Yamaha Grizzly 350 4WD IRS (YFM35FGIW) 2007 ATV Service Manual (P/N LIT-11616-20-46)

Yamaha Service Manual LIT-11616-20-46, First Edition, November 2006, covers the 2007 YFM35FGIW Grizzly 350 4WD IRS. The original cover also carries identifier 4S2-F8197-10.

Searchable Text, Section Bookmarks and Wiring Detail

Search and diagram access: The PDF supports text search and includes embedded section bookmarks. Main chapter entries generally open the corresponding contents pages, while section entries link to the service material. Small wire-color codes and connector labels in the checked diagrams are readable when enlarged.

One printable English PDF contains 374 pages: 354 numbered chapter pages, 17 pages of front matter—including the front cover and one blank page—and three final pages containing the wiring-diagram key, rear cover and full wiring diagram.

Engine, Shaft-Drive and Electrical Service

The following selected coverage highlights outline the main workshop content. Other topics include body-panel removal, speed-limiter adjustment and spark-arrester cleaning.

• Engine repair: Step-by-step procedures for engine removal, cylinder-head and valve-train work, piston inspection, crankcase separation, and crankshaft removal and installation.

• Automatic transmission and clutch: Primary and secondary sheave service, wet centrifugal-clutch inspection, internal transmission checks, and sub-transmission and reverse-gear information.

• Shaft-drive service: Front and rear CV-joint work, middle-gear shim selection, differential repair, and final-drive positioning and gear-lash adjustment.

• Mikuni BSR33 carburetor: Disassembly, component inspection, reassembly and fuel-level adjustment, supported by jetting, float-height and idle-speed specifications.

• Brakes and chassis: Front master-cylinder and caliper repair, hydraulic brake bleeding, wet rear-brake inspection, steering-stem and tie-rod service, and suspension-component checks.

• Electrical diagnosis: DC-CDI ignition, electric starting, AC-magneto charging, lighting, signaling, oil-cooler fan control, and On-Command 2WD/4WD and differential-lock troubleshooting.

Yamaha wrote this manual primarily for its dealers and qualified mechanics; it assumes basic vehicle-repair knowledge and access to the proper service tools.

Internal Engine Work and Assembly References

Cylinder-head coverage extends to valve-guide replacement and reaming, valve-seat inspection and lapping, and camshaft and rocker-arm checks. Timing-chain installation and alignment are documented alongside piston, cylinder, crankshaft, balancer-gear and oil-pump inspection.

The six-position Cylinder Head Tightening Sequence distinguishes the four M10 bolts from the two M8 bolts, with separate torque specifications and staged tightening. Exploded diagrams and numbered job/part charts connect the assembly views with removal, disassembly and installation instructions.

Tool references identify the equipment required for deeper work, including crankcase separator 90890-01135 / YU-01135-B and sheave spring compressor 90890-04134 / YM-04134. Clutch data distinguish engagement speed from stall speed, while inspection procedures address the housing, shoes and one-way clutch.

Middle Gear, Differential and Final-Drive Setup

Gear repair includes middle drive/driven gear shim selection, final-drive pinion and ring-gear positioning, and ring-gear thrust-clearance measurement with Plastigauge. Separate middle-gear, differential and final-drive backlash specifications support the corresponding adjustment procedures, including use of gear-lash measurement tool 90890-01467 / YM-01467.

The middle-gear cautions identify a left-hand-thread bearing retainer and warn of pinion-thread damage from direct press loading. The final-drive section warns that overtightening the ring-gear fixing bolt during lash measurement can damage the ring gear.

Wet Rear Brake, Suspension and Maintenance

The sealed rear brake operates inside the final gear case. Yamaha specifies Friction Modified Shaft Drive Gear Oil, P/N ACC-SHAFT-LU-00, for that assembly; the lubrication tables distinguish engine-oil changes, filter changes and total fills from the separate final-gear and differential quantities.

Chassis coverage includes front and rear double-wishbone suspension, wheel-travel specifications, ball-joint and steering-knuckle work, shock-absorber inspection, and rear stabilizer checks.

Maintenance charts use months, distance and operating hours, with separate initial and recurring schedules. They also address more frequent air-filter service in wet or dusty conditions and age-based replacement of brake fluid, master-cylinder/caliper internal components and brake hoses.

Circuit Tests and Symptom-Based Troubleshooting

Electrical fault charts combine wiring checks with component resistance, continuity and voltage tests. They address relays, switches, the pickup coil/stator assembly, starter motor, charging components and differential gear motor, with pocket tester 90890-03112 / YU-03112-C referenced for testing.

These charts help trace a system fault through its supply, wiring and components before a replacement decision. The oil-cooler fan section, for example, separates checks of the motor, relay, circuit breaker, temperature sensor and control-unit wiring.

Visual references include Cable Routing, the Ignition System Circuit Diagram, Charging System Circuit Diagram, 2WD/4WD Selecting System Circuit Diagram, and YFM35FGIW 2007 Wiring Diagram.

Chapter 9 addresses hard starting, idle and high-speed performance, drivetrain noise, shifting, clutch faults, overheating, braking, handling and lighting. Yamaha describes this section as a troubleshooting guide rather than an exhaustive list of causes and refers users to the related inspection and repair procedures.

Compression, Valve Clearance and Carburetor Fuel Level

Compression data specify 1,050 kPa at sea level and 750 r/min, with a 910 kPa minimum and 1,180 kPa maximum. The compression-test procedure calls for a warmed engine and an open throttle and identifies compression gauge 90890-03081 / YU-33223.

Cold valve clearance is 0.06–0.10 mm intake and 0.16–0.20 mm exhaust. Carburetor fuel level is specified at 3.0–4.0 mm above the float-chamber mating surface, with a dedicated gauge-based checking and adjustment procedure.

Safety Note: These figures are a preview of the manual’s contents. Use the complete Yamaha procedures and their safety precautions for hands-on engine, drivetrain, brake and electrical work.