2008 Yamaha Grizzly 350 Service Manual

The 2008 Yamaha Grizzly 350 is a four-wheel-drive all-terrain vehicle (ATV) featuring a 348cc air-cooled, four-stroke engine, Ultramatic automatic transmission with engine braking, On-Command 2WD/4WD with differential lock, independent front and rear suspension, front and rear hydraulic disc brakes, electric start, and a towing capacity of 850 lbs. This manual provides comprehensive information for maintenance, troubleshooting, and repair procedures to ensure optimal performance and safety.

Features at a Glance

Key components: 348cc engine, Ultramatic transmission, On-Command 4WD system, front and rear racks, digital instrument panel, and towing hitch.

Installation & Assembly

Uncrate and inspect all components. Assembly requires basic tools.

1. Install handlebars: Align and tighten clamp bolts to specified torque.
2. Install front wheels: Mount wheels, install axle nuts, and tighten to specification.
3. Install battery: Connect positive (red) terminal first, then negative (black). Secure battery holder.
4. Add fluids: Fill engine oil (SAE 10W-30, 2.1 qt). Fill coolant (if equipped). Fill fuel tank with unleaded gasoline (87 octane or higher).
5. Install accessories: Follow instructions for winch, plow, or additional lighting.

WARNING! ATV is heavy; use proper lifting equipment or assistance. Ensure all fasteners are tightened to specified torque values.

First-Time Setup & Pre-Ride Inspection

Before first ride, perform a thorough inspection and setup.

1. Check tire pressure: Front 3.5 psi (24 kPa), Rear 3.5 psi (24 kPa) for standard terrain.
2. Check all fluid levels: Engine oil, coolant, brake fluid.
3. Test controls: Throttle, brakes, steering, On-Command switch, and differential lock for smooth operation.
4. Test lights and indicators: Headlights, taillight, brake light, and instrument panel.
5. Perform a short test ride in a safe, open area to familiarize yourself with handling.

CAUTION! Always wear a helmet, eye protection, and protective clothing. Never operate on public roads unless designated for ATV use.

Specifications

• Engine Type: 4-stroke, SOHC, air-cooled, 4-valve.
• Displacement: 348cc.
• Bore x Stroke: 83.0 mm x 64.5 mm.
• Compression Ratio: 8.3:1.
• Fuel System: Mikuni BSR33 carburetor.
• Ignition System: DC-CDI.
• Transmission: Ultramatic automatic V-belt with H, L, N, R, P ranges.
• Final Drive: Shaft drive.
• Suspension Travel (Front/Rear): 6.7 in (170 mm) / 7.9 in (200 mm).
• Brakes: Dual hydraulic disc front / Single hydraulic disc rear.
• Tires (Front/Rear): AT22 x 7-10 / AT22 x 10-10.
• Dimensions (L x W x H): 81.1 in x 46.1 in x 47.6 in (2060 mm x 1170 mm x 1210 mm).
• Dry Weight: 551 lbs (250 kg).

Controls and Indicators

Main controls located on handlebars and dash. Instrument Panel: Speedometer, Odometer, Trip Meter, Hour Meter, Fuel Gauge, Gear Position, 4WD/Diff Lock Indicators.

Handlebar Controls (Left): Headlight Dimmer Switch, Turn Signal Switch (if equipped), Horn Button, On-Command 2WD/4WD/Diff Lock Switch. (Right): Electric Start Button, Engine Stop Switch, Throttle Lever, Front Brake Lever.

Foot Controls: Rear Brake Pedal (right), Shift Pedal (H, L, N, R, P - left).

Key Switch: OFF/ON/START positions. Parking Brake Lever: Located near left footrest.

Connecting Accessories

Common accessories: Winch, plow, auxiliary lights, cargo racks.

1. Turn ignition OFF and disconnect battery negative terminal before any electrical work.
2. Follow accessory-specific wiring diagrams. Connect to provided accessory terminals or use an inline fuse for direct battery connections.
3. Route wires securely away from heat, moving parts, and sharp edges.
4. Reconnect battery, test accessory function, and ensure no wires are pinched.

Tip: Use dielectric grease on electrical connectors to prevent corrosion.

Maintenance Procedures

Follow the periodic maintenance schedule in the manual. Key procedures:

1. Engine Oil Change: Warm engine, drain oil, replace filter, refill with 2.1 qt of SAE 10W-30 (API SG or higher).
2. Air Filter Service: Clean foam filter in solvent, re-oil with specified air filter oil.
3. Drive Belt Inspection: Check for cracks, fraying, and wear. Adjust deflection if necessary.
4. Valve Clearance Adjustment: Check and adjust when engine is cold. Intake: 0.10–0.15 mm (0.004–0.006 in). Exhaust: 0.15–0.20 mm (0.006–0.008 in).
5. Front & Rear Differential Oil: Change per schedule (SAE 80W-90 API GL-5).
6. Brake System: Check pad wear, fluid level, and bleed system if spongy.
7. Spark Plug: Clean and regap to 0.6–0.7 mm (0.024–0.028 in). Replace if worn.

WARNING! Allow engine to cool before servicing. Support ATV securely on a level surface using a stand or jack. Always dispose of fluids properly.

Safety Features

Key safety systems: Engine Stop Switch (right handlebar), Parking Brake, Speed Limiter (for novice mode if equipped), and protective front and rear skid plates.

Care & Storage

For long-term storage (over 30 days):

1. Change engine oil and filter.
2. Add fuel stabilizer to a full tank and run engine for 5 minutes.
3. Disconnect battery negative terminal; store battery on a trickle charger.
4. Clean entire ATV thoroughly and apply protectant to plastic and rubber.
5. Elevate tires off ground and cover ATV in a dry, cool place.

CAUTION! Do not store near open flame or heat sources. Gasoline vapors are explosive.

Regulatory Information

This vehicle conforms to U.S. EPA and California emissions regulations for 2008 model year off-road motorcycles/ATVs. Manufactured by Yamaha Motor Corporation, U.S.A. For emissions warranty information, refer to the separate Emissions Control Warranty. Always follow local and state laws regarding ATV operation. For genuine Yamaha parts and service, contact an authorized Yamaha dealer.

Troubleshooting

Reset: Disconnecting the battery for 5 minutes may reset the electronic control unit (ECU) if experiencing erratic behavior.

Service: For complex repairs, consult an authorized Yamaha dealer. Use only genuine Yamaha parts.