Yamaha YFZ350 User Manual

2002

YFZ350

(

)

3GG-AE2

SUPPLEMENTARY SERVICE MANUAL

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and new data for the YFZ350(P) 2002. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.

YFZ350T SERVICE MANUAL: 2GU-28197-20 YFZ350 SUPPLEMENTARY SERVICE MANUAL: 3GG-28197-20 YFZ350 SUPPLEMENTARY SERVICE MANUAL: 3GG-28197-21

YFZ350(J)/(K) ’97/’98 SUPPLEMENTARY SERVICE MANUAL: 3GG-AE1

YFZ350(P) 2002 SUPPLEMENTARY SERVICE MANUAL



2001 by Yamaha Motor Co., Ltd.

First Edition, May 2001

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. 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.

OTE:

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

CAUTION:

NOTE:

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.

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 symbols”)

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

2nd title 2: This title appears on the upper of each page on the left of the chapter sym-

bol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.)

3rd title 3: 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 4 is placed between a line of asterisks “ dure preceded by “

●

”.

IMPORTANT FEATURES

●

Data and a special tool are framed in a box preceded by a relevant symbol 5.

●

An encircled numeral 6 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 8.

●

A condition of a faulty component will precede an arrow symbol 9 and the course of action will follow it.

” with each proce-

EXPLODED DIAGRAM

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

GEN

INFO

SPEC

CHK

ADJ

CARB

ENG

COOL

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 Cooling system 7 Chassis 8 Electrical 9 Troubleshooting

CHAS

ELEC

– +

TRBL SHTG

GHI

Illustrated symbols 0 to F are used to identify the specifications appearing in the text.

0 Filling fluid A Lubricant B Special tool C Torque D Wear limit, clearance E Engine speed

Ω, V, A

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

KLM

New

G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease M Apply silicon grease

Illustrated symbols N to O in the exploded diagrams indicate where to apply a locking agent N and when to install a new part O.



N Apply the locking agent (LOCTITE O Replace

)

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS ...................................................................1

MAINTENANCE SPECIFICATIONS ..........................................................2

ENGINE .................................................................................................2

CHASSIS ...............................................................................................3

ELECTRICAL.........................................................................................4

CABLE ROUTING ......................................................................................5

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION......................................................................................12

PERIODIC MAINTENANCE/LUBRICATION INTERVALS.......................12

CHASSIS..................................................................................................14

ADJUSTING THE FRONT BRAKE......................................................14

ADJUSTING THE REAR BRAKE LIGHT SWITCH..............................14

ADJUSTING THE REAR SHOCK ABSORBER...................................15

ELECTRICAL

CHECKING THE SWITCH .......................................................................18

CHECKING THE SWITCH...................................................................18

CHECKING A SWITCH SHOWN IN THE MANUAL ............................18

SIGNAL SYSTEM ....................................................................................19

CIRCUIT DIAGRAM.............................................................................19

CHECKING THE SIGNAL SYSTEM....................................................20

.............................................................................................1

...................................................12

..................................................................................................18

YFZ350(P) 2002 WIRING DIAGRAM

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model YFZ350(P) 2002

Model code number 5FKF: (CDN)

5FKG: (Europe and Oceania)

Lubrication system: Premix

Premix ratio YAMALUBE “R” 24 : 1

CASTROL R30 20 : 1 CASTROL A545 20 : 1 CASTROL A747 20 : 1

Transmission oil YAMALUBE 4 or SAE 10W30 type SE motor oil

Spark plug:

Type BR8ES Manufacturer NGK Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.032 in)

Tire:

Type Tubeless Size: Front AT21 × 7-10

Rear AT22 × 10-9

Manufacturer/type: Front DUNLOP/KT851A

Rear DUNLOP/KT877

Wear Limit 3 mm (0.12 in)

Shock absorber:

Front Coil spring/oil damper Rear Coil spring/gas-oil damper

Wheel travel:

Front 230 mm (9.06 in) Rear 220 mm (8.66 in)

Electrical:

Ignition system C.D.I. Generator system C.D.I. magneto Headlight type Bulb type Headlight bulb type Krypton bulb Bulb voltage/watage × quantity:

Headlight 12 V 30 W/30 W × 2 Tail/brake light 12 V 5 W/21 W × 1

– 1 –

MAINTENANCE SPECIFICATIONS

ENGINE

Model YFZ350(P) 2002

Carburetor:

I.D. mark 2GU 01 Fuel level (F.L.) (With special tool) 0.5 ~ 1.5 mm (0.020 ~ 0.059 in) Float height (F.H.) 20.5 ~ 21.5 mm (0.81 ~ 0.85 in) Main jet (M.J.) #200 Main air jet (M.A.J.) ø1.6 Jet needle (J.N.) 5N7-3 Needle jet (N.J.) O-8 Cutaway (C.A.) 2.0 Pilot outlet (P.O.) ø0.6 Pilot jet (P.J.) #25 Bypass 1 (B.P.1.) 1.4 Air screw (A.S.) 2.0 turns out Valve seat size (V.S.) 2.8 Starter jet (G.S.) ø1.4 Engine idle speed 1,450 ~ 1,550 r/min

Cooling system:

Radiator core size:

Width 210 mm (8.27 in) Height 350 mm (13.8 in) Thickness 32 mm (1.26 in)

Radiator cap opening pressure 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm

13.8 ~ 18.1 psi)

Reservoir tank

Capacity 0.28 L (0.246 Imp qt, 0.296 US qt) From low to full level 0.07 L (0.06 Imp qt, 0.07 US qt)

Water pump

Type Single-suction centrifugal pump

Reduction ratio 32/20 (1,600)

SPEC

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