Table of Contents
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Table of Contents
Related Manuals for Yamaha YFZ350(P) 2002
Summary of Contents for Yamaha YFZ350(P) 2002
- Page 1 2002 YFZ350 3GG-AE2 SUPPLEMENTARY SERVICE MANUAL...
- Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFZ350(P) 2002. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. YFZ350T SERVICE MANUAL: 2GU-28197-20...
- Page 4 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.
- Page 5 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.
- Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 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 Cooling system 7 Chassis 8 Electrical...
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Page 7: Table Of Contents
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... -
Page 9: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFZ350(P) 2002 Model code number 5FKF: (CDN) 5FKG: (Europe and Oceania) Lubrication system: Premix Premix ratio YAMALUBE “R” 24 : 1 CASTROL R30 20 : 1 CASTROL A545 20 : 1 CASTROL A747 20 : 1... -
Page 10: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model YFZ350(P) 2002 Carburetor: I.D. mark 2GU 01 Fuel level (F.L.) (With special tool) 0.5 ~ 1.5 mm (0.020 ~ 0.059 in) Float height (F.H.) 20.5 ~ 21.5 mm (0.81 ~ 0.85 in) Main jet (M.J.) -
Page 11: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model YFZ350(P) 2002 Rear disc brake: Type Single Disc outside diameter × thickness 220.0 × 3.6 mm (8.66 × 0.142 in) Pad thickness Inner 4.5 mm (0.18 in) <Limit> <1 mm (0.039 in)> Pad thickness Outer 4.5 mm (0.18 in) -
Page 12: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model YFZ350(P) 2002 Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 17 °/1,200 r/min Advanced timing (B.T.D.C.) 10 °/9,500 r/min Advancer type Digital type Engine speed (× 10 r/min) C.D.I.: Magneto model/manufacture TVCF57/DENSO 94 ~ 140 Ω at 20 °C (68 °F) Pickup coil resistance (color) (White/Red–White/Green) -
Page 13: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING 1 Throttle switch lead A Main switch lead È Pass the hose through the han- 2 Front brake light switch lead B Handle switch lead dle protector hole. 3 Throttle cable C Park switch lead É... - Page 14 SPEC CABLE ROUTING 1 Main switch È Pass the wire harness through the guide. Align 2 Throttle switch lead the marking tape in front of the guide. 3 Front brake light switch lead É Pass the hose through the guide. 4 Wire harness Ê...
- Page 15 SPEC CABLE ROUTING 1 CDI unit lead 2 Tail/brake light lead È Clamp the CDI unit lead and Tail/Brake light lead. – 7 –...
- Page 16 SPEC CABLE ROUTING 1 Carburetor switch lead Ê Route the hose behind the clutch and parking 2 Throttle cable cable. Pass the hose between both carburetor 3 Band joints. 4 Clutch cable Ë Pass the hoses inside the wire harness. 5 Parking brake cable 6 Breather hose 7 Front brake light switch lead...
- Page 17 SPEC CABLE ROUTING 1 Clamp È Pass the wire harness and hoses through the 2 Band guide on the air cleaner. 3 Rear brake light switch É Route the cable behind the rear brake hose. 4 CDI magneto lead 5 Cable guide 6 Rear brake light switch wire 7 Wire guide 8 Rear brake hose...
- Page 18 SPEC CABLE ROUTING 1 Headlight È Ignition coil lead (Orange) 2 Ignition coil É Ignition coil lead (Black) 3 Wire harness 4 Carburetor switch lead 5 T.O.R.S. control unit – 10 –...
- Page 19 SPEC CABLE ROUTING 1 Reserver tank 2 Voltage regulator 3 Body earth 4 Tail/brake light lead 5 Clamp 6 CDI unit – 11 –...
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Page 20: Periodic Checks And Adjustments
• Check routing and connection. cable • Lubricate. Outside nuts and • Retighten. bolts Frame • Clean and inspect. Lighting equipment • Inspect. It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease – 12 –... - Page 21 PERIODIC MAINTENANCE/LUBRICATION INTERVALS NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 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.
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Page 22: Chassis
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: Brake lever free play a Out of specification → Bleed the front brake system. Refer to “AIR BLEEDING” in CHAPTER 6. (Manual No.: 2GU-28197-20) Brake lever free play (at brake lever end): 0 mm (0 in) -
Page 23: Adjusting The Rear Shock Absorber
ADJUSTING THE REAR SHOCK ABSORBER ADJUSTING THE REAR SHOCK ABSORBER 1.Adjust: Spring preload *********************************************** Adjustment steps: Elevate the rear wheels by placing a suitable stand under the frame. Loosen the locknut 1. Turn the adjusting ring 2 in direction a or Spring preload is Direction a increased (suspension... - Page 24 ADJUSTING THE REAR SHOCK ABSORBER 2.Adjust: Rebound damping force *********************************************** Adjustment steps: Turn the adjuster 1 in direction a or b. Rebound damping force Direction a is increased. Rebound damping force Direction b is decreased. From the fully turned-in position: Standard: 13 clicks out Minimum: 20 clicks out Maximum: 3 clicks out...
- Page 25 ADJUSTING THE REAR SHOCK ABSORBER CAUTION: Do not forc the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. *********************************************** – 17 –...
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Page 26: Electrical
– ELEC CHECKING THE SWITCH ELECTRICAL CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: P/N. YU-03112, 90890-03112 NOTE: Set the pocket tester to “0” before starting the test. -
Page 27: Signal System
– ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM – 19 –... -
Page 28: Checking The Signal System
– ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continu- ity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”. - Page 29 – ELEC SIGNAL SYSTEM 4.Lighting coil resistance Disconnect the CDI magneto leads (Yel- low/Red and Black). Connect the pocket tester (Ω × 1) to the lighting coil leads. Tester (+) lead → Yellow 1 lead Tester (–) lead → Black 2 lead OUT OF SPECIFICATION Replace the stator assembly.
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Page 31: Yfz350(P) 2002 Wiring Diagram
YFZ350(P) 2002 WIRING DIAGRAM 1 CDI magneto 2 Voltage regulator W/G R 3 CDI unit W/R G 4 Park switch 5 Ignition coil R W/G 6 Spark plug G W/R 7 T.O.R.S. control unit 8 Throttle switch 9 Carburetor switch...