Page 14 of 389

Cooling system ...................................8-23
Spark plug inspection .........................8-39
Air filter cleaning .................................8-43
Carburetor settings .............................8-51
Idle speed adjustment ........................8-67
Throttle lever adjustment ....................8-71
Front and rear brake pad
inspection .........................................8-73
Inspecting the brake fluid level ...........8-75
Brake fluid replacement ......................8-79
Front brake adjustment ......................8-81
Rear brake adjustment .......................8-83
Parking brake adjustment ...................8-85
Adjusting the rear brake light switch ...8-89
Clutch adjustment ...............................8-91
Drive chain slack check ......................8-91
Drive chain slack adjustment ..............8-93
Lubricating the drive chain .................8-95
Cable inspection and lubrication ........8-99Brake and shift pedal/brake and
clutch lever lubrication ....................8-101
Upper arm and lower arm pivot
lubrication .......................................8-101
Rear arm pivot lubrication ................8-103
Wheel removal .................................8-105
Wheel installation .............................8-105
Replacing the headlight bulb ............8-107
Headlight beam adjustment ..............8-109
Tail/brake light bulb replacement .....8-111
Troubleshooting ................................8-113
Troubleshooting chart .......................8-117
CLEANING AND STORAGE ...................9-1
A. Cleaning ...........................................9-1
B. Storage ............................................9-7
SPECIFICATIONS .................................10-1
109
5FK-9-63-0~3 2/7/02 1:24 PM Page 14
Page 46 of 389
3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Tail/brake light 13. Rear wheel
2. Seat 14. Starter (choke)
3. Kick starter 15. Shift pedal
4. Fuel tank cap 16. Clutch lever
5. Headlight 17. Parking brake
6. Brake pedal 18. Main switch
7. Rear brake light switch 19. Front brake lever
8. Front wheel 20. Throttle lever
9. Front shock absorber 21. Handlebar switch
10. Radiator
11. Fuel cock
12. Rear shock absorberNOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
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!8!9
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!4 !5
5FK-9-63-0~3 2/7/02 1:24 PM Page 46
Page 90 of 389
5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Brakes9Check operation, free play, fluid level and fluid leakage. 5-5 ~ 5-9
9Fill with DOT 4 brake fluid if necessary. 8-73 ~ 8-83
Clutch9Check operation, condition and lever free play. 8-91
Parking brake9Check operation, condition and free play. 8-85 ~ 8-87
Fuel 9Check fuel level.
9Fill with fuel if necessary.5-11 ~ 5-13
Transmission oil9Check oil level.
9Fill with oil if necessary.5-17, 8-17 ~ 8-23
Coolant reservoir 9Check coolant level.
9Fill with coolant if necessary.8-23 ~ 8-37
Drive chain9Check chain slack and condition.
9Adjust if necessary.5-19, 8-91 ~ 8-97
Throttle9Check for proper throttle cable operation. 5-19, 8-71
Wheels and tires9Check tire pressure, wear and damage. 5-23 ~ 5-29, 8-105
Fittings and Fasteners9Check all fittings and fasteners. 5-19
Lights9Check for proper operation. 5-21, 8-107 ~ 8-111
5FK-9-63-4~5 2/7/02 1:25 PM Page 36
Page 128 of 389
6-9
EBU00180Starting a warm engine
To start a warm engine, refer to the “Starting a
cold engine” section. The starter (choke) should
not be used. The throttle should be opened
slightly.EBU00538Warming up
To get maximum engine life, always warm up
the engine before starting off. Never accelerate
hard with a cold engine! To see whether or not
the engine is warm, check if it responds to the
throttle normally with the starter (choke) turned
off.NOTE:
When the parking brake is used, engine speed
is limited to 2,300 r/min. Be sure the parking
brake is released before moving the throttle
lever. Otherwise, the engine will misfire, pre-
venting normal operation.
5FK-9-63-6 2/7/02 1:26 PM Page 10
Page 326 of 389
8-89
EBU00833Adjusting the rear brake light switch
The rear brake light switch, which is activated by
the brake pedal and brake lever, is properly
adjusted when the brake light comes on just
before braking takes effect. If necessary, adjust
the brake light switch as follows.
Turn the adjusting nut while holding the rear
brake light switch in place. To make the brake
light come on earlier, turn the adjusting nut in
direction a. To make the brake light come on
later, turn the adjusting nut in direction b.
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1. Rear brake light switch
2. Adjusting nut1. Contacteur de feu stop sur frein arrière
2.Écrou de réglage1. Interruptor de la luz de freno trasero
2. Tuerca de ajuste
5FK-9-63-8 2/7/02 1:28 PM Page 90
Page 348 of 389
8-111
EBU00861Tail/brake light bulb replacement
1. Remove the bulb holder (together with the
bulb) by turning it counterclockwise.
2. Remove the defective bulb from the bulb
holder by pushing it inward and turning it
counterclockwise.
3. Install a new bulb in the bulb holder by
pushing it inward and turning it clockwise.
4. Install the bulb holder (together with the
bulb).
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1. Bulb holder1. Fixation d’ampoule1. Portabombillas
1. Bulb holder 2. Bulb1. Fixation d’ampoule 2. Ampoule1. Portabombillas 2. Bombilla
5FK-9-63-8 2/7/02 1:28 PM Page 112
Page 374 of 389
10-5
Model YFZ350
Suspension:
Front suspension Double wishbone
Rear suspension Swingarm (link suspension)
Shock absorber:
Front shock absorber Coil spring/Oil damperRear shock absorber Coil spring/Gas-oil damper
Wheel travel:
Front wheel travel 230 mmRear wheel travel 220 mm
Electrical:
Ignition system C.D.I.Generator system C.D.I. magnetoHeadlight type: Krypton bulb
Bulb voltage, wattage ×quantity:
Headlight 12V, 30 W/30 W ×2
Tail/brake light 12V, 5 W/21 W ×1
5FK-9-63-9~11 2/7/02 1:29 PM Page 16