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Yamaha TT350 TT350S 1985-2000 Service Repair Workshop Manual

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The Yamaha TT350 and TT350S are dual-sport motorcycles produced from 1985 to 2000, renowned for their reliable air-cooled engines, robust chassis, and capable off-road performance combined with street legality. These...
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Tipo: Motorcycle
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SKU: 57968
Yamaha TT350 TT350S 1985-2000 Service Repair Workshop ManualYamaha TT350 TT350S 1985-2000 Service Repair Workshop ManualYamaha TT350 TT350S 1985-2000 Service Repair Workshop ManualYamaha TT350 TT350S 1985-2000 Service Repair Workshop Manual
The Yamaha TT350 and TT350S are dual-sport motorcycles produced from 1985 to 2000, renowned for their reliable air-cooled engines, robust chassis, and capable off-road performance combined with street legality. These models represent a commitment to producing dependable and versatile machines, offering a balanced experience for riders tackling varied terrains. With a 4-stroke, single-cylinder engine displacing approximately 347cc, featuring SOHC and CDI ignition, the TT350 series provides a solid foundation for both adventure and everyday riding. Its heritage is rooted in extensive experience in motorcycle engineering, particularly in the dual-sport segment, positioning it as a capable alternative to contemporaries like the Honda XR and Suzuki DR series. This comprehensive service repair workshop manual provides detailed information for the Yamaha TT350 and TT350S models spanning the years 1985 through 2000. It covers all essential aspects of maintenance, repair, and troubleshooting, including complete engine overhaul, transmission service, fuel system maintenance, electrical system diagnostics, suspension and brake servicing, and frame and bodywork. The manual offers step-by-step instructions for routine maintenance, disassembly and assembly procedures, and in-depth technical specifications. Its purpose is to empower owners, mechanics, and technicians with the knowledge required to effectively maintain, diagnose, and repair these motorcycles, ensuring optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TT350 / TT350S
Codes
Model Codes:
TT350, TT350S
👋 Introduction
Market Position
Segment:
Dual-sport / Enduro Motorcycle
Competitive Analysis
Competitors:
Honda XR series, Kawasaki KLR series, Suzuki DR series
Key Features
Attributes:
Reliable air-cooled engine, robust chassis, capable off-road performance with street legality
📋 Manual Details
Coverage Areas
Applicable Years:
1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, tuning, troubleshooting, component identification, specifications
Transmission:
Gearbox inspection, repair, clutch service, shift mechanism, lubrication
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel pump, fuel lines, tank maintenance
Electrical System:
Ignition system, stator, CDI unit, lighting, wiring diagrams, battery service, starting system
Suspension:
Front forks (telescopic), rear monoshock, linkages, adjustments, servicing
Brakes:
Front and rear brake system maintenance, caliper overhaul, pad replacement, fluid bleeding, drum brake service
Frame And Bodywork:
Chassis inspection, swingarm, steering head bearings, body panel removal and installation, seat, fenders
Wheels And Tires:
Wheel bearing service, spoke tensioning, tire selection and installation, rim maintenance
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, spark plug service
Troubleshooting:
Diagnostic procedures for common problems, electrical faults, engine performance issues
Repair:
Step-by-step repair instructions for all major components and systems
Disassembly And Assembly:
Detailed guides for dismantling and reassembling various motorcycle parts
Technical Depth
Depth:
Comprehensive coverage from basic owner maintenance to full engine and transmission rebuilds
📊 Manual Specifications
File Format
Compatibility:
Compatible with all PDF readers on PC, Mac, tablets, and smartphones
Print Quality
Quality:
High-resolution scans for clear text and diagrams
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
4-stroke, Single-cylinder, SOHC
Displacement:
347 cc (approx.)
Bore X Stroke:
74.0 x 80.0 mm (Typical for this era and displacement)
Compression Ratio:
9.5:1 (Approximate)
Cooling System:
Air-cooled
Ignition:
CDI (Capacitor Discharge Ignition)
Performance
Horsepower:
Approx. 25-30 HP (Estimated based on typical class performance)
Torque:
Approx. 20-24 Nm (Estimated)
Fuel System
Carburetor Type:
Single Mikuni carburetor (e.g., VM34 or similar)
Fuel Type:
Unleaded gasoline (87 octane or higher recommended)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Features
Clutch:
Wet, multi-plate
Drive Type:
Chain Drive
📐 Dimensions
Exterior
Length:
Approx. 2170 mm (Varies slightly by year/spec)
Width:
Approx. 830 mm (Handlebar width)
Height:
Approx. 1220 mm (Seat height varies)
Weights
Dry Weight:
Approx. 125-130 kg
Fuel Tank Capacity:
Approx. 10 Liters (2.6 US gal)
🛡️ Safety Features
Ratings
Crash Test Data:
N/A (Motorcycle specific crash ratings not typically applicable in the same way as cars)
Active Features
Braking System:
Front: Disc brake, Rear: Drum brake (early models) or Disc brake (later/S models)
💡 Technology Features
Infotainment
Features:
N/A (Basic motorcycle instrumentation: speedometer, odometer, neutral indicator, high beam indicator)
Driver Assistance
Features:
N/A (No electronic rider aids typical for this era of dual-sport)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 km or 6 months (refer to manual for specifics)
Air Filter Cleaning:
Every 1,000 km or as needed in dusty conditions
Spark Plug Replacement:
Every 6,000 km (or check gap and condition)
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher (e.g., Yamalube 4-stroke motorcycle oil)
Engine Oil Capacity:
Approx. 1.6 Liters without filter change, 1.8 Liters with filter change (confirm in manual)
Brake Fluid Type:
DOT 3 or DOT 4 (Check caliper/master cylinder for specific recommendation)
Transmission Oil Type:
Refer to engine oil specifications, as it's often a shared sump.
Known Issues
Common Wear Items:
Cam chain tensioner, carburetor jetting issues due to age, fork seal leaks, exhaust pipe corrosion.
Electrical Quirks:
Stator output degradation over time, CDI unit failure (less common but possible), aging wiring harness insulation.
📚 Vehicle History
Brand Heritage
Heritage:
Yamaha's long-standing reputation for reliable and performance-oriented motorcycles, especially in off-road and dual-sport categories.
Model Evolution
Evolution:
The TT350 was part of Yamaha's 'True Dual-Purpose' line, evolving from earlier TT models and contributing to the development of modern dual-sport bikes. The 'S' designation often indicated sportier or slightly upgraded features, potentially including disc brakes front and rear or revised suspension.
Production
Production Period:
1985 - 2000
🏆 Awards & Recognition
Recognitions
Historical Acclaim:
The TT350 series was generally well-regarded for its reliability and balance of off-road capability and street manners within its class during its production run. Specific awards are not widely documented for individual model years.
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