Yamaha 2002 YFM350X, Supplemental Service Manual

Page 1: ...YFM350X P SUPPLEMENTARY SERVICEMANUAL 3GD AE6 2002 ...

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Page 3: ...edures 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 ...

Page 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 ...

Page 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...

Page 6: ...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 indic...

Page 7: ...ANCE 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 ...

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Page 9: ...park 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 ...

Page 10: ... 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 7...

Page 11: ...t 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 ...

Page 12: ... 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...

Page 13: ...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 ...

Page 14: ... 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 ...

Page 15: ...tral 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 ...

Page 16: ...Rear brake cable 5 Rear brake hose 6 Rectifier regulator 7 CDI unit 8 Carburetor overflow hose 9 Rear brake light switch lead È Pass the wire harness and starter motor lead through the holder É Fasten the wire harness starter motor lead and handlebar switch lead with the band CABLE ROUTING ...

Page 17: ...ery 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 Tighten if necessary Replace gasket s if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine before drainin...

Page 18: ...cement 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 ...

Page 19: ...vement of 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 nu...

Page 20: ... 12 CHAS FRONT SUSPENSION CHASSIS FRONT SUSPENSION 1 Thrust cover 2 Bushing 3 Front upper arm 4 Collar 5 Front lower arm 6 Shock absorber 7 Steering knuckle ...

Page 21: ...e switch 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 ...

Page 22: ...W B GRAY GRAY Y Br BLACK B B BLACK B R W W W B B R W R W G R B L W O B W B B Y G W G Y R W L W R W L W B G Y B B G Y L W R B W B G W B Y L W R W R W R W R W R B B R R B B R G Y B Y G B G Y B G Y B Y G B Y G B Br B Y L Y Br Sb B G Y B G Y G L Y 1 2 3 5 6 7 9 8 0 A B F C Br G L W B Br Sb Sb G W G W G W G W G H D J Y Br BLACK B B BLACK Br Y I K L L M N O P Br R GRAY 4 E 1 AC magneto 3 Main switch 4 F...

Page 23: ...der Use the following special tool s for trouble shooting Dynamic spark tester P N YM 34487 Ignition checker P N 90890 06754 Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Manual No 3GD AE5 Open circuit voltage 12 8 V or more...

Page 24: ...witch and increase the spark gap until a misfiring occurs Minimum spark gap 6 0 mm 0 24 in MEETS SPECIFICATION The ignition system is not faulty For Europe and Oceania OUT OF SPECIFICATION OR NO SPARK 4 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the dynamic spark tester 1 as shown 2 Spark plug cap Turn the main switch to ON Check the ignition spark gap a Crank the...

Page 25: ...ance Spark plug cap resistance 10 kΩ at 20 C 68 F OUT OF SPECIFICATION Replace the spark plug cap 6 Ignition coil resistance Disconnect the ignition coil connector from the wire harness Connect the pocket tester Ω 1 to the ignition coil Tester lead Orange lead terminal Tester lead Ignition coil base Check that the primary coil has the speci fied resistance Primary coil resistance 0 18 0 28 Ω at 20...

Page 26: ...HE SWITCH INCORRECT Replace the handlebar switch left CORRECT 8 Main switch Refer to CHECKING THE SWITCH INCORRECT Replace the main switch 9 Pickup coil resistance Disconnect the AC magneto coupler from the wire harness Connect the pocket tester Ω 100 to the pickup coil terminal Tester lead White Red terminal 1 Tester lead White Green terminal 2 MEETS SPECIFICATION Check the pickup coil for the sp...

Page 27: ...er lead Red terminal 1 Tester lead White Blue terminal 2 Check the charging rotor rotation direction detection coil for the specified resistance Rotor rotation direction detec tion coil resistance 0 083 0 101 Ω at 20 C 68 F Red White Blue OUT OF SPECIFICATION Replace the pickup coil stator assembly CORRECT 11 Wiring connection Check the connections of the entire ignition system Refer to CIRCUIT DI...

Page 28: ...W O B W B B Y G W G Y R W L W R W L W B G Y B B G Y L W R B W B G W B Y L W R W R W R W R W R B B R R B B R G Y B Y G B G Y B G Y B Y G B Y G B Br B Y L Y Br Sb B G Y B G Y G L Y 1 2 3 5 6 7 9 8 0 A B F C Br G L W B Br Sb Sb G W G W G W G W G H D J Y Br BLACK B B BLACK Br I K L L M N O P Br R GRAY 4 E 3 Main switch 4 Fuse 5 Battery C Neutral relay D Drive select lever switch E Neutral switch F Neu...

Page 29: ...es Refer to CHECKING THE SWITCH NO CONTINUITY Replace the brake switch 3 Voltage Connect the pocket tester DC 20V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V of the Yellow lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main...

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Page 31: ...CK B B BLACK Br Y I K L L M N O P Br R GRAY 4 E 1 AC magneto 2 Rectifier regulator 3 Main switch 4 Fuse 5 Battery 6 Starter relay 7 Starter motor 8 Clutch switch 9 CDI unit 0 Ignition coil A Spark plug B Park switch C Neutral relay D Drive select lever switch E Neutral switch F Neutral indicator light G Reverse indicator light H Reverse switch I Rear brake light switch J Front brake light switch K...