YAMAHA. 81MMDBIlE. SUPPLEMENTARY SERVICE l 8J LIT

Transcription

1 YAMAHA 81MMDIlE SUPPEMENTARY SERVICE l [ Frme seril number: 8J J ] Engine seril number: E E IT J

2 CONTENTS 1. NEW SERVICE PROCEDURE MAINTENANCE INTERVAS SPECiFiCATION S SPECIA TOOS WI RING DIAGRAM WI RE AND PIPE ROUTING DIAGRAM " NEW SERVICE PROCEDURE (New service procedure pplied to the ) Crburetor 1. To chieve the precise fitting of the min nozzle, the min nozzle is pressfitted to the mixing chmber body, nd ccordingly the min nozzle cnnot be removed. 2. For better performnce, the recommended type of the min jet which is more effective t ltitudes is chnged. [Min jet setting chrt] - Altitude.. #24 #22 Se level.... (Std) # #22 6m (2 ft) #24.. (Std) 12m (4 ft) 3 C -2 C -1 C ooe 1Qoe 2 C (-22 F) (- 4 F) (14 F) (32 F) (5 F) (68 F) I I I I I I. # r-.-#24 #21 (Std). # m (6 ft) #2_ # #2 24m (8 ft) # #19 3m (1 ft) - - #19 or more # Newly chnged specifiction.

3 2. MAINTENANCE INTERVAS [PERIOorc MAINTENANCE] ENGINE Tightness of bolts nd nuts ends. crcks nd wer Abnorml noise Check point oose connection nd breks of fuel nd pulse pipes oose connection nd breks of oil pipes oose connction nd breks of oil delivery pipe Mnul rope strter system Crburetor Opertion of strter jet Mixing djuster (pilot screw) Idling speed djustment Opertion nd djustment of oil pump Ignition timing Cylinder compressions Cylinder hed/exhust pipe decrbonize Sprk plug condition. gp nd clening Tightening of the cylinder hed-- D RIVE : Tightness of bolts nd nuts Wer on slide runners Primry drive system V-belt Secondry drive system Sheve distnce Sheve offset rke pd wer rke opertion nd djustment Guide wheel rubber Wer of drive trck wheel sprocket Drive trck djustment reks in drive trck ends in front nd rer xles Checking of lock wshers Drive chin djustment Drive chin oil level ODY: Tightness of bolts nd nuts ends nd crcks Welded riveted. joints Ski djustment Ski runner wer reks in fuel tnk Clening of fuel tnk Fuel filter oose connection nd breks in fuel pipe reks in oil tnk Oil filter 2 hrs. or 4km (2 5 mi) Every 4 hrs. or 8 hrs or When 8 km 16 km necessry (5mi) (1 mi) Sesonlly -2-

4 EECTRICA Every Check point 2 hrs. or 4 hrs. or 8 hrs or When 4 km 8 km 16 km necessry 125 mil 15 md 11 mr) Wer. brekge of wire covering reks;n high-tension cord Voltge regultor working voltge Opertion of engine stop switch Opertion of tether switch () Hedlight (, Tillight (, rke light Sesonlly ( ttery fluid top up/specific grvity nd brether pipe Retighten every 1 hours from the first use. [URICATION INTERVAS] ENGINE Every ubriction point 2 hrs. or 4 hrs. or O hrs or When O,l/Greilse Sesonlly 4 km OO km 16 km necessry rnd nme 125 mil 15 mil 11 mil Strter cse,l pump control box Pump drive cover Aeroshell grese ;1 7 A or Esso econ 325 grese ll In the 11 tnk C YAMAUE 2 -cycle 11 DRIVE Primry sheve weight nd roller pins Secondry shft nd sliding sheve Molybdenum disulfide snowmobile grese Molybdenum disulfide snowmobile grese Front xle housing Shft 1 nd shft 2 ISlide ril! Drive chin oil replcement O DY : Steering column lower bering Steering column upper bering ight ll -purpose grese Ger oil API "G-3" SAE #75 or #8 ight ll -purpose grese Motor oil Steering links Ski column Ski wer plte Ski retining pin rke wire end stopper nd brke lever ight ll -purpose grese Esso econ 325 grese -3-

5 3. SPECIFICATIONS Generl NOTE :... New specifiction (Compred with 1979 ET34EC) Model: Model (I..M. No.) Model Frme 1.. & strting number 8J9-411 Engine 1.. & strting number E Dimension: Overll length Overll width (std) Overll height (w/windshield) ET34ED (8J9) mm (1.6 in) 97 mm (38.2 in) 1.4 mm (4.9 in) ET34ED Engine Description: Engine type Engine model Displcement Fn cooled two-stroke 5-port. twin cylinders E cc (2.6 cu.in) ore X Stroke 6 X 59.6 mm (2.36 X 2.35 in) Effective compression rtio 6.5: 1 Strting system Ignition system ubriction system Cylinder hed: Combustion chmber volume (with sprk plug) Compression chmber type Hed gsket thickness Cylinder: Mteril ore size Tper limit Out of round limit Piston: Piston skirt clernce (Mesuring point) Piston oversize Piston pin outside dimeter X length Piston ring: Piston ring design (Top) Piston ring design (2nd) Ring end gp (instlled) (Top) Ring end gp (instlled) (2nd) Recoil hnd strter nd electric strter C.D.I. "Autolube" oil inspection 21.3 cc (1.3 cu.in) Dome + Squish.5 mm (.2 in) Cst iron sleeves luminum 6 mm (2.362 in).5 mm (.2 in).1 mm (.4 in).4.45 mm ( in) (1 mm from piston skirt end) 1 st 6.25 mm (2.372 in) 2nd 6.5 mm (2.382 in) 3rd 6.75 mm (2.392 in) 4th 61. mm (2.42 in) 16 X 47 mm (.63 X 1.85 in) Keystone Keystone mm ( in) mm ( in) Smll end bering: ig end bering: Crnkshft: Crnkshft ssembly width (A) Needle bering Needle bering 16 ±.1 mm (6.3 ±.4 in) -4-

6 198 ET34EO Crnkshft ssembly width (F) 52 g5mm (2.47 g2 in) Crnkshft deflection ().3 mm (-1).4 mm (-2).4 mm (-3).3 mm (-4) Connecting rod lrge end side clernce (C) mm (.1O. 14 in) Connecting rod smll end deflection (P) 2. mm (.79 in). ---P Q -1 D-4 EA6 I :J Crnk pin outside dimeter X length Crnk pin type Crnk bering type (eft) X q'ty Crnk bering type (Center) X q'ty Crnk bering type (Right) X q'ty Crnk oil sel type (eft) X q'ty Crnk oil sel type (Center) X q'ty Crnk oil sel type (Right) X q'ty Crburetor: 22 X 5 1 mm (.866 X 2.8 in) Solid shft ssembly type with serrtion, #636 specil 1 pc. #626 specil X 2 pcs. #635 specil X 1 pc. FPJ TS X 1 pc. byrinth sel X 1 pc. FPJ TS X 1 pc. & mnufcturer/quntity MIKUNI X 1 pc. I.D. Mrk 8J6 Min jet (MJ.) #24 Pilot jet (PJ.) #75 Pilot screw (P.S.) 1. turns out Throttle v lve (ThV) #19 Vlve set (V.S. ) 1.5 mm (.59 in) Flot height 25 ± 1 mm (.98 ±.4 in) Idling engine speed 17 r/min Min jet setting chrt Altitude Se level - 3' C - 2' C - 1' C O C 1 C 2 C 1-22 FI 1-4 FI 114 FI 132 FI ISO FI 168 FI I I I I I I. #24 #22 IStdl f---#2s m 12 It I #24 IStdl - 12m 14 Itl c #21-1 8m 16 Itl _#2. _ #22 #22 #22 # m 18 It I #2 #21 - # 19-3m 11 It I #19 or more #2 Newly chnged specifiction. -5-

7 198 ET34GED lubriction: Autolube pump - Autolube pump - Autolube pump - Color code Minimum stroke Mximum stroke Autolube pump - Reduction rtio Autolube pump - Output Min/2 strokes Autolube pump - Output Mx/2 strokes Autolube pump wire free ply Oil tnk cpcity Oil grde White mm (79.98 in) mm ( in) 1/ cc ( oz) cc ( oz) 25 ± 1 mm (.98 ±.4 in) t idle 2.4 liter (25 US.qt) YAMAlUE 2-cycle Drive nd trck suspension Trnsmission: Drive rtio Enggement rpm Primry spring: Prt No. Color code Secondry spring: Prt No. Color code Secondry spring pre-lod (twist) Sheve distnce Sheve off-set V-belt width nd outer line length V-belt wer limit Trck suspension: Dmper type Spring color code (Front) Spring color code (Rer) Slide runner wer limit Trck width Trde deflection length on ground Wheel sprocket mteril nd number of teeth Stopper bnd length Secondry drive: Reduction rtio Chin pitch X Number of links Free ply Chin housing oil quntity Chin housing oil grde rke: rke pd thickness rke pd wer limit Gp between pd nd disc V-belt utomtic centrifugl enggement 3.5: 1 1 : 1 3 r/min Red No pinted ± 2 mm (1.47 ±.8 in) 11 ± 1 mm (.43 ±.4 in) 31.6 X 1.99 mm (1.24 X 43.3 in) 26 mm (1.2 in) Slide ril suspension Oil nd gs dmper Red No pinted 1 mm (.394 in) 38 mm (15 in) 25 3 mm/1 kg ( in/22 Ib) 76 mm (29.9 in) Polyethylene 11 T mm (7.34 in) (1 st hole from the bottom) Chin (#4K-2) 22/13 (1.692) 12.7 mm (.5 in) X 6l mm (.4 _. 8 In) 4 cc (13.5 oz) Ger oil API "Gl3" (SAE #75 or 85) Disc brke 7.3 mm (.287 in) 1. mm (.4 in).2 1. mm (8.39 in) -6 -

8 Chssis c Frme : Mteril Aluminum + Steel Steering system: Cster (ski column) 25 Cmber Ski length X width X thickness 98 x 12 x 1.6 mm (386 x 4.7 x.6 in) Ski stnce 85 mm (33.5 in) Ski toe-out o 6 mm (.23 mm) Steering linkge type Tie-rod ock to lock ngle (Ski) Right ski. : 27.6 R 24.8 eft ski R: 27.6 ock to lock ngle (Steering column) Right: 54.3 Front suspension: Dmper type Fuel tnk: Cpcity Fuel grde eft: 56.3 ef spring Oil dmper 22.7 liter (6 US. gl) Regulr gsoline Electricl Ignition system - flywheel mgneto (C.D.I. ) M odel/ m nufctu rer F3T352/ MITSUISHI Voltge 12V r Pulser coil resistnce 9.n t 2 C (68 F) (White/ Red- lck) Chrging coil resistnce 35n t 2 C (68 F) (rown-lck) Chrging coil resistnce 15.n t 2 C (68 F) (lue- lck) Ignition timing.t.d.c. Ignition coil: M odel/m nufcturer Sprk gp 1.6 ±.1 mm (.6 ±.4 in) CM62-2/HITACHI 9 mm (4 in)/ 3 r/ min 11 mm (.6 in)/ 3. r/ min Primry winding resistnce.15n t 2 C (68 F) Secondry winding resistnce 3.6kn t 2 C (68 F) Diode (Yes or No) No Sprk plug: & quntity NGK R-9ES x 2 pcs. Sprk plug gp.7. 8 mm ( in) Sprk plug cp: Rubber type with noise suppressor r Noise suppressor resistnce 5kn t 2 C (68 F) c C.D.I. unit Model/Mnufcturer 8H4-2/MITSUISHI Strter motor type: HITACHI S18-73 Armture coil resistnce.14nt2 C(68 F) Field coil resistnce.8n t 2 C (68 F) rush length: stndrd minimum 13.5 mm (.53 in) 9.5 mm (.37 in) rush spring pressure Armture mic undercut 7 g (24.7 oz).2 mm (.8 in) - 7-

9 ttery type: Chrging rte YUASA Y-14-2A 1.4 Amps for 1 Hours Specific grvity 1.28/2 C (68 F) Chrging system Flywheel mgneto Chrging coil resistnce.22n t 2 C (68 F) (White-lck) Strter rely switch: Hitchi A Cut-in voltge 6.5V Winding resistnce 3.n t 2 C (68 F) Rectifier: Model/mnufcturer Cpcity With stnd voltge l-element type (Hlf wve) D E544/ST AN EY 6A 4V ighting system: ighting output 12V-llW ighting coil resi stnce.19n t 2 C (68 F) (Yellow- lck) Hed light type Semi shield ulb wttge/q'ty 12V-6/ 6W X 1 pc. Til/brke light wttge A.C. regultor: Model/Mnufcturer 12V-8W/23W Voltge 13.8 ±.5V TRIZ-24/H ITACH I or S85 16 / TOSH I A Tightening torque Engine : Prt to be tightened Thred size Tightening torque Remrks Sprk plug M14 Pl m-kg (2 ft-ib) Cylinder hed M8 Pl m-kg (18 ft-ib) Flywheel mgneto M16 Pl. 7.3 m-kg (53 ft-ib) Crnkcse upper nd lower M8 P1.25 First 1. m -kg (7.5 ft-ib) Finl 2. m -kg (15 ft-ib) Tightening sequence rr - / -$ 6 3$$ 2 7t-- _. -$5 1$ $4 8$ \v Strter pulley M8 Pl m-kg (11.5ft-lb) Crnkcse nd Engine brcket Ml Pl m -kg (21.5 ft-ib) -8-

10 Drive nd trck suspension Primry sliding sheve nd Cp M6 Pl. 1.1 m-kg (8 ft-ib) Instlltion of primry sheve UNF1/2" Initil Use Motor oil 12 m-kg (88 ft-ib) oosen once nd retighten: 6. m-kg (43.5 ft-ib) Instlltion of drive chin sprocket M12 Pl m-kg (29 ft-ib) Use cotter pin Instlltion of driven chin sprocket Ml Pl m-kg (25 ft-ib) Chin housing nd Frme M8 Pl m -kg (1 8 ft-ib) Chin housing cp M8 Pl m-kg (11.5 ft-ib) Chin tensioner lock nut Ml Pl m -kg (24 ft-ib) Instlltion of front xle R.H. M2 Pl. 9. m-kg (65 ft-ib) Front xle housing nd Frme M8 Pl m-kg (1 8 ft-ib) Wheel sprocket nd Front xle.5 m -kg (3.5 ft-ib) Shft 1 nd Frme Ml Pl m-kg (4 ft-ib) Use OCK-TITE Shft 2 nd Rer brcket Ml Pl m-kg (4 ft-ib) Use OCK-TITE Rer brcket nd Frme M8 Pl m-kg (18 ft-ib) Use O CK-TITE rcket 2 nd Frme sliding 1 M6 Pl. 1.2 m-kg (9 ft-i b) Instlltion of suspension wheel M6 Pl. 1.1 m-kg (8 ft-ib) Instlltion of rer guide wheel M8 Pl m-kg (18 ft-ib) Use OCK-TITE Instlltion of runner sliding 1 M6 Pl..25 m-kg (2 ft-i b) Use OCK-TITE Instlltion of runner sliding 2 M6 Pl..6 m-kg (4 ft-ib) Use OCK-TITE Pivot rm 1 nd rcket 2 M6 P1. 5. m-kg (36 ft-ib) Use OCK-TITE Pivot 5 & 6 nd Frme sliding 1 M6 Pl. 1.3 m-kg (9 5 ft-ib) Use C K-TITE Frme sliding 1 nd 2 & 3 M8 Pl m-kg (18 ft-ib) Instlltion of stopper 1 M6 Pl..35 m-kg (2.5 ft-ib) Chssis: Engine mounting bolt Ml Pl m -kg (22 ft-ib) Ski runner M8 P1.25 I 1.4 m-kg (1 ft-i b) Use plin wsher nd OCK-TITE Steering column nd Gte M8 Pl m-kg (14.5 ft-ib) Use lock wsher Steering rely rod djusting nut Ml Pl m-kg (18 ft-ib) Out side rm nd Ski column Ml Pl m -kg (22 ft-i b) Use lock wsher nd wve wsher Steering lower brcket M8 Pl m-kg (145ft-lb) Use lock wsher nd OCK-TITE Instlltion of steering column 1,2 M8 Pl m-kg (1 5ft-lb) Use lock wsher Steering rely ss'y Ml Pl m-kg (22 ft-ib) Use cotter pin Universl joint Ml Pl m-kg (18 ft-i b) Steering gte M8 P m-kg (1 ft-ib) - 9-

11 4. SPECIA TOOS <1. 4-e. 6_ 11. No. Description Tool No. 1 Dil guge Dil guge stnd No Dil guge needle (56 mm) Flywheel puller bolt b Flywheel puller ttchment c Flywheel puller screw d Drive hndle e Flywheel puller body Rotor holding tool Primry fixed sheve puller Shelle sub-ssembly tool ushing tool Sheve guge Pocket tester Electro tester A.C. Regultor checker

12 n f J n () () () ) Hed light en (12V 6W/ 6 )W) G[ yor rke light s Y G ON Tether swite Y G Speedometer light (12V3.4W) I r= ed Min switch OFF = 1= bnllghts START MV R/W r R = FO Fe Rectifier r-l (2A) G"7 ffi ttery (12V14AH).. f I e.. J r G - y,\ Engine st op switch o l - - J e8rl'j r Y /W 1 r 11 i '-- l = R -rgr -rn?! _.. I- h I i'o - I = = G/Y! n W : l11=c:.- G y 8.(,y ---- r- em swite h - -I I-- t ) 3 l ] J [ : r=- -1 R W._-U JP [ - C.D.I. mgneto I R [] -n r '. -= ( Strter switch r><><" :IW i '-- 8_ Til/brke light (12V 8W/ 2.- ', GIY,k y : Y Il W/R 8r lw..,'- 1 I =- (J1 Spr k plug I 8 ( r-o> J [J :[ f,. r iwi! C.D.I. unit :;: : :;:.. W) - JJ 2 G) C - l> G) JJ l> S Ignition coil - =- Strting motor G Y I 9J',', Voltge regultor Color code W... White G... Green r rown..... lck Gy... Gry Y... Ye ll ow W/ R... White/ Red... lue R/ W... Red/ White O... Orne r.. /V r,rpn / Yp l ln\aj CD CO o m -I o m o

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