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Yamaha XT350 Maintenance Schedule and Service Intervals

2000 Yamaha XT350

This is the maintenance schedule and associated service intervals for the Yamaha XT350, a single-cylinder air-cooled carburettor-fed dual sport that was kick-start only (but also very light!). It was made from 1991 until 2000, staying the same in the whole period. But many are still in service today, because they’re bulletproof.

The XT350 is powered by a 346cc single-cylinder engine with a gentle compression ratio of 9.0:1. Its dry weight is a featherweight 120kg, which means its 23kW of power (31 hp) gets it really far — it’ll even do highway time, if you’re brave!

After its retirement, the Yamaha XT350 was effectively discontinued. These days, the equivalent is the more advanced Yamaha XT250.

yamaha XT350 photo from manual

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What you need to service a Yamaha XT350

If you’re servicing a Yamaha XT350, you need to start with basic motorcycle maintenance tools.

After that, here are the basic consumables you need to service your XT350.

Your XT350 is a carburettor-fed, air-cooled motorcycle with a chain drive. It has a disc front brake, a drum rear brake, and… precious little else. Keep it lubed and hopefully it’ll go for a while (though not forever, some complain that the valves tend to fail after about 50K miles).

PartYamaha XT350 Spec
OilThe XT350 isn’t a demanding bike — use a basic oil like Yamalube 10W-40.
Oil filterHiflofiltro HF143 oil filter.
Spark plugUse an NGK D8EA spark plug.
Air FilterYou need a Hiflofiltro HFF4019 foam air filter. Keep it maintained with Yamalube air filter oil
ChainMaintain your chain with a Motul chain care kit or Motul chain paste
GreaseKeep external pivot points greased with lithium soap-based grease.
Brake padsUse EBC graphite brake pads, FA101X for the XT350.
Maintenance parts for the Yamaha XT350

Yamaha XT350 Maintenance Schedule

Below is the maintenance schedule for the Yamaha XT350.

The maintenance for the Yamaha XT350 is broken into two sections: periodic maintenance for emission control systems, and general maintenance and lubrication.

Yamaha recommends you get a mechanic or dealer to service everything other than the chain, oil, and major lubrication points. Not likely!!

Notes:

  • Beyond the end of the maintenance schedule, follow it in the same period with 4K mile or 10K km intervals
  • The distances in miles are from the US manual, and the distances in Km are from the European manuals. They don’t quite match up.
  • R = Replace
  • Brake fluid replacement
    • When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally Check the brake fluid level and add fluid as required.
    • On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years
    • Replace the brake hose every four years, or if cracked or damaged.

Periodic Maintenance Emission Control System

Miles60040008000120001600020000
Kms100010000200003000040000
Months1612182430
Valve clearance* Check and adjust valve clearanceXXXXXX
Spark plug* Check condition
* Adjust gap and clean
* Replace as indicated
XRXRX
Crankcase ventilation* Check ventilation hose for cracks or damage
* Replace if necessary
XXX
Fuel line* Check fuel hose for damage
* Replace if necessary
XXXXX
Exhaust system* Check for leakage
* Retighten if necessary
* Replace gaskets if necessary
XXXXX
Spark arrester* CleanXXXXX
Idle speed* Check and adjust engine idle speed
* Adjust cable freeplay
XXXXX
Decompression* Check and adjust decomp cable free playXXXXX
Evaporative emission control system* Check control system for damage
* Replace if necessary
XX
Maintenance for the XT350 – General emissions systems

General Maintenance and Lubrication Chart

Miles60040008000120001600020000
Kms100010000200003000040000
Months1612182430
Engine oil * Drain and replaceXXXXXX
Oil filter/strainer* Replace filter element
* Clean oil strainer, replace if damaged
XXX
Air filter* Wash and dampen with oil (Yamaha air filter oil)XXXXX
Brake system* Adjust free play
* Check fluid leakage (front)
* Correct if necessary
* Replace pads if necessary (front)
* Replace shoes if necessary (rear)
XXXXXX
Clutch* Adjust free playXXXXXX
Drive chain* Check chain condition
* Adjust and lubricate chain thoroughly (Motul chain paste)
Control meter and cable* Lubricate thoroughly (Protect all cable life)XXXXXX
Rear arm pivot shaft and suspension link pivots* Grease (Lithium soap-based grease)XXXXX
Brake/clutch lever pivot shaft* Lubricate lightly (Lithium soap-based grease)XXXXX
Brake pedal and shift pedal shaft* LubricateXXXXX
Sidestand pivot and kick crank boss* Check operation and lubricate
* Lubricate lightly
XXXXX
Front fork oil* Check operation and leakageXXXXX
Steering bearings* Check bearing assembly for looseness
* Moderately repack with grease every 24K km (16K mi)
XXXRepackX
Wheel bearings* Check bearing for smooth rotationXXXXX
Battery* Check specific gravity
* Check that the breather pipe is working properly.
* Correct if necessary
XXXXX
Sidestand switch* Check and clean or replace if necessaryXXXXX
Yamaha XT350 maintenance table

About the Yamaha XT350

The Yamaha XT350 is a lightweight dual-purpose bike that packs plenty of usable punch for both occasional road hauls and off-road exploration. It’s exceptionally maneuverable and ready to tackle rough terrain.

The XT350’s single-cylinder air-cooled 4-stroke engine provides a broad range of torque, making it reassuring in pretty much any scenario. You may not want to cross the country on high-speed freeways on it… but you could… in the slow lane!

Thanks to the precise steering that the short wheelbase provides and convenient 5-speed transmission, the Yamaha XT350 is easy to ride, especially with quickly-adjustable suspensions to offer the best damping and compression for all kinds of surfaces.

Many people have a special place in their heart for the XT350. Even decades after the last one was made, there are lots to be found in people’s garages — though relatively few on the used market. It’s one of those bikes that people either regret selling, or know they’ll regret selling.

What’s quite impressive is that you can actually push the XT350 to some serious speed — north of 120 km/h (75 mph) or even 140 mph (90 mph) if you’re patient. Of course, riding the XT350 isn’t about getting to top speed — but it’ll do it if you need it to.

Manual for the Yamaha XT350

2000 Yamaha XT350 Maintenance schedule screenshot from manual

The above information was gleaned from the owner’s manual for the 2000 Yamaha XT350.

You can download it from Yamaha’s website here.

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