YFM350X(P)

SUPPLEMENTARY

SERVICE MANUAL

3GD-AE6

2002

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and new data for

the YFM350X(P) 2002. For complete information on service procedures, it is necessary to use this

Supplementary Service Manual together with the following manual.

YFM350X(J) ’97 SERVICE MANUAL: 3GD-AE5

YFM350X(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.

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 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:

NOTE:

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 4 is placed between a line of asterisks “*” with each proce-

dure preceded by “G”.

IMPORTANT FEATURES

G Data and a special tool are framed in a box preceded by a relevant symbol 5.

G An encircled numeral 6 indicates 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.

G A condition of a faulty component will precede an arrow symbol 9 and 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 1 to 9 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 Carburetion

6 Drive train

7 Chassis

8 Electrical

9 Troubleshooting

Illustrated symbols 0 to F are used to identify

the specifications appearing in the text.

0 Filling fluid

A Lubricant

B Special tool

C Torque

D Wear limit, clearance

E Engine speed

F Ω, V, A

Illustrated symbols G to M in the exploded

diagrams indicate the types of lubricants and

lubrication points.

G Apply engine oil

H Apply gear oil

I Apply molybdenum disulfide oil

J Apply wheel bearing grease

K Apply lightweight lithium soap base grease

L Apply molybdenum disulfide grease

M Apply silicon grease

Illustrated symbols N to O in the exploded

diagrams indicate where to apply a locking

agent N and when to install a new part O.

N Apply the locking agent (LOCTITE^)

O Replace

1

2

3

4

5

6

7

8

9

0

A

B

C

D

E

F

G

H

I

J

N

O

GEN

INFO

SPEC

CHK

ADJ

ENG

CARB

DRIV

CHAS

–

+

ELEC

TRBL

SHTG

T R

.

.

E

G

M

B

LS

M

S

K

L

M

LT

New

CONTENTS

SPECIFICATIONS ............................................................................................1

GENERAL SPECIFICATIONS ..................................................................1

MAINTENANCE SPECIFICATIONS .........................................................2

ENGINE ................................................................................................2

CHASSIS ..............................................................................................4

ELECTRICAL ........................................................................................4

CABLE ROUTING .....................................................................................5

PERIODIC CHECKS AND ADJUSTMENTS ....................................................9

INTRODUCTION .......................................................................................9

PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................9

CHASSIS .................................................................................................11

ADJUSTING THE FRONT BRAKE......................................................11

ADJUSTING THE REAR BRAKE LIGHT SWITCH .............................11

CHASSIS ........................................................................................................12

FRONT SUSPENSION ...........................................................................12

ELECTRICAL .................................................................................................13

CHECKING THE SWITCH ......................................................................13

CHECKING THE SWITCH ..................................................................13

CHECKING A SWITCH SHOWN IN THE MANUAL ...........................13

IGNITION SYSTEM .................................................................................14

CIRCUIT DIAGRAM ............................................................................14

TROUBLESHOOTING ........................................................................15

SIGNAL SYSTEM ...................................................................................20

CIRCUIT DIAGRAM ............................................................................20

CHECKING THE SIGNAL SYSTEM ...................................................21

YFM350X(P) 2002 WIRING DIAGRAM

– 1 –

SPEC

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model

YFM350X(P) 2002

Model code number:

5NF6 (CDN, Europe and Oceania)

Spark plug:

Type/manufacturer

DR8EA (NGK)

Gap

0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

Electrical:

Ignition system

DC. C.D.I.

Charging system

A.C. magneto

Battery capacity

12 V 12AH

Battery type

GM12CZ-4A-2

Bulb wattage × quantity:

Headlight

12 V 30 W/30 W × 2

Tail/brake light

12 V 5 W/21 W × 1

Neutral indicator light

12 V 3.4 W × 1

Reverse indicator light

12 V 3.4 W × 1

– 2 –

SPEC

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

Model

YFM350X(P) 2002

Cylinder:

Bore size

82.97 ~ 83.02 mm (3.267 ~ 3.269 in)

Taper limit

<0.05 mm (0.002 in)>

Piston:

Piston size “D”

82.92 ~ 82.97 mm (3.265 ~ 3.267 in)

Measuring point “H”

5.5 mm (0.22 in)

(From bottom line of piston skirts)

Piston clearance

0.040 ~ 0.060 mm

(0.00157 ~ 0.00236 in)

Oversize

2nd

83.5 mm (3.287 in)

4th

84.0 mm (3.307 in)

Piston off-set

0.5 mm (0.02 in)

Piston off-set direction

Intake side

Inside diameter (piston pin bore)

19.004 ~ 19.015 mm (0.7481 ~ 0.7486 in)

Outside diameter (piston pin)

18.991 ~ 19.000 mm (0.7477 ~ 0.7480 in)

Piston ring:

Sectional sketch

Top ring:

Barrel

B

1.2 mm (0.047 in)

T

3.3 mm (0.130 in)

2nd ring:

Tapper

B

1.5 mm (0.059 in)

T

3.4 mm (0.134 in)

Oil ring:

B

2.8 mm (0.110 in)

T

2.8 mm (0.110 in)

End gap (installed)

Top ring

0.20 ~ 0.40 mm (0.00787 ~ 0.0157 in)

2nd ring

0.20 ~ 0.40 mm (0.00787 ~ 0.0157 in)

Oil ring

0.30 ~ 0.90 mm (0.012 ~ 0.035 in)

Side clearance

Top ring

0.03 ~ 0.09 mm (0.0012 ~ 0.0035 in)

2nd ring

0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in)

Clutch:

Friction plate thickness/quantity

2.74 ~ 2.86 mm (0.107 ~ 0.113 in)/6

Warp limit

<2.64 mm (0.104 in)>

Friction plate thickness/quantity

2.94 ~ 3.06 mm (0.116 ~ 0.120 in)/1

Warp limit

<2.84 mm (0.112 in)>

Clutch plate thickness/quantity

1.5 ~ 1.7 mm (0.059 ~ 0.066 in)/4

1.9 ~ 2.1 mm (0.0748 ~ 0.0827 in)/2

Max. warpage

<0.2 mm (0.00787 in)>

Clutch spring free length/quantity

47.8 mm (1.882 in)/5

Clutch spring minimum free length

46.5 mm (1.831 in)

Clutch release method

Outer push (rack and pinon)

H

D

B

T

B

T

B

T

– 3 –

SPEC

MAINTENANCE SPECIFICATIONS

Carburetor:

I. D. mark

3GD 00

Main jet

(M.J)

#145

Main air jet

(M.A.J)

0.6

Jet needle

(J.N)

5J18-3

Needle jet

(N.J)

O-6

Pilot jet

(P.J)

#42.5

Pilot air jet

(P.A.J.1)

1.0

(P.A.J.2)

0.7

Pilot outlet

(P.O)

0.75

Bypass 1

(B.P.1)

0.8

Bypass 2

(B.P.2)

0.8

Bypass 3

(B.P.3)

0.8

Pilot screw (turns out)

(P.S)

2

Valve seat

(V.S)

2.5

Starter jet

(G.S.)

#62.5

Throttle valve size

(Th.V)

#125

Fuel level

(F.L)

2 ~ 3 mm (0.08 ~ 0.12 in)

Float height

11.4 ~ 13.4 mm (0.45 ~ 0.53 in)

Engine idling speed

1,450 ~ 1,550 r/min

Intake vacuum

33.3 kPa (250 mmHg, 9.83 inHg)

Model

YFM350X(P) 2002

– 4 –

SPEC

MAINTENANCE SPECIFICATIONS

CHASSIS

ELECTRICAL

Model

YFM350X(P) 2002

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 (0.315 in)

Model

YFM350X(P) 2002

C.D.I.:

Magneto model/manufacturer

F4T466/MITSUBISHI

Pickup coil resistance

459 ~ 561 Ω at 20 °C (68 °F)

(Color)

(White/Red-White/Green)

Rotor rotation direction detection coil resis-

tance

0.083 ~ 0.101 Ω at 20 °C (68 °F)

(Color)

(Red-White/Blue)

C.D.I. unit-model/manufacturer

F8T38675/MITSUBISHI

Ignition coil:

Model/manufacturer

2JN/YAMAHA

Minimum spark gap

6 mm (0.24 in)

Primary winding resistance

0.18 ~ 0.28 Ω at 20 °C (68 °F)

Secondary winding resistance

6.32 ~ 9.48 kΩ at 20 °C (68 °F)

Charging system:

Model/manufacturer

F4T466/MITSUBISHI

Nominal output

14 V 15 A at 5,000 r/min

Charging coil resistance/color

0.51 ~ 0.63 Ω at 20 °C (68 °F)/White-White

0.47 ~ 0.57 Ω at 20 °C (68 °F)/White-White

Rectifier/regulator:

Regulator type

Semi conductor-short circuit

Model/manufacturer

SH640-11/SHINDENGEN

No load regulated voltage

14.1 ~ 14.9 V

Rectifier capacity

14 A

Withstand voltage

200 V

Starter relay:

Model/manufacturer

MS5D-611/JIDECO

Amperage rating

100 A

Coil winding resistance

3.9 ~ 4.7 Ω

– 5 –

SPEC

CABLE ROUTING

1 Clutch switch

2 Rear brake cable

3 Clutch cable

4 Front brake hose

5 Front brake light switch

6 Throttle cable

7 Band

È Install the fuel tank breather hose into the hole of

the handlebar cover.

CABLE ROUTING

– 6 –

SPEC

1 Main switch lead

2 Handlebar switch lead

3 Clutch switch lead

4 Park switch lead

5 Front brake light switch lead

6 Fuel tank breather hose

CABLE ROUTING

– 7 –

SPEC

1 Starter relay

2 Neutral relay

3 Tail/brake light

4 CDI unit

5 Rectifier/regulator

6 Fuse

7 Battery breather hose

È Pass the battery breather hose through the inside

of the frame bracket.

É Pass the battery breather hose through the guide.

CABLE ROUTING