2003 YAMAHA YFM350R service

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
** Lithium-soap-based grease
NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
1. When disassembling the master cylinders or calipers, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
2. On the inner parts of the master cylinders and calipers, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
Wheel bearings*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Steering system*•Check operation.
•Repair if damaged.
•Check toe-in.
•Adjust if necessary.Front and rear
suspension*•Check operation.
•Correct if necessary.Upper and lower arm
pivot and steering shaft*•Lubricate every 6 months.**Rear arm pivot*
•Lubricate every 6 months.**Fittings and fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.Battery*•Check specific gravity.
•Check breather hose for proper routing.
•Correct if necessary.Lights and switches*•Check operation.
•Adjust headlight beam.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5NF62.book Page 8 Wednesday, May 8, 2002 1:40 PM

8-39 1. Locknut 2. Adjusting bolt
a. Throttle lever free play
1. Contre-écrou 2. Boulon de réglage
a. Jeu du levier d’accélération
1. Contratuerca 2. Perno de ajuste
a. Juego libre de la palanca del acelerador
EBU00307
Throttle lever adjustmentNOTE:Adjust the engine idling speed before adjusting the
throttle lever free play.1. Loosen the locknut.
2. Turn the adjusting bolt until the throttle lever
free play is 3–5 mm.
3. Tighten the locknut.
EBU00303
Valve clearance adjustment
The correct valve clearance changes with use, re-
sulting in improper fuel/air supply or engine noise.
To prevent this, the valve clearance must be ad-
justed regularly. This adjustment however, should
be left to a professional Yamaha service techni-
cian.
U5NF62.book Page 39 Wednesday, May 8, 2002 1:40 PM

8-47
EBU01186
Brake fluid replacement
Complete fluid replacement should be done only
by trained Yamaha service personnel. Have a
Yamaha dealer replace the following components
during periodic maintenance or when they are
damaged or leaking.

Replace the oil seals every two years.


Replace the brake hoses every four years.
U5NF62.book Page 47 Wednesday, May 8, 2002 1:40 PM

8-49 a. Brake lever free play
a. Jeu du levier de frein
a. Juego libre de la palanca de freno
EBU01188
Front brake lever free play
The front brake lever should have a free play of
zero mm at the lever end. If not, have a Yamaha
dealer check the brake system.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U5NF62.book Page 49 Wednesday, May 8, 2002 1:40 PM

8-51 a. Brake pedal position
a. Position de la pédale de frein
a. Posición del pedal de freno
EBU01079
Brake pedal height adjustment
The top of the brake pedal should be positioned
10 mm below the top of the footrest. If not, have a
Yamaha dealer adjust it.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident. After servic-
ing:

Make sure the brakes operate smoothly
and that the brake pedal position is cor-
rect.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U5NF62.book Page 51 Wednesday, May 8, 2002 1:40 PM

8-65 1. O-rings
1. Joints toriques
1. Juntas tóricas
EBU00805
Lubricating the drive chain
The drive chain must be cleaned and lubricated at
the intervals specified in the periodic maintenance
and lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or wet areas.
Service the drive chain as follows.CAUTION:_ The drive chain must be lubricated after wash-
ing the ATV or riding in the rain. _1. Clean the drive chain with kerosene and a
small soft brush.CAUTION:_ To prevent damaging the O-rings, do not clean
the drive chain with steam cleaners, high-pres-
sure washers or inappropriate solvents. _2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a
special O-ring chain lubricant.CAUTION:_ Do not use engine oil or any other lubricants
for the drive chain, as they may contain sub-
stances that could damage the O-rings. _
U5NF62.book Page 65 Wednesday, May 8, 2002 1:40 PM

8-94
7. Mettre une nouvelle ampoule de phare en place et
la fixer à l’aide de la fixation d’ampoule.ATTENTION:_ Ne jamais toucher le verre d’une ampoule de phare
afin de ne pas laisser de résidus graisseux. La graisse
réduit la transparence du verre mais aussi la lumino-
sité de l’ampoule, ainsi que sa durée de service. Net-
toyer soigneusement toute crasse ou trace de doigts
sur l’ampoule avec un chiffon imbibé d’alcool ou de
diluant pour peinture. _8. Mettre le cache de la fixation d’ampoule en place.ATTENTION:_ S’assurer de remettre le cache correctement en place
sur la fixation d’ampoule. _9. Remettre le cache de phare en place et le fixer à
l’aide de sa vis.
10. Remettre l’optique de phare en place et le fixer à
l’aide de son boulon.
11. Connecter les coupleurs de phare.
12. Remettre le bloc phare en place et le fixer à l’aide
de ses boulons.
13. Si nécessaire, ajuster le faisceau de phare.7. Coloque una bombilla del faro nueva en la po-
sición correcta y sujétela con el portabombillas.
AT E N C I O N :_ No toque la parte de vidrio de la bombilla del faro
para que no se ensucie de grasa, porque de lo
contrario se afectarían adversamente la transpa-
rencia del vidrio, la luminosidad de la bombilla, y
la vida útil de la bombilla. Limpie bien toda la su-
ciedad y las huellas dactilares de la bombilla del
faro empleando un paño humedecido en alcohol
o disolvente. _8. Instale la cubierta del portabombillas del faro.AT E N C I O N :_ Asegúrese de que la cubierta del portabombillas
del faro esté fijada con seguridad encima del
portabombillas. _9. Instale la cubierta de la unidad del faro enros-
cando el tornillo.
10. Instale la unidad del faro enroscando los
pernos.
11. Conecte los acopladores del faro.
12. Instale el conjunto de la unidad del faro enros-
cando los pernos.
13. Ajuste la orientación de la luz del faro si es ne-
cesario.
U5NF62.book Page 94 Wednesday, May 8, 2002 1:40 PM

8-99
EBU00413
Troubleshooting
Although Yamaha machines receive a rigid in-
spection before shipment from the factory, trouble
may occur during operation.
Any problem in the fuel, compression, or ignition
systems can cause poor starting and loss of pow-
er. The troubleshooting chart describes a quick,
easy procedure for making checks. If your ma-
chine requires any repair, take it to a Yamaha
dealer.
The skilled technicians at a Yamaha dealership
have the tools, experience, and know-how to prop-
erly service your machine. Use only genuine
Yamaha parts on your machine. Imitation parts
may look like Yamaha parts, but they are often in-
ferior. Consequently, they have a shorter service
life and can lead to expensive repair bills.
WARNING
Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe in-
jury or property damage. Make sure there are
no open flames or sparks in the area, including
pilot lights from water heaters or furnaces.
U5NF62.book Page 99 Wednesday, May 8, 2002 1:40 PM