Yamaha YFM350FW User manual

PROTECT YOUR INVESTMENT
Use Genuine YAMAHA Parts And Accessories
LIT-11616-FM-37
YFM350FW
LIT-11616-FM-37
Service Manual
YAMAHA MOTOR CORPORATION, U.S.A.
PRINTED IN U.S.A.
Service Manual
YFM350FW
11616-FM-37_00_D 05/13/2002 3:02 PM Page 1
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YAMAHA
sales@mi anuails.com
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LIT-11616-10-30
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EBOO1000
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 main-
tenance 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.
NOTE: ______________________________________________________ _
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
A WARNING
NOTE:
The Safety Alert Symbol means ATIENTIONI 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.
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EBOO2000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual is intended as a handy, easy-to-read reference book for the mechanic. It is
divided
into chapters, sections and sub-sections. Comprehensive explanations of all installa-
tion, removal, disassembly, assembly, repair and inspection procedures are laid
out with the
individual steps in sequential order.
PAGE FEATURES
The circled numbers below refer to the features indicated in the sample page.
CD :An abbreviation and symbol in the upper right corner of each page indicates the current
chapter.
® :The current section title is shown at the top of each page.t
@ : Sub-section titles appear in smaller print than the section title.t
@ : Lines of asterisks (*) mark the beginning and end of a particularly important procedure.
The steps
of such procedures are marked with bullets (.).
@ :
Important information such as fluids, special tools and torques are framed and marked
with a corresponding symbol.
® :A circled number refers to an illustrated part.
(j) : A circled
lower case letter refers to an illustrated dimension or alignment mark.
@ : An upper case letter in a box refers to other illustrated details.
® :An arrow mark after a given defect suggests the recommended course of action.
t : In Chapter
3, "Periodic Inspection and Adjustment", it is usually the current sub-section
title that appears at the top of each page, instead of the current section title.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each disassembly section.
2.A.mo ....·
WCttnk,h"tt (,II
UN 1he cnn~e ..... pI'eline toal (JI
119 cr;::~~;: ............. :
iN'S'PeCTION AND REPAIR
CYllNDE" HEAD
l.E.lImin."
"C.Oonapot4u
U ... ,Oundflodlc:tl.,.r
IIIOTE:-----
T_'elf.to~oio!ttdtI'nlCllNtl"! •• P.,,,PkHI
thr..... 00 not loiS' • ,h.,p i,..trum."t.
'----------' -'yoid.c' .. c:hinglh ...... mi ... \oIM
2.~ •• "r.:
• CyNndM hIoH ",fP4tet
Out "" .... clfie.tiMI ....... llrIK41
I~ W::":!-::'~'''l
w........ ""' .. "'~ ...,. 'HUff .. e.
~.,.,:
• A1tRh •• ,,!l4tht" (j) 111G. t~i«lkM-
r---t-ijII~GrF~~-w-{ .:'::::;-:';:,lWMfNM
." th4J W.,"", i, ovt Of SPKlflcetlon, ,.-
.....'4IIC.1"'t<:';'MftClffMtd,
'----_"""--_---="':::..1- • frtac •• 400 ..... lOOgrrlt W.' ""'",,,,'M
I~I d~E:':::'=*:
t rna".,. too muth mM.tllll 'rom ...... Iidto
- '. ... ~ ......................... " ....... ~ ........ ..
(~'\I
, ~ ,/1
-~
Ytm ..... c .... n ... be6t
.Qi,IIv. •• nl
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CD
®
1~~~lcltel
ISPECI U-I
® @
II~g~I-1
I ENG 1\,.1
® ®
ICARSI re' I
IDR1VI-te .. 1
(j) ®
I CHASI #;61
IELEClol
®
@)
[1}]
IJ~¥~ ? I
®
E1
@
~
@
~
®
~
@>
[8]
@)
~
®
@) @)
1 1 1
m
~
~
® ® @
~
~
-cM»I
@ @
"
I~.
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols <D to ® are printed on
the top right
of each page and indicate the
subject
of each chapter.
CD General information
® Specifications
@ Periodic inspections and adjustments
@Engine
@ Carburetion
®Drive train
(j) Chassis
® Electrical
® Troubleshooting
Illustrated symbols ®> to ® are used to
identify the specifications appearing in the
text.
@) Filling fluid
® Lubricant
@ Special tool
@Torque
® Wear limit, clearance
@> Engine speed
@)O, V,A
Illustrated symbols @ to @l in the exploded
diagrams indicate the types
of lubricants
and lubrication points.
@ Apply engine oil
@) Apply gear oil
@ Apply molybdenum disulfide oil
® Apply wheel bearing grease
® Apply lightweight lithium-soap base grease
@ Apply molybdenum disulfide grease
Illustrated symbols @ to <8 in the exploded
diagrams indicate where to apply a locking
agent @ and when to install a new part @.
@ Apply the locking agent (LOCTITE®)
@ Replace
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CONTENTS
GENERAL INFORMATION .............................................................................. 1
MACHINE IDENTIFICATION .................................................................... 1
VEHICLE IDENTIFICATION NUMBER ................................................ 1
ENGINE SERIAL NUMBER ................................................................. 1
MODEL LABEL ..................................................................................... 1
SPECIFICATIONS ............................................................................................. 2
GENERAL SPECIFICATIONS ................................................................... 2
MAINTENANCE
SPECIFICATIONS ......................................................... 2
ENGINE ................................................................................................ 2
ELECTRiCAL.........................................................................................6
CABLE ROUTING .....................................................................................7
PERIODIC INSPECTION AND ADJUSTMENT.............................................. 13
SEAT, CARRIERS, FENDERS AND FUEL TANK................................... 13
REMOVAL .......................................................................................... 13
INSTALLATION ................................................................................. 15
ELECTRiCAL ................................................................................................... 17
ELECTRICAL COMPONENTS ................................................................ 17
YFM350FWJ WIRING DIAGRAM
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MACHINE IDENTIFICATION I ~~~ 1.-.1
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 a licensing
authority in your state.
-1-
ENGINE SERIAL NUMBER
The engine serial number <D is stamped
into the right side
of the engine.
MODEL LABEL
The model label CD is affixed to the frame.
This information
will be needed to order
spare parts.
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GENERAL SPECIFICATIONSI I I I
MAINTENANCE SPECIFICATIONS SPEC ~
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Model code number:
Dimensions:
Overall length
Overall
width
Overall height
Seat height
Wheelbase
Minimum ground clearance
MAINTENANCE SPECIFICATIONS
ENGINE
Model
Camshaft:
Drive Method
Cam Dimensions:
Intake:
"A"
<Limit>
liB"
<Limit>
I'C"
<Limit>
Exhaust
"A"
<Limit>
JIB"
<Limit>
"C"
<Limit>
l
r----B-
Camshaft Runout Limit
A
Cam Chain Type/Number of Links
Cam Chain
Adjustment Method
Valve spring:
Inner spring
Free length
IN
<Limit>
Set length (vaIve closed)
Compressed pressure
(installed)
EX
IN
EX
IN
EX
IN
EX
YFM350FWJ
3HNX
1,940 mm (76.4 in)
1,095
mm (43.1 in)
1,130
mm (44.5 in)
850
mm (33.5 in)
1,210
mm (47.6 in)
180 mm (7.1 in)
YFM350FWJ
Chain (Left)
40.28
..., 40.38 mm (1.586..., 1.590 in)
<40.26
mm (1.585 in»
32.14 N 32.24 mm (1.265 .... 1.269 in)
<32.11
mm (1.264 in»
8.28 '" 8.39 mm (0.326 "" 0.330 in)
<8.26
mm (0.325 in»
40.29 ... 40.39 mm (1.586 ... 1.590 in)
<40.25
mm (1.585 in»
32.14 ... 32.24 mm (1.265 .... 1.269 in)
<32.11
mm (1.264 in»
8.29 ... 8.40 mm (0.326 '" 0.331 in)
<8.26
mm (0.325 in»
<0.03 mm (0.0012 in»
BF05M/90 Links
Automatic
39.9
mm (1.57 in)
39.9
mm (1.57 in)
<37.9
mm (1.49 in»
<37.9 mm (1.49 in»
33.6 mm (1.32 in)
33.6
mm (1.32 in)
10.7 ,., 12.3 kg (23.59,., 27.12Ib)
10.7 ,... 12.3 kg (23.59 .... 27.12 Ib)
-2-
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MAINTENANCE SPECIFICATIONS ISPECI u-I
Model
Tilt
limit
Direction of winding
(top view)
Outer spring
Free length
<Limit>
Set length (valve closed)
Compressed pressure
(installed)
Tilt
limit
Direction of winding
(top view)
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
YFM350FWJ
2.5°/1.6
mm (2.5%.06 in)
2.5°/1.6
mm (2.5%.06 in)
Counterclockwise
Counterclockwise
n
43.27 mm (1.70 in)
43.27 mm (1.70 in)
<41.27
mm (1.62 in»
<41.27 mm (1.62 in»
36.6 mm (1.44 in)
36.6
mm (1.44 in)
22.99
... 26.59 kg (50.68 ... 58.62 Ib)
22.99
.... 26.59 kg (50.68 ... 58.62 Ib)
2.5°/1.6
mm (2.5%.06 in)
2.5°/1.6
mm (2.5%.06 in)
Clockwise
EX Clockwise
n
-3-
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MAINTENANCE SPECIFICATIONS \SPEC\ U-\
Model
Piston:
Piston
to cylinder clearance
<Limit>
Piston size
liD"
Measuring point "H"
Oversize 2nd
4th
Piston
off~set
Piston off-set direction
Piston pin bore inside diameter
Piston pin outside diameter
Piston rings:
Top ring:
2nd ring
Oil ring
End gap (installed)
<Limit>:
g=IB
I \Je
I T I
~]B
1 T .1
Top ring
2nd ring
Oil ring
YFM350FWJ
0.04
,.,. 0.06 mm (0.0016 '" 0.0024 in)
<0.15
mm (0.0059 in»
82.92 .... 82.97 mm (3.265 ..., 3.267 in)
5.5 mm (0.217 in)
83.5
mm (3.29 in)
84.0
mm (3.31 in)
0.5
mm (0.02 in)
IN side
19.004
,., 19.015 mm (0.7482 "" 0.7486 in)
18.991 -19.000
mm (0.7477 .... 0.7480 in)
Barrel
B =
1.2 mm (0.05 in)
T = 3.3 mm (0.13 in)
Taper
B =
1.5 mm (0.06 in)
T = 3.4 mm (0.13 in)
Expander
B= 2.8 mm (0.11 in)
T = 2.8
mm (0.11 in)
0.2 .... 0.4 mm (0.008 .... 0.016 in)
0.2
.... 0.4 mm (0.008"" 0.016 in)
0.3
,.,. 0.9 mm (0.012 .... 0.035 in)
Top ring <0.5
mm (0.020 in»
Side clearance:
<Limit>:
2nd ring <0.5
mm (0.020 in»
Oil ring -
Top ring
2nd ring
Top ring
2nd ring
0.03
.... 0.09 mm (0.0012 .... 0.0035 in)
0.03
"" 0.07 mm (0.0012 ... 0.0028 in)
<0.12
mm (0.0047 in»
<0.12 mm (0.0047 in»
-4-
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MAINTENANCE SPECIFICATIONS ISPECI u-I
Model YFM350FWJ
Clutch:
Friction plate thickness 2.94
..., 3.06 mm (0.116 -0.120 in)
Quantity 7
Friction plate
wear limit
2.8 mm (0.11 in)
Clutch plate thickness
1.5 .... 1.7 mm (0.059 ... 0.067 in)
Quantity 4
<Warp limit> <0.2
mm (0.008 in»
Clutch plate thickness 1.9 N
2.1 mm (0.075 '" 0.083 in)
Quantity 2
Clutch spring free length
44 mm (1.73 in)
Quantity 5
<Minimum length> <40 mm (1.57 in»
Clutch release method Outer push, cam push
Automatic centrifugal clutch
Clutch shoe thickness 2
mm (0.08 in)
<Wear
limit>
<1.5 mm (0.06 in»
Clutch shoe spring free length 43.5
mm (1.71 in)
Clutch~in revolution 1,750 -1,950 r/min
Clutch~stall revolution 2,900
... 3,200 r/min
Carburetor:
I. D. mark
3HN 00
Main jet (M.J) #120
Main air
jet
(M.A.J) 0.8
Jet needle (J.N)
5H26~3
Needle jet (N.J) N-8
Pilot air
jet
(P.A.J.1) 1.0
Pilot air jet (P.A.J.2) 0.9
Pilot outlet (P.O) 0.75
Pilot
jet
(P.J) #45
Bypass 1
(B.P.1 ) 0.8
Bypass 2 (B.P.2) 0.8
Bypass 3 (B.P.3) 1.0
Pilot screw (P.S) 2-3/8
Valve seat size (V.S) 2.5
Starter jet
(G.S.1 ) #75
Throttle vaIve size (Th.V) #130
Float height (F.H) 11.4
.... 13.4 mm (0.45 .... 0.53 in)
Fuel level
(F.L)
1 '" 2 mm (0.04 .... 0.08 in)
Below the float chamber mating surface
Engine idle speed 1,350
... 1,450 r/min
Intake vacuum 32.9
kPa (250 mmHg, 9.843 inHg)
-5-
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MAINTENANCE SPECIFICATIONS ISPECI U-I
Model YFM350FWJ
Lubrication system:
Oil
filter type Wire mesh type
Oil pump type Trochoid type
Tip clearance "A" or liB" 0.15
mm (0.006 in)
<Limit>
<0.2 mm (O.OOB in»
Side clearance 0.04
.... 0.09 mm (0.002 ,." 0.004 in)
Bypass valve setting pressure
40 ,... BO kPa (0.4 '" 0.8 kg/cm2,5.55 ,.. 11.09 psi)
Relief valve operating pressure
60 kPa (0.6 kg/cm2, B.53 psi)
Oil pressure (hot) 8
kPa (0.08 kg/cm2, 1.14 psi) at 1,400 r/min
Pressure check location HEAD CYLINDER
ELECTRICAL
Model
YFM350FWJ
C.D.I.:
Magneto model/ manufacturer F3T43575/MITSUBIS
HI
Pickup coil resistance / color
459 .... 561 n at 20°C (68°F) / (Red-White)
Source coil resistance /
color
270 '" 330 n at 20°C (6BOF) / (Brown/Green)
C.D.1. unit model/ manufacturer FBT32372/MITSUBISHI
Ignition coil:
Model/ manufacturer
F6T53573/MITSUBISHI
Minimum spark gap
6 mm (0.24 in)
Primary
winding resistance 0.36
'" 0.48 n at 20°C (6BOF)
Secondary winding resistance 5.44
""' 7.36 kn at 20°C (68°F)
Rectifier/regulator:
Model/ manufacturer
SH640-12 I SHINDENGEN
Capacity
20A
Withstand voltage
200 V
Starter relay:
Model/ manufacturer
MS5E/JIDECO
Amperage rating 100 A
Coil
winding resistance I color
4.1B ,.. 4.62 n at 20°C (6BOF) / (R/W-L/W)
-6-
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CABLE ROUTING
<D Rear brake switch
® Rear brake cable
@ Terminal (option)
@ Front brake hose
® Throttle cable
® Terminal lead (option)
(j) Indicator light lead
® Speedometer cable
® Speedometer light lead
@> Front brake switch lead
® Handlebar switch lead
CABLE ROUTING ISPECI U-I
@Clip
@ Backing plate
@ Select lever control cable 2
@> Breather hose (front differential)
@ Breather hose (front brake)
@ Brake pipe
@) Brake hose
3
-7-
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CABLE ROUTING I SPEC I ~ I
~ Pass the indicator light leads between the speedometer and handlebar holders, then connect the
leads on the inside
of the handlebar cover. Be sure the indicator light leads are not caught between
the handlebar cover clamps and the handlebar.
I:ru Insert the breather hose (fuel tank) into the hole of the handlebar cover.
(g Fasten the speedometer light lead, indicator light lead, handlebar switch lead, and front brake
switch lead.
[Q] Pass the speedometer cable, rear brake cable and throttle cable in the given order.
[1] Be sure the section of the breather hose (front brake) between the clips is as taut as the brake hose.
(£] Install the breather hose (front brake) so that it is not squeezed by the brake hose.
3
F
-8-
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CD Terminal (option)
® Breather hose (fuel tank)
® Breather hose (crankcase)
@Fuel hose
®COI unit
® Starter relay
(j) Battery positive lead
® Battery negative lead
@ Terminal fuse (option)
@) Breather hose (battery)
-9-
CABLE ROUTING 1 SPEC 1 0-1
® Carburetor overflow hose
@ COl magneto lead
@ Neutral switch lead
@ Select lever control cable 2
@Oil hose 1
@ Breather hose (final gear case)
@ Breather hose (rear brake)
@ Carburetor air vent hose
@ Throttle cable
~Oil hose 2
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CABLE ROUTING ISPECIU-I
IN Pass the breather hose (rear brake), breather hose (final gear case) and carburetor air vent hose
through the hole in the bracket.
rnl Fasten the wire harness, neutral switch lead and COl magneto lead.
~ Fasten the starter motor lead.
[Q] Pass the breather hose (rear brake) through the guide.
[f] Pass the breather hose (final gear case) through the guide.
E-E
-
-10-
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CD Brake rod
® Select lever control cable 2
® Speedometer cable
@ Select lever control cable 1
® Ignition coil
® Breather hose (front differential)
(j) Breather hose (front brake)
® Starter motor lead
® Rear brake cable
@) Wire harness
® Oil hose 2
A
CABLE ROUTING ISPECI 0-1
[8J Align the white tape on the wire harness with the cross pipe.
[§] With a plastic band, fasten the wire harness to the frame at
the point in
front of the welding.
[g Fasten the wire harness.
[Q] Pass the select lever control cable 1through the guide.
III Pass the brake cable to the right of the starter motor.
!£] Pass the rear brake cable over the fender stay.
@] Install the select lever control cable 2 without bending it.
C-c
0-0 11
- 11 -
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CD Headlight lead
® Main switch lead
® Rectifier / regulator
@ Neutral relay
® Starting circuit cut-off relay
® Reverse relay
(j) Main fuse
® Carburetor air vent hose
® Taillight lead
CABLE ROUTING ISPECI u-I
~ Insert the ends of the breather hose (front differential) into the
frame pipe.
[§] Fasten the wire harness at the point where the white tape is
affixed
to it.
[g Fasten the wire harness and battery negative lead.
1m Fasten the select lever control cable 2.
III Insert the ends of the breather hoses (front brake) into the
frame pipe.
-12 -
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SEAT, CARRIERS, FENDERS AND FUEL TANK II:gs ltill
PERIODIC INSPECTION AND
ADJUSTMENT
SEAT, CARRIERS, FENDERS AND
FUEL TANK
REMOVAL
1.Place the machine on a level place.
2.Remove:
• Seat
CD
NOTE: ____________________ __
Pull up the seat lock lever ®, then remove
by pulling up on the rear of the seat.
3.Remove:
• Front carrier
CD
4.Remove:
• Fuel tank cap
<D
• Fuel tank cover ®
• Rubber seat @
5.lnstall:
• Fuel tank cap
<D
6.Disconnect:
• Main switch coupler
<D
• Headlight couplers ®
-13-
7.Remove:
• Front fender
[8] Left side
[§] Right side
• Front bumper
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SEAT, CARRIERS, FENDERS AND FUEL TANK I ,:g~ I_I
8.Turn the fuel cock lever to "OFF".
9.Disconnect:
• Fuel hose
CD
NOTE: ______________________ __
Place a rug on the engine to absorb any
spilt fuel.
A WARNING
Gasoline is highlyflammable.
Avoid spilling fuel on
the hot engine.
10.Remove:
• Fuel tank
CD
11.Remove:
• Rear carrier
<D
12.Remove:
• Rear fender
<D
-14-
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