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SPEC

CABLE ROUTING

1

Throttle switch lead

2

Front brake light switch lead

3

Throttle cable

4

Fuel tank breather hose

5

Band

6

Handle switch

7

Park switch

8

Parking brake cable

9

Clutch cable

0

Front brake hose

A

Main switch lead

B

Handle switch lead

C

Park switch lead

D

Breather hose

E

Front brake pipe

F

Headlight lead

G

Radiator hose

È

Pass the hose through the han-
dle protector hole.

É

Clamp the hoses.

CABLE ROUTING

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Содержание YFZ350(P) 2002

Страница 1: ...YFZ350 P SUPPLEMENTARY SERVICEMANUAL 3GG AE2 2002 ...

Страница 2: ......

Страница 3: ...h 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 Yama...

Страница 4: ...fications 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 ...

Страница 5: ...nic 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 IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol 5 An encircled numeral 6 indicates a part name and an encir...

Страница 6: ...t 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 ind...

Страница 7: ...DUCTION 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 ...

Страница 8: ......

Страница 9: ...anufacturer 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...

Страница 10: ...t 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...

Страница 11: ...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 ...

Страница 12: ...C 68 F White Red White Green Charging coil resistance color 13 7 20 5 Ω at 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 Ω at 20 C 68 F Yellow Black 30 20 10 0 3 5 7 9 1 2 4 6 8 10 Engine speed 103 r min Ignition...

Страница 13: ...ther hose 5 Band 6 Handle switch 7 Park switch 8 Parking brake cable 9 Clutch cable 0 Front brake hose A Main switch lead B Handle switch lead C Park switch lead D Breather hose E Front brake pipe F Headlight lead G Radiator hose È Pass the hose through the han dle protector hole É Clamp the hoses CABLE ROUTING ...

Страница 14: ...s 5 Fuel hose 6 Crankcase breather hose 7 Carburetor over flow hose 8 Radiator hose 9 Park switch lead 0 Handle switch lead È Pass the wire harness through the guide Align the marking tape in front of the guide É Pass the hose through the guide Ê Pass the hose through the guide CABLE ROUTING ...

Страница 15: ... 7 SPEC 1 CDI unit lead 2 Tail brake light lead È Clamp the CDI unit lead and Tail Brake light lead CABLE ROUTING ...

Страница 16: ... 6 Breather hose 7 Front brake light switch lead 8 Wire harness È Pass the lead above the hoses and cables É Pass the cable through the guide Ê Route the hose behind the clutch and parking cable Pass the hose between both carburetor joints Ë Pass the hoses inside the wire harness CABLE ROUTING ...

Страница 17: ...light switch 4 CDI magneto lead 5 Cable guide 6 Rear brake light switch wire 7 Wire guide 8 Rear brake hose È Pass the wire harness and hoses through the guide on the air cleaner É Route the cable behind the rear brake hose CABLE ROUTING ...

Страница 18: ... 10 SPEC 1 Headlight 2 Ignition coil 3 Wire harness 4 Carburetor switch lead 5 T O R S control unit È Ignition coil lead Orange É Ignition coil lead Black CABLE ROUTING ...

Страница 19: ... 11 SPEC 1 Reserver tank 2 Voltage regulator 3 Body earth 4 Tail brake light lead 5 Clamp 6 CDI unit CABLE ROUTING ...

Страница 20: ...lter 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 ...

Страница 21: ...acement 1 When disassembling the master cylinder or caliper replace the brake fluid Normally check the brake fluid level and add fluid as required 2 On the inner parts of the master cylinder and caliper replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged ...

Страница 22: ... the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts Brake lever free play at brake lever end 0 mm 0 in 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in di...

Страница 23: ...adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjusting ring beyond the maximum or minimum setting Tighten the locknut 1 NOTE Always tighten the locknut against the adjust ing ring then torque it to specification Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased susp...

Страница 24: ... damping force is increased Direction b Rebound damping force is decreased From the fully turned in position Standard 13 clicks out Minimum 20 clicks out Maximum 3 clicks out 3 Adjust Compression damping force Adjustment steps Turn the adjuster 1 in direction a or b Direction a Compression damping force is increased Direction b Compression damping force is decreased From the fully turned out posit...

Страница 25: ... 17 CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER CAUTION Do not forc the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged ...

Страница 26: ...witch on and off a few times when checking it Pocket tester P N YU 03112 90890 03112 CHECKING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position ind...

Страница 27: ...Y R BLACK B B B R B R B B BLACK B B BLACK Y R Y G B 4 B G Y B B B D G Y B D W G W R B G R W G G Y G Y W R G B R R B O Y R B L 2 1 Y B B W B W B Y B Y B B W B B Y 9 7 Y B B Y Y B B GRAY GRAY B Y B 9 B Y B Y B B GRAY GRAY B B B Y B Y 8 B B Y B Y B BLACK BLACK B W O G Y B W R B B G Y O B W R B B Y R L B W B Y G L Y R B B W Y G 3 1 CDI magneto 2 Voltage regulator E Tail brake light F Rear brake light ...

Страница 28: ...HE SWITCH NO CONTINUITY Replace the brake switch 3 Voltage Connect the tachometer to the spark plug lead Connect the pocket tester DC 20V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 OUT OF SPECIFICATION Start the engine and accelerate to about 5 000 r min CAUTION Do not run the engine in neutral above 8 000 r min for more than 5 seconds Lighting voltage ...

Страница 29: ...ads Tester lead Yellow 1 lead Tester lead Black 2 lead Measure the lighting coil resistance Lighting coil resistance 0 26 0 38 Ω at 20 C 68 F OUT OF SPECIFICATION Replace the stator assembly CORRECT 5 Wiring connections Check the connections of the entire lighting system Refer to CIRCUIT DIAGRAM Replace the voltage regulator POOR CONNECTION Properly connect the lighting system ...

Страница 30: ......

Страница 31: ...B GRAY GRAY B B B Y B Y 8 B B Y B Y B BLACK BLACK B W O G Y B W R B B G Y O B W R B B Y R L B W B Y G L Y R B B W Y G 3 1 CDI magneto 2 Voltage regulator 3 CDI unit 4 Park switch 5 Ignition coil 6 Spark plug 7 T O R S control unit 8 Throttle switch 9 Carburetor switch 0 Main switch A Engine stop switch B Lights switch C Handle switch left D Headlight E Tail brake light F Rear brake light switch G ...

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