2004 Yamaha Raptor 350 Service Manual

This 2004 Yamaha Raptor 350 service manual covers all maintenance and repair procedures. It includes detailed diagrams and part numbers to assist with servicing. PN LIT-11616-07-50.

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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

Yamaha Models Covered & Key Technical Specifications

Models: Yamaha Raptor 350, YFM350XA
Build Years: 1990
Serial Numbers: Starting serial number JY43GDW0*LC051101, Engine starting serial number 3GD-051101
Technical Data:

  • Engine displacement: 348 cc
  • Engine type: 4-stroke, SOHC, gasoline
  • Compression ratio: 9.2:1
  • Compression pressure: 834 kPa (121 psi)
  • Lubrication system: Wet sump
  • Engine oil capacity (with filter change): 2.5 L
  • Transmission type: 6-speed forward, 1-speed reverse
  • Spark plug gap: 0.6–0.7 mm
  • Ignition timing: 10° at 1,000 r/min, 33° at 5,000 r/min
  • Front tire pressure: 30 kPa (4.3 psi)
  • Rear tire pressure: 25 kPa (3.6 psi)
  • Battery capacity: 12V 12AH
Technical Specifications
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Document Number / Seller:
26798 / Cynthia Collins
File Size:
44.38 MB
File Type:
PDF
Language:
English
Pages:
402
Printable:
Yes
Category:
ATV
Last updated / verified
Oct 19, 2025

Yamaha Manual Features & Content Preview

Yamaha YFM350XA Raptor 350 Service Manual

  • Covers 1990 Yamaha Raptor 350, model YFM350XA with 348cc 4-stroke engine and 6-speed transmission
  • Official Yamaha publication P/N LIT-11616-07-50, first edition May 1990
  • Contains 8 major chapters with detailed exploded-view diagrams, electrical circuit schematics, and comprehensive torque specifications
  • Stored against your account so you can retrieve it after a hard-drive loss
  • File link appears in your order confirmation straight away
  • Page spreads stay legible when printed at original size
  • Indexed PDF search covers every chapter and appendix
  • This 1990 first edition serves as the foundational reference for the YFM350XA, documenting essential baseline specifications for the inaugural build cycle.

Yamaha Raptor 350 Technical Scope

This factory manual outlines critical maintenance and overhaul procedures for the 1990 Yamaha Raptor 350. The content is structured into distinct chapters, beginning with machine identification and special tools, followed by specific engine overhaul, carburetion, chassis, and electrical system analysis. Troubleshooting charts address common performance concerns, while cable routing diagrams assist in system assembly and maintenance. Users will find guidance on valve clearance, spark plug inspection, oil system management, and air filter maintenance, all provided within the manufacturer-specified framework.

Specification Highlights

Engine internal tolerances and clearance data for the 1990 Yamaha Raptor 350 include camshaft runout limits of 0.03 mm. Valve clearance for the intake is documented at 0.06–0.10 mm in the engine specification table. Crankcase oil capacity during a filter change is specified at 2.5 liters. Piston ring end gap is 0.20–0.40 mm for top and 2nd rings. The compression pressure range at sea level is 800–900 kPa. Electrical system health is defined by magneto charging current, which must exceed 12A at 3,000 r/min. Factory-recommended what an OEM service publication covers includes torque values for head bolts (40 Nm) and drive sprocket nuts (75 Nm). An official 402-page Yamaha OEM workshop manual covering the 1990 YFM350XA, documenting engine, chassis, electrical, and carburetor specifications for the 3GD5-series build.

Manual FAQ, Purchase & Download Details

Can I view the included electrical starting, charging, ignition, and lighting system circuit diagrams in this document? keyboard_arrow_down

Yes, Chapter 7 of the manual provides comprehensive circuit diagrams for the electrical starting, charging, ignition, and lighting systems. These diagrams illustrate the system configurations specific to the YFM350XA model.

Which engine overhaul sections are listed in the chapter contents for the YFM350XA? keyboard_arrow_down

Chapter 4 covers the engine overhaul process, detailing sections for engine removal, disassembly, inspection, and assembly of major components such as the cylinder, piston, and transmission.

What kind of maintenance and tightening specifications are found in the specification tables? keyboard_arrow_down

Specification tables in Chapter 2 list general torque specifications and maintenance data including engine, chassis, and electrical reference values. These sections organize technical information required to maintain the specified performance standards.

Does this manual correspond to a specific edition or publication identifier? keyboard_arrow_down

Document is identified as the 1st Edition published in May 1990 with the publication reference number LIT-11616-07-50.

Are there exploded views available in the document to assist with component identification? keyboard_arrow_down

Yes, each chapter provides exploded diagrams before the respective disassembly sections to aid in visual identification of components. These illustrations show part relationships and assembly orientations for various systems throughout the manual. The diagrams are specifically designed to clearly represent the construction of the machine without providing repair steps.

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