Engine Overhaul

ENGINE REMOVAL 4-1

ENGINE OIL 4-1

SEAT, HEADLIGHT UNIT AND FUEL TANK 4-1

CARBURETOR 4-1

CLUTCH CABLE 4-2

EXHAUST PIPE AND MUFFLER 4-2

DRIVE SELECT LEVER AND CRANKCASE VENTILATION HOSE 4-3

DRIVE CHAIN SPROCKET 4-3

FOOTRESTS 4-3

LEADS 4-4

ENGINE REMOVAL 4-5

ENGINE DISASSEMBLY 4-6

DECOMPRESSION CAM, CAM CHAIN SPROCKET AND

CYLINDER HEAD 4-6

CYLINDER AND PISTON 4-8

LEFT CRANKCASE COVER AND CDI MAGNETO 4-9

CAM CHAIN AND STARTER MOTOR 4-11

OIL FILTER AND NEUTRAL SWITCH 4-12

RIGHT CRANKCASE COVER 4-12

CLUTCH 4-13

PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 4-14

OIL PUMP 4-14

SHIFT SHAFT 4-15

OIL PIPE 4-15

CRANKCASE 4-15

BEARINGS AND OIL SEALS 4-19

CRANKSHAFT/ROCKER ARMS/VALVES 4-20

INSPECTION AND REPAIR 4-22

CYLINDER HEAD 4-22

VALVE SEAT 4-23

VALVE/VALVE GUIDE 4-26

CAMSHAFT 4-27

ROCKER ARM/ROCKER ARM SHAFT 4-28

VALVE SPRING 4-29

TIMING CHAIN/CHAIN GUIDE/SPROCKET 4-29

CYLINDER/PISTON 4-30

PISTON RING 4-32

PISTON PIN 4-33

CRANKSHAFT/CONNECTING ROD 4-34

ELECTRIC STARTER DRIVES 4-34

PRIMARY DRIVE 4-35

CLUTCH 4-36

OIL PUMP 4-38

SHIFTER 4-38

TRANSMISSION 4-39

SPEC

1NSP"

a

3

ELEC

7

9 •

TRBL SHTQ

8

BALANCER DRIVE GEAR 4-40

CRANKCASE 4-40

BEARING AND OIL SEALS 4-41

ENGINE ASSEMBLY AND ADJUSTMENT 4-42

CAMSHAFT/ROCKER ARMS/VALVES 4-42

TRANSMISSION/BALANCER/CRANKSHAFT 4-45

CRANKCASE 4-51

OIL PIPE 4-52

SHIFT SHAFT 4-52

OIL PUMP 4-53

BALANCER DRIVEN GEAR AND PRIMARY DRIVE GEAR 4-53

CLUTCH 4-54

RIGHT CRANKCASE COVER 4-57

NEUTRAL SWITCH AND OIL FILTER 4-57

STARTER MOTOR AND CAM CHAIN 4-58

CDI MAGNETO AND LEFT CRANKCASE 4-58

CYLINDER HEAD/CYLINDER/PISTON 4-60

REMOUNTING ENGINE 4-67

CHAPTER 5. CARBURETION

CARBURETOR 5-1

SECTION VIEW 5-2

REMOVAL 5-3

DISASSEMBLY 5-4

INSPECTION 5-6

ASSEMBLY 5-7

INSTALLATION 5-8

FLOAT HEIGHT ADJUSTMENT 5-9

FUEL LEVEL ADJUSTMENT 5-10

WIRE CYLINDER 5-11

REMOVAL; 5-11

INSPECTION 5-11

INSTALLATION 5-12

CHAPTER 6. CHASSIS

FRONT WHEEL AND WHEEL HUB 6-1

REMOVAL 6-2

INSPECTION 6-3

INSTALLATION 6-4

REAR WHEEL AND WHEEL HUB 6-6

REMOVAL 6-7

INSPECTION 6-8

INSTALLATION 6-9

FRONT BRAKE 6-12

BRAKE PAD REPLACEMENT 6-14

CALIPER 6-15

AIR BLEEDING 6-18

MASTER CYLINDER DISASSEMBLY 6-19

BRAKE DISC 6-20

REAR BRAKE 6-22

BRAKE PAD REPLACEMENT 6-23

CALIPER DISASSEMBLY 6-24

MASTER CYLINDER DISASSEMBLY 6-26

INSPECTION AND REPAIR 6-27

ASSEMBLY 6-27

AIR BLEEDING 6-29

FRONT SUSPENSION 6-30

REMOVAL 6-31

INSPECTION 6-32

INSTALLATION 6-33

STEERING SYSTEM 6-34

REMOVAL 6-35

INSPECTION 6-36

INSTALLATION 6-37

REAR SHOCK ABSORBER AND SWINGARM 6-39

HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 6-40

DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 6-40

REMOVING THE REAR SHOCK ABSORBER 6-41

CHECKING THE REAR SHOCK ABSORBER 6-41

CHECKING THE RELAY ARM AND CONNECTING ARM 6-41

INSTALLING THE REAR SHOCK ABSORBER 6-42

REMOVING THE SWINGARM 6-42

CHECKING THE SWINGARM 6-42

CHECKING THE DRIVE CHAIN 6-43

INSTALLING THE SWINGARM 6-44

CHAPTER 7. ELECTRICAL

YFA350XA CIRCUIT DIAGRAM 7-1

ELECTRICAL COMPONENTS 7-3

GEN

1

PI

SPEC

CM

%9

ENG

4

0*

CHAS

6

•o

TRBL SHTG

8

CHECKING OF SWITCHES 7-4

SWITCH CONNECTION AS SHOWN IN MANUAL 7-4

CHECKING SWITCH FOR TERMINAL CONNECTION 7-4

CHECKING OF BULBS(FOR HEADLIGHT, TAIL/BRAKE LIGHT,

FLASHER LIGHT, METER LIGHT, ETC.) 7-7

KIND OF BULBS 7-7

CHECKING BULB CONDITION 7-7

ELECTRICAL STARTING SYSTEM 7-9

CIRCUIT DIAGRAM 7-9

STARTING CIRCUIT OPERATION 7-11

TROUBLESHOOTING 7-12

CHARGING SYSTEM 7-21

CIRCUIT DIAGRAM 7-21

TROUBLESHOOTING 7-23

IGNITION SYSTEM 7-27

CIRCUIT DIAGRAM 7-27

TROUBLESHOOTING 7-29

LIGHTING SYSTEM 7-35

CIRCUIT DIAGRAM 7-35

TROUBLESHOOTING 7-39

SIGNAL SYSTEM 7-41

CIRCUIT DIAGRAM 7-41

TROUBLESHOOTING 7-43

SIGNAL SYSTEM CHECK 7-45

CHAPTER 8. TROUBLESHOOTING

STARTING FAILURE/HARD STARTING 8-1

POOR IDLE SPEED PERFORMANCE 8-3

POOR MEDIUM AND HIGH SPEED PERFORMANCE 8-3

FAULTY GEAR SHIFTING 8-4

CLUTCH SLIPPING/DRAGGING 8-4

OVERHEATING 8-5

FAULTY BRAKE 8-5

SHOCK ABSORBER MALFUNCTION 8-6

INSTABLE HANDLING 8-6

FAULTY LIGHTING SYSTEM 8-6

YFM350XA WIRING DIAGRAM

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