maintenance YAMAHA YFM350R-W 2009 User Guide

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EBU28130NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.27*Moving parts and
cablesLubricate.√√√√
28*Throttle lever hous-
ing and cableCheck operation and correct if necessary.
Check throttle cable free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.√√√√√
29*Exhaust systemCheck for leakage and replace gasket(s) if neces-
sary.
Check for looseness and tighten all screw clamps
and joints if necessary.√√√
30 Spark arresterClean.√√√
31*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
32*Lights and switchesCheck operation and correct if necessary.
Adjust headlight beam.√√√√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300U10P60E0.book Page 6 Thursday, June 15, 2006 4:19 PM

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EBU23211Checking the spark plug The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.2. Remove the spark plug as shown, with the
spark plug wrench included in the owner’s tool
kit.
To check the spark plug
1. Check that the porcelain insulator around the
center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).
NOTE:If the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. In-stead, have a Yamaha dealer check the ATV.
1. Spark plug cap
1. Spark plug wrench
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NOTE:If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque assoon as possible.
4. Install the spark plug cap.EBU23273Engine oil and oil filter element The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter element cleaned at the intervals speci-
fied in the periodic maintenance and lubrication
chart.
To check the engine oil level
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Wait a few minutes until the oil settles before
checking.
4. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.5. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.
NOTE:The engine oil should be between the minimumand maximum level marks.
6. If the engine oil is at or below the minimum
level mark, add sufficient oil of the recom-
mended type to raise it to the correct level.1. Dipstick
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler cap
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CAUTION:ECB00300
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 CONSERV-
ING II” or higher.
Make sure that no foreign material enters thecrankcase.
12. Start the engine, and then let it idle for several
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
13. Turn the engine off, and then check the oil lev-
el and correct it if necessary.
EBU23740Cleaning the air filter element The air filter element should be cleaned at the in-
tervals specified in the periodic maintenance and
lubrication chart. Clean the air filter element more
frequently if you are riding in unusually wet or dusty
areas.NOTE: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. (See page 4-14.) Recommended oil:
See page 10-1.
Oil quantity:
Without oil filter element replacement:
2.50 L (2.64 US qt) (2.20 Imp.qt)
With oil filter element replacement:
2.60 L (2.75 US qt) (2.29 Imp.qt)1. Air filter case check hose
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5. Wash the sponge material gently but thor-
oughly in solvent.
WARNING
EWB01940Always use parts cleaning solvent to clean the
sponge material. Never use low-flash-point
solvents or gasoline to clean the sponge mate-
rial because the engine could catch fire or ex-plode.
6. Squeeze the excess solvent out of the sponge
material and let it dry.
CAUTION:ECB00440Do not twist the sponge material when squeez-ing it.
7. Check the sponge material and replace it if
damaged.
8. Apply a quality foam air filter oil to the sponge
material.NOTE:The sponge material should be wet but not drip-ping.
9. Pull the sponge material over the air filter ele-
ment frame.
10. Apply all-purpose grease to the air filter ele-
ment seat.
11. Insert the air filter element into the air filter
case, and then install the air filter case cover
by hooking the holders onto the air filter case.
12. Install the seat.NOTE:The air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the ATV is operated in extremely dusty ar-
eas. Each time the air filter element maintenance
is performed, check the air inlet of the air filter case
1. Air filter element retaining plate
2. Air filter element frame
3. Sponge material
4. Air filter element seatU10P60E0.book Page 15 Thursday, June 15, 2006 4:19 PM

8-17
8 4. Insert the tailpipe into the muffler and align the
bolt holes.
5. Install and tighten the bolt.
WARNING
EWB02340Do not start the engine when cleaning the
spark arrester, otherwise it could cause injury
to the eyes, burns, carbon monoxide poison-
ing, possibly leading to death, and start a fire.
Always let the exhaust system cool prior totouching exhaust components.
EBU23940Adjusting the carburetor The carburetor should be checked and, if neces-
sary, adjusted at the intervals specified in the peri-
odic maintenance and lubrication chart. The
carburetor is an important part of the engine and
requires very sophisticated adjustment. Therefore,
most carburetor adjustments should be left to a
Yamaha dealer, who has the necessary profes-
sional knowledge and experience. The adjustment
described in the following section, however, may
be performed by the owner as part of routine main-
tenance.CAUTION:ECB00480The carburetor has been set and extensively
tested at the Yamaha factory. Changing these
settings without sufficient technical knowl-
edge may result in poor performance of ordamage to the engine.EBU24000Adjusting the engine idling speed The engine idling speed must be checked and, if
necessary, adjusted as follows at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
1. Tailpipe
2. Spark arresterU10P60E0.book Page 17 Thursday, June 15, 2006 4:19 PM

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EBU24043Adjusting the throttle cable free play The throttle cable free play should be checked
and, if necessary, adjusted at the intervals speci-
fied in the periodic maintenance and lubrication
chart.
The throttle cable free play should measure 2.0–
4.0 mm (0.08–0.16 in) at the throttle lever. Period-
ically check the throttle cable free play and, if nec-
essary, adjust it as follows.NOTE:The engine idling speed must be checked, and ad-
justed if necessary, before adjusting the throttle ca-ble free play.
1. Loosen the locknut.
2. To increase the throttle cable free play, turn
the adjusting bolt in direction (a). To decrease
the throttle cable free play, turn the adjusting
bolt in direction (b).3. Tighten the locknut.
EBU24060Valve clearance The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.1. Locknut
2. Throttle cable free play adjusting bolt
3. Throttle cable free play
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8Observe these precautions:

When checking the fluid level, make sure that
the top of the brake fluid reservoir is level.
Use only the recommended quality brake fluid,
otherwise the rubber seals may deteriorate,
causing leakage and poor braking performance.
Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor braking performance.
Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and may
result in vapor lock.
Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid imme-
diately.
As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.
EBU24290Changing the brake fluid Have a Yamaha dealer change the brake fluid at
the intervals specified in the NOTE after the peri-
odic maintenance and lubrication chart. In addi-
tion, have the oil seals of the master cylinders and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.EBU24390Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have a
free play of zero mm (zero in) as shown. If the free
play is incorrect, have a Yamaha dealer check the
brake system. Recommended brake fluid:
DOT 4
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WARNING
EWB02070Operating 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 proceduresshould be performed by a Yamaha dealer.
EBU24591Checking the brake pedal position The brake pedal position must be checked and, if
necessary, adjusted at the intervals specified in the
periodic maintenance and lubrication chart.
The top of the brake pedal should be positioned
50.2 mm (1.98 in) above the top of the frame as
shown. If the brake pedal is not positioned as spec-
ified, have a Yamaha dealer adjust it.
WARNING
EWB02110Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
1. Brake lever free play
1. Brake pedal position
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8After servicing:

Make sure the brakes operate smoothly and
that the brake pedal position 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 proceduresshould be performed by a Yamaha dealer.EBU24710Adjusting the parking brake free play The parking brake free play must be checked and,
if necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
Cable length “A” should measure 64–68 mm
(2.52–2.68 in). Adjust the parking brake free play
as follows.1. Release the parking brake by moving the
parking brake lever to the right.
2. Fully loosen the locknut and the adjusting bolt
at the rear brake caliper.
3. Loosen the locknut on the brake cable.
4. Turn the adjusting nut on the brake cable in di-
rection (a) to increase the cable length, and in
direction (b) to decrease it.
1. Locknut
2. Adjusting bolt
3. Cable length “A”
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