Yamaha BANSHEE YFZ350R User manual

YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2002·3–1.5×1!
This ATV should not be ridden by anyone under 16 years of age.
OWNER’S MANUAL
5FK-28199-15
YFZ350R
READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIT-11626-16-29
(E)
w
Improper ATV use can result in SEVERE INJURY or DEATH.
qWARNING
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
9without proper training or instruction.
9at speeds too fast for your skills or the
conditions.
9 on public roads - a collision can occur with
another vehicle.
9with a passenger - passengers affect
balance and steering and increase risk
of losing control.
ALWAYS:
9use proper riding techniques to avoid
vehicle overturns on hills and rough
terrain and in turns.
9avoid paved surfaces - pavement may
seriously affect handling and control.
EBU00438
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)

EBU00923
INTRODUCTION
Congratulations on your purchase of the Yamaha YFZ350. It represents the result of many years
of Yamaha experience in the production of fine sporting, touring, and pacesetting racing
machines. With the purchase of this Yamaha, you can now appreciate the high degree of crafts-
manship and reliability that have made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this
machine. This manual includes important safety information. It provides information about
special techniques and skills necessary to ride your machine. It also includes basic main-
tenance and inspection procedures. If you have any questions regarding the operation or
maintenance of your machine, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
8READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND
COMPLETELY BEFORE OPERATING YOUR MACHINE. MAKE SURE YOU UNDERSTAND
ALL INSTRUCTIONS.
8PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MACHINE.
8NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE
TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR
MORE INFORMATION.
8THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE
UNDER 16 YEARS OF AGE.
8THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT TYPE
RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.
5FK-9-15-1 4/8/02 1:13 PM Page 1

EBU00801
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN
SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
QThe Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
wFailure to follow WARNING instructions could result in severe injury or
death to the machine operator, a bystander or a person inspecting or
repairing the machine.
cCA CAUTION indicates special precautions that must be taken to avoid
damage to the machine.
NOTE: A NOTE provides key information to make procedures easier or clearer.
5FK-9-15-1 4/8/02 1:13 PM Page 2

EBU00011
IMPORTANT NOTICE
This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to
operate this machine on any public street, road or highway.
This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and
regulations in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this machine.
AFFIX DEALER
LABEL HERE
EBU00981
YFZ350R
OWNER’S MANUAL
©2002 by Yamaha Motor Corporation,
U.S.A.
1st edition, March 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission
of Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-16-29
5FK-9-15-1 4/8/02 1:13 PM Page 3

LOCATION OF THE WARNING AND
SPECIFICATION LABELS....................1-1
SAFETY INFORMATION......................2-1
DESCRIPTION AND MACHINE
IDENTIFICATION .................................3-1
Identification number records............3-2
Key identification number..................3-2
Vehicle identification number ............3-3
Model label........................................3-3
CONTROL FUNCTIONS ......................4-1
Main switch........................................4-1
Handlebar switches...........................4-2
Throttle lever .....................................4-3
Throttle OverRide System.................4-4
Speed limiter .....................................4-4
Clutch lever .......................................4-6
Front brake lever ...............................4-6
Brake pedal .......................................4-7
Parking brake ....................................4-7
Shift pedal .........................................4-9
Kick starter ........................................4-9
Fuel tank cap...................................4-10
Fuel cock.........................................4-10
Starter (choke).................................4-11
EBU00014
w
Indicates a potential hazard that could
result in serious injury or death.
CONTENTS
1
2
3
4
5FK-9-15-1 4/8/02 1:13 PM Page 4

Seat.................................................4-12
Front shock absorber
adjustment.....................................4-13
Rear shock absorber
adjustment.....................................4-14
PRE-OPERATION CHECKS ................5-1
Front and rear brakes........................5-3
Fuel ...................................................5-5
Engine mixing oil ...............................5-6
Transmission oil ................................5-7
Chain.................................................5-7
Throttle lever .....................................5-8
Fittings and fasteners........................5-8
Lights.................................................5-8
Switches............................................5-8
Tires ..................................................5-9
How to measure tire pressure .........5-10
Tire wear limit ..................................5-11
OPERATION .........................................6-1
Starting a cold engine........................6-1
Starting a warm engine .....................6-3
Warming up .......................................6-3
Shifting ..............................................6-4
To start out and accelerate................6-5
To decelerate.....................................6-6
Engine break-in .................................6-7
Parking ..............................................6-8
Parking on a slope ............................6-9
Accessories and loading .................6-10
Riding Your ATV ....................................7-1
Getting to know your ATV ..................7-3
Ride with care and good
judgement .......................................7-4
Be careful where you ride ...............7-16
Turning your ATV ............................7-23
Climbing uphill.................................7-25
Riding downhill ................................7-30
5
6
7
5FK-9-15-1 4/8/02 1:13 PM Page 5

Crossing a slope .............................7-32
Crossing through shallow water ......7-34
Riding over rough terrain.................7-36
Sliding and skidding ........................7-38
What to do if... ................................7-40
What to do... ...................................7-40
PERIODIC MAINTENANCE AND
ADJUSTMENT......................................8-1
Owner’s manual and tool kit..............8-1
Periodic maintenance/Lubrication .....8-3
Transmission oil ................................8-6
Cooling system..................................8-8
Spark plug inspection......................8-13
Air filter cleaning..............................8-14
Spark arrester cleaning ...................8-17
Carburetor settings..........................8-19
Idle speed adjustment .....................8-26
Throttle lever adjustment.................8-27
Front and rear brake pad
inspection ......................................8-28
Brake fluid level inspection..............8-29
Brake fluid replacement ..................8-30
Front brake adjustment ...................8-31
Rear brake adjustment....................8-32
Parking brake adjustment ...............8-33
Adjusting the rear brake light
switch ............................................8-35
Clutch adjustment ...........................8-35
Drive chain slack check...................8-36
Drive chain slack adjustment ..........8-36
Lubricating the drive chain ..............8-37
Cable inspection and lubrication .....8-38
Brake and shift pedal/brake and
clutch lever lubrication...................8-39
Front upper and lower arm pivot
lubrication......................................8-39
Rear arm pivot lubrication ...............8-40
Wheel removal ................................8-41
Wheel installation ............................8-41
Replacing the headlight bulb...........8-42
Headlight beam adjustment ............8-43
8
5FK-9-15-1 4/8/02 1:13 PM Page 6

Tail/brake light bulb replacement.....8-44
Troubleshooting...............................8-45
Troubleshooting chart......................8-46
No spark..........................................8-49
CLEANING AND STORAGE ................9-1
A. Cleaning........................................9-1
B. Storage .........................................9-3
SPECIFICATIONS ..............................10-1
NOISE REGULATION.........................11-1
MAINTENANCE RECORD.................12-1
ATV LIMITED WARRANTY ................13-1
9
10
11
12
13
5FK-9-15-1 4/8/02 1:13 PM Page 7

Read and understand all of the labels on your
machine. They contain important information
for safe and proper operation of your ATV.
Never remove any labels from your ATV. If a
label becomes difficult to read or comes off, a
replacement label is available from your
Yamaha dealer.
1-1
EBU00464
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
qe
t
wr y
5FK-9-15-1 4/8/02 1:13 PM Page 8

1-2
qw 1
e
5FE-21568-01
qWARNING
NEVER ride as a
passenger.
Passengers can cause
a loss of control,
resulting in SEVERE
INJURY or DEATH.
5FE-2151H-40
5FE-2151H-01
5FK-21696-01
5FK-9-15-1 4/8/02 1:13 PM Page 9

1-3
r
t y
5FE-21697-01
5FK-9-15-1 4/8/02 1:13 PM Page 10

2-1
EBU00927
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently from other vehicles including motorcycles and cars. A collision or
rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or
over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
8Read this manual and all labels carefully and follow the operating procedures described.
8Never operate an ATV without proper training or instruction. Take a Training Course.
Beginners should receive training from a certified instructor. Contact an authorized ATV dealer
or call 1-800-887-2887 to find out about the training courses nearest you.
8Always follow these age recommendation:
– A child under 16 years old should never operate an ATV with engine size greater than 90cc.
8Never allow a child under age 16 to operate an ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she does not have the abilities to operate it safely.
8Never carry a passenger on an ATV.
qSAFETY INFORMATION 2
5FK-9-15-1 4/8/02 1:13 PM Page 11

2-2
8Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking
lots and streets.
8Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
8Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or
jacket, and long pants.
8Never consume alcohol or drugs before or while operating this ATV.
8Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is
proper for the terrain, visibility and operating conditions, and your experience.
8Never attempt wheelies, jumps, or other stunts.
8Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in this
manual.
8Always keep both hands on the handlebars and both feet on the footpegs of the ATV during
operation.
8Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
5FK-9-15-1 4/8/02 1:13 PM Page 12

2-3
8Never operate on excessively rough, slippery or loose terrain until you have learned and prac-
ticed the skills necessary to control the ATV on such terrain. Always be especially cautious on
these kinds of terrain.
8Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
8Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller
hills before attempting larger hills.
8Always follow proper procedures for climbing hills as described in this manual. Check the ter-
rain carefully before you start up any hill. Never climb hills with excessively slippery or loose
surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear
changes. Never go over the top of a hill at high speed.
8Always follow proper procedures for going down hills and for braking on hills as described in
this manual. Check the terrain carefully before you start down any hill. Shift your weight back-
ward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause
the vehicle to lean sharply to one side. Go straight down the hill where possible.
8Always follow proper procedures for crossing the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the
ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning tech-
nique described in this manual on level ground. Avoid crossing the side of a steep hill if possi-
ble.
5FK-9-15-1 4/8/02 1:13 PM Page 13

2-4
8Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid
stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for braking described in this manual. Dismount on the
uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the
procedure described in this manual.
8Always check for obstacles before operating in a new area.
Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always fol-
low proper procedures when operating over obstacles as described in this manual.
8Always be careful when skidding or sliding. Learn to safely control skidding or sliding by prac-
ticing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice,
go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con-
trol.
8Never operate an ATV in fast flowing water or in water deeper than that recommended in this
manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
8Always use the size and type tires specified in this manual.
Always maintain proper tire pressure as described in this manual.
8Never modify an ATV through improper installation or use of accessories.
5FK-9-15-1 4/8/02 1:13 PM Page 14

8Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY,
call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s
Safety Hotline at 1-800-852-5344.
2-5
5FK-9-15-1 4/8/02 1:13 PM Page 15

2-6
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could
be burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refuel-
ing.
Do not refuel right after the engine has
been running and is still very hot.
Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or while in
the vicinity of sparks, open flames, or
other sources of ignition such as the
pilot lights of water heaters and clothes
dryers.
qWARNING When transporting the ATV in another
vehicle, be sure it is kept upright and
that the fuel cock is in the “OFF” posi-
tion. Otherwise, fuel may leak out of the
carburetor or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause
injuries.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your
doctor immediately.
If gasoline spills on your skin, wash with
soap and water. If gasoline spills on
your clothing, change your clothes.
5FK-9-15-1 4/8/02 1:13 PM Page 16

2-7
POTENTIAL HAZARD
Starting or running the engine in a
closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with
adequate ventilation.
qWARNING
5FK-9-15-1 4/8/02 1:13 PM Page 17

3-1
1. Tail/brake light 12. Rear shock absorber
2. Seat 13. Spark arrester
3. Kick starter 14. Rear wheel
4. Fuel tank cap 15. Starter (choke)
5. Headlight 16. Shift pedal
6. Brake pedal 17. Clutch lever
7. Rear brake light switch 18. Parking brake
8. Front wheel 19. Main switch
9. Front shock absorber 20. Front brake lever
10. Radiator 21. Throttle lever
11. Fuel cock 22. Handlebar switch
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
EBU00032
DESCRIPTION AND MACHINE IDENTIFICATION
wer t
y
q
u
io!0 !1 !2 !3!4
!5!6
!7 !8 !9 @0
@1
@2
5FK-9-15-1 4/8/02 1:13 PM Page 18