Yamaha YFM350XP Supplementary Service Manual

Download or browse on-line these Supplementary Service Manual for Yamaha YFM350XP Motorcycle, Offroad Vehicle.

Yamaha YFM350XP Manual Information:

This manual for Yamaha YFM350XP, given in the PDF format, is available for free online viewing and download without logging on. The guide contains 29 pages, and the size of the file at download is 0.46 Mb. The document type is Supplementary Service Manual.

Download Manual

More Manuals:

In case you failed to obtain relevant information in this document, please, look through related operating manuals and user instructions for Yamaha YFM350XP. Just click one of the links below to go to the selected manual:

Summary of Contents:

[Page 1] Yamaha YFM350XP

YFM350XP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-09 3GD-28197-16 ...

[Page 2] Yamaha YFM350XP

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 followin...

[Page 3] Yamaha YFM350XP

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...

[Page 4] Yamaha YFM350XP

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...

[Page 5] Yamaha YFM350XP

EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the 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 Carburetion 6 Drive train ...

[Page 6] Yamaha YFM350XP

CONTENTS SPECIFICATIONS ........................................................................................... 1 GENERAL SPECIFICATIONS ................................................................. 1 MAINTENANCE SPECIFICATIONS ..............

[Page 7] Yamaha YFM350XP

– 1 – SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFM350XP Model code number: 5NF4 (except for California) 5NF5 (for California) Spark plug: Type/manufacturer DR8EA (NGK) Gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Electrical:...

[Page 8] Yamaha YFM350XP

– 2 – 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) ...

[Page 9] Yamaha YFM350XP

– 3 – SPEC MAINTENANCE SPECIFICATIONS Carburetor: I. D. mark 3GD 00 (except for California) 3GD 10 (for California) Main jet (M.J) #145 Main air jet (M.A.J) 0.6 Jet needle (J.N) 5J18-3 (except for California) 5J31-1 (except for California) Needle...

[Page 10] Yamaha YFM350XP

– 4 – SPEC MAINTENANCE SPECIFICATIONS CHASSIS ELECTRICAL 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) Model YFM350XP C.D.I.: M...

[Page 11] Yamaha YFM350XP

– 5 – SPEC CABLE ROUTING 1 Clutch switch 2 Rear brake cable 3 Clutch cable 4 Front brake hose 5 Front brake light switch 6 Throttle cable 7 Band È Install the fuel tank breather hose into the hole of the handlebar cover. CABLE ROUTING ...

[Page 12] Yamaha YFM350XP

– 6 – SPEC 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 CABLE ROUTING ...

[Page 13] Yamaha YFM350XP

– 7 – SPEC 1 Starter relay 2 Neutral relay 3 Tail/brake light 4 CDI unit 5 Rectifier/regulator 6 Fuse 7 Battery breather hose È Pass the battery breather hose through the inside of the frame bracket. É Pass the battery breather hose through the...

[Page 14] Yamaha YFM350XP

– 8 – SPEC 1 Battery negative lead 2 Rear brake light switch 3 Drive select lever switch 4 Rear brake cable 5 Rear brake hose 6 Rectifier/regulator 7 CDI unit 8 Carburetor overflow hose 9 Rear brake light switch lead È Pass the wire harness and ...

[Page 15] Yamaha YFM350XP

– 9 – CHK ADJ INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive ma...

[Page 16] Yamaha YFM350XP

– 10 – CHK ADJ 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 ...

[Page 17] Yamaha YFM350XP

– 11 – CHK ADJ 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 BRAK...

[Page 18] Yamaha YFM350XP

– 12 – 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 ...

[Page 19] Yamaha YFM350XP

– 13 – –+ 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. N OTE: ● Set the pocket tester to...

[Page 20] Yamaha YFM350XP

– 14 – –+ ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM OFF LO HI OFF ON OFF PUSH ON OFF W/G W/G W/R R W/G W/R R OO W W W W R Br Br R/B R/W B W W R W/GR W/RW/G RW/G W/LW/R LR/B R/WBr G/YBBB RBr W WW R/BL Br R/W W WW B (GRAY) RB ...

[Page 21] Yamaha YFM350XP

– 15 – –+ ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING Procedure Check: 1.Fuse 2.Battery 3.Spark plug 4.Ignition spark gap 5.Spark plug cap resistance 6.Ignition coil resistance IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT...

[Page 22] Yamaha YFM350XP

– 16 – –+ ELEC IGNITION SYSTEM CORRECT Spark plug gap: 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) INCORRECT 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 dyna...

[Page 23] Yamaha YFM350XP

– 17 – –+ ELEC IGNITION SYSTEM 5.Spark plug cap resistance ● Remove the spark plug cap. ● Connect the pocket tester (Ω× 1k) to the spark plug cap. * MEETS SPECIFICATION ● Check that the spark plug cap has the specified resistance. Spar...

[Page 24] Yamaha YFM350XP

– 18 – –+ ELEC IGNITION SYSTEM BOTH MEET SPECIFICATION ● 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 speci...

[Page 25] Yamaha YFM350XP

– 19 – –+ ELEC IGNITION SYSTEM C0NTINUITY MEETS SPECIFICATION 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 chargin...

[Page 26] Yamaha YFM350XP

– 20 – –+ ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM OFF LO HI OFF ON OFF PUSH ON OFF W/G W/G W/R R W/G W/R R OO W W W W R Br Br R/B R/W B W W R W/GR W/RW/G RW/G W/LW/R LR/B R/WBr G/YBBB RBr W WW R/BL Br R/W W WW B (GRAY) RB WWW ...

[Page 27] Yamaha YFM350XP

– 21 – –+ ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for continu- ity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTIN...

[Page 28] Yamaha YFM350XP

YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A. ...

[Page 29] Yamaha YFM350XP

YFM350XP WIRING DIAGRAM OFF LO HI OFF ON OFF PUSH ON OFF W/G W/G W/R R W/G W/R R OO W W W W R Br Br R/B R/W B W W R W/GR W/RW/G RW/G W/LW/R LR/B R/WBr G/YBBB RBr W WW R/BL Br R/W W WW B (GRAY) RB WWW (GREEN) G/WSb Br W/B (GRAY) (GRAY) YBr (BLACK) BB ...