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2002 YAMAHA YFM350 XP BUILD

R. J. Jul 1, 2019

  1. R. J.

    R. J. Supporting Member

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    :hello: I'm rebuilding my Yamaha 350 Warrior Sport Quad motor for the third time in 17 years. It is going to be a 402cc stroker motor. I bought the quad in 2004 for $1800 from a coworker/friend. I've spent the last 6 months slowly buying parts. Hot rod 4 mm stroker crank $200. Wiseco 1 mm over piston kit $130. Hot cam stage 2 $150. All new OEM gaskets, seals and O-rings $110. All new valve train parts. $160. New decals. $20. New OEM tail light $25. IMG_7613.JPG IMG_7614.JPG IMG_7615.JPG
     
    Last edited: Jul 1, 2019
  2. R. J.

    R. J. Supporting Member

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    :hello: The tranny is making noise in my Warrior 350 so I bought all new bearings, seals and shims for it. I just hope that no gears are damaged. IMG_8433.JPG IMG_8438.JPG IMG_8430.JPG IMG_8432.JPG I'm going to try to pull the motor this week for my friend Ron A to rebuild.
     
    markus56 likes this.
  3. R. J.

    R. J. Supporting Member

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    :hello: I've had this 2003 frame with a MICH title for quite some time. $300. I had it powerder coated a few weeks ago. $200. The 2002 frame is bent, cracked and has some rust through on the bottom. I bought new seals and bearing for the lower end of the frame for the steering column. I had to make a 30 mm nut to install the locking set screw that holds the bearing in the frame. Also I bought a set of ELKA Stage 3 shocks a about a year ago. $900. The stock shocks are just plumb wore out. I'm in the process of transfering everything form the 2002 to frame to the 2003 frame. __________ IMG_8510.JPG IMG_8509.JPG IMG_8513.JPG IMG_8514.JPG IMG_8515.JPG IMG_8516.JPG
     
    Last edited: Feb 19, 2020
    madmanncr500 likes this.
  4. R. J.

    R. J. Supporting Member

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    :hello: I worked on the Warrior today for 3 hours or so transfering parts from the old frame to the new one. IMG_8517.JPG IMG_8518.JPG
     
  5. R. J.

    R. J. Supporting Member

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    :hello: Yesterday I pulled the motor out of the frame and took it to my friend Ron A. to have him rebuild it. Today I went through the wiring harness. Checked it for nicks, cleaned all the connectors, put dielectric grease on all the connecters and rewrapped it. Mounted it and all the electrical parts along with the air box. Also I went to ACE Hardware to get SS Hardware. I'm doing away with all the 17 year old hardware. ________________ IMG_8519.JPG IMG_8520.JPG IMG_8521.JPG IMG_8522.JPG
     
  6. lowlife

    lowlife ZL Mad Scientist/ Supporting member Technical Author Supporting Member

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    Gonna be sexy when you are done with it
     
    R. J. likes this.
  7. R. J.

    R. J. Supporting Member

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    :hello: Today I got the front end off the Warrior. I had a hell of a time getting the ball joints out of the ball joint spindles/disk rotor/hub assembleys. For some reason YAMAHA had to build the ball joints into the upper and lower A arms. The ball joints are good in tight and the boots are not tore. New OEM A arms cost $130 each. I replaced them in 2016 with used low hour OEM ones from a 2004 Warrior. $70 for all 4. You can buy CHINA knock off upper and lower A arms for $40 each. I got a new aftermarket axle carrier (JAPAN) along with bearings, seals and spacer for $50 (OEM costs $200) and a new 14 tooth counter shaft sprocket $12. The stock is 13 tooth. I now have 13 through 16 tooth front sprockets. Also I got 1.5 inch wheel spacers. $120 for all 4. I have all new OEM parts to rebuild the rear shock linkage. I also ordered all 3 chain rollers and chain guide. Ordered all after market bearing and seals for all 4 A arms. _____________________________________________________________________________________ IMG_8528.JPG IMG_8529.JPG IMG_8530.JPG IMG_8526.JPG IMG_8527.JPG IMG_8523.JPG IMG_8531.JPG
     
    Last edited: Feb 26, 2020
    markus56 likes this.
  8. R. J.

    R. J. Supporting Member

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    :hello: Today I did some more wrenching on the 350 Warrior. Also I got some more replacement parts. FS DYNATEK Digital Ignition. $180. It changes the rev curve and adds 1000 RPM to the rev limiter. It will complement the 4 mm stroker hot rod crankshaft along with the wiseco 1 mm over piston and the stage 2 Hot Cam. I got new chain rollers and a new swingarm chain guide all made in the USA. $40 for all 4. I also got new front wave rotors. They are made in JAPAN. $120. The old ones are wore pretty bad and they are warped. I also have a JAPAN wave rotor $60 coming for the rear brake along with more OEM parts.
    IMG_8534.JPG IMG_8542.JPG IMG_8543.JPG IMG_8535.JPG IMG_8544.JPG IMG_8546.JPG IMG_8545.JPG IMG_8547.JPG IMG_8548.JPG IMG_8549.JPG
     
  9. Jonathan

    Jonathan Member

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    Man what a fun project!!!
     
    R. J. likes this.
  10. R. J.

    R. J. Supporting Member

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    :hello: Ya I'm enjoying this build. The weather has been perfect. It's been in the 70s. I've owned my 2003 Yamaha YFM 350 XR Warrior sport quad since 2004. I paid $1800 for it. I've road many other sport/race quads. My Warrior will go head to head with most race quads and handels better than most. It's never been stock. Top speed is just shy of 100 MPH when using a 16 tooth front sprocket. Stock is 13 tooth. The 350 Warriors have a lower center of gravity than the race quads and it corners like a dream. It's short fall has always been the suspension. That's why I spent the monry on the ELKA stage 3 shocks. They are made in CANDA. I special ordered them for my weight class B woods rider.
     
    Jonathan likes this.
  11. lowlife

    lowlife ZL Mad Scientist/ Supporting member Technical Author Supporting Member

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    Last time I raced an enduro on my dirt bike was about3 years ago....though I was gonna have a heart attack, slightly out of shape
     
  12. R. J.

    R. J. Supporting Member

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    :hello: It's been awhile since I've heard the word Enduro. They now call them Duel Sport bikes or Adventure Bikes. I have 3. A SUZUKI DR 200, a 74 HONDA XL 70 (mine) and a 72 CT 70 (Wifes). :laughing7:. These little old HONDAS are a blast to ride.
     
    Last edited: Mar 1, 2020
  13. 87kawzl

    87kawzl Supporting Member

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    5a2fef0385600a6111428510.jpg
    Duel

    Kawasaki-KLX-230-dual-sport-motorcycle.jpg
    Dual

    Lowlife probably probably felt like he was on the wrong end of the duel after the dual sport run in the enduro race. :)
     
    2manybikes and R. J. like this.
  14. R. J.

    R. J. Supporting Member

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    :hello: In 2017 I once raced my Sons friend Myles (19 me (59). I was on my 350 Warrior and he was on his CR 250 F. I told him we was doing an old school 45 minute moto + 2 laps race. He didn't make it to the 30 minute mark. :laughing7:. I new I'd wear him out. We was racing in a 10 acre dryed up lake bed.
     
    Last edited: Mar 1, 2020
  15. R. J.

    R. J. Supporting Member

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    :hello: Today I removed the swingarm and rear suspension. I Knocked out the bearings and seals from the swingarm, shock linkage and the axle carrier. Cleaned out all the old grease from all said parts. For the second time in 4 years I used my blind bearing puller kit. I'm glad to get rid of the stock shocks. Now I'm waiting on parts. I'm at a good stopping point for now so I won't be doing any more work on the Warrior until March 10 th. IMG_8551.JPG IMG_8552.JPG IMG_8553.JPG IMG_8554.JPG IMG_8555.JPG IMG_8556.JPG IMG_8557.JPG IMG_8558.JPG
     
    Jonathan and 87kawzl like this.
  16. R. J.

    R. J. Supporting Member

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    :hello: Today I spent 4 hours prepping and painting the upper and lower A arms. I used duplicolor caliper enamel paint with ceramic. IMG_8574.JPG IMG_8575.JPG IMG_8576.JPG IMG_8577.JPG IMG_8550.JPG
     
  17. R. J.

    R. J. Supporting Member

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    :hello: Yesterday I picked up my YFM 400 XR motor from my friend Ron A. He boared the cyn 1 mm over for the 84 mm Wisesco piston, Insalled the +4 mm hot rod stroker crank, replaced all the tranny bearings with all new OEM ones along with new OEM shims. The old ones was in rough shape. Also he installed all new OEM seals and O-rings along with all new OEM gaskets. He Rebuilt the head with new Kimble White racing valves and springs. Also he opened up the intake and exhaust ports a bit more. This motor was ported when I bought the bike. Labor for this complete rebuild was $225. In the mail today I got new Pivot Works rear shock linkage rebuild kit, two sets of front and rear brake pads, new upper and lower A arm bushings (USA made). Also I got new OEM bearings, spacers and seals for the swingarm. ______________________________________________________ IMG_8581.JPG IMG_8582.JPG IMG_8584.JPG IMG_8586.JPG IMG_8585.JPG IMG_8590.JPG IMG_8587.JPG IMG_8589.JPG IMG_8588.JPG
     
  18. R. J.

    R. J. Supporting Member

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    :hello: I got the rest of the OEM parts from partzilla late this afternoon. I installed the new self lubing black polycarbonate bushings and their associated OEM collars which go inside the bushings. I used the old OEM plates and dust quad-rings. They are only about a year old. IMG_8592.JPG IMG_8595.JPG IMG_8594.JPG IMG_8591.JPG
     
  19. R. J.

    R. J. Supporting Member

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    :hello: While I found out that the stock rims for my Warrior 350 started to crack at the 4 wheel lug holes. When YAMAHA made the OEM rims they was manufactured with 3 layers of pressed in aluminium with no welds and the top layer on all four rims has at least one lug nut hole cracking. So I bought 4 new ITP rims with lug nuts for $250 shipped from Dave at PowderKote Plus in South Daytona. Other bike shops wanted $350/$400 for them. IMG_8673.JPG IMG_8674.JPG
     
  20. R. J.

    R. J. Supporting Member

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    :hello: Today I installed the upper and lower A-arms, the new ELKA stage 3 front shocks, The new IMS over sized fuel tank and the new OEM tierod ends along with the new CNC machine tierod links. The stock ones kept bending. I'm picking up some Warrior powder coated parts Sat. IMG_8678.JPG IMG_8679.JPG IMG_8680.JPG IMG_8681.JPG IMG_8675.JPG IMG_8676.JPG IMG_8677.JPG IMG_8682.JPG IMG_8683.JPG
     

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