1990-2004 Yamaha Warrior 350 Service & Repair Manual

Yamaha Warrior Service Manual 1990-2004 This manual is comprised of a base manual, plus four additional supplement manuals for the updates made to the Yamaha Warrior over the years. Use the links below or the bookmarks to the left to get to the manual that covers your model. 1990-1991 models base manual 1992-1996 models supplement manual 1997 models supplement manual 1998-2001 models supplement manual 2002-2004 models supplement manual

YAMAHA

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

HOW TO USE THIS MANUAL CONSTRACTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See ""'ustrated symbols") This is a chapter with its symbol on the upper right of each page. 1 st title ill: 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 A" 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 a" disassembly, repair, assembly, and inspections. A set of particularly important procedure @ is placed between a line of asterisks" *" with each j:1rocedure 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 re- quired the symbol ®. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identif- ying correct disassembly and assembly procedures. ~~~~-------~----------- ~ =:::::::NANDREP~ ENG I ~I _______ '_RON_TF_DR_K ICHASI~I • -C'lnk,halt I • I Us. Ihe crankcase "'"I.llong 1001 ? ~ .".. Q) 1}id:J Cr.Mc." •• par.Un' tool: .0 YU-0113fi iNSPECTION AND REPAIR CYLINDER HEAD • C.rbon depolill UN. rounded Icrlper NOTE:----'----- hke c:ere to Ivoide damaging the 1"lrk plug '--____ ----' ~h::~:~'~I:h~.:t~::I:mi~~ • .:: in",umlnl w ...... ,. "" ........... m ,ltd ... u,f,cI- mlnta'lp: • AUlch I straight edge CD and I thickne- 4 )----H~-frr~~~.t.l .=':~~I~.:.:::::tindef h •• d • If Ihe w"P~ i, 01,11 01 Iplclliulien, ,,_ lurfaea the cylind'r ilIad. '----~""'""'-~_=.=''''' .PI,cI' 400 - 8OO,rit wet .. nII"l"a, on I~I :ff::::':'=::': ~ - ~:::~:::.~:::.::'~:~'::~:~~.:: ... 1 Inloec! "Inne. 'ork lube I • Oule. fo.k lube ~ Sc • .,'chesIBendsrOemage .... Replace rlII.'.miIIIImI ___ _ 00 not l!templ 10 IUIlghlen I bent inn .. fo.k lubl IS thie "lilY dlnge.oully we,"en chetube • Jo,nlldrivech8,nl • CI,p Idrive che,n! 6 9 7 8

CD ~ II~~~I'-I ISPECI yJ~ I @ @ I~~~I"I I ENG I ~.I @ @ ICOOLI:I: I ICARBI.I Q) @ IOR1VI+: .. 1 I CHASI fls61 ® ® I ELECI 53 I IJn¥~1 ? I • @ ~ @ ~ (j) ~ @ Ixl @ ~ ® [8] @ m @ 1 t\ @) @ @ 1 1 1 m ~ ~ @ @ @ ~L- ~L- ~L- I llUSTRA TED SYM BOlS (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 Q) Drive train @ Chassis ® Electrical ® Troubleshooting Illustrated symbols ® to @ are used to identify the specifications appearing in the text. @ Filling fluid @ Lubricant (j) Special tool @ Tightening @ Wear limit, clearance ® Engine speed @O,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

INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING SPEC .... @1I ENG § ELEC ? •

CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ... .................................... 1-1 VEHICLE IDENTIFICATION NUMBER .............................. 1-1 ENGINE SERIAL NUMBER ....................................... 1-1 IMPORTANT INFORMATION ...................................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ............... 1-2 ALL REPLACEMENT PARTS ..................................... 1-3 GASKETS, OIL SEALS, AND O-RINGS ............................ 1-3 LOCK WASHERS/PLATES AND COTTER PINS .................... 1-3 BEARINGS AND OIL SEALS ..................................... 1-3 CIRCLIPS ....................................................... 1-4 SPECIAL TOOLS .................................................. 1-4 FOR TUNE-UP .................................................. 1-4 FOR ENGINE SERVICE ........................................... 1-5 FOR CHASSIS SERVICE ......................................... 1-7 FOR ELECTRICAL COMPONENTS ................................. 1-8 CHAPTER 2. SPECIFICATIONS GENERAL SPECiFiCATIONS ...................................... . 2-1 SPEC ,- ENG MAINTENANCE SPECiFiCATIONS ................................ . 2-4 • ENGINE ........................................................ 2-4 CHASSIS ...................................................... 2-10 ELECTRiCAL ................................................... 2-14 GENERAL TORQUE SPECiFiCATIONS ............................ . 2-16 DEFINITION OF UNITS ..... ...................................... 2-16 LUBRICATION DIAGRAM ........................................ 2-17 CABLE ROUTING . ................................................ 2-19 Ea ELEC ? •

CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION ................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ......................... 3-1 ENGINE ........................................................... 3-2 VALVE CLEARANCE ADJUSTMENT .............................. 3-2 SPARK PLUG INSPECTION ...................................... 3-5 CRANKCASE VENTILATION SySTEM ................... ; ......... 3-7 FUEL LINE ...................................................... 3-7 INTAKE MANIFOLD ............................................. 3-7 EXHAUST SySTEM ............................................. 3-7 IDLING SPEED ADJUSTMENT .................................... 3-8 TIMING CHAIN ADJUSTMENT ................................... 3-9 ENGINE OIL LEVEL INSPECTION .................................. 3-9 ENGINE OIL REPLACEMENT .................................... 3-10 CLUTCH ADJUSTMENT ........................................ 3-13 IGNITION TIMING CHECK ....................................... 3-13 COMPRESSION PRESSURE MEASUREMENT ..................... 3-14 AIR FILTER CLEANING ......................................... 3-16 THROTTLE CABLE ADJUSTMENT ............................... 3-19 SPEED LIMITER ADJUSTMENT ................................. 3-21 CHASSIS ........................................................ 3-22 BRAKE PAD INSPECTION ....................................... 3-22 BRAkE FLUID LEVEL INSPECTION ............................... 3-22 FRONT BRAKE ADJUSTMENT .................................. 3-23 REAR BRAKE ADJUSTMENT .................................... 3-24 PARKING BRAKE ADJUSTMENT ................................ 3-26 AIR BLEEDING ................................................. 3-27 DRIVE CHAIN SLACK ADJUSTMENT ............................ 3-28 DRIVE CHAIN LUBRiCATION .................................... 3-30 FRONT AND REAR SHOCK ABSORBER ADJUSTMENT ........... 3-30 BRAKE AND CHANGE PEDAL/BRAKE AND CLUTCH LEVERS LUBRiCATION ................................ 3-33 CABLE INSPECTION AND LUBRiCATION ......................... 3-33 STEERING AND SUSPENSION LUBRiCATION .................... 3-34 WHEEL BEARINGS ............................................. 3-34 STEERING SySTEM ............................................ 3-34 TOE-IN ADJUSTMENT .......................................... 3-35 TIRE INSPECTION .............................................. 3-36 WHEEL INSPECTION ........................................... 3-39 ELECTRICAL ..................................................... 3-39 BATTERY INSPECTION ......................................... 3-39 FUSE INSPECTION ........................................... , .3-41 HEADLIGHT BEAM ADJUSTMENT .............................. 3-43 HEADLIGHT BULB REPLACEMENT .............................. 3-43

CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL ................................................ 4-1 ENGINE OIL .................................................... 4-1 SEAT, HEADLIGHT UNIT AND FUEL TANK ....................... 4-1 CARBURETOR .................................................. 4-1 CLUTCH CABLE ................................................ 4-2 EXHAUST PIPE AND MUFFLER .................................. 4-2 DRIVE SELECT LEVER AND CRANKCASE VENTILATION HOSE ..... 4-3 DRIVE CHAIN SPROCKET ........................................ 4-3 D • FOOTRESTS .................................................... 4-3 LEADS ......................................................... 4-4 ENGINE REMOVAL .............................................. 4-5 2 SPEC ENGINE DiSASSEMBLy ........................................... 4-6 DECOMPRESSION CAM, CAM CHAIN SPROCKET AND CYLINDER HEAD ................................................ 4-6 CYLINDER AND PISTON ......................................... 4-8 LEFT CRANKCASE COVER AND COl MAGNETO ................... 4-9 CAM CHAIN AND STARTER MOTOR ........................... .4-11 OIL FILTER AND NEUTRAL SWITCH ............................. 4-12 RIGHT CRANKCASE COVER .................................... 4-12 CLUTCH ...................................................... 4-13 PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR .......... 4-14 OIL PUMP ..................................................... 4-14 SHIFT SHAFT ................................................. 4-15 OIL PIPE ...................................................... 4-15 CRANKCASE .................................................. 4-15 BEARINGS AND OIL SEALS .................................... 4-19 .. CRANKSHAFT/ROCKER ARMS/VALVES ......................... 4-20 INSPJ:CTION AND REPAIR ....................................... 4-22 CYLINDER HEAD ............................................... 4-22 VALVE SEAT .................................................. 4-23 VALVE/VALVE GUIDE .......................................... 4-26 CAMSHAFT ................................................... 4-27 ROCKER ARM/ROCKER ARM SHAFT ............................ 4-28 VALVE SPRING ................................................ 4-29 TIMING CHAIN/CHAIN GUIDE/SPROCKET ....................... 4-29 CYLINDER/PISTON ........................................... .4-30 a PISTON RING .................................................. 4-32 PISTON PIN ................................................... 4-33 CRANKSHAFT/CONNECTING ROD .............................. 4-34 ELEC ELECTRIC STARTER DRIVES .................................... 4-34 PRIMARY DRIVE ............................................... 4-35 CLUTCH ...................................................... 4-36 ? OIL PUMP ..................................................... 4-38 • SHIFTER ...................................................... 4-38 TRANSMISSION ............................................... 4-39

BALANCER DRIVE GEAR ....................................... 4-40 CRANKCASE .................................................. 4-40 BEARING AND OIL SEALS ...................................... 4-41 ENGINE ASSEMBLY AND ADJUSTMENT ........................ . 4-42 CAMSHAFT/ROCKER ARMS/VALVES ........................... 4-42 TRANSMISSION/BALANCER/CRANKSHAFT ..................... 4-45 CRANKCASE ................................................. .4-51 OIL PIPE ...................................................... 4-52 SHIFT SHAFT ................................................ .4-52 OIL PUMP ..................................................... 4-53 BALANCER DRIVEN GEAR AND PRIMARY DRIVE GEAR ......... .4-53 CLUTCH ...................................................... 4-54 RIGHT CRANKCASE COVER ................................... .4-57 NEUTRAL SWITCH AND OIL FILTER ............................. 4-57 STARTER MOTOR AND CAM CHAIN ........................... .4-58 COl MAGNETO AND LEFT CRANKCASE ........................ .4-58 CYLINDER HEAD/CYLINDER/PISTON ........................... .4-60 REMOUNTING ENGINE ........................................ .4-67 CHAPTER 5. CARBURETION CARBURETOR ................................................... . 5-1 SECTION VIEW ................................................. 5-2 REMOVAL ...................................................... 5-3 DISASSEMBLY ................................................. 5-4 INSPECTION .................................................... 5-6 ASSEMBLY ..................................................... 5-7 INSTALLATION ................................................. 5-8 FLOAT HEIGHT ADJUSTMENT ................................... 5-9 FUEL LEVEL ADJUSTMENT ..................................... 5-10 WIRE CyLINDER ........................................ ········ .5-11 REMOVAL, ..................................................... 5-11 INSPECTION ................................................... 5-11 INSTALLATION ................................................ 5-12 CHAPTER 6. CHASSIS FRONT WHEEL AND WHEEL HUB ....................... ····.···· .6-1 REMOVAL ...................................................... 6-2 INSPECTION .................................................... 6-3 INSTALLATION ................................................. 6-4

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1990-2004 Yamaha Warrior 350 Service & Repair Manual

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