YFM35XV

SERVICE

INFORMATION

3D5-F8197-E0-SI

FOREWORD

This Service Information has been prepared to introduce new service and data for the YFM35XV.

For complete service information procedures it is necessary to use this Service Information together

with the following manual.

YFM35XV SERVICE MANUAL: 3D5-F8197-E0

YFM4FAR/YFM400FAR SERVICE INFORMATION: 5TE2-SE1

YFM35AS/YFM350AS SERVICE INFORMATION: 5WH2-SE1

YFM35XV

SERVICE INFORMATION

©2005 by Yamaha Motor Co., Ltd.

First edition, December 2005

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 vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle

repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle 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.

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 vehicle operator, a bystander or a person inspecting or repairing the

vehicle.

A CAUTION indicates special precautions that must be taken to avoid

damage to the vehicle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 0 are printed on the

top right of each page and indicate the subject

of each chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Engine

5 Cooling system

6 Carburetion

7 Drive train

8 Chassis

9 Electrical

0 Troubleshooting

Illustrated symbols A to H are used to identify

the specifications appearing in the text.

A Can be serviced with engine mounted

B Filling fluid

C Lubricant

D Special tool

E Torque

F Wear limit, clearance

G Engine speed

H Ω, V, A

Illustrated symbols I to N in the exploded

diagrams indicate the types of lubricants and

lubrication points.

I Apply engine oil

J Apply gear oil

K Apply molybdenum disulfide oil

L Apply wheel bearing grease

M Apply lithium-soap-based grease

N Apply molybdenum disulfide grease

Illustrated symbols O to P in the exploded

diagrams indicate where to apply a locking

agent O and when to install a new part P.

O Apply the locking agent (LOCTITE^®)

P Replace

1

2

3

4

5

6

7

8

9

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

CARB

DRIV

CHAS

–

+

ELEC

TRBL

SHTG

T R

.

.

E

G

M

B

LS

M

LT

New

CONTENTS

GENERAL INFORMATION ................................................................................ 1

VEHICLE IDENTIFICATION ........................................................................ 1

VEHICLE IDENTIFICATION NUMBER.................................................. 1

MODEL LABEL ...................................................................................... 1

SPECIFICATIONS.............................................................................................. 2

GENERAL SPECIFICATIONS..................................................................... 2

MAINTENANCE SPECIFICATIONS............................................................ 4

ENGINE ................................................................................................. 4

CHASSIS ............................................................................................... 5

ELECTRICAL......................................................................................... 6

CABLE ROUTING........................................................................................ 7

PERIODIC CHECKS AND ADJUSTMENTS.................................................... 20

INTRODUCTION........................................................................................ 20

PERIODIC MAINTENANCE AND LUBRICATION CHART ...................... 20

YFM35XV 2006 WIRING DIAGRAM

– 1 –

GEN

INFO

GENERAL INFORMATION

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is

stamped into the left side of the frame.

MODEL LABEL

The model label 1 is affixed to the frame. This

information will be needed to order spare

parts.

VEHICLE IDENTIFICATION

– 1 –

– 2 –

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard

Model code:

3D53 (Europe)

Dimensions:

Overall length

1,978 mm (77.9 in)

Overall width

1,063 mm (41.9 in)

Overall height

1,095 mm (43.1 in)

Seat height

840 mm (33.1 in)

Wheelbase

1,233 mm (48.5 in)

Minimum ground clearance

220 mm (8.66 in)

Minimum turning radius

3,000 mm (118.1 in)

Basic weight:

With oil and full fuel tank

229.0 kg (505 lb)

Engine:

Engine type

Air-cooled 4-stroke, SOHC

Cylinder arrangement

Forward-inclined single cylinder

Displacement

348 cm³

Bore × stroke

83.0 × 64.5 mm (3.27 × 2.54 in)

Compression ratio

9.2 : 1

Standard compression pressure (at sea level)

1,050 kPa (10.5 kg/cm², 149.3 psi) at 750 r/min

Starting system

Electric starter

Fuel:

Type

Regular unleaded gasoline only

Fuel tank capacity

14.5 L (3.19 Imp gal, 3.83 US gal)

Fuel reserve amount

4.5 L (0.99 Imp gal, 1.19 US gal)

Chassis:

Frame type

Steel tube frame

Caster angle

4°

Camber angle

1°

Kingpin angle

11°

Kingpin offset

0 mm (0 in)

Trail

19.3 mm (0.76 in)

Tread (STD)

front

820.0 mm (32.28 in)

rear

850.0 mm (33.46 in)

Toe-in

0 ~ 10 mm (0 ~ 0.39 in)

Tires:

Type

Tubeless

Size

front

AT23 × 8–12

rear

AT23 × 10–12

Manufacturer

front

MAXXIS

rear

MAXXIS

Type

front

M937

rear

M938

GENERAL SPECIFICATIONS

– 2 –

– 3 –

SPEC

GENERAL SPECIFICATIONS

Tire pressure (cold tire):

Maximum load*

100 kg (220 lb)

Off-road riding

front

22 ~ 28 kPa (0.22 ~ 0.28 kg/cm², 3.2 ~ 4.1 psi)

rear

22 ~ 28 kPa (0.22 ~ 0.28 kg/cm², 3.2 ~ 4.1 psi)

*Load in total weight of rider accessories

Item

Standard

– 3 –

– 4 –

SPEC

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

Tightening torques

Item

Standard

Limit

Air filter oil grade:

Yamaha foam air filter oil or other

quality foam air filter oil

----

Carburetor:

I. D. mark

3D52 00

----

Main jet

(M.J)

#128.8

----

Main air jet

(M.A.J)

#70

----

Jet needle

(J.N)

5ETY4-2

----

Needle jet

(N.J)

P-2M

----

Pilot air jet

(P.A.J.1)

#80

----

Pilot air jet

(P.A.J.2)

1.3

----

Pilot outlet

(P.O)

0.8

----

Pilot jet

(P.J)

#17.5

----

Bypass 1

(B.P.1)

0.8

----

Bypass 2

(B.P.2)

0.8

----

Bypass 3

(B.P.3)

0.8

----

Pilot screw

(P.S)

2-1/4 turns out

----

Valve seat size

(V.S)

2.0

----

Starter jet

(G.S.1)

57.5

----

Starter jet

(G.S.2)

0.9

----

Throttle valve size

(Th.V)

100

----

Float height

(F.H)

13.0 mm (0.51 in)

----

Fuel level

(F.L)

4.0 ~ 5.0 mm (0.16 ~ 0.20 in)

----

Engine idle speed

1,450 ~ 1,550 r/min

----

Intake vacuum

32 kPa (240 mmHg, 9.4 inHg)

----

Part to be tightened

Part

name

Thread

size

Q’ty

Tightening torque

Remarks

Nm

m·kg

ft·lb

Collar

Bolt

M10

1

55

5.5

40

Access cover

Bolt

M6

4

10

1.0

7.2

– 4 –

– 5 –

SPEC

MAINTENANCE SPECIFICATIONS

CHASSIS

Tightening torques

Item

Standard

Limit

Front suspension:

Shock absorber travel

99 mm (3.90 in)

----

Spring free length

276.7 mm (10.89 in)

----

Spring fitting length

231.9 mm (9.13 in)

----

Spring rate

(K1)

16.5 N/mm

(1.68 kg/mm, 94.22 lb/in)

----

Stroke

(K1)

0 ~ 99 mm (0 ~ 3.90 in)

----

Optional spring

No

----

Rear suspension:

Shock absorber travel

126 mm (4.96 in)

----

Spring free length

317 mm (12.48 in)

----

Spring fitting length

283.1 mm (11.15 in)

----

Spring rate

(K1)

31.6 N/mm

(3.22 kg/mm, 180.44 lb/in)

----

Stroke

(K1)

0 ~ 126 mm (0 ~ 4.96 in)

----

Optional spring

No

----

Part to be tightened

Thread size

Tightening torque

Remarks

Nm

m·kg

ft·lb

Front guard and frame

M8

34

3.4

24

Rear guard and frame

M8

34

3.4

24

Headlight and headlight bracket

M6

7

0.7

5.1

Front grill and headlight bracket

M6

7

0.7

5.1

– 5 –

– 6 –

SPEC

MAINTENANCE SPECIFICATIONS

ELECTRICAL

Item

Standard

Limit

Electric starter system:

Type

Constant mesh

----

Starter motor

Model/manufacturer

SM-13/MITSUBA

----

Output

0.7 kW

----

Armature coil resistance

0.0015 ~ 0.0025 Ω at

20 °C (68 °F)

----

Brush overall length

12.0 mm (0.47 in)

4 mm

(0.16 in)

Spring force

7.65 ~ 10.01 N (780 ~ 1,021 g,

27.53 ~ 36.04 oz)

----

Commutator diameter

28 mm (1.10 in)

27 mm

(1.06 in)

Mica undercut

0.7 mm (0.03 in)

----

Starter relay

Model/manufacturer

MS5F-721/JIDECO

----

Amperage rating

180 A

----

Coil winding resistance

4.18 ~ 4.62 Ω at 20 °C (68 °F)

----

Headlight relay:

Model/manufacturer

G8HN-1C4T-DJ-Y52/OMRON

----

Coil winding resistance

94.5 ~ 115.5 Ω at 20 °C (68 °F)

----

Circuit breakers:

Type

Fuse

----

Amperage for individual circuit

Main fuse

20 A × 1

----

Headlight fuse

15 A × 1

----

Ignition fuse

15 A × 1

----

Signaling system fuse

10 A × 1

----

Spare

20 A × 1

----

Spare

15 A × 1

----

Spare

10 A × 1

----

– 6 –

– 7 –

SPEC

CABLE ROUTING

CABLE ROUTING

1 Front brake light switch lead

2 Throttle cable

3 Handlebar switch lead

4 Handlebar switch

5 Rear brake switch lead

6 Starter cable

7 Rear brake lever cable

8 Front brake hose

9 Main switch lead

È Fasten the front brake light switch lead under the

handlebar with the plastic bands.

É Fasten the starter cable, handlebar switch lead,

and rear brake switch lead under the handlebar

with the plastic band.

Ê Fasten the handlebar switch lead and rear brake

switch lead under the handlebar with the plastic

band.

Ë Fasten the front brake light switch lead, rear

brake switch lead, handlebar switch lead, and

main switch lead with the plastic band.

1

2

3

4

5

6

7

6

5

3

7

9

1

8

2

È

É ^Ê

Ë

8

– 7 –

– 8 –

SPEC

CABLE ROUTING

1 Right headlight lead

2 Wire harness

3 Left headlight lead

4 Headlight coupler (same on right side of vehicle)

È 20 mm (0.79 in)

É 35 mm (1.38 in)

È

A-A

A

A

È

4

1

2

3

É

É

– 8 –

– 9 –

SPEC

CABLE ROUTING

1 Starter cable

2 Fuel tank breather hose

3 Cylinder head breather hose

4 Fuel hose

5 Rear brake lever cable

6 Oil cooler outlet pipe

7 Reverse indicator light

8 Neutral indicator light

9 Oil temperature warning light

0 Fan motor lead

È Insert the fuel tank breather hose into the hole in

the handlebar cover.

É Pass the plastic band through the hole in the

rubber cover, and then fasten the starter cable to

the frame with the band.

Ê Fasten the rear brake lever cable to the frame

with the plastic band.

Ë Secure the plastic band by inserting the projec-

tion on the band into the hole in the front upper

arm bracket, and then fasten the oil cooler outlet

pipe with the band.

Í

Í

7

9

8

9

7

6

0

8

A

B

E

C

F-F

G-G

D-D

5

5

3

4

1

6

5

3

6

Ï

Ð

4

3

2

1

È

Ì

Ë

Ê

É

Î

B

A

E

C

F

F

G

G

D

D

– 9 –

– 10 –

SPEC

CABLE ROUTING

Ì Fasten the oil cooler outlet pipe to the frame with

the plastic band.

Í 7 ~ 17 mm (0.28 ~ 0.67 in)

Î Fasten the cylinder head breather hose to the

frame with the plastic beaded tie, making sure to

tighten the tie past the second bead as shown in

the illustration.

Ï Secure the plastic band by inserting the projec-

tion on the band into the hole in the footrest

board bracket, and then fasten the rear brake

lever cable with the band.

Ð Fasten the rear brake lever cable and oil cooler

outlet pipe to the frame with the plastic band.

Í

Í

7

9

8

9

7

6

0

8

A

B

E

C

F-F

G-G

D-D

5

5

3

4

1

6

5

3

6

Ï

Ð

4

3

2

1

È

Ì

Ë

Ê

É

Î

B

A

E

C

F

F

G

G

D

D

– 10 –