1985–2000 Yamaha XT350 & TT350 Dual-Purpose Service & Repair Manual (P/N 9780892878352)

• Covers 1985-2000 Yamaha XT350 dual-purpose models from XT350N/NC through XT350M/MC and 1986-1987 Yamaha TT350 off-road models TT350S and TT350T, with engine/frame serial-number tables for exact model identification.
• A 388-page PDF of the third-party Clymer shop manual produced under PRIMEDIA Business Magazines & Media; it is not an OEM Yamaha factory publication.
• Details engine removal and complete top- and lower-end repair, including camshafts and cam timing, cylinder head and valves, valve guides and seats, cylinder, piston and rings, crankcase, crankshaft, connecting rod, bearings, oil seals, and engine break-in.
• Walks through the wet multiplate clutch, release mechanism, kickstarter, oil pump, balancer drive, external shift mechanism, six-speed transmission, internal shift mechanism, and paired Teikei carburetors, including inspection, overhaul, synchronization, and adjustment work.
• Separates XT350 and TT350 electrical systems for charging, ignition, lighting, switches, and fault tracing, with output tests, coil and resistance checks, connector views, circuit diagrams, and model-specific troubleshooting charts.
• Covers front hubs and wheel bearings, steering-head service, separate XT350 and TT350 fork procedures, Monocross shock and linkage work, swingarm bearings, front hydraulic disc brakes, rear drum brakes, master cylinders, calipers, hoses, discs, and brake bleeding.
• Illustrated references include cylinder-head torque-sequence drawings; XT350 and TT350 carburetor exploded views; ignition and lighting troubleshooting flowcharts; flasher, brake-switch, and ignition-control-unit connector views; fork and Monocross linkage exploded views; and four full-page wiring diagrams covering the 1986-1987 TT350, 1985 XT350, 1986-1995 XT350, and 1996-2000 XT350.

Clymer writes this manual for users ranging from first-time do-it-yourself mechanics to professional technicians. It explains routine work in detail, but also identifies major disassembly and press operations that call for sound mechanical judgment, special tools, or a properly equipped repair shop.

Engine, Driveline, and Fuel-System Depth

The air-cooled, four-stroke, DOHC four-valve single receives full repair coverage rather than tune-up information alone. The top-end chapter handles removal, inspection, service, and reassembly of the camshafts, valves, cylinder head, cylinder, piston, and rings. Lower-end procedures continue through engine removal, crankcase separation and assembly, crankshaft inspection and overhaul, bearing and seal replacement, and the post-rebuild break-in procedure.

Special-tool references are specific. The manual calls out the Yamaha YM-4106 tappet-adjusting tool, YM-01122 valve-guide remover, YM-01129 valve-guide installer, YM-01196 valve-guide reamer, and YM-01312 fuel-level gauge tube. Its carburetor section goes beyond cleaning: it covers removal, full primary/secondary carburetor disassembly, fuel-level inspection, float-arm adjustment, synchronization, needle and pilot-air-screw settings, and high-altitude main-jet changes. Fuel-tank and shutoff-valve work, exhaust removal, and exhaust repair are included as well.

Production Changes and Configuration Differences

The model tables track every listed XT350 and TT350 code and the associated engine/frame number range. TT350S is listed as 1RG-000101-015100 and TT350T as 1RG-015101-on. The XT350 entries run from N/NC through M/MC; the table notes that serial data is unavailable for the 1999 L/LC models and gives VIN-style identifiers for the 2000 M/MC models.

For the XT350, the specifications distinguish 1985-1995 and 1996-on builds where clutch friction plates, oil-pump clearances, secondary reduction, carburetor identification and jetting, charging output, and ignition-coil data changed. The 1985-1995 pressurized-fork arrangement is also identified separately.

California XT350 models receive their own evaporative-emissions coverage for the charcoal canister, unvented cap, rollover valve, hose routing, modified carburetor, and fuel tank. That section is limited to inspection and replacement of damaged emission-control parts; it does not authorize modification or removal of the system.

Shop Reference, Limits, and Repair Cautions

Chapter-end tables supply component-specific torque specifications, maintenance schedules, fluid and lubricant data, carburetor settings, valve and engine service limits, clutch and oil-pump inspection data, transmission ratios, electrical test values, suspension specifications, and disc- and drum-brake wear limits. Rear-suspension repair coverage includes shock removal, spring service, preload and rebound adjustment, linkage lubrication, and bearing replacement, but not an internal shock-absorber rebuild.

The repair cautions are component-specific. Clymer warns that substituting ordinary bolts for the hardened Yamaha camshaft-sprocket bolts can lead to bolt failure and severe engine damage; it also notes that prying between the clutch housing and clutch boss can break the housing fingers. Support the motorcycle securely before engine or chassis work, treat the TT350 remote shock reservoir and pressurized fork legs as pressure hazards, and verify correct brake operation before riding after hydraulic brake service.

The supplied file is an image-based scan with visible courtesy watermarks throughout. Its embedded text layer contains the repeated watermark rather than the manual body, so keyword lookup of repair procedures or specifications will not work reliably.