Yamaha YFM350S Service Manual
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Yamaha YFM350S Service Manual

Yamaha YFM350S Service Manual

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YFM350S
3GD-AE7
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha YFM350S

  • Page 1 YFM350S 3GD-AE7 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFM350S. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YFM350X(J) ’97 SERVICE MANUAL: 3GD-AE5...

  • Page 4: Important Information

    EBS00002 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

    EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 8 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 Chassis 7 Electrical 8 Troubleshooting...

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION ................1 MACHINE IDENTIFICATION ............... 1 MODEL LABEL ..................1 SPECIAL TOOLS ..................2 SPECIFICATIONS ....................3 GENERAL SPECIFICATIONS ..............3 MAINTENANCE SPECIFICATIONS ............5 ENGINE ....................5 CHASSIS ....................7 ELECTRICAL ..................10 CABLE ROUTING ..................11 PERIODIC CHECKS AND ADJUSTMENTS............
  • Page 8 ASSEMBLING THE REAR BRAKE CALIPER ........53 REAR SHOCK ABSORBER AND SWINGARM ......... 54 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER................. 56 DISPOSING OF THE REAR SHOCK ABSORBER AND GAS CYLINDER................. 56 ELECTRICAL ....................57 ELECTRICAL COMPONENTS..............57 YFM350S WIRING DIAGRAM...

  • Page 9: General Information

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. – 1 –...

  • Page 10: Special Tools

    SPECIAL TOOLS INFO EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country.

  • Page 11: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFM350S Model code number 5YT1 (For USA and Oceania) 5YT2 (For CDN) 5YT3 (For Europe) Dimensions Overall length 1,770 mm (69.7 in) Overall width 1,095 mm (43.1 in) Overall height 1,080 mm (42.5 in) Seat height 820 mm (32.3 in)
  • Page 12 SPEC GENERAL SPECIFICATIONS Model YFM350S Transmission Primary reduction system Spur gear Primary reduction ratio 76/24 (3.167) Secondary reduction system Chain drive Secondary reduction ratio 38/13 (2.923) Transmission type Constant mesh, 6-speed forward, 1-speed reverse Operation Left foot operation 36/16 × 20/27 × 29/18 (2.685) Gear ratio 33/20 ×...

  • Page 13: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model YFM350S Rocker arm/rocker arm shaft Rocker arm inside diameter 11.980 ~ 11.998 mm (0.4717 ~ 0.4724 in) Rocker arm shaft outside diameter 11.961 ~ 11.971 mm (0.4709 ~ 0.4713 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) Carburetor I.D.
  • Page 14 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Carburetor joint Bolt Carburetor clamp (cylinder head side) Screw Carburetor clamp (air filter case side) Screw Air filter case Screw Muffler and exhaust pipe...

  • Page 15: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model YFM350S Steering system Lock-to-lock angle Left 42.5° Right 42.5° Front suspension Shock absorber stroke 90.0 mm (3.54 in) Shock absorber spring free length 232.5 mm (9.15 in) Spring rate (K1) 32.00 N/mm (3.26 kg/mm, 182.72 lb/in) (K2) 45.00 N/mm (4.59 kg/mm, 256.95 lb/in)
  • Page 16 SPEC MAINTENANCE SPECIFICATIONS Model YFM350S Brake lever and brake pedal Brake lever free play 0 mm (0 in) Brake pedal position 50.2 mm (1.98 in) From the top of the frame to the top of the brake pedal Throttle lever free play 2 ~ 4 mm (0.08 ~ 0.16 in)
  • Page 17 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Swingarm guard and swingarm Driven chain sprocket and boss Front bumper Rear bumper Drive chain guard Foot protectors (left and right) and frame Foot protectors (left and right), rear fender stay and frame Foot protectors (left and right) and footrest...

  • Page 18: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model YFM350S C.D.I. Magneto model/manufacturer F4T466/MITSUBISHI 459 ~ 561 Ω at 20 °C (68 °F) Pickup coil resistance (Color) (White/Red-White/Green) 0.083 ~ 0.101 Ω at 20 °C (68 °F) Rotor rotation direction detection coil resis- tance...

  • Page 19: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Clutch switch lead 0 Handlebar switch lead 2 Starter cable 3 Clutch cable È Fasten the front brake light switch lead with two 4 Parking brake cable plastic bands. 5 Front brake hose É Fasten the starter cable, clutch switch lead, and 6 Front brake light switch lead handlebar switch lead with a plastic band.
  • Page 20 SPEC CABLE ROUTING 1 Parking brake cable È Pass the clutch switch lead, handlebar switch 2 Clutch cable lead, neutral/reverse indicator light lead, front 3 Starter cable brake light switch lead, and starter cable through 4 Clutch switch lead the guide. 5 Handlebar switch lead É...
  • Page 21 SPEC CABLE ROUTING Ê Route the clutch switch lead, handlebar switch lead, neutral/reverse indicator light lead, and front brake light switch lead in front of the guide. Ë Pass the throttle cable, clutch cable, and parking brake cable to the right side of the steering shaft. È...
  • Page 22 SPEC CABLE ROUTING 1 Rectifier/regulator B Neutral switch lead 2 Ignition coil C Starter motor lead 3 Wire harness D Clutch cable 4 Starter cable E Parking brake cable 5 Fuel tank breather hose 6 Fuel hose 7 Carburetor air vent hose 8 Crankcase breather hose 9 Reverse switch lead 0 Negative battery lead...
  • Page 23 SPEC CABLE ROUTING È Pass the parking brake cable and clutch cable Ì Fasten the A.C. magneto lead, neutral switch through the cable guide. lead, reverse switch lead, and negative battery É Pass the carburetor air vent hose through the lead with a plastic band.
  • Page 24 SPEC CABLE ROUTING Ï Fasten the parking brake cable and clutch cable Ò Pass a plastic band through the hole in the fuel with the clip. Fasten the clip to the clutch cable tank shield, and then fasten the wire harness, between the cable protector and the clutch cable starter motor lead, and starter cable with the adjuster.
  • Page 25 SPEC CABLE ROUTING 1 Tail/brake light lead È Pass the wire harness, negative battery lead, 2 Battery and starter motor lead through the hole in the 3 C.D.I. unit rear fender. 4 Wire harness É More than 15 mm (0.6 in) 5 Starter motor lead 6 Negative battery lead 7 Carburetor air vent hose...
  • Page 26 SPEC CABLE ROUTING 1 Drive select lever switch B Rear brake light switch 2 Ground terminal C Rear brake light switch lead 3 Throttle cable D Drive select lever switch connector 4 Drive select lever switch lead 5 Main switch lead È...
  • Page 27 SPEC CABLE ROUTING Ë Route the drive select lever switch lead on the Ð Pass the starter motor lead through the guide. Ñ Fasten the rear brake light switch lead under the outside of the drive select lever bracket, and then under the ground lead.
  • Page 28 SPEC CABLE ROUTING 1 Ignition coil È Fasten the wire harness with the holder. 2 Headlight lead É Route the headlight lead over the frame. 3 Main switch lead Ê Fasten the main switch lead with the holder on 4 Spark plug lead the front fender.
  • Page 29 SPEC CABLE ROUTING 1 Starter relay È Fasten the wire harness by inserting the projec- 2 Positive battery lead tions on the plastic tab into the hole in the rear 3 C.D.I. unit fender. 4 Battery É Pass the tail/brake light lead through the guide 5 Tail/brake light lead on the rear fender.
  • Page 30 SPEC CABLE ROUTING Ì Connect the end of the negative battery lead with the gray tape to the negative battery termi- nal. Í Cover the positive battery lead terminal and starter motor lead terminal with the covers. Í È 6Ì Ê...

  • Page 31: Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. 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. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 32 Lights and • Check operation. switches* • Adjust headlight beams. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice. NOTE: • Recommended brake fluid: DOT 4 • Brake fluid replacement: •...

  • Page 33: Seat, Fenders And Fuel Tank

    SEAT, FENDERS AND FUEL TANK EBS00033 SEAT, FENDERS AND FUEL TANK SEAT, SIDE COVERS, AND FRONT PANEL Order Job/Part Q’ty Remarks Removing the seat, side covers, and Remove the parts in the order listed. front panel Seat NOTE: Pull back the seat lock lever, than pull up on the rear of the seat.

  • Page 34: Foot Protectors, Engine Skid Plate, And Front Bumper

    SEAT, FENDERS AND FUEL TANK EBS00034 FOOT PROTECTORS, ENGINE SKID PLATE, AND FRONT BUMPER 17 Nm (1.7 m kg, 12 ft • • 17 Nm (1.7 m kg, 12 ft • • 12 Nm (1.2 m kg, 8.7 ft • •...

  • Page 35: Headlights And Front Fender

    SEAT, FENDERS AND FUEL TANK EBS00036 HEADLIGHTS AND FRONT FENDER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 36: Rear Fender

    SEAT, FENDERS AND FUEL TANK EBS00039 REAR FENDER 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 37 SEAT, FENDERS AND FUEL TANK 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...

  • Page 38: Fuel Tank

    SEAT, FENDERS AND FUEL TANK EBS00042 FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Seat/side covers (left and right) Refer to “SEAT, SIDE COVERS, AND FRONT PANEL”.
  • Page 39 SEAT, FENDERS AND FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Fuel tank shield For installation, reverse the removal pro- cedure. – 31 –...

  • Page 40: Chassis

    CHECKING THE FRONT BRAKE PADS/ ADJUSTING THE PARKING BRAKE CHASSIS CHECKING THE FRONT BRAKE PADS 1. Remove: • front wheels Refer to “FRONT WHEEL AND WHEEL HUB” in chapter 6. (Manual No.: 3GD-AE5) 2. Check: • brake pads Wear indicator 1 almost in contact with the brake disc →...

  • Page 41: Adjusting The Rear Shock Absorber

    ADJUSTING THE PARKING BRAKE/ ADJUSTING THE REAR SHOCK ABSORBER i. Slide the rubber cover to its original posi- tion. WARNING After this adjustment is performed, lift the rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag.
  • Page 42 ADJUSTING THE REAR SHOCK ABSORBER NOTE: • Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjustment. • The length of the spring (installed) changes 1 mm (0.04 in) per turn of the adjuster. CAUTION: Never attempt to turn the adjusting ring beyond the maximum or minimum setting.

  • Page 43: Electrical System

    CHECKING AND CHARGING THE BATTERY EBS00120 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 44 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 45 CHECKING AND CHARGING THE BATTERY 6. Charge: Charging Ambient temperature 20 °C (68 °F) • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. • Never remove the MF battery sealing caps.
  • Page 46 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before Charger Ammeter measuring its open-circuit voltage. Connect a charger and NOTE: Set the charging voltage to 16 ~ ammeter to the battery and...
  • Page 47 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

  • Page 48: Adjusting The Headlight Beams

    CHECKING AND CHARGING THE BATTERY/ ADJUSTING THE HEADLIGHT BEAMS 7. Install: • battery 8. Install: • battery holding bracket Refer to “REAR FENDER”. 9. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2.

  • Page 49: Replacing A Headlight Bulb

    REPLACING A HEADLIGHT BULB EBS00124 REPLACING A HEADLIGHT BULB 1. Disconnect: • headlight lead coupler 1 2. Remove: • headlight bulb holder cover 2 3. Remove: • bulb holder 1 • bulb NOTE: Push the headlight bulb holder inward, turn it counterclockwise and remove the defective bulb.

  • Page 50: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL INSTALLING THE ENGINE WARNING Securely support the machine so there is no danger of it falling over. 1. Install: • engine assembly 2. Install: • engine lower mounting bolt (rear)/nut 1 • engine upper mounting bolt (rear)/nut 2 •...

  • Page 51: Clutch

    CLUTCH CLUTCH INSTALLING THE RIGHT CRANKCASE COVER 1. Install: • right crankcase cover 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: When installing the right crankcase cover, push the push lever in direction a and check that the punch mark b on the push lever aligns with the mark c on the right crankcase cover.

  • Page 52: Carburetor

    CARB CARBURETOR EBS00141 CARBURETOR CARBURETOR 20 Nm (2.0 m kg, 14 ft • • Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Fuel tank/air filter case Refer to “SEAT, FENDERS AND FUEL TANK”. Plastic band Drive select lever assembly Throttle valve cover Throttle cable...
  • Page 53 CARB CARBURETOR Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order below. Throttle stop screw Vacuum chamber cover Piston valve spring Jet needle holder/jet needle set Piston valve Coasting enricher assembly Float chamber Float pin Float Needle valve Needle valve seat Starter jet...
  • Page 54 CARB CARBURETOR Order Job/Part Q’ty Remarks Main jet holder Needle jet Pilot air jet Pilot screw For assembly, reverse the disassembly procedure. – 46 –...

  • Page 55: Chassis

    CHAS REAR WHEELS AND REAR AXLE HUB CHASSIS REAR WHEELS AND REAR AXLE HUB 120 Nm (12.0 m kg, 85 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...
  • Page 56 CHAS REAR WHEELS AND REAR AXLE HUB 120 Nm (12.0 m kg, 85 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 160 Nm (16.0 m kg, 115 ft •...

  • Page 57: Removing The Rear Axle

    CHAS REAR WHEELS AND REAR AXLE HUB EBS00393 REMOVING THE REAR AXLE 1. Place the machine on a level surface. 2. Remove: • bolts 1 3. Loosen: • nut 2 NOTE: • Apply the parking brake so that the rear axle does not turn, when loosening the nut.

  • Page 58: Installing The Rear Axle

    CHAS REAR WHEELS AND REAR AXLE HUB 8. Remove: • rear axle 1 CAUTION: • Never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. • Attach a suitable socket 2 on the axle end and tap it with a soft hammer, then pull out the rear axle to the right.

  • Page 59: Front Arms And Front Shock Absorber

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBER EBS00468 FRONT ARMS AND FRONT SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft • • 48 Nm (4.8 m kg, 35 ft • • 25 Nm (2.5 m kg, 18 ft • •...
  • Page 60 CHAS FRONT ARMS AND FRONT SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft • • 48 Nm (4.8 m kg, 35 ft • • 25 Nm (2.5 m kg, 18 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 61: Rear Brake

    CHAS REAR BRAKE REAR BRAKE ASSEMBLING THE REAR BRAKE CALIPER 1. Install: • parking brake arm 1 NOTE: Install the parking brake arm so that the park- ing-brake-arm-to-parking-brake-bracket dis- tance a is approximately 73 mm (2.87 in). – 53 –...

  • Page 62: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 73 Nm (7.3 m kg, 53 ft • • 80 Nm (8.0 m kg, 58 ft • • 85 Nm (8.5 m kg, 61 ft 73 Nm (7.3 m kg, 53 ft •...
  • Page 63 CHAS REAR SHOCK ABSORBER AND SWINGARM 73 Nm (7.3 m kg, 53 ft • • 80 Nm (8.0 m kg, 58 ft • • 85 Nm (8.5 m kg, 61 ft 73 Nm (7.3 m kg, 53 ft • • •...

  • Page 64: Handling The Rear Shock Absorber And Gas Cylinder

    CHAS REAR SHOCK ABSORBER AND SWINGARM EBS00485 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information.

  • Page 65: Electrical

    – ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS 1 Rectifier/regulator 9 Starting circuit cut-off relay 2 Main switch 0 Fuse 3 Neutral indicator light A Starter relay 4 Reverse indicator light B Reverse switch 5 Ignition coil C Neutral switch 6 Drive select lever switch D Rear brake light switch 7 Battery E Wire harness...
  • Page 68 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

  • Page 69: Yfm350S Wiring Diagram

    YFM350S WIRING DIAGRAM 1 A.C. magneto 2 Rectifier/regulator R/B L/W O 3 Main switch R W/R W/G W/B B/Y 4 Battery 5 Fuse R W/G W/G R 6 Starter relay W/L W/R W/R W/G 7 Starter motor 8 Clutch switch W W W 9 C.D.I.

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