Target Audience:
Enthusiasts and owners seeking to maintain and repair their Yamaha Warrior 350.
Key Competitors:
Suzuki QuadSport 250/300, Honda TRX300EX, Kawasaki Mojave 250.
Vehicle Positioning:
A popular, reliable, and capable sport ATV known for its sporty handling and accessible power.
Manual Value Proposition:
Provides essential, detailed information for maintaining peak performance and extending the lifespan of the Warrior 350.
Engine:
Full disassembly, inspection, repair, and reassembly of the 348cc engine.
Fuel System:
Carburetor (Mikuni BSR32) tuning, cleaning, and overhaul; fuel tank and lines inspection and maintenance.
Ignition System:
CDI system testing, spark plug specifications, ignition timing.
Transmission:
Clutch operation, gearbox (5-speed with reverse) disassembly, repair, and fluid service.
Drive Train:
Shaft drive system maintenance, U-joints, differential.
Suspension:
Front telescopic forks (adjustable), rear mono-shock absorber (Pro-Link system) service, lubrication, and adjustment.
Brakes:
Front and rear hydraulic disc brakes, caliper overhaul, brake pad replacement, bleeding procedures.
Electrical System:
Wiring diagrams, lighting system, starter motor, battery maintenance, fuses, switches.
Frame And Bodywork:
Chassis inspection, body panel removal and installation, seat, fenders.
Cooling System:
Air-cooled engine, but includes oil cooler inspection and maintenance if applicable to specific sub-models.
Scheduled Maintenance:
Detailed steps for routine checks, lubrication, filter changes, and fluid top-offs.
Troubleshooting:
Diagnostic charts and guidance for identifying and resolving common mechanical and electrical issues.
Engine Repair:
Complete engine rebuild procedures, including piston, rings, valve timing, and seal replacement.
Transmission Repair:
Gearbox disassembly, inspection of gears, shift forks, and bearings.
Brake Service:
Disc brake pad replacement, caliper overhaul, master cylinder service, and brake bleeding.
Suspension Overhaul:
Fork seal replacement, oil changes, shock absorber adjustment and rebuild.
Carburetor Tuning:
Step-by-step instructions for cleaning, adjusting, and rebuilding the Mikuni BSR32 carburetor.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and component testing.
Torque Specifications:
Precise torque values for critical fasteners throughout the vehicle.
Depth Level:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds.
Diagnostic Capability:
Advanced diagnostics with detailed troubleshooting charts and component testing procedures.
Illustration Quality:
Illustrated with clear, step-by-step instructions, including diagrams and exploded views.
Engine Type:
4-Stroke, Air-Cooled, SOHC
Bore X Stroke:
83 mm x 64.5 mm
Horsepower Estimated:
~22-25 HP (at crankshaft, manufacturer estimates vary)
Torque Estimated:
~20-22 lb-ft (at crankshaft, manufacturer estimates vary)
Carburetor Model:
Mikuni BSR32 (single)
Fuel Type Required:
Unleaded gasoline (87 octane minimum recommended)
Fuel Tank Capacity:
2.6 US gal (9.8 L)
Atv Safety Standards:
Conforms to ANSI standards for recreational ATVs.
Braking System:
Dual front hydraulic disc brakes, single rear hydraulic disc brake.
Throttle Limiter:
Adjustable thumb throttle for controlled acceleration.
Handlebar Design:
ATV-specific handlebars with protective padding.
Footwells:
Wide, sturdy footwells with integrated heel guards.
Oil Change Interval:
Every 1000 km (600 miles) or 6 months (refer to manual for specific riding conditions).
Air Filter Cleaning:
Every 500 km (300 miles) or more frequently in dusty conditions.
Spark Plug Replacement:
Refer to manual; typically every 3000-5000 km (2000-3000 miles).
Valve Clearance Check:
Every 3000 km (2000 miles).
Engine Oil Type:
Yamalube 4 (10W-40) or equivalent API SE, SF, SG, SH, SJ rated 4-stroke motorcycle oil.
Engine Oil Capacity:
1.90 US qt (1.8 L) with filter change.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Item:
Clutch plates (due to aggressive riding).
Carburetor Tuning:
Can require periodic adjustment for optimal performance, especially with aftermarket exhaust or air filter modifications.
Suspension Bushings:
Wear on suspension bushings can occur with heavy use.
Electrical Connections:
Corrosion on electrical connectors can lead to intermittent issues.
