Yamaha RZ350L/N/NC 1984–1985 OEM Service Manual Set (P/N LIT-11616-04-70)

Use the RZ350L manual for the repair procedures and the supplement for N/NC model identification and maintenance specifications. The supplement supplies revised ignition and generator data for those two variants.

PDF Bookmarks and Wiring Diagram Detail

Navigation and text search: Bookmarks open chapters in the base manual and sections in the supplement. PDF text search is unavailable. Small wire codes in the wiring diagrams are readable when zoomed in.

The ZIP contains one printable PDF with 240 pages. The total includes the base manual’s cover, imprint, notice, index, and appendix, plus the supplement’s foreword, imprint, and contents.

Two-Stroke Repair and Electrical Diagnosis

These selected service topics show the scope of the workshop coverage. The manual also covers wheel balancing and drive-chain wear checks.

• Engine repair: Engine removal and installation, crankcase separation, crankshaft inspection, wet-clutch overhaul, and service of the six-speed constant-mesh transmission.

• Y.P.V.S.: Power-valve removal and cleaning, cable adjustment, servomotor and potentiometer tests, and control-unit troubleshooting.

• Mikuni carburetors: Twin VM26SS disassembly, float and fuel level inspection, and vacuum-gauge synchronization.

• Yamaha Autolube: Pump-output testing, minimum-stroke adjustment, and bleeding procedures for the pump and oil delivery lines.

• Cooling system: Radiator-cap and cooling-circuit pressure tests, water-pump inspection, and thermostatic-valve testing.

• Chassis repair: Step-by-step procedures for caliper and master-cylinder overhaul, hydraulic bleeding, fork disassembly and seal replacement, and swingarm clearance adjustment.

• Electrical diagnosis: The RZ350L Wiring Diagram and circuit tests for C.D.I. ignition, charging, lighting, and the catalytic-converter warning system.

Yamaha wrote these manuals for dealers and qualified mechanics and assumes a working knowledge of motorcycle repair.

In-Frame Work and Engine Overhaul

The engine chapter identifies cylinder-head, cylinder, piston, and clutch work that can be done with the engine in the frame. Internal inspections cover piston rings, connecting-rod play, crankshaft runout, gear engagement dogs, and shift forks. The Engine Lubrication Chart identifies lubrication points for reassembly.

Exploded assembly views accompany reference data on clearances, wear limits, fluid capacities, and tightening torques in Nm and ft-lb. The special-tool listings identify universal clutch holder YM-91042, flywheel puller YM-01189, and fork-seal driver YM-33963 with adapter YM-01369.

Fuel, Cooling, and Periodic Service

The carburetor Sectional View shows the fuel and air passages. The identification tables list carburetor mark 48H00 for RZ350L and RZ350N and 1EL00 for RZ350NC. Intake reed-valve checks cover petal fatigue, seating, and stopper clearance.

Maintenance charts separate emission-control work from general lubrication and service. The troubleshooting guide groups hard starting, poor idle, and weak midrange or high-speed performance by ignition, fuel, and engine or exhaust causes.

Cooling illustrations show how the thermostatic valve changes the flow path as the engine warms. Yamaha flags the risk of damaging the water-pump seal lip or dislodging its spring during impeller-shaft installation.

Brakes, Fork, and Monocross Suspension

The brake chapter covers pad replacement with the hydraulic lines connected. The chassis sections explain the air-assisted fork’s variable damper and the link-type Monocross suspension, with procedures for steering bearings, linkage bushings, and the belt-driven rear spring preload adjuster.

Bottoming the fork’s inner tube during disassembly can damage the taper spindle. The nitrogen-charged rear damper is covered for removal, inspection, and replacement as a unit.

Interlocks and Warning Circuits

The sidestand and neutral-switch tests help isolate an interlock-related no-spark fault before tracing the rest of the ignition circuit. The electrical chapter also covers self-canceling turn signals and the water-temperature gauge. The YPVS System circuit diagram and Catalyzer Block Diagram support component checks. Cable Routing drawings show harness, control-cable, and hose placement.

Always follow the factory specifications and safety warnings, particularly for brake hydraulics and the pressurized cooling system.

Selected Float and Charging Coil Specifications

The Mikuni VM26SS float-height specification is 21.0 ± 0.5 mm for all three models. The carburetion chapter shows the measurement from the float-bowl mating surface with the gasket removed and the float resting lightly on the inlet needle.

For charging diagnosis, the white-to-white coil resistance at 20°C is 0.4 Ω ±20% on the RZ350L and 0.5 Ω ±20% on the RZ350N and RZ350NC. The supplement gives the applicable reading for the later variants.