Yamaha XT350N/NC 1985–2000 Factory Service Manual (P/N LIT-11616-04-73)

Yamaha’s factory service manual covers the XT350N (57T) and California XT350NC (56R), P/N LIT-11616-04-73, 1st Edition, October 1984. This is the N/NC base manual; later-model supplements are not included.

PDF Bookmarks, Diagram Detail and Page Gaps

Search and navigation: The service pages do not support PDF text search; selectable text is limited to the cover. Chapter and subsection bookmarks provide navigation, but “Back to Index” links to a separate file that is not included. Small circuit-diagram labels are readable when enlarged.

Missing printed pages: The PDF skips pages 3-3 in engine removal, 5-1 at the start of the front-wheel section, and 6-31 in the signal-system/horn section. The neutral-indicator troubleshooting chart and horn instructions are therefore incomplete.

The ZIP contains one printable English PDF with 215 pages. That total includes the cover, four introductory/index pages, one supplemental page, and four blank or nearly blank pages.

Engine Overhaul, Dual-Carburetor Service and Electrical Diagnosis

The following selected contents outline the main service areas rather than reproduce the full table of contents. Other topics include fuel-cock inspection and headlight-bulb replacement and adjustment.

• Scheduled maintenance: Valve-clearance inspection and pad selection, decompression-cable adjustment, oil and filter service, oil-strainer cleaning, ignition-timing checks, and compression testing.

• Engine overhaul: Step-by-step disassembly, inspection, repair, assembly, and cam-timing procedures for the DOHC four-valve engine, crankshaft, balancer, clutch, transmission, and kick starter.

• Primary and secondary carburetors: Labeled section views, component inspection, reassembly, fuel-level adjustment, full-throttle linkage adjustment, synchronization, and air-cleaner/crankcase-ventilation service.

• Wheels and brakes: Wheel inspection and bearing replacement, rear drum-brake service, front-brake pad replacement, caliper and master-cylinder repair, and hydraulic bleeding.

• Suspension and steering: Front-fork overhaul, steering-head bearing work, rear-shock removal and adjustment, linkage inspection, swingarm service, and drive-chain inspection and installation.

• Electrical diagnosis: XT350N/NC circuit diagram, component-location drawings, charging and ignition tests, lighting and signal troubleshooting charts, and switch-continuity checks.

Written primarily for Yamaha dealers and qualified mechanics, this manual assumes an understanding of motorcycle repair concepts and procedures; internal overhaul and electrical testing require suitable tools and measuring equipment.

Maintenance and Internal Engine Repair

Routine service: Separate emission-control and maintenance/lubrication schedules accompany the adjustment procedures. Coverage extends to spark plugs, intake and exhaust connections, fuel lines, the wet-element air filter, clutch controls, cables, control pivots, tires, spokes, wheel bearings, battery electrolyte, and circuit-breaker inspection.

In-frame work: The engine-removal section identifies piston, clutch, carburetor, and AC magneto service as jobs that do not require engine removal. This distinction helps plan the extent of disassembly before starting a repair.

Inspection and assembly: Factory checks address valves, guides and seats, camshafts and cam chains, cylinder and piston wear, rings, crankshaft and connecting rod, oil pump, clutch pack, transmission gears, shift forks, and bearings and oil seals. Reassembly covers balancer alignment, transmission and shifter setup, crankcase closing, cam timing, final adjustment, and engine remounting.

The oil-service section explains the risk of engine seizure if oil circulation is absent. Cam-timing cautions identify the potential for piston and valve damage from excessive camshaft rotation, while crankcase assembly includes a transmission-operation check before final tightening.

Staged Carburetion and Variant Identification

The carburetor section separates the primary piston-valve and secondary vacuum-piston systems, including the starter and coasting-enricher circuits. Inspection covers jets and passages, the float-valve assembly, jet needles, starter plunger, and rubber diaphragms.

Model-identification and specification pages distinguish the standard and California versions through frame and engine starting numbers and carburetor identification marks. The labeled carburetor section view connects those component descriptions with the fuel-level and linkage-adjustment procedures.

Brake, Fork and Rear-Suspension Work

Chassis inspection includes wheel runout, spoke tension, wheel balance, brake-disc condition, brake-shoe thickness, and steering-bearing condition. Fork procedures cover the damper rod, guide bushings, oil seals, and internal tubes.

Rear-suspension coverage addresses shock removal, preload and damping adjustment, relay-arm and connecting-rod inspection, and swingarm play and shimming. The nitrogen-charged shock cylinder is not an internal-overhaul procedure: Yamaha warns against opening, heating, or damaging it. Fork-oil cautions also address contamination of the front brake.

System-Specific Electrical Fault Tracing

Charging diagnosis links battery checks, generator-output testing, charging-coil resistance, and rectifier/regulator connections. Ignition diagnosis follows weak or missing spark through the plug cap, ignition coil, pickup and source coils, CDI unit, and ignition-control circuit.

Neutral- and sidestand-switch tests explain the ignition interlock. Lighting and signal charts address headlight/high-beam, taillight, turn-signal, brake-light, and neutral-indicator faults, subject to the page gap noted above. Horn-adjustment data and switch-continuity tables remain included.

The XT350N/NC circuit diagram, electrical component-location drawings, lubrication diagram, engine and transmission exploded views, and three-page cable-routing layout support component identification and reassembly.

Factory Tools and Workshop References

The special-tool section identifies the universal clutch holder YM-91042, flywheel puller YM-01189 with attachment YM-1382, crankcase separator YU-01135, crankshaft installing set YU-90050, front-fork seal driver YM-08010, and electrical tester set YU-33260.

Appendices collect component-specific and general fastener torques, lubricant and fluid specifications, capacities, clearances, wear limits, and electrical test data.

Motorcycle repair involves fuel, hot engine parts, hydraulic brakes, pressurized suspension components, and live electrical circuits. Support the motorcycle securely and follow Yamaha’s model-specific cautions and test conditions for the 57T or 56R configuration being serviced.

Sample Dual-Carburetor Jetting and Fuel-Level Data

For the covered N/NC configurations, the carburetor tables specify a #125 main jet for the primary carburetor and #106 for the secondary.

The fuel-level procedure specifies 6 ± 1.0 mm, checked with the motorcycle level after warming and stopping the engine. Its illustrated gauge check relates the specification to the float-chamber measurement.