YFM350XP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-09 3GD-28197-16
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM350XP. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.
HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is a chapter with its symbol on the upper right of each page. 2nd title 2: This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.) 3rd title 3: This is a final title.
1 EB003000 2 GEN INFO ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting ENG 5 6 CARB DRIV 7 8 CHAS – ELEC + 0 Illustrated symbols 0 to F are used to identify the specifications appearing in the text.
CONTENTS SPECIFICATIONS ........................................................................................... 1 GENERAL SPECIFICATIONS ................................................................. 1 MAINTENANCE SPECIFICATIONS ........................................................ 2 ENGINE ................................................................................................ 2 CHASSIS ..............................................................................................
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code number: Spark plug: Type/manufacturer Gap Electrical: Ignition system Charging system Battery capacity Battery type Bulb wattage × quantity: Headlight Tail/brake light Neutral indicator light Reverse indicator light YFM350XP 5NF4 (except for California) 5NF5 (for California) DR8EA (NGK) 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) DC. C.D.I. A.C. magneto 12 V 12AH GM12CZ-4A-2 12 V 30 W/30 W × 2 12 V 5 W/21 W × 1 12 V 3.4 W × 1 12 V 3.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Model YFM350XP Cylinder: Bore size Taper limit Piston: Piston size “D” Measuring point “H” 82.97 ~ 83.02 mm (3.267 ~ 3.269 in) <0.05 mm (0.002 in)> Piston clearance Oversize H 2nd 4th D Piston off-set Piston off-set direction Inside diameter (piston pin bore) Outside diameter (piston pin) Piston ring: Sectional sketch Top ring: B T 2nd ring: B T Oil ring: B 82.92 ~ 82.97 mm (3.265 ~ 3.267 in) 5.5 mm (0.
MAINTENANCE SPECIFICATIONS Model YFM350XP Carburetor: I. D. mark Main jet Main air jet Jet needle (M.J) (M.A.J) (J.N) Needle jet (N.J) Pilot jet Pilot air jet (P.J) (P.A.J.1) (P.A.J.2) (P.O) (B.P.1) (B.P.2) (B.P.3) (V.S) (G.S.) (Th.V) (F.L) Pilot outlet Bypass 1 Bypass 2 Bypass 3 Valve seat Starter jet Throttle valve size Fuel level Float height Engine idling speed Intake vacuum SPEC 3GD 00 (except for California) 3GD 10 (for California) #145 0.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Model Brake lever and brake pedal: Brake lever free play Brake pedal position Brake pedal free play YFM350XP 0 mm (0 in) at lever end 10 mm (0.4 in) 8 mm (0.315 in) ELECTRICAL Model C.D.I.: Magneto model/manufacturer Pickup coil resistance (Color) Rotor rotation direction detection coil resistance (Color) C.D.I.
CABLE ROUTING SPEC CABLE ROUTING 1 Clutch switch 2 Rear brake cable 3 Clutch cable 4 Front brake hose 5 Front brake light switch 6 Throttle cable 7 Band È Install the fuel tank breather hose into the hole of the handlebar cover.
CABLE ROUTING 1 Main switch lead 2 Handlebar switch lead 3 Clutch switch lead 4 Park switch lead 5 Front brake light switch lead 6 Fuel tank breather hose –6– SPEC
CABLE ROUTING 1 Starter relay 2 Neutral relay 3 Tail/brake light 4 CDI unit 5 Rectifier/regulator 6 Fuse 7 Battery breather hose SPEC È Pass the battery breather hose through the inside of the frame bracket. É Pass the battery breather hose through the guide.
CABLE ROUTING 1 Battery negative lead 2 Rear brake light switch 3 Drive select lever switch 4 Rear brake cable 5 Rear brake hose 6 Rectifier/regulator 7 CDI unit 8 Carburetor overflow hose 9 Rear brake light switch lead SPEC È Pass the wire harness and starter motor lead through the holder. É Fasten the wire harness, starter motor lead and handlebar switch lead with the band.
INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS CHK ADJ EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS CHK ADJ NOTE: ● Recommended brake fluid: DOT4 ● Brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 2.On the inner parts of the master cylinder and caliper, replace the oil seals every two years. 3.Replace the brake hoses every four years, or if cracked or damaged.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: ● Brake lever free play a Out of specification → Bleed the front brake system. Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)” in CHAPTER 3. (Manual No.: 3GD-28197-12) Brake lever free play (at brake lever end): 0 mm (0 in) ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal.
FRONT SUSPENSION CHASSIS FRONT SUSPENSION 1 Thrust cover 2 Bushing 3 Front upper arm 4 Collar 5 Front lower arm 6 Shock absorber 7 Steering knuckle – 12 – CHAS
CHECKING THE SWITCH ELEC – + ELECTRICAL CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: P/N. YU-03112, 90890-03112 NOTE: ● Set the pocket tester to “0” before starting the test. ● The pocket tester should be set to the “Ω × 1” range when testing the switch for continuity. ● Turn the switch on and off a few times when checking it.
W W W W W W B W W W W R W/G W W W W – 14 – B G B Y G L Y R/B Br R/W R/B M R G B Y OFF LO HI N ON OFF 3 W/R W/G W/G R W/G Br R/W Br 4 R/B R/W R R B L/W 6 L/W Br R/B L/W O B Y L Br Br R B L G Y G B Y G G OFF ON O B Y (GRAY) (GRAY) R Y B G L G B Y B K B 7 R/W 5 OFF PUSH P B B B R R R/W B L Y Y Br B B J R/W Br (BLACK) Y (BLACK) R/W R/W L/W Y B Br (BLACK) Y (BLACK) B I B W/B B/Y G/Y G/W 8 B/Y G/W
IGNITION SYSTEM ELEC – + EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Fuse 2.Battery 3.Spark plug 4.Ignition spark gap 5.Spark plug cap resistance 6.Ignition coil resistance 7.Engine stop switch 8.Main switch 9.Pickup coil resistance 10.Charging/rotor rotation direction detection coil resistance 11.
IGNITION SYSTEM ELEC INCORRECT Spark plug gap: 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) CORRECT Repair or replace the spark plug. For USA and CDN 4.Ignition spark gap ● ● Disconnect the spark plug cap from the spark plug. Connect the dynamic spark tester 1 as shown. 2 Spark plug cap 3 Spark plug ● ● ● Turn the main switch to “ON”. Check the ignition spark gap. Crank the engine by pushing the starter switch, and increase the spark gap until a misfiring occurs. MEETS SPECIFICATION Minimum spark gap: 6.
IGNITION SYSTEM ELEC * 5.Spark plug cap resistance ● ● ● Remove the spark plug cap. Connect the pocket tester (Ω × 1k) to the spark plug cap. OUT OF SPECIFICATION Check that the spark plug cap has the specified resistance. Spark plug cap resistance: 10 kΩ at 20 °C (68 °F) Replace the spark plug cap. MEETS SPECIFICATION 6.Ignition coil resistance ● ● Disconnect the ignition coil connector from the wire harness. Connect the pocket tester (Ω × 1) to the ignition coil.
IGNITION SYSTEM ● ELEC – Connect the pocket tester (Ω × 1k) to the ignition coil. Tester (+) lead → Orange lead terminal Tester (–) lead → Spark plug lead ● Check that the secondary coil has the specified resistance. Secondary coil resistance: 6.32 ~ 9.48 kΩ at 20 °C (68 °F) BOTH MEET SPECIFICATION Replace the ignition coil. INCORRECT 7.Engine stop switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the handlebar switch (left). INCORRECT 8.Main switch Refer to “CHECKING THE SWITCH”.
IGNITION SYSTEM * ELEC – C0NTINUITY 10.Charging/rotor rotation direction detection coil resistance ● ● Disconnect the AC magneto coupler from the wire harness. Connect the pocket tester (Ω × 100) to the charging/rotor rotation direction detection coil terminal. Tester (+) lead → Red terminal 1 Tester (–) lead → White/Blue terminal 2 ● Check the charging/rotor rotation direction detection coil for the specified resistance. OUT OF SPECIFICATION Rotor rotation direction detection coil resistance: 0.
W W W W W W B W W W W W W W W – 20 – B G B Y G L Y R/B Br R/W R/B M R G B Y OFF LO HI N ON OFF 3 W/R W/G W/G R W/G Br R/W Br 4 R/B R/W R R B L/W 6 L/W Br R/B L/W O B Y L Br Br R B L G Y G B Y G G OFF ON O B Y (GRAY) (GRAY) R Y B G L G B Y B K B 7 R/W 5 OFF PUSH P B B B R R R/W B L Y Y Br B B J R/W Br (BLACK) Y (BLACK) R/W R/W L/W B Br (BLACK) Y (BLACK) B I B W/B B/Y G/Y G/W 8 B/Y G/W W/B R/B
SIGNAL SYSTEM ELEC – + CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: 1.Bulb and bulb socket ● NO CONTINUITY Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the brake switch. 3.Voltage ● Connect the pocket tester (DC 20V) to the bulb socket connector.
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
W W W W W W B W W W W R W/G W W B G B Y G L Y R/B M G B Y OFF LO HI N ON OFF 3 W/R W/G W/G R Br R/W R/B R Br R/W Br 4 R/B R/W R R B L/W 6 L/W Br R/B L/W O B Y L Br Br R B L G Y G B Y G G OFF ON O B Y (GRAY) (GRAY) R Y B G L G B Y B K B 7 R/W 5 OFF PUSH P B B B R R R/W B L Y Y Br B B J R/W Br Y B Br (BLACK) Y (BLACK) B I B 8 B/Y G/W W/B R/B L/W G/L Br H G COLOR CODE B ............Black Br .....
