Yamaha YFZ350(P) 2002 Manual

YFZ350(P)
SUPPLEMENTARY
SERVICE MANUAL
3GG-AE2
2002

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and new data for
the YFZ350(P) 2002. For complete information on service procedures, it is necessary to use this
Supplementary Service Manual together with the following manual.
YFZ350T SERVICE MANUAL: 2GU-28197-20
YFZ350 SUPPLEMENTARY SERVICE MANUAL: 3GG-28197-20
YFZ350 SUPPLEMENTARY SERVICE MANUAL: 3GG-28197-21
YFZ350(J)/(K) ’97/’98 SUPPLEMENTARY SERVICE MANUAL: 3GG-AE1
YFZ350(P) 2002
SUPPLEMENTARY
SERVICE MANUAL
 2001 by Yamaha Motor Co., Ltd.
First Edition, May 2001
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

EB001000
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 maintenance 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 sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
N
OTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
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 dam-
age to the machine.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
N
O
TE:

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 1: This is a chapter with its symbol on the upper right of each page.
2nd title 2: This title appears on the upper of each page on the left of the chapter sym-
bol. (For the chapter “Periodic inspection and adjustment” the 3rd title
appears.)
3rd title 3: This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4is placed between a line of asterisks “*” with each proce-
dure preceded by “●”.
IMPORTANT FEATURES
●Data and a special tool are framed in a box preceded by a relevant symbol 5.
●An encircled numeral 6indicates a part name, and an encircled alphabetical letter data or an
alignment mark 7, the others being indicated by an alphabetical letter in a box 8.
●A condition of a faulty component will precede an arrow symbol 9and the course of action will fol-
low it.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.

EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1to 9are printed on the
top right of each page and indicate the subject
of each chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Carburetion
6Cooling system
7Chassis
8Electrical
9Troubleshooting
Illustrated symbols 0to Fare used to identify
the specifications appearing in the text.
0Filling fluid
ALubricant
BSpecial tool
CTorque
DWear limit, clearance
EEngine speed
FΩ, V, A
Illustrated symbols Gto Min the exploded
diagrams indicate the types of lubricants and
lubrication points.
GApply engine oil
HApply gear oil
IApply molybdenum disulfide oil
JApply wheel bearing grease
KApply lightweight lithium soap base grease
LApply molybdenum disulfide grease
MApply silicon grease
Illustrated symbols Nto Oin the exploded
diagrams indicate where to apply a locking
agent Nand when to install a new part O.
NApply the locking agent (LOCTITE)
OReplace
12
34
56
78
90
AB
CD
EF
GHI
J
NO
GEN
INFO SPEC
CHK
ADJ ENG
CARB COOL
CHAS
–+
ELEC
TRBL
SHTG
T
R
.
.
EGM
BLS MS
KLM
LT New

CONTENTS
SPECIFICATIONS .............................................................................................1
GENERAL SPECIFICATIONS ...................................................................1
MAINTENANCE SPECIFICATIONS ..........................................................2
ENGINE .................................................................................................2
CHASSIS ...............................................................................................3
ELECTRICAL.........................................................................................4
CABLE ROUTING ......................................................................................5
PERIODIC CHECKS AND ADJUSTMENTS...................................................12
INTRODUCTION......................................................................................12
PERIODIC MAINTENANCE/LUBRICATION INTERVALS.......................12
CHASSIS..................................................................................................14
ADJUSTING THE FRONT BRAKE......................................................14
ADJUSTING THE REAR BRAKE LIGHT SWITCH..............................14
ADJUSTING THE REAR SHOCK ABSORBER...................................15
ELECTRICAL ..................................................................................................18
CHECKING THE SWITCH .......................................................................18
CHECKING THE SWITCH...................................................................18
CHECKING A SWITCH SHOWN IN THE MANUAL ............................18
SIGNAL SYSTEM ....................................................................................19
CIRCUIT DIAGRAM.............................................................................19
CHECKING THE SIGNAL SYSTEM....................................................20
YFZ350(P) 2002 WIRING DIAGRAM

–1 –
SPEC
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model YFZ350(P) 2002
Model code number 5FKF: (CDN)
5FKG: (Europe and Oceania)
Lubrication system: Premix
Premix ratio YAMALUBE “R”24 : 1
CASTROL R30 20 : 1
CASTROL A545 20 : 1
CASTROL A747 20 : 1
Transmission oil YAMALUBE 4 or SAE 10W30 type SE motor oil
Spark plug:
Type BR8ES
Manufacturer NGK
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.032 in)
Tire:
Type Tubeless
Size: Front AT21 ×7-10
Rear AT22 ×10-9
Manufacturer/type: Front DUNLOP/KT851A
Rear DUNLOP/KT877
Wear Limit 3 mm (0.12 in)
Shock absorber:
Front Coil spring/oil damper
Rear Coil spring/gas-oil damper
Wheel travel:
Front 230 mm (9.06 in)
Rear 220 mm (8.66 in)
Electrical:
Ignition system C.D.I.
Generator system C.D.I. magneto
Headlight type Bulb type
Headlight bulb type Krypton bulb
Bulb voltage/watage ×quantity:
Headlight 12 V 30 W/30 W ×2
Tail/brake light 12 V 5 W/21 W ×1

–2 –
SPEC
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Model YFZ350(P) 2002
Carburetor:
I.D. mark 2GU 01
Fuel level (F.L.)
(With special tool) 0.5 ~ 1.5 mm (0.020 ~ 0.059 in)
Float height (F.H.) 20.5 ~ 21.5 mm (0.81 ~ 0.85 in)
Main jet (M.J.) #200
Main air jet (M.A.J.) ø1.6
Jet needle (J.N.) 5N7-3
Needle jet (N.J.) O-8
Cutaway (C.A.) 2.0
Pilot outlet (P.O.) ø0.6
Pilot jet (P.J.) #25
Bypass 1 (B.P.1.) 1.4
Air screw (A.S.) 2.0 turns out
Valve seat size (V.S.) 2.8
Starter jet (G.S.) ø1.4
Engine idle speed 1,450 ~ 1,550 r/min
Cooling system:
Radiator core size:
Width 210 mm (8.27 in)
Height 350 mm (13.8 in)
Thickness 32 mm (1.26 in)
Radiator cap opening pressure 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm2,
13.8 ~ 18.1 psi)
Reservoir tank
Capacity 0.28 L (0.246 Imp qt, 0.296 US qt)
From low to full level 0.07 L (0.06 Imp qt, 0.07 US qt)
Water pump
Type Single-suction centrifugal pump
Reduction ratio 32/20 (1,600)

–3 –
SPEC
MAINTENANCE SPECIFICATIONS
CHASSIS
Model YFZ350(P) 2002
Rear disc brake:
Type Single
Disc outside diameter ×thickness 220.0 ×3.6 mm (8.66 ×0.142 in)
Pad thickness Inner 4.5 mm (0.18 in)
<Limit> <1 mm (0.039 in)>
Pad thickness Outer 4.5 mm (0.18 in)
<Limit> <1 mm (0.039 in)>
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 33.96 mm (1.34 in)
Brake fluid type DOT #4
Brake lever and brake pedal:
Brake lever free play 0 mm (0 in) at lever end
Brake pedal position 10 mm (0.4 in)
Brake pedal free play 8 mm (0.3 in)
Throttle lever free play 4 ~ 6 mm (0.16 ~ 0.24 in)

–4 –
SPEC
MAINTENANCE SPECIFICATIONS
ELECTRICAL
Model YFZ350(P) 2002
Voltage 12 V
Ignition system:
Ignition timing (B.T.D.C.) 17 °/1,200 r/min
Advanced timing (B.T.D.C.) 10 °/9,500 r/min
Advancer type Digital type
C.D.I.:
Magneto model/manufacture TVCF57/DENSO
Pickup coil resistance (color) 94 ~ 140 Ωat 20 °C (68 °F)
(White/Red–White/Green)
Charging coil resistance (color) 13.7 ~ 20.5 Ωat 20 °C (68 °F) (Green–Red)
C.D.I. unit model/manufacture QAC68/DENSO
Spark plug cap:
Type Resin type
Resistance 5 kΩ
F.W.magneto:
Model/manufacturer TVCF57/DENSO
Lighting voltage 13.5 ~ 14.1 V/5,000 r/min
Lighting coil resistance (color) 0.26 ~ 0.38 Ωat 20 °C (68 °F)
(Yellow–Black)
30
20
10
0 35791246810
Engine speed (×103r/min)
Ignition timing
(B.T.D.C.)
15
10
20
5
0 35791246810
Engine speed (×103r/min)
Lighting voltage (V)

–5 –
SPEC
CABLE ROUTING
1Throttle switch lead
2Front brake light switch lead
3Throttle cable
4Fuel tank breather hose
5Band
6Handle switch
7Park switch
8Parking brake cable
9Clutch cable
0Front brake hose
AMain switch lead
BHandle switch lead
CPark switch lead
DBreather hose
EFront brake pipe
FHeadlight lead
GRadiator hose
ÈPass the hose through the han-
dle protector hole.
ÉClamp the hoses.
CABLE ROUTING

–6 –
SPEC
1Main switch
2Throttle switch lead
3Front brake light switch lead
4Wire harness
5Fuel hose
6Crankcase breather hose
7Carburetor over flow hose
8Radiator hose
9Park switch lead
0Handle switch lead
ÈPass the wire harness through the guide. Align
the marking tape in front of the guide.
ÉPass the hose through the guide.
ÊPass the hose through the guide.
CABLE ROUTING

–7 –
SPEC
1CDI unit lead
2Tail/brake light lead
ÈClamp the CDI unit lead and Tail/Brake light lead.
CABLE ROUTING

–8 –
SPEC
1Carburetor switch lead
2Throttle cable
3Band
4Clutch cable
5Parking brake cable
6Breather hose
7Front brake light switch lead
8Wire harness
ÈPass the lead above the hoses and cables.
ÉPass the cable through the guide.
ÊRoute the hose behind the clutch and parking
cable. Pass the hose between both carburetor
joints.
ËPass the hoses inside the wire harness.
CABLE ROUTING

–9 –
SPEC
1Clamp
2Band
3Rear brake light switch
4CDI magneto lead
5Cable guide
6Rear brake light switch wire
7Wire guide
8Rear brake hose
ÈPass the wire harness and hoses through the
guide on the air cleaner.
ÉRoute the cable behind the rear brake hose.
CABLE ROUTING

–10 –
SPEC
1Headlight
2Ignition coil
3Wire harness
4Carburetor switch lead
5T.O.R.S. control unit
ÈIgnition coil lead (Orange)
ÉIgnition coil lead (Black)
CABLE ROUTING

–11 –
SPEC
1Reserver tank
2Voltage regulator
3Body earth
4Tail/brake light lead
5Clamp
6CDI unit
CABLE ROUTING

–12 –
CHK
ADJ
INTRODUCTION/
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as to new vehicles that are being prepared
for sale. All service technicians should be familiar with this entire chapter.
EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
* It is recommended that these items be serviced by a Yamaha dealer.
** Lithium-soap-based grease
ITEM ROUTINE
INITIAL EVERY
1
month
3
months
6
months
6
months
1
year
Transmission •Replace oil.
Cooling system
•Check coolant leakage.
•Repair if necessary.
•Replace coolant every 24 months.
Spark plug
•Check condition.
•Adjust gap and clean.
•Replace if necessary.
Air filter •Clean.
•Replace if necessary.
Every 20 ~ 40 hours.
(More often in wet or dusty areas)
*Carburetor •Check idle speed/starter operation.
•Adjust if necessary.
* Crankcase
breather system
•Check breather hose for cracks or damage.
•Replace if necessary.
* Exhaust system
•Check for leakage.
•Retighten if necessary.
•Replace gasket(s) if necessary.
* Fuel line •Check fuel hose for cracks or damage.
•Replace if necessary.
Throttle operation •Inspect and adjust free play if necessary.
* Front and rear
brake operation
•Check operation/fluid leakage/See NOTE Page 13.
•Correct if necessary.
* Front and rear
brake pads
•Check pad wear.
•Replace if necessary.
*Clutch •Inspect free play and operation.
•Replace if necessary.
Drive chain
•Check chain slack/alignment.
•Adjust if necessary.
•Clean and lube.
•Replace if necessary.
* Drive chain guard
and rollers •Check wear and replace if necessary.
* Steering system •Inspect free play, clean and lubricate.
* Front and rear
suspension •Inspect and lubricate.**
Tires, wheels
•Inspect air pressure, wheel runout, and tire wear.
•*Inspect bearings.
•*Replace bearings if necessary.
Throttle, control
cable
•Check routing and connection.
•Lubricate.
Outside nuts and
bolts •Retighten.
Frame •Clean and inspect.
Lighting equipment •Inspect.