Yamaha XT350 Service Guide 1985–2000 – Technical Training

Yamaha’s XT350 Service Guide, Second Edition (January 1985), is a technical training publication from Yamaha Motor Corporation, U.S.A. It explains the XT350’s mechanisms and provides pre-delivery and service notes. For detailed repair procedures, it refers readers to the separate service manual.

PDF Access and Wiring Detail

Search and diagram navigation: PDF text search and embedded bookmarks are not available. Small wire-color codes and connector labels in the overall wiring diagram require zooming.

One English-language, printable 28-page PDF includes 24 numbered technical pages plus the front cover, foreword/contents, publication-details page and back cover.

Valve Gear, Y.D.I.S. and Electrical Fault Tracing

These selected topics show the guide’s main service and training content. Additional examples include wet air-cleaner maintenance and crankcase-ventilation routing.

• Valve gear: Camshaft and camcap installation procedures, valve-clearance adjustment notes, valve-pad selection charts and illustrations of the adjusting tool.

• Carburetion: Y.D.I.S. operating principles, coasting-enricher circuit explanations, primary-carburetor full-open adjustment and secondary-carburetor synchronization procedures.

• Engine assembly: Lubrication diagrams, clutch component views, and assembly notes for the balancer driven gear, kick starter, shifter and crankshaft.

• Suspension: Front-fork assembly drawings and service-tool references, rear-shock preload and damping adjustments, and rear-arm lubrication details.

• Front brake: Hydraulic brake component drawings and illustrated, step-by-step brake-pad replacement instructions with wear-limit information.

• Electrical diagnosis: Ignition, charging, lighting and signal-system schematics, resistance-test illustrations, troubleshooting charts and an overall wiring diagram.

Written for new-model service training, this guide suits technicians learning the XT350’s mechanisms and model-specific service checks.

Camshaft, Valve-Pad and Crankshaft References

The valve-train drawings show the adjusting pad above the lifter. Separate intake and exhaust pad-selection tables accompany rounding examples, while the adjustment notes identify tool YM4106 and explain the relevance of decompression-cable and lifter-slot positioning.

Camshaft illustrations identify timing marks, camshaft-to-cap clearance data and lubrication points. The clutch exploded view distinguishes the plate types, push rods, ball and pressure-plate alignment marks.

Balancer and kick-starter drawings emphasize alignment marks; the shifter illustration identifies shift-fork orientation. The crankshaft notes highlight oil-passage alignment, where incorrect assembly can restrict lubrication and damage the crank assembly.

Understanding the Dual-Carburetor Setup

The coasting-enricher cross-sections distinguish normal operation from sudden throttle closure and show how the diaphragm-controlled air passage affects the pilot circuit.

The carburetor adjustment sheet separates full-open positioning from secondary-linkage synchronization and supplies fuel-level and float-height references. Together, these drawings help connect carburetor behavior with the linkage and enrichment circuit when assessing service needs.

Fork Tooling, Rear Suspension and Brake Pads

The front-fork drawing identifies the YM0132611 T-handle, a cylinder holder, and seal/guide-bush installation tools. It provides component relationships and tooling information rather than a complete fork-overhaul walkthrough.

Rear-shock references distinguish solo-rider and passenger preload settings. The rear-arm drawing identifies bushings, seals, linkage components and grease points.

The brake-pad section explains replacement without disconnecting the brake hose or dismantling the caliper, with notes on replacing pads and pad springs as sets. Before beginning hands-on work, secure the motorcycle on a stable stand and follow the applicable service procedures.

Ignition and Charging Troubleshooting

The ignition chart covers spark checks, wiring connections, switches, ignition-coil resistance, pickup and charge coils, and the C.D.I. unit. Illustrated meter connections link the test specifications to the components being checked.

Charging diagnosis addresses battery condition, current load, the circuit breaker and rectifier/regulator. Separate lighting and signal references cover the headlight, tail/brake light, turn indicators and horn, supported by switch diagrams and wire-color identification.

Examples of Carburetor and Ignition Test Data

The carburetor synchronization reference specifies a primary valve height of 2.5 mm (0.10 in) at the secondary-linkage contact point, alongside separate full-open, fuel-level and float-height data.

For ignition testing, the pickup-coil specification is 221 Ω ±10% at 20°C (68°F). The ignition-coil primary specification is 0.79 Ω ±20% at the same temperature. These values accompany illustrated meter connections and the ignition troubleshooting chart.