Welcome to the comprehensive service manual for the 2004 Yamaha Wolverine 350, a robust All-Terrain Vehicle (ATV) celebrated for its reliable performance and versatility. Engineered with a torquey, air-cooled 348cc single-cylinder engine and a durable 5-speed manual transmission featuring an automatic clutch, this model offers a balanced blend of power and user-friendliness. Its independent front suspension and swingarm rear suspension provide a comfortable ride across varied terrains, making it ideal for recreational riders, trail enthusiasts, and utility tasks. The shaft-driven, two-wheel-drive system further enhances its low-maintenance appeal, reflecting a commitment to quality and durability in its renowned ATV lineup. This factory service repair manual is meticulously designed to guide both professional mechanics and DIY enthusiasts through the complete maintenance and repair of your 2004 Yamaha Wolverine 350. Within its approximately 400 pages, you will find detailed instructions covering every aspect of the vehicle, from engine mechanicals, fuel and ignition systems, to transmission, drivetrain, suspension, steering, brakes, and the electrical system. It includes essential procedures such as preventative maintenance schedules, in-depth troubleshooting guides, complete disassembly and reassembly instructions, crucial adjustment procedures, and precise torque specifications. This manual is an indispensable resource for ensuring your Wolverine 350 remains in optimal condition, offering clear guidance for diagnostics, repairs, and upkeep. 🏷️ Basic Information Identification Make: Yamaha Model: Wolverine 350 Year: 2004 Vehicle Type: ATV (All-Terrain Vehicle) Codes Chassis Code: YFM350X 👋 Introduction Market Position Vehicle Segment: Entry-level to mid-range sport ATV, known for its reliability and versatility. Target Demographic: Recreational riders, trail enthusiasts, and utility users. Competitive Analysis Key Competitors 2004: Honda FourTrax 350, Suzuki LT-F300 King Quad, Kawasaki Bayou 300. Key Features Engine Configuration: Torquey, air-cooled single-cylinder engine providing reliable power. Transmission: Durable 5-speed manual transmission with an automatic clutch. Suspension Type: Independent front suspension and a swingarm rear suspension for comfortable trail riding. Drive System: Shaft-driven, two-wheel drive (2WD) system known for its low maintenance. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF Download Page Count: Approximately 400 pages (estimated based on typical service manual scope for this model) Target Audience: Professional Mechanics and DIY Enthusiasts 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and reassembly of the engine, including cylinder head, piston, crankshaft, connecting rod, and valve train. Fuel System: Carburetor overhaul, adjustment, fuel pump, fuel lines, and fuel tank maintenance. Ignition System: CDI unit, ignition coil, spark plug, and troubleshooting. Lubrication System: Oil pump, oil filter, oil passages, and oil change procedures. Cooling System: Air cooling system analysis, maintenance, and potential issues. Transmission: 5-speed manual transmission service, clutch operation, gear inspection, and lubrication. Drivetrain: Drive shafts, differential, and wheel hub maintenance. Suspension: Front and rear suspension component inspection, adjustment, and replacement (shocks, springs, control arms). Steering: Handlebar, steering shaft, and tie rod end maintenance and alignment procedures. Brakes: Hydraulic brake system service, pad replacement, caliper maintenance, fluid bleeding, and drum brake (if applicable) procedures. Electrical System: Wiring diagrams, battery maintenance, lighting system, starter motor, generator, and fuse box troubleshooting. Body And Frame: Body panel removal, installation, chassis inspection, and seat maintenance. Wheels And Tires: Tire inspection, pressure recommendations, and wheel bearing service. Procedures Included Preventative Maintenance: Regular inspection and replacement schedules for filters, fluids, and wear items. Troubleshooting Guides: Detailed diagnostic charts for common starting, running, and electrical issues. Repair Procedures: Step-by-step instructions for all major component repairs and replacements. Disassembly And Reassembly: Comprehensive guides for taking apart and putting back together all major systems. Adjustments: Carburetor synchronization, valve lash adjustment, chain tensioning, and brake adjustments. Torque Specifications: Precise torque values for critical fasteners throughout the vehicle. Technical Depth Diagnostic Capabilities: Covers basic diagnostic procedures and interpretation of symptoms. Rebuild Scope: Provides sufficient detail for complete engine and transmission rebuilds. Electrical Diagrams: Includes detailed wiring diagrams for accurate electrical system diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for efficient information retrieval. Printability: Printable pages for on-site reference. Resolution: High resolution for clear diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, air-cooled Displacement: 348 cc (21.2 cu. in.) Bore X Stroke: 83.0 mm x 64.5 mm (3.27 in x 2.54 in) Compression Ratio: 9.2:1 Carburetor: Mikuni BSR33/1 (single) Performance Horsepower Estimate: Approx. 20-22 HP @ 6500 RPM (estimated, not officially published) Torque Estimate: Approx. 20-22 lb-ft @ 5000 RPM (estimated, not officially published) Fuel System Fuel Type: Unleaded gasoline Fuel Tank Capacity: 3.1 US gal (11.7 L) 🔧 Transmission Standard Transmission Type: 5-speed manual with automatic clutch and reverse Optional Optional Transmission: N/A Features Clutch Type: Wet, multi-disc, automatic Drive Method: Shaft drive 📐 Dimensions Exterior Overall Length: 73.4 inches (1865 mm) Overall Width: 42.7 inches (1085 mm) Overall Height: 43.7 inches (1110 mm) Wheelbase: 49.2 inches...