Yamaha GRIZZLY 350 400 YFM350 YFM400 2WD Full Service & Repair Manual 2003-2012
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🏷️ Basic Information Identification Make: Yamaha Model: Grizzly 350 / 400 Model Codes: YFM350, YFM400 Vehicle Type: All-Terrain Vehicle (ATV) Drivetrain: 2WD 👋 Introduction Market Position Target Audience: ATV owners, professional mechanics, and service technicians seeking comprehensive repair and maintenance information. Competitive Analysis Value Proposition: Provides factory-level data at a fraction of the cost of OEM manuals, with lifetime access and broad device compatibility. Key Features Feature 1: Instant PDF download for immediate access. Feature 2: Detailed step-by-step instructions for all repair and maintenance tasks. Feature 3: High-quality illustrations and diagrams for clarity. Feature 4: Comprehensive troubleshooting guides for diagnosing issues. 📋 Manual Details Coverage Areas Applicable Model Years: 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Coverage Scope: Full Service, Repair, and Troubleshooting Page Count Estimated Page Count: Hundreds (specific number not provided, but described as 'very detailed') Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage of engine systems, including disassembly, assembly, tuning, and diagnostics. Fuel System: Detailed information on the carburetor (likely Mikuni BS series for these models), fuel pump, fuel lines, and related components. Cooling System: Information on air cooling (for most models in this range) and potentially oil cooling systems where applicable. Ignition System: Coverage of the CDI unit, ignition coil, spark plug, and timing. Transmission: Detailed procedures for the automatic transmission (likely Ultramatic/CVT), including belt inspection, clutch operation, and gearbox. Drivetrain Components: Covers front and rear drive shafts, differentials (if applicable to 2WD variant), and hub assemblies. Suspension: Front and rear suspension systems, including shocks, springs, A-arms, and bushings. Brakes: Front and rear brake systems, including hydraulic lines, calipers, brake pads, rotors, and master cylinders. Steering: Steering system components, including tie rods, steering knuckles, and handlebars. Electrical System: Wiring diagrams, battery, starter motor, lighting, charging system (stator, regulator/rectifier), and switches. Frame And Body: Frame inspection, body panels, fenders, racks, and seat assembly. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, chain/belt adjustments, and lubrication points. Troubleshooting: Diagnostic flowcharts and symptom-based problem solving for common issues. Routine Inspections: Pre-ride checks, fluid level checks, tire pressure, and brake system inspections. Engine Rebuild: Complete instructions for engine disassembly, component inspection, measuring clearances, and reassembly. Transmission Overhaul: Detailed steps for transmission disassembly, inspection of gears, clutches, and seals, and reassembly. Carburetor Rebuild And Adjustment: Step-by-step guide for carburetor cleaning, jetting, float level adjustment, and idle speed settings. Electrical Diagnostics: Testing of electrical components, circuit tracing using wiring diagrams, and troubleshooting common electrical faults. Brake System Maintenance: Brake bleeding, pad replacement, caliper servicing, and master cylinder overhaul. Technical Depth Depth: Expert-level, suitable for professional mechanics and advanced DIY enthusiasts. Covers full rebuilds and complex diagnostics. Visual Aids: Hundreds of detailed photos and diagrams, including exploded views. 📊 Manual Specifications File Format Digital Format: PDF Searchability: Typically searchable PDF text, allowing for quick information retrieval. Print Quality Printable: Yes, allows printing of single pages or the entire manual. Binding Type Binding Type: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) Licensing License Type: Lifetime use, no expiry, no renewal fees. Device Compatibility Compatibility: Compatible with Windows and MAC computers, tablets, and smartphones. ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 4-stroke, SOHC Displacement 350: Approximately 348cc (for YFM350 models, e.g., YFM350ER, YFM350FX - specifics vary by exact sub-model). Displacement 400: Approximately 386cc (for YFM400 models, e.g., YFM400FW, YFM400A - specifics vary by exact sub-model). Bore X Stroke 350 Approx: Refer to manual for exact specifications; likely around 83mm x 64.5mm. Bore X Stroke 400 Approx: Refer to manual for exact specifications; likely around 84.5mm x 70mm. Performance Horsepower Approx 350: Typically in the 20-25 HP range, dependent on tuning and exact model. Horsepower Approx 400: Typically in the 25-30 HP range, dependent on tuning and exact model. Torque Specs: Refer to manual for specific torque values for engine components. Fuel System Carburetor Type: Likely Mikuni BS series (e.g., BS33 or similar) or Keihin CV carburetor, depending on the specific model year and configuration. Fuel Capacity: Refer to manual; typically around 2.5-3.0 gallons (9.5-11.4 liters). 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission, often branded as Ultramatic by Yamaha). Optional Gearbox Features: High/Low range selection, Neutral, and Reverse. Features Drive System: Shaft drive to rear wheels for 2WD models. Cv Belt Inspection Interval: Refer to manual for specific intervals, typically checked at initial services and then periodically. 📐 Dimensions Exterior Overall Length Approx: Refer to manual; typically around 74-78 inches (1880-1980 mm). Overall Width Approx: Refer to manual; typically around 41-45 inches (1040-1140 mm). Overall Height Approx: Refer to manual; typically around 43-45 inches (1090-1140 mm). Weights Dry Weight Approx: Refer to manual; typically around 400-470 lbs (181-213 kg). Towing Capacity: Refer...
Hundreds (specific number not provided, but described as 'very detailed')
Manual Type
Manual Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage of engine systems, including disassembly, assembly, tuning, and diagnostics.
Fuel System:
Detailed information on the carburetor (likely Mikuni BS series for these models), fuel pump, fuel lines, and related components.
Cooling System:
Information on air cooling (for most models in this range) and potentially oil cooling systems where applicable.
Ignition System:
Coverage of the CDI unit, ignition coil, spark plug, and timing.
Transmission:
Detailed procedures for the automatic transmission (likely Ultramatic/CVT), including belt inspection, clutch operation, and gearbox.
Drivetrain Components:
Covers front and rear drive shafts, differentials (if applicable to 2WD variant), and hub assemblies.
Suspension:
Front and rear suspension systems, including shocks, springs, A-arms, and bushings.
Brakes:
Front and rear brake systems, including hydraulic lines, calipers, brake pads, rotors, and master cylinders.
Steering:
Steering system components, including tie rods, steering knuckles, and handlebars.
Electrical System:
Wiring diagrams, battery, starter motor, lighting, charging system (stator, regulator/rectifier), and switches.
Frame And Body:
Frame inspection, body panels, fenders, racks, and seat assembly.
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, chain/belt adjustments, and lubrication points.
Troubleshooting:
Diagnostic flowcharts and symptom-based problem solving for common issues.
Routine Inspections:
Pre-ride checks, fluid level checks, tire pressure, and brake system inspections.
Engine Rebuild:
Complete instructions for engine disassembly, component inspection, measuring clearances, and reassembly.
Transmission Overhaul:
Detailed steps for transmission disassembly, inspection of gears, clutches, and seals, and reassembly.
Carburetor Rebuild And Adjustment:
Step-by-step guide for carburetor cleaning, jetting, float level adjustment, and idle speed settings.
Electrical Diagnostics:
Testing of electrical components, circuit tracing using wiring diagrams, and troubleshooting common electrical faults.
Brake System Maintenance:
Brake bleeding, pad replacement, caliper servicing, and master cylinder overhaul.
Technical Depth
Depth:
Expert-level, suitable for professional mechanics and advanced DIY enthusiasts. Covers full rebuilds and complex diagnostics.
Visual Aids:
Hundreds of detailed photos and diagrams, including exploded views.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Typically searchable PDF text, allowing for quick information retrieval.
Print Quality
Printable:
Yes, allows printing of single pages or the entire manual.
Binding Type
Binding Type:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format)
Licensing
License Type:
Lifetime use, no expiry, no renewal fees.
Device Compatibility
Compatibility:
Compatible with Windows and MAC computers, tablets, and smartphones.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, SOHC
Displacement 350:
Approximately 348cc (for YFM350 models, e.g., YFM350ER, YFM350FX - specifics vary by exact sub-model).
Displacement 400:
Approximately 386cc (for YFM400 models, e.g., YFM400FW, YFM400A - specifics vary by exact sub-model).
Bore X Stroke 350 Approx:
Refer to manual for exact specifications; likely around 83mm x 64.5mm.
Bore X Stroke 400 Approx:
Refer to manual for exact specifications; likely around 84.5mm x 70mm.
Performance
Horsepower Approx 350:
Typically in the 20-25 HP range, dependent on tuning and exact model.
Horsepower Approx 400:
Typically in the 25-30 HP range, dependent on tuning and exact model.
Torque Specs:
Refer to manual for specific torque values for engine components.
Fuel System
Carburetor Type:
Likely Mikuni BS series (e.g., BS33 or similar) or Keihin CV carburetor, depending on the specific model year and configuration.
Fuel Capacity:
Refer to manual; typically around 2.5-3.0 gallons (9.5-11.4 liters).
🔧 Transmission
Standard
Transmission Type:
Automatic (CVT - Continuously Variable Transmission, often branded as Ultramatic by Yamaha).
Optional
Gearbox Features:
High/Low range selection, Neutral, and Reverse.
Features
Drive System:
Shaft drive to rear wheels for 2WD models.
Cv Belt Inspection Interval:
Refer to manual for specific intervals, typically checked at initial services and then periodically.
📐 Dimensions
Exterior
Overall Length Approx:
Refer to manual; typically around 74-78 inches (1880-1980 mm).
Overall Width Approx:
Refer to manual; typically around 41-45 inches (1040-1140 mm).
Overall Height Approx:
Refer to manual; typically around 43-45 inches (1090-1140 mm).
Weights
Dry Weight Approx:
Refer to manual; typically around 400-470 lbs (181-213 kg).
Towing Capacity:
Refer to manual; typically around 1100-1200 lbs (500-544 kg).
Cargo Capacity Rear Rack Approx:
Refer to manual; typically around 198 lbs (90 kg).
🛡️ Safety Features
Ratings
Atv Safety Standards:
Designed to meet applicable industry safety standards for ATVs.
Active Features
Braking System:
Hydraulic disc brakes, front and rear.
Passive Features
Lighting:
Headlights, taillight, and brake light.
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation; typically includes speedometer, odometer, trip meter, and indicator lights.
Driver Assistance
Driver Assistance Features:
None (ATVs of this era typically do not feature advanced electronic driver assistance systems).
Connectivity
Connectivity Features:
None.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Refer to manual for specific hours/miles; typically every 100 hours or 6 months.
Air Filter Cleaning Interval:
Refer to manual; often recommended every 20-30 hours of use or annually.
Spark Plug Inspection Interval:
Refer to manual; typically inspected with oil changes and replaced as needed.
Brake Fluid Flush Interval:
Refer to manual; usually every 2 years or as needed based on condition.
Fluid Specifications
Engine Oil Type:
Yamalube (or equivalent) SAE 10W-40 API SG or higher, or 20W-50 API SG or higher for higher temperatures. Refer to manual for specific viscosity recommendation.
Engine Oil Capacity:
Refer to manual for exact capacity with filter change; typically around 1.5-1.8 liters.
Gear Oil Type:
Yamalube Gear Oil 80W-90 (or equivalent API GL-4).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Common Issue 1:
CVT belt wear or slippage, especially under heavy load or with aggressive riding.
Common Issue 2:
Carburetor tuning issues, requiring periodic cleaning and adjustment for optimal performance.
Common Issue 3:
Electrical connector corrosion, particularly in wet environments, affecting lights or ignition.
Common Issue 4:
Wear on suspension bushings and tie rod ends due to rough terrain and use.
📚 Vehicle History
Brand Heritage
Yamaha Atv Legacy:
Yamaha has a long-standing reputation for producing reliable and capable ATVs, with the Grizzly line being a cornerstone of their utility segment.
Model Evolution
Grizzly 350 400 Positioning:
These models represented Yamaha's mid-range utility ATVs, offering a balance of power, maneuverability, and durability for various tasks and terrains.
Production
Production Period:
The Grizzly 350 and 400 lines were popular throughout the 2000s and early 2010s, with continuous updates and refinements during their production run.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Yamaha Grizzly models generally receive positive reviews for their reliability, durability, and capability in the utility ATV market.
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