2004–2013 Yamaha Raptor 350 YFM35RB Owner's Manual (P/N LIT-11626-25-08)

• 543-page, two-PDF Yamaha factory set: a 140-page YFM35RB Owner's Manual, first edition March 2011, P/N LIT-11626-25-08, plus a 403-page repair file headed by the YFM350S Supplementary Service Manual.
• Model-specific service coverage combines YFM350S with the included YFM350XP, YFM350XKC, YFM350XJ, and YFM350XE supplements and the YFM350XA base manual, including regional and California configuration data.
• Engine and drivetrain procedures cover engine removal and installation, internal inspection, crankshaft and balancer service, oil-pump work, clutch repair, six-speed transmission inspection, and timing-system assembly.
• Chassis repair sections address wheels and hubs, rear-axle removal, steering, suspension, swingarm and linkage, drive chain, front and rear brake hydraulics, and bleeding.
• Electrical diagnosis includes component locations, switch checks, starting, charging, DC-CDI ignition, lighting, and signal-system fault isolation, supported by circuit diagrams and model-specific wiring diagrams.
• Workshop reference data includes exploded job diagrams, cable-routing views, special-tool numbers, torque tables, fluid and lubrication data, carburetor settings, wear and clearance limits, and electrical test specifications.

Model and Publication Coverage

The owner's book covers controls, pre-operation inspection, riding technique, and scheduled maintenance for the YFM35RB. The repair material was produced primarily for Yamaha dealers and qualified mechanics and assumes a basic understanding of mechanical principles and repair procedures. The owner's manual suits riders performing routine checks and adjustments; the repair PDF is for technicians and experienced owners equipped for component testing and accurate reassembly.

The service file is cumulative by design. Yamaha's 2004 YFM350S supplement, LIT-11616-17-57, directs the mechanic to use it with the earlier books, all of which are present in the PDF: YFM350XP LIT-11616-15-09, California YFM350XKC LIT-11616-10-89, YFM350XJ LIT-11616-10-28, YFM350XE LIT-11616-08-60, and YFM350XA LIT-11616-07-50. The 403 pages divide into 66 pages for YFM350S, 29 for YFM350XP, 9 for YFM350XKC, 20 for YFM350XJ, 12 for YFM350XE, and 267 for the YFM350XA base manual.

Match the machine's model label rather than relying on model-year shorthand. The YFM350S data distinguishes USA/Oceania, Canadian, and European model codes 5YT1, 5YT2, and 5YT3. The XP supplement separates non-California 5NF4 from California 5NF5 specifications, and the older XA and XE sections include starting vehicle and engine identifiers for configuration checks.

Repair and Diagnostic Depth

The base repair manual goes beyond routine maintenance. Its engine-overhaul chapter follows removal, disassembly, inspection, repair, assembly, adjustment, and remounting of the air-cooled SOHC single. Covered assemblies include the cylinder head, valves, camshaft, timing chain, piston, crankshaft, starter drives, clutch, oil pump, shifter, constant-mesh transmission, balancer, bearings, and seals. Carburetor coverage includes a section view plus removal, disassembly, inspection, assembly, installation, float-height adjustment, and fuel-level adjustment.

Chassis procedures include brake-pad replacement, caliper and master-cylinder disassembly, disc inspection, air bleeding, wheel and hub service, steering-shaft work, suspension inspection, swingarm removal, and rear-axle repair. Electrical chapters provide circuit-based troubleshooting for starting, charging, ignition, lighting, and signal systems. Representative graphics include the YFM350S, YFM350XP, YFM350XJ, and YFM350XA wiring diagrams, the carburetor section view, and the electrical-starting and charging-system circuit diagrams.

The special-tool lists identify both purpose and Yamaha number. Examples include the steering nut wrench YU-33975 / 90890-01443, 46 mm axle nut wrench YM-37134 / 90890-01498, crankcase separator YU-01135 with adapter YM-1382, flywheel puller YM-01404, and dynamic spark tester YM-34487.

Owner Operation and Maintenance

The YFM35RB owner's manual explains cold and warm starting, reverse selection, six-speed shifting, break-in, parking, loading, and riding on hills, slopes, shallow water, rough ground, and low-traction surfaces. Two periodic-maintenance tables separate emission-control items from general maintenance and lubrication. Procedures cover the spark plug, engine oil and filter, air filter, spark arrester, idle and throttle adjustment, brakes, clutch, drive chain, suspension preload, battery, lighting, wheels, and a no-start troubleshooting chart.

This is an off-road, high-performance sport ATV publication, not a utility-ATV manual. Yamaha specifies experienced operators and prohibits riders under 16.

Specifications and Service Cautions

Engine, chassis, carburetor, and electrical sections supply assembly-specific torque values, capacities, lubrication points, service limits, clearances, jetting and fuel-level data, charging and ignition test values, and model-specific cable routing. These references support the repair procedures without turning the product description into a list of isolated measurements.

The manual also flags repair mistakes that can damage expensive parts. Directly striking the rear axle can ruin its threads and splines. The nitrogen-charged rear shock and gas cylinder must not be opened, heated, or deformed; improper handling can damage damping components and create a pressure hazard. Brake, drivetrain, electrical, and pressurized-shock work should be performed with the machine secured and the factory warnings followed.