Yamaha RZ350L N NC Service Repair Manual – PDF Download
$19.95
Factory service manual for Yamaha RZ350L/N/NC models, 1984–1985.
Includes full engine overhaul, chassis service, YPVS system, wiring diagram, and troubleshooting.
Covers inspection, adjustment, and complete repair procedures for both standard and supplemental editions.
Description
Yamaha RZ350L N NC Service Repair Manual – PDF Download
Description:
Scope & Purpose
This official Yamaha RZ350L/N/NC Service Manual (1984–1985) is the complete factory guide for maintenance, service, and repair. Designed for workshop use, it includes diagnostic charts, wiring diagrams, and disassembly/assembly steps for every system.
Yamaha RZ350L/N/NC Service Manual Bookmarks
The PDF appears to have a structured outline based on its index and chapter sub-sections. Below is a hierarchical presentation of all the bookmarks extracted from the manual’s table of contents and sub-headings. This includes the main chapters and their detailed sub-sections, including page references where available from the contents lists.
- General Information (Chapter 1)
- Motorcycle Identification
- Vehicle Identification Number (1-1)
- Engine Serial Number (1-1)
- Major Features (1-2)
- Y.P.V.S. (Yamaha Power Valve System) (1-2)
- Front Fork (Air Assisted Fork with Variable Damper) (1-6)
- Link Type Monocross Suspension (1-11)
- Special Tools (1-12)
- For Tune-Up (1-12)
- For Engine Service (1-12)
- For Chassis Service (1-13)
- For Electrical Components (1-14)
- Motorcycle Identification
- Periodic Inspections and Adjustments (Chapter 2)
- Maintenance Schedules and Procedures
- Periodic Checks for Chain Tension
- Brake Fluid
- Coolant
- Oil Pump Adjustment
- Oil Pump
- Minimum Pump Stroke (0.10-0.15 mm)
- Adjustment Using Shims
- Measuring Gap with Thickness Gauge
- Bleeding the Autolube Pump and Delivery Lines
- Carburetor Synchronization
- Valve Clearance (General Adjustments)
- Steering Head Adjustment
- Tire Pressure
- Battery Check
- Maintenance Schedules and Procedures
- Engine Overhaul (Chapter 3)
- General Notes
- Cleaning Frame and Engine
- Fire Prevention
- Using Special Tools
- New Gaskets
- Genuine Yamaha Parts
- Engine Removal (From Frame, Disconnecting Components)
- Disassembly
- Crankcase Cover Removal
- Clutch Assembly (Springs, Pressure Plate, Friction Plates)
- Primary Drive Gear
- Transmission Sub-Assemblies
- Shift Fork
- Kick Starter
- Inspection
- Clutch Plates for Wear/Galling
- Push Rod Bending (Limit 0.2 mm)
- Cushion Rings Fatigue
- Driven Gear Dogs
- Circlips
- Reassembly
- Installing Circlips
- Transmission
- Shift Cam Stopper
- Power Valves with Molybdenum Disulfide Grease
- Rotor Holding
- Torque Specifications
- Various Bolts (e.g., 80 Nm for Some, 6 Nm for Power Valve Bolts)
- YPVS Linkage and Servomotor
- General Notes
- Cooling System (Chapter 4)
- System Overview
- Liquid-Cooled with Radiator
- Thermostat Valve
- Bypass Hose
- Coolant Pump
- Hoses
- Reservoir Tank
- Removal and Installation
- Radiator
- Thermostat Housing
- Water Pump
- Inspection
- Coolant Leaks
- Thermostat Operation (Opens at Specific Temps)
- Radiator Cap Pressure Test
- Maintenance
- Flushing Coolant
- Checking Hoses
- Tightening Torques (e.g., 8 Nm for Housing Cover)
- Operation
- Thermostat Valve Automatic Opening Based on Coolant Temp
- System Overview
- Carburetion (Chapter 5)
- Carburetor Inspection
- Joints for Cracks/Damage
- Idle Mixture
- Synchronization
- Reed Valves
- Petals for Fit/Flush Against Neoprene Seats
- Stopper Height (10.3 ±0.2 mm)
- Bending Limit (0.5 mm)
- Assembly with New Gaskets
- Fuel System
- Carburetor Side Clearance
- Leak Checks
- Torque Specs (15 Nm for Securing Bolts)
- Carburetor Inspection
- Chassis (Chapter 6)
- Steering
- Head Adjustment
- Bearing Check
- Stem Bolt Torque (85 Nm)
- Pinch Bolt (20 Nm)
- Front Wheel
- Bearings Inspection
- Axle Torque
- Wheel Rumble Check
- Rear Wheel
- Bearings
- Swingarm Side Clearance (0.2-0.4 mm)
- Bushings
- Shims (0.3 mm Thickness)
- Brakes
- Front/Rear Disc Thickness Limit (4.5 mm)
- Pad Wear (0.8 mm)
- Caliper Reassembly
- Piston Seals
- Master Cylinder (Front/Rear)
- Brake Fluid (DOT #3)
- Bleeding
- Union Bolts (26 Nm)
- Suspension
- Front Fork Disassembly
- Rear Shock Absorber
- Frame (General Checks)
- Steering
- Electrical (Chapter 7)
- Ignition
- Pickup Coil Resistance (1150 ±20% at 20°C)
- Ignition Coil Tests (Primary 0.332 Ω, Secondary 5.6kΩ)
- Spark Gap (6 mm Min)
- Timing (B.T.D.C.)
- Charging
- Coil Resistance
- Regulator Voltage (14.5 ±0.5V)
- Battery (12.5-13.5V Charging)
- Lighting
- Headlight Bulb Replacement
- Checks for Continuity
- Fuses
- Voltage Drops
- Switches
- Sidestand Control Unit (Neutral Switch)
- Main Switch
- Horn (Max 2.5A)
- Wiring
- Diagrams
- Troubleshooting Flowcharts for No Spark, Poor Charging
- Components
- AC Generator
- Rectifier
- Flasher Relay
- Thermo Unit
- Ignition
- Appendices (Chapter 8)
- Troubleshooting Guide (For Engine, Electrical, Chassis Issues)
- Specifications
- General (Dimensions, Weight)
- Engine (347cc 2-Stroke, Compression)
- Chassis (Tires, Brakes)
- Electrical (Battery, Bulbs, Fuses)
- Consumer Information (Warranty, Maintenance Records)
- General Torque Specifications (Bolt Sizes and Torques)
- Definition of Units (Conversions, e.g., Nm to ft-lb)
- Conversion Tables (Metric to Imperial)
- Exploded Diagrams
- Cylinder Head/Cylinder
- Crankshaft
- Crankcase
- Clutch
- Transmission
- Shift Fork
- Tachometer Gear
- Carburetor
- Steering
- Front Fork
- Front Wheel
- Front Master Cylinder
- Swingarm
- Rear Wheel
- Rear Brake
- Rear Shock Absorber
- AC Generator
- Electrical 1/2
- Cable Routing
- Wiring Diagram
- Cable Routing Diagrams
IMAGES:
Chapters & Content
Chapter 1 – General Information
Motorcycle identification and serial numbering
Major features and specifications
Special tools and metric conversion tables
Chapter 2 – Periodic Inspection & Adjustment
Maintenance schedule and intervals
Engine, chassis, and electrical inspection points
Oil pump, carb synchronization, brake clearance, chain slack, and steering checks
Chapter 3 – Engine Overhaul
Engine removal and installation procedures
Crankcase, cylinder, and piston disassembly
Gearbox and clutch inspection
Reassembly with torque and lubrication chart
Chapter 4 – Cooling System
Operation, radiator maintenance, coolant replacement
Water pump repair and hose routing diagrams
Chapter 5 – Carburetion
Mikuni carburetor service and adjustment
Reed valve cleaning and assembly inspection
Chapter 6 – Chassis
Front and rear wheel service
Hydraulic brake overhaul and bleeding
Steering head and suspension service (Monocross system)
Chapter 7 – Electrical System
Full wiring diagram with color-coded harness layout
Ignition, charging, and lighting systems
YPVS (Yamaha Power Valve System) diagnosis and setting procedure
Chapter 8 – Appendices
Troubleshooting guide for mechanical and electrical issues
Technical specifications and torque chart
Cable routing and exploded diagrams
Technical Highlights
Two-stroke, liquid-cooled, parallel-twin engine
YPVS exhaust control with electronic servo motor
Mikuni carburetors with precise jetting tables
Electric and kick start with 12V DC system
Torque and alignment specs for all major fasteners
File Details
Document Title: Yamaha RZ350L/N/NC Service Manual
Models Covered: RZ350L, RZ350N, RZ350NC (1984–1985)
Engine: 347cc liquid-cooled 2-stroke parallel twin
System Coverage: Engine, YPVS, Cooling, Carburetion, Chassis, Electrical
Pages: ~241
Format: Searchable PDF (OCR-enabled)
Languages: English
File Size: ~41.5 MB
Quality Notes: Factory scan with clear text, crisp schematics, OCR searchable; diagrams sharp and legible.
✅ Verified factory technical content.System Key Specs Covered Engine 347cc liquid-cooled 2-stroke parallel twin, bore x stroke 64 x 54 mm, compression 6.2:1, max power 59 PS at 9,000 RPM. Cooling Coolant capacity 1.3 L, thermostat opening 80°C. Carburetion Mikuni VM28SS x 2, main jet #140, pilot #25. Chassis Frame type double cradle, caster 27°, trail 100 mm, tires 90/90-18 front, 110/80-18 rear. Electrical Battery 12V 5.5Ah, alternator 14V 20A, headlight 12V 60/55W. What is Not Covered
- Owner’s manual content like riding techniques, basic operation, or safety gear recommendations (focus is service/repair).
- Parts catalog or ordering numbers (though exploded diagrams show assemblies, no part numbers).
- Modifications for racing or performance upgrades beyond factory specs.
- Advanced diagnostics with modern tools (e.g., OBD, no EFI system).
- Environmental disposal guidelines or modern emissions standards (1984 manual).
- Non-mechanical aspects like paint repair, seat upholstery, or accessories installation.
