Market Position:
The Yamaha TT350S was a dual-sport motorcycle targeted at riders looking for off-road capability with street-legal amenities for recreational use and light trail riding. It competed in a segment with other Japanese dual-sport bikes of the era.
Competitive Analysis:
Competitors included models like the Honda XL350R, Suzuki DR350, and Kawasaki KLR250. The TT350S aimed to offer a balance of performance, reliability, and a user-friendly experience for its intended market.
Key Features:
Air-cooled four-stroke engine, robust suspension for off-road use, street-legal equipment, reliable Yamaha engineering. Known for its torque and manageable power delivery.
Coverage Areas:
Engine, Transmission, Chassis, Electrical System, Suspension, Brakes, Fuel System, Cooling System
Page Count:
Estimated 200-300 pages (typical for a full service manual of this era)
Manual Type:
Service Manual / Repair Manual / Workshop Manual
Format:
PDF Download (Paper Scan)
Systems Covered:
Engine Mechanical, Engine Lubrication, Cooling System, Fuel System (Carburetor), Ignition System, Transmission, Clutch, Brakes (Front & Rear), Suspension (Front Forks, Rear Monoshock), Wheels & Tires, Electrical System (Lighting, Charging, Ignition Circuits), Frame, Bodywork
Frame And Suspension:
Detailed procedures for inspecting, adjusting, and servicing front forks (including oil levels and seal replacement) and the rear monoshock suspension system, including shock absorber maintenance and linkage checks.
Wheel And Tire Service:
Information on wheel balancing, spoke tension adjustment, bearing maintenance, tire selection, and replacement procedures, including safety aspects.
Electrical System Details:
Complete wiring diagrams, component location, charging system testing (stator, regulator/rectifier), ignition system testing, and troubleshooting for lights and switches.
Clutch System Service:
Detailed instructions for clutch lever adjustment, clutch cable lubrication and replacement, and clutch disc replacement procedure, including necessary tools and specifications.
Procedures Included:
Routine Maintenance, Periodic Inspections, Engine Disassembly & Reassembly, Carburetor Tuning & Rebuild, Ignition Timing Adjustment, Clutch Adjustment & Service, Brake System Bleeding & Pad Replacement, Suspension Servicing, Wheel Bearing Maintenance, Electrical Troubleshooting & Wiring Diagrams, Torque Specifications, General Specifications & Settings, Lubrication Procedures, Diagnostic Flowcharts
Torque Specifications:
Extensive list of torque values for critical fasteners, including engine bolts, suspension components, wheel nuts, and bodywork, ensuring correct assembly and preventing damage.
Engine Rebuild Procedures:
Step-by-step instructions for engine disassembly, component inspection (piston, rings, cylinder, crankshaft, valves), measuring tolerances, and complete engine reassembly, including timing system setup.
Technical Depth:
Comprehensive, covering everything from basic maintenance and adjustments to complete engine overhauls and detailed electrical system diagnostics. Intended for professional technicians and advanced DIY mechanics.
Diagnostic Information:
Includes troubleshooting guides for common problems, with flowcharts and symptom-based diagnosis for engine, electrical, and mechanical issues.
Primary Engine:
347cc, Air-cooled, Four-stroke, SOHC, Single-cylinder
Horsepower:
Estimated 25-30 HP (at crank, typical for the era and displacement)
Torque:
Estimated 20-25 lb-ft (at crank, typical for the era and displacement)
Fuel System:
Carburetor (likely a Mikuni VM series, e.g., VM34)
Ignition System:
CDI (Capacitor Discharge Ignition)
Service Intervals:
The manual will detail specific intervals for oil changes (e.g., every 3,000 km or 6 months), air filter cleaning/replacement, spark plug inspection, brake fluid checks, chain adjustment, and valve clearance checks. Expect initial checks at 1,000 km and then regular intervals thereafter.
Engine Oil Type:
Yamaha recommends API SE or SF classification, SAE 10W-40 or 20W-40 motorcycle oil. (Consult manual for exact OEM specification).
Transmission Oil Type:
Separate transmission oil, typically SAE 80W API GL-4 or GL-5 gear oil. (Consult manual for exact OEM specification).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Type:
N/A (Air-cooled engine)
Known Issues:
Common issues for bikes of this age and type can include carburetor gumming from old fuel, wear on suspension seals, aging electrical connectors, and potential clutch wear. The manual will guide on diagnosing and resolving these.
Air Filter Part Number:
Likely requires a specific Yamaha part number, detailed in the manual.
Oil Filter Part Number:
Likely a reusable mesh oil strainer, not a spin-on filter. Manual will specify cleaning procedure and part number for seals if applicable.
Spark Plug Part Number:
Likely NGK DR8ES or equivalent. Manual will confirm.
Brand Heritage:
Yamaha has a long and successful history in motorcycle manufacturing, known for innovation, performance, and reliability across various disciplines, including off-road and dual-sport motorcycles.
Model Evolution:
The TT series evolved from Yamaha's successful motocross bikes, adapting them for dual-sport use. The TT350S was part of this lineage, offering a more accessible and versatile option compared to pure competition machines.
Production Years:
The Yamaha TT350 was produced in the mid-to-late 1980s, with the 1985 model being a key year in its initial run.
Manufacturing Locations:
Primarily Japan
