YAMAHA I I. 8NMMDRIli SUPPLEMENTARY SERVICE IINUII LIT KO

Size: px

Start display at page:

Download "YAMAHA I I. 8NMMDRIli SUPPLEMENTARY SERVICE IINUII LIT KO"

Daniel Burke
6 years ago
Views:

YAMAHA 8NMMDRIli I I SUPPLEMENTARY SERVICE IINUII [ Frame serial number: SKO-009101

1 YAMAHA 8NMMDRIli I I SUPPLEMENTARY SERVICE IINUII [ Frame serial number: SKO SKO ] Engine serial number: E E LIT KO

2 CONTENTS ( NEW SERVICE PROCEDURE MAINTENANCE INTERVALS SPECIFICATIONS SPECIAL TOOLS WIRING DIAGRAM WIRE AND PIPE ROUTING DIAGRAM NEW SERVICE PROCEDURE (New se rvi e proedure applied to the 1980 ET300D) There are no partiular new servie proedure. - 1-

3 2. MAINTENANCE INTERVALS [PERIODIC MAINTENANCE] ENGINE: Every Chek point 20 hrs. or 40 hrs. or 80 hrs or When 400 km 800km 1600 km neessary (250mi) (500mi) (1000 mil Seasonally Tightness of bolts and nuts a a Bends. raks and wear a a Abnormal noise a a Loose onnetion and breaks of fuel and pulse pipes a a Loose onnetion and breaks of oil pipes a a Loose onnetion and breaks of oil delivery pipe a a Manual rope starter system a a Carburetor Operation of starter jet a a Mixing adjuster (pilot srew) a a Idling speed adjustment a a Operation and adjustment of oil pump a a Ignition timing a Cylinder ompressions a a Cylinder head/exhaust pipe dearbonize a Spark plug ondition. gap and leaning a a Tightening of the ylinder head-- a DRIVE: Tightness of bolts and nuts a a Wear on slide runners a a Primary drive system a a V-belt a a Seondary drive system a a Sheave distane a a Sheave offset a a Brake pad wear a a Brake operation and adjustment a a Guide wheel rubber a 0 Wear of drive trak wheel sproket 0 0 Drive trak adjustment Initial 100km (60mi) & a a 300 km (200mi) Breaks in drive trak a 0 Bends in front and rear axles a a Cheking of lok washers a a Drive hain adjustment a a Drive hain oil level a 0 BODY: Tightness of bolts and nuts a 0 Bends and raks 0 0 Welded riveted. joints 0 a Ski adjustment 0 a Ski runner wear a a Breaks in fuel tank a 0 Cleaning of fuel tank 0 Fuel filter Loose onnetion and breaks in fuel pipe 0 a Breaks in oil tank 0 0 Oil filter a a - 2 -

4 ELECTRICAL: Every Chek point 20 hrs. or 40 hrs. or 80 hrs or When 400 km 800km 1600 km neessary (250mi) (500mi) (1000 mil Wear. breakage of wire overing 0 0 Breaks in high-tension ord 0 0 'Voltage regulator working voltage 0 Operation of engine stop swith 0 0 Operation of tether swith 0 0 Headlight 0 0 Taillight 0 0 Brake light 0 0 Retighten every 10 hours from the fi rst use. Seasonally [LUBRICATION INTERVALS] ENGINE: Every Lubriation point 20 hrs. or 40 hrs. or 80 hrs or When Oil/Grease Seasonally 400 km 800 km 1600 km neessary Brand name (250 mil (500mi) (1000 mil Starter ase 0 Oil pump ontrol box 0 0 Pump drive over 0 0 Aeroshell grease #7 A or Esso Beaon 325 grease Oil in the oil tank 0 YAMALUBE 2-yle oil DRIVE: Primary sheave weight and roller pins Seondary shaft and sliding sheave Front axle housing 0 0 Shaft 1 and shaft 2 (Slide rail) 0 0 Molybdenum disulfide snowmobile grease Molybdenum disulfide snowmobile grease Light all-purpose grease Drive hain oil Gear oil API "GL-3" 0 0 replaement SAE #75 or #80 BODY Steering olumn lower bearing Steering olumn upper bearing 0 0 Light all-purpose grease 0 0 Motor oil Steering links 0 0 Ski olumn 0 0 Ski wear plate 0 Ski retaining pin 0 0 Brake wire end stopper and brake lever 0 Light all-purpose grease 0 0 Esso Beaon 325 grease -3-

5 3. SPECIFICATIONS NOTE: *... New speifiation (Compared with 1979 ET300C) General Model Model (I.B.M. No.) Frame I.D. & starting number ET300D (8KO) * 8KO Engine I.D. & starting number * E Dimension: Overall length Overall width (std) Overall height (w/windshield) * mm (93.9 in) 935 mm (36.8 in) 965 mm (38.0 in) ET300D Engine Desription: Engine type Engine model Displaement Fan ooled two-stroke 5-port. twin ylinders E (17.94 u.in) Bore X Stroke 56 X 59.6 mm (2.21 X 2.35 in) Effetive ompression ratio 6.5: 1 Starting system Reoil hand starter Ignition system C.D.1. Lubriation system "Autolube" oil injetion Cylinder head: Combustion hamber volume Compre ssion hamber type Head gasket thikness Cylinder: Material Bore size Taper limit Out of round limit Piston: 18.3 (1.12 u.in) with spark plug Dome + Squish 0.5 mm (0.02 in) Cast iron sleeves aluminum 56 mm (2.21 in) 0.05 mm ( in) 0.01 mm ( in) Piston skirt learane (Measuring point) mm ( in) (10 mm from piston skirt end) Piston oversize 1 st mm (2.213 in) Piston pin outside diameter X length Piston ring: Piston ring design (Top) Piston ring design (2nd) Ring end gap (installed) (Top) Ring end gap (installed) (2ng; Ring groove side learane (2nd) Small end bearing: Big end bearing: 2nd mm (2.224 in) 3rd mm (2.234 in) 4th mm (2.244 in) 4>16 X 47 mm (4)0.630 X 1.85 in) Keystone Plane mm ( in) mm ( in) mm ( in) Needle bearing Needle bearing -4 -

6 Crankshaft: Crankshaft assembly width (A) Crankshaft assembly width (F) 160 ± 0.1 mm (6.30 ± in) mm ( m) Crankshaft defletion (D) 0.03 mm (0-1) 0.04 mm (0-2) 0.04 mm (0-3) 0.03 mm (0-4) Conneting rod big end side learane (C) mm ( in) Conneting rod small end defletion (P) mm (0079 in) -jl--p Q 0-4 I J udl A ( Crank pin outside diameter X length Crank pin type Crank bearing type (Left) X q'ty Crank bearing type (Center) X q'ty Crank bearing type (Right) X q'ty Crank oil sea l type (Left) X q'ty Crank oil seal type (Center) X q'ty Crank oil sea l type (Right) X q'ty 22 X 51 mm ( X in) Solid shaft assembly type with serration #6306 speial 1 p. #6206 speial X 2 ps. #6305 speial X 1 p. FPJ TS X 1 p. Labyrinth sea l X 1 p. FPJ TS X 1 p. Carburetor: & manufaturer/quantity MIKUNI X 1 p Mark 8H900 Main jet (MJ.) #210 Pilot jet (P.J.) #90 Pilot srew (P.S.) 1-1/4 turns out Throttle valve (ThV) #185 Valve seat (V.S.) 1.5 mm (0.059 in) Float height Idling engine speed 25 ± 1 mm (0.98 ± 0.04 in) 1600 r/ min Main jet setting hart: - 30 C - 20 Altitude (-22 F) (- 4 F) (14 FI (32 F) (50 F) (6B OF) Sea level - 600m (2000 ft) # # (SId) U C _ looe ooe 10 e 20 e #2 10 (SId) m (4000 ft) #200 '-# (SId) - 1 BOOm (6000 ftl #200 # m (B OOO ft) m (10000 ft) or more #200 #190 #200 # 190 #200 #190 --#1 BO- #180 #i8o -5 -

7 Lubriation: Autolube pump - Autolube pump - Autolube pump - Autolube pump - Color ode Minimum stroke Maximum stroke Redution ratio Autolube pump - Output Min./200 strokes Autolube pump - Output Max./200 strokes Autolube pump wire free play Oil tank apaity Oil grade Blue mm ( in) mm ( in) 1/ ( oz) ( z) 25 ± 1 mm (0.98 ± 0.04 in) at idle 2.4 liter (2.5 US. qt) YAMALUBE 2-yle Drive and trak suspension Transmission: Drive ratio Engagement rpm Primary spring: Part No. Color ode Seondary spring: Part No. Color ode Seondary spring pre-load (twist) Sheave distane Sheave off-set V-belt width and outer line length V-belt wear limit Trak suspension: Damper type Spring olor ode (Rear) Sl ide runner wear limit Trak width T rak defletion Length on ground Wheel sproket material and number of teeth Stopper band length Seondary drive: Redution ratio Chain pith X Number of links Free play Chain housing oil quantity - Cha in housing oil grade Brake: Brake pad thikness Brake pad wear limit Gap between pad and dis V-belt automati entrifugal engagement 3.5: 1 1 : r/min Red-Red No. painted ± 2 mm (10.47 ± 0.08 in) 11 ± 1 mm (0.43 ± 0.04 in) X mm (1.24 X 43.3 in) 26 mm (1.02 in) Slide rail suspension Oil and gas damper No. painted 10 mm (0.394 in) 380 mm (15 in) mm/l 0 kg ( in/22 Ib) 650 mm (2 5.6 in) Polyethylene 11 T 210 mm (8.27 in) Chain (#40K-l) 22/13 (1.692) 12.7 mm (0.5 in) X 60L mm ( In) 450 (15.2 oz) Gear oil API "GL3" (SAE #75 or 85) Dis brake 7.3 mm (0.287 in) 1.0 mm (0.04 in) mm ( in) -6 -

8 Chassis Frame: Material Aluminum + Steel Steering system: Caster (ski olumn) 25 Camber 0 Ski length X width X thikness 980 X 120 X 1.6 mm ( X 4.7 X 0.06 in) Ski stane 800 mm (31.5 in) Ski toe-out o 6 mm (O 0.23 in) Steering linkage type Tie-rod Lok to lok angle (ski) Right ski, L: 27.6 R: 24.8 Left ski, L: 24.8 R: 27.6 Lok to lok angle (steering olumn) Right: 54.3 Left: 56.3 Front suspension: Damper type Fuel tank Capaity Fuel grade Leaf spring Oil damper 22.7 liter (6 US. gal) Regular gasoline Eletrial Ignition system : - flywheel magento (C.D.I. type) Model/manufaturer Voltage Pul ser oil resistane Charging oil resistane Charging oil resistane Ignition timing: B.T.D.C. Ignition oil: Model: M anufaturer Spark gap F3T352/M ITSU BISH I 12V 9.0n at 20 C (68 F) (White/Red-Blak) 350n at 20 C (68 F) (Brown-Blak) 15.0n at 20 C (68 F) (Blue-Blak) 1.4 ± 0.1 mm (0.055 ± in) CM62-20 HITACHI 9 mm (0.4 in)/300 r/min 11 mm (0.6 in)/3,ooo r/ min Primary winding resistane 0.15n at 20 C (68 F) Seondary winding re sistane 3.6kn at 20 C (68 F) Diode (Yes or No) No Spark plug: & quantity Spa rk plug gap Spark plug ap: Noise suppressor resistane C. D.I. unit: Model/Manufaturer Lighting system: Lighting output Lighting oil resistane Headlight type Bulb wattage/q'ty Tail/stop light wattage A.C. regulator: * NGK BR -SES X 2 pes. O mm ( in) Rubber type with noise suppressor 5kn at 20 C (68 F) 8H4-20/MITSUBISHI 12V-100W 0.19n at 20 C (68 F) (Yellow-Blak) Semi shield 12V-60/60W X 1 p. 12-8W/23W Model/manufaturer TRIZ-24B/ HITACHI or S8516B/TOSHIBA Voltage 13.8 ± 0.5V -7-

9 Tightening torque Part to be tightened Thread size Tightening torque Remarks Engine: Spark plug M14 Pl m-kg (20 ft-ib) Cylinder head MB Pl m-kg (lb ft-ib) Flywheel magneto M16 Pl m-kg (53 ft-ib) Crankase upper and lower MB Pl.25 First: 1.0 m-kg (7 ft-ib) Final 2.0 m-kg (15 ft-ib) -$6 33+_ A- 9 / - - $5 1$$4 $ Starter pulley MB Pl m-kg (11.5 ft-ib) Crankase and engine braket Ml0 Pl m-kg (21. 5 ftlb) Drive and trak suspension: Primary sliding sheave and ap M6 Pl m-kg (B ft-ib) Installation of primary sheave UNF 1/2" Initial Use Motor oil 10 m-kg (72 5 ft-ib) Loosen one and retighten: 6.0 m-kg (435 ft-ib) Installation of drive hain sproket M12 Pl m-kg (29 ft-ib) Use otter pin Installation of driven hain sproket Ml0 Pl m-kg (25 ft-ib) Chain housing and frame MB Pl m-kg (16.5 ft-ib) Chain housing ap MB Pl m-kg (11.5 ft-ib) Chain tensioner lok nut Ml0 Pl m-kg (24 ft-ib) Installation of front axle R.H. M20 Pl.0 B.O m-kg (5B ft-ib) Front axle housing and frame MB Pl m-kg (16.5 ft-ib) Wheel sproket and front axle 0.5 m-kg (3 5 ft-ib) Shaft 1 and frame Ml0 Pl m-kg (40 ft-lb) Pivot arm 1 and sliding frame 1 Ml0 Pl m-kg (3 6 ft-ib) Use LOCK-TITE Suspension wheel M12 Pl m-kg (53 ft-ib) Spring hook MB Pl m-kg (16.5 ft-ib) Sliding frame 1 MB Pl m-kg (16.5ft-lb) Rear guide wheel MB Pl m-kg (165ft-lb) Use LOCK-TITE Sliding runner 1 M6 Pl m-kg (2 ft-ib) Use LOCK-TITE Sliding runner 2 M6 Pl m-kg (5 ft-ib) Stopper 1 M6 Pl m-kg (3 ft-ib) Suspension bar M8 Pl m-kg (16.5 ft-i b) Chassis: Engine mounting bolt Ml0 Pl m-kg (22 ft-ib) Ski runner M8 Pl m-kg (10 ft-ib) Steering olumn and gate M8 Pl m-kg (145 ft-ib) Use lok washer Steering relay rod adjusting nut Ml0 Pl m-kg (lb ft-ib) Outside arm and ski olumn Ml0 Pl m-kg (2 2 ft-ib) Use lok w ash er Steering lower braket MB Pl m-kg (16.5 ft-ib) Use lok washer Installation of steering olumn 1. 2 M8 Pl m-kg (10. 5 ft-ib) Steering relay ass'y Ml0 Pl m-kg (22 ft-ib) Universal joint Ml0 Pl m-kg (lb ft-ib) Steering gate MB Pl m-kg (10 ft-ib) ) - 8 -

4. SPECIAL TOOLS 1. 4-a. 4-d. 9. 2. 4 b. 4-e. 3. 4-. 5. 11. ( 12._--... r No. Desription Tool No. 1 Dial gauge 90890-03097 2 Dial gauge stand No.

10 4. SPECIAL TOOLS 1. 4-a. 4-d b. 4-e ( 12._--... r No. Desription Tool No. 1 Dial gauge Dial gauge stand No Dial gauge needle (56 mm) a Flywheel puller bolt b Flywheel puller attahment Flywheel puller srew d Drive handle e Flywheel puller body Rotor holding tool Primary fixed sheave puller Sheave holder Sheave sub-assembly tool r 9 Bushing tool Sheave gauge Main swith ring nut tool Poket tester Eletro tester A.C. Regulator heker

11 o I Headlight (12V 60W/60W) GGL yob I Brake light swith 7 Tether swith m r\ '"';"' 'w, 'W;"h61 ill Beam swith -- L- j Main swith \ [f] B ii,h I s L L ' y I B L -- l,' G : G B WIR L Y Br L Y Gy Gy L BMi Blw o n ILr-_-j -! ', ', J J ---- y B ' B \ I 0,--- G Y Gy o L : :l' W o F L GY : Q = tj,--- - C.D.I. magneto Color ode G,,""'"... Gree n, B Blak -- Y... "..... Yellow G Y Y I I I inht hlllq Voltage regulator G/Y g < m -l w 0 0'1 18 :ll - 2 G') C '/23W)» "-" L G/y B l' "- o IB I V B 0 JI B,LBrO W R B C.D.I. unit 0 Gy Gray Br, Brown --=- B/W Blak/white WIR WhitQ / r t.:l n G') :ll» S Ignition oil Sparl plug h. (t:::::::::::::::; g :; * 'I II.-:::::::::::::::;:.

12 6. WIRE AND PIPE ROUTING DIAGRAM B 160mm

13 31 A 1. To taillight 2. Fuel pipe 3. Fuel tank breather pipe 4. Through pipe inside the steering gate 5. Voltage regulator 6. Ground to body 7. Clamp voltage regulator ground wire 8. Fuel delivery pipe 9. Pulse pipe 10. Band 11. Wire harness assembly 12. Ground to body 13. Clamp 14. Fuel level pipe 15. Clamp 16. Pipe protetor (Coil spring) 17. Clip 18. Band (Clamp the engine stop swith lead wire) 19. Starter wire 20. Oil pipe 21. Oil filter 22. Clamp 23. Brake wire 24. Throttle wire 25. Band (Clamp the beam swith and brake light swith lead wire) 26. Grommet 27. To brake aliper 28. When installing breather pipe. route it inside the instrument panel. 29. Oil tank breather pipe 30. Through the breather pipe end into the fuel pump braket hole. 31. Bearing holder (Through the throttle wire. brake wire. beam swith lead wire. engine stop swith lead wire and brake light lead wire.) 32. Hook band (Through the beam swith lead wire. engine stop swith lead wire and brake light lead wire.) 33. Brake light swith lead wire oupler 34. Beam swith lead wire oupler 35. Engine stop swith lead wire oupler 36. Tether swith lead wire oupler 37. Main swith lead wire oupler 38. Through the main swith lead wire. tether swith lead wire and fuel tank breather pipe under the braket Grommet (Through the main swith lead wire. tether swith lead wire. fuel tank breather pipe and fuel pipe.) -12-

_YAMAHA. supp 8J LIT Frame serial number: 8J ~ 8J ] Engine serial number: S ~ S

_YAMAHA. supp 8J LIT Frame serial number: 8J ~ 8J ] Engine serial number: S ~ S _YAMAHA supp [ Frame serial number: 8J5-038101 ~ 8J5-049999 ] Engine serial number: S246-038101 ~ S246-049999 LIT -12618-00-22 8J5-28197-10 1980 ET 250D CONTENTS ( 1. NEW SERVICE PROCEDURE..............