1995-2000 Yamaha WOLVERINE 350 4x4 Service Manual and ATV Owners Manual - Workshop Repair

YFM35FXG Service Manual

YAMAHA LIT-11616-09·95

' FOREWORD This Supplementary Service Manual has been prepa,.red to introduce new service and data for the YFM35FXH . For complete service information procedures, it is necessary to use this Supplementary Service Manual together with the following manual. YFM35FXG SERVICE MANUAL: 4KB-28197-20 YFM35FXH SUPPLEMENTARY SERVICE MANUAL @1995 by Yamaha Motor Co., Ltd. 1st Edition, September 1995 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

NOTICE This manual was written by the Yamaha Motor Company, Ltd. primarily for use b,y Yamaha dealers and qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so persons using this book to perform maintenance and repairs on Yamaha machines should have a basic understanding of the mechanical concepts and procedures inherent in machine repair technology. Without such knowledge, attempted repairs or service to the machine 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 for- warded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of 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 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 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 inspec- tions. A set of particularly important procedure@ is placed between a line of asterisks"*" with each procedure preceded by "e". 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@. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures. UsethltCrlnkc .. eHplrltingtool Cl'. lt=i Ueeeroundlld*<:rlper. NOTE,----'---'------- hkiCai'IIO..,Ooded .......... lhelpllfkplug '-------------' .. onstr..,.nl . ...... -· ..... ··-·-- _...,.,, •Auachestreightedgol CD endethiciiM- .::.=.!:,:::.lind•rhud. elfthltwllfO ... iloutofepecifiellliol'l,re· '---- ...... !._ __ ePIM:ee400- IOOtrit •" Nl'ldlNI,.. on FRONT •""• icHASI A I ----------------- 1 lnSPKI

CD ® lsPEcl u--1 @ @ l•:g!l-.1 IENGI\.1 ® ® lcARBI Iii I (j) @ lcHAsl6lOI IELEcjol ® @) [1)] I ® B @ @ ® ® [8] ® @ @) @ l l l m ® @ @ ....... ....... @ ® A 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) 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 diagram indicate grade of lubricant and loca- tion 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®) ®Use new one

CONTENTS GENERAL INFORMATION .......................................................................................... 1 MACHINE IDENTIFICAtiON ................................................................................. 1 VEHICLE IDENTIFICATION NUMBER ............................................................ 1 FRAME SERIAL NUMBER .............................................................................. 1 ENGINE SERIAL NUMBER ............................................................................. 1 SPECIFICATIONS ........................................................................................................ 2 GENERAL SPECIFICATIONS ................................................................................. 2 MAINTENANCE SPECIFICATIONS ....................................................................... 2 ENGINE ............................................................................................................. 2 ELECTRICAL .................................................................................................... 3 TIGHTENING TORQUE ................................................................................... 4 CABLE ROUTING ................................................................................................... 6 CARBURETION .. .. .. .. ... .... .. .. ....... ..... .... . .. ......... ...... ..... .. .. ..... .... ... .. ............. ... .. .. .. ... .. .. 11 CARBURETOR ..................................................................................................... 11 ELECTRICAL ............................................................................................................... 12 IGNITION SYSTEM .............................................................................................. 12 CIRCUIT DIAGRAM ....................................................................................... 12 ENGINE REVOLUTION LIMITER SYSTEM .................................................. 13 YFM35FXH WIRING DIAGRAM

MACHINE IDENTIFICATION I I o'el GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number <D 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 au- thority in your state. Starting serial number: For USA JY 44KBAO* TA026101 ForCDN JV 44KBNO* TA048101 FRAME SERIAL NUMBER The frame serial number <D is stamped into the left side of the frame. Starting serial number: For Europe 4KB-052101 ENGINE SERIAL NUMBER The engine serial number <Dis stamped into the right side of the engine. -1- NOTE: Starting serial number: For USA 4KB-026101 ForCDN 4KB-048101 For Europe 4KB-052101 Designs and specifications are subject to change without notice.

GENERAL SPECIFICATIONS/ I I I MAINTENANCE SPECIFICATIONS SPEC a-- SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code: Engine starting number: Vehicle identification number: Frame starting number: Carburetor: Type/ quantity Manufacturer MAINTENANCE SPECIFICATIONS ENGINE Model Carburetor: I. D. mark Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N) Needle jet (N.J) Pilot air jet (P.A.J.1) Pilot air jet (P.A.J.2) Pilot outlet (P.O) Pilot jet (P.J) Bypass 1 (B.P.1) Bypass 2 (B.P.2) Bypass 3 (B.P.3) Pilot screw (P.S) Valve seat size (V.S) Starter jet (G.S.1) (G.S.2) Throttle valve size (Th.V) Float height (F.H) Fuel level (F.L) Engine idle speed Intake vacuum YFM35FXH For USA: 4KB3 For CON: 4KB4 For Europe: 4KB5 For USA: 4KB-026101 For CON: 4KB-048101 For Europe: 4KB-052101 For USA: JY44KBAO*TA026101 For CON: JY44KBNO*TA048101 For Europe: 4KB-052101 BST34 X 1 MIKUNI YFM35FXH 4KB 10 #135 0.8 5H45-3 P-0 (#781) #80 1.3 0.85 #42.5 0.8 0.8 0.8 2 turns out 2.0 #45 0.7 #130 12- 14 mm (0.47- 0.55 in) 2.0- 3.0 mm (0.08- 0.12 in) Above the float chamber mating surface 1,450- 1,550 r/min 36.0 kPa (270 mmHg, 10.6 inHg) -2-

MAINTENANCE SPECIFICATIONS lsPECI o-1 ELECTRICAL Model C.O.I.: Magneto model/manufacturer Pickup coil resistance/color Source coil resistance/color C.O.I. unit model/manufacturer Charging system: Type Model/manufacturer Nominal output Stator coil resistance/color Rectifier: Model/manufacturer Capacity Withstand voltage Starter relay: Model/manufacturer Amperage rating Coil winding resistance/color YFM35FXH For USA: F004T20471/MITSUBISHI For CON, Europe: F004T42371/MITSUBISHI For USA: 459 - 561 nat 2o·c (68.F)/ (White/Green-White/Red) 459 - 561 nat 2o·c (68.F)/ (Blue-White/Red) For CON, Europe: 459 - 561 nat 20°C (68°F)/(White/Red-White/ Green) 270- 330 0 at 2o·c (68.F)/(Brown-Green) For USA: F008T17571/MITSUBISHI For CON, Europe: F008T3237 4/MITSUBISHI A.C. magneto For USA: F004T20471/MITSUBISHI For CON, Euorpe: F004T42371/MISTSUBISHI For USA: 14V 12.5A at 3,000 r/min For CON, Europe: 14V 12A at 3,000 r/min For USA: 0.45 - 0.55 nat 2o·c (68.F)/(White-White) For CON, Europe: 0.70 - 0.86 Qat 20°C (68°F)/(White-White) SH640-12/SHINOENGEN 14A 200V MS5E-541/JIOOSHAOENKI 100A 4.18- 4.62 nat 2o·c (68.F)/ (Blue/White-Red/White) -3-

1995-2000 Yamaha WOLVERINE 350 4x4 Service Manual and ATV Owners Manual - Workshop Repair

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