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Yamaha Bruin 350 4x4 ATV 2004-2006 Service Repair Workshop Manual

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The Bruin 350 4x4 (YFM350FGH) is a versatile All-Terrain Vehicle (ATV) manufactured for the model years 2004, 2005, and 2006. Engineered with a reliable air-cooled, 348cc, SOHC, 4-stroke engine and...
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Taper: Atv
Distributeur:
UGS: 98998
Yamaha Bruin 350 4x4 ATV 2004-2006 Service Repair Workshop Manual
The Bruin 350 4x4 (YFM350FGH) is a versatile All-Terrain Vehicle (ATV) manufactured for the model years 2004, 2005, and 2006. Engineered with a reliable air-cooled, 348cc, SOHC, 4-stroke engine and featuring renowned Ultramatic Automatic Transmission with high/low range and reverse, this ATV is well-suited for recreational riding, light work, and navigating challenging trails. Its robust 4x4 drivetrain, independent front suspension, and hydraulic disc brakes ensure capable performance and confident control in various conditions. The Bruin 350 4x4 embodies a legacy of producing dependable and user-friendly ATVs, offering a balanced combination of power, comfort, and durability. This comprehensive Service Repair Workshop Manual in English provides detailed information for maintaining and repairing your Bruin 350 4x4. It covers all essential systems, including the engine, transmission, drivetrain, suspension, brakes, steering, and electrical components. The manual offers step-by-step procedures for routine maintenance, diagnostics, and complex repairs, supported by hundreds of detailed photos and exploded diagrams. Essential technical specifications, fluid recommendations, and troubleshooting guidance are included to empower owners, DIY mechanics, and professional technicians in keeping the ATV in optimal condition and ensuring its longevity.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Bruin 350 4x4
Model Variant:
YFM350FGH
Production Years Covered:
2004, 2005, 2006
Category:
All-Terrain Vehicle (ATV)
Drivetrain:
4x4 (Four-wheel drive)
👋 Introduction
Market Position
Segment:
Mid-size utility ATV, popular for recreational riding, light work, and trail use.
Competitive Analysis
Competitors:
Suzuki King Quad 300/345, Honda FourTrax 350 4x4, Kawasaki Prairie 360 4x4, Polaris Sportsman 400/500 (earlier models).
Key Features Vehicle
Engine Type:
Air-cooled, SOHC, 4-stroke, single-cylinder.
Transmission Type:
Ultramatic Automatic Transmission with High/Low range and Reverse.
Drive System:
Shaft drive with on-demand 4WD engagement and locking front differential.
Suspension Front:
Independent double-wishbone with pre-load adjustable shocks.
Suspension Rear:
Swingarm with pre-load adjustable shock.
Braking System:
Hydraulic disc brakes front and rear.
Tire Size Front:
AT25x8-12
Tire Size Rear:
AT25x10-12
Manual Value Proposition
Target Audience:
DIY mechanics, ATV owners, technicians seeking in-depth repair and maintenance information.
Benefits:
Empowers owners to perform maintenance and repairs, saving on labor costs and extending vehicle life; provides detailed technical specifications and troubleshooting guidance.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Workshop Manual
Language:
English
Format:
Digital Download (PDF)
Distribution:
Instant Download
Licensing:
Lifetime Use, No Expiry
Platform Compatibility:
Windows and MAC Computers, Tablets, Smartphones
Manual Specifications
File Format:
PDF (Portable Document Format)
Print Quality:
Printable pages, allowing for paper copies of any section or the entire manual.
Binding Type:
N/A (Digital format, no physical binding)
Paper Type:
N/A (Digital format, no physical paper)
Searchable:
Yes (Typically PDF search functionality available)
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive engine overhaul, diagnostics, tuning, lubrication system, cooling system, fuel system, ignition system, emission control system, engine disassembly and reassembly.
Transmission:
Automatic transmission (Ultramatic) service, maintenance, troubleshooting, removal, installation, internal components, fluid specifications, torque converter.
Drivetrain:
Front and rear differential service, driveshafts, CV joints, propeller shafts, hub assemblies, four-wheel drive engagement system.
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, ball joints, bushings, steering knuckle, wheel bearings, geometry adjustments.
Brakes:
Hydraulic brake system, front and rear brake caliper service, brake pad replacement, rotor inspection/replacement, brake fluid flush, bleeding procedures, parking brake mechanism.
Steering:
Steering column, tie rods, steering rack, steering knuckle, universal joints, adjustments, troubleshooting.
Electrical:
Starter system, charging system (generator/stator, regulator/rectifier), battery maintenance, lighting system (headlights, taillights, brake lights), ignition system components, wiring diagrams, fuses, relays, switches, troubleshooting electrical faults.
Body Chassis:
Frame inspection and repair, body panel removal/installation, fenders, racks, seat, handlebar, footrests, plastics, fairings, and trim components.
Fuel System:
Carburetor service, cleaning, adjustment, fuel pump, fuel lines, fuel tank maintenance, fuel filter replacement.
Cooling System:
Radiator, cooling fan, thermostat, coolant specifications, flushing, leak testing.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, tire pressure checks, chain/belt adjustments (if applicable), battery checks, general inspection checklists.
Troubleshooting:
Step-by-step diagnostic procedures for common problems, symptom-based troubleshooting charts, fault code interpretation (if applicable).
Repair Procedures:
Detailed instructions for component removal, installation, rebuilding, and replacement.
Special Tools:
Identification and usage of specific tools required for various repair and maintenance tasks.
Technical Depth
Depth Level:
Comprehensive; covers basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and electrical system repairs.
Diagrams Illustrations:
Hundreds of detailed photos and exploded diagrams for clear visual guidance.
⚙️ Engine Specifications
Primary Engine
Engine Code:
4XF (Likely, specific code may vary slightly).
Engine Type:
Single-cylinder, 4-stroke, SOHC, 2-valve.
Displacement:
348 cc (21.2 cu. in.)
Bore:
83.0 mm (3.27 in.)
Stroke:
64.5 mm (2.54 in.)
Compression Ratio:
9.2:1
Cooling System:
Forced air cooling with an auxiliary fan.
Performance
Horsepower Est:
Approximately 19-22 HP (Varies with tuning and conditions).
Torque Est:
Approximately 18-20 lb-ft (Varies with tuning and conditions).
Fuel System
Carburetor Type:
Mikuni BSR33/1 (Single).
Fuel Type:
Unleaded gasoline (87 octane or higher recommended).
Fuel Tank Capacity:
3.2 U.S. gal. (12 L) including 0.7 U.S. gal. (2.7 L) reserve.
Lubrication System
Oil Type:
Yamalube 4 (or SAE 10W-30) API service SG or higher.
Oil Capacity W Filter:
1.70 L (1.80 US qt)
Oil Filter Part Number Yamaha:
5JX-13440-00-00 or equivalent.
🔧 Transmission
Standard
Type:
Ultramatic Automatic Transmission (CVT - Continuously Variable Transmission).
Gear Selection:
Forward (High/Low range), Neutral, Reverse.
Drive Type:
Shaft drive.
Transmission Fluid Type:
Yamalube 4 (or SAE 10W-30) API service SG or higher (same as engine oil).
Transmission Fluid Capacity:
1.20 L (1.27 US qt).
📐 Dimensions
Exterior
Length:
1995 mm (78.5 in.)
Width:
1075 mm (42.3 in.)
Height:
1155 mm (45.5 in.)
Wheelbase:
1280 mm (50.4 in.)
Ground Clearance:
240 mm (9.4 in.)
Weights
Dry Weight:
255 kg (562 lbs)
Wet Weight:
268 kg (591 lbs)
Cargo
Front Rack Capacity:
99 lbs (45 kg)
Rear Rack Capacity:
187 lbs (85 kg)
Towing Capacity:
N/A (Not designed for towing)
🛡️ Safety Features
Ratings
Atv Safety Standards:
Compliant with ANSI/SVIA 1-2003 and 2010 standards (typical for Yamaha ATVs of this era).
Active Features
Braking System Type:
Hydraulic disc brakes front and rear offer strong stopping power.
4Wd System:
On-demand 4WD with locking differential enhances traction in challenging terrain.
Passive Features
Chassis Design:
Durable steel frame provides a stable platform.
Ergonomics:
Comfortable seating position and handlebar placement for rider control.
💡 Technology Features
Infotainment
Audio System:
N/A (No integrated infotainment system, typically aftermarket options available).
Driver Assistance
Traction Control:
N/A (No electronic traction control).
Hill Descent Control:
N/A.
Connectivity
Bluetooth Usb:
N/A (No built-in connectivity features).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1,000 km (600 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 1,000 km (600 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 500 km (300 miles) or monthly; replace as needed.
Spark Plug Inspection:
Every 1,000 km (600 miles) or 6 months.
Brake Fluid Change:
Every 2 years or as needed.
Transmission Oil Change:
Every 1,000 km (600 miles) or 6 months, whichever comes first.
Fluid Specifications
Engine Oil:
Yamalube 4, SAE 10W-30 (API SG or higher).
Transmission Fluid:
Yamalube 4, SAE 10W-30 (API SG or higher).
Brake Fluid:
DOT 3 or DOT 4.
Known Issues
Carburetor Clogging:
Can be prone to fuel-related clogging if fuel is left standing for extended periods, requiring cleaning or rebuild.
Cv Joint Wear:
High mileage or aggressive use can lead to wear on CV joints and boots, requiring replacement.
Cooling Fan Reliability:
Occasional issues with the electric cooling fan engaging or operating correctly may arise, often related to wiring or the fan motor itself.
Starter Solenoid Failure:
A common point of failure on many ATVs of this era, leading to inability to crank the engine.
📚 Vehicle History
Brand Heritage
Yamaha Atv Legacy:
Yamaha has a long history of producing reliable and innovative ATVs, dating back to the early days of the sport.
Model Evolution
Bruin Positioning:
The Bruin 350 4x4 was introduced as a capable mid-size utility ATV, bridging the gap between smaller recreational models and larger, more powerful utility ATVs. It aimed to offer a blend of comfort, ease of use, and reliable 4WD performance.
Predecessors Successors:
The Bruin 350 4x4 succeeded models like the Timberwolf 250 4x4 and was eventually replaced by the Grizzly 350 4x4, which offered a more robust chassis, more features, and a slightly different styling, though sharing many of the same core mechanical components and the same engine family.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the Bruin 350 4x4 are not widely publicized, Yamaha ATVs are consistently recognized for reliability and performance within the powersports industry.
Ratings
Owner Satisfaction:
Generally high owner satisfaction due to robust engineering and longevity, a hallmark of Yamaha products.
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