Yamaha Terra Pro YFP350U ATV Service Manual 1987–1988 (P/N LIT-11616-06-46)

Yamaha’s factory YFP350U Service Manual, P/N LIT-11616-06-46, covers the TerraPro in the 2NL configuration and the Canadian 2TX configuration. This is the first edition, February 1987, with cover code 2NL-28197-10.

PDF Bookmarks, Page Gaps, and Wiring Detail

Navigation and diagram detail: PDF text search is not available. Embedded bookmarks cover the chapters and major sections, although “Back to Index” points to a separate file that is not included. Small labels in the full wiring diagram require zooming.

Page gaps: Printed page 3-79 is absent between the loading/towing information and the following maintenance section. Printed pages 8-55 and 8-75 are also absent, leaving gaps in the taillight troubleshooting chart and the beginning of the PTO-indicator troubleshooting chart.

The ZIP download contains one printable, 435-page PDF, including 13 front-matter pages, 418 technical pages, and four memo pages.

Engine, Governor, PTO, and Chassis Service

Selected coverage: These highlights represent part of the manual’s contents. Further topics include fender removal and installation, fuse inspection, and headlight-beam adjustment.

• Periodic maintenance: Engine, clutch, cooling-fan belt, brakes, parking brake, PTO clutch, governor controls, differential lock, drive-select system, steering, suspension, battery, and lighting inspection and adjustment.

• Engine repair: Step-by-step removal, disassembly, inspection, repair, reassembly, and timing procedures for the cylinder head, valve train, piston and cylinder, crankshaft, transmission, clutch, and PTO drive.

• Carburetor and governor: Mikuni BTM32SH carburetor service, float and fuel-level adjustment, mechanical-governor overhaul, solenoid-valve inspection, governor-clutch service, and three-cable wire-cylinder repair.

• Drivetrain service: Differential gear, constant-velocity joint, sub-transmission, and PTO gearbox removal, inspection, reassembly, installation, and operational checks, with PTO gear-lash measurement and shim selection.

• Brake repair: Front mechanical drum-brake service and rear hydraulic drum-brake overhaul, including master-cylinder and wheel-cylinder inspection, seal replacement, reassembly, and brake-system bleeding.

• Electrical diagnosis: CDI ignition, electric-starting, charging, lighting, and signal-system circuit diagrams and fault-isolation charts, plus checks of the machine’s starting and operating interlocks.

• Workshop reference: Yamaha special-tool numbers, tightening-torque tables, lubricant types and capacities, cable settings, wear limits, clearances, carburetor specifications, and electrical test values.

Written primarily for Yamaha dealers and qualified mechanics, this manual assumes a basic understanding of mechanical concepts and machine-repair procedures.

Engine Overhaul and In-Chassis Work

The engine chapter distinguishes work that can be handled in the chassis from a complete engine pull. It states that the cylinder, flywheel magneto, and sub-transmission gears can be removed without taking the entire engine out.

Internal coverage extends to crankcase covers, balancer gears, the oil pump and shifter, and the PTO drive pulley and gear. Bearing checks, valve-seat work, cam-chain and CDI-rotor service, cam timing, and component-specific torque data accompany the overhaul procedures.

Cooling-fan and pulley service is included. The Canadian 2TX configuration also receives dedicated recoil-starter disassembly, inspection, and assembly coverage.

Carburetor, Governor, and Control Cables

The carburetor sectional view maps the main-metering, starter, pilot, and float circuits. Governor overhaul covers the flyweights, sleeve, fork, link rod, butterfly valve, solenoid valve, clutch shaft, and lifter.

Adjustment coverage includes governor speed, governor-clutch cable setup, control-lever holding-cable adjustment, and governor oil service. The governor clutch’s lifter and case indexing matters: incorrect installation can leave the clutch shaft unable to turn.

Drivetrain Diagnosis and PTO Gear Setup

Noise and leakage checks help distinguish wheel-bearing, CV-joint, rear-axle, and gear faults before components are opened. The PTO section provides gear-position calculations when the gear case or drive shaft is replaced, along with the measurement and shim-selection procedures.

PTO tooling is identified by number: ring-nut wrench YM-36626, shaft holder YM-36625, gear-lash tool YM-01230, and dial gauge YM-03097. Engine-service references include crankcase separating tool YU-01135 and flywheel puller YM-01404.

Incorrect shim placement or excessive bearing-housing tightening can leave too little gear lash and damage the gear teeth.

Chassis and Rear-Brake Repair

Chassis procedures cover wheel bearings, the steering shaft, tie-rods, steering knuckles, lower arms, front struts, rear shocks, swingarm, rear axle, and differential housing.

Rear-brake coverage includes pipe and hose service, fluid requirements, and seal-replacement rules. Its cautions explain how solvent can damage hydraulic seals, excess sealant can block fluid passages, and grease contamination can reduce lining friction.

Electrical Fault Isolation and Interlock Logic

Tests cover ignition spark, ignition/source/pickup coils, CDI and governor inputs, starter motor and cut-off relays, magneto output and regulation, and headlight and taillight supply. Signal-system checks address the neutral, reverse, temperature, parking-brake, and PTO indicators, subject to the page gaps noted above.

The engine-operation-pattern charts provide a reference for distinguishing normal interlock shutdowns from electrical faults. They relate the seat, clutch, PTO, differential, 2-point hitch, transmission position, speedometer reed switch, and governor circuits to starting, stalling, and ground-speed limiting.

Illustrations include engine and PTO drive-axle lubrication diagrams, governor and PTO exploded assemblies, cable-routing layouts, the CDI internal circuit diagram, and the full YFP350U wiring diagram.

Use secure supports for drivetrain and suspension work, follow the circuit-specific precautions for electrical tests, and keep clear of the cooling-fan and PTO belts during running checks. Any opened rear-brake hydraulic circuit must be restored and bled before the machine is returned to service.

Selected Valve-Clearance and PTO Gear-Lash Data

Cold valve-clearance specifications list 0.06–0.10 mm for the intake and 0.16–0.20 mm for the exhaust, alongside the adjustment procedure.

For PTO gear setup, the manual distinguishes 0.2–0.3 mm of actual lash at the gear teeth from a 0.5–0.8 mm reading with the specified measurement tool. That distinction matters when using its gear-lash and shim-selection procedures.