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    17 views28 pages

    Yamaha XT 350 Manual de Reparatie WWW - Manualedereparatie.info PDF

    Uploaded by

    Rubn

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    X1IS350 SERVICE GUIDE | @ e e technical training FOREWORD This ser 1¢ guide provides service information for new mechanism of the NEW XT350 and is intended for use in your new model service training school For detailed procedures, you can refer to the respective service manual. As this guide describes pre-delivery and service notes, it also serves as a guide for initial inspection steps. It is our sincere hope and belief that this guide will help enhance the technical knowledge and servicing ability of all of you TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE OPERATIONS YAMAHA MOTOR CO., LTD. CONTENTS ENGINE CHASSIS Y.D.LS. : ceseeeeesesseeeT FRONT FORK. 213 LUBRICATION ...... teveeeeee2 FRONT BRAKE “ AIR CLEANER AND CRANKCASE REAR SHOCK 16 VENTILATION. . : 3 REAR ARM 7 IGNITION TIMING. ceveeeeee el CYLINDER HEAD AND CAMSHAFT..5 — ELECTRICAL CAMSHAFT AND CAMCAP. :..6 IGNITION SYSTEM... VALVE CLEARANCE. 7 CHARGING SYSTEM . BALANCER..... -9 LIGHTING SYSTEM KICK STARTER . ..9 SIGNAL SYSTEM. . SHIFTER ....... ..9 WIRING DIAGRAM. CRANKSHAFT . 8 CLUTCH....... COASTING ENRICHER. CARBURETOR SYNCLONIZATION. .. XT350 SERVICE GUIDE 1985 by Yamaha Motor Corporation, U.S.A. Second Edition, January 1985 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. ENGINE * 4.VALVE SYSTEM (2 INTAKE AND 2 EXHAUST VALVES) e * DOHC WITH BALANCER * Y.D.1.8. (YAMAHA DUAL-INTAKE SYSTEM) Y.D.LS. THROTTLE COMBUSION VALVE CHAMBER —> moxture Flow \ ld OO exaust wet ES J TT exhaust INTAKE < SECONDARY = vacuum “THROTTLE PISTON VALVE 2) e OPERATION From idle to half throttle, primary carburetor supplies air-fuel mixture and it operates with secon- dary carburetor at high speed and full throttle. Due to two venturis, intake port area of each valve is smaller than in conventional engine, their combined area is about 20 percent greater than single. Since 4-valve layout offsetes intake port e relative to cylinder-bore axis, strong swirl is produced along cylinder wall in low-to-middle range. Combustion efficiency is significantly enhanced due to this swirl, resulting in improved fuel economy at usefull engine speed. PRIMARY = “aN | lo JIOW 3S edAL OPMMOZ AVS #10 pepuoUILO.EY ‘opis wiBuo $008) (3) 9P Y ‘8y-Werp) WN Ey :OMId NIVEG */) i oNi-o aoa (are2-64.wee) WN ze Onto ONIudS NOISS3udWOD LUBRICATION a /4000°938 md 10 a i (1 000’) “Pt 000'g Areng ueyeosoy (14009) W4 090"L :Urfeoug, pue 110 euibug AIR CLEANER AND CRANKCASE VENTILATION SYSTEM AIR CLEANER AIR CLEANER ELEMENT (WET TYPE) | CRANKCASE VENTILATION PIPE_\————~ f { > mona —> siow.sy Gas ZSTROKE ENGINE OIL SOLVENT ES FOAM-AIRFILTER OIL CLEANING v Maintenance interval: every 6,000 kim (4,000 mi) IGNITION TIMING ~riming ugHT * When removing rotor assembly, use magneto puller attachment. Gog? B.T.D.C. 12° 1,400 r/min P/No. YArI382 (CRANKSHAFT PROTECTOR SPARK PLUG 07-0.8mm (0.028 ~0.032in) 75Nm (1.75 mn'kg, 125010) NGK DR7ES DRBES. DRBES ‘© Maintenance intervals Intial: 1,000 km, (600 mi) Thereafter: evey 6,000 km (4,000 mi) CYLINDER HEAD AND CAMSHAFTS APPLY’ Uaui SEALANT i [70m (1.0m: kg. 7.21) @ DECOMPRESSION x2pes LEVER [FREE PLAY: 3- 5mm (0x2 0.2010) MEMO— DISULFIDE oI 6. —— VALVE [VALVE CLEARANCE] IN: 0.08~ 0.12 mm [EN (0.8m kg. 6.8 1) (.000 0.08 in) e PLASTIGAGE a ‘Standard: 0.0200. (0.0008 ~ 0.002%) Maximum: 0.160 mm (0.006) [APPLY MOLYBDENUM Ex: 0.13~ 0.17 mm (0.006 -0,007n} EAP EARAEE oer foo a xApes ~ cam cHaIN TENSIONER _srane Pwo [SNe (1.75 mkg. 12.5 1b) UP SIDE Oi RING TOP RING (UPPER RAIL lL, RING (LOWER RAIL) 2ND RING CAMCAP INSTALLATION 6 ue 7 OW MUST BE INSTALLED. ‘ALIGN MARKS IN CAMSHAFT ‘CAPS AND CAMSHAFT CAMSHAFT cap CAM LOBES FACE OUTWARD PROCEDURE 1. Align crankcase mark with keyways of crankshaft sprocket and crankshaft. 2. Align marks in camshaft and camshaft cap, and install camchain sprocket. CAM SHAFT INSTALLATION 1. Turn crankshaft to counterclockwise, and align “T"" mark on flywheel with stationary pointer. EXHAUST. ‘CAMSHAFT INTAKE CAMSHAFT CAMCHAIN _ ‘TENSIONER CRANKCASE__ MARK ‘STRAIGHT — Key ° CRANKSHAFT ‘SPROCKET =/ 2. Install camshaft on cylinder head. The identification mark must be faced up side. IDENTIFICATION MARK VALVE CLEARANCE DECOMPRESSION FREE PLAY 3—Smm (0.120.20in) © Align T mark with stationary pointer at Top Dead Center (T.D.C.. * When adjust valve clearance, remove stop- per bolt and pull lever towards front VALVE ADJUSTING TOOL Pap urrer * The slots in lifter must be positioned op- posite each other on Ex and IN side before tool is installed. Rounded value Hundredths digit Oor2 0 5 | (NOT ROUNDED OFF) 8 10 "Too! No. YMA106 (SAME AS XT2504) For example, if the original pad number is 258 (2.58 mm), the rounded off number is 260. * Maintenance intervals Intake valve (Cold) 0.08 ~ 0.12 mm (0.003 ~ 0.005 in) Exhaust valve (Cold): 0.13 ~ 0.17 mm (0.005 ~ 0.007 in) nl ras gm | Thereafter: (600 mir | 8¥@"¥ 6,000 ken (4,000 mi Intake MEASURED TNSTATLED PAD NUMBER 7 (CLEARANCE |200|206]210]215 220 |[225]230[235 240 [245] 250[256 [260 [265 (a10|316)320 '200|206 210 216 220|205|2a0 236) 240|245|250 26 200306) 310 "00205 210|215|220 25, 220205 20 245250285 '306]310/315| |205| 210 215 220 225 230] 236| 240 [246 |250| 255260 |266 [270 275 260| 265290) 316 320 20215] 220|225|230| 236 [240 245| 250| 255 260|265|270| 275200 [2a [20] |215|220|225|220 736 240|245| 250 265 |260 265|270|275|200 286 200 |220| 25 |230|735 240 |245|250| 255260 266 |270| 275 280 [285 |200 [295 |225|230| 235240 |2a6 |250|255| 260265 270 275| 280| 286 290 296 300 1 [2s0| 235 240 245 250| 255] 260265, 270|275| 260|285|280| 296 |300| 306] '235|240| 246 250| 255 | 260266 270|275| 280| 86 280] 295| 900 | 30510] 240,245) 250) 255| 260265 '220)295|300|05|310|316| 246 260) 256] 260| 265| 270] 295 300| 305] 310[315|320] [260|255 260 265 270275 '300)305|310|315| 320] [285|260|265 [270275 280 '306)310)315| 320] (260265 270275 780 285 '30/315|220 265 270] 276| 280| 285| 290 316) 320 "275| 280| 235 |200 295 zo) 275 |280|285| 230| 295| 300] |2e0|285| 290296 300 305 [285 | 290296 300 306) 210 |280| 235 300 306 310/315 '310|315|320| \VALVE CLEARANCE [engine cold 0,080.12 mm (31 ~ 0,048 35320) EnampleIstaed is 250 » Measured cenance is 0.22 mn (0.013 in} Replace 250 pad with 270, Ped number (exams) Pad No, 250~2.50 me (0.098 in) Pad No, 285~2.5 men (0.100 md Always intl pad with number down Exhaust MEASURED | — _——— TNSTALLED_PAD NUMBER — | CLEARANCE (230 |236 [200 [245] 250 265 270] 276280 |285| 25 [295 |300| 305] 310 [316] 320 000-0002 [215220 |226| 230] 235 '250| 256) 260/265 270| 275 |280 286] 290| 296 300305 (0.03=0.07, '220|225 230) 235|240|246 260 |256|260| 2651 270|275| 20 286 290| 205300 |305| 210 | 0.08=0.12 '225|230 236, 240|245|260 [265 |260| 265] 270/275|280| 285 |200 [295] 300| 206 310] 315] 0.13-0.17 '0.18~0.22 |205|210|216 220] 225| 290] 235|240 [246 260] 255 20286 300 [305/310] 316 | 320 '0.230.27 [210/218 220) 226) 230|235| 240| 246 |260|256| 260 "296 300|305|310|316|200| '0.28~0.32 |215|220]226 220 2a] 205 '300| 305 310 315 320 (0.33-0.37 |220|226|230)236 "250 | 256 [260 [266] 270 '306)310[315|320] 230/236 240 285 |260 [266 |270| 27 '310|318]320| '230|236 240 245 20] 0] '315|320) 235 240) 246, 250 265 35 240 246) 260/255 [270] [20] 245 250 255 200 EB 215 320 20) VALVE CLEARANCE lngino col) 0180.17 mem 10.052-0.068 nd Example Inte i 20 ‘00/05 310/315 ‘2_[05/310/315 200 Mies cere is 32 rm 0012) ‘zr [sto 315/300, ose 20 od wt 126-12 315 20) -Pat mu oot 20-250 rn 0088) Lassie teat areas eee BALANCER ‘BALANCER DRIVEN GEAR Nm Om kg, ATT LOCK WASHER poweL pin MATCH MARK 7 Drive GEAR 70m (7.0m“kg, 50ft-1b) * Align punch marks. SHIFTER KICK STARTER CRANKSHAFT ILGN are with MatcH em MARK CRANK PIN ‘O1L PASSAGE CRANKSHAFT ‘SHIFT, FORK ‘SHIFT. FORK 1 NuMBER Number of shift fork faces toward left-side crankcase. The crankshaft oil passage and the crank pin oil passage MUST be properly aligned. The deviation of one center line from the other must be LESS THAN 1.0 mm (0.04 in} CLUTCH [ENm (08m-kg. 6.8% 1] e LockNuT CLUTCH PRESSURE PLATE (anim 08mg.) wut (Son i6 mg. TT] J, soon wasven / PUSH PLATE -oiGren Pare ~“ithickness: 2.0 mm) FRICTION PLATE [WEAR Linr. 25mm (0.038 n) CLUTCH Boss THRUST WASHER cLuTcH PLATE (Thickness: 1.6 mm) PusH ROD +t O-RING ALL PRIMARY DRIVEN GEAR @, GB mrt R @ ‘STOPPER SCREW * When installing, align mark (©) on clutch both with mark (2) clutch pressure plate. e =10- COASTING ENRICHER This model is equipped with an afterburning protection device (coasting enricher).. => AIR = vaive 2 FUEL YF ouaprinacm vacuum => MIXTURE ROD ASSEMBLY CIRCUIT uot Am cincurT FN ove gear ium AIR INLET sraRTER am Jer MAIN AIR. a vrass Woe paar sot wave | \ vatve ss AIR JET. SECONDARY MAINS Pn gaiminter NS | ain cineurr i THROTTLE = \\p ron " oy VALVE FOR en aim iNT (A) main ain / , oF Sy PA moon GE Tue NY ) frig! Stanren gi RO) Hora TT gramen Female HW TYE saw wozzie STARTER SYSTEM IK MAIN AIR Homan ser—@h\ VACUUM Jae ies AA vat peace NBELNEEDLE. UatvE™ | vauve sear JET NEEDLE MAIN AIR JET SECONDARY PRIMARY SYSTEM FUEL SYSTEM SECONDARY svSreM GioaNG THE THROTTLE NOMAL OPERATION eAosING THE ovpnnacM vaue BiAPHinaGM ‘erin Senin vacuum Fos trom > SeconDaRY a am SRRBORETOR acu en JOINT nuanen SECONDARY to puor or 10 or ver & ce FROM ENRICHER _& FROM ENRICHER FROM MAIN AIR JeT AIR JET FROM MAIN AIR JET AIR JET OPERATION OF ENRICHER The air valve is pulled left by the negative pressure developed as the result of the sudden closing of the throttle valve. Thus, the enricher air passage is closed at the air valve seat and the air which flows into the pilot air passage is stopped, enabling only the air from the slow air jet to flow into the pilot air passage. This makes the air-fuel mixture flow to the pilot outlet and bypass port now relatively richer. CARBURETOR SYNCRONAIZATION PRIMARY CARB. FULL-OPEN ADJUSTMENT Turn the grip to move the drum-wire assembly to the full-throttle position. Then turn the full-open adjusting screw in or out so the carb valve bottom is positioned within the limits as specified, then secure the locknut on. it Fuel Level: 6.0 + 1.0mm (0.24 + 0.04 in) below the carb body edge Float Height: 27.0£2.5 mm (1.06+0.10 in) FULL OPENING ADJUSTING SoneW LOCKNUT ‘oven T | SCREW ‘SYNCHRONIZING SCREW FULL OPENING ADJUSTING SECONDARY CARB—SYNCHRONIZATION Raise the primary carb valve to a height of 2.5, mm (0.10 in) as indicated. Then adjust the syn- cchronizing screw so the secondary throttle shaft just contacts the secondary throttle push lever. As the primary carb valve is further opened, the secondary butterfly vaive will finally be ‘opened to its full horizontal position. (a= b) ‘SYNCHRONIZING SCREW \ “oe ah 25 mm ‘oroin 12 CHASSIS FRONT FORK FRONT FORK AIR PRESSURE: | "stp: 0 kPa (0 ka/em’, 0 psid | MAX: 20 kPe (02 kg/em® 3 psi * Level top of inner tube with top of steering crown. FORK Oil (EACH LEG, 319 om’ (11.2 imp o2, 10.8 US oz OWL Level: 226 mm {8.90 in} on: Fork oll 10 we ge x ~ “O-RING (agate aa ero FORK SPRING FREE LENGTH: 80 mm LIMIT: 575mm (22.6380) | [Nm 23 m-kg. 17 ib Front-frk-evnder Holder (22mm (0.87inl)_ PIN, ¥M35298, ® Thandie PIN Yetorsz601 ‘COLLAR S ® re L SEAT FORK Rs SPRING ~circur ~pusr seat coven bust seat. “on seat, “PLATE WASHER ‘euie Bus FORWARD DRAIN BOLT. [18 Wm (016m kp, 145% 1) 2] sh—wasner 7 / nam ig, 7) St fppty vocrite Front fork sal ond Guide-bush instaling Too! Weight ~ PIN. YM399637° o ‘Adopter PIN, YMBO108"0 @ ‘Thess tole are used to loosen andor tighten the front ferkeyinder bot. ‘These tools are used when instaling guide ‘bush and/or of selinta the outer fork tube -B- FRONT BRAKE [BNm 23 m-ka. 7A) [Nm a7. moka OA) e Cp, & 4 . [Z7Nm 27 m-ka, 19 fb) Pad ‘, a 1 BiNm BS miko, 7 TI) ae Spon —14— BRAKE PAD Brake Pad Replacement It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Remove the retaining bolt 2. Turn the caliper body counterclockwise. 3. Remove the pads (1) and pad springs (2). NoTe: — ‘© Replace the pad springs as a set if pad replacement is required. Replace the pads as a set if either is found to be worn to the wear limit. Sas?

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