Manual for Yamaha Grizzly 350, 2003-2010

Product Information

General Information
- Machine Identification
- Vehicle Identification Number
- Model Label
- Important Information
- Preparation for Removal Procedures
- Replacement Parts
- Gaskets, Oil Seals and O-Rings
- Lock Washers/Plates and Cotter Pins
- Bearings and Oil Seals
- Circlips
- Checking of Connections
- Special Tools
Specifications
- General Specifications
- Maintenance Specifications
  - Engine
  - Chassis
  - Electrical
- How to Use the Conversion Table
- General Torque Specifications
- Lubrication Points and Lubricant Types
  - Engine
- Coolant Flow Diagrams
- Oil Flow Diagrams
- Cable Routing
Periodic Checks and Adjustments
- Introduction
- Periodic Maintenance/Lubrication
- Seat, Carriers, Fenders and Fuel Tank
  - Seat and Side Panels
  - Front Carrier, Front Bumper and Front Fender
  - Rear Carrier and Rear Fender
  - Fuel Tank
- Footrest Boards
- Engine
  - Adjusting the Valve Clearance
  - Adjusting the Idling Speed
  - Adjusting the Throttle Lever Free Play
  - Adjusting the Speed Limiter
  - Adjusting the Starter Cable
  - Checking the Spark Plug
  - Checking the Ignition Timing
  - Measuring the Compression Pressure
  - Checking the Engine Oil Level
  - Changing the Engine Oil
  - Cleaning the Air Filter
  - Checking the Coolant Level
  - Changing the Coolant
  - Checking the Coolant Temperature Warning Light
  - Checking the V-Belt
  - Cleaning the Spark Arrester
- Chassis
  - Adjusting the Rear Brake
  - Checking the Front Brake Fluid Level
  - Checking the Front Brake Pads
  - Checking the Rear Brake Shoes
  - Checking the Brake Hoses
  - Bleeding the Hydraulic Brake System
  - Adjusting the Select Lever Control Cable and Shift Rod
  - Adjusting the Rear Brake Light Switch
  - Checking the Final Gear Oil Level
  - Changing the Final Gear Oil
  - Changing the Differential Gear Oil
  - Checking the Constant Velocity Joint Dust Boots
  - Checking the Steering System
  - Adjusting the Toe-In
  - Adjusting the Front Shock Absorbers
  - Adjusting the Rear Shock Absorber
  - Checking the Tires
  - Checking the Wheels
  - Checking and Lubricating the Cables
  - Lubricating the Levers, Pedal, Etc.
- Electrical
  - Checking the Battery
  - Checking the Fuses
  - Adjusting the Headlight Beams
  - Changing the Headlight Bulb
Engine
- Engine Removal
  - Air Ducts, Muffler and Exhaust Pipe
  - Select Lever Unit and Coolant Reservoir
  - Hoses and Leads
  - Engine Mounting Bolts
  - Installing the Engine
- Cylinder Head
  - Removing the Cylinder Head
  - Checking the Tappet Covers
  - Checking the Timing Chain Tensioner
  - Checking the Camshaft Sprocket
  - Checking the Cylinder Head
  - Installing the Cylinder Head
- Camshaft, Rocker Arms and Valves
  - Removing the Camshaft and Rocker Arms
  - Removing the Valves and Valve Springs
  - Checking the Camshaft
  - Checking the Rocker Arms and Camshaft
  - Checking the Valves and Valve Springs
  - Installing the Valves and Valve Springs
  - Installing the Camshaft and Rocker Arms
- Cylinder and Piston
  - Removing the Piston
  - Checking the Timing Chain Guide
  - Checking the Cylinder and Piston
  - Checking the Piston Rings
  - Checking the Piston Pin
  - Installing the Piston
  - Installing the Cylinder
- Recoil Starter and A.C. Magneto
  - Removing the A.C. Magneto
  - Disassembling the Recoil Starter
  - Checking the A.C. Magneto
  - Checking the Starter Clutch
  - Checking the Starter Pulley
  - Checking the Recoil Starter
  - Assembling the Recoil Starter
  - Installing the A.C. Magneto
- Primary and Secondary Sheaves
  - Primary Sliding Sheave
  - Secondary Sheave
  - Removing the Primary and Secondary Sheaves
  - Disassembling the Secondary Sheave
  - Checking the Primary Sheave
  - Checking the Secondary Sheave
  - Assembling the Primary Sheave
  - Assembling the Secondary Sheave
  - Installing the Primary and Secondary Sheaves
- Clutch
  - Removing the Clutch
  - Checking the Clutch
  - Installing the Clutch
- Crankcase
  - Starter Motor, Timing Chain and Oil Filter
  - Crankcase
  - Crankcase Bearings
  - Removing the Oil Pump Drive Gear
  - Separating the Crankcase
  - Checking the Timing Chain and Guide
  - Checking the Oil Strainer and Oil Delivery Pipe
  - Checking the Crankcase
  - Checking the Bearings
  - Assembling the Crankcase
  - Installing the Shift Lever
  - Installing the Oil Pump Drive Gear
- Crankshaft and Oil Pump
  - Oil Pump
  - Removing the Crankshaft
  - Checking the Oil Pump
  - Checking the Crankshaft
  - Installing the Crankshaft and Balancer
- Transmission
  - Checking the Shift Forks
  - Checking the Shift Cam
  - Checking the Transmission
  - Checking the Secondary Shaft and Driven Sprocket
  - Checking the Chain
  - Installing the Transmission
- Middle Gear
  - Middle Drive Shaft
  - Middle Driven Shaft
  - Removing the Middle Drive Shaft
  - Removing the Middle Driven Shaft
  - Checking the Pinion Gears
  - Selecting the Middle Drive and Driven Gear Shims
  - Installing the Middle Driven Shaft
  - Installing the Middle Drive Shaft
  - Measuring the Middle Gear Backlash
Cooling System
- Radiator
  - Checking the Radiator
  - Installing the Radiator
- Thermostat
  - Checking the Thermostat
  - Installing the Thermostat
- Water Pump
  - Disassembling the Water Pump
  - Checking the Water Pump
  - Assembling the Water Pump
Carburetion
- Carburetor
  - Disassembling the Carburetor
  - Checking the Carburetor
  - Assembling the Carburetor
  - Adjusting the Fuel Level
Drive Train
- Troubleshooting
- Front Constant Velocity Joints and Differential Gear
  - Removing the Differential Gear Assembly
  - Checking the Constant Velocity Joints
  - Checking the Differential Gear
  - Assembling the Front Constant Velocity Joints
  - Assembling the Differential Gear
  - Measuring and Adjusting the Differential Gear Lash
  - Checking the Differential Gear Operation
- Rear Axle/Final Drive Gear and Drive Shaft
  - Removing the Rear Axle
  - Disassembling the Final Drive Gear
  - Replacing the Final Drive Roller Bearings
  - Positioning the Final Drive Pinion Gear and Ring Gear
  - Checking the Rear Axle
  - Checking the Drive Shaft
  - Checking the Final Drive Gear
  - Measurement and Adjusting the Final Gear Lash
  - Assembling the Final Drive Gear
  - Installing the Final Drive Gear
Chassis
- Front and Rear Wheels
  - Front Wheels
  - Rear Wheels
  - Checking the Wheels
  - Checking the Wheel Hubs
  - Checking the Brake Discs
  - Installing the Wheel Hubs
  - Installing the Wheels
- Front Brake
  - Front Brake Pads
  - Replacing the Front Brake Pads
  - Front Brake Master Cylinder
  - Checking the Master Cylinder
  - Assembling the Front Brake Master Cylinder
  - Installing the Front Brake Master Cylinder
  - Front Brake Caliper
  - Disassembling the Front Brake Calipers
  - Checking the Front Brake Calipers
  - Assembling the Front Brake Calipers
  - Installing the Front Brake Calipers
- Rear Brake
  - Removing the Rear Brake
  - Checking the Rear Brake
  - Installing the Rear Brake
- Steering System
  - Handlebar
  - Removing the Rear Brake Switch
  - Checking the Handlebar
  - Installing the Handlebar
  - Installing the Rear Brake Lever
  - Installing the Master Cylinder Assembly
  - Steering Stem
  - Removing the Bearing Retainer
  - Checking the Steering Stem
  - Installing the Bearing Retainer
  - Installing the Cable Guide
  - Tie Rods and Steering Knuckles
  - Removing the Steering Knuckles
  - Checking the Tie Rods
  - Checking the Steering Knuckles
  - Installing the Tie Rods
- Front Arms and Front Shock Absorbers
  - Removing the Front Arms
  - Checking the Front Arms
  - Checking the Front Shock Absorber
  - Installing the Front Arms and Front Shock Absorber
- Rear Shock Absorber and Swingarm
  - Removing the Swingarm
  - Checking the Rear Shock Absorber
  - Checking the Swingarm
  - Checking the Rubber Boot
  - Installing the Rubber Boot
  - Installing the Rear Axle Housing
Electrical
- Electrical Components
- Checking the Switches
  - Checking a Switch
  - Checking a Switch Shown in the Manual
  - Checking the Switch Continuity
- Checking the Bulbs and Bulb Sockets
  - Types of Bulbs
  - Checking the Condition of the Bulbs
  - Checking the Condition of the Bulb Sockets
- Ignition System
  - Circuit Diagram
  - Troubleshooting
- Electric Starting System
  - Circuit Diagram
  - Troubleshooting
  - Starter Motor
  - Checking the Starter Motor
  - Assembling the Starter Motor
- Charging System
  - Circuit Diagram
  - Troubleshooting
- Lighting System
  - Circuit Diagram
  - Troubleshooting
  - Checking the Lighting System
- Signal System
  - Circuit Diagram
  - Troubleshooting
  - Checking the Signal System
- Cooling System
  - Circuit Diagram
  - Troubleshooting
- 2WD/4WD Selecting System
  - Circuit Diagram
  - Troubleshooting
Troubleshooting
- Starting Failure/Hard Starting
  - Fuel System
  - Electrical System
  - Compression System
- Poor Idle Speed Performance
  - Poor Idle Speed Performance
- Poor Medium and High-Speed Performance
  - Poor Medium and High-Speed Performance
- Faulty Drive Train
- Faulty Gear Shifting
  - Hard Shifting
  - Shift Lever Does Not Move
  - Jumps Out of Gear
- Faulty Clutch Performance
  - Engine Operates but Machine Will Not Move
  - Clutch Slipping
  - Poor Starting Performance
  - Poor Speed Performance
- Overheating
  - Overheating
- Faulty Brake
  - Poor Braking Effect
- Shock Absorber Malfunction
  - Malfunction
- Unstable Handling
  - Unstable Handling
- Lighting System
  - Headlight Dark
  - Bulb Burnt Out

2003-2010 Yamaha YFM350 Bruin Grizzly Auto 4X4 YFM400 Kodiak 4WD service manual

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