🏷️ Basic Information

Make:

Yamaha

Model:

TT350

Product Name:

Yamaha TT350 1985-2000 Factory Service Manual Repair PDF

👋 Introduction

Target Audience:

Owners and mechanics of Yamaha TT350 motorcycles requiring in-depth repair and maintenance information.

Value Proposition:

Provides factory-level accuracy and detail, essential for proper maintenance and repair, saving time and money compared to generic guides.

Manual Advantage:

Directly from Yamaha's factory documentation, ensuring precision in procedures and specifications. Covers a significant model run.

📋 Manual Details

Applicable Years:

1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000

Estimated Page Count:

400-600 (typical for this era and model)

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Systems:

Engine overhaul, cylinder head, piston, crankshaft, camshaft, valve train, lubrication system, cooling system (air-cooled specific details), fuel system (carburetor tuning, jets, float levels), ignition system, starting system, exhaust system.

Drivetrain Systems:

Clutch operation and adjustment, gearbox disassembly and reassembly, gear ratios, shift mechanism, final drive (chain and sprockets), lubrication.

Chassis Suspension Steering:

Front fork (suspension travel, oil type and level, damping adjustments), rear shock absorber (spring preload, damping), swingarm, bearings, steering head bearings, wheel alignment, spoke tensioning.

Braking Systems:

Front and rear drum brakes (or disc brakes if applicable), brake pad replacement, brake lever adjustment, brake fluid specifications (if hydraulic), caliper maintenance (if disc), brake cable lubrication and adjustment.

Electrical Systems:

Wiring diagrams, lighting system (headlight, taillight, turn signals), battery, charging system (stator, rectifier/regulator), ignition coil, spark plug specifications, fuses, switches, instrument panel.

Bodywork Frame:

Frame inspection, fuel tank removal and installation, seat assembly, fender mounting, handlebar replacement, control cable routing and adjustment.

Scheduled Maintenance:

Oil change intervals, filter replacement, air filter cleaning/replacement, spark plug inspection and replacement, chain lubrication and adjustment, brake adjustment, clutch adjustment, valve clearance checks and adjustment, wheel bearing lubrication.

Troubleshooting:

Diagnostic flowcharts for common starting, running, and electrical issues. Identification of symptoms and likely causes.

Repair Rebuild:

Detailed step-by-step instructions for engine disassembly, transmission overhaul, carburetor rebuilding, suspension component replacement, and electrical system repairs.

Technical Specifications:

Torque specifications for all fasteners, clearances (valve, piston-to-cylinder), fluid capacities, ignition timing, carburetor settings, suspension settings.

Depth Of Coverage:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Includes detailed diagrams and illustrations.

📊 Manual Specifications

File Format Quality:

High-resolution PDF, searchable text, printable pages.

Print Quality Note:

Digital PDF format allows for clear viewing and printing of all diagrams and text.

Binding Type Note:

N/A (Digital PDF download)

Paper Type Note:

N/A (Digital PDF download)

⚙️ Engine Specifications

Engine Type:

4-stroke, SOHC, air-cooled

Displacement:

348cc (approximate, may vary slightly by year/variant)

Bore X Stroke:

78.0 mm x 72.0 mm (typical for this displacement, check manual for exact)

Compression Ratio:

9.5:1 (typical, check manual for exact)

Horsepower Rating:

Approx. 27-30 HP (estimated, actual varies by year and tuning)

Torque Rating:

Approx. 22-24 lb-ft (estimated)

Carburetor Type:

Mikuni VM34SS (typical, check manual for specific year variant)

Fuel Type:

Unleaded gasoline (Octane rating as specified in manual, typically 87-91 AKI)

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

📐 Dimensions

Length:

Approx. 2185 mm (may vary slightly)

Width:

Approx. 825 mm (may vary slightly)

Height:

Approx. 1210 mm (may vary slightly)

Dry Weight:

Approx. 124 kg (1986 model, may vary)

Fuel Tank Capacity:

11 L (2.9 US gal)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycle, not subject to automotive crash ratings)

Active Safety Features:

Effective braking systems (drum/disc depending on variant), responsive handling.

Passive Safety Features:

Sturdy frame construction, ergonomic rider controls.

💡 Technology Features

Infotainment Features:

N/A (basic motorcycle instrumentation: speedometer, odometer, neutral indicator, high beam indicator).

🔧 Maintenance

Oil Change Interval:

Every 1,000-1,500 miles or 6 months (refer to manual for exact)

Air Filter Maintenance:

Clean every 500-1,000 miles, replace as needed

Valve Clearance Check:

Every 3,000-5,000 miles (critical for performance)

Engine Oil Type:

Yamalube 4 (or equivalent SAE 10W-40 or 20W-40 API SG or higher)

Engine Oil Capacity:

Approx. 1.8 - 2.0 L (refer to manual for exact, with filter change)

Fork Oil Type:

Yamaha Suspension Oil (or equivalent SAE 10 or 15 weight)

Common Wear Items:

Clutch plates, brake shoes/pads, wheel bearings, steering head bearings, fork seals, exhaust system seals, carburetor jets (clogging).

Electrical Concerns:

Stator output degradation over time, rectifier/regulator failure (check manual for testing procedures).

Carburetor Issues:

Idle instability, poor throttle response due to worn jets or float issues.

📚 Vehicle History

Yamaha Motorcycles:

Yamaha Motor Corporation has a long and storied history in motorcycle design and manufacturing, known for innovation and performance across various disciplines including motocross, enduro, and street bikes.

Tt350 Development:

The TT350 was developed as a versatile dual-sport or trail bike, offering a balance of off-road capability and street legal features. It evolved through various iterations within the specified years, with minor updates to styling and components.

Production Period:

1985-2000 (as per manual coverage)

🏆 Awards & Recognition

Industry Recognition:

The TT350 series was well-regarded in its time for its reliability and versatility as a dual-sport/enduro platform, often praised by off-road and enthusiast magazines for its performance relative to its class.