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Yamaha BRUIN 350 400 Shop Manual 2004-2006

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Basic Information Identification Make: Yamaha Model: Bruin Model Variant: 350 / 400 Model Years Covered: 2004, 2005, 2006 Codes Vehicle Type: ATV (All-Terrain Vehicle) Generation Vehicle Generation: First Generation (2004-2006) Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, ATV owners seeking to perform their own maintenance and repairs Competitive Analysis Value Proposition: Offers significant cost savings over dealership labor rates by empowering owners with expert knowledge and procedures Key Features Ease Of Use: User-friendly layout with clear, step-by-step instructions and visual aids Accessibility: Compatible with all major operating systems (Windows, macOS, Linux) and devices (PCs, tablets, smartphones) Delivery Method: Instant digital download upon payment, eliminating shipping delays and costs Manual Details Coverage Areas Manual Scope: Comprehensive Service and Repair Page Count Estimated Page Count: 400-600 pages (estimated based on typical comprehensive shop manuals) Manual Type Manual Classification: Professional Workshop Manual / Service Manual Language Language: English Format Digital Format: PDF Download Manual Coverage Systems Covered Engine Service: Engine overhaul, disassembly, reassembly, top-end, bottom-end, valve timing, lubrication system, cooling system, fuel system, ignition system, starting system, charging system Drivetrain Service: Transmission (CVT), final drive, driveshafts, clutch, differential (if applicable), wheel bearings Chassis Service: Suspension (front and rear), steering system, braking system (hydraulic lines, calipers, master cylinder, rotors), frame, subframe, body panels, seats Electrical Service: Wiring diagrams, charging system (stator, rectifier/regulator), ignition system (CDI, coil), lighting, instrumentation, switches, battery, starter motor Procedures Included Maintenance Procedures: Routine maintenance checks, oil changes, filter replacements, lubrication points, spark plug inspection/replacement, air filter cleaning/replacement, brake fluid flush, coolant flush Repair Procedures: Step-by-step instructions for component removal, installation, adjustment, and troubleshooting for all major vehicle systems Troubleshooting Guides: Diagnostic procedures for common problems, symptom-based troubleshooting charts, electrical diagnostic flowcharts Technical Depth Diagnostic Capability: Advanced diagnostics, including detailed explanations of system operation and fault finding methodologies Rebuild Instructions: Complete engine and transmission rebuild procedures with detailed specifications and torque values Wiring Diagrams: Full-color, high-resolution wiring diagrams for all electrical systems Manual Specifications File Format PDF Quality: High-resolution, searchable PDF with printable pages Print Quality Printability: Designed for easy printing of individual pages or entire sections Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Emulation: N/A (Digital Download) Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 2-valve (350) / 4-stroke, SOHC, 4-valve (400) Bore X Stroke 350: 95.0 mm x 71.0 mm (typical for 348cc variants) Bore X Stroke 400: 92.0 mm x 73.7 mm (typical for 398cc variants) Compression Ratio 350: 8.8:1 (typical) Compression Ratio 400: 10.1:1 (typical) Cooling System: Liquid-cooled Performance Horsepower 350: Approx. 20-25 HP (at crankshaft, estimated) Horsepower 400: Approx. 28-32 HP (at crankshaft, estimated) Fuel System Fuel Delivery: Carbureted (Mikuni BSR series, typically 33mm for 350, 36mm for 400) Fuel Type: Unleaded gasoline, 87 octane minimum Lubrication Oil Type Recommendation: Yamaha Yamalube 4T 10W-40 or equivalent API SG, JASO MA certified SAE 10W-40 or 20W-40 Oil Capacity With Filter Change: Approx. 2.4 L (2.5 US qt) for 350 / Approx. 2.5 L (2.6 US qt) for 400 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) with High/Low range and Reverse Optional Gear Selection: Forward, Neutral, Reverse Features Drive System: Shaft drive, selectable 4x4 (on applicable models) Dimensions Exterior Length Approx 350: 76.4 inches (1940 mm) Width Approx 350: 45.1 inches (1145 mm) Height Approx 350: 43.7 inches (1110 mm) Wheelbase Approx 350: 49.2 inches (1250 mm) Weights Dry Weight Approx 350: 570 lbs (259 kg) Dry Weight Approx 400: 602 lbs (273 kg) Safety Features Ratings Atv Safety Standards: Adheres to ANSI/SVIA safety standards Active Features Braking System: Hydraulically actuated, sealed drum brakes (front and rear) or Disc brakes on some models (e.g., 400 with independent rear suspension) Parking Brake: Mechanical parking brake Passive Features Lighting: Dual 30W headlights, 8W taillight/stoplight Technology Features Infotainment Instrumentation: Digital LCD display with speedometer, odometer, trip meter, clock, 2WD/4WD indicator, neutral indicator, reverse indicator, oil change indicator Driver Assistance Selectable 4Wd: Electric push-button engagement of 4WD system on 4x4 models Connectivity Charging System: 12V DC electrical system powered by AC magneto (stator) with rectifier/regulator for battery charging Maintenance Service Intervals Engine Oil Change Interval: Every 1000 km (620 miles) or 6 months, whichever comes first Air Filter Cleaning Interval: Every 500 km (310 miles) or 3 months; Replace every 1000 km (620 miles) or 12 months Spark Plug Inspection Interval: Every 1000 km (620 miles) or 6 months Brake Fluid Change Interval: Every 12 months Fluid Specifications Engine Oil Specification: API SG, JASO MA certified SAE 10W-40 or 20W-40 Gear Oil Specification: Yamaha Gear Oil 80W-90 API GL-4 or SAE 80W-90 Brake Fluid Specification: DOT 3 or DOT 4 Hydraulic Brake Fluid Coolant Specification: Permanent Antifreeze/Coolant (ethylene glycol based) with distilled water, 50/50 mix Known Issues Common Wear Items: CVT belt wear, brake component wear, suspension bushings, wheel bearings Carburetor Issues: Clogged...
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Yamaha BRUIN 350 400 Shop Manual 2004-2006
Basic Information
Identification
Make: Yamaha
Model: Bruin
Model Variant: 350 / 400
Model Years Covered: 2004, 2005, 2006
Codes
Vehicle Type: ATV (All-Terrain Vehicle)
Generation
Vehicle Generation: First Generation (2004-2006)
Introduction
Market Position
Target Audience: DIY enthusiasts, independent repair shops, ATV owners seeking to perform their own maintenance and repairs
Competitive Analysis
Value Proposition: Offers significant cost savings over dealership labor rates by empowering owners with expert knowledge and procedures
Key Features
Ease Of Use: User-friendly layout with clear, step-by-step instructions and visual aids
Accessibility: Compatible with all major operating systems (Windows, macOS, Linux) and devices (PCs, tablets, smartphones)
Delivery Method: Instant digital download upon payment, eliminating shipping delays and costs
Manual Details
Coverage Areas
Manual Scope: Comprehensive Service and Repair
Page Count
Estimated Page Count: 400-600 pages (estimated based on typical comprehensive shop manuals)
Manual Type
Manual Classification: Professional Workshop Manual / Service Manual
Language
Language: English
Format
Digital Format: PDF Download
Manual Coverage
Systems Covered
Engine Service: Engine overhaul, disassembly, reassembly, top-end, bottom-end, valve timing, lubrication system, cooling system, fuel system, ignition system, starting system, charging system
Drivetrain Service: Transmission (CVT), final drive, driveshafts, clutch, differential (if applicable), wheel bearings
Chassis Service: Suspension (front and rear), steering system, braking system (hydraulic lines, calipers, master cylinder, rotors), frame, subframe, body panels, seats
Electrical Service: Wiring diagrams, charging system (stator, rectifier/regulator), ignition system (CDI, coil), lighting, instrumentation, switches, battery, starter motor
Procedures Included
Maintenance Procedures: Routine maintenance checks, oil changes, filter replacements, lubrication points, spark plug inspection/replacement, air filter cleaning/replacement, brake fluid flush, coolant flush
Repair Procedures: Step-by-step instructions for component removal, installation, adjustment, and troubleshooting for all major vehicle systems
Troubleshooting Guides: Diagnostic procedures for common problems, symptom-based troubleshooting charts, electrical diagnostic flowcharts
Technical Depth
Diagnostic Capability: Advanced diagnostics, including detailed explanations of system operation and fault finding methodologies
Rebuild Instructions: Complete engine and transmission rebuild procedures with detailed specifications and torque values
Wiring Diagrams: Full-color, high-resolution wiring diagrams for all electrical systems
Manual Specifications
File Format
PDF Quality: High-resolution, searchable PDF with printable pages
Print Quality
Printability: Designed for easy printing of individual pages or entire sections
Binding Type
Digital Binding: N/A (Digital Download)
Paper Type
Digital Paper Emulation: N/A (Digital Download)
Engine Specifications
Primary Engine
Engine Type: 4-stroke, SOHC, 2-valve (350) / 4-stroke, SOHC, 4-valve (400)
Bore X Stroke 350: 95.0 mm x 71.0 mm (typical for 348cc variants)
Bore X Stroke 400: 92.0 mm x 73.7 mm (typical for 398cc variants)
Compression Ratio 350: 8.8:1 (typical)
Compression Ratio 400: 10.1:1 (typical)
Cooling System: Liquid-cooled
Performance
Horsepower 350: Approx. 20-25 HP (at crankshaft, estimated)
Horsepower 400: Approx. 28-32 HP (at crankshaft, estimated)
Fuel System
Fuel Delivery: Carbureted (Mikuni BSR series, typically 33mm for 350, 36mm for 400)
Fuel Type: Unleaded gasoline, 87 octane minimum
Lubrication
Oil Type Recommendation: Yamaha Yamalube 4T 10W-40 or equivalent API SG, JASO MA certified SAE 10W-40 or 20W-40
Oil Capacity With Filter Change: Approx. 2.4 L (2.5 US qt) for 350 / Approx. 2.5 L (2.6 US qt) for 400
Transmission
Standard
Transmission Type: Automatic Continuously Variable Transmission (CVT) with High/Low range and Reverse
Optional
Gear Selection: Forward, Neutral, Reverse
Features
Drive System: Shaft drive, selectable 4x4 (on applicable models)
Dimensions
Exterior
Length Approx 350: 76.4 inches (1940 mm)
Width Approx 350: 45.1 inches (1145 mm)
Height Approx 350: 43.7 inches (1110 mm)
Wheelbase Approx 350: 49.2 inches (1250 mm)
Weights
Dry Weight Approx 350: 570 lbs (259 kg)
Dry Weight Approx 400: 602 lbs (273 kg)
Safety Features
Ratings
Atv Safety Standards: Adheres to ANSI/SVIA safety standards
Active Features
Braking System: Hydraulically actuated, sealed drum brakes (front and rear) or Disc brakes on some models (e.g., 400 with independent rear suspension)
Parking Brake: Mechanical parking brake
Passive Features
Lighting: Dual 30W headlights, 8W taillight/stoplight
Technology Features
Infotainment
Instrumentation: Digital LCD display with speedometer, odometer, trip meter, clock, 2WD/4WD indicator, neutral indicator, reverse indicator, oil change indicator
Driver Assistance
Selectable 4Wd: Electric push-button engagement of 4WD system on 4x4 models
Connectivity
Charging System: 12V DC electrical system powered by AC magneto (stator) with rectifier/regulator for battery charging
Maintenance
Service Intervals
Engine Oil Change Interval: Every 1000 km (620 miles) or 6 months, whichever comes first
Air Filter Cleaning Interval: Every 500 km (310 miles) or 3 months; Replace every 1000 km (620 miles) or 12 months
Spark Plug Inspection Interval: Every 1000 km (620 miles) or 6 months
Brake Fluid Change Interval: Every 12 months
Fluid Specifications
Engine Oil Specification: API SG, JASO MA certified SAE 10W-40 or 20W-40
Gear Oil Specification: Yamaha Gear Oil 80W-90 API GL-4 or SAE 80W-90
Brake Fluid Specification: DOT 3 or DOT 4 Hydraulic Brake Fluid
Coolant Specification: Permanent Antifreeze/Coolant (ethylene glycol based) with distilled water, 50/50 mix
Known Issues
Common Wear Items: CVT belt wear, brake component wear, suspension bushings, wheel bearings
Carburetor Issues: Clogged jets, pilot screw adjustment issues due to ethanol fuels or debris, leading to hard starting or poor idling
Electrical Component Reliability: Occasional issues with stator output or rectifier/regulator failure, especially on higher mileage units
Vehicle History
Brand Heritage
Yamaha Atv Legacy: Yamaha has a long-standing reputation for producing durable, reliable, and performance-oriented ATVs since the early 1980s.
Model Evolution
Bruin Introduction: The Bruin line was introduced as Yamaha's more utility-focused, comfortable, and accessible ATV, often positioned as a step up from entry-level models.
Bruin Distinction: The Bruin 350 often featured a solid rear axle and simpler suspension, while the 400 typically offered independent rear suspension (IRS) for improved comfort and ground clearance.
Production
Manufacturing Region: Primarily manufactured in Japan and/or USA
Awards & Recognition
Recognitions
Industry Awards: While specific awards for the Bruin are not prominently documented, Yamaha ATVs consistently receive positive reviews for reliability and performance in industry publications.
Ratings
Owner Satisfaction: Generally high owner satisfaction due to durability and ease of maintenance
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