Yamaha XT350 Maintenance Schedule and Service Intervals

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 fluidUse Castrol DOT 4 or similar
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 original maintenance schedule for the Yamaha XT350 was broken into two sections: periodic maintenance for emission control systems, and general maintenance and lubrication. But these have been combined for simplicity

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 pattern shown
  • The break-in schedule is omitted as the XT350 is no longer sold new.
  • The below maintenance schedule is for the US-delivered XT350. The European spec is a little different.
mi x 100048121620
km x 1000713192531
Months612182430Every
Drain and replace engine oil (Yamalube 10W-40)XXXXX
Replace oil filter element (HF153)XX
Clean oil strainer, replace if damagedXX
Wash and dampen air filter with oil (Yamaha air filter oil)XXXXX
Check and adjust valve clearanceXXXXX
Check spark plug condition. Adjust gap and cleanXXX
Replace spark plugs (D8EA)XX
Replace brake fluid (Castrol DOT 4) and rubber parts of brake master cylinder / caliper2 years
Replace brake hoses4 years, or earlier if damaged
Adjust brake system free play. Check hoses for fluid leakageXXXXX
Replace brake pads (front)
or shoes (rear) if necessary
XXXXX
Adjust clutch free playXXXXX
Check drive chain condition. Adjust and lubricate chain thoroughly (Motul chain paste)300 mi / 500 km or when chain gets dirty / wet
Lubricate control and meter cables thoroughly (Protect all cable life)XXXXX
Grease rear arm pivot shaft and suspension link pivots (Lithium soap-based grease)XXXXX
Lubricate brake lever, clutch lever, and brake pedal shafts lightly (Lithium soap-based grease)XXXXX
Check sidestand operation and lubricate lightlyXXXXX
Check front fork operation and for leakageXXXXX
Check steering bearing assembly for loosenessXXXX
Repair steering bearings with lithium soap-based greaseX
Check wheel bearing for smooth rotationXXXXX
Check battery specific gravity, and that the breather pipe is working properly.XXXXX
Check sidestand switch and clean or replace if necessaryXXXXX
Check crankcase ventilation hose for cracks or damage XXX
Check fuel hose for damage XXXXX
Check exhaust for leakage. Retighten / replace gaskets as necessaryXXXXX
Clean spark arresterXXXXX
Check and adjust engine idle speed, and adjust throttle cable freeplayXXXXX
Check and adjust decomp cable free playXXXXX
Check evap control system for damage. Replace if necessaryXX
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 US owner’s manual for the 2000 Yamaha XT350.

You can download it from Yamaha’s website here.

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