Checking Of Switches

Check the switches for the continuity between the terminals to determine correct connection. Read the following for switch inspection. SWITCH CONNECTION AS SHOWN IN MANUAL The manual contains a connection chart as shown left showing the terminal connections of the switches (e.g., main switch, handlebar switch, brake switch, lighting switch, etc.) The extreme left column indicates the switch positions and the top line indicates the colors of leads connected with the terminals in the switch...

Periodic Inspection And Adjustment

PERIODIC MAINTENANCE LUBRICATION 3-1 VALVE CLEARANCE SPARK PLUG INSPECTION CRANKCASE VENTILATION FUEL INTAKE EXHAUST SYSTEM IDLING SPEED TIMING CHAIN ENGINE OIL LEVEL ENGINE OIL REPLACEMENT CLUTCH IGNITION TIMING COMPRESSION PRESSURE AIR FILTER CLEANING THROTTLE CABLE SPEED LIMITER ADJUSTMENT CHASSIS BRAKE PAD BRAKE FLUID LEVEL FRONT BRAKE REAR BRAKE PARKING BRAKE AIR DRIVE CHAIN SLACK DRIVE CHAIN FRONT AND REAR SHOCK ABSORBER ADJUSTMENT 3-30 CLUTCH LEVERS LUBRICATION CABLE INSPECTION AND...

Note

Loosen the nut clutch boss while holding the clutch boss with the rotor holder. PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR Lock washer 2 Washer Primary drive gear 4 Balancer drive gear assembly 5 Key f Oil pump drive gear 7 Key D Nut D Lock washer Balancer driven gear 0 Key Place a piece of rolled rag or lead between gears when loosening balancer driven gear 2 and primary drive gear Housing connecting screws Oil pump housing 2 1. Remove Shift shaft Washer 2 Bolt 3 Stopper 4 Stopper spring

Lubrication Diagrams

Yamaha Xvs650 Dragstar Ignition Wiring

Camshaft Oil cleaner Main axle Drive axle Crankshaft Oil filter Oil pump Counter axle Out-put axle Brake hose D Clutch switch D Brake cable 4 Clutch cable Brake hose Thbrottle cable 8 Handlebar switch Left D Main switch Pass the breather pipe through the hole on the handlebar protector. E Route outside the clamp and between the wire harness and the frame pipe. 3 Route inside the throttle cable and brake hose. Ground bolt Headlight To right headlight Main switch cord Clutch switch cord Handlebar...

Front And Rear Shock Absorber Adjustment

This shock absorber contains highly pressurized nitrogen gas read and understand the following information before handling the shock absorber. The manufacture cannot be held responsible for property damage or personal injury that may result from improper handling. Do not tamper with or attempt to open the cylinder assembly. Do not subject shock absorber to an open flame or other high hear source. This may cause the unit to explode due to excessive gas pressure. Do not deform or damage the...

Drive Chain Lubrication Front And Rear Shock Absorber Adjustment

Yamaha Yfm 350 Warrior Custom Rear

The chain should be cleaned and lubricated after every use of the machine. The chain consists of many parts which work against each other. If the chain is not maintained properly, it will wear out rapidly, therefore, form the habit of periodically servicing the chain. This service is especially necessary when riding in dusty conditions. This motorcycle has a drive chain with small rubber O-rings between the chain plates. Steam cleaning, high-pressure washes, and certain solvents can damage...

Chassis

Yamaha Warrior 350 Rear Brake Reservoir

BRAKE PAD INSPECTION Front brake pad 1. Activate the brake lever or brake pedal. Brake pad Wear indicator D almost contacts brake disc- Replace brake pad as a set. Refer to the BRAKE PAD REPLACEMENT section. Brake pads wear indicator D almost contacts disc Replace pads. Refer to the BRAKE PAD REPLACEMENT section. 1. Place the machine on a level surface. Fluid level Fluid level is under LOWER level line - Replenish. IfDOT No4is not available. No.3 can be used If DOT No.4 is not available, DOT...

General Torque Specifications

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature. A Distance across flats B Outside thread...

Engine Overhaul

ENGINE ENGINE OIL SEAT, HEADLIGHT UNIT AND FUEL TANK 4-1 CLUTCH CABLE EXHAUST PIPE AND MUFFLER DRIVE SELECT LEVER AND CRANKCASE VENTILATION HOSE 4-3 DRIVE CHAIN ENGINE ENGINE DECOMPRESSION CAM, CAM CHAIN SPROCKET AND CYLINDER CYLINDER AND LEFT CRANKCASE COVER AND CDI MAGNETO 4-9 CAM CHAIN AND STARTER OIL FILTER AND NEUTRAL RIGHT CRANKCASE CLUTCH PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 4-14 OIL SHIFT SHAFT OIL PIPE BEARINGS AND OIL SEALS CRANKSHAFT ROCKER INSPECTION AND REPAIR CYLINDER VALVE...

Ignition Timing Check Compression Pressure Measurement

Timing Light

Timing light and inductive tachometer To the spark plug lead. Timing light and inductive tachometer To the spark plug lead. P N YM-33277-A Inductive tachometer P N YU-8036-A Ignition timing Warm up the engine and keep it at the specified speed. Visually check the stationary pointer to verify it is within the required firing range D indicated on the flywheel. Incorrect firing range- Check flywheel and or pickup assembly tightness damage . Insufficient compression pressure will result in...

Cable Routing

Starter Yfm350 Warrior Relay

Fuel tank breather hose lt D Fuel hose Crankcase breather hose Starter relay Starting circuit cut-off relay Neutral relay CDI unit Main fuse Battery breather hose CDI magneto lead Jl Neutral switch lead 0 Pass the air vent hose through hole on the fuel tank rubber damper. M Pass the battery breather hose through the inside of frame bracket, c Pass the battery breather hose through the guide. Pass the wire harness and starter motor lead through the holder. Fasten the wire harness, starter motor...

Crankcase Ventilation Systemfuel Line Intake Manifoldexhaust System

Drain Plug 1998 Yamaha Warrior

Crankcase ventilation hose 3 Cracks Damage- Replace. 1. Inspect Fuel hoses Cracks Damage- Replace. Gaskets Cracks Damage- Replace. Exhaust pipe gasket s D Damage- Replace. Exhaust gas leakage- Repair. 1. Start the engine and let it warm up for several minutes. Inductive tachometer to the spark plug lead . Engine idling speed Out of specification Adjust. Engine idling speed 1,450 1,550 r min Engine idling speed Adjustment steps Turn in the pilot air screw until it is lightly seated. Turn out...

Engine

Yamaha 250 Timing Marks

The valve clearance should be adjusted when the engine is cool to the touch. The piston must be at Top Dead Center TDC on compression stroke to check or adjust the valve clearance. 5. Turn the fuel cock to the OFF D position. 6. Disconnect Fuel hose D Tappet cover lt D exhaust Turn the crankshaft counterclockwise with a wrench. Align the T mark J on the crankshaft web with the stationary pointer . Measure the valve clearance by using a feeler gauge 3 . Valve clearance Insert the feeler gauge 3...

Illustrated Symbols Refer to the illustration

Yamaha Warrior 350 Neutral Switch

Illustrated symbols 0 to 0 are designed as thumb tabs to indicate the chapter's number and content. S General information Specifications 3 Periodic inspection and adjustment 5 Cooling system Carburetion Drive train Chassis D Electrical Troubleshooting Illustrated symbols to are used to identify the specifications appearing in the text. Filling fluid Lubricant Special tool Tightening Wear limit, clearance Engine speed , V, A Illustrated symbols to in the exploded diagram indicate grade of...

Gen Info

Yamaha Warrior 350 Serial Number

The vehicle identification number is stamped into the left side of frame. Starting serial number JY43GDW0 LC051101 The vehicle identification number is used to identify your machine and may be used to register your machine with the licensing authority in your state. The engine serial number T is stamped into the right side the engine. The first three digits of these numbers are for model identifications the remaining digits are the unit production number. Designs and specifications are subject...

Caution

Yamaha Part Ym01404

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip , make sure that the sharp edged corner is positioned opposite to the thrust it receives. See the sectional view. Shaft The prepare special tools are necessary for complete and accurate tune-up and assembly. Using the correct special...

Particularly Important Information

Yamaha Dragstar 650 Carb Diagram

This material is distinguished by the following notation. 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 damage to the machine. A NOTE provides key information to make procedures easier or clearer. This manual consists of chapters for...

System

Ignition Magneto Circuit

A switch is newly provided on the parking brake lever on the left of the handlebar to sense the parking brake condition. The ignition unit which receives a sensed signal becomes activated as follows according to the parking brake condition. switch OFF - gt Ignition occurs normally. Parking brake is applied, switch ON Misfire occurs at 2300 r min. engine will not rev up beyond 2300 r min. Ignition timing control circuit Parking switch CDI magneto source coil and pickup coil Handlebar switch left...