Yamaha YFM350 Bruin Grizzly 4X4 YFM400 Kodiak 4WD 2003-2010 Service Repair Manual

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Taper: Atv

Distributeur:

UGS: 85100

Mots clés: 2003 2004 2005 2006 2007 2008 2009 2010 ATV Bruin Models Powersports Yamaha YFM350 Bruin Grizzly 4X4 YFM400 Kodiak 4WD

Variantes de produits

Description

This manual covers the YFM350 Bruin Grizzly and YFM400 Kodiak all-terrain vehicles produced between 2003 and 2010. These versatile utility ATVs are known for their robust engineering, reliability, and user-friendly automatic transmissions, making them suitable for a wide range of recreational and work applications. The Bruin and Kodiak lines represent a commitment to durable, capable off-road vehicles, offering features like selectable 2WD/4WD and efficient liquid-cooled engines across various configurations, including 2WD, 4WD, and specialized Hunter editions. This comprehensive workshop service repair manual provides detailed information essential for the maintenance, troubleshooting, and repair of your ATV. It covers all aspects of the vehicle, from general information and specifications to in-depth procedures for the engine, cooling system, fuel system, drivetrain, chassis, and electrical system. With step-by-step instructions, high-quality diagrams, and detailed troubleshooting guides, this manual is an indispensable resource for owners and technicians alike, ensuring optimal performance and longevity of your Bruin or Kodiak.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YFM350 Bruin Grizzly / YFM400 Kodiak

Model Variants:

• YFM350 Bruin

• YFM350 Bruin 4x4

• YFM350 Bruin Auto 2WD

• YFM350 Bruin Auto 4x4

• YFM400 Kodiak

• YFM400 Kodiak 2WD

• YFM400 Kodiak 4WD

• YFM400 Kodiak 4x4 Hunter

• YFM400 Kodiak Auto 4x4

Model Years Covered:

2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Product Type:

Service Repair Manual (PDF Download)

👋 Introduction

Market Position

Target Audience:

Owners and mechanics seeking detailed repair and maintenance information for Yamaha ATVs.

Competitive Analysis

Value Proposition:

Provides comprehensive, DIY-friendly guidance for a wide range of model years and variants, saving on dealership service costs.

Key Features

Manual Advantage:

Encompasses multiple model years and variants, offering a broad spectrum of repair knowledge in a single, accessible PDF.

📋 Manual Details

Coverage Areas

Scope:

Comprehensive from front bumper to rear

Detailed Sections:

• General Information

• Specifications

• Periodic Checks and Adjustments

• Engine

• Cooling System

• Carburetion

• Drive Train

• Chassis

• Electrical System

• Troubleshooting

Specific Model Years:

Explicitly covers 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 model years, including specific variant codes listed in product information.

Page Count

Estimated Page Count:

Likely several hundred pages (typical for comprehensive service manuals, actual count not provided but implied by scope and file size).

Manual Type

Type:

Workshop Service Repair Manual

Purpose:

Intended for DIY repairs and comprehensive maintenance, providing step-by-step instructions and technical data.

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Mechanical Systems:

• Engine (internal components, cylinder head, piston, crankshaft, etc.)

• Cooling System (radiator, fan, coolant flow)

• Fuel System (carburetor, fuel pump, fuel lines)

• Lubrication System (oil pump, oil passages)

• Ignition System (spark plugs, ignition coil, CDI unit)

• Exhaust System

• Transmission/Drive Train (CVT, gearbox, driveshafts, differentials, final drive)

• Suspension System (front and rear suspension, shocks, A-arms)

• Braking System (hydraulic brakes, calipers, master cylinder, brake lines)

• Steering System

• Frame and Bodywork

Electrical Systems:

• Battery and Charging System (stator, regulator/rectifier)

• Ignition System

• Lighting System (headlights, taillights, brake lights)

• Instrumentation (speedometer, indicator lights)

• Wiring Diagrams

• Starter System

Vehicle Specific Systems:

4x4 drivetrain operation, Ultramatic transmission engagement and maintenance, handlebar controls, lighting, and instrument panel functions.

Procedures Included

Maintenance And Routine Service:

• Oil and filter changes

• Spark plug replacement

• Air filter cleaning/replacement

• Coolant checks and flushes

• Brake fluid checks and changes

• Lubrication points

• Tire pressure and wear checks

• Battery maintenance

• Carburetor cleaning and adjustment

• Drive belt inspection and replacement (CVT)

Repair And Rebuild:

• Engine disassembly and reassembly

• Transmission overhaul

• Suspension component replacement

• Brake system repair

• Electrical component troubleshooting and replacement

• Carburetor rebuilding

• Chassis alignment and repair

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault finding guides, symptom analysis.

Diagnostic Procedures:

Includes detailed troubleshooting trees and diagnostic steps for electrical issues, starting problems, running issues, and drive train malfunctions.

Technical Depth

Depth:

Complete workshop level detail, suitable for DIY mechanics and professional technicians. Covers detailed disassembly, assembly, specifications, and diagnostic procedures.

Wiring Diagrams:

Detailed electrical wiring diagrams are included for accurate diagnosis and repair of electrical systems.

📊 Manual Specifications

File Format

Quality:

High quality diagrams and instructions, searchable text (typical for well-produced PDFs).

Compatibility:

Compatible with all versions of Windows & Mac.

File Size Potential:

Up to 1 Gigabyte (indicative of comprehensive content).

Print Quality

Printability:

Designed for digital access, but printable for workshop use.

Binding Type

Type:

N/A (Digital PDF Download)

Paper Type

Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Type:

Four-stroke, SOHC, 4-valve, single-cylinder (common across most variants).

Displacement Yfm350:

348cc

Displacement Yfm400:

400cc class (specific variants might vary slightly, but generally around this range).

Bore X Stroke Yfm350:

72.5 mm x 65.0 mm (approximate, consult manual for exact spec).

Performance

Cooling System:

Liquid-cooled (radiator and fan) for most models, some early variants might have air-cooling components or specifications.

Compression Ratio:

Approximately 9.2:1 (consult manual for exact spec).

Fuel System

Carburetion:

Teikei or Mikuni carburetors (specific model depends on year/variant, e.g., Teikei Y26P for YFM350).

Ignition:

DC-CDI (Digital CDI)

Fuel Type:

Unleaded gasoline, minimum octane rating of 87.

Lubrication

Oil Type:

Yamaha recommends Yamalube or equivalent SAE 10W-40 API SG or higher oil.

Oil Capacity:

Approximately 1.7-1.8 Liters (check manual for exact specification per model).

🔧 Transmission

Standard

Type:

Automatic Ultramatic Transmission (CVT - Continuously Variable Transmission)

Optional

Features:

Includes engine braking capabilities.

Features

Drive Modes:

2WD/4WD selectable (on applicable models).

Transmission Fluid:

Yamaha recommends Yamalube ATV Special or equivalent SAE 10W-30 API SE, SF, SG type transmission oil.

📐 Dimensions

Exterior

General Layout:

Full-size ATV with independent front suspension and swingarm rear suspension.

Weights

Dry Weight Approx:

Around 250-270 kg (600-670 lbs), varies by model and specific features like 2WD/4WD.

Fuel Capacity:

Approximately 14 Liters (3.7 Gallons).

🛡️ Safety Features

Ratings

Atv Safety Considerations:

Standard ATV safety precautions apply. Manual will detail safe operation, pre-ride checks, and maintenance for safe performance.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Passive Features

Lighting:

Dual 30W halogen headlights, 8W/27W taillight/brake light.

💡 Technology Features

Infotainment

Features:

Primarily utility-focused; does not typically feature advanced infotainment systems. Basic digital displays for odometer, trip meter, gear indicator, and warning lights.

Driver Assistance

Features:

Selectable 2WD/4WD is the primary driver assistance technology. Some models may have differential lock indicators or features.

Connectivity

Features:

N/A (No electronic connectivity features typical for this era and class of ATV).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1,000 km (600 miles) or 6 months, whichever comes first (or more frequently under severe use). Consult manual for exact intervals.

Spark Plug Check Replace:

Check every 2,000 km (1,200 miles), replace as needed. Specific plug type: NGK CR7E or equivalent.

Air Filter Cleaning:

Inspect every 1,000 km (600 miles), clean as needed. Replace if damaged.

Cv Belt Inspection:

Inspect every 2,000 km (1,200 miles) for wear and damage.

Coolant Change:

Every 2 years or 24,000 km (15,000 miles) (refer to manual for specific interval for ATVs).

Fluid Specifications

Engine Oil Spec:

Yamalube or equivalent SAE 10W-40 API SG or higher.

Transmission Oil Spec:

Yamalube ATV Special or equivalent SAE 10W-30 API SE, SF, SG type.

Brake Fluid Spec:

DOT 3 or DOT 4 hydraulic brake fluid.

Coolant Spec:

Use a 50/50 mixture of antifreeze and de-ionized water. Specific coolant type typically required is ethylene glycol-based.

Known Issues

Common Wear Items:

• CVT belt wear

• Front suspension bushings

• Brake pad wear

• Carburetor jet clogging (if not maintained)

Typical Repairs:

Carburetor cleaning/rebuild, suspension component replacement, CVT belt replacement, routine fluid changes.

Electrical Components:

Potential for stator failure or voltage regulator issues, especially on higher-mileage units. Troubleshooting guidance for these is crucial.

📚 Vehicle History

Brand Heritage

Yamaha Atv Legacy:

Yamaha has a long-standing reputation for robust and reliable ATVs, with the Grizzly and Kodiak lines being core offerings in the utility ATV segment.

Model Evolution

Bruin Kodiak Positioning:

The Bruin (350cc) and Kodiak (400cc) models represent Yamaha's mid-range utility ATVs, known for their versatility, durability, and user-friendly operation, particularly the automatic transmission.

Production

Manufacturing Origin:

Yamaha Motor Corporation, primarily manufactured in Japan and/or North America.

🏆 Awards & Recognition

Recognitions

Industry Reputation:

Yamaha Grizzly and Kodiak models are consistently well-regarded in the utility ATV market for their reliability, durability, and capability.