Yamaha Bruin 350 Service Manual Repair 2004 YFM350
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🏷️ Basic Information Identification Make: Yamaha Model: Bruin 350 Vehicle Code: YFM350 Model Year: 2004 Vehicle Type: All-Terrain Vehicle (ATV) Drive Type: 2WD and 4x4 Engine Configuration: Single-cylinder, 4-stroke 👋 Introduction Market Position Target Audience: Owners seeking to perform their own maintenance and repairs, DIY enthusiasts, independent repair shops. Competitive Analysis Advantage: Provides factory-level detail and coverage for a specific model year, offering comprehensive guidance beyond basic owner's manuals. Key Features Navigation: Clickable chapters for easy navigation. Searchability: Full text search functionality for quick information retrieval. Accessibility: Instant download availability. Support: Free replacement of lost manuals. 📋 Manual Details Coverage Areas Primary Focus: Service and Repair Additional Coverage: Maintenance, Troubleshooting, Diagnostics Related Models Covered: 2003-2006 Kodiak (with Bruin 350 updates), potentially newer models Page Count Total Pages: 596 Manual Type Type: Factory Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine tear down, rebuild, lubrication, valve clearance, piston, connecting rod, crankshaft, camshaft, ignition, charging system, magneto, starter, flywheel, rotor, cylinder, head, intake, exhaust, crankcase, crankcase seals Fuel System: Carburetor (carb), carburetor adjustments (pilot jet, main jet, mixture screw, idle), fuel pump, fuel tank, fuel lines, fuel filter, PGM-FI (mentioned as a possible related technology due to Kodiak overlap, though Bruin 350 is typically carbureted) Transmission Drivetrain: Transmission overhaul, gearshift mechanism, primary reduction gear, reverse gear, drive shaft, clutch, clutch components, drive train maintenance Suspension Steering: Front forks, rear suspension, swingarm (swinger), struts, triple trees, linkages, wheel bearings, steering system, handlebars, steering column Brakes: Brake system maintenance, brake calipers, brake pads, brake rotors, brake lines, hydraulic brakes, parking brake Electrical System: Ignition system, charging system (rectifier, stator, regulator), battery, starter motor, lights (headlights, taillights), switches, error codes, wiring diagrams (implied by comprehensive coverage), electronic components Bodywork Chassis: Frame, body panels, fenders, seat, storage, plastic components, hull (if applicable to certain parts) Procedures Included Maintenance: Scheduled maintenance, fluid changes (engine oil, coolant, brake fluid), lubrication schedule, filter replacement, battery maintenance, tire pressure checks Troubleshooting: Comprehensive troubleshooting guide, diagnosing common problems (e.g., no spark, starting issues, performance problems), error code interpretation Repair Rebuild: Complete tear down and rebuild procedures for all major components, engine rebuilding, transmission rebuilding, suspension repair, brake service Installation Replacement: Installation and replacement of parts, accessory installation (implied), component replacement procedures Technical Depth Depth: Highly detailed, covering complete disassembly, inspection, repair, and reassembly of all major vehicle systems. Diagnostics Support: Includes information on error codes and troubleshooting steps for identifying and resolving issues. Visual Aids: Includes pictures and part diagrams to aid in identification and assembly. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text Printing: No restrictions on printing Saving: No restrictions on saving/burning to disc Print Quality Quality: High-quality digital reproduction of factory documentation Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 2-valve Displacement: 348cc Bore X Stroke: 83.0 mm x 64.5 mm Cooling System: Liquid-cooled Compression Ratio: 9.2:1 Performance Horsepower: Approx. 21-23 HP (Estimate based on similar models) Torque: Not explicitly stated in product info, but typical for this displacement. Fuel System Fuel Delivery: Mikuni BSR33 carburetor Recommended Fuel: Unleaded gasoline (87 octane or higher recommended) Carburetor Jetting Details: Manual covers pilot jet, main jet, mixture screw, and idle adjustments. Lubrication Recommended Engine Oil Type: Yamalube 4 (or equivalent SAE 10W-30 or 10W-40 API SG or higher, JASO standard MA) Engine Oil Capacity: Approx. 2.2 Liters (with filter change) Ignition Ignition System: CDI (Capacitor Discharge Ignition) Starting System Starting Method: Electric start and manual kickstart 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Features Gear Selection: Forward, Neutral, Reverse (F-N-R) Drive System: Shaft drive Fluid Specifications Cvt Fluid: Yamaha recommends specific CVT fluid for optimal performance and longevity. Consult manual for exact specification. 📐 Dimensions Weights Dry Weight: Approx. 248 kg (547 lbs) for 4x4 models Wet Weight: Not specified in product info, but generally higher than dry weight. Ground Clearance: Approx. 256 mm (10.1 inches) Dimensions Length: Approx. 1995 mm (78.5 in) Width: Approx. 1090 mm (42.9 in) Height: Approx. 1155 mm (45.5 in) Wheelbase: Approx. 1260 mm (49.6 in) Tire Size Front: AT25x8-12 Tire Size Rear: AT25x10-12 🛡️ Safety Features Ratings Safety Standards: Meets ANSI standards for recreational off-highway vehicles. Active Features Braking System: Hydraulic disc brakes front and rear, increasing stopping power and control. 4X4 System: On-command 4WD for enhanced traction in challenging terrain. Passive Features Lighting: Dual 30W headlights and a 30W brake/taillight for visibility. Ergonomics: Designed for rider comfort and control during operation. 💡 Technology Features Infotainment Infotainment System: N/A (ATV focus on utility and performance, not infotainment). Driver Assistance Traction Control: Limited Slip Differential (LSD) or differential lock in 4x4 models (depending on exact configuration, covered in manual). Connectivity Diagnostic Ports: Diagnostic capabilities via error codes, detailed...
Carburetor (carb), carburetor adjustments (pilot jet, main jet, mixture screw, idle), fuel pump, fuel tank, fuel lines, fuel filter, PGM-FI (mentioned as a possible related technology due to Kodiak overlap, though Bruin 350 is typically carbureted)
Yamaha recommends specific CVT fluid for optimal performance and longevity. Consult manual for exact specification.
📐 Dimensions
Weights
Dry Weight:
Approx. 248 kg (547 lbs) for 4x4 models
Wet Weight:
Not specified in product info, but generally higher than dry weight.
Ground Clearance:
Approx. 256 mm (10.1 inches)
Dimensions
Length:
Approx. 1995 mm (78.5 in)
Width:
Approx. 1090 mm (42.9 in)
Height:
Approx. 1155 mm (45.5 in)
Wheelbase:
Approx. 1260 mm (49.6 in)
Tire Size Front:
AT25x8-12
Tire Size Rear:
AT25x10-12
🛡️ Safety Features
Ratings
Safety Standards:
Meets ANSI standards for recreational off-highway vehicles.
Active Features
Braking System:
Hydraulic disc brakes front and rear, increasing stopping power and control.
4X4 System:
On-command 4WD for enhanced traction in challenging terrain.
Passive Features
Lighting:
Dual 30W headlights and a 30W brake/taillight for visibility.
Ergonomics:
Designed for rider comfort and control during operation.
💡 Technology Features
Infotainment
Infotainment System:
N/A (ATV focus on utility and performance, not infotainment).
Driver Assistance
Traction Control:
Limited Slip Differential (LSD) or differential lock in 4x4 models (depending on exact configuration, covered in manual).
Connectivity
Diagnostic Ports:
Diagnostic capabilities via error codes, detailed in the manual.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first (refer to manual for specific conditions).
Air Filter Cleaning:
Check and clean every 20 hours, replace as needed. More frequent cleaning in dusty conditions.
Spark Plug Maintenance:
Inspect and clean/gap at 100-hour intervals, replace as needed.
Valve Clearance Adjustment:
Inspect and adjust every 100 hours.
Fluid Specifications
Engine Oil Viscosity:
SAE 10W-30 or 10W-40 API SG or higher, JASO standard MA
Coolant:
Permanent type antifreeze (ethylene glycol based) with corrosion inhibitor. Refer to manual for specific mixture ratio and type.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. Do not mix types.
Known Issues
Common Problems:
Carburetor adjustments/cleaning (common with age/usage), occasional starter solenoid issues, general wear and tear on suspension components. Manual provides detailed troubleshooting for these and more.
Troubleshooting Support:
The manual's troubleshooting section is invaluable for diagnosing and rectifying common and uncommon issues, including 'no spark' scenarios.
📚 Vehicle History
Brand Heritage
Heritage:
Yamaha has a long-standing reputation for producing reliable and high-performance powersports vehicles, including ATVs known for their durability and engineering.
Model Evolution
Development:
The Bruin 350 built upon Yamaha's experience with models like the Kodiak, offering a balance of performance and utility for recreational riders.
Production
Production Years Covered By Manual:
Primarily 2004, with applicability to 2003-2006 Kodiak and potentially later Bruin models.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Yamaha ATVs are generally well-regarded for their reliability, durability, and performance in the powersports industry.
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