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2001-2004 Yamaha Warrior 350 Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: Warrior 350 Model Nickname: Banshee Killer Codes Model Code Range: YFM350X Engine Code Family: 350cc 4-stroke OHV 👋 Introduction Market Position Vehicle Segment:...
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Type: Motorcycle
Vendor:
Sku: 496900
2001-2004 Yamaha Warrior 350 Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Warrior 350
Model Nickname:
Banshee Killer
Codes
Model Code Range:
YFM350X
Engine Code Family:
350cc 4-stroke OHV
👋 Introduction
Market Position
Vehicle Segment:
Performance Sport ATV
Target Audience:
Enthusiasts, off-road riders, recreational users seeking performance and reliability
Competitive Analysis
Key Competitors:
Suzuki LT250R, Honda TRX250R, Kawasaki Tecate-4
Key Features
Engine Characteristic:
Torquey and reliable air-cooled engine known for its low-end grunt
Handling:
Agile and predictable handling, popular for trail riding and general sport use
Durability:
Renowned for its robust construction and long-term reliability
Value Proposition
Manual Value:
Essential resource for owners to maintain, diagnose, and repair their Warrior 350 efficiently
📋 Manual Details
Coverage Areas
Applicable Years:
2001, 2002, 2003, 2004
General Coverage:
Comprehensive service and repair for all major components
Page Count
Estimated Page Count:
300-400 pages (estimated for comprehensive factory service manual)
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, inspection, overhaul, and reassembly
Fuel System:
Carburetor service and tuning, fuel tank, fuel lines, fuel pump
Ignition System:
CDI unit, ignition coil, spark plug specifications, timing
Transmission Drivetrain:
Clutch operation, gear shifting mechanisms, final drive, axle maintenance
Cooling System:
Radiator, fan, coolant specifications, flow diagnostics (if applicable)
Electrical System:
Wiring diagrams, battery, starter, lighting, charging system
Suspension Steering:
Front and rear suspension, steering components, alignment specifications
Braking System:
Hydraulic brake system, caliper service, rotor inspection, brake fluid specifications
Wheels Tires:
Tire pressure, wheel bearing service, tire replacement guidelines
Frame Chassis:
Frame inspection, component mounting, skid plate installation
Bodywork Plastics:
Panel removal and installation, decal placement
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, lubrication points
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based repair guidance
Repair:
Detailed step-by-step instructions for component disassembly, repair, and reassembly
Rebuilds:
Full engine and transmission rebuild procedures
Diagnostics:
Diagnostic tests for electrical components and engine performance
Technical Depth
Depth Level:
Factory Level / Professional Technician
Detail Level:
Comprehensive, including torque specifications, clearances, and tolerances
Special Tools:
Identification and usage of specialized tools required for certain procedures
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable (typically for official factory manuals)
Print Quality
Image Resolution:
High-resolution diagrams and images for clarity
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, air-cooled
Displacement:
348cc
Bore X Stroke:
83.0 mm x 64.5 mm
Compression Ratio:
9.5:1
Valve Configuration:
SOHC, 2 valves per cylinder
Performance
Horsepower:
Approximately 21-23 HP (estimated, varies with tuning)
Torque:
Approximately 20-22 lb-ft (estimated, varies with tuning)
Fuel System
Carburetor Type:
Mikuni VM34SS (single carburetor)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Lubrication
Oil Type:
Yamalube 4 (or equivalent SAE 10W-40 motorcycle oil)
Oil Capacity:
1.75 L (1.85 US qt) without filter change, 1.90 L (2.01 US qt) with filter change
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed manual with reverse
Optional
Transmission Options:
N/A (standard 6-speed manual)
Features
Clutch Type:
Wet, multi-plate
Final Drive:
O-ring sealed chain drive
Fluid Specifications
Transmission Oil Type:
Yamalube 4 (or equivalent SAE 10W-40 motorcycle oil)
Transmission Oil Capacity:
0.90 L (0.95 US qt)
📐 Dimensions
Exterior
Overall Length:
1,845 mm (72.6 in)
Overall Width:
1,150 mm (45.3 in)
Overall Height:
1,020 mm (40.2 in)
Wheelbase:
1,280 mm (50.4 in)
Ground Clearance:
110 mm (4.3 in)
Weights
Curb Weight:
Approximately 208 kg (459 lbs)
Fuel Tank Capacity:
11 L (2.9 US gal)
🛡️ Safety Features
Ratings
Atv Safety Standards:
Designed to meet ANSI standards for recreational ATVs
Active Features
Throttle Limiter:
Adjustable throttle stop screw for controlling speed (user adjustable)
Passive Features
Frame Construction:
High-tensile steel frame for rigidity and durability
Parking Brake:
Integrated parking brake system
💡 Technology Features
Infotainment
Infotainment System:
N/A (basic sport ATV)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first
Air Filter Cleaning:
Every 20 hours or before riding in dusty conditions
Spark Plug Inspection:
Every 100 hours or 12 months
Chain Lubrication Adjustment:
Every 500 km (300 miles) or weekly during heavy use
Fluid Specifications
Engine Oil Spec:
SAE 10W-40 API SG or higher (Yamalube 4)
Brake Fluid Spec:
DOT 3 or DOT 4 hydraulic brake fluid
Known Issues
Carburetor Fouling:
Can occur due to infrequent use or poor fuel quality, leading to starting or running issues.
Camshaft Wear:
In some high-mileage units, wear on the camshaft lobes can occur, affecting valve timing and performance.
Rear Axle Bearings:
Can require periodic inspection and replacement, especially under heavy use or after submersion.
Recommended Maintenance Items
Air Filter Part Number:
3X4-14451-00-00 (example, confirm with manual)
Oil Filter Part Number:
5JX-13440-00-00 (example, confirm with manual)
📚 Vehicle History
Brand Heritage
Yamaha Atv Legacy:
Yamaha has a long-standing reputation for producing reliable and high-performance ATVs.
Model Evolution
Warrior Lineage:
The Warrior 350 is an evolution of Yamaha's popular sport ATV line, offering a blend of performance and usability.
Production
Production Period:
Originally introduced in the mid-1980s, with continuous updates through the early 2000s.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards may vary, the Warrior 350 is widely recognized for its enduring popularity and capability in the sport ATV market.
Ratings
Owner Satisfaction:
Consistently high owner satisfaction due to reliability and performance.
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