Table of Contents
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Table of Contents
Related Manuals for Yamaha YFM350XP
Summary of Contents for Yamaha YFM350XP
- Page 1 YFM350XP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-09 3GD-28197-16...
- Page 2 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 Supple- mentary Service Manual together with the following manual. YFM350XA SERVICE MANUAL: 3GD-28197-12...
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Page 3: Important Information
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 4: How To Use This Manual
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 5 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...
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Page 6: Table Of Contents
CHECKING THE SWITCH ..............13 CHECKING A SWITCH SHOWN IN THE MANUAL ......13 IGNITION SYSTEM ................14 CIRCUIT DIAGRAM ................14 TROUBLESHOOTING ............... 15 SIGNAL SYSTEM ................... 20 CIRCUIT DIAGRAM ................20 CHECKING THE SIGNAL SYSTEM ..........21 YFM350XP WIRING DIAGRAM... -
Page 7: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFM350XP Model code number: 5NF4 (except for California) 5NF5 (for California) 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... -
Page 8: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model YFM350XP 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”... - Page 9 SPEC MAINTENANCE SPECIFICATIONS Model YFM350XP Carburetor: I. D. mark 3GD 00 (except for California) 3GD 10 (for California) Main jet (M.J) #145 Main air jet (M.A.J) Jet needle (J.N) 5J18-3 (except for California) 5J31-1 (except for California) Needle jet (N.J)
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Page 10: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model YFM350XP Brake lever and brake pedal: Brake lever free play 0 mm (0 in) at lever end Brake pedal position 10 mm (0.4 in) Brake pedal free play 8 mm (0.315 in) ELECTRICAL Model YFM350XP C.D.I.:... -
Page 11: 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 12 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 13 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 14 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.
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Page 15: 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 16 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.
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Page 17: 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-28197-12) Brake lever free play (at brake lever end):... -
Page 18: 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 19: 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 ●... -
Page 20: Ignition System
– ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM – 14 –... -
Page 21: 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 22 – 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 ●...
- Page 23 – 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 24 – 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 25 – 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 →...
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Page 26: Signal System
– ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM – 20 –... -
Page 27: 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 28 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.