.

YAMAHA

278 Pgs + 1 flo

YFZ350

YAMAHA

LlT-11616-10-95

3GG-28197-12

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the YFZ350J/K. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with following manual:

YFZ350T'86 SERVICE MANUAL: 2GU-10

YFZ350A '89 SUPPLEMENTARY SERVICE MANUAL: 3GG-10 YFZ350B '90 SUPPLEMENTARY SERVICE MANUAL: 3GG-11

YFZ350J/K SUPPLEMENTARY SERVICE MANUAL ©1997 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 1997 All rights reserved.

Any reprinting or unauthorized use without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A. LlT-11616-10-95

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 machines has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE: ___

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

£WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.

CAutiON:

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL

This manual consists of chapters for the main categories of subjects. (See "Illustrated svrnbols")

1st title CD: This is a chapter with its symbol on the upper right of each page.

2nd title ~ :

This title appears on the upper of each page on the left of the chapter symbol. (For the chapter "Periodic inspection and adjustment "the 3rd title appears.)

3rd title@:

This is a final title.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly and inspections.

A set of particularly important procedure (@) is placed between aline of asterisks (*); with each procedure preceded by (.) .

IMPORTANT FEATURES

• Data and a special tool are framed in a box preceded by a relevant symbol (@).

• An encircled numeral (@) indicates a part name, and an encircled alphabetical letter data or an alignment mark ((7»), the others being indicated by an alphabetical letter in a box (@).

• A condition of a faulty component will precede an arrow symbol and course of action

required the symbol (@).

EXPLODED DIAGRAM

Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

2."- __ :

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u .. t .. c ....... c_ .cillQt_~'.

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ENG

@ @

ICOOLI ~ IlcARBI ~ I

(j) ®

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EBOO3000

ILLUSTRATED SYMBOLS

Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content.

<D General information @ Specifications

® Periodic inspection and adjustment @ Engine

® Cooling system ® Carburetion

(j) Drive train

® Chassis

® Electrical

@ Troubleshooting

Illustrated symbols @ to @ are used to identify the specifications appearing in the text.

@ Filling fluid @Lubricant @ Special tool @ Tightening

@ Wear limit, clearance @ Engine speed @Q,V,A

Illustrated symbols @to @ in the exploded diagrams indicate the types of lubricants and lubrication points.

@ Apply engine oil

@ Apply gear oil

® Apply molybdenum disulfide oil @ Apply wheel bearing grease

@ Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease

Illustrated symbols ® to @ in the exploded diagrams indicate the where to apply locking agent ® and when to install new parts

@.

® Apply locking agent (LOCTITP)) @Use new one

CONTENTS

GENERAlINFORMATION 1

MACHINE IDENTIFICATION 1

VEHICLE IDENTIFICATION NUMBER 1

MODEL LABEL 1

SPECIFICATIONS 2

GENERAL SPECIFICATIONS 2

MAINTENANCE SPECIFICATIONS 2

ENGINE 2

ELECTRICAL 2

CABLE ROUTING 3

PERIODEC INSPECTIONS AND ADJUSTMENTS 7

INTRODUCTION 7

PERIODEC MEINTENANCE/lUBRICATION INTERVALS 7

ElECTRICAl 9

IGNITION SYSTEM 9

CIRCUIT DIAGRAM 9

ENGINE REVOLUTION LIMITER SYSTEM 10

TROUBLESHOOTING 11

YFZ350J/K WIRING DIAGRAM

MACHINE IDENTIFICAnON II~~~ I.-I

EB100000

GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER

The vehicle identification number CD is stamped into the left side of the down tube.

NOTE: _

The vehicle identification number is used to identify your machine.

MODEL LABEL

The model label CD is affixed to the frame under the seat. Record the information on this label in the space provided.

This information will be needed to order spare parts.

-1-

GENERAL SPECIFICATIONS I SPEC I ~ I SPECIFICATIONS

GENERAL SPECIFICATIONS

Model YFZ350J/K
Model code number: YFZ350J('97): 3GGS (US)
3GGT (F)
YFZ350K('98): 3GGW(US)
3GGV(CDN)
3GGX(F)
Basic weight:
With oil and full fuel tank 187 kg (412 Ib)
Spark plug:
Type B8ES/W24ES
Manufacturer NGK/DENSO
Gap 0.7-0.8 mm (0.028-0.031 in) MAINTENANCE SPECIFICATIONS ENGINE

Model YFZ350J/K
Piston ring: ~B
Top ring:
Type Keystone
Dimensions (B x T) T 1.2 x 2.6 mm (0.047-0.102 in)
End gap (Installed) 0.6-0.8 mm (0.024-0.031 in)
<Limit> 1.0 mm (0.39 in)
Side clearance (Installed) 0.02-0.06 mm (0.0008-0.0024 in)
<Limit> ~=iB 0.12 mm (0.0047 in)
2nd ring:
Type Keystone
Dimensions (B x T) T 1.5 x 2.5 mm (0.059-0.098 in)
End gap (Installed) 0.6-0.8 mm (0.024-0.031 in)
<Limit> 1.0 mm (0.39 in)
Side clearance (Installed) 0.02-0.06 mm (0.0008-0.0024 in)
<Limit> 0.12 mm (0.0047 in)
Carburetor:
Float height (F.H.) 20.5-21.5 mm (0.807-0.845 in) ELECTRICAL

Model YFZ350J/K
C.D.I:
Magneto model/Manufacturer VCE33/DENSO
C.D.I. unit model/Manufacturer 3GG-10/DENSO
. Ignition coil:
. Model/Manufacturer J0146/DENSO
Flywheel magneto:
Model/Manufacturer VCE33/DENSO ... 2-

_____________________ C_A_B_LE_R_O_U_T_IN_G __ ~sPECI~1

CABLE ROUTING

G) Throttle switch lead @ Throttle cable

@ Fuel tank breather hose @Band

@ Parking brake switch @ Parking brake cable (j) Clutch cable

@ Front brake hose ® Clamp

@ Breather hose

~ Pass the cable in front of the front brake hose. lID Pass the cables behind the front brake hose.

[g Pass the hose through the handle protector hole

[Q] Pass the hose and lead in front of the cable guide. Pass the handlbar switch lead and parking switch lead behind the cable guide.

[g] Clamp the hoses.

[£] Pass the hoses through the hose guide.

-3-

_____________________ C_A_B_LE __ RO_U_T_IN_G __ lsPECI~1

CD Main switch ® Wireharness @ Fuel hose

@ Crankcase breather hose @ Carburetor over flow hose ® Radiator hose

(j) Throttle switch lead

® Engine stop switch lead ® Handle switch lead

[6] Pass the wireharness into the guide. Align the marking tape at the guide.

[ID Pass the hose into the guide.

[g Do not pass the hose into the guide. Pass the hose behind the brake hose.

-4-

_________ ISPECI g-I

CD Carburetor switch lead @ Throttle cable

@ Band

@ Clutch cable

@ Parking brake cable @ Breather hose

(j) Cable guide

@ C.D.I. magneto lead ® Wireharness

@ Clamp

!Al Pass the wireharness and hoses through the

guide on the air cleaner.

[ill Pass the lead above the hoses and cables. [Q] Pass the cable through the guide.

[Q] Route the hose behind the clutch and parking cable. Pass the hose between both carburetor joint.

[gJ Route the cable behind the rear brake hose. III Pass the hoses inside the wireharness.

-5-

_________ ISPECI g-I

CD Headlight

@ Ignition coil @ Wireharness @ Reservoir tank

@ Voltage regulator @ Body earth

(f) Band

@Clamp

® C.D.I. unit

@ Carburetor switch lead @ T.O.R.S. control unit

IA]lgnition coil lead (Orange) [§] Ignition coil lead (Black)

-6-

INTRODUCTION/ II~S I ~ I

PERIODIC MAINTENANCE/LUBRICATION INTERVALS _ . ~ .

EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION

This chapter includes all information necessary to perform recommended inspections 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. All service technicians should be familiar with this entire chapter.

YP301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INITIAL EVERY
ITEM ROUTINE , 3 6 6 ,
month months months months year
Transmission Replace oil 0 0 0 0
Check coolant leakage.
Cooling system Repair if necessary 0 0 0 0 0
Replace coolant every 24 months.
Spark plug Check condition. 0 0 0 0 0
Clean or replace if necessary.
Air filter Clean. Replace if necessary. Every 20-40 hours.
(More often in wet or dusty areas)
Carburetor" Check idle speed/starter operation. 0 0 0 0
Adjust if necessary.
Fuelline* Check fuel hose for cracks or damage. 0 0 0
Replace if necessary.
Throttle operation Inspect and adjust free play, if necessary. 0 0 0 0 0
Front and rear Check operation/fluid leakage/See NOTE. 0 0 0 0 0
brake operation* Correct if necessary.
Front and rear Check pads wear. 0 0 0
brake pads* Replace if necessary.
Clutch* Inspect free play and operation. 0 0 0 0
Replace if necessary.
Drive chain Check chain slack/aliment. Adjust if necessary. 0 0 0 0
Clean and lube. Replace if necessary.
Drive chain guard Check wear and replace if necessary. 0 0 0
and rollers*
Steering system" Inspect free play, clean and lubricate. 0 0 0 0 0
Front and rear Inspect and lubricate. ** 0 0 0 0 0
suspension*
Inspect air pressure, wheel runout, and tire wear.
Tires, wheels Inspect bearings. * 0 0 0 0 0
Replace bearings ifnecessary.*
Throttle, control cable Check routing and connection. Lubricate. 0 0 0 0 0
Outside nuts and bolts Retighten. 0 0 0 0 0
Frame Clean and inspect. 0 0 0 0
Lighting equipment Inspect. 0 0 0 0 0 It is recommended that these items be serviced by a Yamaha dealer. **. Lithium soap base grease.

*.

-7-

II:gSI~1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS. . ~ _

NOTE: ___

Brake fluid replacement:

1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid.

Normally check the brake fluid level and add the fluid as required.

2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.

3. Replace the brake hoses every four years, or if cracked or damaged.

-9-

IGNITION SYSTEM 1 ELEC 11::=31

ENGINE REVOLUTION LIMITER SYSTEM when the parking brake is applied, the engine revolution limiter system becomes activated, thereby letting the rider know that the parking brake is on.

System

A switch is newly provided on the parking brake lever on the left of the handlebar to sense the parking brake condition.

The ignition unit which receives a sensed signal becomes activated as follows according to the parking brake condition. I

• Parking brake is released.

(switch OFF) --7 Ignition occurs normally .

• Parking brake is applied.

(switch ON) --7 Misfire occurs at 2,300 r/mln.

(engine will not rev up beyond 2,300 r/min.)

CD C.D.I. unit

@ Ignition timing control circuit

@ Engine revolution limiter control circuit @ Parking switch

-10-

IGNITION SYSTEM I ELEC I u I

TROUBLESHOOTING

IF THE ENGINE REVOLUTION LIMITER SYSTEM FAILS TO OPERATE.

(WHEN THE PARKING BRAKE IS APPLIED, ENGINE WILL REV OVER THE 2,300 r/min.l

Procedure Check:

1. Engine misfiring range

2. Parking switch

NOTE: ___

.Remove the following parts before troubleshooting.

1) Seat 3) Rear fender

3. Wiring connection (entire ignition system)

2) Front fender

.Use the special tools specified in the trouble shooting section.

~~~--------------------------,

Inductive Tachometer YU-08036

Engine Tachometer 90890-03113

Pocket tester:

YM-03112/90890-03112

1. Engine misfiring range
.Attach the Inductive Tachometer or en-
gine tachometer to the spark plug lead .
• Start the engine, then, shift the gear in
neutral position and set the parking
brake .
• Check the misfiring nearly 2,300 r/min. MEET SPECIFICATION
C) Misfiring engine speed:
~
nearly 2,300 r/min
OUTOF Engine revolution limiter system is good.
"'I ,.. SPECIFICATION
2. Parking switch D
.Disconnect the parking switch coupler

from the wireharness. IO§¢
.Connect the pocket tester (Ox1) to the 1--- IS
parking switch coupler. I
I B B I [ B I G/v)
.Check the switch for continuity. rG/vT B-(1"'o-t~B
Parking
brake Good condition Bad condition G/V ----- ......

Apply o (Continuity) X 10 Ix BAD CONDITION
Release X (Nocontinuity) xlo 10 1
GOOD CONDITION
'Ii 7' I Replace the parking switch. I *

-11-

IGNITION SYSTEM I ELEC I u I

*

~

3. Wiring connection POOR CONNECTIONS
.Check the connection of the entire engine I
revolution limiter system. ..
Refer to "CIRCUIT DIAGRAM". I Correct. I

CORRECT
'-.;~ I Replace the C.D.1. unit.

-12-

YAMAHA

LIT -11616-07-86

FOREWORD

This Supplementary Service manual has been prepared to introduce new service and new data for the YFZ350B. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with following manual.

YFZ350T Service Manual (L1T-11616-05-87) YFZ350A Service Manual (L1T-11616-07-46)

YFZ350B SUPPLEMENTARY SERVICE MANUAL

©1990 by Yamaha Motor Corporation, U.S.A. 1st Edition, November 1990

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

L1T-11616-07-86

NOTICE

This manual was by the Yamaha Motor Company primary for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that person using this book to perform maintenance and repairs on Yamaha machine have a basic understanding of the mechanical concepts and procedures inherent in machine repair technology. Without such knowledge, attempt repairs or service to this model may render it unfit to use and/or unsafe.

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, there applicable, appear in future editions of this manual.

TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO .• LTD.

PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

AWARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

CONSTRACTION OF THIS MANUAL

This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols")

1 st title CD: 2nd title ®:

This is a chapter with its symbol on the upper right of each page.

This title appears on the upper of each page on the left of the chapter symbol. (For the chapter "Periodic inspection and adjustment" the 3rd title appears.)

This is a final title.

3rd title @:

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections.

A set of particularly important procedure @ is placed between a line of asterisks" *" with each procedure preceded by " • ",

IMPORTANT FEATURES

• Data and a special tool are framed in a box preceded by a relevant symbol ® .

• An encircled numeral ® indicates a part name, and an encircled alphabetical letter data or an alignment mark (j), the others being indicated by an alphabetical letter in a box ®.

• A condition of a faulty component will precede an arrow symbol and the course of action required the symbol ® .

EXPLODED DIAGRAM

Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

FRONT FORK ICHAsi #:r01

--------------------

1, Ef;minal~

1. Inspect

°Ca.bondeposits

9

USI!Ihecrankcaseseparaiinglool2

11:1 C,~~~~~~;;.p.'lllnll tool"

INSPECTION AND REPAIR

21nSPI!ct

US(I8 loundedscrapl!f NOTE"-------

• Grommet ScralcheslOamage-l eplace

Takeca.e!Qllvoidedam8gingthesparkplug threads. 00 nOI use a sharp ;nStrumllnt Avoidscratchinlllhe.'uminum

W""08 m ••• ""mant Ind ,,,url.ce· mental.p:

• An.ell a straight edge CD andathickne·

)---+l~-:;4~~~~ .:':e~:~:t~ .. :::~:;:.linderhI!8d.

<..J j alftheWarpallei.ou\ofIPecifiC8tion.r e-

_~-..,.-(tJ surfaeetIl8<:ylind.rhnd.

'----"~~-=-~ ....:=..I • ;1\'::U:,:e' ;.~~~~:.::::::~:~.:

~ ... , {i N;~;~_·'·'''·'''"'''"d;'''''''''".

Rotat'th,h'lKI "ve •• 1 limn to Ivoid removing too mUel! mat,rlal from on. lide •

....................................

'Orivechain ·Joinlld.ivflchainl

CD (2)
II~~I~I ISPECI P7 I
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IDR1VI.;: .. 1 ICHASI~I
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@ ~ @
•
a
@ ® @
1 1 1
cQ C?) e
@ @ @
~..-:__ ~..-:__ ~..-:__ ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content.

CD General information (2) Specifications

@ Periodic inspection and adjustment @ Engine

® Cooling system @ Carburetion

Q) Drive train

@ Chassis

® Electrical

® Troubleshooting

Illustrated symbols dJ) to @ are used to identify the specifications appearing in the text.

(j]) Filling fluid

© Lubricant

©l Special tool

@ Tightening

® Wear limit, clearance ® Engine speed

@n, V, A

Illustrated symbols @ to ®J in the exploded diagram indicate grade of lubricant and location of lubrication point.

@ Apply locking agent (LOCTITE'"') @ Apply engine oil

® Apply gear oil

@ Apply molybdenum disulfide oil @ Apply wheel bearing grease

@ Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease

CONTENTS

GENERAL INFORMATION 1

MACHINE IDENTIFICATION 1

VEHICLE IDENTIFICATION NUMBER 1

ENGINE SERIAL NUMBER 1

SPECIFICATIONS 2

GENERAL SPECIFICATIONS 2

MAINTENANCE SPECIFICATIONS 2

CHASSIS 2

TIGHTENING TORQUE 3

CHASSIS 4

FRONT SHOCK ABSORBER AND FRONT ARMS 4

REMOVAL 5

FREE PLAY INSPECTION 5

INSPECTION 6

INSTALLATION 7

MACHINE IDENTIFICATION II~~~ I~I GENERAL INFORMATION

MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER

The vehicle identification number CD is stamped into the left side of the frame.

NOTE: ___

The vehicle identification number is used to identify your machine and may be used to register your machine with the licensing authority in your state.

Starting serial number:

JY43GGAO*MC025101

ENGINE SERIAL NUMBER

The engine serial number CD is stamped into the right side of the engine.

Starting serial number: 3GG-025101

NOTE: _

.The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.

• Designs and specifications are subject to change without notice.

-1-

GENERAL SPECIFICATIONS/ I I 0 I

MAINTENANCE SPECIFICATIONS SPEC rp I

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model YFZ350B
Model Code Number 3GG4
Engine Starting Number 3GG-025101
Vehicle Identification Number JY 43GGAO* MC0251 01
BASIC WEIGHT:
With Oil and Full Fuel Tank 186 kg (410 Ib)
CHASSIS:
Frame Type Steel Tube Frame
Caster Angle 9°
Trail 40 mm (1.57 in)
Tread (Standard): Rear 840 mm (33.1 in)
Front 900 mm (35.4 in)
Toe-in 0-10 mm (0-0.39 in)
TIRE:
Type Tubeless
Size: Front AT21 x7-10
Rear AT20x 10-9
Wear Limit 3 mm (0.12 in)
TIRE PRESSURE: Front Rear
30 kPa 30 kPa
(0.30 kq/crrr', 4.4 psi) (0.30 kq/crrr', 4.4 psi) MAINTENANCE SPECIFICATIONS CHASSIS

Model YFZ350B
FRONT SUSPENSION:
Cushion stroke 110 mm (4.33 in)
Suspension Spring Free Length 286.5 mm (11.3 in)
Spring Rate (K1) 21.6 N/mm (2.7 kg/mm, 123 lb/in)
(K2) 33.3 N/mm (3.4 kg/mm, 190 lb/In)
Stroke (K1) Zero-93 mm (Zero-3.66 in)
(K2) 93 mm-133 mm (3.66-5.24 in)
REAR SUSPENSION:
Shock Absorber Travel 89 mm (3.50 in)
Spring Free Length 240.5 mm (9.47 in)
Fitting Length 220.5 mm (8.68 in)
Spring Rate (K1 ) 53.9 N/mm (5.5 kg/mm, 308 lb/in)
Stroke (K1) Zero-109 mm (Zero-4.29 in)
FRONT DISC BRAKE:
Type Dual
Disc Outside Dia. x Thickness 161.0x3.5 mm (6.34xO.138 in)
Pad Thickness 4.5 mm (0.18 in)
< Limit> < 1.0 mm (0.04 in) >
Master Cylinder Inside Diameter 14 mm (0.55 in)
Caliper Cylinder Inside Diameter 31.75 mm (1.25 in)
Brake Fluid Type DOT#4 or DOT#3 -2-

MAINTENANCE SPECIFICATIONS 1 SPEC 1 1>71

Model YFZ350B
REAR DISC BRAKE:
Type Single
Disc Outside Dia. x Thickness 220.0 x 3.5 mm (8.66 x 0.138 in)
Pad Thickness Inner 4.5 mm (0.18 in)
<Limit> < 1.0 mm (0.04 in) >
Pad Thickness Outer 4.5 mm (0.18 in)
<Limit> < 1.0 mm (0.04 in) >
Master Cylinder Inside Diameter 12.7 mm (0.50 in)
Caliper Cylinder Inside Diameter 33.96 mm (1.34 in)
Brake Fluid Type DOT#4 or DOT#3 TIGHTENING TORQUE

The following shows only the differences from the YFZ350A.

Tightening torque
Part to be tightened Thread size Nm m.kg ft·lb Remarks
Lower arm & Frame M10x1.25 32 3.2 23
Pivot shaft M16x 1.5 95 9.5 68
Upper arm & Frame M10x1.25 38 3.8 27
Wheel panel & Wheel collar M10x1.25 45 4.5 32
Sprocket shaft collar & Driven sprocket M8x 1.25 24 2.4 17 -3-

FRONT SHOCK ABSORBER AND FRONT ARMS ICHASlhl CHASSIS

FRONT SHOCK ABSORBER AND FRONT ARMS

CD Thrust cover <Z) Bushing

® Collar

@ Front arm (upper) @ Front arm (lower)

@ Front shock absorber (j) Steering knuckle

@ Knuckle arm

A FRONT SHOCK ABSORBER B STANDARD POSITION: C C SOFTEST POSITION: A

I ~~ C ~ I

U~~

D STIFFEST POSITION: E

38 Nm (3.8 m.kg, 27 ft·lb)

45 Nm (4.5 m.kg, 32 ft.lb)

@

45 Nm (4.5 m·kg, 32 ft.lb)

25 Nm (2.5 m.kg, 18 ft·lb)

38 Nm (3.8 m.kg, 27 ft.lb)

-4-

FRONT SHOCK ABSORBER AND FRONT ARMS ICHASlcfJol REMOVAL

1. Remove: ·Seat

• Rear fender .Wheel hub

• Knuckle arm

• Front shock absorber

• Front bumber .Steering knuckle ·Silencer

·Spring

.Stay (Exhaust pipe)

Refer to "YFZ350T Service Manual CHAPTER 6. FRONT SHOCK ABSORBER AND FRONT ARMS-REMOVAL" section for details.

2. Remove:

• Nuts (Front arm) CD ·Bolts (Front arm) (2) .Thrust cover @

• Collars

·Bushings

NOTE: ___

Remove the. bolt (2) while pulling the exhaust pipe toward you.

FREE PLAY INSPECTION

1. Remove:

• Front wheels

• Front brake calipers .Front hubs ·Tie-rods

.Steering knuckles

• Front shock absorbers

Refer to "REMOVAL" section.

2. Check:

.Front arms (Side play)

Side play~ Replace spacer and bushings as a set.

Move the front arms from side to side. There should be no noticeable side play.

-5-

FRONT SHOCK ABSORBER AND FRONT ARMS ICHASI~I

3. Check:

• Front arms (Vertical movement) Tightness/ Binding/ Rough spots-» Replace spacer and bushings as a set.

Move the front arms up and down.

INSPECTION

Front Arms Inspection

1. Check:

.Spacer free play

Spacer is loose-r+ Replace spacer and bushings as a set.

Insert the spacer into the front arm, and check for free play.

2. Inspect:

• Thrust covers

·Bushings Wear/Damage-+Replace as a set.

-6-

FRONT SHOCK ABSORBER AND FRONT ARMS ICHASI~I INSTALLATION

~(j

®

When installing the front arms and shock absorber, reverse the removal procedure. Note the following points.

1. Install:

• Front arms

NOTE: ___

Be sure to position the bolts (upper and lower) CD, (2), @ so that the bolt head face outward.

@ Front arm (Upper) @ Front arm (Lower) @ Forward

2. Tighten:

=Nuts (Front arm)

Nut (Front Upper Arm):

38 Nm (3.8 m-kq, 27 ft-lb) Nuts (Front Lower Arm):

32 Nm (3.2 m-kq, 23 ft.lb)

AWARNING

-Make sure the brake hoses are properly routed, and are not damage or twisted.

3 Lubricate:

• Pivot points (Front arms) Use a grease gun.

~ Lithium Base Grease

Refer to "YFZ350T Service Manual CHAPTER 6. FRONT SHOCK ABSORBER AND FRONT ARMS-INSTALLATION" section for details of installation for other than above specification.

-7-

YAMAHA MOTOR CO. ,LTD.

PRINTED IN U.S.A.

LlT·11616-07 ·46

FOREWORD

This Supplementary Service manual has been prepared to introduce new service and new data for the YFZ350A. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with following manual.

YFZ350T Service Manual (LlT·11616·05·87)

YFZ350A SUPPLEMENTARY SERVICE MANUAL

© 1989 by Yamaha Motor Corporation, U.S.A. 1st Edition, December 1989

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in U.S.A. LlT·11616·07·46

NOTICE

This manual was by the Yamaha Motor Company primary for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that person using this book to perform maintenance and repairs on Yamaha machine have a basic understanding of the mechanical concepts and procedures inherent in machine repair technology. Without such knowledge, attempt repairs orserviceto this model may render it unfitto use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, there applicable, appear in future editions of this manual.

TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO., LTD.

PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation.

The Safety Alert Symbol means ATIENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

AWARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

CONSTRACTION OF THIS MANUAL

This manual consists of chapters for the main categories of subjects. (See " lllustrated symbols")

1 st title CD : 2nd title ®:

This is a chapter with its symbol on the upper right of each page.

This title appears on the upper of each page on the left of the chapter symbol. (For the chapter "Periodic inspection and adjustment" the 3rd title appears.)

This is a final title.

3rd title ®:

MANUAL FORMAT

A" ofthe procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of a" disassembly, repair, assembly, and inspections. Asetofparticularlyimportantprocedure @ is placed between a line of asterisks "*" with each procedure preceded by ".".

IMPORTANT FEATURES

• Data and a special tool are framed in a box preceded by a relevant symbol ®.

• An encircled numeral ® indicates a part name, and an encircled alphabetical letter data or an align ment mark (J) , the others being indicated by an alphabetical letter in a box ® .

• A condition of a faulty component will precede an arrow symbol and the course of action required the symbol ®.

EXPLODED DIAGRAM

Each cha pter provides exp loded diag rams before each disassembly section for ease in identifyi ng correct disassembly and assembly procedures.

2.RlmO"1 ·C'.llk.h,ft CD

U .. lh.cr.nkc ..... p.r.'invloo100

11:1 c.~~:~~;;-,.,.tI ... IOOI:

INSPECTION AND REPAIR

CYLINDfltH(AO

U ... roundldICrlp .. NOTE:-----

Tlklclrel0.,.oi.dlmaain.glhl,pl,kplui:!

L- ---' ~~::::~r~l:tt~,:t~:-fIII.m:-: inwu .... ee

W ........ _ .. ""._IOt4' .. url.o.· ~.t.p:

.AtllICh •• tllight .. <D.nd.thick ... •

>---H~A~~~;j.j .::'::I~:.::::.lmdefhelld .

• " Ihe """rplllet' i, out of 'PRilie'lion, ftlu,laclthteylind.,ht-.d .

• PIlle,. 400 - 800grit WI' unc:lp,pe, on t ..... utfec:.pIIt.,.nd •• au'I ..... 'h.IMM

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Raltt,1helMad ., " .. tl",.. to ltVold re-

!flO ... ;"" 100 much mlt.ti,l 'rom _ .Ide .

....................................

_______ FR_ONT_F_OR_K ICHASIA I

1,lnspect

CD ®
I~EF~I~I ISPECI jJ~1
® ®
I~Jlfil ENG "
..

® ®
ICOOll XI ICARBI'I
(j) ®
IORIVI-ra-1 ICHASIcfJ61
® @
I HECI ilii I I~~¥~I? I
@ ~ @ ~
@ @ .-
[lj ~
@ ~ @ ~
@ [mJ @
1
I'
@ 1 ® i ® 1
m m e
@ @ ®
~ ~ ~ ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols CD to @ are designed as thumb tabs to indicate the chapter's number and content.

CD General information ® Specifications

® Periodic inspection and adjustment ®Engine

® Cooling system ® Carburetion

(j) Drive train

® Chassis

® Electrical

@ Troubleshooting

Illustrated symbols @ to @ are used to identify the specifications appearing in the text.

® Filling fluid @ Lubricant @ Special tool @ Tightening

@ Wear limit, clearance @ Engine speed @n,V,A

Illustrated symbols @ to ® in the exploded diagram indicate grade of lubricant and location of lubrication point.

@ Apply locking agent (LOCTITE®) @ Apply engine oil

®> Apply gear oil

® Apply molybdenum disulfide oil @Apply wheel bearing grease

@ Apply lightweight lithium-soap base grease ® Apply molybdenum disulfide grease

CONTENTS

GENERAL INFORMATION 1

MACHINE IDENTIFICATION 1

VEHICLE IDENTIFICATION NUMBER 1

ENGINE SERIAL NUMBER 1

SPECIAL TOOLS 2

FOR CHASSIS SERVICE 2

SPECIFICATIONS 3

GENERAL SPECIFICATIONS 3

MAINTENANCE SPECIFICATIONS 4

ENGINE 4

CHASSIS 4

TIGHTENING TORQUE 5

PERIODIC INSPECTION AND ADJUSTMENT 7

CHASSIS 7

FRONT BRAKE 7

FRONT AND REAR SHOCK ABSORBER ADJUSTMENT 7

CHASSIS 11

FRONT BRAKE 11

BRAKE CALIPER AND BRAKE DISC 11

BRAKE PAD REPLACEMENT 12

CALIPER 13

REAR AXLE 16

INSTALLATION 16

MACHINE IDENTIFICATION 1 ~ Ij:~ 1.-.1

GENERAL INFORMATION

MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER

The vehicle identification number CD is stamped into the left side of the frame.

NOTE: __

The vehicle identification number is used to identify your machine and may be used to register your machine with the licensing authority in your state.

Starting serial number:

JY 43GGAO * Le01 01 01

ENGINE SERIAL NUMBER

The engine serial number CD is stamped into the right side of the engine.

NOTE: __

The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.

Starting serial number: 3GG-010101

NOTE: __

Designs and specifications are subject to change without notice.

-1-

SPECIAL TOOLS I~EF~ldt8l

SPECIAL TOOLS

The following shows only the difference(s) from the YFZ350T.

FOR CHASSIS SERVICE

1. Rear axle nut wrench PIN YM-37132

This tool is used to loosen and tighten the Nut (Rear axle).

-2-

GENERAL SPECIFICATIONS ISPECI jOfl SPECIFICATIONS

GENERAL SPECIFICATIONS

Model YFZ350A
Model Code Number 3GG2
Engine Starting Number 3GG-010101
Vehicle Identification Number JY43GGAO*LC010101
DIMENSIONS:
Overall Length 1,855 mm (73 in)
Overall Width 1,100 mm (43.3 in)
Overall Height 1,080 mm (42.5 in)
Seat Height 800 mm (31.5 in)
Wheelbase 1,280 mm (50.4 in)
Minimum Ground Clearance 135 mm (5.31 in)
BASIC WEIGHT:
With Oil and Full Fuel Tank 185 kg (408 Ib)
FUEL:
Type PREMIUM UNLEADED FUEL, Premix (20:1)
Capacity: Total 12 L (2.64 Imp gal, 3.17 US gal)
Reserve Amount 2.5 L (2.2 Imp qt, 2.64 US qt)
TRANSMISSION:
Primary Reduction System Helical Gear
Primary Reduction Ratio 66/23 (2.869)
Secondary Reduction System Chain Drive
Secondary Reduction Ratio 41/14 (2.929)
Transmission Type Constant Mesh 6-Speed
Operation Left Foot Operation
Gear Ratio: 1st 32/13 (2.461)
2nd 29/16 (1.812)
3rd 27/18 (1.500)
4th 25/20 (1.250)
5th 23/22 (1.045)
6th 21/24 (0.875)
CHASSIS:
Frame Type Steel Tube Frame
Caster Angle 9·
Trail 40 mm (1.57 in)
Tread (Standard): Rear 870 mm (34.3 in)
Front 900 mm (35.4 in)
Toe-in 0- 10 mm (0 - 0.39 in)
TIRE:
Type Tubeless
Size: Front AT21 x 7-10
Rear AT20 x 11-10
Wear Limit 3 mm (0.12 in) -3-

MAINTENANCE SPECIFICATIONS ISPECI ffl

Model YFZ350A
TIRE PRESSURE: Front Rear
30 kPa 25 kPa
(0.30 kg/cm2, 4.4 psi) (0.25 kg/cm2, 3.6 psi)
WHEEL TRAVEL:
Front 220 mm (B.66 in)
Rear 230 mm (9.1 in) MAINTENANCE SPECIFICATIONS ENGINE

Model YFZ350A
CARBURETOR:
1.0. Mark 2GU-01
Fuel Level (F.L)
(With Special Tool) 0.5 - 1.5 mm (0.020 - 0.059 in)
Float Height (F.H) 20 - 22 mm (O.BO - O.BB in)
Main Jet (M.J.) #200
Main Air Jet (M.A.J.) 01.6
Jet Needle (J.N.) 5N7-3
Needle Jet (N.J.) O-B
Cutaway (C.A.) 2.0
Pilot Outlet (P.O.) 00.6
Pilot Jet (P.J.) #25
Bypass 1 (B.P.1.) 1.4
AirScrew (A.S.) 2.0 turns out
Valve Seat Size (V.S.) 2.B
Starter Jet (G.S.) 01.4 CHASSIS

Model YFZ350A
FRONT SUSPENSION:
Cushion stroke 110 mm (4.33 in)
Suspension Spring Free Length 2B2 mm (11.1 in)
Spring Rate (K1) 2B.4 N/mm (2.9 kg/mm, 162 Ib/in)
(K2) 33.3 N/mm (3.4 kg/mm 190 Ib/in)
Stroke (K1) Zero - 65 mm (Zero - 2.56 in)
(K2) 65 mm - 135.5 (2.56 - 5.33 in)
REAR SUSPENSION:
Shock Absorber Travel B9 mm (3.50 in)
Spring Free Length 234.5 mm (9.23 in)
Fitting Length 218.5 mm (8.6 in)
Spring Rate (K1) 63.7 N/mm (6.5 kg/mm, 364 Ib/in)
Stroke (K1) Zero - 110 mm (Zero - 4.3 in)
DRIVE CHAIN:
Type/Manufacturer 520V6/DAIDO
No. of Links 104
Chain Free Play 15 - 20 mm (0.6 - 0.78 in) -4-

MAINTENANCE SPECIFICATIONS ISPECll'fl

TIGHTENING TORQUE

Part to be tightened Thread size Tightening torque Remarks
Nm rn-kq ft-Ib
Steering knuckle & Castle nut M14x 1.5 85 8.5 61
Wheel panel nut Ml0 x 1.25 45 4.5 32
Steering knuckle & Knuckle arm Ml0 x 1.25 38 3.8 27
Caliper (Front) M 8x 1.25 28 2.8 20
Brake disc (Front & Rear) M 8xl.25 28 2.8 20
Steering knuckle & Ball joint Ml0 x 1.25 25 2.5 18
Ball joint (Tie-rod) & Knuckle arm Ml0 x 1.25 25 2.5 18
Ball joint (Tie-rod) & Steering shaft Ml0 x 1.25 25 2.5 18
Ball joint & Tie-rod Ml0 x 1.25 30 3.0 22
Steering shaft & Frame Ml0 x 1.25 30 3.0 22
Steering bearing bracket & Frame M 8 x 1.25 23 2.3 17 Use lock washer
Handlebar holder M 8 x 1.25 20 2.0 14
Bearing holder (Steering shaft) M42 x 1.0 40 4.0 29
Upper & Lower arm & Frame Ml0 x 1.25 30 3.0 22
Front shock absorber (Upper & Lower) Ml0 x 1.25 45 4.5 32
Engine mount:
Frame & Front engine stay M 8 x 1.25 30 3.0 22
Engine & Front engine stay Ml0 x 1.25 45 4.5 32
Engine & Rear engine stay Ml0 x 1.25 45 4.5 32
Tension rod & Engine Ml0 x 1.25 25 2.5 18
Tension rod & Tension rod stay Ml0 x 1.25 45 4.5 32
Tension rod stay & Frame Ml0 x 1.25 45 4.5 32
Pivot shaft M16x 1.5 85 8.5 61
Rear shock absorber (Upper & Lower) Ml0 x 1.25 30 3.0 22
Relay arm & Frame Ml0 x 1.25 30 3.0 22
Connecting rod & Swingarm Ml0 x 1.25 30 3.0 22
Relay arm & connecting rod Ml0 x 1.25 30 3.0 22
Footrest Ml0 x 1.25 55 5.5 40
Caliper (Rear) M 8 x 1.25 23 2.3 17
Rear axle ring nut M33 x 1.5 - - - SEE NOTE
Rear axle & Castle nut M14 x 1.5 120 12.0 85
Rear hub & Swingarm (Upper) M12 x 1.25 120 12.0 85
(Lower) Ml0 x 1.25 60 6.0 43
Brake hose union bolt Ml0 x 1.25 25 2.5 18
Brake hose & Caliper Ml0 x 1.25 25 2.5 18
Brake hose joint & Brake pipe Ml0 x 1.0 18 1.8 13
Brake hose joint M 8 x 1.25 20 2.0 14
Rear master cylinder M 8 x 1.25 20 2.0 14
Driven sprocket Ml0 x 1.25 60 6.0 43
Chain puller & Locknut M 8 x 1.25 16 1.6 11
Locknut (Rear brake caliper adjustment) M 8 x 1.25 16 1.6 11
Swingarm & Swingarm guard M 8 x 1.25 28 2.8 20
Fuel tank & Fuel cock M 6 x 1.0 5 0.5 3.6
Bumper: (Front) M 8 x 1.25 23 2.3 17
(Rear) M 8 x 1.25 23 2.3 17
Master cylinder & bracket M 6 x 1.0 10 1.0 7.2
Fender stay & Frame M 6 x 1.0 10 1.0 7.2
Stay & Frame M 8 x 1.25 23 2.3 17 -5-

MAINTENANCE SPECIFICATIONS ISPECI Pfl

NOTE: _

1. Tighten the inside-ring nut to 55 Nm (5.5 m • kg, 40 ft· Ib) while holding the rear axle.

2. Hold the inside-ring nut and tighten the outside-ring nut to 190 Nm (19.0 m • kg, 140 ft· lb).

3. Hold the outside-ring nut and tighten back the inside-ring nut to 240 Nm (24.0 m • kg, 170 ft ·1 b).

-6-

FRONT BRAKE I 1~8.r1~1

FRONT AND REAR SHOCK ABSORBER ADJUSTMENT . _ IP!Z:._

PERIODIC INSPECTION AND ADJUSTMENT CHASSIS

FRONT BRAKE

Front Brake Pad

1. Activate the brake lever.

2. Inspect:

• Brake pads

Wear indicator CD (White line) almost contacts brake disc -+ Replace brake pads a-s a set. Refer to the "BRAKE PAD REPLACEMENT" section.

Front Brake Pad Wear Limit: ® 1.0 mm (0.04 in)

FRONT AND REAR SHOCK ABSORBER ADJUSTMENT

Front Shock Absorber

1. Adjust:

• Spring preload

Turn the adjuster CD to increase or decrease the spring preload.

Front Shock Absorber Preload
Preload Softer® Standard Stiffer ®
f- ~
Position A,B C D,E Rear Shock Absorber

AWARNING

This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacture cannot be held responsible for property damage or personal injury that may result from improper handling.

• Do not tamper with or attempt to open the cylinder assembly.

• Do not subject shock absorber to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure.

• Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance.

-7-

FRONT AND REAR SH~~fJ~-?~:~ I ~S:I"'I

1.Adjust:

• Spring preload

****************************** Spring preload adjustment steps:

• Elevate the rear wheels by placing the suitable stand.

• Loosen the locknut ® .

• Adjust the spring preload.

NOTE: _

The length ofthe spring (lnstalledl changes 1 mm (0.04 in) per turn of the adjuster.

® Spring length

Stiffer ® -t Increase the spring preload. (Turn the adjuster CD in.) Softer @ -t Decrease the spring preload. (Turn the adjuster CD out.)

Standard Spring Length (Installed): 218.5 mm (8.6 in)

Minimum Length (Installed):

213.5 mm (8.4 in)

Maximum Length (Installed):

228.5 mm (9.0 in)

Never attempt to turn the adjuster beyond the maximum or minimum setting.

• Tighten the locknuts.

Locknut:

54 Nm (5.4 m • kg, 39 ft • Ib)

******************************

-8-

FRONT AND REAR SHOCK ABSORBER IINSPI~I ADJUSTMENT ADJ ~

..... ..;;,,;;;;;;.....;:; ...... -_--'

2. Adjust:

• Rebound damping force

******************************

Rebound damping force adjustment steps: .Turn the adjuster CD12 clicks back from the fully turned-in position. (It is standard position) .Adjust the rebound damping force.

Slower ® -t Increase the rebound damping force. (Turn the adjuster CD in.) Faster ® -t Decrease the rebound damping force. (Turn the adjuster CD out.)

Standard setting:

12 clicks turns out (From the fully turned-in position)

Minimum setting:

8 clicks turns out (From standard position)

Maximum setting:

12 clicks turns in (From standard position)

20 clicks

12 clicks out

MAX

MIN STD

~.~------~II~------------~

8 clicks out 12 clicks in

(From STD) (From STD)

Do not turn out (in) the adjuster from the damping force minimum (maximum) setting.

******************************

-9-

FRONT AND REAR SHOCK ABSORBER IINSPI~I ADJUSTMENT ADJ ~

..... ,.;;,;;;;;~__.,--__,

3. Adjust:

• Compression damping force

****************************** Compression damping force adjustment steps:

.Turn the adjuster CD 11 clicks back from the fully

turned-out position. (It is standard position) .

• Adjust the compression damping force.

Stiffer ® ~ Increase the compression damping force. (Turn the adjuster CD clockwise.)

Softer @ ~ Decrease the compression damping force. (Turn the adjuster CD counterclockwise.)

Standard setting:

8 clicks turn in (From the fully turned out position)

Minimum setting:

11 clicks out (From standard setting) Maximum setting:

9 clicks in (From standard setting)

20 clicks

11 clicks in

MAX

MIN STO

.,_ _,IIL.- •

11 clicks out (FromSTO)

9 clicks in (From STO)

Do not turn out (in) the adjuster from the damp" ing force minimum (maximum) setting.

AWARNING

The compression damping adjuster is very hot immediately after a run.

Never allow your bare hand or part of your body to touch it.

******************************

-10-

FRONT BRAKE ICHASlcf:Jol CHASSIS

FRONT BRAKE

BRAKE CALIPER AND BRAKE DISC CD Brake disc

® Brake pads

@ Caliper piston assembly @ Piston seal kit

®Shim

® Air bleed screw (j) Retaining bolt

NOTE: __

• Drain the brake fluid before removing the brake hose.

• Always replace the brake pads as a set.

A BRAKE PAD WEAR LIMIT:
1.0 mm (0.04 in)
B BRAKE DISC WEAR LIMIT:
3.0 mm (0.12 in)
C MAXIMUM DEFLECTION:
0.5 mm (0.02 in) 28 Nm (2.8 m • kg, 20 ft· Ib)

-11-

Disc brake components rarely require disassembly. DO NOT:

• Disassembly components unless absolutely

necessary.

• Use solvents on internal brake component.

• Use contaminated brake fluid for cleaning.

• Use only clean brake fluid.

• Allow brake fluid to come in contact with the eyes otherwise eye injury may occur.

• Allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur.

• Disconnect any hydraulic connection otherwise the entire system must be disassembled, drained, cleaned, and then properly fined and bled after reassembly.

NOTE: __

Drain the brake fluid before removing brake hose.

BRAKE PAD REPLACEMENT

1. Remove:

• Front wheel

• Disc cover (Outer)

• Bolt (Caliper) CD

2. Remove:

• Retaining bolt CD

• Brake pads ®

-12-

FRONT BRAKE ICHASI~I

NOTE: __

Replace pads as a set ifeither is found to be worn to the wear limit.

Brake Pad Wear limit: 1.0 mm (0.04 in)

3. Install:

• Pads (New) CD

• Shim ®

• Retaining bolt ®

NOTE: _

Be sure to install the shim ® at piston side.

Retaining Bolt:

18 Nm 11.8 m- kg, 13 ft ·Ib)

4. Install:

• Disc cover (Outer) CD

• Front wheel

Nut (Wheel Panel):

45 Nm (4.5 m • kg, 32 ft • Ib)

NOTE: _

Install the disc cover (Outer)CDwith punched burrs ®on the hub side.

CALIPER Caliper Removal

1. Remove:

• Front wheel

• Disc cover (Outer)

• Brake hose CD

• Drain the brake fluid.

• Bolt (Caliper) ®

• Disc cover (Inner)

• Brake pads

• Pad spring

-13-

FRONT BRAKE ICHASlhl

Caliper Disassembly

1. Remove:

• Dust seal CD

• Piston seal ®

• Piston ®

Use compressed air and proceed carefully.

AWARNING

• Cover piston with rag and use extreme caution when expelling piston from cylinder.

• Never attempt to pry out piston.

****************************** Caliper piston removal steps:

• Insert the rag into the ca liper to lock the piston.

• Blow compressed air into the hose joint opening to force out the piston from the caliper body.

******************************

Inspection

1. Inspect:

• Piston

Rust/Wear Replace.

• Caliper cylinder body Wear/Scratches Replace.

Installation

1. Assemble:

• Brake caliper (s)

Reverse disassembly steps.

AWARNING

• All internal parts should be cleaned in new brake fluid only.

• Internal parts should be lubricated with brake fluid when installed.

Recommend Brake Fluid:

DOT #4 If DOT #4 is not available, #3 can be used.

• Replace the dust seal, piston seal and clip whenever a caliper is disassembled.

-14-

FRONT BRAKE ICHASI~I

2. Tighten:

• Bolt (Caliper) CD

Bolt (Caliper):

28 Nm (2.8 m • kg, 20 ft • Ib)

• Bolt (Brake hose) ®

Bolt (Brake Hose):

27 Nm (2.7 m • kg, 19 ft ·Ib)

3. Bleed the air completely from the brake system.

4. Install:

• Disc cover (Outer)

• Front wheel

-15-

Nut (Wheel Panel):

45 Nm (4.5 m • kg, 32 ft • Ib)

~~~~~~~~~~~~R_EA_R_A_X_L_E~H~I~I REAR AXLE

The following shows only the difference(s) from the YFZ350T.

INSTALLATION

1. Tighten:

• Nuts (Rear axle) CD, ®

****************************** Nuts tightening steps:

NOTE: _

Before tightening the nuts, apply the LOCTITE® to the thread portion of the rear axle .

• Finger tighten the inside nut ® while checking the ring gear engagement .

• Tighten the inside nut with Rear Axle Nut Wrench to specification while holding the rear axle.

Rear Axle Nut Wrench:

YM-37132

Inside Nut (First Tightening): 55 Nm (5.5 m • kg, 40 ft • Ib)

• Hold the inside nut®and tighten the outside nut CD with Rear Axle Nut Wrench to specification.

Outside Nut:

190 Nm (19.0 m • kg, 140 ft • Ib)

• Draw the line ® on inside and outside nut .

• Hold the outside nut CD and tighten BACK the inside nut ® with Rear Axle Nut Wrench to specification.

Inside Nut (Final Tightening):

240 Nm (24.0 m • kg, 170 ft • Ib)

.Measure the distance ® between lines. If distance ®is less than 3 mm (0.12 in), retighten BACK the inside nut.

******************************

-16-

• YAMAHA ,~~TOR CO.,LTD.

PRINTED IN U.S.A.

OYAMAHA

LlT-11616-05-87

YFZ350T SERVICE MANUAL

©1986 by Yamaha Motor Corporation, U.S.A. ~st Edition, August 1986

All rig~ts reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited.

Printed in U.S.A.

PIN LlT-11616-05-87

NOTICE

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha machines have a basic understanding of the mechanical concepts and procedures inherent in machine repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe.

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE OPERATIONS YAMAHA MOTOR CO., LTD.

HOW TO USE THIS MANUAL

PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

A CAUTION indicates special procedures that must be followed to avoid damage to the machine.

WARNING:

A WARNING indicates special procedures that must be followed to avoid injury to a machine operator or person inspecting or repairing the machine.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.,

• Bearings

Pitting / Damage -+ Replace.

EXPLODED DIAGRAM

Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and asse nbly procedures.

CD ®
1=1~1 l~g~1 §ll
@ @
IENGI~ .. I P>oLI ~I
® ®
EAR~'I §iAS~
(J) ®
I ELEe I 91 ~ppxl."1
® ~ ® ~
\!J) ~ @ ~
@ [B \1A'l ~
,LID 1 ~_§) 1 @ 1
m Gl a
lW d~ ®
~L- ~Si'-L- ~
(iJ)
1
IT! ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and

content.

CD General information

(2) Periodic inspection and adjustment @ Engine

@ Cooling system @ Carburetion

@ Chassis

(J) Electrical

® Appendices

Illustrated symbols ® to @ are used to identify the specifications appearing in the text.

® Filling fluid

® Lubricant

@ Tightening

@ Wear limit, clearance @ Engine speed

(j]) n. V, A

Illustrated symbols ® to @ in the exploded diagram indicate grade of lubricant and location of lubrication point.

® Apply engine oil

® Apply gear oil

@ Apply molybdenum disulfide oil ® Apply wheel bearing grease

@ Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease

@ Apply locking agent (LOCTITE®)

INDEX

..

GEN INFO

GENERAL INFORMATIO-N

PERIODIC INSPECTIONS AND ADJUSTMENTS

ENGINE OVERHAUL

COOLING SYSTEM

____________________ I~~~I~I

CHAPTER 1 GENERAL INFORMATION

MACHINE IDENTIFICATION 1-1

VEHICLE IDENTIFICATION NUMBER 1-1

ENGINE SERIAL NUMBER 1-1

u

IMPORTANT INFORMATION 1~2

ALL REPLACEMENT PARTS 1-2

GASKETS, OIL SEALS AND O-RINGS 1-2

LOCK WASHERS/PLATES AND COTTER PINS 1-2

BEARINGS AND OIL SEALS 1-2

CIRCLIPS : 1-3

SPECIAL TOOLS 1-3

FOR TUNE-UP <" •••••••• 1-3

FOR ENGINE SERVICE 1-4

FOR CHASSIS SERVICE 1-5

FOR ELECTRICAL COMPONENTS 1-5

GENERAL INFORMATION

MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER

The vehicle identification number CD is stamped into the left side of the lower pipe.

Starting Serial Number:

JY 42G UOO* H COOO101

ENGINE SERIAL NUMBER

The engine serial number CD is stamped into the left side of the engine.

NOTE: _

The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.

Starting Serial Number:

YFZ350T 2GU-000101

NOTE: __

Designs and specifications are subject to change without notice.

1-1

IMPORTANT INFORMATION II~~ IAI IMPORTANT INFORMATION

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

GASKETS, OIL SEALS AND a-RINGS

1. All gaskets, seals and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.

2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

LOCK WASHERS/PLATES AND COTTER PINS

1. All lock washers/ plates CD and cotter pins must be replaced when they are removed. Lock tabls) should be bent along the bolt for nut flat(s) after the bolt or nut has been properly tightened.

BEARINGS AND OIL SEALS

1. Install the bearing(s) CD and oil seal(s) @ with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil sealts). apply a light coating of light-weight lithium base grease to the seal iipls). Oil the bearings liberally when installing.

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

1-2

I ~~ IAI IMPORTANT INFORMATION/SPECIAL TOOLS CIRCLIPS

1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD, make sure that the sharp-edged corner @ is positioned opposite to the thrust @ it receives. See the sectional view.

® Shaft

1-3

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.

FOR TUNE-UP

1. Inductive Tachometer PIN. YU-08036

This tool is needed for detecting engine rpm.

2. Inductive Timing Light PIN. YM-33277

This tool is necessary for checking ignition timing.

3. Cooling system Tester PIN. YU-24460-01

This tester is needed for checking the cooling system.

SPECIAL TOOLS I ~~~ IAJ

4. Fuel Level Gauge PIN. YM-01312

This gauge is used to measure the fuel level in the float chamber.

FOR ENGINE SERVICE

1. Universal Clutch Holder PIN. YM-91042

This tool is used to hold the clutch when removing or installing the clutch boss locknut.

2. Flywheel Magneto Puller PIN. YM-Ol189

This tool is used to remove the flywheel.

3. Piston Pin Puller PIN. YU-01304

This tool is used to remove the piston pin.

4. Rotor Holder PIN. YU-01235

This tool is used when loosening or tightening the flywheel magneto securing bolt.

1-4

I,~~~ I'-I SPECIAL TOOLS

1-5

5. Yamabond No.4®

PIN. ACC-11001-30-00

This sealant (bond) is used for crankcase mating surfaces, etc.

FOR CHASSIS SERVICE

1. Ring Nut Wrench

PIN. YU-01268 CD

YU-33975 ~

These tools are used to loosen and tighten the ring nut.

FOR ELECTRICAL COMPONENTS

1. Electro Tester

PIN YU-33260 - CD

This instrument is necessary for checking the ignition system components.

2. Pocket Tester

PIN YU-33263 - ~ or PIN YU-03112 - ®

This instrument is invaluable for checking the electrical system.

___________________ I~~I§l1

CHAPTER 2.

PERIODIC INSPECTIONS AND ADJUSTMENTS

MAINTENANCE INTERVALS 2-1

ENGINE 2-3

CARBURETOR SYNCHRONIZATION 2-3

IDLE SPEED ADJUSTMENT 2-4

THROTTLE LEVER ADJUSTMENT 2-6

SPEED LIMITER ADJUSTMENT 2-6

FUEL LINE INSPECTION 2-7

AIR FILTER CLEANING 2-7

EXHAUST SYSTEM INSPECTION 2-9

TRANSMISSION OIL LEVEL INSPECTION 2-9

TRANSMISSION OIL REPLACEMENT 2-10

RADIATOR HOSE INSPECTION 2-10

COOLANT LEVEL INSPECTION 2-11

COOLANT REPLACEMENT 2-12

CLUTCH ADJUSTMENT 2-15

CHASSIS 2-18

FUEL COCK CLEANING 2-18

FRONT BRAKE LEVER ADJUSTMENT 2-18

REAR BRAKE PEDAL ADJUSTMENT 2-19

BRAKE PADS INSPECTION 2-19

BRAKE FLUID INSPECTION 2-20

PARKING BRAKE ADJUSTMENT 2-20

DRIVE CHAIN SLACK ADJUSTMENT 2-21

DRIVE CHAIN LUBRICATION 2-23

DRIVE CHAIN AND SPROCKETS INSPECTION 2-24

CHAIN TENSIONER AND CHAIN GUIDE INSPECTION 2-25

STEERING SYSTEM INSPECTION 2-25

CABLE INSPECTION AND LUBRICATION 2-26

FRONT AND REAR SHOCK ABSORBER ADJUSTMENT 2-27

LEVERS, PEDAL, ETC. LUBRICATION 2-31

FRONT ARMS AND REAR ARM PIVOTS LUBRICATION 2-31

TIRES CHECK 2-32

WHEELS CHECK o __ ••••••••••••••••• 2-34

ELECTRICAL 2-34

IGNITION TIMING CHECK 2.:34

SPARK PLUG INSPECTION 2-35

HEADLIGHT BULB REPLACEMENT 2-36

HEADLIGHT BEAM ADJUSTMENT 2-37

IIANOSJP I b I

~ MAINTENANCE INTERVALS

-------------------------------------------------------

PERIODIC INSPECTION AND ADJUSTMENT

MAINTENANCE INTERVALS

The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals.

After Every 30
Item break-in operation Every year Remarks
days
TRANSMISSION Yamalube 4-cycle oil or
Replace oil • • SAE 10W30 SE motor oil
COOLING SYSTEM Replace coolant every 2 years
Check coolant leakage • •
SPARK PLUG
Inspect and clean • • STD plug: B8ES or W24ES
Replace if necessary
AIR FILTER
Clean and oil • • Use Foam air-filter oil
Replace if necessary
*CARBURETOR
Inspect adjust and clean • •
*FUEL LINE
Check fuel hose for cracks or •
damage
Replace if necessary
THROTTLE OPERATION
Inspect • •
FRONT AND REAR BRAKE
OPERATION
Inspect and adjust free play • •
if necessary
FRONT AND REAR BRAKE FLUID Fluid: DOT #4
Check fluid level and leakage • •
*FRONT AND REAR BRAKE PAD
Check pads wear •
Replace if necessary
*CLUTCH
Inspect free play and operation • •
Adjust if necessary
DRIVE CHAIN Use chain lube or SAE 30 - 50
Lubricate, free play, alignment • • motor oil
Replace if necessary Free play: 15 mm (0.59 in)
*DRIVE CHAIN GUARD AND
ROLLERS Wear and alignment
Check wear and replace if •
necessary
*STEERING SYSTEM Medium weight wheel bearing
I nspect free play • •
Clean and lube • grease
*FRONT SUSPENSION Lithium base grease
Inspect and lubricate • •
*REAR SUSPENSION Lithium base grease
Inspect and lubricate • • 2-1

IIANOSJP I d I

MAINTENANCE INTERVALS ~

-------------------------------------------------------

After Every 30
Item break-in operation Every year Remarks
days
TIRE, WHEELS
Inspect air pressure, wheel • • Medium weight wheel bearing
run-out, and tire wear
*Inspect bearings grease
Replace bearings if necessary
THROTTLE, CONTROL CABLE Yamaha cable lube
Check routing and connection • • SAE 10W30 motor oil
*Lubricate •
OUTSIDE NUTS AND BOLTS
Retighten • •
FRAME
Clean and inspect •
LIGHTING EQUIPMENT
Inspect • • *It is recommended that these items be serviced by a Yamaha dealer.

NOTE: _

Brake fluid replacement:

1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required.

2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.

3. Replace the brake hoses every four years, or if cracked or damaged.

Recommended brake fluid:

DOT #4

If DOT #4 is not available, #3 can be used.

2-2

IIANDSJPI21_~~~~~~~~_

. . ~. CARBURETOR SYNCHRONIZATION

ENGINE

•

2-3

CARBURETOR SYNCHRONIZATION Carburetors must be adjusted to open and close simultaneously.

1. Remove: -Seat

- Radiator cover

2. Remove:

- Fuel tank cover

3. Remove:

- Front fender CD

- Front fender stay (2)

4. Turn the fuel cock to the "OFF" position.

5. Disconnect:

- Fuel hose CD

6. Remove: -Fuel tank

7. Check:

- Alignment marks CD On the throttle valve.

Not aliqned-r Adjust the throttle cable.

Throttle cable adjustment steps: -Snap the throttle lever a few times.

=Open the throttle lever until the alignment mark appears in the center of the window CD of the right carburetor.

-While keeping the throttle lever at this position, check the left carburetor window for the presence of the alignment mark at the same position.

-If not, adjust the throttle cable for the left carburetor.

- Loosen the locknut (2).

-Turn the adjuster ® in or out until the align-

ment mark comes to the same position. - Tighten the locknut.

- Finally check that both alignment marks ap-

pear at the same position at the same time. -If not, repeat the above steps.

8. Check: -Idle speed

Refer to "IDLE SPEED ADJUSTMENT" section.

9. Check:

- Throttle lever free play

Refer to "THROTTLE LEVER ADJUSTMENT" section.

10. Install: -Fuel tank

- Front fender

- Fuel tank cover

- Radiator cover

-Seat

IDLE SPEED ADJUSTMENT

NOTE: ___

The carburetor synchronization should be set properly before adjusting the idle speed.

1. Remove: -Seat

2-4

•

2-5

2. Adjust: -Idle speed

Idle speed adjustment steps:
-Turn in both pilot air screw CD until they
lightly seat.
NOTE:
Right-hand carburetor pilot air screw located
on inboard side of right carburetor.
-Turn out both pilot air screw to specification.
Pilot air screw (Turns out):
2.0
-Start the engine and let it warm up.
- Adjust the idle speed by turning the idle speed
adjust screw CD in or out until the specific en-
gine speed is obtained.
W Engine Idle Speed:
1,450-1,550 r/min
NOTE:
- Idle speed adjust screws were preset at the
factory. When-adjusting idle speed, turn the
right hand and left hand idle speed adjust
screws in the same extent, or synchroniza-
tion will be out.
- The pilot air screws and idle speed adjust
screws are separate adjustments but they
must be adjusted at the same time to achieve
optimum operating condition at engine idle
speeds. 3. Install: -Seat

4. Check:

- Throttle lever free play

Refer to "THROTTLE LEVER ADJUSTMENT" section.

THROTTLE LEVER ADJUSTMENT/ IINSP Id· I SPEED LIMITER ADJUSTMENT ADJ ~

&.,..,;;;...;;;,;;.;....;;;..._'----~""'"

THROTTLE LEVER ADJUSTMENT

NOTE: _

Before adjusting the throttle lever free play, the carburetor synchronization should be set properly.

1. Check:

.Throttle lever free play @ Out of specification -+ Adjust.

Throttle Lever Free Play @: 4-6 mm (0.16-0.24 in)

2. Adjust:

·Throttle lever free play

Throttle lever free play adjustment steps: ·Loosen the locknut CD.

·Turn the adjuster @ clockwise or counterclockwise until proper free play is attained .

• Tighten the locknut.

SPEED LIMITER ADJUSTMENT

The speed limiter keeps the carburetor throttle from becoming full-open even when the throttle grip is turned to a maximum. Screwing in the adjuster stops the engine speed from increasing.

1. Adjust:

= Speed limiter length

Speed limiter length adjustment steps: ·Loosen the locknut CD .

• Turn the adjuster @ clockwise or counterclockwise until proper length is attained.

Speed Limiter Length @: 12 mm (0.47 in)

• Tighten the locknut.

WARNING:

.Particularly for a beginner rider, the speed limiter should be screwed in completely. Screw it out little by little as his riding technique improves. Never remove the speed limiter from the outset.

2-6

IIANOSJP I ~ I

~ FUEL LINE INSPECTION/AIR FILTER CLEANING

-------------------------------------------------------

2-7

• For proper throttle lever operation do not turn out the adjuster more than 12 mm (0.47 in). Also adjust the throttle lever free play always to 4-6 mm (0.16-0.24 in).

FUEL LINE INSPECTION

1. Inspect:

• Fuel hoses CD

Cracks/ Damage ...... Replace.

AIR FILTER CLEANING

NOTE: _

There is a check hose CD at the bottom of the air filter case. If dust and/ or water collects in this hose, clean the air filter element and air filter case.

1. Remove: ·Seat

• Filter case CD

2. Remove:

• Air filter CD

The engine should never be run without the air filter element; excessive piston and/or cylinder wear may result.

IIANOSJP I ~ I

AIR FILTER CLEANING ~

-------------------------------------------------------

(

3. Remove:

• Element plate CD From the guide.

• Element holder (2)

4. Remove:

·Air filter element

5. Clean:

• Air filter element Clean it with solvent.

NOTE: _

After cleaning, remove the remaining solvent by squeezing the element.

Do not twist the filter element when squeezing the filter element.

WARNING:

Never use low flash point solvents such as gasoline to clean the air filter element. Such solvent may lead to a fire or explosion.

6. Inspect:

• Element

Damage-+ Replace.

7. Apply:

.SAE 10W30 motor oil

8. Squeeze out the excess oil.

NOTE: __

The element should be wet but not dripping.

9. Apply:

=All-purpose grease To the air filter seat.

10. Install:

• Air filter element

• Element holder CD

• Element plate

NOTE: _

The arrow mark @ on the element holder CD must point to the element guide (2).

2-8

IIANDSJPI~I_E_X_H_A_U_S_T_S_Y_S_T_E_M_'_N_S_P_EC_T_'_O_N_I __

. . ~. TRANSMISSION OIL LEVEL INSPECTION

2-9

11. Install: .Air filter

NOTE: _

The arrow mark CD on the air filter guide should point to the upward of the air filter.

EXHAUST SYSTEM INSPECTION

1. Inspect:

·O-ring (Exhaust pipe) CD .Joint (Exhaust pipe) Q) = Jolnt (Silencer) @

Darnaqe-» Replace.

Exhaust gas leakaqe-» Repair.

TRANSMISSION OIL LEVEL INSPECTION

1. Inspect:

.Transmission oil level

Oil level 10w-4 Add sufficient oil.

Transmission oil level inspection steps: =Place the machine on a level place .

• Warm up the engine for several minutes, and stop it.

• Screw the dipstick CD completely out, and then just rest the dipstick in the hole .

• Pull up the dipstick, and inspect the oil level whether or not it is between maximum Q) and minimum level @ .

• If the level is lower, add the oil up to the proper level.

TRANSMISSION OIL REPLACEMENT/ I ';!g~ Id I

RADIATOR HOSE INSPECTION . . ~ .

TRANSMISSION OIL REPLACEMENT

1. Place the machine on a level place.

2. Warm up the engine for several minutes, and stop it.

3. Place an oil pan under the engine.

4. Remove: .Dip stick

• Drain plug CD

Drain the transmission oil.

5. Inspect:

.Gasket (Drain plug) Darnaqe-» Replace.

6. Tighten: .Drain plug

Drain Plug:

20 Nm (2.0 m.kg, 14 ft-Ib]

7. Fill:

• Crankcase

Recommended Oil:

SAE 10W30 Type SE Motor Oil Periodic Oil Change:

1.5 LJ1.3 Imp qt. 1.6 US qt)

Do not allow foreign material to enter the crankcase.

8. Install: ·Dipstick

9. Inspect: ·Oilleaks ·Oillevel

RADIATOR HOSE INSPECTION

1. Inspect:

• Radiator hoses CD

Crack/ Damage/ Coolant leakaqe-» Repair or replace.

2. Inspect:

·Cylinder .Crankcase cover

Coolant leakaqe-» Repair or replace.

2-10

1 !ANDsJPI~ 1 _

. . ~. COOLANT LEVEL INSPECTION

..

•

2-11

COOLANT LEVEL INSPECTION

WARNING:

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.

1. Inspect: .Coolant level

Coolant level low~ Add sufficient coolant.

CD "FULL" level (2) "LOW" level @ Reservoir tank

@ Reservoir tank cap

Recommended Coolant:

High Quality Ethylene Glycol Anti-freeze Containing Anti-corrosion for

Aluminum Engine Inhibitors

Coolant and Water (soft water) Mixed Ratio:

50%/50%

Total Amount:

2.5 L (2.20 Imp qt, 2.64 US qtl Reservoir Tank Capacity:

0.28 L (0.25 Imp qt, 0.30 US qtl

Hard water or salt water is harmful to the engine parts. You may use boiled water or distilled water, if you can't get soft water.

COOLANT REPLACEMENT I ,:g~ I ~ I

Handling notes of coolant

The coolant is harmful so it should be handled with special care.

-When coolant splashes to your eye.

Thoroughly wash your eye with water and see your doctor.

-When coolant splashes to your clothes.

Quickly wash it away with water and then with soap.

-When coolant is swallowed.

Quickly make him vomit and take him to a doctor.

COOLANT REPLACEMENT

Replace the coolant every two years. Before replacing, remove the radiator cap and check the color of the coolant and mineral deposits in the radiator. Flush the coolant system, as required.

1. Remove:

- Radiator cover

2. Remove:

- Radiator cap CD

2-12

2-13

3. Remove:

• Drain bolts CD

IAl Left side [BJ Right side

4. Remove:

= lnlet hose CD

5. Drain:

·Coolant (completely)

NOTE: __

Thoroughly flush the cooling system with clean tap water.

Take care so that coolant does not splash to painted surfaces. If splashes, wash it away with water.

6. Inspect:

• Drain bolt gaskets Damaqe-» Replace.

7. Tighten:

• Drain bolts

Drain Bolt:

14 Nm (1.4 m-kq, 10 ft-Ibl

8. Connect:

=lnfet hose

NOTE: __

Connect the inlet hose with its white painted mark CD upward.

9. Fill:

= Coolant

Fill the coolant into the radiator until the radiator is full.

COOLANT REPLACEMENT I ~g~ I §\ I

-

Recommended Coolant:

High Quality Ethylene Glycol Anti-Freeze Containing AntiCorrosion for Aluminum Engine Inhibitors

Coolant and Water Mixed Ratio: 50%/50%

Total Amount:

2.5 L (2.20 Imp qt. 2.64 US qt) Reservoir Tank Capacity:

0.28 L (0.25 Imp qt, 0.30 US qt) From "LOW" to "FULL" Level: 0.07 L (0.06 Imp qt. 0.07 US qtl

• Hard water or salt water is harmful to the engine. You may use distilled water if you can't get soft water .

• Do not mix more than one type of ethylene glycol antifreeze containing corrosion for aluminum engine inhabltors,

10. Install:

- Radiator cap

11. Run the engine several minutes.

12. Inspect:

= Cootant level CD in the radiator Coolant level low_. Fill.

Fill the coolant until it reaches the top of the radiator.

13. Remove: -Seat

• Reservoir tank cap CD

2-14

2-15

14. Fill:

·Coolant

Fill the coolant in the reservoir tank until it reaches the "FULL" level line CD of the reservoir tank.

15. Install:

• Reservoir tank cap ·Seat

16. Inspect:

• Cooling system Coolant leaks-Repair.

Always check coolant level, and check for coolant leakage before starting engine.

17. Install:

• Radiator cover

CLUTCH ADJUSTMENT

Clutch Lever Free Play Adjustment

1. Loosen:

• Adjuster locknut CD

2. Adjust:

• Free play ®

Turn the adjuster (2) in or out until correct free play is obtained.

Clutch Lever Free Play: 10-15 mm (0.4-0.6 in)

3. Tighten: • Locknut

Mechanism Adjustment

1. Loosen:

• Clutch cable

2. Remove:

• Footrest (Right) ·Circlip CD ·Spring (2)

CLUTCH ADJUSTMENT I ~~~ l§t I

3. Remove:

- Bolts CD (Rear brake master cylinder)

- Rear brake pedal

4. Drain: -Transmission oil

Refer to "TRANSMISSION OIL REPLACEMENT" section.

-Coolant

Refer to "COOLANT REPLACEMENT" section.

5. Disconnect:

- Radiator hose CD

6. Disconnect: -Breather hose CD

7. Remove:

- Kick crank CD

-Crankcase cover (Right) ~

-Dowel pin

2-16

CLUTCH ADJUSTMENT

2-17

8. Loosen: -Locknut CD

9. Adjust:

-Free play

Move the push lever @ toward the front with your finger until it stops. With the push lever in this position, turn the adjuster @ to align the mark @ on the end of the push lever with the mark @ (protuberance) on the crankcase.

10. Tighten: -Locknut

Locknut:

8 Nm (0.8 m-kg, 5.8 ft.lb)

11. Install: =Dowel pin

-Crankcase cover (Right)

NOTE: _

Tighten the crankcase cover holding screws in stage, using a crisscross pattern.

Screws (Crankcase Cover): 7 Nm (0.7 m-kq, 5.1 ft-lb)

12. Install:

-Kick crank

NOTE: __

Install the kick crank so that it does not contact the case.

Bolt (Kick Crank):

25 Nm (2.5 rn-kq, 18 ft-Ibl

13. Connect:

- Radiator hose

NOTE: _

Connect the radiator hose with its white painted mark CD upward.

14. Install:

- Rear brake pedal

- Rear brake master cylinder

-Footrest

Rear Brake Master Cylinder: 20 Nm (2.0 rrr-kq, 14 ft-Ibl Footrest:

55 Nm (5.5 rrr-kq, 40 ft·lb)

FUEL COCK CLEANING! IINSP I ** I FRONT BRAKE LEVER ADJUSTMENT ADJ ~

CHASSIS

FUEL COCK CLEANING

1. Turn the fuel cock lever to the "OFF".

2. Disconnect: -Fuel pipe

3. Remove: -Seat

- Radiator cover

- Fuel tank cover

-Fuel tank

-Fuel cock

4. Clean:

- Filter screen CD Clean it with solvent.

5. Inspect:

= Gasket ~

- Filter screen CD

-O-ring ®

Darnaqe-» Replace.

6. Install:

=Components in above list (Steps "3 and 2")

NOTE: _

Be careful not to clamp the fuel cock too tightly as this may unseat the O-ring and gasket, and lead to a fuel leak.

FRONT BRAKE LEVER ADJUSTMENT

Proper lever free play is essential to avoid excessive brake drag.

1. Loosen:

- Adjuster locknut ~

2. Rotate:

- Adjuster CD

Turn it clockwise or counterclockwise until proper lever end free play ® is attained.

Front Brake Lever Free Play ®: 4-8 mm (0.16-0.32 in)

3. Tighten: -Locknut

2-18

CD ~

~m\\\\\\\\\(twl ( ~

2-19

t

REAR BRAKE PEDAL ADJUSTMENT

1. Loosen: =Locknut CD

2. Rotate: ·Adjuster ~

Turn it clockwise or counterclockwise until proper brake pedal height ® is attained.

Brake Pedal Height ®: 10 mm (0.4 in)

@ Footrest

3. Tighten: - Locknut

, WARNING:

After adjusting the brake pedal height, visually check the adjuster end CD through the hole ® of the joint holder. The adjuster end must appear within this hole.

BRAKE PADS INSPECTION

Front Brake Pads

1. Remove:

- Front wheel

2. Activate the brake lever.

3. Inspect:

·Wear indicator CD

Indicator almost contacts disc~ Replace pads as a set.

Refer to "CHAPTER 6- FRONT BRAKE" section.

BRAKE FLUID INSPECTION/ I ,:g~ I ~ I

PARKING BRAKE ADJUSTMENT _ . ~ _

Rear Brake Pads

1. Depress the brake pedal.

2. Inspect:

·Wear indicator CD

Indicator almost contacts disc~ Replace pads as a set.

Refer to "CHAPTER 6.-REAR BRAKE" section.

BRAKE FLUID INSPECTION

NOTE: __

Before checking the brake fluid level, inspect the brake pads wear limit.

1. Check:

.Brake fluid level

Low level CD~Replenish.

NOTE: _

If DOT No.4 is not available, No.3 can be used.

Brake Fluid:

DOT No.4

NOTE: _

Be sure that:

.Water does not enter the master cylinder when refilling .

• Spilled fluid is cleaned up immediately to prevent painted surfaces or plastic parts from eroding.

IAl FRONT BRAKE [ffi REAR BRAKE

PARKING BRAKE ADJUSTMENT

The parking brake adjustment may be required if the parking brake does not hold properly.

2-20

l~g~I§\1

-------------------------------------------------------

PARKING BRAKE ADJUSTMENT/ DRIVE CHAIN SLACK ADJUSTMENT

2-21

1. Adjust:

• Parking brake

Parking brake adjustment steps:

• Apply rear brake pedal 2 or 3 times.

• Loosen the locknut CD and fully loosen the parking brake cable adjuster (2) on the left lever holder.

• Loosen the locknut @ and adjusting bolt @ on the rear caliper.

=Slowlv screw in the adjusting bolt @ by tool until it feels tight and screw it out 1/8 turn. Then tighten the locknut @.

Locknut @:

16 Nm (1.6 m-kq, 11 ft-Ibl

When tightening the locknut, hold the adjusting bolt with a spanner so that the adjusting bolt is not turned together with the locknut.

• Adjust parking brake cable length @ by turning cable adjuster (2) in or out.

Parking Brake Cable Length: 46-50 mm (1.81-1.97 in)

·Tighten the locknut CD.

WARNING:

After this adjustment is performed, block the rear of the machine off the ground, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed, perform the above steps again.

DRIVE CHAIN SLACK ADJUSTMENT Drive Chain Slack Check

1. Measure:

• Drive chain slack ®

At the position shown in the photograph. Out of specification ~ Adjust.

DRIVE CHAIN SLACK ADJUSTMENT I ':~~ I till

Drive chain slack measurement steps:
• Elevate the rear wheels by placing a suitable
stand under the engine.
• Rotate the rear wheel several times.
• Check the chain slack several times to find the
point where the chain is the tightest.
= Check the chain slack when the wheel ., in
this "tight chain" position.
I~ Drive Chain Slack @:
Standard: 15 rnm \0.6 in)
Limit: 40 mm (1.6 in)
·If the chain slack exceeds the limit [40 mm
(1.6 in)], adjust the cham slack. Drive Chain Slack Adjustment

1. Adjust:

• Drive chain slack

Drive chain slack adjustment steps:

• Loosen the rear wheel hub upper bolts G).

• Loosen the rear wheel hub lower bolts ~. - Loosen the adjuster locknut @.

- Adjust chain slack by turning the adjuster @.

To Tlqhteri-e Turn adjuster @ clockwise.

To Loosen-s Turn adjuster @ counterclockwise and push wheel forward.

=Turn each adjuster exactly the same amount to maintain correct axle alignment. (There are marks ® on each side of chain puller alignment.)

Excessive chain slack will overload the engine and other vital parts; keep the slack within the specified limits.

-If the chain slack cannot be adjusted, replace the sprockets and drive chain as a set.

2-22

IIANOSJP I d I

~ DRIVE CHAIN LUBRICATION

-------------------------------------------------------

2-23

-Tighten the rear wheel hub bolts and
locknuts.
I~ Rear Wheel Hub Lower Bolt:
60 Nm (6.0 m.kg, 43 ft·lb)
Rear Wheel Hub Upper Bolt:
120 Nm (12 m-kq, 85 ft.lb)
Locknuts (Chain Puller):
16 Nm (1.6 rn-kq, 11 ft-Ibl
NOTE:
The chain should be cleaned and lubricated af-
ter every use of the machine. DRIVE CHAIN LUBRICATION

1. Remove:

-Master link clip CD

-Joint

- Drive chain

2. Clean:

-Drive chain

Place it in kerosene, and brush off as much dirt as possible. Then remove the chain from the kerosene and dry the chain.

NOTE: _

This machine has a drive chain with small rubber O-rings CD between the chain plates. Steam cleaning, high-pressure washes, and certain solvent can damage these O-rings. Use only kerosene to clean the drive chain.

3. Lubricate:

• Drive chain

Drive Chain Lubricant:

SAE 30 - 50 Motor oil or chain lubricants for "O-ring" chains

IIANOSJP I d I

DRIVE CHAIN AND SPROCKET INSPECTION ~

-------------------------------------------------------

Do not use any other lubricants or O-rings damage may occur.

4. Install:

Drive chain

NOTE: __

During reassembly, the master link clip must be installed with the rounded end facing the direction of travel.

CD Turning direction

5. Adjust:

• Drive chain slack

Refer to "DRIVE CHAIN SLACK ADJUSTMENT" section.

DRIVE CHAIN AND SPROCKETS INSPECTION

1. Remove:

• Drive chain

Refer to "DRIVE CHAIN LUBRICATION" section.

2. Check:

• Drive chain stiffness

Clean and oil the chain and hold as illustrated.

Refer to "DRIVE CHAIN LUBRICATION" section.

3. Inspect:

• Drive sprocket/ Driven sprocket

More than 1/4 teeth CD wear-» Replace sprocket.

Bent teeth~ Replace sprocket.

Refer to "CHAPTER 6- REAR WHEEL AND WHEEL HUB" section.

CZ) Correct @ Roller @ Slip off

4. Install:

• Drive chain

Refer to "DRIVE CHAIN LUBRICATION" section.

2-24

2-25

CHAIN TENSIONER AND CHAIN GUIDE INSPECTION

1. Remove:

= Chein tensioner (Upper and lower) CD

2. Inspect:

·Chain tensioner roller (Upper-Big) CD ·Chain tensioner roller (Lower-Small) CZ) Excessive wear-» Replace.

3. Check:

.Chain tensioner bearing @ Tightness/ Binding/ Damaqe-» Replace.

4. Inspect:

·Chain support @ Chain guide @ Darnaqe-» Replace.

5. Install:

·Chain tensioner (Upper and lower)

Bolt (Chain Tensioned:

9 Nm (0.9 rn -kq, 6.8 ft-Ib]

STEERING SYSTEM INSPECTION

1. Place the machine on a level place.

2. Check:

.Steering assembly bushings

Move the handlebar up and down, and/or back and forth.

Excessive plav-« Replace the steering shaft bushings.

3. Check:

.Tie-rod ends

Turn the handlebar to the left and/or right until it stops completely, then slightly move the handlebar from left to right.

Tie-rod end CD has any vertical play ~ Replace the tie-rod endls).

STEERING SYSTEM INSPECTION/CABLE IINSP I ~ I INSPECTION AND LUBRICATION ADJ ~

I-,,;....;;,;;;....;;;;..._L-... .... ..-.-'

4. Raise the front end of the machine so that there is no weight on the front wheels.

5. Check:

-Ball joints CD and/or wheel bearings Move the wheels laterally back and forth. Excessive free plav-» Replace the front arms and/ or wheel bearings.

CABLE INSPECTION AND LUBRICATION

1. Damage to the outer housing of the various cables may cause corrosion. Often free movement will be obstructed. An unsafe condition may result. Replace such cables as soon as possible.

2. If the inner cables do not operate smoothly lubricate or replace them.

Yamaha Chain and Cable Lube or SAE 10W30 Motor Oil

2-26

I ~~~ I §t 1_~_~_O_J~_1_T_AM_N_r_N~_E_A_R_S_H_O_C_K_A_B_S_O_R_B_E_R _

I ~_£ D F I U lJ~

2-27

FRONT AND REAR SHOCK ABSORBER ADJUSTMENT

Front Shock Absorber

1. Adjust:

= Sprlnq preload

Turn the adjuster CD to increase or decrease the spring preload.

Front Shock Absorber Preload
Preload Softer ® Standard Stiffer @
<-- -->
Position A B C,D,E Rear Shock Absorber

WARNING:

This shock absorber contains highly pressurized nitrogen gas Read and understand the following information before handling the shock absorber. The manufacture cannot be held responsible for property damage or personal injury that may result from improper handling.

• Do not tamper with or attempt to open the cylinder assembly.

• Do not subject shock absorber to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure.

• Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance.