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Yamaha_TT350S Service Repair & Maintenence Manual
TOTAL 229 PAGES
CONTENTS
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY ALL REPLACEMENT PARTS GASKETS, OIL SEALS, AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS
SPECIAL TOOLS
FOR TUNE UP FOR ENGINE SERVICE FOR CHASSIS SERVICE FOR ELECTRICAL COMPONENTS
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE CHASSIS ELECTRICAL
GENERAL TORQUE SPECIFICATIONS
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE CHASSIS
LUBRICATION DIAGRAM
CABLE ROUTING
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION
SEAT, FUEL TANK AND COVERS
REMOVAL INSTALLATION
ENGINE
VALVE CLEARANCE ADJUSTMENT TIMING CHAIN ADJUSTMENT IDLING SPEED ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT SPARK PLUG INSPECTION IGNITION TIMING CHECK COMPRESSION PRESSURE MEASUREMENT ENGINE OIL LEVEL INSPECTION ENGINE OIL REPLACEMENT OIL PRESSURE INSPECTION CLUTCH ADJUSTMENT AIR FILTER CLEANING SPARK ARRESTER CLEANING CRANKCASE BREATHER HOSE INSPECTION FUEL LINE INSPECTION EXHAUST SYSTEM INSPECTION CARBURETOR JOINT INSPECTION
CHASSIS
FRONT BRAKE ADJUSTMENT REAR BRAKE ADJUSTMENT BRAKE FLUID LEVEL INSPECTION AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE PAD INSPECTION BRAKE HOSE INSPECTION DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN LUBRICATION STEERING HEAD ADJUSTMENT FRONT FORK INSPECTION
FRONT FORK ADJUSTMENT
REAR SHOCK ABSORBER ADJUSTMENT TIRE INSPECTION WHEEL INSPECTION SPOKES INSPECTION AND TIGHTENING CABLE INSPECTION AND LUBRICATION LEVER AND PEDAL LUBRICATION SIDESTAND LUBRICATION
ELECTRICAL
BATTERY INSPECTION FUSE INSPECTION HEADLIGHT BEAM ADJUSTMENT HEADLIGHT BULB REPLACEMENT
CHAPTER 4
ENGINE OVERHAUL
ENGINE REMOVAL
SEAT, FUEL TANK AND COVERS CARBURETOR ENGINE GUARD ENGINE OIL BATTERY EXHAUST PIPE CRANKCASE BREATHER HOSE STARTER MOTOR CLUTCH CABLE AND LEADS DRIVE SPROCKET FOOTREST AND BRAKE PEDAL ENGINE REMOVAL
ENGINE OISASSEMBLY
CYLINDER HEAD, CAMSHAFTS, CYLINDER AND PISTON CLUTCH, OIL PUMP AND BALANCER GEAR SHIFT SHAFT ROTOR AND STARTER DRIVES OIL FILTER
CRANKCASE BALANCER, TRANSMISSION AND SHIFTER CRANKSHAFT BEARINGS AND OIL SEALS VALVE
INSPECTION AND REPAIR
CYLINDER HEAD VALVE SEAT VALVE AND VALVE GUIDE VALVE SPRING CAMSHAFT VALVE LIFTER TIMING CHAIN, SPROCKET AND CHAIN GUIDE CYLINDER AND PISTON PISTON RING PISTON PIN CRANKSHAFT BALANCER DRIVE GEAR AND BALANCER GEAR PRIMARY DRIVE CLUTCH TRANSMISSION AND SHIFTER OIL PUMP AND STRAINER ELECTRIC STARTER DRIVE CRANKCASE BEARING AND OIL SEAL CIRCLIP AND WASHER
ENGINE ASSEMBLY AND ADJUSTMENT
CRANKSHAFT AND BALANCER CRANKSHAFT AND BALANCER SHAFT TRANSMISSION SHIFTER TRANSMISSION AND SHIFTER CRANKCASE CRANKCASE (RIGHT) SHIFT SHAFT OIL PUMP CLUTCH OIL PUMP CLUTCH OIL FILTER ROTOR AND STARTER DRIVES ROTOR AND STARTER DRIVES CYLINDER AND
PISTON CYLINDER AND PISTON
CYLINDER HEAD VALVE, CAMSHAFT AND CAM CHAIN VALVE AND CAMSHAFT CYLINDER HEAD REMOUNTING ENGINE
CARBURETOR
REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION FUEL LEVEL ADJUSTMENT THROTTLE VALVE POSITION
CHAPTER 6
CHASSIS
FRONT WHEEL
REMOVAL INSPECTION INSTALLATION WHEEL STATIC BALANCE ADJUSTMENT
REAR WHEEL
REMOVAL INSPECTION INSTALLATION WHEEL STATIC BALANCE ADJUSTMENT
FRONT AND REAR BRAKE
BRAKE PAD REPLACEMENT CALIPER DISASSEMBLY MASTER CYLINDER DISASSEMBLY INSPECTION AND REPAIR CALIPER ASSEMBLY MASTER CYLINDER ASSEMBLY
FRONT FORK
REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION STEERING HEAD AND HANDLEBAR REMOVAL INSPECTION INSTALLATION
REAR SHOCK ABSORBER AND SWINGARM HANDLING NOTES NOTES ON DISPOSAL REMOVAL INSPECTION INSTALLATION
DRIVE CHAIN AND SPROCKETS REMOVAL INSPECTION INSTALLATION
CHAPTER 7
ELECTRICAL
TTR250L(C) CIRCUIT DIAGRAM
ELECTRICAL COMPONENTS
CHECKING OF CONNECTIONS
IGNITION SYSTEM
ELECTRICAL STARTING SYSTEM STARTING CIRCUIT OPERATION STARTER MOTOR
CHARGING SYSTEM
LIGHTING SYSTEM
LIGHTING SYSTEM CHECK
STARTING FAILURE/HARD STARTING FUEL SYSTEM ELECTRICAL SYSTEM COMPRESSION SYSTEM
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
FAULTY GEAR SHIFTING HARD SHIFTING SHIFT PEDAL DOES NOT MOVE JUMP-OUT GEAR
CLUTCH SLIPPING/DRAGGING CLUTCH SLIPPING CLUTCH DRAGGING
OVERHEATING
OVERHEATING
FAULTY BRAKE
POOR BRAKING EFFECT
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LEAKAGE MALFUNCTION
INSTABLE HANDLING
INSTABLE HANDLING
FAULTY SIGNAL AND LIGHTING SYSTEM HEADLIGHT DARK BULB BURNT OUT
TTR250L(C) WIRING DIAGRAM
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