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Yamaha YFM350S 2003 User Manual

Yamaha YFM350S 2003
42 pages
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5YT-28107-70
YFM350S
ASSEMBLY MANUAL
MANUEL DE MONTAGE
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Yamaha YFM350S 2003 Specifications

General IconGeneral
BrandYamaha
ModelYFM350S 2003
CategoryOffroad Vehicle
LanguageEnglish

Summary

Assembly Manual Foreword

Assembly Manual Introduction

Provides essential information for the correct assembly of the Yamaha machine before delivery.

Assembly Notices and Symbols

Safety and Operational Notices

Explains warning symbols, caution notes, and general notices for safe assembly.

Key Assembly Symbols Explained

Explains common symbols for fluids, tools, torque, and directions.

Preparation for Assembly

Setup Requirements and Safety

Outlines necessary supplies, workshop conditions, and self-protection measures.

Crate Handling and Unpacking

Details crate symbols and step-by-step unpacking instructions.

Unpacking Procedures

Step-by-Step Unpacking Guide

Detailed steps for removing the machine and its components from packaging.

Parts Location and Identification

Component Location Diagrams

Illustrates the location of parts within packaging, including bubble wrap and carton boxes.

Detailed Parts Identification

Lists specific parts found in bubble wrap packs and carton boxes, including dimensions.

Setup and Predelivery Checklist

Installation of Crate Parts

Checklist for installing parts that were included in the crate.

Tightening Torque Specifications

Lists parts and their required tightening torque values for assembly.

Wire and Cable Routing

Lists items requiring specific wire and cable routing during setup.

Pre-Delivery Adjustments

Lists various adjustments to be performed before delivering the machine.

Function and Performance Checks

Verifies the proper operation of lights, indicators, and brake system.

Accessories for Delivery

Confirms that essential accessories like manuals and toolkits are provided.

Machine Setup Procedures

Step-by-Step Assembly Instructions

Follow numerical order for assembly steps involving various parts of the machine.

Front Shock Absorber Installation

Instructions for installing front shock absorbers and tightening related hardware.

Front Wheel Installation

Guide for installing front wheels and tightening nuts to specification.

Rear Wheel Installation

Steps for installing rear wheels and ensuring proper nut tightening.

Handlebar Installation

Guidance on installing the handlebar, holders, and tightening bolts.

Front Brake Master Cylinder Installation

Steps for mounting the front brake master cylinder and tightening bolts.

Clutch and Parking Brake Lever Assembly

Instructions for installing the clutch/parking brake lever assembly and checking operation.

Handlebar Cable Ties

Securing handlebar switch leads and clutch switch leads using bands.

Handlebar Cover Installation

Installing indicator light sockets and routing the fuel tank breather hose.

Foot Protector Installation

Steps for installing foot protectors, including tightening nuts and bolts.

Engine Skid Plate Installation

Instructions for mounting the engine skid plate and tightening its bolts.

Front Bumper Installation

Guide for installing the front bumper and tightening associated bolts.

Swingarm Guard Installation

Steps for attaching the swingarm guard and tightening nuts.

Battery Installation and Connection

Procedures for charging, mounting the battery, and connecting leads correctly.

Owner's Manual Storage

Instructions for properly storing the owner's manual in the vehicle's storage box.

Owner's Tool Kit Securing

How to secure the owner's tool kit and low-pressure air gauge.

Seat Installation

Guide for installing the seat by engaging its lobes and pressing down.

Front Reflector Installation

Details for installing front reflectors, including part numbers and quantities.

Rear Reflector Installation

Instructions for installing rear reflectors, specifying parts and quantities.

Cable Routing Guide

Cable Routing Procedures

Detailed steps for routing brake hoses, throttle cables, and electrical leads.

Battery Connection and Lead Management

Battery Lead Management

Guidance on connecting battery leads and routing the tail/brake light lead.

Adjustments and Predelivery Service Guide

Predelivery Service Sequence

Outlines the order of operations for pre-delivery service based on letter indicators.

Battery Check and Charge

Step-by-step guide for checking battery charge and proper charging procedures.

Tire Pressure Check

Instructions for checking tire pressure with crucial warnings about inflation levels.

Tire Inflation Specifications and Warnings

Details recommended and minimum tire pressures, and warnings about pressure extremes.

Fuel Draining Procedure

Safe steps for draining fuel from the carburetor, including flammable warnings.

Engine Oil Level Check

Guide to checking engine oil level, recommended lubricants, and cautions.

Engine Idling Speed Adjustment

Procedures for setting the correct engine idling speed.

Throttle Lever Free Play Adjustment

Steps to adjust the throttle lever free play for proper operation.

Rear Brake Pedal Height Adjustment

Guide for adjusting the rear brake pedal height and checking for drag.

Rear Brake Light Switch Adjustment

Adjusting the timing of the rear brake light switch activation.

Brake Fluid Level Check

Procedures for checking and topping up the brake fluid level.

Clutch Cable Free Play Adjustment

Steps to adjust the clutch cable free play for optimal clutch operation.

Hydraulic Brake System Bleeding

Detailed steps for bleeding the hydraulic brake system to remove air.

Parking Brake Adjustment

Guide for adjusting the parking brake cable end length and checking for drag.

Drive Chain Slack Adjustment

Steps for adjusting the drive chain slack and ensuring proper alignment.

Front Shock Absorber Adjustment

Guide for adjusting the spring preload on front shock absorbers.

Rear Shock Absorber Adjustment

Steps for adjusting the rear shock absorber spring preload.

Headlight Beam Adjustment

Instructions for vertically adjusting the headlight beams.

Technical Appendices

Service Data Specifications

Provides key specifications such as engine idling speed, spark plug gap, fuel type, and valve clearance.

Standard Equipment Included

Lists the standard equipment provided with the machine, including manuals and tools.

Owner's Tool Kit Contents

Details the specific tools and items included in the owner's tool kit.

Tightening Torque Specifications

Chassis and Engine Fastener Torques

Comprehensive list of torque values for chassis and engine fasteners.

Suspension and Drivetrain Fastener Torques

Torque specifications for suspension, drivetrain, and wheel hub components.

Brake and Accessory Fastener Torques

Torque values for brake system parts, bumpers, guards, and accessories.

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