Yamaha Banshee 350 Service Repair Manual - All Years

Yamaha Banshee Service Manual 1987-2006 This manual is comprised of a base manual, plus four additional supplement manuals for the updates made to the Yamaha Banshee over the years. Use the links below or the bookmarks to the left to get to the manual that covers your model. 1987-1989 models base manual 1990 models supplement manual 1991-1996 models supplement manual 1997-2001 models supplement manual 2002-2006 models supplement manual

OYAMAHA 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: WARNING: 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. 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 ~§l 1 (LV 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]) fl, 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 GENERAL INFORMATIO-N PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL COOLING SYSTEM .. GEN INFO

____________________ I~~~I~I CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFiCATION ...................................... . 1-1 VEHICLE IDENTIFICATION NUMBER .............................. 1-1 ENGINE SERIAL NUMBER ....................................... 1-1 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 u

II~~~ IAI MACHINE IDENTIFICATION 1-1 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.

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 dur- ing 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 tab(s) 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 seal(s), apply a light coat- ing of light-weight lithium base grease to the seal lip(s). 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 1-3 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 op- posite to the thrust @ it receives. See the sectional view. ® Shaft SPECIAL TOOLS The proper special tools are necessary for com- plete 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 remov- ing 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

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Yamaha Banshee 350 Service Repair Manual - All Years

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