Yamaha BRUIN 350 400 Digital Workshop Repair Manual 2004-06
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๐ท๏ธ Basic Information Identification Make: Yamaha Model: Bruin Model Variants: 350, 400 Model Years Covered: 2004, 2005, 2006 Product Type: Digital Workshop Repair Manual ๐ Introduction Market Position Target Audience: Yamaha Bruin ATV owners and independent repair shops Competitive Analysis Value Proposition: Significant cost savings on dealership service and repairs, empowers DIY maintenance Key Features Content Depth: A-Z repair procedures, detailed diagnostics, high-quality visuals User Experience: Easy to view and print, no advanced computer skills required ๐ Manual Details Coverage Areas Overall Coverage: Comprehensive repair and maintenance for Yamaha Bruin 350 and 400 models Specific Systems Covered: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Fuel System, Cooling System, Exhaust System, Chassis, Bodywork, Troubleshooting Page Count Estimated Page Count: Likely 500+ pages (typical for comprehensive workshop manuals of this era and type) Manual Type Type: Workshop Repair Manual Language Language: English Format Format: PDF Download ๐ Manual Coverage Systems Covered Engine Mechanical: Disassembly, inspection, assembly, torque specifications, piston, rings, cylinder, crankshaft, camshaft, valve train, timing Engine Management: Fuel injection system (EFI), ignition system, sensors, ECU diagnostics, emission control Drivetrain: Automatic Transmission (AT), Continuously Variable Transmission (CVT) operation (if applicable), gearboxes, differentials, driveshafts, CV joints, final drive Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications Steering: Steering system components, tie rods, steering linkage, steering wheel, power steering (if equipped) Brakes: Hydraulic system, brake calipers, master cylinder, brake pads, brake rotors, bleeding procedures, parking brake Electrical System: Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, ignition switch, fuses, relays, wiring diagrams Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, pressure regulator Cooling System: Radiator, cooling fan, thermostat, water pump, coolant specifications Exhaust System: Exhaust pipes, muffler, catalytic converter (if applicable) Chassis And Body: Frame, body panels, seat, handlebars, fenders, plastics Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication, adjustments Troubleshooting: Diagnostic flowcharts, symptom analysis, common problem identification and solutions Repair: Step-by-step instructions for component removal, repair, and reinstallation Rebuild: Complete engine and transmission rebuild procedures Diagnostic Procedures: Fault code retrieval (if applicable), circuit testing, component testing Technical Depth Depth: Professional Technician Level, covering everything from basic checks to complete overhauls ๐ Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within the PDF Print Quality Printability: Designed for printing individual pages or entire sections Visuals Quality: High Quality Photos, Illustrations And Diagrams Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Software Compatibility Operating Systems: Microsoft Windows (95, 98, 98SE, 2000, NT, ME, XP, VISTA, Windows 7) and all Mac computers Licensing Usage Rights: No expiry date, unlimited personal use after download โ๏ธ Engine Specifications Primary Engine Bruin 350 Engine Type: 4-stroke, SOHC, 4-valve Displacement: 348cc Bore X Stroke: 83.0 mm x 64.5 mm Cooling System: Liquid-cooled Primary Engine Bruin 400 Engine Type: 4-stroke, SOHC, 4-valve Displacement: 386cc Bore X Stroke: 83.0 mm x 71.5 mm Cooling System: Liquid-cooled Performance Horsepower Approx 350: Approx. 21-23 HP (specific figures vary by exact model and testing) Torque Approx 350: Approx. 20-22 lb-ft (specific figures vary by exact model and testing) Horsepower Approx 400: Approx. 25-27 HP (specific figures vary by exact model and testing) Torque Approx 400: Approx. 24-26 lb-ft (specific figures vary by exact model and testing) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline ๐ง Transmission Bruin 350 400 Type: Automatic Transmission (AT) with Ultramaticยฎ CVT system Drive Modes: 2WD/4WD selectable with Electric Power Steering (EPS) on some models Features: High/Low range, Neutral, Reverse Transmission Fluid: Yamalube High-Performance Gear Oil (specific grade to be confirmed in manual, typically SAE 80W-90 or similar) ๐ Dimensions General Atv Length: Approx. 76.2 inches (1935 mm) Width: Approx. 42.5 inches (1080 mm) Height: Approx. 45.3 inches (1150 mm) Wheelbase: Approx. 49.4 inches (1255 mm) Ground Clearance: Approx. 7.1 inches (181 mm) Dry Weight Approx 350: Approx. 562 lbs (255 kg) Dry Weight Approx 400: Approx. 573 lbs (260 kg) Towing Capacity: 903 lbs (410 kg) Front Tire Size: AT25x8-12 Rear Tire Size: AT25x10-12 ๐ก๏ธ Safety Features General Atv Notes: ATVs are inherently dangerous vehicles. Always wear appropriate safety gear, including a helmet, eye protection, gloves, and sturdy footwear. Operate responsibly and follow all posted trail rules and regulations. ๐ก Technology Features Infotainment Features: Basic instrumentation (speedometer, odometer, fuel gauge, engine hour meter). No advanced infotainment systems expected for this model and era. Driver Assistance Features: Electric Power Steering (EPS) available on some models for reduced steering effort, especially at low speeds and with larger tires. Connectivity Features: Not applicable. Primarily mechanical and electrical systems. ๐ง Maintenance Service Intervals Engine Oil Change: Every 600 miles or 6 months, whichever comes first (refer to manual for exact specification and type). Air Filter Cleaning: Check every 300 miles, clean or replace as needed. Spark...
Professional Technician Level, covering everything from basic checks to complete overhauls
๐ Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text within the PDF
Print Quality
Printability:
Designed for printing individual pages or entire sections
Visuals Quality:
High Quality Photos, Illustrations And Diagrams
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
Software Compatibility
Operating Systems:
Microsoft Windows (95, 98, 98SE, 2000, NT, ME, XP, VISTA, Windows 7) and all Mac computers
Licensing
Usage Rights:
No expiry date, unlimited personal use after download
โ๏ธ Engine Specifications
Primary Engine Bruin 350
Engine Type:
4-stroke, SOHC, 4-valve
Displacement:
348cc
Bore X Stroke:
83.0 mm x 64.5 mm
Cooling System:
Liquid-cooled
Primary Engine Bruin 400
Engine Type:
4-stroke, SOHC, 4-valve
Displacement:
386cc
Bore X Stroke:
83.0 mm x 71.5 mm
Cooling System:
Liquid-cooled
Performance
Horsepower Approx 350:
Approx. 21-23 HP (specific figures vary by exact model and testing)
Torque Approx 350:
Approx. 20-22 lb-ft (specific figures vary by exact model and testing)
Horsepower Approx 400:
Approx. 25-27 HP (specific figures vary by exact model and testing)
Torque Approx 400:
Approx. 24-26 lb-ft (specific figures vary by exact model and testing)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
๐ง Transmission
Bruin 350 400
Type:
Automatic Transmission (AT) with Ultramaticยฎ CVT system
Drive Modes:
2WD/4WD selectable with Electric Power Steering (EPS) on some models
Features:
High/Low range, Neutral, Reverse
Transmission Fluid:
Yamalube High-Performance Gear Oil (specific grade to be confirmed in manual, typically SAE 80W-90 or similar)
๐ Dimensions
General Atv
Length:
Approx. 76.2 inches (1935 mm)
Width:
Approx. 42.5 inches (1080 mm)
Height:
Approx. 45.3 inches (1150 mm)
Wheelbase:
Approx. 49.4 inches (1255 mm)
Ground Clearance:
Approx. 7.1 inches (181 mm)
Dry Weight Approx 350:
Approx. 562 lbs (255 kg)
Dry Weight Approx 400:
Approx. 573 lbs (260 kg)
Towing Capacity:
903 lbs (410 kg)
Front Tire Size:
AT25x8-12
Rear Tire Size:
AT25x10-12
๐ก๏ธ Safety Features
General Atv
Notes:
ATVs are inherently dangerous vehicles. Always wear appropriate safety gear, including a helmet, eye protection, gloves, and sturdy footwear. Operate responsibly and follow all posted trail rules and regulations.
๐ก Technology Features
Infotainment
Features:
Basic instrumentation (speedometer, odometer, fuel gauge, engine hour meter). No advanced infotainment systems expected for this model and era.
Driver Assistance
Features:
Electric Power Steering (EPS) available on some models for reduced steering effort, especially at low speeds and with larger tires.
Connectivity
Features:
Not applicable. Primarily mechanical and electrical systems.
๐ง Maintenance
Service Intervals
Engine Oil Change:
Every 600 miles or 6 months, whichever comes first (refer to manual for exact specification and type).
Air Filter Cleaning:
Check every 300 miles, clean or replace as needed.
Spark Plug Inspection:
Inspect every 600 miles, replace as needed (specific plug type will be in the manual).
Fluid Specifications
Engine Oil:
Yamalube 4-stroke Motorcycle Oil SAE 10W-40 (or equivalent API SG or higher, JASO MA standard). Capacity: 2.20 L (2.32 US qt) with filter change.
Coolant:
Permanent type anti-freeze coolant (50/50 mixture with distilled water). Capacity: 2.20 L (2.32 US qt).
Known Issues
Common Wear Items:
CV joint boots, brake pads, front suspension bushings, starter motor brushes (typical for ATVs of this age).
Electrical Gremlins:
Can occur due to water ingress, vibration, and age. Wiring harness integrity and grounds are crucial.
Efi Related:
Fuel pump, injectors, and TPS (Throttle Position Sensor) can be sources of issues if not maintained or if contaminants are present.
๐ Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Company
Specialty:
World-renowned for motorcycles, marine products, and powersports vehicles, including ATVs.
Model Evolution
Bruin Series:
The Bruin series was Yamaha's entry into the utility-focused ATV market, offering a balance of performance and comfort for recreational and light-duty work. It served as a predecessor or companion to models like the Grizzly.
Production
Production Years:
2004-2006 for these specific manual coverage years. The Bruin model itself had a broader production run.
๐ Awards & Recognition
Recognitions
Market Reputation:
The Bruin was generally well-regarded for its reliability and capability within its class during its production run.
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