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2003 2004 2005 2006 Yamaha Bruin YFM350 & 2007 2008 2009 2010 2011 Yamaha Grizzly YFM35 2wd ATV models Service Manual

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This manual covers the Bruin YFM350 and Grizzly YFM35 2WD All-Terrain Vehicles. The Bruin, produced from 2003-2006, and the Grizzly, from 2007-2011, represent a commitment to reliable and capable off-road vehicles. These ATVs, powered by a 348cc air-cooled, 4-stroke engine, are designed for a variety of terrains and uses, reflecting a long-standing reputation for engineering quality and durability in the ATV market. This comprehensive service manual provides detailed information for the maintenance, repair, and troubleshooting of your ATV. It covers all aspects of the vehicle, including the engine, fuel system, cooling system, transmission, brakes, suspension, steering, frame, and electrical systems. With clear instructions, diagrams, and illustrations, this manual is an essential resource for DIY mechanics and owners looking to maintain their vehicles effectively and ensure optimal performance and longevity. 🏷️ Basic Information Identification Make: Yamaha Model: Bruin YFM350 / Grizzly YFM35 Model Variant: 2WD ATVs Codes Manual Part Number: LIT-11616-BN-20 Generation Model Generation Bruin: YFM350 Bruin series production spanned several years before being integrated or succeeded by other lines. Model Generation Grizzly: Grizzly line evolved significantly, with the YFM35 designation covering the earlier 350cc models of this generation. 👋 Introduction Market Position Target Audience: DIY mechanics, ATV owners seeking to perform maintenance and repairs, saving on dealer labor costs. Competitive Analysis Value Proposition: Provides extensive repair information at a fraction of dealer service costs. Enables owners to maintain their ATVs effectively. Key Features Benefits: Cost savings on labor, empowerment for self-maintenance, comprehensive repair guidance, instant access to technical data. 📋 Manual Details Coverage Applicable Years: 2003, 2004, 2005, 2006 (Bruin YFM350); 2007, 2008, 2009, 2010, 2011 (Grizzly YFM35) Coverage Areas: All repair topics including general information, periodic maintenance, fuel system, cooling system, engine top end, engine lubrication system, engine removal/installation, crankshaft/crankcase, transmission, wheels/tires, final drive, brakes, suspension, steering, frame, electrical system, diagnostics. Page Count Total Pages: 483 Bruin Specific Pages Start: 367 Type Manual Type: Complete Service Manual / Repair Manual Language Language: English Format File Format: PDF Supplementary Info Supplement Note: The 350 Bruin models are presented as a supplement to a base manual for the 450 model, indicating shared chassis and some systems but specific engine/drivetrain details for the 350. 📖 Manual Coverage Systems Systems Covered: Engine (Top End, Lubrication, Removal/Installation, Crankshaft/Crankcase), Fuel System, Cooling System, Transmission, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System. Procedures Procedures Included: Periodic Maintenance, Troubleshooting, Diagnostics, Repair, Overhaul, Component Replacement, System Adjustments. Depth Technical Depth: Comprehensive, from basic maintenance to detailed engine and transmission rebuilds, including diagnostic procedures and component-level repair instructions. Visuals Visual Aids: Detailed diagrams, illustrations, photographs, and exploded views. Diagnostics Diagnostic Procedures: Detailed troubleshooting charts and diagnostic procedures for common problems within each system. Special Tools Special Tool Requirements: Manual may list specific Yamaha special tools required for certain repair procedures. 📊 Manual Specifications File Quality Print Quality: High-resolution, suitable for printing all pages. Searchability: Likely text-searchable PDF (standard for modern manuals). Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Compatibility Operating Systems: Compatible with all versions of Windows & Mac. Requirements Software Requirements: Adobe PDF Reader. Delivery Download Speed: Instant Download (No Waiting). Content Enhancements Illustrations Quality: High-quality, clear illustrations and diagrams that aid in understanding complex procedures. ⚙️ Engine Specifications Primary Engine Engine Type Bruin: Air-cooled, 4-stroke, SOHC, 2-valve Engine Displacement Bruin: 348cc Engine Type Grizzly: Air-cooled, 4-stroke, SOHC, 2-valve Engine Displacement Grizzly: 348cc (YFM35 designation likely refers to the 350cc class, not an exact 35cc displacement) Performance Cooling System: Air-cooled Compression Ratio: Refer to manual for specific compression ratio figures for these engine variants. Fuel System Fuel Delivery: Carburetor (specific model/size detailed in manual) Lubrication Lubrication System: Wet Sump (details on oil type and capacity in manual) Engine Identification Bore Stroke: Specific bore and stroke measurements for the 348cc engine are detailed in the manual. 🔧 Transmission Standard Transmission Type: Automatic (likely Ultramatic or similar Yamaha CVT system for these models) Features Transmission Features: Continuously Variable Transmission (CVT) with engine braking. Details on belt inspection/replacement, fluid type and changes are critical. Gear Ratios Gear Ratios: Manual provides detailed gear ratios for the transmission and final drive, crucial for performance and maintenance. 📐 Dimensions Exterior Body Style: All-Terrain Vehicle (ATV) Weights Dry Weight Approx Bruin: Refer to manual for exact figures (typically around 500-550 lbs) Dry Weight Approx Grizzly: Refer to manual for exact figures (typically around 570-610 lbs) Wheels Tires Wheel Size: Refer to manual for specific front and rear wheel sizes (typically 12-inch). Tire Size: Refer to manual for specific front and rear tire size recommendations and specifications. 🛡️ Safety Features Ratings Safety Standards: Adherence to relevant ATV safety standards (details and precautions in manual). Active Features Braking System: Hydraulic disc brakes (front and rear). Manual covers brake system maintenance, bleeding, pad replacement. Passive Features Throttle Limiter:...
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2003 2004 2005 2006 Yamaha Bruin YFM350 & 2007 2008 2009 2010 2011 Yamaha Grizzly YFM35 2wd ATV models Service Manual2003 2004 2005 2006 Yamaha Bruin YFM350 & 2007 2008 2009 2010 2011 Yamaha Grizzly YFM35 2wd ATV models Service Manual2003 2004 2005 2006 Yamaha Bruin YFM350 & 2007 2008 2009 2010 2011 Yamaha Grizzly YFM35 2wd ATV models Service Manual2003 2004 2005 2006 Yamaha Bruin YFM350 & 2007 2008 2009 2010 2011 Yamaha Grizzly YFM35 2wd ATV models Service Manual
This manual covers the Bruin YFM350 and Grizzly YFM35 2WD All-Terrain Vehicles. The Bruin, produced from 2003-2006, and the Grizzly, from 2007-2011, represent a commitment to reliable and capable off-road vehicles. These ATVs, powered by a 348cc air-cooled, 4-stroke engine, are designed for a variety of terrains and uses, reflecting a long-standing reputation for engineering quality and durability in the ATV market. This comprehensive service manual provides detailed information for the maintenance, repair, and troubleshooting of your ATV. It covers all aspects of the vehicle, including the engine, fuel system, cooling system, transmission, brakes, suspension, steering, frame, and electrical systems. With clear instructions, diagrams, and illustrations, this manual is an essential resource for DIY mechanics and owners looking to maintain their vehicles effectively and ensure optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Bruin YFM350 / Grizzly YFM35
Model Variant:
2WD ATVs
Codes
Manual Part Number:
LIT-11616-BN-20
Generation
Model Generation Bruin:
YFM350 Bruin series production spanned several years before being integrated or succeeded by other lines.
Model Generation Grizzly:
Grizzly line evolved significantly, with the YFM35 designation covering the earlier 350cc models of this generation.
👋 Introduction
Market Position
Target Audience:
DIY mechanics, ATV owners seeking to perform maintenance and repairs, saving on dealer labor costs.
Competitive Analysis
Value Proposition:
Provides extensive repair information at a fraction of dealer service costs. Enables owners to maintain their ATVs effectively.
Key Features
Benefits:
Cost savings on labor, empowerment for self-maintenance, comprehensive repair guidance, instant access to technical data.
📋 Manual Details
Coverage
Applicable Years:
2003, 2004, 2005, 2006 (Bruin YFM350); 2007, 2008, 2009, 2010, 2011 (Grizzly YFM35)
Coverage Areas:
All repair topics including general information, periodic maintenance, fuel system, cooling system, engine top end, engine lubrication system, engine removal/installation, crankshaft/crankcase, transmission, wheels/tires, final drive, brakes, suspension, steering, frame, electrical system, diagnostics.
Page Count
Total Pages:
483
Bruin Specific Pages Start:
367
Type
Manual Type:
Complete Service Manual / Repair Manual
Language
Language:
English
Format
File Format:
PDF
Supplementary Info
Supplement Note:
The 350 Bruin models are presented as a supplement to a base manual for the 450 model, indicating shared chassis and some systems but specific engine/drivetrain details for the 350.
📖 Manual Coverage
Systems
Systems Covered:
Engine (Top End, Lubrication, Removal/Installation, Crankshaft/Crankcase), Fuel System, Cooling System, Transmission, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System.
Procedures
Procedures Included:
Periodic Maintenance, Troubleshooting, Diagnostics, Repair, Overhaul, Component Replacement, System Adjustments.
Depth
Technical Depth:
Comprehensive, from basic maintenance to detailed engine and transmission rebuilds, including diagnostic procedures and component-level repair instructions.
Visuals
Visual Aids:
Detailed diagrams, illustrations, photographs, and exploded views.
Diagnostics
Diagnostic Procedures:
Detailed troubleshooting charts and diagnostic procedures for common problems within each system.
Special Tools
Special Tool Requirements:
Manual may list specific Yamaha special tools required for certain repair procedures.
📊 Manual Specifications
File Quality
Print Quality:
High-resolution, suitable for printing all pages.
Searchability:
Likely text-searchable PDF (standard for modern manuals).
Binding Type
Binding Type:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
Compatibility
Operating Systems:
Compatible with all versions of Windows & Mac.
Requirements
Software Requirements:
Adobe PDF Reader.
Delivery
Download Speed:
Instant Download (No Waiting).
Content Enhancements
Illustrations Quality:
High-quality, clear illustrations and diagrams that aid in understanding complex procedures.
⚙️ Engine Specifications
Primary Engine
Engine Type Bruin:
Air-cooled, 4-stroke, SOHC, 2-valve
Engine Displacement Bruin:
348cc
Engine Type Grizzly:
Air-cooled, 4-stroke, SOHC, 2-valve
Engine Displacement Grizzly:
348cc (YFM35 designation likely refers to the 350cc class, not an exact 35cc displacement)
Performance
Cooling System:
Air-cooled
Compression Ratio:
Refer to manual for specific compression ratio figures for these engine variants.
Fuel System
Fuel Delivery:
Carburetor (specific model/size detailed in manual)
Lubrication
Lubrication System:
Wet Sump (details on oil type and capacity in manual)
Engine Identification
Bore Stroke:
Specific bore and stroke measurements for the 348cc engine are detailed in the manual.
🔧 Transmission
Standard
Transmission Type:
Automatic (likely Ultramatic or similar Yamaha CVT system for these models)
Features
Transmission Features:
Continuously Variable Transmission (CVT) with engine braking. Details on belt inspection/replacement, fluid type and changes are critical.
Gear Ratios
Gear Ratios:
Manual provides detailed gear ratios for the transmission and final drive, crucial for performance and maintenance.
📐 Dimensions
Exterior
Body Style:
All-Terrain Vehicle (ATV)
Weights
Dry Weight Approx Bruin:
Refer to manual for exact figures (typically around 500-550 lbs)
Dry Weight Approx Grizzly:
Refer to manual for exact figures (typically around 570-610 lbs)
Wheels Tires
Wheel Size:
Refer to manual for specific front and rear wheel sizes (typically 12-inch).
Tire Size:
Refer to manual for specific front and rear tire size recommendations and specifications.
🛡️ Safety Features
Ratings
Safety Standards:
Adherence to relevant ATV safety standards (details and precautions in manual).
Active Features
Braking System:
Hydraulic disc brakes (front and rear). Manual covers brake system maintenance, bleeding, pad replacement.
Passive Features
Throttle Limiter:
Likely adjustable or programmable throttle limiter for certain models/conditions (covered in manual).
💡 Technology Features
Infotainment
Display Features:
Basic LCD instrument panel displaying speed, odometer, trip meter, fuel level, 4WD indicator (if equipped), and warning lights. Detailed diagnostics available in manual.
Driver Assistance
Engine Braking:
CVT system provides engine braking for downhill control, a key feature for ATVs.
Connectivity
Diagnostic Tools:
Manual facilitates diagnostics through visual inspection, measurement, and adherence to specified procedures, rather than electronic OBD-II type systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific intervals (typically every 1000 km or 6 months for engine oil).
Air Filter Maintenance:
Regular inspection and cleaning/replacement based on usage conditions (detailed in manual).
Spark Plug Replacement:
Refer to manual for recommended intervals and correct spark plug type (e.g., NGK).
Fluid Specifications
Engine Oil Type:
Yamalube 4-stroke motorcycle oil (specific viscosity, e.g., 10W-40 or 20W-50, and API classification listed in manual).
Coolant Type:
Permanent type antifreeze coolant (specified in manual).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (specified in manual).
Gear Oil Type:
Yamaha Hypoid Gear Oil or equivalent (specified for final drive and transmission if separate).
Known Issues
Common Wear Items:
Brake pads, wheel bearings, drive belts (CVT), suspension bushings, steering components are common wear items. Manual provides inspection procedures.
Carburetor Issues:
Carburetor clogging due to fuel varnish, especially after storage, is a common issue. Manual details cleaning and adjustment.
Torque Specs
Torque References:
Manual provides detailed torque specifications for critical fasteners, including engine, suspension, and wheel components.
Fluid Capacities
Engine Oil Capacity:
Refer to manual for exact engine oil capacity with and without filter change.
Coolant Capacity:
Refer to manual for exact coolant system capacity.
📚 Vehicle History
Brand Heritage
Yamaha Atv Legacy:
Yamaha has a long-standing reputation for producing reliable and capable ATVs, pioneering many features in the industry.
Model Evolution
Bruin Grizzly Relation:
The Bruin (YFM350) often served as a precursor or parallel model to the Grizzly lineup, sharing many mechanical components and design philosophies. The Grizzly is typically positioned as a more premium or specialized model within Yamaha's ATV range.
Production
Manufacturing Region:
Yamaha ATVs are typically manufactured in Japan or at Yamaha's global production facilities.
🏆 Awards & Recognition
Recognitions
Yamaha Atv Awards:
While specific awards for these exact older models might be scarce, Yamaha ATVs, including the Bruin and Grizzly lines, have consistently been recognized for reliability, performance, and value within the ATV market.
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