Yamaha BRUIN 350 400 2004 2005 2006 Workshop Repair Manual

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Tipo: Atv

Proveedor:

SKU: 91208

Etiquetas: 2004 2005 2006 ATV BRUIN 350 BRUIN 400 Bruin Models Powersports Yamaha

Variantes de producto

Descripción

This manual covers the utility all-terrain vehicles, produced between 2004 and 2006. Known for their reliable engines, selectable 4WD, and comfortable independent front suspension, these ATVs are designed for a range of uses, from recreational riding to property management and agricultural tasks. The Bruin series emphasizes a balance of capability and user-friendliness, making it a dependable choice for various demanding applications. This comprehensive workshop repair manual provides in-depth guidance for the repair, maintenance, and restoration of your vehicle. It details procedures for all major systems, including the engine, transmission, drivetrain, brakes, suspension, steering, and electrical components. With clear, step-by-step instructions, detailed illustrations, and factory specifications, this manual is an essential resource for owners and technicians aiming to keep their vehicle in optimal condition and ensure its longevity.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Bruin 350 / Bruin 400

Model Variants:

350, 400

Production Years Covered:

2004, 2005, 2006

Generation

Generation Code:

YFM350X (350), YFM400K (400)

👋 Introduction

Market Position

Vehicle Segment:

Utility All-Terrain Vehicle (ATV)

Target Audience:

Recreational riders, utility users, property owners, agricultural use.

Competitive Analysis

Key Competitors:

Honda FourTrax, Polaris Sportsman, Arctic Cat 400/500, Suzuki King Quad, Kawasaki Bayou/Prairie.

Key Features

Features:

Reliable Yamaha engine, selectable 4WD, automatic transmission, independent front suspension, comfortable seating.

📋 Manual Details

Coverage Areas

Overall Coverage:

Comprehensive repair, maintenance, restoration, and diagnosis

System Coverage Summary:

Engine, transmission, chassis, electrical, bodywork, suspension, steering, brakes, fuel system, cooling system, exhaust system, drivetrain.

Page Count

Estimated Page Count:

High, likely 500+ pages (based on typical workshop manuals and file size mention)

Manual Type

Type:

Workshop Repair Manual

Origin:

Original Manufacturer (Yamaha)

Language

Language:

English (implied by product description, typical for international manuals)

Format

Digital Format:

PDF Download

File Size Potential:

Up to 5 GB

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, internal component specifications, timing, ignition, lubrication, cooling, fuel delivery, emissions.

Transmission:

Automatic transmission (CVT) disassembly, assembly, adjustments, fluid specifications, troubleshooting.

Drivetrain:

Driveshaft, differential (front/rear), 4WD system engagement, wheel hubs, CV joints.

Brakes:

Hydraulic system, brake caliper servicing, pad replacement, bleeding procedure, master cylinder, parking brake.

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications.

Steering:

Handlebar assembly, steering shaft, tie rods, steering knuckle servicing, lubrication.

Electrical:

Wiring diagrams, lighting system, starting system, charging system (alternator/stator), battery maintenance, fuses, relays, ignition system components.

Fuel System:

Carburetor (Mikuni BSR33), fuel tank, fuel pump, fuel lines, filters, choke operation.

Cooling System:

Radiator, fan, coolant, thermostat, water pump, hose replacement.

Exhaust System:

Muffler, exhaust pipe, heat shields, inspection, replacement.

Body And Chassis:

Frame inspection, body panels, plastics, seat removal, fender maintenance, rack installation.

Procedures Included

Maintenance:

Regular servicing, oil changes, filter replacements, lubrication points, valve adjustments, spark plug replacement.

Repair:

Component removal, installation, replacement, and adjustment for all covered systems.

Troubleshooting:

Diagnostic charts, symptom analysis, root cause identification for common problems.

Rebuilding:

Detailed instructions for engine and transmission rebuilds.

Diagnostics:

Electrical system diagnostics, fuel system checks, engine performance analysis.

Specifications:

Torque values, clearances, fluid capacities, electrical resistance, engine specifications.

Technical Depth

Depth:

Factory-level detail suitable for professional technicians and advanced DIY users.

Illustrations:

Clear, step-by-step illustrated instructions, exploded views, zoomable illustrations.

Component Breakdowns:

Detailed breakdowns of all major and minor components.

Part Identification:

Detailed breakdown of all part numbers for every aspect of the vehicle.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable within the PDF document.

Print Quality

Print Ability:

Printable from any computer and printer.

Illustration Quality:

High quality, designed for clarity and detail.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

Delivery

Delivery Method:

Instant Digital Download

Download Window:

Three days after payment

Support:

Free support available for download issues.

⚙️ Engine Specifications

Primary Engine

Engine Type 350:

4-stroke, SOHC, 2-valve, single cylinder

Engine Type 400:

4-stroke, SOHC, 4-valve, single cylinder (often a variant of the Raptor 350/660 engine architecture, but 400cc)

Bore X Stroke 350:

81.0 mm x 81.2 mm

Bore X Stroke 400:

84.0 mm x 70.0 mm (approximate, specific to Bruin 400)

Displacement 350:

348cc

Displacement 400:

386cc (approximate, specific to Bruin 400)

Cooling System:

Liquid-cooled

Performance

Horsepower 350:

Approx. 21 HP @ 6500 RPM

Torque 350:

Approx. 20 lb-ft @ 5500 RPM

Horsepower 400:

Approx. 23 HP @ 6000 RPM

Torque 400:

Approx. 25 lb-ft @ 5000 RPM

Fuel System

Fuel Delivery:

Carburetor (Mikuni BSR33, single)

Fuel Type:

Unleaded gasoline (87 octane recommended)

Fuel Tank Capacity:

3.7 gallons (14 L)

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Engine Components

Spark Plug 350:

NGK CR6HSA or Denso U20FS-U

Spark Plug 400:

NGK CR7HSA or Denso U22FS-U (likely)

🔧 Transmission

Standard

Type:

Automatic (CVT - Constant Variable Transmission) with reverse

Drive System:

Shaft Drive

Features

Drive Modes:

2WD / 4WD (selectable, often push-button on handlebars)

Transmission Fluid Spec:

Yamaha Genuine ATF Type-III or equivalent DEXRON-III compatible fluid

Transmission Fluid Capacity:

Refer to manual for exact specification, typically around 0.5-0.7 L

📐 Dimensions

Exterior

Overall Length:

Approx. 77.2 inches (1960 mm)

Overall Width:

Approx. 45.7 inches (1160 mm)

Overall Height:

Approx. 43.3 inches (1100 mm)

Wheelbase:

Approx. 49.2 inches (1250 mm)

Weights

Dry Weight 350:

Approx. 573 lbs (260 kg)

Dry Weight 400:

Approx. 595 lbs (270 kg)

Ground Clearance:

Approx. 7.4 inches (188 mm)

Cargo

Front Rack Capacity:

Approx. 88 lbs (40 kg)

Rear Rack Capacity:

Approx. 176 lbs (80 kg)

🛡️ Safety Features

Ratings

Safety Certification:

Meets EPA emissions standards. Not intended for highway use.

Active Features

Brakes:

Hydraulic disc brakes front and rear

Parking Brake:

Drum brake on rear axle, operated by lever

Passive Features

Lighting:

Dual halogen headlights, taillight, brake light

Chassis Design:

Rugged steel frame for durability

💡 Technology Features

Infotainment

Infotainment System:

Basic analog instrument cluster (speedometer, odometer, fuel gauge, warning lights). No advanced infotainment features.

Driver Assistance

Driver Assistance Features:

Selectable 2WD/4WD system.

Connectivity

Connectivity Features:

None (basic utility vehicle design).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 6 months, whichever comes first.

Air Filter Cleaning:

Every 20 hours or 3 months, replace as needed.

Spark Plug Inspection:

Every 100 hours or 12 months.

Valve Clearance Check:

Every 500 hours or 24 months.

Fluid Specifications

Engine Oil Type:

Yamaha Genuine Yamalube 4 (or equivalent 4-stroke motorcycle oil) 10W-30 or 10W-40

Engine Oil Capacity:

Approx. 2.2 L (2.3 US qt) with filter change

Coolant Type:

Yamaha Genuine All-Weather Coolant (or equivalent ethylene glycol based coolant with corrosion inhibitors) mixed 50/50 with distilled water.

Coolant Capacity:

Approx. 1.6 L (1.7 US qt)

Known Issues

Common Wear Items:

Brake pads, suspension bushings, tie rod ends, drive belts (CVT).

Potential Issues:

Carburetor gumming if fuel sits too long, occasional starter solenoid issues, CV joint boot tears if not inspected regularly.

📚 Vehicle History

Brand Heritage

Yamaha Atv History:

Yamaha has a long-standing reputation for producing reliable and performance-oriented ATVs since the introduction of the ATV (All-Terrain Vehicle) in the early 1980s with the YT125 Tri-Moto.

Model Evolution

Bruin Lineage:

The Bruin series was introduced to offer a more utility-focused and comfortable ATV compared to Yamaha's sport-oriented models like the Warrior and Banshee. It positioned itself as a workhorse for various tasks while still being enjoyable for recreational riding.

Production

Manufacturing Location:

Likely manufactured in Japan or North America by Yamaha Motor Corporation.