Yamaha YFZ350 1987-2003 Full Service Repair Manual

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Type: Atv

Vendor:

Sku: 57719

Tags: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 Atv Misc Motorcycles Yamaha YFZ350

Product variants

Description

The Yamaha YFZ350, affectionately known as the Banshee, is a high-performance Sport ATV that defined an era of off-road recreation from 1987 through 2003. Renowned for its explosive power delivery, stemming from a potent liquid-cooled, two-stroke, parallel-twin cylinder engine, the Banshee offers an exhilarating riding experience. Its engineering quality and reliability are hallmarks of a legacy in producing durable and capable off-road vehicles, making it a sought-after machine for enthusiasts who demand top-tier performance and a thrilling ride. This comprehensive service repair manual provides detailed guidance for the YFZ350 (1987-2003). It covers essential maintenance procedures, routine service checks, and in-depth repair instructions for all major systems, including the engine, fuel, ignition, cooling, transmission, drivetrain, suspension, brakes, and electrical systems. The manual also includes troubleshooting guides, diagnostic procedures, and technical specifications, making it an invaluable resource for owners and technicians alike to ensure the optimal performance, longevity, and safe operation of this iconic Sport ATV.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YFZ350

Model Nickname:

Banshee

Product Name:

Yamaha YFZ350 1987-2003 Full Service Repair Manual PDF Download

Codes

Chassis Code:

Engine Code Prefix:

👋 Introduction

Market Position

Category:

Performance Sport ATV

Target Audience:

Enthusiasts seeking high-performance off-road recreation

Competitive Analysis

Key Competitors Era:

Polaris Predator, Suzuki LT250R, Kawasaki KXT250 (Tecate)

Key Features

Engine Configuration:

High-performance, liquid-cooled, two-stroke, parallel-twin cylinder

Performance Characteristics:

Renowned for its explosive power delivery and top-end speed

Manual Benefit:

Essential for maintaining peak performance and longevity of a complex machine

📋 Manual Details

Coverage Areas

Covered Years:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Vehicle Type:

Sport ATV

Page Count

Estimated Page Count:

High (Detailed Service Manual typically exceeds 300 pages, exact count not specified)

Manual Type

Manual Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, disassembly, assembly, inspection, tuning, performance modifications

Fuel System:

Carburetor identification, adjustment, cleaning, rebuilding, fuel pump, fuel lines

Ignition System:

CDI, ignition timing, stator, coil, spark plug specifications

Cooling System:

Liquid cooling system, radiator, hoses, water pump, coolant type and capacity

Transmission:

Clutch operation, gearbox disassembly and assembly, gear ratios, lubrication

Drivetrain:

Chain adjustment, sprocket inspection, rear axle assembly

Suspension:

Front and rear suspension component inspection, adjustment, replacement, shock absorber specifications

Brakes:

Hydraulic brake system diagnosis, pad replacement, caliper service, master cylinder, brake fluid specifications

Electrical System:

Wiring diagrams, lighting, battery, starter, charging system, troubleshooting electrical faults

Frame And Bodywork:

Chassis inspection, repair, plastics, seat, handlebar components

Troubleshooting:

Common problems, diagnostic charts, fault finding procedures

Procedures Included

Preventive Maintenance:

Regular service checks, lubrication, fluid changes, filter replacements

Routine Maintenance:

Chain adjustment, air filter cleaning, spark plug replacement, oil changes

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation

Rebuild Instructions:

Detailed guidance for engine and transmission overhauls

Diagnostic Procedures:

Methods for identifying and resolving mechanical and electrical issues

Performance Tuning:

Carburetor jetting, exhaust modifications, engine tuning for optimal performance

Technical Depth

Depth Level:

Comprehensive (Suitable for DIY enthusiasts and professional mechanics)

Diagnostic Tools:

Includes information for standard mechanic tools and basic diagnostic techniques

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF for efficient information retrieval

Print Quality

Quality Description:

High-resolution digital reproduction of original factory manual

Binding Type

Binding:

Not Applicable (PDF Download)

Paper Type

Paper Type:

Not Applicable (PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke, reed-valve, parallel-twin

Displacement:

347cc (for most models within the range, some minor variations may exist)

Bore X Stroke:

64.0mm x 54.0mm

Compression Ratio:

Approx. 6.5:1 (stock, varies slightly by year)

Carburetion:

Dual Mikuni VM26SS (or similar, specific model may vary by year)

Performance

Horsepower Estimated:

40-50+ HP (stock, highly dependent on year and state of tune)

Torque Estimated:

Approx. 25-30 lb-ft (stock)

Fuel System

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Fuel Oil Mixture:

50:1 ratio (Yamalube 2-stroke oil or equivalent)

Fuel Tank Capacity:

Approx. 3.2 gallons (12 Liters)

🔧 Transmission

Standard

Transmission Type:

6-speed manual with constant mesh, wet multi-plate clutch

Optional

Optional Transmission:

N/A (Standard)

Features

Gear Ratios:

Detailed in manual (specific ratios vary by year and model)

Transmission Fluid Type:

Yamaha Gear Oil (or API GL-4, SAE 80W-90, or equivalent)

Transmission Fluid Capacity:

Approx. 0.8 quarts (0.75 Liters)

📐 Dimensions

Exterior

Overall Length:

Approx. 70.9 inches (1800 mm)

Overall Width:

Approx. 45.5 inches (1155 mm)

Overall Height:

Approx. 43.3 inches (1100 mm)

Weights

Dry Weight:

Approx. 397 lbs (180 kg)

Ground Clearance:

Approx. 4.3 inches (110 mm)

Wheelbase

Wheelbase:

Approx. 49.6 inches (1260 mm)

🛡️ Safety Features

Ratings

Atv Safety Considerations:

High-performance ATV requiring experienced operation; review of safety chapter in manual recommended.

Active Features

Braking System:

Hydraulic disc brakes front and rear

Passive Features

Chassis Design:

Durable steel frame providing structural integrity

💡 Technology Features

Infotainment

Infotainment System:

N/A (Pure performance ATV, no integrated infotainment)

Driver Assistance

Driver Assistance Features:

N/A (Manual operation focus)

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Consult manual; typically every 20-40 engine operating hours or annually.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (refer to manual for specific intervals).

Spark Plug Replacement:

Refer to manual; typically every 100-200 operating hours.

Chain Lubrication Adjustment:

Frequent checks and lubrication recommended, typically every 500-750 miles or 20-30 operating hours.

Fluid Specifications

Engine Oil Type:

2-stroke pre-mix oil (Yamalube 2M or equivalent)

Coolant Type:

Permanent type anti-freeze coolant (50/50 mix with distilled water recommended)

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Known Issues

Common Wear Items:

Clutch plates, pistons, rings, seals, and wear on the transmission components due to high performance.

Carburetor Tuning Sensitivity:

Highly sensitive to altitude, temperature, and modifications; requires diligent tuning.

Cooling System Maintenance:

Crucial to maintain proper coolant levels and a clean radiator to prevent overheating.

📚 Vehicle History

Brand Heritage

Yamaha Atv Legacy:

Yamaha has a long-standing reputation for producing high-performance and reliable off-road vehicles.

Model Evolution

Yfz350 Launch:

Introduced in 1987, the YFZ350 (Banshee) quickly became an icon in the sport ATV segment.

Key Updates Within Range:

Minor updates to suspension, styling, and engine tuning occurred throughout its production life until 2003.

Production

Production Period Covered:

1987-2003

🏆 Awards & Recognition

Recognitions

Industry Recognition:

The Yamaha YFZ350 Banshee is widely recognized as one of the most iconic and performance-oriented sport ATVs ever produced.

Ratings

Performance Ratings:

Consistently rated highly by enthusiasts and media for its power and handling capabilities.