Yamaha BRUIN 350 400 PDF Service Repair Workshop Manual 2004 Download
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🏷️ Basic Information Identification Make: Yamaha Model: Bruin Model Variant: 350 / 400 Model Year: 2004 Vehicle Type: ATV (All-Terrain Vehicle) Codes Chassis Code: YFA125 (for reference, specific Bruin codes vary by sub-model) 👋 Introduction Market Position Market Position: The Yamaha Bruin was positioned as a reliable and capable utility ATV, catering to a wide range of users including recreational riders, farmers, and outdoorsmen. Its focus was on a balance of power, comfort, and durability. Competitive Analysis Competitive Analysis: Competed with models from Honda (e.g., FourTrax Foreman), Polaris (e.g., Sportsman), Kawasaki (e.g., Prairie), and Suzuki (e.g., KingQuad) in the mid-size utility ATV segment. Differentiated by its smooth power delivery, comfortable ride, and Yamaha's reputation for reliability. Key Features Key Features: Independent Front Suspension (IFS), shaft drive, selectable 2WD/4WD, automatic transmission (V-belt), powerful 4-stroke engine, comfortable seating. 📋 Manual Details Coverage Areas Coverage Areas: All Models Page Count Page Count: Hundreds of pages (precise count not specified, indicative of comprehensive content) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English (Implied by product description and target market) Format Format: PDF Download 📖 Manual Coverage Systems Covered Systems Covered: Engine, Fuel System, Carburetion, Ignition System, Electrical System, Starting System, Charging System, Transmission, Clutch, Drivetrain, Suspension, Steering, Brakes, Chassis, Bodywork, Cooling System, Exhaust System, Frame, Wheels and Tires, Lubrication System, Troubleshooting Procedures Included Procedures Included: Routine Maintenance, Scheduled Servicing, Detailed Repair Procedures, Rebuilding, Refurbishing, Restoration, Diagnostic Procedures, Troubleshooting Faults, Component Replacement, Electrical Wiring Diagrams, Torque Specifications, Special Tool Requirements Technical Depth Technical Depth: Comprehensive, from basic adjustments to complete engine and transmission overhauls. Designed for DIY mechanics and professional technicians. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution, suitable for printing and digital viewing. 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 (for 350) / liquid-cooled (for 400) Displacement: 348cc (for 350), 386cc (for 400 - exact variations may exist) Bore X Stroke: Specific to each engine variant (e.g., 83 mm x 64.5 mm for 350) Performance Horsepower: Approximately 20-25 HP (estimated, varies by specific model/tuning) Torque: Approximately 20-25 lb-ft (estimated, varies by specific model/tuning) Fuel System Fuel Delivery: Carburetor (e.g., Mikuni BSR33 for 350) Fuel Type: Unleaded gasoline Fuel Tank Capacity: Approx. 3.2 gallons (12 liters) Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Lubrication System Oil Type: Yamalube 4 (or equivalent 4-stroke motorcycle oil, SAE 10W-30 or 20W-40 recommended depending on temperature) Oil Capacity: Approx. 2.0-2.5 quarts (1.9-2.4 liters) with filter change Engine Management Timing: Specific valve and ignition timing specifications provided in the manual. 🔧 Transmission Standard Transmission Type: Automatic (V-belt transmission with torque converter) Drive System: Shaft drive Gear Selection: Forward (Hi/Lo range), Neutral, Reverse Clutch Type: Automatic centrifugal clutch Features Differential: Sealed rear differential, limited-slip front differential (on some models) Fluid Specifications Transmission Oil Type: Yamaha Slip-Resistant ATF or equivalent automatic transmission fluid Transmission Oil Capacity: Approx. 0.6 gallons (2.3 liters) 📐 Dimensions Exterior Overall Length: Approx. 76.5 inches (1945 mm) Overall Width: Approx. 42.5 inches (1080 mm) Overall Height: Approx. 43.1 inches (1095 mm) Wheelbase: Approx. 49.2 inches (1250 mm) Weights Dry Weight: Approx. 540-570 lbs (245-259 kg) Ground Clearance: Approx. 7.1 inches (180 mm) Cargo Front Rack Capacity: Approx. 88 lbs (40 kg) Rear Rack Capacity: Approx. 176 lbs (80 kg) Tires Front Tires: AT25x8-12 (e.g., Dunlop) Rear Tires: AT25x10-12 (e.g., Dunlop) Wheels Wheel Type: Steel Bolt Pattern: 4-bolt pattern (specific offset and bolt size detailed in manual) 🛡️ Safety Features Ratings Safety Ratings: ATVs are not typically crash-tested by organizations like NHTSA or IIHS. Safety relies heavily on operator skill and adherence to manufacturer guidelines. Active Features Braking System: Hydraulic disc brakes front and rear Parking Brake: Mechanical drum brake on rear axle (typically) Passive Features Lighting: Dual 30W headlights, 12V 5/21W taillight/brake light Operator Safety: Handlebar controls, footrests, thumb throttle with safety lever, engine kill switch, seat safety switch (on some models). 💡 Technology Features Infotainment Infotainment System: N/A (ATV technology focused on function, not typically equipped with infotainment systems) Driver Assistance Driver Assistance: N/A (Standard ATV design, basic controls) Connectivity Connectivity: N/A Engine Technology Engine Features: SOHC design for efficient valve operation, robust air/liquid cooling systems, reliable CDI ignition for consistent spark. Transmission Technology Transmission Features: Torque converter for smooth power delivery and automatic engagement, dual range (Hi/Lo) for varied terrain and towing needs. 🔧 Maintenance Service Intervals Initial Service: First service typically around 10-20 hours or 1 month (check oil, chain tension, air filter, etc.) Regular Maintenance: Engine oil and filter change: every 100 hours or 6 months. Air filter cleaning/replacement: every 20-40 hours. Spark plug inspection/replacement: every 100 hours or 1 year. Valve clearance check: every 200 hours or 1 year....
YFA125 (for reference, specific Bruin codes vary by sub-model)
👋 Introduction
Market Position
Market Position:
The Yamaha Bruin was positioned as a reliable and capable utility ATV, catering to a wide range of users including recreational riders, farmers, and outdoorsmen. Its focus was on a balance of power, comfort, and durability.
Competitive Analysis
Competitive Analysis:
Competed with models from Honda (e.g., FourTrax Foreman), Polaris (e.g., Sportsman), Kawasaki (e.g., Prairie), and Suzuki (e.g., KingQuad) in the mid-size utility ATV segment. Differentiated by its smooth power delivery, comfortable ride, and Yamaha's reputation for reliability.
Specific to each engine variant (e.g., 83 mm x 64.5 mm for 350)
Performance
Horsepower:
Approximately 20-25 HP (estimated, varies by specific model/tuning)
Torque:
Approximately 20-25 lb-ft (estimated, varies by specific model/tuning)
Fuel System
Fuel Delivery:
Carburetor (e.g., Mikuni BSR33 for 350)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 3.2 gallons (12 liters)
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition)
Lubrication System
Oil Type:
Yamalube 4 (or equivalent 4-stroke motorcycle oil, SAE 10W-30 or 20W-40 recommended depending on temperature)
Oil Capacity:
Approx. 2.0-2.5 quarts (1.9-2.4 liters) with filter change
Engine Management
Timing:
Specific valve and ignition timing specifications provided in the manual.
🔧 Transmission
Standard
Transmission Type:
Automatic (V-belt transmission with torque converter)
Drive System:
Shaft drive
Gear Selection:
Forward (Hi/Lo range), Neutral, Reverse
Clutch Type:
Automatic centrifugal clutch
Features
Differential:
Sealed rear differential, limited-slip front differential (on some models)
Fluid Specifications
Transmission Oil Type:
Yamaha Slip-Resistant ATF or equivalent automatic transmission fluid
Transmission Oil Capacity:
Approx. 0.6 gallons (2.3 liters)
📐 Dimensions
Exterior
Overall Length:
Approx. 76.5 inches (1945 mm)
Overall Width:
Approx. 42.5 inches (1080 mm)
Overall Height:
Approx. 43.1 inches (1095 mm)
Wheelbase:
Approx. 49.2 inches (1250 mm)
Weights
Dry Weight:
Approx. 540-570 lbs (245-259 kg)
Ground Clearance:
Approx. 7.1 inches (180 mm)
Cargo
Front Rack Capacity:
Approx. 88 lbs (40 kg)
Rear Rack Capacity:
Approx. 176 lbs (80 kg)
Tires
Front Tires:
AT25x8-12 (e.g., Dunlop)
Rear Tires:
AT25x10-12 (e.g., Dunlop)
Wheels
Wheel Type:
Steel
Bolt Pattern:
4-bolt pattern (specific offset and bolt size detailed in manual)
🛡️ Safety Features
Ratings
Safety Ratings:
ATVs are not typically crash-tested by organizations like NHTSA or IIHS. Safety relies heavily on operator skill and adherence to manufacturer guidelines.
Handlebar controls, footrests, thumb throttle with safety lever, engine kill switch, seat safety switch (on some models).
💡 Technology Features
Infotainment
Infotainment System:
N/A (ATV technology focused on function, not typically equipped with infotainment systems)
Driver Assistance
Driver Assistance:
N/A (Standard ATV design, basic controls)
Connectivity
Connectivity:
N/A
Engine Technology
Engine Features:
SOHC design for efficient valve operation, robust air/liquid cooling systems, reliable CDI ignition for consistent spark.
Transmission Technology
Transmission Features:
Torque converter for smooth power delivery and automatic engagement, dual range (Hi/Lo) for varied terrain and towing needs.
🔧 Maintenance
Service Intervals
Initial Service:
First service typically around 10-20 hours or 1 month (check oil, chain tension, air filter, etc.)
Regular Maintenance:
Engine oil and filter change: every 100 hours or 6 months. Air filter cleaning/replacement: every 20-40 hours. Spark plug inspection/replacement: every 100 hours or 1 year. Valve clearance check: every 200 hours or 1 year. Transmission oil change: every 200 hours or 1 year. Brake inspection: periodically. Drive shaft boot inspection: periodically.
Fluid Specifications
Engine Oil:
Yamalube 4 (SAE 10W-30 or 20W-40 recommended based on ambient temperature)
Transmission Oil:
Yamaha Slip-Resistant ATF or equivalent
Coolant:
Yamaha Yamalube Coolant (or equivalent ethylene glycol-based antifreeze with corrosion inhibitor) for liquid-cooled models.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid
Known Issues
Common Issues:
Carburetor tuning/cleaning, potential for starter motor issues, V-belt wear and replacement, suspension component wear (bushings, ball joints), occasional electrical connector corrosion. The manual provides detailed diagnostics for these.
Part Numbers
Oil Filter Part Number:
Yamaha OEM part number typically 5TA-13440-00-00 or equivalent.
Air Filter Part Number:
Yamaha OEM part number typically 5XD-14451-00-00 or equivalent.
V Belt Part Number:
Yamaha OEM part number typically 5UY-17641-00-00 or equivalent.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Yamaha Motor Corporation, established in 1955, has a long-standing reputation for engineering excellence and innovation in recreational vehicles, including motorcycles, ATVs, and personal watercraft.
Model Evolution
Model Evolution:
The Bruin model line was introduced to offer a more user-friendly and comfortable utility ATV experience. It built upon Yamaha's experience with previous ATV models, incorporating features like independent front suspension for improved ride quality and handling. It served as a precursor to later, more advanced Yamaha utility ATVs.
Production
Production Period:
The Bruin line was produced for several years, with the 2004 model representing a key year in its development. Specific production dates and locations varied.
🏆 Awards & Recognition
Recognitions
Recognitions:
Yamaha ATVs are consistently recognized for their durability, reliability, and performance in industry reviews and by owner satisfaction surveys. Specific awards for the 2004 Bruin may not be widely publicized but reflect Yamaha's market standing.
Ratings
Ratings:
Owner satisfaction ratings typically reflect high marks for reliability and capability, though some may note the older technology compared to newer models.
Certifications
Certifications:
Manufactured to meet relevant industry safety standards for ATVs.