The Yamaha TT350 and TT350S are dual-sport motorcycles produced from 1985 to 2000, renowned for their reliable air-cooled engines, robust chassis, and capable off-road performance combined with street legality. These models represent a commitment to producing dependable and versatile machines, offering a balanced experience for riders tackling varied terrains. With a 4-stroke, single-cylinder engine displacing approximately 347cc, featuring SOHC and CDI ignition, the TT350 series provides a solid foundation for both adventure and everyday riding. Its heritage is rooted in extensive experience in motorcycle engineering, particularly in the dual-sport segment, positioning it as a capable alternative to contemporaries like the Honda XR and Suzuki DR series. This comprehensive service repair workshop manual provides detailed information for the Yamaha TT350 and TT350S models spanning the years 1985 through 2000. It covers all essential aspects of maintenance, repair, and troubleshooting, including complete engine overhaul, transmission service, fuel system maintenance, electrical system diagnostics, suspension and brake servicing, and frame and bodywork. The manual offers step-by-step instructions for routine maintenance, disassembly and assembly procedures, and in-depth technical specifications. Its purpose is to empower owners, mechanics, and technicians with the knowledge required to effectively maintain, diagnose, and repair these motorcycles, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Yamaha Model: TT350 / TT350S Codes Model Codes: TT350, TT350S 👋 Introduction Market Position Segment: Dual-sport / Enduro Motorcycle Competitive Analysis Competitors: Honda XR series, Kawasaki KLR series, Suzuki DR series Key Features Attributes: Reliable air-cooled engine, robust chassis, capable off-road performance with street legality 📋 Manual Details Coverage Areas Applicable Years: 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000 Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, tuning, troubleshooting, component identification, specifications Transmission: Gearbox inspection, repair, clutch service, shift mechanism, lubrication Fuel System: Carburetor disassembly, cleaning, adjustment, fuel pump, fuel lines, tank maintenance Electrical System: Ignition system, stator, CDI unit, lighting, wiring diagrams, battery service, starting system Suspension: Front forks (telescopic), rear monoshock, linkages, adjustments, servicing Brakes: Front and rear brake system maintenance, caliper overhaul, pad replacement, fluid bleeding, drum brake service Frame And Bodywork: Chassis inspection, swingarm, steering head bearings, body panel removal and installation, seat, fenders Wheels And Tires: Wheel bearing service, spoke tensioning, tire selection and installation, rim maintenance Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, spark plug service Troubleshooting: Diagnostic procedures for common problems, electrical faults, engine performance issues Repair: Step-by-step repair instructions for all major components and systems Disassembly And Assembly: Detailed guides for dismantling and reassembling various motorcycle parts Technical Depth Depth: Comprehensive coverage from basic owner maintenance to full engine and transmission rebuilds 📊 Manual Specifications File Format Compatibility: Compatible with all PDF readers on PC, Mac, tablets, and smartphones Print Quality Quality: High-resolution scans for clear text and diagrams Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 4-stroke, Single-cylinder, SOHC Displacement: 347 cc (approx.) Bore X Stroke: 74.0 x 80.0 mm (Typical for this era and displacement) Compression Ratio: 9.5:1 (Approximate) Cooling System: Air-cooled Ignition: CDI (Capacitor Discharge Ignition) Performance Horsepower: Approx. 25-30 HP (Estimated based on typical class performance) Torque: Approx. 20-24 Nm (Estimated) Fuel System Carburetor Type: Single Mikuni carburetor (e.g., VM34 or similar) Fuel Type: Unleaded gasoline (87 octane or higher recommended) 🔧 Transmission Standard Type: 5-speed constant mesh Features Clutch: Wet, multi-plate Drive Type: Chain Drive 📐 Dimensions Exterior Length: Approx. 2170 mm (Varies slightly by year/spec) Width: Approx. 830 mm (Handlebar width) Height: Approx. 1220 mm (Seat height varies) Weights Dry Weight: Approx. 125-130 kg Fuel Tank Capacity: Approx. 10 Liters (2.6 US gal) 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle specific crash ratings not typically applicable in the same way as cars) Active Features Braking System: Front: Disc brake, Rear: Drum brake (early models) or Disc brake (later/S models) 💡 Technology Features Infotainment Features: N/A (Basic motorcycle instrumentation: speedometer, odometer, neutral indicator, high beam indicator) Driver Assistance Features: N/A (No electronic rider aids typical for this era of dual-sport) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 km or 6 months (refer to manual for specifics) Air Filter Cleaning: Every 1,000 km or as needed in dusty conditions Spark Plug Replacement: Every 6,000 km (or check gap and condition) Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or higher (e.g., Yamalube 4-stroke motorcycle oil) Engine Oil Capacity: Approx. 1.6 Liters without filter change, 1.8 Liters with filter change (confirm in manual) Brake Fluid Type: DOT 3 or DOT 4 (Check caliper/master cylinder for specific recommendation) Transmission Oil Type: Refer to engine oil specifications, as it's often a shared sump. Known Issues Common Wear Items: Cam chain tensioner, carburetor...