1987-1990 Yamaha ATV YFM350ER Master Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YFM350ER Model Nickname: Big Bear Model Variant: 2WD (Rear-Wheel Drive) Generation Generation Code: First Generation (YFM350ER Series) Codes Engine Code: 350cc Air-Cooled 4-Stroke...

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Type: Atv

Vendor:

Sku: 41524

Tags: 1987 1988 1989 1990 Atv Misc Motorcycles Yamaha YFM350ER

Product variants

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YFM350ER

Model Nickname:

Big Bear

Model Variant:

2WD (Rear-Wheel Drive)

Generation

Generation Code:

First Generation (YFM350ER Series)

Codes

Engine Code:

350cc Air-Cooled 4-Stroke SOHC

👋 Introduction

Market Position

Atv Segment:

Utility/Recreational ATV

Target Audience:

Outdoor enthusiasts, farmers, hunters, and recreational riders.

Competitive Analysis

Competitors Era:

Honda FourTrax 300, Suzuki QuadSport LT-F250, Kawasaki Bayou 300.

Key Features

Vehicle Strengths:

Reliability, torquey engine, comfortable suspension for its time, ease of maintenance.

Manual Value Proposition:

Essential resource for owners to maintain, diagnose, and repair their YFM350ER, extending its lifespan and performance.

📋 Manual Details

Coverage Areas

Covered Years:

1987, 1988, 1989, 1990

Primary Coverage:

Comprehensive service and repair for Yamaha YFM350ER ATV

Page Count

Estimated Pages:

High, exceeding 300 pages (typical for master service manuals of this era)

Manual Type

Manual Type:

Master Service Manual

Manual Category:

Official Factory Service Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, overhaul, and reassembly of the 350cc engine.

Fuel System:

Carburetor (Mikuni VM Series) tuning, cleaning, and rebuilding; fuel tank, lines, and petcock service.

Ignition System:

CDI ignition system, spark plug specifications, troubleshooting, and component testing.

Exhaust System:

Muffler and exhaust pipe inspection, maintenance, and potential replacement.

Cooling System:

Air-cooling system optimization, cylinder head temperature considerations.

Transmission Drivetrain:

5-speed constant mesh transmission with reverse, clutch operation, final drive (chain and sprocket) maintenance.

Suspension Front:

Independent front suspension (IFS) maintenance, shock absorber adjustment, and fork seal replacement.

Suspension Rear:

Swingarm rear suspension, monoshock absorber adjustment, and linkage maintenance.

Brakes:

Front and rear drum brake system service, adjustment, and replacement of brake shoes.

Wheels Tires:

Wheel bearing inspection and service, tire pressure recommendations, and chain tension adjustment.

Electrical System:

Wiring diagrams, battery maintenance, lighting system, and starter motor operation.

Frame Chassis:

Frame inspection, steering system maintenance, and lubrication points.

Bodywork Plastics:

Fender, seat, and other body panel maintenance and removal/installation procedures.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain adjustments, brake adjustments, lubrication.

Troubleshooting:

Diagnostic charts and procedures for common problems across all major systems.

Engine Rebuild:

Detailed instructions for complete engine disassembly, part inspection, machining specifications, and reassembly.

Transmission Overhaul:

Step-by-step guide for transmission disassembly, gear inspection, and reassembly.

Carburetor Rebuild:

Instructions for dismantling, cleaning, reassembling, and adjusting the Mikuni VM carburetor.

Suspension Service:

Fork seal replacement, shock absorber adjustments, and linkage lubrication.

Brake System Maintenance:

Drum brake shoe replacement, adjustment procedures, and lever play settings.

Electrical Diagnostics:

Testing of ignition components, lighting circuits, and starting system.

Technical Depth

Depth Level:

Expert-level diagnostic and repair procedures, suitable for professional technicians and experienced DIYers.

Detail Level:

Includes torque specifications, clearance measurements, timing procedures, and detailed diagrams.

📊 Manual Specifications

File Format

Compatibility:

Compatible with all major operating systems (Windows, macOS, Linux).

Searchability:

Likely text-searchable PDF, allowing for quick access to specific topics.

Print Quality

Printability:

Printable, allowing users to create physical copies for workshop use.

Binding Type

Binding Type Digital:

N/A (Digital PDF Download)

Paper Type

Paper Type Digital:

N/A (Digital PDF Download)

Requirements

Software Requirement:

Adobe Acrobat Reader or compatible PDF viewer.

Delivery

Download Speed:

Instant High-Speed Download

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, air-cooled

Displacement:

348 cc

Bore X Stroke:

83.0 mm x 64.5 mm

Compression Ratio:

8.7:1

Performance

Horsepower Estimated:

Approx. 20-25 HP (at flywheel, may vary)

Torque Estimated:

Approx. 20-24 lb-ft (at flywheel, may vary)

Fuel System

Carburetor Model:

Mikuni VM34SS (or similar variant)

Fuel Type:

Unleaded gasoline

Lubrication

Oil Capacity:

1.7 Liters (Dry)

Recommended Oil:

Yamalube 4 (or equivalent API SE, SF, SG or higher, SAE 10W-30, 10W-40, or 20W-40)

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Spark Plug Type:

NGK DR8EA (or equivalent)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh with reverse

Clutch Type:

Wet multi-plate

Final Drive:

O-ring sealed chain

Features

Gear Selection:

Semi-automatic (foot shifter)

Fluid Specifications

Transmission Oil Type:

Yamalube 4 (or equivalent API SE, SF, SG or higher, SAE 10W-30, 10W-40, or 20W-40)

📐 Dimensions

Exterior

Overall Length:

Approx. 70.5 inches (1790 mm)

Overall Width:

Approx. 41.1 inches (1045 mm)

Overall Height:

Approx. 41.5 inches (1055 mm)

Wheelbase:

Approx. 47.2 inches (1200 mm)

Ground Clearance:

Approx. 4.9 inches (125 mm)

Weights

Dry Weight:

Approx. 456 lbs (207 kg)

Fuel Capacity:

2.6 gallons (9.8 Liters)

Tires

Front Tire Size:

AT22x7-10

Rear Tire Size:

AT22x10-10

Wheels

Wheel Type:

Steel, stamped

Suspension Travel

Front Suspension Travel:

Approx. 5.5 inches (140 mm)

Rear Suspension Travel:

Approx. 5.1 inches (130 mm)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Designed to meet ANSI standards for All-Terrain Vehicles (may not have specific crash ratings like cars).

Active Features

Braking System:

Front and rear drum brakes, parking brake.

Passive Features

Ergonomics:

Designed for rider stability and control with handlebars and footwells.

Lighting:

Halogen headlights and taillight for visibility.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Basic utility ATV, no infotainment systems).

Driver Assistance

Driver Assistance Features:

N/A (Basic utility ATV, no electronic driver assistance features).

Connectivity

Connectivity Features:

N/A (No electronic connectivity features).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1000 km (600 miles) or 6 months, whichever comes first.

Oil Filter Change:

At every engine oil change.

Spark Plug Inspection:

Every 2000 km (1200 miles) or 12 months.

Air Filter Cleaning:

Every 500 km (300 miles) or 3 months, or more frequently in dusty conditions.

Chain Lubrication:

Every 500 km (300 miles) or after riding in wet conditions.

Chain Tension Adjustment:

Every 1000 km (600 miles) or 6 months.

Brake Adjustment:

As needed, checking lever play and drum clearance.

Fluid Specifications

Transmission Oil Spec:

Yamalube 4 (or equivalent SAE 10W-30/10W-40)

Brake Fluid Type:

DOT 3 (typically, manual will specify)

Known Issues

Common Wear Items:

Brake shoes, rear brake cables, swingarm bushings, carburetor jets due to fuel variations.

Potential Problems:

Carburetor performance degradation over time, potential for overheating if air cooling is obstructed.

Preventative Maintenance

Importance Of Cleaning:

Regular cleaning of air filter and cooling fins is crucial for engine longevity and performance.

📚 Vehicle History

Brand Heritage

Yamaha Atv Legacy:

Yamaha has been a pioneer in the ATV industry, known for robust engineering and off-road performance.

Model Evolution

Yfm350Er Introduction:

Introduced as a successor to earlier 250cc models, offering increased displacement and improved chassis design.

Key Updates Era:

Received minor updates throughout its production run, primarily in styling and accessory options.

Production

Production Period:

1987-1990 for the YFM350ER model (part of the broader YFM350 lineage).

Manufacturing Location:

Japan (Typical for Yamaha ATVs of this era)

🏆 Awards & Recognition

Recognitions

Historical Atv Awards:

While specific awards for the YFM350ER are not widely documented, Yamaha's ATVs of this era were generally well-regarded for their durability and utility.