Segment:
Mid-size utility ATV, known for its reliable 4WD system and versatility for recreational and light work tasks.
Competitors:
Honda Foreman, Kawasaki Prairie, Suzuki King Quad, Polaris Sportsman (similar displacement models of the era).
Standout Features:
Robust 4WD system, reliable air-cooled engine, comfortable riding position, and a reputation for durability within its class.
Primary Coverage:
All Models and Repairs A-Z
Secondary Coverage:
Mechanical, Electrical, Troubleshooting, Maintenance, Repair
Estimated Page Count:
Not specified, but described as 'Tons of detailed pictures & diagrams'.
Type:
Workshop Service Repair Manual
Engine:
Complete engine overhaul, internal components, cooling system, lubrication system, fuel system (carburetor, fuel pump, lines), ignition system, exhaust system.
Transmission:
Automatic transmission (likely Ultramatic), gear shifting mechanisms, clutch, lubrication, maintenance, and repair procedures.
Drivetrain:
4WD system operation, front and rear differentials, driveshafts, CV joints, hubs, and related components.
Suspension:
Front and rear suspension components (shocks, springs, control arms), wheel bearings, alignment procedures.
Brakes:
Front and rear brake systems (hydraulic disc brakes), master cylinder, calipers, brake lines, pads, rotors, and bleeding procedures.
Electrical:
Wiring diagrams, lighting system, starting system, charging system (stator, rectifier/regulator), battery, fuses, relays, sensors, and basic electrical troubleshooting.
Chassis:
Frame inspection and repair, body panels, handlebars, controls, seating, and accessory mounting.
Maintenance:
Regular service intervals, oil changes, filter replacements, lubrication points, valve adjustments, spark plug replacement, and battery maintenance.
Repair:
Complete step-by-step repair instructions for all major and minor components, including engine teardown, transmission rebuild, suspension overhauls, and electrical component replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, and diagnostic flowcharts.
Diagnostics:
Identification of faulty components, testing methods for electrical and mechanical systems, and interpretation of diagnostic codes (if applicable).
Depth:
Comprehensive, covering everything from basic rider maintenance to complete engine and transmission rebuilds. Detailed torque specifications, measurements, and clearances.
๐ Manual Specifications
Searchability:
Likely text-searchable PDF for easy navigation and information retrieval.
Print Capability:
All pages are printable.
Binding:
N/A (Digital download, printing and binding are user's responsibility).
Paper Quality:
N/A (Digital download, but historically service manuals are printed on durable, often glossy paper for shop environments).
โ๏ธ Engine Specifications
Engine Type:
Four-stroke, SOHC, Air-cooled
Bore X Stroke:
83 mm x 64.5 mm
Lubrication System:
Wet sump with oil cooler
Horsepower:
Approximately 19-20 HP (exact figures vary by dyno and test conditions, typically not published by manufacturer for ATVs).
Torque:
Approximately 20-22 lb-ft (exact figures vary, typically not published by manufacturer for ATVs).
Carburetor:
Teikei Y26 with TPS (Throttle Position Sensor)
Fuel Type:
Unleaded gasoline, 87 octane or higher
Ignition System:
CDI (Capacitor Discharge Ignition) with TCI (Transistor Controlled Ignition)
Cooling Method:
Forced Air Cooling with Oil Cooler
Length:
Approximately 76.1 inches (1933 mm)
Width:
Approximately 42.7 inches (1085 mm)
Height:
Approximately 45.1 inches (1145 mm)
Wheelbase:
Approximately 49.2 inches (1250 mm)
Dry Weight:
Approximately 559 lbs (253 kg)
Ground Clearance:
Approximately 7.2 inches (184 mm)
Front Rack Capacity:
33 lbs (15 kg)
Rear Rack Capacity:
176 lbs (80 kg)
Towing Capacity:
N/A (ATVs are generally not rated for towing in the same manner as vehicles)
Safety Standard Compliance:
Complies with ANSI standards.
Braking System:
Hydraulic disc brakes front and rear.
4Wd Engagement:
On-Commandยฎ 2WD/4WD system for adaptable traction.
Chassis Design:
Rugged steel frame for stability and durability.
Lighting:
Dual halogen headlights and a rear brake light.
Display:
Digital LCD multi-function meter displaying speedometer, odometer, tripmeter, clock, 2WD/4WD indicator, and gear indicator (likely a basic setup).
Traction Control:
Not applicable for this model; relies on mechanical 4WD system and rider input.
Connectivity Features:
N/A (No integrated Bluetooth or smartphone connectivity).
Oil Change Interval:
Every 1,000 km or 6 months, whichever comes first (refer to manual for precise details based on usage).
Air Filter Cleaning:
Regular inspection and cleaning, especially in dusty conditions. Replacement as needed.
Spark Plug Replacement:
Recommended every 3,000 km or as per manual's schedule.
Valve Adjustment Interval:
First check at 1,000 km, then every 3,000 km or as specified.
Engine Oil Type:
Yamaha Genuine Yamalube 4 Stroke SAE 10W-40 or 20W-40, API SG or higher (refer to manual for exact specification and API category).
Engine Oil Capacity:
Approximately 1.90 L (2.0 US qt) without filter change, 2.10 L (2.2 US qt) with filter change.
Gear Oil Type:
Yamaha Genuine Gear Oil SAE 80 or 90 API GL-4 (for final drive and gearbox).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Brake pads, wheel bearings, CV boots, drive belts (if applicable), and general suspension components due to off-road use.
Potential Issues:
Overheating in extreme conditions (due to air cooling), carburetor tuning sensitivity, potential for CVT belt wear if operated aggressively.
Manufacturer:
Yamaha Motor Corporation, known for its long history in powersports and musical instruments.
Predecessors:
The Grizzly 350 4WD succeeded earlier Yamaha 2WD and 4WD utility ATVs, building on their proven designs.
Positioning:
Positioned as a value-oriented, reliable mid-size utility ATV, offering essential features for recreational riding and light utility work.
Production Years Covered:
2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Manufacturing Location:
Likely manufactured in Japan or the United States by Yamaha.
