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Yamaha 2002 YFM350X Supplemental Service Manual

Yamaha 2002 YFM350X Supplemental Service Manual

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2002
YFM350X
P
(
)
3GD-AE6
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha 2002 YFM350X

  • Page 1 2002 YFM350X 3GD-AE6 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 Supplementary Service Manual together with the following manual. YFM350X(J) ’97 SERVICE MANUAL: 3GD-AE5 YFM350X(P) 2002 SUPPLEMENTARY SERVICE MANUAL  2001 by Yamaha Motor Co., Ltd. First Edition, May 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
  • Page 4 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.
  • Page 5 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 sym- bol.
  • Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the SPEC top right of each page and indicate the subject INFO of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical...
  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS ....................1 GENERAL SPECIFICATIONS ..............1 MAINTENANCE SPECIFICATIONS ............2 ENGINE ....................2 CHASSIS ....................4 ELECTRICAL ..................4 CABLE ROUTING ..................5 PERIODIC CHECKS AND ADJUSTMENTS ............9 INTRODUCTION ..................9 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ......9 CHASSIS ....................11 ADJUSTING THE FRONT BRAKE ............11 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......11 CHASSIS ......................12 FRONT SUSPENSION ................12 ELECTRICAL ....................13...
  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFM350X(P) 2002 Model code number: 5NF6 (CDN, Europe and Oceania) Spark plug: Type/manufacturer DR8EA (NGK) 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Electrical: Ignition system DC. C.D.I. Charging system A.C. magneto Battery capacity 12 V 12AH Battery type GM12CZ-4A-2...
  • Page 10: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model YFM350X(P) 2002 Cylinder: Bore size 82.97 ~ 83.02 mm (3.267 ~ 3.269 in) Taper limit <0.05 mm (0.002 in)> Piston: Piston size “D” 82.92 ~ 82.97 mm (3.265 ~ 3.267 in) Measuring point “H” 5.5 mm (0.22 in) (From bottom line of piston skirts) Piston clearance...
  • Page 11 SPEC MAINTENANCE SPECIFICATIONS Model YFM350X(P) 2002 Carburetor: I. D. mark 3GD 00 Main jet (M.J) #145 Main air jet (M.A.J) Jet needle (J.N) 5J18-3 Needle jet (N.J) Pilot jet (P .J) #42.5 Pilot air jet (P .A.J.1) (P .A.J.2) Pilot outlet (P .O) 0.75 Bypass 1...
  • Page 12: Chassis

    (Color) (Red-White/Blue) C.D.I. unit-model/manufacturer F8T38675/MITSUBISHI Ignition coil: Model/manufacturer 2JN/YAMAHA Minimum spark gap 6 mm (0.24 in) 0.18 ~ 0.28 Ω at 20 °C (68 °F) Primary winding resistance Secondary winding resistance 6.32 ~ 9.48 kΩ at 20 °C (68 °F)
  • Page 13: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Clutch switch È Install the fuel tank breather hose into the hole of 2 Rear brake cable the handlebar cover. 3 Clutch cable 4 Front brake hose 5 Front brake light switch 6 Throttle cable 7 Band –...
  • Page 14 SPEC 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 –...
  • Page 15 SPEC CABLE ROUTING 1 Starter relay È Pass the battery breather hose through the inside 2 Neutral relay of the frame bracket. 3 Tail/brake light É Pass the battery breather hose through the guide. 4 CDI unit 5 Rectifier/regulator 6 Fuse 7 Battery breather hose –...
  • Page 16 SPEC CABLE ROUTING 1 Battery negative lead È Pass the wire harness and starter motor lead 2 Rear brake light switch through the holder. 3 Drive select lever switch É Fasten the wire harness, starter motor lead and 4 Rear brake cable handlebar switch lead with the band.
  • Page 17: Periodic Checks And Adjustments

    • Check all chassis fittings and fasteners. Fasteners* • Correct if necessary. • Check specific gravity. Battery* • Check breather pipe for proper routing. • Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease – 9 –...
  • Page 18 PERIODIC MAINTENANCE/LUBRICATION INTERVALS 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.
  • Page 19: Chassis

    ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE LIGHT SWITCH 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-AE5) Brake lever free play (at brake lever end):...
  • Page 20: Chassis

    CHAS 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 –...
  • Page 21: Electrical

    – ELEC CHECKING THE SWITCH 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.
  • Page 22: Ignition System

    – ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM – 14 –...
  • Page 23: Troubleshooting

    – ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Fuse 7.Engine stop switch 2.Battery 8.Main switch 3.Spark plug 9.Pickup coil resistance 4.Ignition spark gap 10.Charging/rotor rotation direction detection 5.Spark plug cap resistance coil resistance 6.Ignition coil resistance 11.Wiring connection (the entire ignition sys-...
  • Page 24 – ELEC IGNITION SYSTEM 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.
  • Page 25 – ELEC IGNITION SYSTEM 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...
  • Page 26 – ELEC IGNITION SYSTEM 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...
  • Page 27 – ELEC IGNITION SYSTEM C0NTINUITY 10.Charging/rotor rotation direction detec- tion 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 →...
  • Page 28: Signal System

    – ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM – 20 –...
  • Page 29: Checking The Signal System

    – ELEC SIGNAL SYSTEM 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 continu- ity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”.
  • Page 31: Yfm350X(P) 2002 Wiring Diagram

    YFM350X(P) 2002 WIRING DIAGRAM 1 AC magneto 2 Rectifier/regulator 3 Main switch 4 Fuse 5 Battery R/B L/W O 6 Starter relay R W/G W/G R R W/R W/G 7 Starter motor W/L W/R W/R W/G 8 Clutch switch 9 CDI unit 0 Ignition coil W/B B/Y A Spark plug...

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2002 yfm350xp