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Yamaha YFM35FAS Supplementary Service Manual

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YFM35FAS
YFM350FAS
5UH2-AE1
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha YFM35FAS

  • Page 1 YFM35FAS YFM350FAS 5UH2-AE1 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFM35FAS/YFM350FAS. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YFM4FAR/YFM400FAR SERVICE MANUAL: 5TE2-AE1...

  • Page 4: 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 5: How To Use This Manual

    EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated 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 0 are printed on the SPEC INFO top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Drive train COOL...

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION SPECIAL TOOLS ..................1 SPECIFICATIONS GENERAL SPECIFICATIONS ..............2 MAINTENANCE SPECIFICATIONS ............5 ENGINE ....................5 CHASSIS ....................15 ELECTRICAL ..................19 LUBRICATION POINTS AND LUBRICANT TYPES .......21 ENGINE ....................21 OIL FLOW DIAGRAMS ................22 CABLE ROUTING ...................26 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..................34 PERIODIC MAINTENANCE/LUBRICATION ...........34 SEAT, CARRIERS, FENDERS AND FUEL TANK ........36 SEAT, FRONT CARRIER, FRONT BUMPER AND...
  • Page 8 OIL COOLER ..................52 PRIMARY AND SECONDARY SHEAVES ..........54 PRIMARY SLIDING SHEAVE .............56 SECONDARY SHEAVE ..............57 ASSEMBLING THE PRIMARY SHEAVE ..........58 ASSEMBLING THE SECONDARY SHEAVE ........58 CLUTCH ....................60 CRANKCASE ..................62 STARTER MOTOR, TIMING CHAIN AND OIL FILTER .....62 CRANKCASE ..................64 CRANKCASE BEARINGS ..............65 SEPARATING THE CRANKCASE .............66 ASSEMBLING THE CRANKCASE .............66 CRANKSHAFT ..................68...
  • Page 9 TROUBLESHOOTING FAULTY GEAR SHIFTING ..............104 HARD SHIFTING ................104 SHIFT LEVER DOES NOT MOVE ............104 JUMPS OUT OF GEAR ..............104 OVERHEATING ..................104 OVERHEATING ................104 FAULTY BRAKE ...................105 POOR BRAKING EFFECT ...............105 YFM35FAS/YFM350FAS WIRING DIAGRAM...

  • Page 11: General Information

    SPECIAL TOOLS INFO GENERAL INFORMATION 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 12: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5UH2 (for CDN) 5UH4 (for Europe) 5UH5 (for Oceania) Dimensions: Overall length 1,984 mm (78.1 in) Overall width 1,085 mm (42.7 in) Overall height 1,120 mm (44.1 in) Seat height 827 mm (32.6 in) Wheelbase 1,233 mm (48.5 in)
  • Page 13 SPEC GENERAL SPECIFICATIONS Item Standard Oil capacity: Engine oil Periodic oil change 2.2 L (1.94 Imp qt, 2.33 US qt) With oil filter replacement 2.3 L (2.02 Imp qt, 2.43 US qt) Total amount 3.1 L (2.73 Imp qt, 3.28 US qt) Final gear case oil Periodic oil change 0.23 L (0.20 Imp qt, 0.24 US qt)
  • Page 14 SPEC GENERAL SPECIFICATIONS Item Standard Tires: Type Tubeless AT25 × 8–12 Size front AT25 × 10–12 rear Manufacturer front MAXXIS (for CDN, Europe) CHENG SHIN (for Oceania) rear MAXXIS (for CDN, Europe) CHENG SHIN (for Oceania) Type front M911Y (for CDN, Europe) C828 (for Oceania) rear M912Y (for CDN, Europe)

  • Page 15: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 82.970 ~ 83.020 mm 83.100 mm (3.2665 ~ 3.2685 in) (3.2720 in) Taper limit ---- 0.05 mm (0.0016 in) Out of round limit ---- 0.01 mm...
  • Page 16 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cam chain: Cam chain type/No. of links 92RH2005/110 ---- Cam chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Rocker arm inside diameter 11.980 ~ 11.998 mm 12.058 mm (0.4717 ~ 0.4724 in) (0.4747 in) Rocker arm shaft outside diameter 11.961 ~ 11.971 mm 11.931 mm...
  • Page 17 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) Valve spring: Inner spring Free length 39.9 mm (1.57 in) 37.9 mm (1.49 in)
  • Page 18 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Outer spring Free length 43.27 mm (1.70 in) 41.27 mm (1.62 in) 43.27 mm (1.70 in) 41.27 mm (1.62 in) Set length (valve closed) 36.6 mm (1.44 in) ---- 36.6 mm (1.44 in) ---- Compressed pressure (installed) 235.4 ~ 251.1 N...
  • Page 19 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston rings: Top ring Type Barrel ---- Dimensions (B × T) 1.2 × 3.3 mm (0.05 × 0.13 in) ---- End gap (installed) 0.20 ~ 0.40 mm 0.65 mm (0.008 ~ 0.016 in) (0.0256 in) Side clearance (installed) 0.03 ~ 0.08 mm 0.13 mm...
  • Page 20 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Balancer: Balancer drive method Gear ---- Automatic centrifugal clutch: Clutch shoe thickness 1.5 mm (0.06 in) 1.0 mm (0.04 in) Clutch-in revolution 1,950 ~ 2,350 r/min ---- Clutch-stall revolution 3,350 ~ 3,850 r/min ---- Transmission: Main axle deflection limit ----...
  • Page 21 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Oil pump: Oil filter type Foam ---- Oil pump type Trochoid ---- Tip clearance 0.15 mm (0.006 in) 0.20 mm (0.008 in) Side clearance 0.04 ~ 0.09 mm ---- (0.002 ~ 0.004 in) Bypass valve setting pressure 78 ~ 118 kPa (0.78 ~ 1.18 kg/cm ---- 11.3 ~ 17.1 psi)
  • Page 22 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cylinder head tightening sequence: – 12 –...
  • Page 23 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Cylinder head (exhaust pipe) Stud bolt Cylinder head Bolt Bolt Camshaft bearing retainer Bolt Spark plug — Oil gallery bolt Bolt Cylinder Bolt Starter pulley...
  • Page 24 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Pickup coil Bolt Starter one-way clutch Bolt Recoil starter Bolt Clutch carrier assembly 14.0 100 Stake. Clutch housing assembly Bolt Torx Middle drive shaft bearing retainer screw Middle drive shaft drive pinion gear 13.0...

  • Page 25: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Ball and race bearing ---- Front suspension: Shock absorber travel 99 mm (3.90 in) ---- Spring free length 265 mm (10.43 in) ---- Spring fitting length 231.9 mm (9.13 in) ---- Spring rate (K1)
  • Page 26 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Type Dual ---- Disc outside diameter × thickness 200.0 × 3.5 mm (7.87 × 0.14 in) ---- Pad thickness inner 4.5 mm (0.18 in) 1 mm (0.04 in) Pad thickness outer 4.5 mm (0.18 in) 1 mm (0.04 in)
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Engine bracket (front-upper) and frame Engine bracket (front-lower) and frame Engine bracket (front-upper) and engine Engine bracket (front-lower) and engine Engine and frame (rear-upper) Engine and frame (rear-lower) Frame and bearing retainer (steering stem holder bearing)
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Master cylinder and handlebar Footrest bracket and frame Front bumper and frame Front carrier and frame Front carrier and front bumper Rear carrier and frame Engine skid plate Differential gear oil filler bolt Differential gear oil drain bolt Differential gear case and bearing housing...

  • Page 29: Electrical

    Rotor rotation direction sensing coil ---- resistance/color Red – White/Blue C.D.I. unit model/manufacturer F8T40371/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...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Brush overall length 12.0 mm (0.47 in) 4 mm (0.16 in) Spring force 7.65 ~ 10.01 N (780 ~ 1,021 g, ---- 27.53 ~ 36.04 oz) Commutator diameter 28 mm (1.10 in) 27 mm (1.06 in) Mica undercut 0.7 mm (0.03 in)

  • Page 31: Lubrication Points And Lubricant Types

    Gear coupling (middle driven shaft) Shift shaft Shift fork/guide bar Shift shaft stopper ball Shift lever collar ® Sealant (Quick Gasket Crankcase mating surface Yamaha Bond No.1215 ® Sealant (Quick Gasket Stator lead grommet (left side crankcase) Yamaha Bond No.1215 – 21 –...

  • Page 32: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Oil pump 4 Oil strainer – 22 –...
  • Page 33 SPEC OIL FLOW DIAGRAMS 1 Thermo unit 2 Oil pump 3 Oil filter È To oil cooler É From oil cooler – 23 –...
  • Page 34 SPEC OIL FLOW DIAGRAMS 1 Crankshaft 2 Oil filter – 24 –...
  • Page 35 SPEC OIL FLOW DIAGRAMS 1 Oil cooler 2 Oil cooler outlet pipe 3 Oil cooler inlet pipe È From engine É To engine È É – 25 –...

  • Page 36: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake switch lead 0 Horn switch (for Europe and Oceania) 2 Starter cable A Handlebar switch 3 Rear brake lever cable B Main switch lead 4 Front brake hose C Differential gear case breather hose 5 On-command four-wheel drive switch lead D Gear motor lead 6 On-command four-wheel drive switch...
  • Page 37 SPEC CABLE ROUTING È Fasten the on-command four-wheel drive switch lead behind the handlebar with a plastic band. É Fasten the starter cable, handlebar switch lead, rear brake switch lead, and horn switch lead (for Europe and Oceania) behind the handlebar with a plastic band. Ê...
  • Page 38 SPEC CABLE ROUTING 1 Headlight lead 2 Oil temperature warning light 3 Four-wheel drive indicator light 4 Differential gear case breather hose 5 Indicator light/speedometer light couplers 6 Speedometer cable 7 Wire harness È Fasten the wire harness with a plastic band. É...
  • Page 39 SPEC CABLE ROUTING 1 Fuel tank breather hose È Insert the fuel tank breather hose into the hole of 2 Starter cable the handlebar cover. 3 Cylinder head breather hose É Fasten the starter cable with a plastic band. 4 Rear brake lever cable Ê...
  • Page 40 SPEC CABLE ROUTING 1 Cylinder head breather hose B A.C. magneto lead 2 Fuel hose C Rectifier/regulator 3 Final drive gear case breather hose D Reverse switch lead 4 Rear brake breather hose E Neutral switch lead 5 Wire harness F Carburetor drain hose 6 Starter motor lead G Float chamber air vent hose...
  • Page 41 SPEC CABLE ROUTING È Fasten the wire harness with a plastic band. É Fasten the wire harness, starter motor lead, and negative battery lead with a plastic band. Ê Fasten the final drive gear case breather hose, rear brake breather hose, ground lead, and A.C. magneto lead with a plastic band.
  • Page 42 SPEC CABLE ROUTING 1 Throttle cable È Fasten the select lever control cable, rear brake 2 Spark plug lead light switch lead, and spark plug lead with a 3 Main switch plastic band. 4 Wire harness É Fasten the select lever control cable and rear 5 Select lever control cable brake light switch lead with a plastic band.
  • Page 43 SPEC CABLE ROUTING 1 Front brake hose 2 Throttle cable 3 Wire harness 4 Final drive gear case breather hose 5 Rear brake breather hose 6 Float chamber air vent hose 7 Starter cable 8 Rear brake lever cable – 33 –...

  • Page 44: Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks 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. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 45 • Correct if necessary. • Check operation. Lights and switches* • Adjust headlight beams. Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: When disassembling the master cylinder or caliper, replace the brake fluid.

  • Page 46: Seat, Carriers, Fenders And Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, FRONT CARRIER, FRONT BUMPER AND FRONT FENDER 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 34 Nm (3.4 m kg, 24 ft •...
  • Page 47 SEAT, CARRIERS, FENDERS AND FUEL TANK 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 34 Nm (3.4 m kg, 24 ft • • Order Job name/Part name Q’ty Remarks Indicator lights assembly coupler Disconnect.

  • Page 48: Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK FUEL TANK Order Job name/Part name Q’ty Remarks Removing the fuel tank Remove the parts in the order below. Seat and fuel tank cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. Fuel hose NOTE: Before disconnecting the fuel hose, turn the fuel cock to “OFF”.

  • Page 49: Engine

    CHECKING THE OIL TEMPERATURE WARNING LIGHT ENGINE CHECKING THE OIL TEMPERATURE WARNING LIGHT 1 Oil temperature warning light Oil temperature warning light checking method Turn the main switch to “ON” and the engine stop switch to “ ”. Oil temperature warning Oil temperature warning light does not come on.

  • Page 50: Engine

    CYLINDER HEAD ENGINE CYLINDER HEAD Order Job name/Part name Q’ty Remarks Removing the cylinder head Remove the parts in the order below. Fuel tank/rubber cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. Front fender Air duct assembly 1/air filter case Refer “ENGINE REMOVAL”...
  • Page 51 CYLINDER HEAD Order Job name/Part name Q’ty Remarks Cylinder head breather hose Camshaft sprocket cover/O-ring Tappet cover/O-ring Timing chain tensioner cap bolt Refer to “REMOVING THE CYLINDER Timing chain tensioner/gasket HEAD” “INSTALLING CYLINDER HEAD” in CHAPTER 4. Camshaft sprocket (Manual No.: 5TE2-AE1) Cylinder head Cylinder head gasket Dowel pin...

  • Page 52: Camshaft, Rocker Arms And Valves

    CAMSHAFT, ROCKER ARMS AND VALVES CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty Remarks Removing the camshaft, rocker Remove the parts in the order below. arms and valves Intake manifold/O-ring Oil gallery bolt Lock washer/bearing retainer Camshaft Refer to “REMOVING THE CAMSHAFT AND ROCKER ARMS”...
  • Page 53 CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty Remarks Valve cotter Valve spring retainer Refer to “REMOVING THE VALVES Valve spring (outer) AND VALVE SPRINGS” and Valve spring (inner) “INSTALLING THE VALVES AND Valve (intake) VALVE SPRINGS” in CHAPTER 4. Valve (exhaust) (Manual No.: 5TE2-AE1) Valve stem seal...

  • Page 54: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON Order Job name/Part name Q’ty Remarks Removing the cylinder and piston Remove the parts in the order below. Cylinder head Refer to “CYLINDER HEAD”. Cylinder/O-ring Refer to “INSTALLING THE CYLINDER” in CHAPTER 4. (Manual No.: 5TE2-AE1) Cylinder gasket Dowel pin Dowel pin/O-ring...

  • Page 55: Recoil Starter And A.c. Magneto

    RECOIL STARTER AND A.C. MAGNETO RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty Remarks Removing the A.C. magneto Remove the parts in the order below. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. (Manual No.: 5TE2-AE1) Seat and fuel tank cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
  • Page 56 RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty Remarks Lead holder Pickup coil Stator assembly Starter idle gear shaft Starter idle gear Rotor Refer to “REMOVING THE A.C. MAGNETO” and “INSTALLING THE Starter wheel gear A.C. MAGNETO” in CHAPTER 4. Woodruff key (Manual No.: 5TE2-AE1).

  • Page 57: Balancer Gears And Oil Pump

    BALANCER GEARS AND OIL PUMP BALANCER GEARS AND OIL PUMP Order Job name/Part name Q’ty Remarks Removing the balancer gears and oil Remove the parts in the order below. pump Starter wheel gear Refer to “RECOIL STARTER AND A.C. MAGNETO”. Plate Nut/lock washer Balancer driven gear...
  • Page 58 BALANCER GEARS AND OIL PUMP Order Job name/Part name Q’ty Remarks Balancer drive gear Spring Oil pump assembly/gasket For installation, reverse the removal procedure. – 48 –...

  • Page 59: Oil Pump

    BALANCER GEARS AND OIL PUMP OIL PUMP 5 Nm (0.5 m kg, 3.6 ft • • Order Job name/Part name Q’ty Remarks Disassembling the oil pump Remove the parts in the order below. Rotor cover Oil pump driven gear Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly...

  • Page 60: Removing The Balancer Drive Gear And Balancer Driven Gear

    BALANCER GEARS AND OIL PUMP REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1.Straighten the lock washer tabs. 2.Loosen: Balancer driven gear nut 1 NOTE: Place an aluminum plate 2 between the teeth of the balancer drive gear 3 and balancer driven gear 4.

  • Page 61: Installing The Balancer Drive Gear And Balancer Driven Gear

    BALANCER GEARS AND OIL PUMP INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1.Install: Spring Balancer drive gear (onto the buffer boss) NOTE: Align the punch mark a on the balancer drive gear with the keyway b on the crankshaft. 2.Install: Plate NOTE:...

  • Page 62: Oil Cooler

    OIL COOLER OIL COOLER 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 35 Nm (3.5 m kg, 25 ft • • 21 Nm (2.1 m kg, 15 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 63 OIL COOLER 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 35 Nm (3.5 m kg, 25 ft • • 21 Nm (2.1 m kg, 15 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 64: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES PRIMARY AND SECONDARY SHEAVES 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 100 Nm (10.0 m kg, 72 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 65 PRIMARY AND SECONDARY SHEAVES 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 100 Nm (10.0 m kg, 72 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (14) 10 Nm (1.0 m kg, 7.2 ft...

  • Page 66: Primary Sliding Sheave

    PRIMARY AND SECONDARY SHEAVES PRIMARY SLIDING SHEAVE Order Job name/Part name Q’ty Remarks Disassembling the primary sliding Remove the parts in the order below. sheave Primary sliding sheave cap Primary pulley slider Spacer Primary pulley cam Refer to “ASSEMBLING THE PRIMARY Primary pulley weight SHEAVE”.

  • Page 67: Secondary Sheave

    PRIMARY AND SECONDARY SHEAVES SECONDARY SHEAVE Order Job name/Part name Q’ty Remarks Disassembling the secondary Remove the parts in the order below. sheave Spring seat Refer to “DISASSEMBLING THE Compression spring SECONDARY SHEAVE” in Spring seat CHAPTER 4. (Manual No.: 5TE2-AE1) Guide pin Refer to “ASSEMBLING THE Secondary sliding sheave...

  • Page 68: Assembling The Primary Sheave

    NOTE: Remove any excess grease. 2.Install: Weights 1 NOTE: Apply Yamaha Grizzly grease (90 g) to the whole outer surface of the weights and install. Apply Yamaha Grizzly grease to the inner surface of the collar. Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave.
  • Page 69 PRIMARY AND SECONDARY SHEAVES 3.Install: Guide pins 1 4.Apply: ® BEL-RAY assembly lube (to all guide pin sliding grooves 1, and O-rings 2 5.Install: Spring seat Compression spring Spring seat ***************************************************** Installing steps: Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave assembly.

  • Page 70: Clutch

    CLUTCH CLUTCH Order Job name/Part name Q’ty Remarks Removing the clutch Remove the parts in the order below. Primary and secondary sheaves Refer to “PRIMARY AND SECONDARY SHEAVES”. Clutch housing assembly Refer to “REMOVING THE CLUTCH” Gasket and “INSTALLING THE CLUTCH” in CHAPTER 4.
  • Page 71 CLUTCH Order Job name/Part name Q’ty Remarks Disassembling the clutch housing Remove the parts in the order below. Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. – 61 –...

  • Page 72: Crankcase

    CRANKCASE CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER 10 Nm (1.0 m kg, 7.2 ft • • 25 Nm (2.5 m kg, 18 ft • • 17 Nm (1.7 m kg, 12 ft • • 20 Nm (2.0 m kg, 14 ft •...

  • Page 73: Neutral Switch

    CRANKCASE 10 Nm (1.0 m kg, 7.2 ft • • 25 Nm (2.5 m kg, 18 ft • • 17 Nm (1.7 m kg, 12 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 74: Crankcase

    CRANKCASE CRANKCASE 14 Nm (1.4 m kg, 10 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (12) 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 75: Crankcase Bearings

    CRANKCASE CRANKCASE BEARINGS Order Job name/Part name Q’ty Remarks Removing the crankcase bearings Remove the parts in the order below. Crankshaft and balancer Refer to “CRANKSHAFT”. Transmission Refer to “TRANSMISSION”. Middle drive/driven shaft Refer to “MIDDLE GEAR”. O-ring/collar Oil seal Bearing retainer Bearing For installation, reverse the removal...

  • Page 76: Separating The Crankcase

    Sealant (Quick Gasket (to the mating surfaces of both case halves) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 2.Install: Dowel pins 2 3.Fit the right crankcase onto the left case. Tap lightly on the case with a soft hammer.
  • Page 77 CRANKCASE 4.Tighten: È Crankcase bolts 1 20 Nm (2.0 m • kg, 14 ft • lb) (follow the proper tightening sequence) Crankcase bolts 2 10 Nm (1.0 m • kg, 7.2 ft • lb) (follow the proper tightening sequence) È Right crankcase É...

  • Page 78: Crankshaft

    CRANKSHAFT CRANKSHAFT 4 Nm (0.4 m kg, 2.9 ft • • Order Job name/Part name Q’ty Remarks Removing the crankshaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Oil strainer Balancer Refer to “REMOVING THE CRANK- SHAFT”...

  • Page 79: Removing The Crankshaft

    CRANKSHAFT REMOVING THE CRANKSHAFT 1.Remove: Crankshaft seal 1 NOTE: Mark a note of the position of each crankshaft seal so that they can be installed in the correct place and in the correct direction. 2.Remove: Crankshaft Use a crankcase separating tool 1. Crankcase separating tool: P/N.

  • Page 80: Transmission

    TRANSMISSION TRANSMISSION Order Job name/Part name Q’ty Remarks Removing the transmission Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Driven sprocket Chain Secondary shaft Guide bar Shift fork Clutch dog Drive axle assembly Shift shaft stopper Shift shaft For installation, reverse the removal procedure.

  • Page 81: Installing The Transmission

    TRANSMISSION INSTALLING THE TRANSMISSION 1.Install: Shift shaft 1 Drive axle assembly 2 Clutch dog 3 Shift fork 4 Guide bar 5 NOTE: Install the shift fork with the “L” mark facing towards the left side of the crankcase. Be sure that the shift fork guide pin is properly seated in the shift shaft groove.

  • Page 82: Middle Gear

    MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVE SHAFT Order Job name/Part name Q’ty Remarks Removing the middle drive shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Bearing housing assembly Middle driven gear Refer to “REMOVING THE MIDDLE DRIVE SHAFT”...

  • Page 83: Middle Driven Shaft

    MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job name/Part name Q’ty Remarks Removing the middle driven shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Circlip Refer to “REMOVING THE MIDDLE Bearing DRIVEN SHAFT” and “INSTALLING THE Universal joint MIDDLE DRIVEN SHAFT”...
  • Page 84 MIDDLE GEAR Order Job name/Part name Q’ty Remarks Front drive shaft coupling Bearing retainer Middle driven shaft For installation, reverse the removal procedure. – 74 –...

  • Page 85: Selecting The Middle Drive And Driven Gear Shims

    MIDDLE GEAR SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS When the drive and driven gear, bearing housing assembly and/or crankcase are replaced, be sure to adjust the gear shims. 1.Select: Middle drive gear shim 1 Middle driven gear shim 2 ***************************************************** Selection steps: Position middle drive and driven gear by...
  • Page 86 MIDDLE GEAR Example: 1) If the bearing housing is marked “–2”, ..a is 4.48. 2) b is 15.0 3) c is 55 4) If the crankcase (right) is marked “75.01”, ..d is 75.01. 5) Therefore, the shim thickness is 0.53 mm. A = 75.01 –...
  • Page 87 MIDDLE GEAR Where: e = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “76”. f = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “59”. g = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from...
  • Page 88 MIDDLE GEAR Shims are supplied in the following thickness. Middle drive pinion gear shim 0.10 0.40 0.15 0.50 Thickness (mm) 0.20 0.60 0.30 ***************************************************** – 78 –...

  • Page 89: Drive Train

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR DRIVE TRAIN FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Removing the front constant Remove the parts in the order below. velocity joints and differential gear Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
  • Page 90 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Gear motor coupler/four-wheel drive Disconnect. switch connector Differential gear case breather hose Disconnect. Differential gear Drive shaft Compression spring Coupling gear For installation, reverse the removal procedure.

  • Page 91: Measuring And Adjusting The Differential Gear Lash

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH Measuring the differential gear lash 1.Secure the gear case in a vise or another supporting device. 2.Remove: Drain plug Gasket 3.Install: A bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring...
  • Page 92 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Adjusting differential gear lash 1.Remove: Shim(s) (left) 1 Differential gear assembly 2 Shim(s) (right) 3 2.Adjust: Gear lash ***************************************************** Adjustment steps: Select the suitable shims using the following chart. Reduce shim Too little gear lash thickness.

  • Page 93: Chassis Rear Brake

    CHAS REAR BRAKE CHASSIS REAR BRAKE Order Job name/Part name Q’ty Remarks Removing the rear brake drum Remove the parts in the order below. Rear wheel (left) Refer to “FRONT AND REAR WHEELS” in CHAPTER 8. (Manual No.: 5TE2-AE1) Brake drum cover Dust seal Brake drum Adjusting nut...
  • Page 94 CHAS REAR BRAKE Order Job name/Part name Q’ty Remarks Brake camshaft lever Refer to “REMOVING THE REAR BRAKE” in CHAPTER 8. Brake shoe wear indicator (Manual No.: 5TE2-AE1) Brake camshaft Refer to “INSTALLING THE REAR O-ring BRAKE”. Dust seal Brake shoe plate For installation, reverse the removal procedure.

  • Page 95: Checking The Rear Brake

    CHAS REAR BRAKE CHECKING THE REAR BRAKE 1.Check: Brake drum 1 Cracks/damage → Replace. Splines 2 Wear/damage → Replace. 2.Check: Brake shoe plate 1 Pivot pins 2 Brake camshaft 3 Bends/cracks/damage → Replace. Dust seal 4 Wear/damage → Replace. 3.Check: Brake shoes 1 Brake shoe springs 2 Cracks/damage →...

  • Page 96: Installing The Rear Brake

    CHAS REAR BRAKE 5.Measure: Brake shoe lining thickness a Out of specification → Replace. 1 Measuring points NOTE: Replace the brake shoes as a set if either is worn to the wear limit. Brake shoe lining thickness limit: 2.0 mm (0.08 in) 6.Measure: Brake drum inside diameter a Out of specification →...
  • Page 97 4.Apply: Sealant 3 (onto the mating surfaces of swingarm) ® Sealant (Quick Gasket) P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 5.Install: Brake shoe plate 1 Bearing retainer 2 Brake shoes 3 Spring 4 Plate 5...
  • Page 98 CHAS REAR BRAKE 6.Check: Brake camshaft operation Unsmooth operation → Repair. 7.Lubricate: Dust seal 1 Lithium-soap-based grease 8.Connect: Rear brake lever cable 1 Rear brake pedal cable 2 9.Install: Springs 3 Pins 4 Adjusting nuts 5 Brake drum Brake drum cover 10.Install: Rear wheel hub (left) Rear wheel (left)

  • Page 99: Steering System

    CHAS STEERING SYSTEM STEERING SYSTEM STEERING STEM Order Job name/Part name Q’ty Remarks Removing the steering stem Remove the parts in the order below. Handlebar Refer to “HANDLEBAR” in CHAPTER 8. (Manual No.: 5TE2-AE1) Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
  • Page 100 CHAS STEERING SYSTEM Order Job name/Part name Q’ty Remarks Oil seal Bearing retainer Refer to “REMOVING THE BEARING RETAINER” and “INSTALLING THE BEARING RETAINER” in CHAPTER 8. (Manual No.: 5TE2-AE1) Bearing Oil seal For installation, reverse the removal procedure. – 90 –...

  • Page 101: Front Arms And Front Shock Absorbers

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job name/Part name Q’ty Remarks Removing the front arms and front Remove the parts in the order below. shock absorbers Engine skid plate Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
  • Page 102 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job name/Part name Q’ty Remarks Refer to “REMOVING THE FRONT Bolt/nut ARMS” and “INSTALLING THE FRONT Front lower arm/bushing ARMS AND FRONT SHOCK Bolt/nut ABSORBER” in CHAPTER 8. Front shock absorber (Manual No.: 5TE2-AE1) Bolt/nut Front upper arm/bushing Circlip...

  • Page 103: Electrical

    – ELEC ELECTRIC STARTING SYSTEM ELECTRICAL ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Removing the starter motor Remove the parts in the order below. Starter motor lead Starter motor/O-ring For installation, reverse the removal procedure. Disassembling the starter motor Remove the parts in the order below.

  • Page 104: Assembling The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM ASSEMBLING THE STARTER MOTOR 1.Install: Brush holder set 1 NOTE: Align the projection a on the brush seat with the slot b on the bracket. 2.Install: Yoke Brackets NOTE: Align the match marks a on the yoke with the match marks b on the brackets.

  • Page 105: Signal System

    – ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM – 95 –...
  • Page 106 – ELEC SIGNAL SYSTEM 3 Main switch 4 Battery 5 Main fuse 8 CDI unit A Thermo unit B Reverse switch C Neutral switch G Oil temperature warning light H Four-wheel drive indicator light I Diode J Four-wheel drive fuse L Gear motor O Neutral indicator light P Reverse indicator light...
  • Page 107 – ELEC SIGNAL SYSTEM 1.If the oil temperature warning light does not come on: Check that the light comes on when the start switch is pushed on. Check that the light comes on when the oil temperature is 145 °C (293 °F) or higher. NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for...
  • Page 108 – ELEC SIGNAL SYSTEM C0NTINUITY 4.Diode Remove the diode from the coupler. Connect the pocket tester (Ω × 1) to the diode terminals as shown. Check the diode for continuity as follows. NOTE: When you switch the tester’s positive and negative probes, the readings in the left chart will be reversed.

  • Page 109: Cooling System

    – ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse 8 CDI unit A Thermo unit D Circuit breaker (fan motor) E Fan motor relay F Fan motor R Ignition fuse – 99 –...

  • Page 110: Troubleshooting

    – ELEC COOLING SYSTEM TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1.Fuses (main, ignition) 7.Thermo unit 2.Battery 8.Wiring connections 3.Main switch (the entire cooling system) 4.Fan motor 5.Circuit breaker (fan motor) 6.Fan motor relay NOTE: Pocket tester: Remove following part(s)
  • Page 111 – ELEC COOLING SYSTEM C0NTINUITY 4.Fan motor Disconnect the fan motor coupler. Connect the battery (12 V) as shown. Battery (+) lead → Red terminal 1 Battery (–) lead → Black terminal 2 DOES NOT TURN Replace the fan motor. Check the operation of the fan motor.
  • Page 112 – ELEC COOLING SYSTEM C0NTINUITY 6.Fan motor relay Remove the fan motor relay from the wire harness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the fan motor relay terminals. R/W R/B Tester (+) lead → Red/Black terminal 1 Tester (–) lead →...
  • Page 113 – ELEC COOLING SYSTEM C0NTINUITY EB803028 POOR CONNECTION 8.Wiring connections Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the cooling system. CORRECT Replace the CDI unit. – 103 –...

  • Page 114: Troubleshooting

    TRBL FAULTY GEAR SHIFTING/ OVERHEATING SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for checking, adjusting and replacing of parts.

  • Page 115: Faulty Brake

    TRBL FAULTY BRAKE SHTG EBS00549 FAULTY BRAKE POOR BRAKING EFFECT Front disc brake Worn brake pads Worn disc Air in brake fluid Leaking brake fluid Faulty master cylinder kit cup Faulty caliper kit seal Loose union bolt Broken brake hose and pipe Oily or greasy disc/brake pads Improper brake fluid level Rear drum brake...
  • Page 118 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

  • Page 119: Yfm35Fas/Yfm350Fas Wiring Diagram

    YFM35FAS/YFM350FAS WIRING DIAGRAM 1 A.C. magneto R/B L/W 2 Rectifier/regulator W/R W/G 3 Main switch (BLACK) (BLACK) (BLACK) 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor W/G R R W/G W/R W/G W/L W/R 8 CDI unit...

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