaha
dealer to replace them.
EBU00737
Brake and shift pedal/brake and clutch lever lu-
brication
Lubricate the pivoting parts of each lever and pedal.Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5NF61.book Page 65 Wednesday, June 13, 2001 5:18 PM

8-77
WARNING
Battery electrolyte is poisonous and danger-
ous, causing severe burns, etc. It contains sul-
furic acid. Avoid contact with skin, eyes or
clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg
or vegetable oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get
prompt medical attention. Batteries produce
explosive gases. Keep sparks, flame, ciga-
rettes or other sources of ignition away. Venti-
late when charging or using in an enclosed
space. Always shield your eyes when working
near batteries. KEEP OUT OF REACH OF CHIL-
DREN.
U5NF61.book Page 77 Wednesday, June 13, 2001 5:18 PM

8-83 1. Fuse 2. Spare fuse
1. Fusible 2. Fusible de rechange
1. Fusible 2. Fusible de repuesto
EBU00395
Fuse replacement
1. The fuse case is located below the fender.
2. If the fuse is blown, turn off the main switch
and install a new fuse of the specified amper-
age. Then turn on the switches, if the fuse im-
mediately blows again, consult a Yamaha
dealer.
WARNING
Always use a fuse of the specified rating. Nev-
er use a material in place of the proper fuse. An
improper fuse can cause damage to the electri-
cal system which could lead to a fire.CAUTION:
To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse.Specified fuse: 15 A
U5NF61.book Page 83 Wednesday, June 13, 2001 5:18 PM

8-89 1. Headlight bulb holder cover
1. Cache de la fixation d’ampoule
1. Cubierta del portabombillas del faro
1. Headlight bulb holder
1. Fixation d’ampoule
1. Portabombillas del faro
5. Remove the headlight bulb holder cover.
6. Turn the headlight bulb holder counterclock-
wise and remove the defective bulb.
WARNING
_ The headlight bulb is hot when it is on and im-
mediately after it is turned off. Wait for the bulb
to cool before touching or removing it. You can
be burned, or a fire could start if the bulb
touches something flammable. _
U5NF61.book Page 89 Wednesday, June 13, 2001 5:18 PM

8-97
EBU00413
Troubleshooting
Although Yamaha machines receive a rigid in-
spection before shipment from the factory, trouble
may occur during operation.
Any problem in the fuel, compression, or ignition
systems can cause poor starting and loss of pow-
er. The troubleshooting chart describes a quick,
easy procedure for making checks. If your ma-
chine requires any repair, take it to a Yamaha
dealer.
The skilled technicians at a Yamaha dealership
have the tools, experience, and know-how to prop-
erly service your machine. Use only genuine
Yamaha parts on your machine. Imitation parts
may look like Yamaha parts, but they are often in-
ferior. Consequently, they have a shorter service
life and can lead to expensive repair bills.
WARNING
Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe in-
jury or property damage. Make sure there are
no open flames or sparks in the area, including
pilot lights from water heaters or furnaces.
U5NF61.book Page 97 Wednesday, June 13, 2001 5:18 PM

9-5
8. Automotive type wax may be applied to all
painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protec-
tive finish. When finished, start the engine
and let it idle for several minutes.
WARNING
Wet brakes may have reduced stopping ability,
increasing the chance of an accident. Test the
brakes after washing. Apply the brakes several
times at slow speeds to let friction dry out the
linings.
U5NF61.book Page 5 Wednesday, June 13, 2001 5:18 PM