1990 Yamaha YFM350X & Raptor 350 Service & Repair Manual Set (P/N LIT-11616-07–50)

This Yamaha service manual set combines the 1990 YFM350XA base manual, P/N LIT-11616-07-50, first edition May 1990, with five supplementary manuals, including the YFM350S publication for the Raptor 350. The supplements provide model-specific changes and are used together with the included base manual.

The download contains a 402-page PDF, combining scanned sections with text-based supplements.

• Engine overhaul: Engine removal, cylinder-head and valve repair, piston inspection, crankshaft and balancer assembly, and oil-pump inspection.

• Transmission and clutch: Crankcase separation, transmission and shift-fork inspection, reverse-drive components, clutch disassembly, wear checks, and assembly adjustments.

• Carburetor service: Removal, disassembly, component inspection, float-height and fuel-level adjustment, throttle-cable adjustment, and model-specific carburetor data.

• Chassis repair: Wheel-hub and rear-axle service, steering inspection, suspension removal, brake-caliper and master-cylinder repair, and hydraulic brake bleeding.

• Electrical troubleshooting: Starting, charging, ignition, lighting, and indicator-circuit diagnosis, supported by circuit diagrams, switch-connection charts, and component test specifications.

Yamaha wrote these publications primarily for its dealers and qualified mechanics, assuming an existing understanding of mechanical repair concepts and procedures.

Engine Overhaul, Clutch and Transmission

The guide also covers the 6-speed constant mesh transmission and the wet-sump lubrication system. Factory torque tables, fluid capacities, clearance specifications, and wear limits support internal component inspection.

Repair coverage extends to valve-guide replacement, valve-seat refacing, cam-chain timing, and starter-clutch inspection. The Crankshaft and Balancer Shaft and Transmission and Shifter exploded views identify internal components, while lubrication diagrams trace the engine's oil passages.

Carburetors and Model-Specific Updates

The base manual covers the Mikuni BTM36SH, including the accelerator pump, coasting enricher, and throttle-cable wire cylinder. Its carburetor section view identifies the main, pilot, float, starter, and acceleration-pump systems. The YFM350S supplement adds BSR36 removal and disassembly information.

California YFM350XKC carburetor data is included. The XP supplement distinguishes carburetor identification marks 3GD 00 for non-California models and 3GD 10 for California models, helping match the specification table to the carburetor being serviced.

The XE supplement revises fuel-tank, lighting, wheel, cable-routing, and throttle-cable information. Later supplements also update piston and clutch specifications.

Starting, Ignition and Battery Diagnosis

The electrical sections detail C.D.I. ignition timing, starter motor resistance, and lighting system circuits. The Electric Starting System circuit diagram and troubleshooting chart cover the clutch, neutral, and drive-select interlocks, helping distinguish an interlock fault from a starter fault.

The XJ supplement explains the parking-brake engine revolution limiter. The XP supplement adds DC C.D.I. diagnosis, including pickup-coil and rotor-rotation detection-coil checks, and specifies DR8EA spark plugs in place of the base manual's D8EA reference.

YFM350S coverage adds an updated wiring diagram and sealed MF battery charging charts. The base manual cautions that applying battery voltage to the C.D.I. unit during testing can damage it.

Rear Axle, Brakes and Suspension

Rear-axle procedures identify different tools: YM-37132 in the base manual and YM-37134 / 90890-01498 for YFM350S. The latter supplement warns that striking the axle end directly can damage its threads and splines.

YFM350S updates cover parking-brake cable adjustment, rear-caliper arm positioning, front-arm removal, and rear shock absorber and swingarm service. Brake work and handling the nitrogen-charged rear shock absorber require the manual's safety precautions and appropriate workshop experience.

File Contents and Readability

The page counts below include each publication's title, introductory, contents, and closing pages where present:

• YFM350XA base manual: 266 pages.
• YFM350XE supplement: 12 pages — P/N LIT-11616-08-60.
• YFM350XJ supplement: 20 pages — P/N LIT-11616-10-28.
• YFM350XKC California supplement: 9 pages — P/N LIT-11616-10-89.
• YFM350XP supplement: 29 pages — P/N LIT-11616-15-09.
• YFM350S supplement: 66 pages — P/N LIT-11616-17-57.

Text search: PDF pages 308–402, containing the XP and S supplements, have searchable text. Pages 1–307 are image scans without a searchable text layer.

Navigation: Internal PDF bookmarks cover the base manual and supplements. The separate “Back to Main” bookmark points to a file outside this download.

Wiring diagrams: Small wire-color codes and connector labels need enlargement for comfortable reading. The scanned XA and XJ wiring sheets are stored sideways; rotating the view makes them easier to follow.