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Yamaha TT350 1990 Digital Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TT350 Year: 1990 Engine Type: 4-stroke, Single Cylinder, SOHC, 4-valve Codes Chassis Code: 48X Engine Code: 48X 👋 Introduction Market Position Vehicle Segment: Dual-sport/Enduro motorcycle. Target Audience: Off-road enthusiasts, dual-sport riders, adventure seekers. Competitive Analysis Key Competitors Era: Honda XR series, Kawasaki KLR series, Suzuki DR series, KTM EXC series. Key Features Manual Value Proposition: Provides comprehensive diagnostic and repair information to empower owners for self-maintenance and problem-solving. Vehicle Key Selling Points: Reliable 4-stroke engine, robust chassis for off-road capability, suitable for both trail riding and light street use. 📋 Manual Details Coverage Areas Systems Covered: General Information, Specifications, Periodic Inspections and Adjustment, Engine Overhaul, Carburetion, Chassis, Electrical, Appendices Page Count Page Count: Unknown (Digital Format) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures for the entire engine, including cylinder head, valves, pistons, crankshaft, and lubrication system. Fuel System: Comprehensive information on the carburetor (likely a VM series Mikuni), including disassembly, cleaning, adjustment, and troubleshooting. Ignition System: Details on the CDI ignition system, including component testing, timing adjustments, and troubleshooting. Electrical System: Wiring diagrams, troubleshooting guides for lighting, charging system (stator and regulator/rectifier), and starting system. Chassis Suspension: Information on front forks (likely telescopic with adjustable damping) and rear monoshock suspension, including seal replacement and oil levels. Braking System: Procedures for front and rear brake systems (likely disc brakes), including caliper overhaul, pad replacement, and fluid bleeding. Wheel And Tires: Information on wheel bearing maintenance, tire pressure recommendations, and likely spoke maintenance for off-road wheels. Bodywork And Frame: Details on body panel removal, frame inspection, and potentially seat and fuel tank mounting. Maintenance Schedules: Periodic inspection and adjustment recommendations for key components. Procedures Included Engine Rebuild: Complete step-by-step instructions for engine disassembly, component inspection, repair, and reassembly. Carburetor Tuning: Guidance on jetting, idle speed adjustment, and mixture control for optimal performance. Fork Seal Replacement: Detailed instructions for disassembling front forks and replacing worn oil seals. Brake Bleeding: Correct procedures for removing air from the hydraulic brake lines. Electrical Troubleshooting: Systematic approaches to diagnosing electrical faults using wiring diagrams and test procedures. Valve Adjustment: Procedures for checking and adjusting valve clearances. Chain And Sprocket Maintenance: Information on chain tension adjustment and sprocket wear inspection. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures for identifying and resolving complex mechanical and electrical issues. Repair Complexity: Covers everything from routine maintenance to complete engine and chassis rebuilds. Diagrams And Illustrations: Likely includes exploded views and detailed diagrams to aid in disassembly and reassembly. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Searchable text content within the PDF document. Zoom Functionality: Supports zoom in/out functionality for detailed viewing. Platform Compatibility: Compatible with all versions of Windows and Mac operating systems. Device Compatibility: Usable on smartphones and tablets with PDF reader applications. Extraction Requirements: Requires WinZip or equivalent for extraction if compressed. Reader Requirement: Adobe PDF Reader or compatible software. Print Quality Print Readability: Designed for clear and legible printing of all content. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Family: Yamaha 48X Single Cylinder Displacement: 347 cc (approx.) Bore X Stroke: 72.0 mm x 84.5 mm (approx.) Compression Ratio: 9.5:1 (approx.) Valve Train: SOHC, 4 valves Performance Horsepower Estimated: Approx. 30-35 HP (at crankshaft) Torque Estimated: Approx. 20-23 lb-ft (at crankshaft) Fuel System Carburetor Type: Mikuni VM Series (likely VM34 or similar) Fuel Capacity: 2.6 US gal (9.8 L) Fuel Type: Unleaded gasoline (minimum 87 octane recommended) Fuel Injection System: N/A (This model features carburetion, not fuel injection) Lubrication Oil Type: SAE 10W-30 or 20W-40 API SE, SF, or SG classification motorcycle oil Oil Capacity With Filter: 1.70 US qt (1.6 L) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Features Clutch Type: Wet, multiple-disc Final Drive: Chain drive Transmission Oil Type: Yamalube SAE 80 or equivalent API GL-4 gear oil Transmission Oil Capacity: 0.70 US qt (0.65 L) 📐 Dimensions Exterior Overall Length: Approx. 85.4 in (2170 mm) Overall Width: Approx. 34.3 in (870 mm) Overall Height: Approx. 47.0 in (1195 mm) Seat Height: Approx. 36.0 in (915 mm) Weights Dry Weight: Approx. 262 lbs (119 kg) Wet Weight: Approx. 287 lbs (130 kg) Gross Vehicle Weight Rating: Not specified, but consider rider and cargo weight. Wheels And Tires Front Tire Size: 80/100-21 51P Rear Tire Size: 110/90-18 61P Front Wheel Type: Spoked Rear Wheel Type: Spoked Wheelbase: Approx. 56.3 in (1430 mm) Ground Clearance: Approx. 11.8 in (300 mm) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety ratings are not typically provided in the same manner as automobiles). Active Features Braking System: Front and rear disc brakes for effective stopping power. Suspension Performance:...
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Yamaha TT350 1990 Digital Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TT350
Year:
1990
Engine Type:
4-stroke, Single Cylinder, SOHC, 4-valve
Codes
Chassis Code:
48X
Engine Code:
48X
👋 Introduction
Market Position
Vehicle Segment:
Dual-sport/Enduro motorcycle.
Target Audience:
Off-road enthusiasts, dual-sport riders, adventure seekers.
Competitive Analysis
Key Competitors Era:
Honda XR series, Kawasaki KLR series, Suzuki DR series, KTM EXC series.
Key Features
Manual Value Proposition:
Provides comprehensive diagnostic and repair information to empower owners for self-maintenance and problem-solving.
Vehicle Key Selling Points:
Reliable 4-stroke engine, robust chassis for off-road capability, suitable for both trail riding and light street use.
📋 Manual Details
Coverage Areas
Systems Covered:
General Information, Specifications, Periodic Inspections and Adjustment, Engine Overhaul, Carburetion, Chassis, Electrical, Appendices
Page Count
Page Count:
Unknown (Digital Format)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul procedures for the entire engine, including cylinder head, valves, pistons, crankshaft, and lubrication system.
Fuel System:
Comprehensive information on the carburetor (likely a VM series Mikuni), including disassembly, cleaning, adjustment, and troubleshooting.
Ignition System:
Details on the CDI ignition system, including component testing, timing adjustments, and troubleshooting.
Electrical System:
Wiring diagrams, troubleshooting guides for lighting, charging system (stator and regulator/rectifier), and starting system.
Chassis Suspension:
Information on front forks (likely telescopic with adjustable damping) and rear monoshock suspension, including seal replacement and oil levels.
Braking System:
Procedures for front and rear brake systems (likely disc brakes), including caliper overhaul, pad replacement, and fluid bleeding.
Wheel And Tires:
Information on wheel bearing maintenance, tire pressure recommendations, and likely spoke maintenance for off-road wheels.
Bodywork And Frame:
Details on body panel removal, frame inspection, and potentially seat and fuel tank mounting.
Maintenance Schedules:
Periodic inspection and adjustment recommendations for key components.
Procedures Included
Engine Rebuild:
Complete step-by-step instructions for engine disassembly, component inspection, repair, and reassembly.
Carburetor Tuning:
Guidance on jetting, idle speed adjustment, and mixture control for optimal performance.
Fork Seal Replacement:
Detailed instructions for disassembling front forks and replacing worn oil seals.
Brake Bleeding:
Correct procedures for removing air from the hydraulic brake lines.
Electrical Troubleshooting:
Systematic approaches to diagnosing electrical faults using wiring diagrams and test procedures.
Valve Adjustment:
Procedures for checking and adjusting valve clearances.
Chain And Sprocket Maintenance:
Information on chain tension adjustment and sprocket wear inspection.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures for identifying and resolving complex mechanical and electrical issues.
Repair Complexity:
Covers everything from routine maintenance to complete engine and chassis rebuilds.
Diagrams And Illustrations:
Likely includes exploded views and detailed diagrams to aid in disassembly and reassembly.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Searchability:
Searchable text content within the PDF document.
Zoom Functionality:
Supports zoom in/out functionality for detailed viewing.
Platform Compatibility:
Compatible with all versions of Windows and Mac operating systems.
Device Compatibility:
Usable on smartphones and tablets with PDF reader applications.
Extraction Requirements:
Requires WinZip or equivalent for extraction if compressed.
Reader Requirement:
Adobe PDF Reader or compatible software.
Print Quality
Print Readability:
Designed for clear and legible printing of all content.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Yamaha 48X Single Cylinder
Displacement:
347 cc (approx.)
Bore X Stroke:
72.0 mm x 84.5 mm (approx.)
Compression Ratio:
9.5:1 (approx.)
Valve Train:
SOHC, 4 valves
Performance
Horsepower Estimated:
Approx. 30-35 HP (at crankshaft)
Torque Estimated:
Approx. 20-23 lb-ft (at crankshaft)
Fuel System
Carburetor Type:
Mikuni VM Series (likely VM34 or similar)
Fuel Capacity:
2.6 US gal (9.8 L)
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended)
Fuel Injection System:
N/A (This model features carburetion, not fuel injection)
Lubrication
Oil Type:
SAE 10W-30 or 20W-40 API SE, SF, or SG classification motorcycle oil
Oil Capacity With Filter:
1.70 US qt (1.6 L)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Features
Clutch Type:
Wet, multiple-disc
Final Drive:
Chain drive
Transmission Oil Type:
Yamalube SAE 80 or equivalent API GL-4 gear oil
Transmission Oil Capacity:
0.70 US qt (0.65 L)
📐 Dimensions
Exterior
Overall Length:
Approx. 85.4 in (2170 mm)
Overall Width:
Approx. 34.3 in (870 mm)
Overall Height:
Approx. 47.0 in (1195 mm)
Seat Height:
Approx. 36.0 in (915 mm)
Weights
Dry Weight:
Approx. 262 lbs (119 kg)
Wet Weight:
Approx. 287 lbs (130 kg)
Gross Vehicle Weight Rating:
Not specified, but consider rider and cargo weight.
Wheels And Tires
Front Tire Size:
80/100-21 51P
Rear Tire Size:
110/90-18 61P
Front Wheel Type:
Spoked
Rear Wheel Type:
Spoked
Wheelbase:
Approx. 56.3 in (1430 mm)
Ground Clearance:
Approx. 11.8 in (300 mm)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety ratings are not typically provided in the same manner as automobiles).
Active Features
Braking System:
Front and rear disc brakes for effective stopping power.
Suspension Performance:
Long-travel suspension for handling rough terrain and maintaining tire contact.
Passive Features
Lighting System:
Headlight, taillight, and brake lights for visibility.
Frame Construction:
Durable steel frame designed to withstand off-road stresses.
💡 Technology Features
Infotainment
Infotainment System:
N/A (This is a 1990s off-road motorcycle; no integrated infotainment system.)
Driver Assistance
Driver Assistance Features:
N/A (No electronic driver assistance features on this model.)
Connectivity
Connectivity Features:
N/A (No connectivity features like Bluetooth or Wi-Fi.)
Engine Management
Ignition System Type:
CDI (Capacitor Discharge Ignition)
Lighting
Headlight Type:
Halogen bulb
Instrumentation
Instrument Panel:
Analog speedometer, odometer, and potentially a tachometer; indicator lights for neutral, turn signals, high beam.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 1,000 miles (1,600 km) or 6 months.
Air Filter Cleaning:
Every 1,000 miles (1,600 km) or more frequently in dusty conditions.
Spark Plug Inspection:
Every 1,000 miles (1,600 km).
Valve Clearance Check:
Every 4,000 miles (6,400 km) or 24 months.
Chain Lubrication Adjustment:
Every 500 miles (800 km) or after riding in wet conditions.
Fluid Specifications
Engine Oil Specification:
SAE 10W-30 or 20W-40 API SE, SF, or SG classification motorcycle oil
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid
Fork Oil Type:
Yamaha Fork Oil (or equivalent suspension fluid) of appropriate viscosity (e.g., 10W)
Known Issues
Common Wear Items:
Clutch plates, valve guides, steering head bearings, wheel bearings due to off-road use.
Carburetor Performance:
Can become finicky with age; requires regular cleaning and adjustment. Clogged pilot jets are common.
Electrical Connections:
Corrosion or loose connections in wiring harness, especially with exposure to elements.
Suspension Seals:
Fork seals and rear shock seals can degrade over time, leading to leaks.
📚 Vehicle History
Brand Heritage
Brand Focus:
Yamaha has a long-standing heritage in motorsports and off-road motorcycles, known for performance and innovation.
Model Evolution
Tt Series Lineage:
The TT series has been a staple for Yamaha in the off-road segment, evolving from earlier motocross and enduro models. The TT350 represented a robust, air-cooled option in its era.
Target Market Evolution:
The TT350 was designed for riders seeking a capable dual-sport machine that could handle trails and also be used for commuting or light touring.
Production
Production Years Range:
Mid-1980s to early 1990s (Specific start/end for 1990 model year)
Manufacturing Location:
Japan (typically for Yamaha motorcycles of this era)
🏆 Awards & Recognition
Recognitions
Historical Awards:
Specific awards for the 1990 TT350 are not widely documented in general automotive press. Yamaha's TT series generally received accolades for off-road performance and durability in its class.
Ratings
Consumer Satisfaction Era:
Yamaha motorcycles of this era were generally well-regarded for reliability and performance by owners and the motorcycling press.
Certifications
Emissions Certifications:
Likely met the emissions standards for its intended markets for the 1990 model year, though specific certifications are not detailed in the product info.
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