Yamaha BANSHEE YFZ350 All-Terrain Vehicle Manuals

Manuals and User Guides for Yamaha BANSHEE YFZ350 All-Terrain Vehicle. We have 2 Yamaha BANSHEE YFZ350 All-Terrain Vehicle manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha BANSHEE YFZ350 Service Manual (279 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 19 MB

How to Use this Manual
6
Illustrated Symbols
7
Contents
8
Machine Identification
9
Model Label
9
Specifications
10
Cable Routing
11
Periodic Maintenance/Lubrication Intervals Table
15
Electrical System
17
Ignition System - Circuit Diagram
17
Engine Revolution Limiter System
18
Ignition System Troubleshooting
19
Yamaha YFZ350B - Supplementary Service Manual
21
To Use this Manual
24
Supplementary Service Manual: Contents
27
General Information
29
Vehicle Identification Number
29
Engine Serial Number
29
General Specifications
30
Maintenance Specifications
30
Tightening Torque
31
Chassis
32
Front Shock Absorber and Front Arms
32
Front Shock Absorber and Front Arms: Removal of Parts
33
Free Play Inspection
33
Front Arms Inspection
34
Front Arms and Shock Absorber Installation
35
Machine Identification, Vehicle Identification Number
43
Special Tools for Chassis Service
44
Specifications Table
45
Maintenance Specifications - Engine
46
Maintenance Specifications - Chassis
46
Tightening Torques
47
Periodic Inspection and Adjustment - Chassis
49
Front Brake Inspection
49
Front Brake Pad Inspection
49
Front and Rear Shock Absorber Adjustment
49
Spring Preload Adjustment Steps
50
Rebound Damping Force Adjustment Steps
51
Compressinon Damping Force Adjustment Steps
52
Front Brake Caliper and Brake Disc
53
Caliper Removal
55
Caliper Disassembly
56
Caliper Installation
56
Rear Axle Installation
58
Identification
68
Gaskets, Oil Seals and O-Rings
69
Lock Washers/Plates and Cotter Pins
69
Bearings and Oil Seals
69
Circlips
70
Special Tools for Tune-Up
70
Tools for Engine Service
71
Tools for Chassis Service
72
Tools for Electrical Components
72
Maintenance Intervals
74
Engine
76
Carburetor Synchronization
76
Throttle Cable Adjustment Steps
77
Idle Speed Adjustment
77
Idle Speed Adjustment Steps
78
Throttle Lever Adjustment
79
Speed Limiter Adjustment
79
Speed Limiter Length Adjustment Steps
79
Fuel Line Inspection
80
Air Filter Cleaning
80
Exhaust System Inspection
82
Transmission Oil Level Inspection
82
Transmission Oil Replacement
83
Radiator Hose Inspection
83
Coolant Level Inspection
84
Recommended Coolant
84
Coolant Replacement
85
Handling Notes of Coolant
85
Clutch Adjustment
88
Clutch Lever Free Play Adjustment
88
Mechanism Adjustment
88
Fuel Cock Cleaning
91
Front Brake Lever Adjustment
91
Rear Brake Pedal Adjustment
92
Brake Pads Inspection
92
Front Brake Pads
92
Rear Brake Pads
93
Parking Brake Adjustment
93
Parking Brake Adjustment Steps
94
Drive Chain Slack Adjustment
94
Drive Chain Slack Adjustment Steps
95
Drive Chain Lubrication
96
Drive Chain and Sprockets Inspection
97
Chain Tensioner and Chain Guide Inspection
98
Steering System Inspection
98
Cable Inspection and Lubrication
99
Front Shock Absorber Preload
100
Rear Shock Absorber
100
Spring Preload Adjustment
101
Rebound Damping Force Adjustment
102
Compression Damping Force Adjustment Steps
103
Levers, Pedal, Etc. Lubrication
104
Front Arms and Rear Arm Pivots Lubrication
104
Tires Check
105
Tire Characteristics
105
Tire Pressure
105
Tires: Maximum Loading Limits
105
Wheels Check
107
Electrical Parts
107
Ignition Timing Check
107
Spark Plug Inspection
109
Headlight Bulb Replacement
109
Headlight Beam Adjustment
110
Engine Overhaul
111
Engine Removal
114
Preparation for Engine Removal
114
Front Fender
115
Rear Fender
115
Fuel Tank
115
Exhaust Pipe and Silencer
116
Carburetor Removal
116
Change Pedal
117
CDI Magneto
117
Drive Chain
118
Tension Rod
118
Cables
119
To Remove Engine
119
Engine Disassembly
121
Cylinder Head Removal
121
Reed Valve Assembly
121
Radiator Hose Removal
121
Cylinder
122
Piston Pin and Piston
122
Kick Crank
122
Crankcase Cover (Right)
123
Clutch and Primary Drive Gear
123
Kick Axle
124
Change Shaft
125
Stator Assembly
125
Cam Stopper Plate
125
Bearing Stopper Plate
125
Crankcase
126
Push Lever
126
Shifter
127
Crankshaft Removal
127
Inspection and Repair
128
Cylinder Head Inspection and Repair
128
Cylinder Inspection and Repair
128
Piston, Piston Ring and Piston Pin Inspection and Repair
129
Piston Inspection and Repair
129
Piston Ring Inspection and Repair
130
Piston Ring Oversize
131
Piston Pin Inspection and Repair
131
Joint Pipe Inspection and Repair
132
Clutch Inspection and Repair
132
Friction Plates Inspection
132
Push Lod Inspection
133
Clutch Housing Inspection
133
Clutch Boss and Pressure Plate Inspection
133
Primary Drive Gear Inspection
134
Kick Starter Inspection
134
Shifter Inspection
134
Transmission Inspection and Repair
135
Shift Fork Inspection
135
Shift Cam Inspectoin
135
Main and Drive Axles Inspection
135
Crankshaft Inspection
136
Bearings and Oil Seals Inspection
137
Circlips and Washers Inspection
137
Crankcase Inspection
137
Engine Assembly and Adjustment
138
Crankshaft Installation
138
Crankshaft/Piston Explosion View
139
Shifter Installation
140
Shifter Exploded View
141
Transmission Installation
142
Transmission Exploded View
143
Crankcase Installation
144
Change Shaft Installation
145
Change Lever Position Adjustment Steps
146
Kick Axle Installation
146
Clutch and Primary Drive Gear Installation
147
Clutch/Push Lever/Primary Drive Gear Exploded View
150
Crankcase Cover (Right) Installation
151
Kick Crank Installation
151
Piston Pin and Piston Installation
151
Cylinder Installation
152
Radiator Hose Installation
153
Reed Valve Assembly Installation
153
Cylinder Head Installation
153
Cylinder/Cylinder Head Exploded View
154
CDI Magneto Installation
155
Remounting Engine
155
Cooling System
159
Radiator Exploded View
160
Radiator Removal
161
Radiator Inspection
162
Radiator Installation
163
Water Pump Removal
164
Water Pump Inspection
166
Water Pump Installation
167
Carburetion
171
Carburetor Exploded View
172
Carburetor Specifications
172
Carburetor Sectional View
173
Carburetor Disassembly
174
Carburetor Inspection
176
Carburetor Assembly
177
Float Height Measurement and Adjustment Steps
177
Carburetor Installation
179
Carburetor Adjustment
179
Fuel Level Measurement and Adjustment Steps
179
Carburetor Setting Change
180
Reed Valve Removal
181
Reed Valve Disassembly
181
Reed Valve Inspection
181
Assembling the Reed Valve
182
Reed Valve Installation
182
Chassis - Contents
183
Front Wheel Exploded View
184
Front Wheel Removal
185
Front Wheel Hub Removal
185
Front Wheel Inspection
186
Rear Wheel and Rear Axle Exploded View
189
Rear Wheel Removal
190
Rear Wheel Hub Removal
190
Rear Wheel Axle Removal
190
Wheel Hub Removal
191
Rear Wheel Inspection
191
Rear Wheel Installation
192
Wheel Hub Installation
192
To Install the Rear Axle
192
Ring Nuts Tightening Steps
193
Rear Wheel Hub Installation
194
To Install the Rear Wheel
194
Front Brake
195
Front Brake Caliper and Brake Disc Exploded View
195
Front Brake Hose and Master Cylinder Exploded View
196
Front Brake Pad Replacement
197
Front Brake Caliper Removal
198
Front Brake Caliper Disassembly
199
Caliper Inspection
199
Front Brake Caliper Installation
199
Master Cylinder Disassembly
200
Master Cylinder Removal
200
Master Cylinder Inspection
201
Master Cylinder Installation
201
Front Brake Disc
202
Front Brake Air Bleeding
203
Rear Brake Exploded View
204
Rear Brake Pad Replacement
205
Rear Brake Caliper Disassembly
207
Rear Brake Caliper Removal
207
Rear Brake Caliper Piston Removal Steps
208
Rear Brake Caliper Inspection
208
Rear Brake Caliper Installation
209
Rear Brake Master Cylnder Disassembly
210
Rear Brake Master Cylinder Removal
210
Rear Brake Master Cylinder Inspection
210
Rear Brake Master Cylinder Installation
211
Rear Brake Disc Inspection
211
Rear Brake Air Bleeding
211
Steering System Exploded View
212
Steering System Removal
213
Steering System: Inspection
214
Steering System Installation
214
Steering Knuckles and Tie-Rod Ends Removal
216
Steering Knuckles and Tie-Rod Ends Inspection
216
Steering Knuckles and Tie-Rod Ends Installation
217
Tie-Rod Assembly Length Adjustment Steps
217
Toe-In Adjustment
218
Front Shock Absorber and Front Arms Exploded View
220
Front Shock Absorber and Front Arms Removal
221
Front Shock Absorber and Front Arms: Free Play Inspection
222
Front Shock Absorber Inspection
223
Inspection of the Front Arms
223
Installation of the Front Arms and Shock Absorber
223
Rear Shock Absorber and Swingarms Exploded View
226
Rebound Damping
226
Compression Damping
226
Spring Preload (Installed Length)
226
Rear Shock Absorber and Swingarms: Handling Notes
227
Rear Shock Absorber and Swingarms: Notes on Disposal
227
Rear Shock Absorber Removal
228
Swingarm Removal
228
Rear Shock Absorber and Swingarms: Free Play Inspection
229
Rear Shock Absorber Inspection
229
Swingarm Inspection
230
Drive Chain Inspection
230
Swingarm Linkage Inspection
230
Rear Shock Absorber and Swingarms Installation
231
Electrical
233
Circuit Diagram
234
Electrical Parts Diagram
235
Electrical Components Diagram
236
Electrical Components Specifications
236
Ignition System: Circuit Diagram
238
Ignition System Parts Diagram
239
Throttle Override System (T.O.R.S.)
240
Ignition System: Troubleshooting
241
If Ignition System Become Inoperative (no Spark or Intermittent Spark)
241
Ignition System: Troubleshooting 2
245
Switches Test
246
Lighting System Circuit Diagram
248
Lighting System Components Diagram
249
Lighting System Troubleshooting
250
Headlight Does Not Come on
250
Taillight Does Not Come on
252
"Lights" (Dimmer) Switch Test
254
Appendices
255
Appendice: General Specifications
256
Maintenance Specifications: Engine
259
Tightening Torque Table
262
Chassis Specifications
263
Maintenance Specifications (Electrical)
266
General Torque Specifications
268
Definition of Units
268
Conversion Tables
269
Cable Routing Diagram
270
Wiring Diagram
275

Yamaha BANSHEE YFZ350 Owner's Manual (140 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 4 MB

Table of Contents
8
Safety Information
11
Location of the Warning and Specification Labels
15
Description
21
- Left View
  21
- Right View
  21
- Controls and Instruments
  22
Instrument and Control Functions
23
- Main Switch
  23
- Handlebar Switches
  24
- Throttle Lever
  24
- Throttle Override System
  25
- Speed Limiter
  25
- Clutch Lever
  26
- Brake Lever
  27
- Brake Pedal
  27
- Parking Brake
  27
- Shift Pedal
  29
- Kickstarter
  29
- Fuel Tank Cap
  29
- Fuel
  30
- Fuel Cock
  31
- Starter (Choke)
  32
- Seat
  33
- Adjusting the Front Shock Absorber Assemblies
  34
- Adjusting the Rear Shock Absorber Assembly
  35
Pre-Operation Checks
39
- Pre-Operation Check List
  39
- Fuel and 2-Stroke Engine Oil Mixing Ratio
  41
- Transmission Oil
  41
- Coolant
  41
- Front and Rear Brakes
  41
- Throttle Lever
  42
- Drive Chain
  42
- Tires
  43
- Measuring the Tire Pressure
  44
- Tire Wear Limit
  44
- Chassis Fasteners
  45
- Instruments, Lights and Switches
  45
Operation
46
- Starting a Cold Engine
  46
- Starting a Warm Engine
  47
- Shifting
  48
- Engine Break-In
  49
- Parking
  50
- Parking on a Slope
  51
- Accessories and Loading
  51
Riding Your Atv
54
- Getting to Know Your Atv
  55
- Ride with Care and Good Judgement
  55
- Be Careful Where You Ride
  61
- Turning Your Atv
  65
- Climbing Uphill
  67
- Riding Downhill
  69
- Crossing a Slope
  70
- Crossing through Shallow Water
  71
- Riding over Rough Terrain
  73
- Sliding and Skidding
  73
- What to Do if
  74
- What to Do
  74
Periodic Maintenance and Minor Repair
76
Transmission Oil
85
Coolant
87
Cleaning the Air Filter Element
92
Cleaning the Spark Arrester
95
Changing the Carburetor Settings
97
Adjusting the Engine Idling Speed
104
Adjusting the Throttle Cable Free Play
106
Checking the Front and Rear Brake Pads
107
Checking the Brake Fluid Level
108
Changing the Brake Fluid
109
Checking the Front Brake Lever Free Play
109
Checking the Brake Pedal Position
110
Adjusting the Parking Brake Free Play
111
Brake Light Switches
113
Adjusting the Clutch Lever Free Play
113
Drive Chain Slack
114
Lubricating the Drive Chain
116
Checking and Lubricating the Cables
117
Checking and Lubricating the Brake and Clutch Levers
118
Checking and Lubricating the Brake and Shift Pedals
118
Checking the Wheel Hub Bearings
118
Lubricating the Rear Suspension Relay Arm and Connecting Arm Pivoting Points
118
Lubricating the Upper and Lower Arm Pivots
119
- Lubricating the Steering Shaft
  120
- Replacing a Headlight Bulb
  120
- Adjusting a Headlight Beam
  123
- Replacing the Tail/Brake Light Bulb
  123
- Removing a Wheel
  124
- Installing a Wheel
  125
- Troubleshooting
  126
- Troubleshooting Charts
  127
- Engine Overheating
  128
Cleaning and Storage
129
- Cleaning
  129
- Storage
  130
Specifications
132
Consumer Information
136
- Identification Numbers
  136

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