YAMAHA WARRIOR 350 RAPTOR 350 ATV Full Service & Repair Manual 1987-2009

YFM350X LIT-11616-07-34 Service Manual

OYAMAHA LIT -11616-07-34 JGD-28197-11

FOREWORD This Supplementary Service manual has been prepared to introduce new service and new data for the YFM350XA. For complete information on service procedures, it is necessary to use this Supplemen- tary Service Manual together with following manual. YFM350XT Service Manual (LIT-11616-05-52) YFM350XU Supplementary Service Manual (LIT-11616-06-43) YFM350XW Supplementary Service Manual (LIT-11616-06-72) YFM350XA SUPPLEMENTARY SERVICE MANUAL ©1989 by Yamaha Motor Corporation, U.S.A. 1st Edition, November 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. LIT-11616-07-34

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 Autho- rized Yamaha dealers and will, where applicable, appear in future editions of this manual. TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO., LTD. HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. A WARNING NOTE: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle 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. 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 cor- rect disassembly and assembly procedures.

CD C2) Ideal lsPEcl f;f I @ @ I ENG I @ ® lcARBifl (f) @ loRivi-F:..I icHAslcPol ® ® I ELEele I ? I • @ © @ ®> ® ® [0] @ ® l a @ ® @ 1 1 l m ® @ @ ® ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols G) to ® are designed as thumb tabs to indicate the chapter's number and content. CD General information C2) Specifications @ Periodic inspection and adjustment @Engine @ Cooling system ® Carburetion (f) Drive train @Chassis ® Electrical ® Troubleshooting Illustrated symbols QD to@ are used to identify the specifications appearing in the text. @ Filling fluid © Lubricant @ Special tool ®> Tightening ® Wear limit, clearance ® Engine speed @0, V,A Illustrated symbols ®to ® in the exploded diagram indicate grade of lubricant and location of lubrication point. @ Appply 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 ELECTRICAL .................................................. 3 CABLE ROUTING ................................................. 5 PERIODIC INSPECTIONS AND ADJUSTMENTS ..................... . 9 INTRODUCTION .................................................. 9 PERIODIC MAINTENANCE/LUBRICATION ........................... 9 ENGINE OVERHAUL ............................................... 10 ENGINE ASSEMBLY AND ADJUSTMENT .......................... 10 RIGHT CRANKCASE COVER ................................... 10 CHASSIS ......................................................... . 11 STEERING SYSTEM .............................................. 11 ELECTRICAL ....................................................... 13 YFM350XA CIRCUIT DIAGRAM ................................... 13 YFM350XA WIRING DIAGRAM

MACHINE IDENTIFICATION 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 43G DWO* LC051101 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: YFM350XA ... 3G D-051101 NOTE: ------------------------ Designs and specifications are subject to change without notice. -1-

GENERAL SPECIFICATIONS/ I I 0 I ______ M_A_I_N_TE_N_A_N_c_E_s_P_E_c_IF_Ic_A_T_Io_N_s_ SPEC f, SPECIFICATIONS GENERAL SPECIFICATIONS Model Model Code Number Vehicle Identification Number Engine Starting Number Dimensions: Overall Length Overall Width Overall Height Seat Height Wheelbase Minimum Ground Clearance Basic Weight: With Oil and Full Fuel Tank Tire: Type Size Manufacturer /Type MAINTENANCE SPECIFICATIONS CHASSIS Model Front Suspension: Shock Absorber Stroke Shock Absorber Spring Free Length YFM350XA 3GD5 JY43GDWO* LC051101 3GD-051101 1,840 mm (72.4 in) 1,080 mm (42.5 in) 1,080 mm (42.5 in) 765 mm (30.1 in) 1,200 mm (47.2 in) 125 mm (4.92 in) 191 kg (421 lb) Front Tubeless AT21 x7-10 DUNLOP KT764A YFM350XA 90 mm (3.54 in) 224.0 mm (8.82 in) Rear Tubeless AT22x 10-9 DUNLOP KT775 Spring Rate (K1) 39.2 N/mm (4.0 kg/mm, 224 lb/in) Stroke (K1) Zero-109.5 mm (Zero-4.31 in) Optional Spring No Rear Disc Brake: Type Single disc Dis Outside Diameter x Thickness 245x3.5 mm (9.65x0.14 in) <Limit> <3.0 mm (0.12 in)> Pad Thickness 4.5 mm (0.177 in) <Limit> < 1.0 mm (0.0394 in)> Drive Chain: Type/ Manufacturer 520V6/ DAI DO Number of Links 98 links Chain Free Play 30-40 mm (1.18-1.57 in) -2-

YAMAHA WARRIOR 350 RAPTOR 350 ATV Full Service & Repair Manual 1987-2009

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