2004–2006 Yamaha YFM350FAS / YFM350AS / YFM400FAR ATV Service Manual & Supplements (P/N 5TE-F8197-10)

This package combines the Yamaha YFM400FAR base service manual (P/N 5TE-F8197-10) with the 2004–2006 YFM350FAS and YFM350AS supplements. The supplements provide model-specific changes to the base procedures and specifications.

• Engine repair: Engine removal, cylinder-head assembly, camshaft and valve service, piston inspection, crankcase separation, crankshaft installation, and oil-pump overhaul.

• Automatic transmission: Primary and secondary sheave disassembly, centrifugal-clutch inspection, shift-mechanism checks, and middle gear shim selection.

• Fuel and cooling: Mikuni BSR33 carburetor overhaul and fuel-level adjustment, oil-cooler service, and YFM400FAR radiator, thermostat, and water-pump procedures.

• Shaft drive: Front constant velocity joint service, differential gear lash measurement, rear axle removal, final-drive bearing replacement, and pinion/ring-gear setup.

• Brakes and chassis: Hydraulic brake bleeding, caliper and master-cylinder repair, rear drum-brake service, toe-in alignment, steering-knuckle work, and swingarm removal.

• Electrical diagnosis: Ignition, starting, charging, lighting, fan, and 2WD/4WD selection tests, supported by circuit diagrams and connector illustrations.

This material suits technicians familiar with internal engine and drivetrain work who have access to precision measuring equipment and the specified service tools.

350 Supplements and 400 Cooling Coverage

Model codes: The YFM350FAS 4WD supplement lists 5UH1, while the YFM350AS 2WD supplement lists 5WH1. The YFM400FAR base manual identifies 5TE1 and 5TE5. Many supplement procedures refer directly to the included base chapters.

Cooling differences: The air-cooled 350 models have oil-cooler and fan-service information. The 401 cm³ liquid-cooled engine belongs to YFM400FAR, with radiator testing, thermostat inspection, water-pump seal replacement, and coolant replacement procedures. Oil flow diagrams and coolant flow diagrams distinguish the lubrication and cooling circuits.

Engine Inspection and Carburetor Service

Maintenance schedules, lubrication charts, fluid-capacity specifications, and component-specific torque tables accompany the service procedures.

Cylinder-head tightening sequences, camshaft and rocker-arm inspections, valve-guide service, and piston/cylinder wear tables support internal engine repair. Exploded diagrams and job instruction charts show component orientation and assembly notes.

Periodic checks include valve-clearance adjustment, compression testing, and ignition-timing verification. The Mikuni BSR33 section goes beyond routine tuning, covering the vacuum diaphragm, coasting enricher, float, needle valve, and fuel-level checks. Recoil starter disassembly and reassembly, along with A.C. magneto removal and installation, are also documented.

Sheaves, Gear Shims, and Differential Limits

Sheave service includes pulley-weight inspection and spring-compressor procedures. The listed sheave spring compressor is YM-04134 / 90890-04134.

Middle gear shim calculations differ between the 350 supplements and the 400 base manual. Keeping those formulas with the matching model data helps select the correct setup information after replacing gears, bearing housings, or crankcases.

Differential scope: Case service, gear-motor installation, and lash adjustment are covered. The factory-assembled differential gear unit is not intended for internal disassembly; the manual warns that opening it can cause malfunction.

The middle-driven-shaft removal notes also identify the risk of thread damage when hydraulic-press force is applied directly to the shaft end.

Brake, Steering, and Suspension Work

The chassis chapters include brake wear inspections, steering-stem bearing service, tie-rod checks, ball-joint replacement, and swingarm bushing inspection. Cable routing diagrams show hose and harness placement around these assemblies.

Chassis work requires secure ATV support, and brake and spring-loaded sheave work requires the precautions specified in the manual.

Electrical Fault Isolation

Troubleshooting charts address no-spark conditions, a starter that will not operate, charging faults, and fan-control problems. The 4WD material also traces the On-command switch and gear motor.

Separate YFM350FAS, YFM350AS, and YFM400FAR wiring diagrams show wire colors and connector arrangements. The 350 supplements distinguish oil-temperature warning and fan-relay circuits from the 400 model's coolant-temperature and radiator-switch circuits.

A Sample of Engine and Ignition Specifications

These examples represent a small selection of the engine and electrical specifications in the manual.

The YFM350FAS idle-speed specification is 1,450–1,550 r/min with the engine warm. Its installed top piston ring side clearance is 0.03–0.08 mm standard, with a 0.13 mm wear limit.

The YFM350FAS CDI pickup coil specification is 459–561 ohms at 20°C (68°F), between the White/Red and White/Green leads.

PDF Navigation and Included Manuals

Text search and diagram detail: Searchable PDF text and embedded bookmarks provide access to the three manual sections and numerous subsections. Small wire-color labels and connector details in the full wiring diagrams require zooming.

The download is one printable, English-language PDF with 588 pages: 111 pages for the YFM350FAS supplement, 113 for the YFM350AS supplement, and 362 for the YFM400FAR base manual. One additional cover page and one navigation-guide page are already included in that total.