1987–2004 Yamaha Warrior 350 YFM350XP, YFM350XA, YFM350XE, YFM350XJ Supplementary Service Manual (P/N LIT-11616-15–09 / 3GD-28197-16)

• YFM350X Warrior publication coverage: 415-page PDF compilation containing the YFM350XA base service manual, YFM350XE, YFM350XJ, YFM350XKC California, and YFM350XP supplements, plus a separate YFM350S supplement dated January 2004.
• Engine and transmission repair: Covers engine removal, cylinder-head and cam-chain service, piston and crankshaft inspection, clutch and primary-drive work, oil pump and balancer service, shifter repair, transmission disassembly, reassembly, and final adjustment.
• Carburetion and routine setup: Details carburetor removal, section views, disassembly and inspection, float and fuel-level adjustment, idle and throttle settings, speed-limiter adjustment, valve-clearance service, ignition-timing checks, compression testing, and air-filter maintenance.
• Chassis and brake work: Covers wheel and hub repair, drive-chain slack and alignment, master-cylinder and caliper service, hydraulic brake bleeding, steering, front suspension, rear-shock, and swingarm work; the YFM350S section adds dedicated rear-axle procedures.
• Electrical diagnosis: Provides switch-continuity charts, starting, charging, ignition, lighting, and signal-system troubleshooting, engine revolution-limiter coverage, component test specifications, and model-specific wiring diagrams.
• Factory reference data: Includes exploded assembly views, cable-routing sheets, lubrication diagrams, component torque tables, fluid capacities, wear limits, clearances, carburetor calibration data, and electrical test values.

Publication Structure and Model Identification

The lead booklet is the YFM350XP Supplementary Service Manual, P/N LIT-11616-15-09 / 3GD-28197-16, First Edition, May 2001. Yamaha identifies it as an update containing new XP service information, not a standalone overhaul manual. Its foreword directs the technician to the YFM350XA base manual and the XE, XJ, and California XKC supplements for procedures and data that did not change. The compilation places those related volumes together: the XA manual carries the main repair chapters, while the supplements record model-specific revisions.

Factory identifiers printed in the publications include 3GD5 for YFM350XA, 3GDB for YFM350XE, 3GDK for YFM350XJ, 3GDM for YFM350XKC, and 5NF4/5NF5 for YFM350XP non-California/California models. The XA material lists starting vehicle and engine identifiers JY43GDW0*LC051101 and 3GD-051101; the XE supplement lists JY43GDA0*PA095101 and 3GD-095101. The final section is the separate YFM350S 3GD-AE7 supplement, first edition January 2004, for model codes 5YT1, 5YT2, and 5YT3. Match the printed model code and identification data before selecting parts, specifications, or repair procedures.

Repair and Diagnostic Coverage

The YFM350XA base manual supplies the workshop depth. Engine sections address removal, decompression and cam-chain components, cylinder head and piston, A.C. magneto, starter drive, clutch, primary drive and balancer, oil pump, shift shaft, crankcase separation, crankshaft, rocker arms, valves, and transmission. Inspection coverage extends to valve seats and guides, camshaft and sprocket condition, piston and ring wear, crankshaft and connecting rod checks, clutch plates, oil-pump clearances, shifter parts, gears, bearings, and oil seals. Assembly material covers cam timing, clutch setup, oil-filter and neutral-switch installation, and engine installation.

Fuel-system content goes well beyond a jetting table. The base manual provides carburetor section views, removal, internal disassembly, inspection, assembly, installation, float-height adjustment, and fuel-level checking. It identifies the BTM36SH/Mikuni carburetor in the XA material, while the YFM350S supplement covers the later BSR36/Mikuni unit. The XKC publication isolates California carburetor data, and the XP tables separate California and non-California identification and calibration information.

Across the chassis sections, the procedures cover wheel and hub removal, brake-pad replacement, caliper and master-cylinder disassembly, hydraulic bleeding, front suspension, steering, rear shock absorber and swingarm, drive-chain inspection, and rear-axle service. Periodic sections add toe-in, wheel-bearing, tire, brake-fluid, clutch, chain, suspension, and steering checks. The YFM350S supplement adds body-panel and fuel-tank removal, sealed MF-battery testing and charging charts, revised rear-axle and front-arm work, rear-brake-caliper assembly, and swingarm procedures.

Electrical diagnosis is organized around circuit diagrams and fault-isolation charts. The manual set covers switch continuity, starting-circuit operation, charging output, ignition spark and coil tests, lighting and signal circuits, and wiring-connection checks. The XJ supplement explains the park-switch-controlled engine revolution limiter; the XP section adds updated ignition and signal-system troubleshooting. Full wiring diagrams identify the CDI unit, relays, switches, starter, indicators, lamps, and color-coded harness connections.

Diagrams, Tools, and Specifications

Visual references include engine lubrication-path diagrams, carburetor section views, exploded engine and chassis assemblies, cable and hose routing sheets, ignition and signal-system circuit diagrams, and full model wiring diagrams. Routing pages map the throttle and clutch cables, brake hoses, switch leads, battery cables, breather and overflow hoses, CDI unit, rectifier/regulator, starter relay, and wire harness.

Special-tool callouts include the YU-01135 crankcase separator with YM-1382 adapter, YM-04019 valve spring compressor, YM-34487 dynamic spark tester, and YU-03112 pocket tester. The YFM350S supplement adds the YU-33975 steering nut wrench and YM-37134 axle nut wrench. Specification sections supply component torque tables, lubrication and capacity data, carburetor calibration, inspection limits, piston and clutch measurements, suspension settings, ignition timing, charging and coil test values, and switch-continuity data.

Manual-Specific Service Cautions

The rear-axle section warns against striking the axle end directly with a hammer because the threads and splines can be damaged. The foam air-filter element must be squeezed rather than twisted or wrung; operating the ATV without it can cause rapid internal engine wear. During right-crankcase-cover installation, the clutch push-lever punch mark must align with the cover mark so the release mechanism is not assembled out of index.

Secure the ATV on a stable stand before engine, axle, suspension, or brake work. Do not open or heat the gas-charged rear shock, and complete hydraulic brake repair with the specified fluid and proper bleeding before returning the machine to service.