CHAPTER 7. APPENDICES

Transcription

1 CHAPTER 7. APPENDICES 7-1. GENERAL SPECIFICATIONS 7-2 A. General 7-2 B. Engine 7-2 C. Chassis 7-4 D. Electrical 7-5 E. Tightening Torque CABLE ROUTING WIRING DIAGRAM 7-11

2 7-1. GENERALSPECIFICATIONS A. General Model: Model (I.B.M. No.) Frame I.D. & Starting Number Engine ID. & Starting Number Dimension: Overall Length Overall Width (standard) Overall Keight (standard) Seat Height Wheelbase Minimum Ground Clearance Weight: Net Weight Performance: Minimum Turning Radius 3L8 3L L ,550 mm (61.0 in) 670 mm (26.4 in) 965 mm (38.0 in) 705 mm (27.8 in) 1,050 mm (41.3 in) 120 mm ( 4.7 in) 43 kg (95 lb) 1,500 mm (59.1 in) B. Engine Description: Engine Engine Model Displacement Bore x Stroke Compression Ratio Starting System Ignition System Lubrication System Cylinder head: Volume (with spark plug) Cylinder: Material Bore Size Taper Limit Out of Round Limit Piston: Piston Clearance Piston Over Size Piston Ring: Piston Ring Design Piston Ring Design Ring End Gap (Installed) Ring End Gap (Installed) Ring Groove Side Clearance Ring Groove Side Clearance Small End Bearing: Big End Bearing: (Top) (2nd) (Top) (2nd) (Top) (2nd) Air cooled 2-stroke, Gasoline, Reed valve 3L5 49 cc (3.0 cu.in) 40.0 mm x 39.2 mm (1.575 in x in) 6.0: 1 Kick C.D.I. Separate lubrication (Yamaha Autolube) 7.0 cc (0.43 cu.in) Special cast iron 40 mm (1.57 in) 0.05 mm (0.002 in) 0.01 mm ( in) ~ mm ( in) mm, mm (1.585 in in) Keystone ring Keystone ring 0.15 ~ 0.35 mm (0.006 ~ in) ~ 0.35 mm (0.006 ~ in) 0.03 ~ 0.05 mm (0.001 ~ in) 0.03 ~ 0.05 mm (0.001 ~ in) Needle bearing Needle bearing 7-2

3 Crankshaft: Crankshaft Assembly Width (F) Crankshaft Deflection (A) Connecting Rod Big End Side Clearance (C) Connecting Rod Small End Deflection (S) 38 _ 005 mm (1.50 _ in) 0.03 mm ( in) 035~ 0.55 mm (0.014~ in) 0.4~ 0.8 mm (0.016 ~ in) S ^1 1 U -c fjfflfo IT p I * Crank Bearing Crank Bearing Crank Oil Sea Crank Oil Seal (Left) (Right) (Left) (Right) 6203-C C 3 SD SD Clutch: Clutch Primary Reduction Ratio & Method Clutch Shoe Thickness Clutch Shoe Spring Free Length Clutch Shoe Spring Set Weight Clutch-in Revolution Clutch-stall Revolution Transmission: Secondary Reduction Ratio & Method Transmission Gear Oil Quantity & Reduction Ratio & Method Kick Starter: Intake: 1 Air Cleaner Reed Valve Bending Limit Valve Lift Tightening Torque Carburetor: & Manufacturer I.D. Mark Main Jet Air Jet Jet Needle-cli p Position Needle Jet Cutaway Pilot Jet Air Screw (tur nsout) Starter Jet Fuel Level Engine Idling Speed (M.J.) (A.J.) (J.N.) (N.J.) (C.A.) (PJ.) (A.S.) (G.S.) (F.L.) Wet. Centrifugal automatic 63/33 (1.909), gear 1.0 mm (0.040 in) 34.5 mm (1.36 in) 3.6 kg (7.94 lb) r/min r/min 19/1 5 (1.266), bevel wheel gear Exchange: 300 cc (0.32 US.qt) Total: 350 cc (0.37 US.qt) Yamalube 4-cycle oil or SAE 10W/30 motor oil 57/10 (5.700), bevel wheel gear Ratchet type Oiled foam rubber 0.8 mm (0.031 in) 4.8 ±0.2 mm (0.19 ± in) 0.08 m-kg (0.6 ft-lb) VM12SC, MIKUNI 3L500 (3L501) ( ): Air cleaner type #75 (#70) 2.5 3Q3-3 (3T3-2) E (4.0) #45 (#40) 1-3/4(1-1/2) # mm ± 1.0 mm (0.87 ± 0.04 in) 1,700 r/min No 3L

4 Lubrication,: Autolube Pump-Color Code Autolube Pump-Minimum Stroke Autolubd Pump-Maximum Stroke Oil Tank Capacity Oil Grade! Yellow 0.20 ~ 0.25 mm (0.008 ~ in) 0.95 ~ 1.10 mm (0.037 ~ in) 0.8 lit (0.8 U.S.qt) Yamalube 2-cycle oil or equivalent C. Chassis Frame: Frame Design Steering System: Caster Trail Number & Size of Balls in Steering Head Upper Rape Lower Race Lock to Look Angle Front Suspension: Damper Front Fork Cushion Travel Front Fork S pring Free Lengt Spring Cor stant Wire Diam ster x Winding Outside Diameter Inner Tube Outside Diameter Rear Suspension: Damper Rear Shock Absorber Travel Rear Wheel ijravel Rear Shock Absorber Spring Free Length Set Length Spring Constant Wire Diameter x Winding Outside Diameter Fuel Tank: Capacity Fuel Grade Wheel: Tire Size (Front) (Rear! Tire Pressure (ffront) (Rear) Rim Size (Fronw (Rear) Rim Run Out Liinit (Front/Rear) Vertical Lateral Drive Shaft Lubricating Grease: Grade 1 Quantity 1 1!*h Steel tube underbone mm (2.95 in) 26 pes 5/32 in 26 pes 5/32 in 100 Telescopic fork Coil spring 45 mm (1.77 in) 78.0 mm (3.86 in) ki = 0.55 kg/mm 03.2 mm (0.13 in) x mm ( mm (0.87 in) Unit swing Coil spring, Oil damper 30 mm (1.18 in) 50 mm (1.97 in) mm (5.93 in) mm (5.73 in) ki = 6.32 kg/mm 06.4 mm (0.25 in) x mm ( lit (0.6 U.S.gal) Regular leaded gasoline PR PR 1.25 kg/cm 2 (18 psi) 2.00 kg/cm 2 (28 psi) 1.20x x mm (0.028 in) 1.3 mm (0.051 in) Lithium base wheel bearing grease (EX. SHELL LETHINAX A) 10g(0.4oz) in) in) 7-4

5 Brake: Front Brakfe Drum Diameter (Limit) Shoe Dialmeter x Width Lining Thickness/Wear Limit Shoe Spiling Free Length Rear Brake, Drum Diameter Shoe Diameter x Width Lining Thickness/Wear Limit Shoe Spring Free Length Drum brake 080 mm (3.15 in) 080 x 17 mm (3.1 5 x 0.67 in) 3.5 mm/2 mm (0.138 in/0.079 in) 44.5 mm (1.75 in) Drum brake 080 mm (3.15 in) 080 x 17 mm (3.15 x 0.67 in) 3.5 mm/2 mm (0.138 in/0.079 in) 44.5 mm (1.75 in)! 1 D. Electrical Ignition System Model/Manufacturer Voltage Pulser Coil Resistance (White/Red-Black) Charge Coif Resistance (Black/Red-Black) Ignition Timing Ignition Coil: Model/Mahufacturer Spark Gap Primary Winding Resistance Secondary Winding Resistance Diode Spark Plug /Mar ufa cture Spark Pluij Gap C.D.I. Unit: Model/Manufacturer C.D.I. Magneto: Model/Me nufacturer Charging Systor Flywheel Magneto Charging Output Charge Coil Resistance (Black-White) Lighting Oijtput Lighting Cojl Resistance (Black-Blue) Rectifier Capacity Withstand Voltage Rating Battery Model/Manufacture Capacity Charging Rate Specific Gravity F3L6/Yamaha 6V 20fl± 10%at20 C(68 F) 295fi± 10%at20 C(68 F) 0.94 mm (0.037 in) (Not adjustable) C2T4/Yamaha 7 mm (0.28 in) 1.6fi± 10%at20 C(68 F) 6.6kQ ± 20% at 20 C (68 F) No BP4HS(N.G.K.) 0.6 ~ 0.7 mm (0.024 ~ in) 2E9-MO/Yamaha F3L6/Yamaha 1.0 ± 0.5A/5.000 r/min 1.7 ± 0.5A/8.000 r/min 0.38Q± 10%at20 C(68 F) 6.5V or more/4,000 r/min 7.7V or less/8,000 r/min 0.28fl± 10%at20 C(68 F) DE4504, S5108 4A 400V Silicon 6N4-2A-2/GS, FURUu^A, YUASA 6V-4AH 0.4Ax 10 hours 1.26at20 C(68 F)

6 Lighting System: Headlight Bulb Wattajge/Q'ty HeadlightjWattage Tail/Stop Light Wattage Flasher Lijjht Wattage Flasher Pilot Light Wattage Meter Ligltit Wattage High Beam Indicator Light Wattage Oil Warninjg Light Wattage Horn: Model Maximum Almperage Flasher Relay: Model Flasher Frequency Fuse: Rating/Q'ty Semi-Sealed beam 6V, 20W/20W 6V. 5.3W/25W 6V, 17W 6V. 3W 6V,3W 6V.3W 3V.3W GF-6 1.5A FR9T11 Heat-Ribbon type 90 cycle/min 10A/1 pc E. Tightening Torque Spark plug M m-kg (14 ft-lb Oil pump M5 0.4 m-kg ( 3 ft-lb Primary drivejgear M m-kg (22 ft-lb Kick crank M6 1.0 m-kg ( 7 ft-lb Reed valve Manifold M6 0.9 m-kg ( 6.5 ft- b) Generator (Rqtor) M m-kg (30 ft-lb Generator (Stator) M6 0.9 m-kg ( 6.5 ft- b) Exhaust pipe M6 1.0 m-kg ( 7 ft-lb Cover plate (Iv ain axle) M6 1.0 m-kg ( 7 ft-lb Screw (Middle driven pinion) M m-kg (43 ft-lb Cover plate (R ng gear) M6 1.0 m-kg ( 7 ft-lb Screw (Drive r. inion) M m-kg (36 ft-lb Chassis: Front wheell slhaft nut M m-kg (30 ft-lb, Rear wheel shaft nut M m-kg (43 ft-lb Rear cushion-} Upper M8 2.3 m-kg (17 ft-lb Rear cushion-4lower M8 2.3 m-kg (17 ft-lb Footrest (Front M8 2.0 m-kg (14 ft-lb Footrest (Rear) M8 2.0 m-kg (14 ft-lb Meter ass'y Fjandle comp. M5 0.4 m-kg ( 3 ft-lb Rear arm Engine M8 2.5 m-kg (18 ft-lb Rear arm Hoipsing M8 2.5 m-kg (18 ft-lb Bracket main stand M6 1.0 m-kg ( 7 ft-lb Engine mounting bolt M m-kg (36 ft-lb 7-6

7 7-2. CABLE ROUTIIMG Starter wire Rear brake wire u Wire harness ftl

8 Stop switch lead wire. Stop switch lead wire. Wire harness ass'y (Headlight) Wire harness ass'y (Main switch) Route wire harness behind horn. Headlight unit 7-8

9 Starter wire Wire harness ass'y Oil delivery pipe Battery lead wire ( ) -Battery After connecting wires, put coupler, lead wires and rectifier inside side cover 3 so that wires are not pinched by cover. Housing fmmmbmmmmmwmsm^w^m^^r

10 High tension lead wire,%.. Switch cord band Clamp wire to upper part of front carrier so that it is not pulled when handlebars are turned fully to left. Wire harness ass'y

11 FRONT STOP SWITCH FRONT FLASHER LIGHT (R) (6V17W) OIL WARNING LIGHT QJ FLASHER INDICATOR LIGHT G > - HIGH BEAM INDICATOR LIGHT Q T - ^ SPEEDOMETER LIGHT CpJ 1 FRONT FLASHER LIGHT(L)(6V17W) REAR STOP SWITCH FLASHER ^r SWITCH HORN SWITCH C.D.I. MAGNETO COLOR CODE R Red L Blue B Black P Pink Y Yellow G Green 0 Orange W White i CO REAR FLASHER LIGHT(R)(6V17W) m 2 Q D > O > TAIL/STOP LIGHT (6V25W) REAR FLASHER LIGHT(L) (6V17W) Dg Dark green Ch Dark brown Gy Gray Br Brown G/Y Green/Yellow B/R Black/Red W/R...:. White/Red Br/W Brown/White L/W Blue/White