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Yamaha YFM350R-W Supplementary Service Manual
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Yamaha YFM350R-W Supplementary Service Manual

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YFM350R-W
N0A1-AE1
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha YFM350R-W

  • Page 1 YFM350R-W N0A1-AE1 SUPPLEMENTARY SERVICE MANUAL...
  • Page 2 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFM350R-W. For complete service information procedures it is necessary to use this Supplemen- tary Service Manual together with the following manual. YFM350X(J) ’97 SERVICE MANUAL: 3GD-AE5...
  • Page 3 EBS00002 NOTICE This manual was produced by MBK industrie 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.
  • Page 4 EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 5 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 8 are printed on the SPEC top right of each page and indicate the subject INFO of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Chassis 7 Electrical 8 Troubleshooting...

  • Page 6: Table Of Contents

    CONTENTS GENERAL INFORMATION ................1 MACHINE IDENTIFICATION ............... 1 VEHICLE IDENTIFICATION NUMBER..........1 SPECIFICATIONS ....................2 GENERAL SPECIFICATIONS ..............2 MAINTENANCE SPECIFICATIONS ............3 ENGINE ....................3 CHASSIS ....................4 ELECTRICAL ..................5 CABLE ROUTING ..................6 PERIODIC CHECKS AND ADJUSTMENTS............ 20 INTRODUCTION ..................
  • Page 7 ELECTRICAL ....................51 ELECTRICAL COMPONENTS..............51 LIGHTING SYSTEM................... 53 CIRCUIT DIAGRAM................53 CHECKING THE LIGHTING SYSTEM ..........54 SIGNALING SYSTEM ................57 CIRCUIT DIAGRAM................57 CHECKING THE SIGNALING SYSTEM..........59 YFM350R-W 2006 WIRING DIAGRAM...

  • Page 8: General Information

    MACHINE IDENTIFICATION INFO EBS00009 GENERAL INFORMATION MACHINE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame. – 1 –...

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFM350R-W Model code number N0A1 Basic weight With oil and full fuel tank 184.0 kg (406 lb) Tires Type Tubeless AT21 × 7-10 24J Size front AT20 × 10-9 34J rear Manufacturer front...

  • Page 10: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model YFM350R-W Carburetor I.D. mark 5YT1 00 Main jet (M.J) #142.5 Main air jet (M.A.J) Jet needle (J.N) 5JFC39-3 Needle jet (N.J) P-0M Pilot jet (P.J) #22.5 Pilot air jet (P.A.J.1) (P.A.J.2) #165 Pilot outlet (P.O)

  • Page 11: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Tightening torques Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Front turn signal light bracket and frame Headlight bracket and front turn signal light bracket Front turn signal light and front turn signal light bracket Headlight and headlight bracket Horn and horn bracket...

  • Page 12: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model YFM350R-W Horn Horn type Plane Model/manufacturer × quantity YF-12/NIKKO × 1 Maximum amperage 3.0 A Performance 105 ~ 120 db/2 m (6.6 ft) 1.15 ~ 1.25 Ω at 20 °C (68 °F) Coil resistance Turn signal relay...

  • Page 13: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING È Fasten the clutch switch lead and handlebar 1 Clutch cable 2 Parking brake cable switch lead with plastic bands. É Fasten the engine stop switch lead and front 3 Starter cable 4 Front brake hose brake light switch lead with plastic bands.
  • Page 14 SPEC CABLE ROUTING 1 Throttle cable B Wire harness 2 Front brake hose C Front turn signal light lead (left) 3 Engine stop switch lead D Front turn signal light lead (right) 4 Front brake light switch lead E Rectifier/regulator lead 5 Meter assembly lead È...
  • Page 15 SPEC CABLE ROUTING É Make sure that the lead connections are posi- tioned in the area shown in the illustration. Ê Fasten the wire harness, front turn signal light lead (right), horn lead, headlight lead, and front turn signal light lead (left) with a plastic locking tie.
  • Page 16 SPEC CABLE ROUTING 1 Headlight lead A Clutch cable 2 Front turn signal light lead (left) B Parking brake cable 3 Brake hose (brake equalizer to brake hose joint) C Brake hose (brake hose joint to front brake cali- 4 Front brake hose per) 5 Ground lead D Brake hose joint...
  • Page 17 SPEC CABLE ROUTING È Pass the parking brake cable and clutch cable Í Fasten the speed sensor lead, sub-wire har- through the cable guide. ness, wire harness, starter cable, and starter É Pass the parking brake cable, clutch cable, and motor lead with a plastic locking tie.
  • Page 18 SPEC CABLE ROUTING 1 Starter cable C Neutral switch lead 2 Fuel hose D Brake hose (rear brake master cylinder to brake 3 Carburetor air vent hose equalizer) 4 Crankcase breather hose E Parking brake cable 5 Speed sensor lead F Frame 6 Tail/brake light lead G Sub-wire harness...
  • Page 19 SPEC CABLE ROUTING È Pass a plastic band through the hole in the fuel Ë Fasten the wire harness and starter motor lead tank shield, and then fasten the wire harness, with a plastic band. Face the end of the plastic starter motor lead, starter cable, speed sensor band inward.
  • Page 20 SPEC CABLE ROUTING 1 Brake hose (rear brake master cylinder to brake A Brake hose (brake hose joint to front brake cali- equalizer) per) 2 Parking brake cable B Spark plug lead 3 Drive select lever switch lead C Starter motor lead 4 Ground terminal D Headlight lead (not used) 5 Throttle cable...
  • Page 21 SPEC CABLE ROUTING È Fasten the rear brake light switch lead and 1 Rear brake hose 2 Parking brake cable speed sensor lead with the plastic band. 3 Brake fluid reservoir hose 4 Rear brake light switch lead 5 Brake hose (rear brake master cylinder to brake equalizer) 6 Speed sensor lead 7 Frame...
  • Page 22 SPEC CABLE ROUTING 1 Front turn signal light lead (left) B Throttle cable 2 Horn lead C Ignition coil lead 3 Headlight lead D Ground lead 4 Front turn signal light lead (right) E Frame 5 Rectifier/regulator lead 6 Main switch lead 7 Spark plug lead 8 Drive select lever switch lead 9 Starter motor lead...
  • Page 23 SPEC CABLE ROUTING È Make sure that the lead connections are posi- Ì Fasten the front turn signal light lead (left), head- tioned in the area shown in the illustration. light lead, front turn signal light lead (right), horn É Fasten the headlight lead with a plastic locking lead, and wire harness with a plastic locking tie.
  • Page 24 SPEC CABLE ROUTING 1 Starter relay A Negative battery lead 2 Positive battery lead B Starting circuit cut-off relay 3 C.D.I. unit C Starter motor lead 4 Battery D Sub-wire harness 5 Ancillary fuse (turn signal, horn, speedometer, E Wire harness auxiliary light, license plate light, taillight) È...
  • Page 25 SPEC CABLE ROUTING È 35 ~ 45 mm (1.38 ~ 1.77 in) 1 Rear turn signal light lead (left) É 15 ~ 25 mm (0.59 ~ 0.98 in) 2 License plate light lead Ê Fasten the license plate light lead with a plastic 3 Rear turn signal light lead (right) clamp.
  • Page 26 SPEC CABLE ROUTING È Fasten the parking brake cable and speed sen- 1 Rear brake hose 2 Parking brake cable sor lead with a plastic locking tie. É Fasten the speed sensor lead at the white mark 3 Speed sensor lead on the lead with a plastic locking tie.

  • Page 27: Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION 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.
  • Page 28 • Correct if necessary. • Check operation. Lights and switches* • Adjust headlight beams. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice. NOTE: • Recommended brake fluid: DOT 4 •...

  • Page 29: Seat, Fenders And Fuel Tank

    SEAT, FENDERS AND FUEL TANK EBS00036 SEAT, FENDERS AND FUEL TANK HEADLIGHTS AND FRONT FENDER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 30 SEAT, FENDERS AND FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...

  • Page 31: Rear Fender

    SEAT, FENDERS AND FUEL TANK EBS00039 REAR FENDER 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 32 SEAT, FENDERS AND FUEL TANK 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...

  • Page 33: License Plate Light And Rear Turn Signal Lights

    SEAT, FENDERS AND FUEL TANK LICENSE PLATE LIGHT AND REAR TURN SIGNAL LIGHTS 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the license plate light and Remove the parts in the order listed.

  • Page 34: Chassis

    BLEEDING THE HYDRAULIC BRAKE SYSTEM CHASSIS EBS00094 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled, • a brake hose is loosened, disconnected or replaced, • the brake fluid level is very low, •...
  • Page 35 BLEEDING THE HYDRAULIC BRAKE SYSTEM c. Connect a clear plastic hose 1 tightly to the È bleed screw 2. È Front brake caliper É Brake equalizer Ê Rear brake caliper NOTE: The bleeding order of the hydraulic brake sys- tem is the following: 1.

  • Page 36: Adjusting The Drive Chain Slack

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE DRIVE CHAIN SLACK k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “BRAKE FLUID LEVEL INSPEC- TION” in chapter 3. (Manual No.: 3GD-AE5) WARNING After bleeding the hydraulic brake system, check the brake operation.
  • Page 37 ADJUSTING THE DRIVE CHAIN SLACK c. Loosen the locknuts 3. d. Turn both adjusting bolts 4 in direction a or b until the specified drive chain slack is obtained. Drive chain slack is Direction a reduced. Drive chain slack is Direction b increased.

  • Page 38: Electrical

    ADJUSTING THE HEADLIGHT BEAM/ REPLACING THE HEADLIGHT BULB ELECTRICAL ADJUSTING THE HEADLIGHT BEAM 5 cm (1.97 in) 1. Check: • headlight beam (vertically) M MMM M MMM M MMM M MMM M MMM a. Set the tire pressures and adjust the shock absorbers to the specifications.
  • Page 39 REPLACING THE HEADLIGHT BULB 2. Remove: • headlight body 1 3. Disconnect: • headlight coupler 1 4. Remove: • auxiliary light bulb socket 2 5. Remove: • headlight bulb cover 1 6. Detach: • headlight bulb holder 1 7. Remove: •...
  • Page 40 REPLACING THE HEADLIGHT BULB 8. Install: • headlight bulb CAUTION: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the trans- parency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lac- quer thinner.

  • Page 41: Chassis

    CHAS REAR WHEELS AND REAR AXLE HUB CHASSIS REAR WHEELS AND REAR AXLE HUB 120 Nm (12.0 m kg, 85 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...
  • Page 42 CHAS REAR WHEELS AND REAR AXLE HUB 120 Nm (12.0 m kg, 85 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 160 Nm (16.0 m kg, 115 ft •...

  • Page 43: Installing The Speed Sensor

    CHAS REAR WHEELS AND REAR AXLE HUB INSTALLING THE SPEED SENSOR 1. Install: • speed sensor bracket 1 120 Nm (12.0 m · kg, 85 ft · lb) NOTE: Make sure that the curved edge a of the speed sensor bracket 1 contacts the rear axle hub 2.

  • Page 44: Rear Brake

    CHAS REAR BRAKE EBS00410 REAR BRAKE REAR BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • 27 Nm (2.7 m kg, 19 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed.
  • Page 45 CHAS REAR BRAKE 7 Nm (0.7 m kg, 5.1 ft • • 27 Nm (2.7 m kg, 19 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Union bolt Copper washer Refer to “INSTALLING Brake hose (rear brake master cylinder Disconnect.

  • Page 46: Installing The Rear Brake Master Cylinder

    CHAS REAR BRAKE EBS00419 INSTALLING THE REAR BRAKE MASTER CYLINDER 180˚ 1. Install: • copper washers • rear brake hose 1 • brake hose (rear brake master cylinder to brake equalizer) 2 • union bolt 3 27 Nm (2.7 m · kg, 19 ft · lb) CAUTION: •...

  • Page 47: Brake Equalizer

    CHAS BRAKE EQUALIZER BRAKE EQUALIZER BRAKE EQUALIZER 27 Nm (2.7 m kg, 19 ft • • 27 Nm (2.7 m kg, 19 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 19 Nm (1.9 m kg, 13 ft •...
  • Page 48 CHAS BRAKE EQUALIZER EBS00411 6 Nm (0.6 m kg, 4.3 ft • • 49 Nm (4.9 m kg, 35 ft • • Order Job/Part Q’ty Remarks Disassembling the brake equalizer Remove the parts in the order listed. Brake equalizer plug O-ring Spring Refer to “DISASSEMBLING THE...

  • Page 49: Disassembling The Brake Equalizer

    CHAS BRAKE EQUALIZER DISASSEMBLING THE BRAKE EQUALIZER 1. Remove: • brake equalizer piston seals • brake equalizer piston 1 NOTE: Drive the piston out of the brake equalizer by inserting a rod 2 into the brake hose installa- tion hole shown. EBS00413 CHECKING THE BRAKE EQUALIZER 1.

  • Page 50: Installing The Brake Equalizer

    CHAS BRAKE EQUALIZER EBS00419 INSTALLING THE BRAKE EQUALIZER 1. Install: • copper washers • brake hose (rear brake master cylinder to 25˚ brake equalizer) 1 • brake hose (brake equalizer to brake hose joint) 2 • front brake hose 3 •...
  • Page 51 CHAS BRAKE EQUALIZER 3. Air bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. 4. Check: • brake fluid level Brake fluid level is under the “LOWER” level line → Add the recommended brake fluid to the proper level. Refer to “BRAKE FLUID LEVEL INSPEC- TION”...

  • Page 52: Steering System

    CHAS STEERING SYSTEM EBS00444 STEERING SYSTEM HANDLEBAR 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 53 CHAS STEERING SYSTEM 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 54: Installing The Left Rearview Mirror Brackets And Clutch Lever

    CHAS STEERING SYSTEM INSTALLING THE LEFT REARVIEW MIRROR BRACKETS AND CLUTCH LEVER 1. Install: • clutch lever • clutch lever bracket 1 • parking brake lever 2 7 Nm (0.7 m · kg, 5.1 ft · lb) • left rearview mirror bracket 3 7 Nm (0.7 m ·...

  • Page 55: Steering Stem

    CHAS STEERING SYSTEM EBS00454 STEERING STEM 48 Nm (4.8 m kg, 35 ft 28 Nm (2.8 m kg, 20 ft • • • • 23 Nm (2.3 m kg, 17 ft • • 28 Nm (2.8 m kg, 20 ft •...
  • Page 56 CHAS STEERING SYSTEM 48 Nm (4.8 m kg, 35 ft 28 Nm (2.8 m kg, 20 ft • • • • 23 Nm (2.3 m kg, 17 ft • • 28 Nm (2.8 m kg, 20 ft • • 25 Nm (2.5 m kg, 18 ft •...

  • Page 57: Installing The Steering Lock Stopper

    CHAS STEERING SYSTEM INSTALLING THE STEERING LOCK STOPPER 1. Install: • steering lock stopper bracket 1 • steering lock stopper 2 28 Nm (2.8 m · kg, 20 ft · lb) NOTE: Make sure that the projection a on the steer- ing lock stopper bracket contacts the pitman arm 3.

  • Page 58: Electrical

    – ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS 1 Rectifier/regulator 9 Drive select lever switch 2 Main switch 0 Rear turn signal light 3 Neutral indicator light A License plate light 4 Reverse indicator light B Turn signal relay 5 Meter assembly C Ancillary fuse (turn signal, horn, speedometer, 6 Engine stop switch auxiliary light, license plate light, taillight)
  • Page 59 – ELEC ELECTRICAL COMPONENTS F Starting circuit cut-off relay G Main fuse H Starter relay I Speed sensor J Reverse switch K Neutral switch L Rear brake light switch M Horn N Front turn signal light O Headlight P Wire harness –...

  • Page 60: Lighting System

    – ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM – 53 –...

  • Page 61: Checking The Lighting System

    – ELEC LIGHTING SYSTEM 2. The high beam indicator light fails to come EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight fails to come on. 1. Voltage 1. Headlight bulb and socket • Connect the pocket tester (DC 20 V) to the •...
  • Page 62 – ELEC LIGHTING SYSTEM EAS00789 EAS00791 3. The meter light fails to come on. 4. The auxiliary light fails to come on. 1. Voltage 1. Auxiliary light bulb and socket • Connect the pocket tester (DC 20 V) to the •...
  • Page 63 – ELEC LIGHTING SYSTEM EAS00792 5. The license plate light fails to come on. 1. License plate light bulb and socket • Check the license plate light bulb and socket for continuity. • Are the license plate light bulb and socket Replace the license plate light...

  • Page 64: Signaling System

    – ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM – 57 –...
  • Page 65 – ELEC SIGNALING SYSTEM 3 Main switch 4 Battery 5 Main fuse (including headlight and brake light) B Starting circuit cut-off relay C Drive select lever switch D Neutral switch F Neutral indicator light G Reverse indicator light H Reverse switch I Ancillary fuse (turn signal, horn, speedometer, auxiliary light, license plate light, taillight) J Rear brake light switch K Front brake light switch...

  • Page 66: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the black lead at the horn ter- minal. 1. Horn switch • Connect a jumper lead 1 to the horn ter- •...
  • Page 67 – ELEC SIGNALING SYSTEM EAS00799 4. Voltage 2. The turn signal light, turn signal indicator light or both fail to blink. • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness 1. Turn signal light bulb and socket side) as shown.
  • Page 68 – ELEC SIGNALING SYSTEM È É 5. Voltage • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. Positive tester probe → brown/white 1 Negative tester probe → ground Ê Ë Br/W Br/L •...
  • Page 69 – ELEC SIGNALING SYSTEM EAS00806 2. Voltage 3. The speedometer fails to operate. • Connect the pocket tester (DC 20 V) to the 1. Speed sensor meter assembly coupler (wire harness • Connect the pocket tester (DC 20 V) to the side) as shown.
  • Page 70 YFM350R-W 2006 WIRING DIAGRAM 1 A.C. magneto COLOR CODE 2 Rectifier/regulator B .... Black 3 Main switch Br... Brown 4 Battery Ch..Chocolate 5 Main fuse (including headlight and brake light) Dg..Dark green 6 Starter relay G ... Green 7 Starter motor L ....

  • Page 72: Yfm350R-W 2006 Wiring Diagram

    YFM350R-W 2006 YFM350R-W 2006 WIRING DIAGRAM SCHÉMA DE CÂBLAGE R/B L/W O R W/R W/G W/B B/Y SUB-WIRE WIRE HARNESS HARNESS W/L W/R W/R W/G W W W W W W SUB-WIRE WIRE HARNESS HARNESS L/W L/B (GRAY) R/B R/W...

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