TABLE OF CONTENTS

GENERAL ENGINE CARBURETION POWER TRAIN CHASSIS ELECTRICAL APPENDIX

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CHAPTER 1.
1-1. 1-2. 1-3. 1-4. 1-5. 1-6.

GENERAL
1-1 1-1 1-2 1-2 1-2 1-3 1-3 1-4 1-5 1-7 1-8

EXTERNAL VIEW MACHINE IDENTIFICATION TERMS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. STRAGE......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. PRE-SEASON PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .. MAINTENANCE.........................................

A. Periodic Maintenance. B. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

11
....I

1-7. HIGH ALTITUDE TUNING 1-8. SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-9. PRECAUTIONS BEFORE SERVICE. . . . . . . . . . . . . . . . . . . . . . . ..

GENERAL
1-1_ EXTERNAL VIEW
ET340TG

EC340G

1-2. MACHINE IDENTIFICATION A. Frame Serial Number The frame serial number is located on the right-hand side of frame (just below the front of seat). The first three digits identify the model. This is followed by a dash. The remaining digits identify the production number of the unit.

C,-----..)

Frame serial number

1-'

Starting frame serial number

1-4. STORAGE
If a snowmobile will not be used for several

EC340G ET340TG
B. Engine Serial Number

ST7-121101 ST9-111101

months, it should be stored in a proper place so that both the engine and the track are not damaged. 1. Completely

The engine serial number is located on the fan case. The prefix indicates the engine type and displacement. the frame The and prefix is followed Normally numbers serial by a both are dash and the serial number. engine identical.

drain the fuel tank, and dis-

connect the fuel line from the carbure-

2.

tor. With the engine running at idle, squirt oil into the carburetor This will distribute until the engine dies. oil evenly throughout suspension, and clean and the

the engine and protect it against rust.

3.

Disassemble the grease all parts, suspension. Lightly coat grease. Oil all fittings

reassemble

4. 5. 6. 7. S.
Starting engine serial number

all shafts and axles with and wire controls with a

lightly oiled cloth. Loosen the track. Block the chassis so that the track is off the floor. Protect the snowmobile with a covering.

EC340G ET340TG

E33S-121101 E33S-1111 01

1-5. PRE-SEASON PREPARATION

Perform the predelivery service as described

in the predelivery check list before operating

1-3. TERMS
Grease: Unless other specified, ture lithium use a low-temperabase grease when instructed to

a snowmobile months.

that has been stored for several

grease a part or component. Thread-locking Use Loctite® other ware. Oil: Use Yamalube 2 to oil components unless another oil is specified. wise thread-locking compound: Lock N' Seal (blue), unless specified, compound when applying a to securing hard-

1-2

1-6. MAINTENANCE
A. Periodic Maintenance
Perform the various inspections and services at the indicated intervals; however use this schedule as a guide only. Depending upon the operating conditions, quent servicing. certain components may require more fre-

PERIODIC MAINTENANCE
Every Check point 20 hrs. or 400 km (250 mil
0 0 0 0 0 0 0

40 hrs. or 800 km (500 mil

80 hrs. or 1600 km (1000 mil

When necessary

Seasonally

ENIGNE: Tightness of bolts and nuts Bends, cracks and wear Abnormal noise Loose connection and breaks of fuel and pulse pipes Loose connection and breaks of oil pipes Loose connection and breaks of oil delivery pipe Manual rope starter system Carburetor Operation of starter jet Mixing adjuster (pilot screw) Idling speed adjustment
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

• •

Operation and adjustment of oil pump Ignition timing Engine compression Cylinder head/exhaust pipe decarbonization

Spark plug condition, gap and cleaning Tightening of the cylinder head** DRIVE: Tightness of bolts and nuts Wear on slide runners Primary drive system V-belt Secondary drive system Sheavedistance Sheaveoffset Brake pad wear Brake operation and adjustment Guide wheel rubber Wear of drive track wheel sprocket Drive track adjustment Breaks in drive track Bends in front and rear axles Checking of lock washers Drive chain adjustment Drive chain oil level ** Retighten every 10 hours from the first use.

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

1-3

Every

.
aODY: Bends and cracks Welded/riveted, joints Ski adjustment Ski runner wear Breaks in fuel tank CIeaning of fuel tan k Fuel filter

Check point

20 hrs. or 400 km (250 mil

0 0 0

40 hrs. or aoo km (500 mil

ao hrs. or 1600 km (1000 mil

When necessary

Seasonally

Tighteness of bolts and nuts

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Loose conneciton and breaks in fuel pipe Breaks in oil tank Oil filter ELECTRICAL: Wear, breakage of wire covering Breaks in high-tension cord Voltage regulator working voltage Operation of engine stop switch Operation of tether switch Headlight Taillight Brake light Battery fluid top up/Specific gravity and breather pipe (EC340)
0 0

0 0 0

0 0 0 0 0

0 0 0 0 0 0

LUBRICATION

INTERVALS
Every

Lubrication

point

20 hrs. or 400 km 250 mil

40 hrs. or aoo km (500 mil

ao hrs. or 1600 km (1000 mil

When necessary

Sesonally

Oil/Grease Brand name

ENGINE: Starter case Oil pump control box Pump drive cover Oil in the oil tank DRIVE: Primary sheave weight and roller pins Secondary shaft and sliding sheave Front axle housing Shaft 1 and shaft 2 (Slide rail) Drive chain oil replacement BODY: Steering colum lower bearing Steering column upper bearing Steeri ng Iinks Ski column Ski wear plate Ski retaining pin Brake wi re end stopper and brake lever
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Aeroshell grease#7 or Essor Beacon 325 grease Y AMALUBE 2-cycle oil

Molybdenum disulfide snowmobil grease Molybdenum disulfide snowmoible grease Li ght all- pu rpose grease Gear oil API "GL-3" SAE #75 or #ao

Light all-purpose grease Motor oil Light all-purpose grease Light all-pu rpose grease Esso Beacon 325 grease

1-4

1-7. HIGH ALTITUDE TUNING

To attain the best performance in high altitude conditions, carefully tune the snowmobiles asoutlined below.
Confirm STD settings • • • Carburetor (Page 3-3) Ignition timing (Page 6-1) Spark plug (Page 6-5)

Adjust main jet size according to the chart (Page3-3)

Test main jet size (performance & plug colour! (Page 3.a)

Not 0 K

---I.~L..I

A_d_j_U_st_m-,---ai_n_j_et_s_iz_e --,

OK

l__

.__j

OK

Not OK

Not OK

OK

OK Not OK OK

Not OK

l__j

Not OK Check engagement seped and

Not OK

High altitude tuning OK

Not OK

Not OK

Adjust secondary clutch as required (Page4-1)

1-5

-MEMO-

...............................................................................................................................................................................

1-6

1-8. SPECIAL TOOLS

1-7

No. 1 2 3 4 4-a 4-b 4-c 4-d 4-e 4-f 5 6-a 6-b 7 8 9 10 11 12 13 Dial Gauge Dial Gauge Stand

Description

Tool No. YAMAHA 90890-03097 -00 90890-01195-00 90890-03098-00 90890-01803-00 90890-01804-00 90890-01906-00 90890-01817 -00 90890-01848-00 90890-01873-00 90890-01235-00 90890-01898-00 90890-01899-00 90890-01858-00 90890-01883-00 90890-01702-00 90890-03112-00 90890-03021 -00 90890-03090-00 90890-01701-00 YS-01880 YU-01235 YS-01881-1 YS-01882-1 YS-91060 YS-01883 YS-91 047-3 YU-03112 YU-03021 Kent more YU-03097 YU-01256-1 YU-01256-2 YU-90105

Dial Gauge Needle (56 mm) 3-Way Puller Ass'y 3-Way Puller Attachment 3-Way Puller Attachment 3-Way Puller Screw Drive Handle 3-Way Puller Body 3-Way Puller Attachment Rotor Holding Tool Primary Sheave Puller (M18) Primary Sheave Puller Attachment Primary Sheave Subassembly Tool Bushing Tool Sheave Gauge Pocket Tester Electro Tester AC Regulator Checker Primary Sheave Holder

1-9_ PRECAUTIONS BEFORE SERVICE Removethe Battery ALWAYS REMOVE THE BATTERY before turning a snowmobile on its side for service. (For EC340G) Sealingthe Carburetor ALWA YS seal the carburetor before turning a snowmobile on its side for service.This will prevent fuel from spilling and creating a hazard. 1. Plug the fuel-tank vent pipe. 2. Plug both float-bowl overflow pipes or connect them together. 3. Drain float bowl.

1-8

CHAPTER 2.
2-1. ENGINE REMOVAL 2-2. DISASSEMBLY AND INSPECTION A. Recoil Starter. . . . . . . . . . . . . . B. Flywheel Magneto. . . . . . . . . . . C. Primary Sheave. . . . . . . . . . . . . D. Oil Pump. . . . . . . . . . . . . . . . . . E. Top End F. Bottom End 2-3. ASSEMBLY AND ADJUSTMENT A. Bottom End B. Top End C. Oil Pump Gear Case D. Primary Sheave E. Flywheel Magneto F. Recoil Starter 2-4. ENGINE INSTALLATION

ENGINE
2-1 2-2 . . . . . . .. 2-2 . . . . . . .. 2-3 . . . . . .. 2-4 . . . . . . .. 2-4 2-6 2-10 2-12 2-12 2-14 2-16 2-17 2-18 2-19 2-21

. . . .

. . . .

.. .. .. ..

.. .. .. ..

. . . .

. . . .

.. .. .. ..

.. .. .. ..

.. .. .. ..

.. .. .. ..

.. .. .. ..

ENGINE
2-1. ENGINE REMOVAL
You do not have to remove the engine in components: 7. 8. 9. pump 10. 11. 12. To remove the enginge, remove or disconnect the following below. 1. 2. 3. 4. Battery (EC340G) Muffler. Drive guard, and V-belt, and primary sheave (Refer 4-3, A "Removel.") Carburetor (Refer to 3-1, A "Removal.") components in the order given 5. 6. Disconnect the starter motor (EC340G) D-handle from the starter rope. Knot the rope so it will starter case. • Cylinder head Cylinder Piston Primary sheave assembly Autolube Flywheel magento Carburetor assembly Spark plug wire. Pulse pipe from the fuel pump. Oil line that feeds the autolube line. Do not let air enter the line. Four flywheel magneto leads. Hood limiter cable. Four engine mounts; remove the engine. pump. Disconnect the joint in the middle of the not be pulled into the order to service the following lead wire.

~Mountnut

Engine bracket

2-'

2·2. DISASSEMBLY A. Recoil Starter

AND INSPECTION

1. 2.

Remove the air shroud and the starter from the engine. Pullout four inches of starter rope from in the sheave drum. Rotate the cutout

the sheave drum five times clockwise to release the preload on the starter spring. 3. Remove the securing nut, and carefully disassemble the starter. Note the relative position of each piece. You will have to reassemble the starter as shown in the illustration above.

Be careful when removing the drive plate and the sheave drum. There is a preloaded spring behind each of these items.

2·2

B. Flywheel Magneto

Flywheel Pulley

Flywheel magneto

Coil plate

Crankshaft

1. Using the rotor holding tool, loosen the securing nut, and remove the flywheel pulley from the magneto.

3-Way Puller Ass'y:

YU-90105

Rotor Holding Tool: YU-01235 90890-01235-00

1. 3-Way Puller Attachment: 3-Way Puller Attachment: 2. 3:Way Puller Screw: 3. 3-Way Puller: 4. Drive handle:

90890-01803-00 90890-01804-00 90890-01906-00 90890-01848-00 90890-01817-00

2. Using the 2-way puller, remove the magneto.

Remove the woodruff key from the crankshaft. Remove the two securing screwsand removethe coil plate. 4. For inspection refer to 6-1, G "Pickup and ChargeCoil."
2-3

3.

5.

Remove the bolts mounting the starter motor, and remove starter motor assembly.

C. Primary Sheave 1. Remove the primary sheave assembly, using the primary fixed sheave puller bolt and primary sheave holding tool.

D. Oil Pump

Loosen the four gear-case bolts, and remove the gear case/oil pump assembly from the engine. 2. Remove the two gear case screws and open the gear case. 3. Remove the snap ring and the washer, and remove the drive gear. Note the relative positions of the washer. The wave washer is against the drive gear.
2-4

1.

4.

5.

Rotate the oil-pump drive shaft until the securing pin is opposite the slot in the gear case. Remove the pin and remove the pump from the gear case. Remove the drive shaft from the oil pump. Inspect the bearing surfaces of the shaft and the gear teeth. If any part of the shaft is worn or pitted, the shaft must be replaced.

B.

Measure the maximum pump stroke: as far as it will go. The cable must be held in this taut position when measuring maximum helpful around sheath. to pump stroke. securely wrap It may be duct tape

a. Pull the oil pump cable out of its sheath

the cable where

it enters the

b. Turn the oil pump gear until the plunger is at its maximum pump body. c. Using a feeler gauge, measure the gap between the adjusting plate and the raised boss on the adjusting pulley. r--ivi~mu distance from the

L~ ~

m pu mp stroke:

1.B7 mm (0.065 ~ 0.074 in)

The

oil

pump

should

not

be disas-

sembled unless the pump stroke must be checked. If a problem with the pump is noted (such as excessive oil consumpttion) proceed as follows:

6. Remove the oil pump cover. 7. Check the minimum pump stroke:
a. Turn the oil pump gear until the plunger is at its maximum pump body. b. Using a feeler gauge, measure the gap between the adjusting plate and the raised boss on the adjusting pulley. Minimum pump stroke: distance from the

1. Oil pump gear 2. Plunger 3. Maximum pump stroke

9.

If either the maximum the minimum pump equal specification,

pump stroke or stroke does not

remove the adjusting

plate and add or remove adjusting shims as required. Adding shims increases the stroke, stroke. removing shims decreases the

0.2 - 0.25 mm (O.OB- 0.01 in)

1. Adjusting 1. Oil pump gear 2. Plunger 3. Minimum pump stroke

2-5

10. Reinstall the adjusting plate and lock

nut. Torque the nut to specification. check stroke. Tightening torque: 7 Nm (0.7 m·kg, 5.1 ft·lb) maximum and minimum Repump

Tightening torque: 2 Nm (0.2 m·kg, 1.45 ft·lb)

11. Grease the adjusting plate, and reinstall

the oil pump cover. Seal the cover with Yamabond cification.

5. Torque the screws to spe-

E. Top End

Disassembly 1. Loosen the spark plug, then remove the air shroud, cylinder head, and cylinder
2-6

from the crankcase. 2. Remove the piston clip from the piston.

NOTE:
crankcase with a clean rag so you will

_
not

Before removing the piston pin clip, cover the accidentally drop the clip into the crankcase. 3. Remove piston, a piston pin clip from the the

and remove the

pin with

universal piston-pin puller. Universal piston-pin puller:

YU-01304 90890-01 304

d. Apply necting

a light film of oil to the pin and rod small end to inspect for

bearing surfaces. Install them in the conwear. Check for play. There should be no noticeable vertical play. If play exists, check the connecting or bearing, as required. rod small end for rod and/ wear. Replace pin, connecting

1. Universalpiston pin puller: 90890-01304

4.

Remove the

piston

and the small-end

bearing from the connecting rod. Inspection 1. Piston pin and bearing inspection: any wear is evident, replace the pin and the bearing. e. The piston pin should have no noticeable free play in the piston. If the piston pin is loose, replace the pin and/or piston. a. Check the piston pin for signs of wear. If

b. Check the pin and bearing for signs of heat discoloration. bearing. c. Check the small-end for signs of flat found, bearing for excessive wear or damage. Check the rollers spots. If such wear is
2-7

If excessive (indenta-

tion on pin, etc.), replace the pin and the

2.

Piston:

a. Remove the piston rings. b. Remove any carbon deposits from piston crown. c. Carefully remove any carbon deposits from the ring grooves.

replace the pin and the bearing.

Piston clearance: Minimum Maximum Piston oversize: 60.25 mm (2.372 in) 60.50 mm (2.382 in) 0.40 mm (0.0016 in) 0.45 mm (0.0018 in)

d. Remove score marks and lacquer deposits from the sides of the piston using 600 ~ 800 grit wet sandpaper. Sand in a crisscross pattern. Do not sand excessively.

1. 10 mm (0.4 in)

3.

Piston rings: scratches are noticed, replace the rings as , a set.

a. Check the rings for scoring. If any severe

b. Measure the installed e. Wash the piston f. Measure the in solvent, and dry it diameter of the

ring end gap in the

un-

rings. If it is beyond tolerance,

replace the rings as a set. with compressed air. outside piston at the piston skirt. The measurement should be made at a point 10 mm (0.4 in) above the bottom edge of the piston. Place the micrometer at a right angle to the piston pin. The maximum piston diameter subtractcylinder diameter hone the ed from the minimum ance next piston. is beyond Ring end gap, free: Top ring: Approx. 7.0 mm (0.26 in) 7.0 mm (0.26 in) Second ring: Approx.

gives the piston clearance. If the cleartolerance, cylinder to tolerance or bore it to the an oversized

oversize

and install

2-8

c. Push the ring into the cylinder, and measure the ring end gap with a feeler gauge. Push the ring into the cylinder with the piston crown so the ring will be at a right angle to the cylinder bore. If the end gap is not within specification, replace the rings as a set. Ring end gap, installed: Minimum 0.35 mm (0.0014 in) Maximum 0.55 mm (0.0022 in)

--><---------- .....
....

..........

---------

"",,"

5. Cylinder head inspection a. Remove the spark plug. b. Using a rounded scraper, remove carbon deposits from combustion chamber. Take care to avoid damaging spark plug thread. Do not use a sharp instrument. Avoid scratching the aluminum.

4. Cylinder a. Remove all carbon deposits from the cylinder and from the ports. Carburetor cleaner will help lift carbon from the cylinder head. Thoroughly wash the cylinder in solvent, and blow it dry with compressed air. b. Inspect the cylinder walls for scratches. If vertical scratches are evident, the cylinder should be rebored or replaced. c. Measure the cylinder wall wear at the places shown in the illustration; use a cylinder bore gauge. If wear is excessive, compression pressure will descrease; rebore or replace the cylinder.

Cylinder bore

Cylinder taper Cylinder out of-round

----

Standard 60mm (2.362 in) -

Wear limit 60.1 mm (2.366 in) 0.05 mm (0.002 in) 0.01 mm (0.0004 in)

2-9

F. Bottom End

Upper crenkcase

tx;~ r;
'.

,
Big-end bearing

..,,C-,
Left crankshaft

~~

~
bearing ''\

Disassembly 1. Remove the engine mounting bracket from the crankcase.

2.

Remove crankcase holding bolts. Each bolt position is numbered. Start with the highest number for disassembly. Loosen each bolt 1/4 turn and proceed to the next.

2-10

3. 4.

Split

crankcase

by

lightly

striking

the

upper and lower crankcases. Remove crankshaft with your hands. by tapping the shaft

3.

Bearing and oil seal installation Install their facing bearing(s) outward. and (In oil other seal(s) with words, the manufacturer's marks or numbers

Inspection 1. Crankcase: wash the case halves in a Blow them dry with comclean the crankcase mating inspect the case halves for 4. a. mild solvent. pressed ai r. b. Thoroughly surfaces. c. Visually cracks or damage. d. Inspect the oil delivery passages in the a. Thoroughly

stamped letters must be on the exposed to view side.) When installing bearing(s) or oil

sealls).

apply the specified lubrication. Crank bearing Crankshaft oil seal lip Yamaha 2-cycle oil Low temperature grease (Esso Beacon 325 or Aeroshell grease # 7A)

Crankshaft inspection Check connection rod axial play at small end (to determine the amount of wear of

transfer ports for signs of blockage. 2. Bearings and oil seals: cleaning and lubricating the outer the bearyour ings, rotate the bearings. race with

crank pin and bearing at big end). If small end play exceeds tolerance, disassemble the crankshaft, Replace defective
o

a. After

check connecPlay after specification. re-

finger. If rough spots are noticed, replace

ting rod, crank pin and big end bearing. parts. assembly should be within

Rod axal clearance: Maximum 2.0 mm (0.079 in)

b. Check the

oil seal lips for damage or

wear. Replace the seals as required.

2-11

b. Check the connecting rod side clearance at big end. If axial play exceeds tolerance, disassemble the crankshaft and replace any worn parts. Big end axial play should be within specification.
Rod side clearance Minumum 0.25 mm (0.010 in) Maximum 0.75 mm (0.030 in)

2-3. ASSEMBLY AND ADJUSTMENT A. Boton End 1. Install the circlip half on crank bearing as photograph. (the primary sheaveside)

1. Circlip

2.

Install the crankshaft assembly with oil seal, align the bearing punch marks and labyrinth ditches with the crankcase lower and upper mating surfaces.

c. Check crankshaft assembly runout (misalignment of crankshaft parts). Dial gauge readings should be within specificaiton. Correct any misalignment by tapping the flywheel with a brass hammer and/or by using a wedge.
Deflection Left side 0.03 mm (0.0012 in) Center (left) (0.04 mm) (0.0016 in) tolerance Center (right) (0.04 mm) (0.0016 in) Right side (0.03 mm) (0.0012 in)
FWD

'----------@
1. 2. 3. 4. Knock pin Sealingsurface Upper case Aligning mark

3. Set the pins of bearing and labyrinth seal with pin holes of crankcase upper by moving the bearings and labyrinth seal.

2·12

The oil seal lip must fit into the crankcase groove.

4. Apply YAMAHA BOND No. 4 to the mating surfacesof both casehalves. Apply thoroughly over all mating surfaces. 5. Set the crankcase half onto lower case half. Install the crankcase holding bolts. Each bolt position is numbered. Tighten all crankcase holding bolts gradually in the order of the numbers marked on crankcase. Tightening torque: First: 10 Nm (1.0 m· kg, 7.5 ft-Ib) Final: 20 Nm (2.0 m· kg, 15 ft-Ib)

6.

Install the engine bracket onto the crankcase. Torque the four bolts to specification. Tightening torque: First: 20 Nm (2.0 rn- kg, 15 tt-Ib) Final: 30 Nm (3.0 rn- kg, 22 tt-lb)

2-13

B. Top End

1. Install the piston rings as shown in the illustration.

Piston crown Top 2nd

/////J/J/J///(jUJ/

///J////
~

':J
7//;7/7 //T//T////T//T/////

Piston ring

2. Add oil to the crankcase through the oil holes. Oil the connecting rod. 3. Cover the crankcase with a clean cloth so nothing will fall into the crankcase.

4.

Oil the small-end bearing and install it in the connecting rod.

2-14

5.

Oil the connecting rod, and install the piston. The arrow on the piston crown must point ot the front of the engine.

Clean the mating surface of cylinder and joint. 10. Coat the mating surfaces of the intake manifold with Three Bond No. 50 and install new intake manifold gaskets.

9.

6.

7.

Oil the piston pin, and install it in the piston. Be sure the piston pin clip is correctly seated in the groove. Oil the piston, and install the cylinder onto the crankcase. Use a new cylinder gasket. Install cylinder head gasket and cylinder head. Working in a crisscross pattern, tighten head nuts in two steps. Head nut torque: First: 20 Nm (2.0 rn- kg, 14 ft·lb) Final: 25 Nm (2.5 rn- kg, 18 ft·lb)

11.

Install intake manifold. Tightening torque 11 Nm (1.1 rn- kg, 8 ft·lb)

8.

2-15

C. Oil Pump Gear Case

Drive gear

Adjusting pulley

1. Place the washer on the oil pump drive shaft, and insert the drive shaft into the oil punp. Be sure the worm gear correctly engages the oil pump gear in the pump. 2. Secure the pump to the gear case. Use a new gasket. Apply Yamahabond No.4 to the gear case side of the gasket only.

3.

4.

5.

Align the hole in the drive shaft with the slot in the gear case and install the securing pin. Thoroughly grease the outer edges of the drive gear onto the oil pump drive shaft. Be sure the gear correctly engages the securing pin. Secure the drive gear in place with the two washers and the snap ring. Be sure the wave washer is against the drive gear.

2-16

6.

Coat the pump drive gear with After reassembly, remove the

grease. Phillips

head screw, and feed grease through the screw hole. Recommended grease: Low temperature grease (Esso Beacon 325 or Aeroshell grease # 7A) Pump case tightening 7 Nm (0.7 torque:
1. Bleed screw

rn- kg, 5.1 ft·lb)

Grease filler screw tightening torque: 6 Nm (0.6 m· kg, 4 ft·lb)

2.

Start the engine and keep it running at idle. Pull the pump stroke wire all the way out to set the pump at maximum stroke. Keep the pump operating at full stroke for about two minutes. This will bleed the air from the oil system.

D. Primary Shave 1. Tighten bolt, tool.

1. Greeas punp

the

primary

sheave mounting sheave cap holding

using primary

Tightening torque: First tighten the bolt ot a torque of A, then loosen it. Retighten bolt to a final torque of B. A: B: 120 Nm (12 m·kg, 85 ft·lb) 60 Nm (6

Bleeding the Oil Pump The oil pump must be bled whenever: Any portion of the oil system has been disconnected. The machine has been turned on its side. Whenever empty. During predelivery. There are two methods for bleeding the pump on this model. Either will work very well. 1. Loosen the bleed screw at the pump. Oil should begin to flow through the line. all air the bleed Keep the bleed screw open until has left the fuel line. tighten screw. the oil tank has been run

rn- kg, 43.5 ft·lb)

2-17

E. Flywheel Magneto

Flywheel pulley

Coil plate

Crankshaft

Install the starter motor into the crankcase. (EC340G) 2. Secure the starter motor in place with the two securing bolts. Torque them to specification. (EC340G) Tightening Torque: 23 Nm (2.3 m- kg, 17 tt-Ib) 3. Feed the magneto leads through the hole in the crankcase, and secure the damper in the case. Install the coil plate onto the crankcase. Align the pry points on the plate with the cutout in the crankcase. Apply a thread-locking compound to both securing screws.
2-18

1.

5.

4.

Place the woodruff key in the crankshaft, and install the flywheel magneto. The keyway in the magneto must align with the key in the crankshaft. Rap the magneto with a plastic mallet to seat it on the crankshaft.

6.

Install the flywheel pulley. The two cutouts on the edge of the pulley must be opposite the holes in the fan. Torque the securingnut to specification.

Tightening torque: 73 Nm (7.3 rn- kg, 5 ft·lb) 7. For timing adjustment (Refer to 6-1, C "Ignition Timing").

F. Recoil Starter

Starter handle

2-19

1.

Hook the outer hook of the starter spring around the post in the starter case. Carefully wind the spring couterclockwise, and fit the spring into the case. Thoroughly grease the spring after installation.

5.

Install the drive plate spring, spring collar, and the drive plate. Be sure the cutout in the drive plate fits over the post on the drive pawl. Install the thrust washer and torque the nut. Grease the pivot point of the drive pawl. Tightening torque: 13 Nm (1.3 m·kg, 9.4 ft·lb)

2.

3.

Feed the starter rope into the sheave dru m, knot the end, and fit the knot into the cutout in the sheave drum. Wind the starter rope 2-114 times counterclockwise around the sheave drum. Insert the drum in the starter case. Be sure the inner hook on the starter spring hooks around the post on the sheave drum.

6.

7. 4. Install the drive pawl and the return spring. Hook the spring around the first post on the sheave drum as shown in the photograph.

8.

Pull about four inches of starter rope from out of the cutout in the sheave drum and form a loop. Rotate the sheave drum five times counterclockwise to preload the starter spring. Check the starter. If it does not operate smoothly, disassemble it, and reassemble it correctly. Install the recoil starter onto the engine. Be sure the hood limiter bracket is on the forward, upper bolts as shown in the photograph.

2-20

9.

Install the air shroud. Use a washer and lock washer with the screw that secures the air shroud to the starter case. Apply a thread-locking compound to the two bolts that thread into the engine. Torque the bolts to specificaiton. Tightening torque: 6.5 Nm (0.65 rn- kg, 4.7 ft-Ib)

2-4. ENGINE INSTALLATION 1. Place the engine in the chassis. Torque the four engine mounts to specificaiton. Tightening torque: B Nut: 30 Nm (3.0 m· kg, 22 ft·lb)

~Mountnut

@
Engine bracket

2-21

2.

Install or connect the following nents in the order given below. •

compo-

V-belt, and drive guard (Refer to 4-4, "Assembly")

• Carburetor laiton") • • • •

(Refer to 3-1, A "Inatal-

Pulse Pipe Oil line that feeds the oil pump Four magneto leads D-handle to the starter rope Battery (EC340G)

• Starter motor lead wire (EC340G) • Spark plug and spark plug wire Spark plug tightening torque:

28 Nm (2.8 rn- kg, 20 ft·lb) • Muffler and hood limiter bracket.

2-22

CHAPTER 3.

CARBURETION
3-1 3-1 3-2 3-2 3-2 3-3 3-3 3-3 3-4 3-4 3-4 3-5 3-5 3-7 3-9

3-1. CARBURETOR A. Removal............................................ B. Disassembly C. Inspection........................................... D. Assembly E. Installation 3-2. TUNING AND ADJUSTMENT A. Carburetor Tuning Data . . . . . . . . . . . . B. Starter Cable Adjustment. . . . . . . . . . . C. Throttle Cable Adjustment. . . . . . . . . . D. Oil Pump Cable Adjustment. . . . . . . . . E. Low SpeedTuning F. Mid-rangeand High SpeedTuning G. Troubleshooting 3-3. INTAKE

.. .. .. ..

.. .. .. ..

.......... .......... ........ .. ..........

.. .. .. ..

. . .. . . .. . . .. . . ..

31
<t o

CARBURETION
3-1. CARBURETOR

Throttle stop screw

f;

I e----

Starter plunger

4 ,/
Carburetor assembly

A. Removal 1. 2. Remove the air box boot assembly. Remove the carburetor and wires: disconnect the from the engine, following control

a. Loosen the throttle b. Remove the pump the stay plate, wire from the lever.

wire holder screw. wire adjuster from

and remove the pump

3-1

c. Remove the cap from the carburetor, together with the starter valve, and disconnect the starter wire. B. Disassembly 1. Carefully remove the jets, float, etc. Never, however, disassemble the throttle valve or the throttle shaft. The threads of the throttle shaft have been crimped so the screw will not come lose. Once the throttle valve is disassembled, it will be very difficult to reassemble it correctly. The original characteristics of this carburetor will be difficult to reproduce, thus performance will be adversely affected. 2. Carefully clean all parts. Blow the jets and passages clear with compressed air. Use a soft brush to clean the outside surfaces so nothing will be scratched or damaged. Do not use a wire or any such object to clear a jet. This will deform the jet and reduce performance. 3. Remove the carbon from the throttle valve and adjacent area. Take care not to scratch the throttle valve or bore. C. Inspection 1. Inspect a II jets an d passages. They must be clear. 2. Check the mating surfaces for wear. Replace jets as required. 3. Check the float valve for damage. If either the float seat or float needle are damaged, replace both parts. 4. Check the slow adjuster for carbon deposits; check the threads for wear.' Clean and replace the jet as required. D. Assembly Use new gasket when assembling the carburetor. Thoroughly grease the contact surfaces of the throttle shaft. Be sure all moving parts in the carburetor operate smoothly. 1. Install the throttle stop screw with its spring. For adjustment (Refer to 3-2, E "Low Speed Tuning".) 2. Install the main jet and the pilot jet. 3; Install the slow adjuster with its spring. For adjustment (Refer to 3-2, E "Low Speed Tuning".)
3-2

4.

Install the float, and insert the float needle into the float valve. 5. Measure the float height. a. Incline the carburetor approximately 20 or 30 degrees until the float valve just barely closes. The float should be resting on the float needle, but not compressing the spring. b. Measure the distance from the carburetor body to tHe top of the float. Float height: 25 ± 1 mm (0.98 ± 0.04 in)

c. If the float height is not within specification, examine the valve seat and the float needle. If either is worn, replace them both. If both are fine, adjust the float height by bending the tang on the float.

1. Tang

d. Reinstall the float and recheck the float height.

6. 7.

Reassemble the float. Apply grease to the following areas so they wi II not freeze: Throttle return spring, Throttle shaft, Both spaces between the throttle shaft and carburetor body, Throttle lock washer, E-ciip, and The wire holder attached to the throttle valve.

3-2. TUNING AND ADJUSTMENT The carburetor is set at the factory to run at temperatures of O°C to -20°C (32° F to _4° F) at seal level. If the machine has to be operated under conditions other than specified above, the carburetor setting so that the piston will not be damaged or seized. A. Carburetor Tuning Data 1. Standard specification
Carburetor 83S-34/MIKUNI ST600 #240 1 ¢2.4 #75 25 ± 1.0 mm (0.98 ± 0.04 in)

E. Installation 1. Install the carburetor in the engine. Be sure the air box boot and the carburetor boot correctly engage the carburetor. Secure the clamp on the carburetor boot, and the air box boot. 2. Attach the throttle cable, starter cable, oil pump cable, and the pulse pipe. refer to the Cable Routing Diagram in the appendix. 2. High altitude tuning

I.D. Mark Main jet Pilot screw (turn out) Starter jet Pilot jet Float height

~r:::::
e Sea level ~ 600 m (2,000 tt) ~ 1,200 m (4,000 ft) r--# ~ 1,800 m (6,000 ft) ~ 2,400 m (S,OOO tt)

-30°C (_22°F) L

-20°C (_4°F) I

_10°C (14° F) I #240 (Std.)

DoC (32°F)
I

10°C (50°F)
I

20°C (6SoF) I #220

#250

-I
#240 (Std.)

#220

#220 240 '(Std.)~ #210 #220

#210

1-f-#210 #200

#200

.. I
# 190

1-# 190-

~ 3,000 m (10,000 ft)

or more

au plus

~-

#200

3·3

B. Starter Cable Adjustment Pull the starter cable outer tube upward, and adjust the free play between the outer tube end and adjuster to specification by turning the adjuster. After the adjustment, tighten the lock nut and replace the rubber cap to keep the lock nut free from dust and water. NOTE: __

Starter cable free play must be adjusted after the cable is correctly routed. (Refer to Cable Routing Diagram.) Lock nut tightening torque: 0.8 Nm (0.08 m- kg, 0.6 ft-Ib)

D. Oil Pump Cable Adjustment

1.5~2.5 rnrn (O.06~O.10 in)

NOTE:
1. Adjuster 2. Lock nut

__ BEFORE

Always adjust the throttle cable adjusting the oil pump cable.

Free play between outer tube end and adjuster: 1.5 ~ 2.5 mm (0.06 ~ 0.10 in) C. Throttle Cable Adjustment Check throttle wire free playas specified when throttle closed (idling throttle).

1. Loosen the lock nut on the oil pump

cable adjusting screw. 2. Pull up the cable to its limit, and turn the adjusting screw until the free play of the outer cable is as specified below: Play: 25
±

1 mm (1.00

0.04 in)

Free play: 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) If free play is not correct, loosen the throttle wire securing screw and adjust throttle wire. After adjusting, be sure to tighten the screw properly. Throttle wire securing screw tightening torque: 4 Nm (0.4 m- kg, 3.0 ft-lb)
2. Adjusting screw

3-4

3.

Lock the adjusting the nut.

screw by tightening

E. Low Speed Tuning The carburetor is built so that low speed tuning can be done by adjusting the slow adjuster and the throttle stop screw.

Always tuning cannot damage without

install air silencer before making adjustment. High performance tuning be done without the silencer. Engine may result from attempting to tune the silencer installed.

1. Tighten the slow adjuster lightly, and back it out from its lightly seated position. Standard slow adjuster (turns out): 1-1/2

NOTE: If the engine shows poor performance in high elevations or in an extremely cold area or when it is suddenly accelerated or run at low speeds, proceed as follows: a. Replace the pilot jet according to operating conditions. Standard pilot jet: # 75

1. Main jet

2. Pilot jet

Start the engine, and fully warm up the engine. 3. Adjust the throttle stop screw until the engine runs at 2,000 ~ 2,500 r/min. 4. Slowly loosen slow adjuster. As the slow adjuster is loosened, the mixture will become leaner and engine rpm will increase. Adjust the slow adjuster to attain the highest possible engine speed. 5. Finally, turn the throttle stop screw counterclockwise so that the engine runs at 1,700 r/min

2.

b. By repeating steps 1 to 5 above, adjust the idle speed. Idle speed: 1,700
±

100 r/min

Idle speed:

1,700 ± 100 r/min

F. Mid-range and High Speed Tuning No adjustment is normally required, but adjustment is sometimes necessary depending on temperatures and/or altitude. Mid-range speed and high-speed tuning (from 1/4 to full-throttle) can be done by adjusting the main jet. 1. Run the engine at high speeds, and make sure the engine operates smoothly.

3-5

2.

Check

the

spark table.

plug.

The

main jet

should be adjusted on the basis of the following (Refer to spark plug color samples.) Standard main jet:

WARNING: Never remove the main jet cover bolt while the engine is hot. Fuel will flow out of the float chamber which could ignite and cause damage to the snowmobile and possible injury to the mechanic. Place a rag under the carburetor so fuel does not spread. Place the main jet cover bolt in a clean place. Keep it away from assembling the carburetor, rubber joint firmly fire. After tighten the

# 240

screw. Make sure the throttle

outer tube is in place and the throttle cable moves smoothly. Clean the carburetor and allow it to dry.

Spark plug color No.1 No.2 No.3 Good (Carburetor is turned properly.) small one. larger one. piston is

Bad (Mixture is too rich.) Replace main jet with one-step Bad (Mixture is too lean.) Replace main jet with one-step Bad (Due to too lean a mixture,

No.4

damaged or seized.] Replace the piston and spark plug. Tune the carburetor again starting low-speed tuning.

with

No. 5

the Bad (Due to too lean a mixture, engine knocks.] Check the piston for holes or seizure. Check the cooling system, gasoline octane rating, and ignition timing. After replacing the spark plug, tune the carburetor again starting with low-speed tuning. the spark Bad (Due to lean a mixture, plug rnelts.) Check the piston for holes or seizure. Check the cooling system, gasoline octane rating, and ignition timing. After replacing the spark plug with colder type, tune the carburetor again starting with lowspeed tuning.

No.6

3-6

G. Troubleshooting
Trouble Hard starting Check point Insufficient fuel Remedy Add gasoline Clean spark plug Return position. Clean Parts other than carbu retor • Clogged ed fuel passage Carburetor • Clogged valve. • If water clean. (Also check for ice.l Overflow Poor idling (Relative speeds • Poor acceleration • Slow response to throttle • Engine tends to stall • Throttle stop screw Adjust troubles) at low Improper adjustment • Slow adjuster Adjust idling speed • Poor performance idling speed Correct Tighten back engine and out the throttle Tightened is higher. Backed out too much Engine does not idle. Damaged slow adjuster Clogged bypass hole Clogged or loose pilot jet Replace slow adjuster Clean Clean and retighten Remove with Air leaking joint Defective Overflow Poor performance mid-range (Relative speeds troubles) slow response Lean mixtures at Clogged air vent Overhau I carbu ret or Clean Remove clean. Clogged or loose main jet Clean and retighten Remove with Overflow Check float and clean Poor performance speeds (Relative troubles) • Power loss • Poor acceleration Clogged air vent Clogged or loose main jet Remove and clean Clean and retighten at high Starter valve is left open Fully close valve Return position. starter lever to its home and float valve main jet, and blow it out the air vent pipe, and at Clogged or loose pilot jet starter valve seat Clean or replace Correct Clean and retighten Remove with pilot jet, and blow it out into carburetor Retighten band screw pilot jet, and blow it out slow adjuster opening. specification. turn turn runs slow faster, speed. Engine speed lightly, Start adjuster back and the in out collects in float chamber, or frozen air vent clogged fuel tank or air vent, clogged cloggfuel filter, starter lever to its seated Adjustment

Excessive use of starter (Excessively opened choke)

Fuel passage is clogged or frozen

check throttle it out and 1/4 stop

If incorrect,

each time. so the

When engine

engine

screw

idles at specified

to much

compressed

air.

compressed

air.

• Momentary to throttle

• Poor acceleration Poor performance normal (Relative speeds troubles)

• Excess fuel consumption • Poor acceleration

compressed

air.

Remove

main

jet,

and

clean

with

compressed Clogged fuel pipe Di rty fuel tan k Ai r leaking into fuel line Clean or replace Clean fuel tan k Check joint and retighten

air, then install.

Low fuel pump performance Clogged fuel filter Clogged intake

Repair pump or replace Replace Check for ice, and remove

3-7

Trouble Abnormal combustion (Mainly backfire)

Check point Lean mixtures Dirty carburetor Dirty or clogged fuel pipe

Remedy Clean carbu retor and adjust Clean carburetor Clean or replace fuel pipe Clean Disassembleand clean Clean or replace float valve and valve seat Replace float If not within the specified range, check the following parts and replace any defective part. Replace float Replace arm pin Replace float
I

Adjustment

Overflow (Relative troubles) • Power idling • Poor performance at low, mid-range, and high speeds • Excessivefuel consumption • Hard starting • Power loss • Poor acceleration

Clogged air vent Clogged float valve 5crached or unevenly worn float valve or valve seat Broken float Incorrect float level

Clean while taking scratch valve seat.

care not

to

Valve seat is press-fitted to body. So body must be replaced if seat is damaged.

• Worn float tang • Worn pin • Deformed float arm

Replace float assembly.

3-8

3-3. INTAKE

Air box boot

carburetor

1. Check to see that fuel moves from the fuel tank, to the fuel pump, then to the carburetor. If fuel leaks, replace the components as required.

2.

Inspect the air box boot and the carburetor boot. Replace as necessary.

3-9

CHAPTER 4. POWER TRAIN

4-1. SHEAVE ALIGNMENT. . . . . . . . . . . . . . . . . . . . 4-2. CLUTCH TUNING A. Clutch Setting Data. . . . . . . . . . . . . . . . . . . . . B. ChangingClutch Engagementand Shift RPM. 4-3. V-BE LT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Removal............................................ B. Inspection........................................... 4-4. PRIMARY SHEAVE A. Removal............................................ B. Disassembly.......................................... C. Inspeciton . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Assembly 4-5. SECONDARY SHEAVE A. Removal B. Inspection C. Assembly 4-6. CHAIN CASE A. Disassembly B. Inspection C. Gearing D. Assembly 4-7. BRAKE A. Disassembly B. Inspection C. Assembly D. Brake Adjustment 4-8. SLIDE RAIL SUSPENSION A. Removal B. Inspection C. Adjustment D. Installation 4-9. DRIVE A. Removal B. Inspection C. Assembly D. Track Adjustment . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. 4-1 4-1 4-2 4-2 4-3 4-3 4-3 4-4 4-5 4-5 4-5 4-7 4-9 4-10 4-10 4-10 4-12 4-13 4-13 4-13 4-13 4-16 4-16 4-17 4-17 4-17 4-18 4-18 4-19 4-20 4-21 4-23 4-23 4-24 4-24 4-25

. . . . . . . . . . . . . ..

4i
o e,

POWER TRAIN
4-1. SHEAVE ALIGNMENT

3.

If either the center-to-center distance or the offset is not within specification, check the engine mounts. If the engine mounting bracket, the frame, or both are bent. Replace as required. Sheave gauge: YS-91 047-3 90890-01702-00

1. Sheave 266 ± 2. Sheave 11 ±3

distance: 2 mm (10.47 ± 0.08 in) offset: mm (0.43 ±0.12 in)

Center-to-center: 266 ± 2 mm (10.47 ± 0.08 in) Sheave offset: 11 ± 1 mm (0.43 ± 0.04 in)

1.

Using the sheave gauge, check the sheave offset. If the gauge does not contact the primary and secondary sheaves at the four indicated points, the sheave offset is incorrect.

4-2. CLUTCH TUNING The clutch may require turning depending upon the area of operation and the disered handling characteristics. The clutch can be tuned by changing engagement & shifting rpm. Clutch engagement r/min is defined as the engine speed where the machine first begins to move from a complete stop. Shifting rpm is the engine speed when the machine passes a point 200 ~ 300 m (650 ~ 1000 tt) from the starting position after the machine has been started at full-throttle from a dead stop. Normally, when a machine reaches shift rpm, the vehicle speed increases but the engine speed remains nearly constant. Under unfavorable conditions, however (wet snow, icy snow, hills, or rough terrain), engine speed can decrease after the engine has reached shifting rpm.

2.

Check the disctance.

sheave

center-tO-center

4-1

Engine r/min Engine r/min Good condition Clutch shifting r/min

Bad condition Clutch shifting r/min

Clutch engagementr/min--

Clutch engagement _ r/min

Starting position 200 ~ 300 m (650 ~ 1,000 ft)

Travelled distance

Travelled distance Starting position 200 ~ 300 m (650 ~ 1,000 ft)

A. Clutch Setting Data

ET340TG S_T_D_ Engagement r/min Shifting r/min Parts No, Primary spring Set weight Spring constant Color Weight rivet Secondary spring Q'ty Parts No. Twist angle Color 3,300 ± 100 6,400 ± 100 90501-50500 25 kg (55 Ib) 1-4 kg/mm (78-4lb/in) Red 2 p.c.s, 90261-06017 160
0

(8T9) High altitude

EC340G (8T7) S.T_D_ 3,000 ± 100 6,600 ± 100 High altitude

~
6,100 ± 100

~
6,100 ± 100

~ ~ ~ ~
None
-

~ ~ ~ ~
2 p.c.s. 90261-06017

~ ~ ~ ~
None

None

~ ~

~ ~

~ ~ __

NOTE: High altitude specifications apply to operation at an altitude of more than 1506 meters (4500 ft).

Since the clutch weights are secured in place by the sheave cap bolts, the centrifugal force that can alter clutch characteristics comes from the weight of the lever on the spider. To adjust clutch engagement and clutch shifting B. Changing Clutch Engagement and Shift RPM

r/min, add or remove weight rivet from the spider as indicated by the chart, Clutch shifing r/min can also be adjusted by changing the preload on the secondary sheave spring: 160 and 280 160 is standard.
0 0 0 •

Clutch engagement r.p.m, Decrease Centrifugal force of weight Torsion spring constant Twist angle Add rivets Increase Remove rivets

Clutch shifting r.p.rn, Decrease Add rivets Decrease Smaller wind Increase Remove rivets Increase Greater wind

4-2

Secondary spring

4-3. V-BELT

A. Removal 1. Turn the secondary sliding sheave clockwise and push it towards the engine.
I I I
\ \

\ \ \ \
\

I I I I I

I I

1. New: 31.5 mm (1.24 in)

2. Wear limit: 26 mm (1.02 in)

3. Measure the length of the V-belt.

should be within specification; replace the belt

It

if not,

2. While holding the sliding sheave in this

ompressed position, primary. remove the V-belt from the secondary sheave then from the

Part No. 820-17641-00

Length of V-Belt

--

1,099 mm (42.8 in)

B. Inspection
1. Visually
damage. damaged. 2. Measure the width belt is worn replace it. Wear limit: of the V-belt. the wear If the limit, beyond inspect the V-belt for signs of Replace the belt if it is

26 mm (1.02 in)

4-3

4-4. PRIMARY

SHE ...,...A~V_E _

Bushing

Spider

Sheave cap bolt

Fixed sheave Weight

Sliding sheave

4-4

A. 1. 2.

Removal Remove the drive guard, and remove the V-belt. Hold the fixed sheave bolt. holder the with Drive sheave with the primary and remove the clutch sheave

2. 3.

Loosen the six sheave-cap bolts. Remove the sheave sub-assembly and remove the sheave cap.

tool,

C. Inspection 1. Inspect shaft the tapered ends of the crankfixed sheave for and the primary

primary the

sheave off the primary

crankshaft puller.

scartches.

If either is severely scratched, with emerly cloth. sheave cap bushing replace the

replace it. If scratches are minor, burnish Primary sheave holder: YS-01880 90890-01701-00 Primary sheave puller: YS-01859 90890-01898-00 2. he component Check If worn bushing. Use the bushing tool if a bushing is difficult to remove. Bushing tool: YS-01883 90890-01883-00 the primary beyond

and the sliding sheave bushing for wear. tolerance,

1. Sheaveholder

2. Sheavepuller

B. Disassembly 1. Install the sheave sub-assembly sheave. tool in

1. Bushing tool

the primary

Primary sheave sub-assembly tool:

I

Bushing clearance, limit

YS-91 060 9_0890_-0_1_8_58 __ -0_0 ~

~
Inside Outside

Small bushing 0,25 mm (O.Ol in) 0,25 mm (O,Ol in)

Large bushing 0,25 mm (O,Ol in) 0,25 mm (O,Ol in)

1. Sheavesub-assembly tool

4-5

5.

Inspect the slides in the sliding sheave for scratches or other damage; replace the sliding sheave as required.

6.

Disassemble and inspect the spider levers; replace any worn parts. Reassemble the levers with new cotter pins.

3. 4.

Remove the sliding sheave from the fixed sheave, and remove the spider. Measure the wear on the slider buttons. If worn beyond specification, replace the buttons. Wear limit: 27.0 mm (1.06 in)

4·6

7.

Inspect the weights for wear; replace as necessary.

5.

Install the spring and the ~h~ave cap. Be sure the "X" on tlJ?: sheave cap aligns with the "X" on,the'sliding sheave.

8.

Check the spring. Replace fatigued or damaged.

it if it is 6. Install the primary sheave sub-assembly tool and secure the sheave cap to the fixed sheave. The two long bolts must also secure the clutch weights in place. Torque all six bolts to specification. Primary sheave subassembly YS-91 060 90890-01858-00 tool:

D. Assembly 1. During assembly, grease the indicated points, but take care to keep the other indicated areas from grease.

Tightening torque: 10 Nm (1.0 rn- kg, 7 ft·lb) 7.

-I
I

+-. Oiling point +- X Free from grease

+- Grease point

Check the movement of the sliding Sheave. If it is not sooth, disassemble the primary sheave and reassemble it correctly.

2.

3. 4.

Install the bushing and the spider into the sliding sheave. Be sure the bottons correctly engage the slider. Thread the sliding sheave onto the fixed sheave. Install the weights. Be sure they are correctly seated in the sliding sheave.

8. 9.

Clean the tapered portions of crankshaft and fixed sheave. Fit the fixed sheave to the tapered portion of crankshaft.

4-7

10.

Apply engine oil to the threaded portion of primary sheave bolt and its contact surface with spring washer.

11.

Hold the primary primary

fixed sheave with the

sheave holder, and torque the

sheave bolt ot specification.

Primary sheave holder: YS-01880 90890-01701-00 Tightening torque:

Tighten the bolt to A to properly seat the primary sheave on the crankshaft. Loosen the bolt, then torque it to B, the final torque. A: B: 120Nm(12m·kg,85ft·lb) 60 Nm (6 m· kg, 43 ft·lb)

4·8

4~. SECONDARY SHEAVE

Slinding

sheave

Fixed sheave

Secondary

shaft

4-9

A. Removal 1. Remove the chain cast cap, and drain oil. (See 0-0-0 Chain cast section) 2. Apply brake, and remove cotter pin, chain drive sprocket nut, and washer.

B. Inspection 1. Check the ramp shoes spring shaft for wear. shoes as required. 3. 4. 5. 6. Remove the brake wire from the brake lever. Remove the chain case from the frame. (See 0-0-0 Chain case section) Remove the brake pad assembly. (See 0-0 Brake section) Hit the secondary shaft slightly and push out the secondary sheave from the chain case.
L.

on secondary Replace ramp

3.

Check torsion spring Tor ir ee 1t:!IIYUI. II excessively fatigued, replace. Check both sheaves and brake disk for warpage. If warped replace.

7.

Remove the spring pin from the secondary shaft and remove the secondary spring shaft, torsion spring, sliding sheave, and fixed sheave.

C. Assembly 1. Press-fit the fixed sheave over the secondary shaft. Before this operation, it is necessary to oil the contact surfaces. 2. Grease the secondary shaft, and mount the sliding sheave on the shaft. 3. Insert the secondary spring into the secondary shaft. Hook one end of the secondary spring on the sliding sheave and the other end on the spring seat.

4-10

4.

Turn the spring seat 160 degrees clockwise from the free position of the spring, and drive the spring pin into the spring seat to lock it to the secondary shaft.

The spring pin must be replaced with a new one. NOTE: After installation, thoroughly clean both primary and secondary sheaves so the they are free of oil. 5. Install the secondary assembly to the chain case before installing chain case to frame. (See chain housing and brake system sections)

NOTE.: Exercise care not to damage oil seal lip when installing secondary shaft into case.

4-11

4-6. CHAIN CASE: _

Driven sprocket

4-12

A. Disassembly 1. 2. 3. 4. Place an oil pan beneath the drain hole under the chain case. Remove the chain case cover, and let the oil drain into the oil pan. Loosen the chain tension. Remove sprockets. NOTE: and driven sprockets. 5. Remove sprockets. the drive chain and both _ the securing hardware and washers from both the drive and driven

2. 3. 4.

Inspect the drive and driven sprockets; replace if worn. Inspect the drive chain; replace as necessary. Inspect the adjusting block. replace the block. If the raised boss is worn to the base of the block,

Set the parking brake before loosen the drive

1. Wear limit 6 mm (0.24 in)

C. Gearing Change the gear reduction the following chart. 13T (12T*) 60 • Std. Drive sprocket: ratio according to

• Std. Driven sprocket: 22T (23T*) • Std. No. of chain links: • 6. 7. Remove sprocket. Remove the four bolts mounting the
p ~ Drive sprocket Driven sprocket No. of chair links Trail and tour Std. Std. Std.

the

collar

from

behind

each

14T Drive sprocket part No.: 806-17682-40 21T Driven sprocket part No.: 8G8-47548-10
Lake surface Std. or 14T (13T*) Std. or 21T (22T*) Std.

chain housing.

* Fnr ET::l40TG D. Assembly 1. Before installing chain case to frame, install brake calipers and secondary sheave assembly to chain case. (See 0-0-0 Secondary 8. Remove the chain case with sheave assembly. B. Inspection 1. Inspect the bearings in the chain case. If the movement is rough or uneven, replace the bearings. secondary Brake sections") 2. Tighten the chain case bolts and torque them to specification. Tightening torque. sheave" and

"0-0

23 Nm (2.3 rn- kg, 17 ft·lb)

4-13

Chain deflection.

10 mm (0.4 in)

Tightening torque: 35 Nm (3.5 m· kg, 25 ft·lb)

3. Install both collars in the chain case. The

larger goes on the drive axle, the smaller on the secondary shaft.

4.

Place both the drive and driven sprockets in the drive chain, and install them in the chain case. Be sure the stepped side of the driven sprocket faces in towards the engine. Tightening torque.

7. Install the chain case cover. Torque the

two bolts to specification. Be sure the seated on the rubber gasket is properly chain case. Tightening torque. 16 Nm (1.6 m· kg, 12 ft·lb)

35 Nm (3.5 rn- kg, 25 ft-Ib)

5. 6.

Install the adjusting block. Adjust adjusting the chain tension. Turn the bolt until the chain deflection Torque the lock nut

equals specification. to specification.

4·14

8.

When filling

with

gear oil, the filler

cap

and oil level screw should be removed.

Oil level screw

Fil until begins to run out the screw hole. Recommended oil.

Gear oil API "G L-3" SAE #75 or #80 Quantity: 0.4 L (0.35 Imp qt, 0.42 US qt] After 9. tighten Adjust lock filling oil, be sure to install and

the level screw and fi Iler cap. chain tension by loosening the and turning bolt in or out.

nut on chain adjuster locknut.

the adjusting Retighten

4-15

4-7. BRAKE
Brake caliper

A. Disassembly

3.

Remove the chain case. (See chain case section). 2. Remove the brake wire from the brake lever. It is necessary to loosen the adjusting screw attached to the caliper so that the brake wire is slack.

1.

Pull out the cotter pin from the upper part of the pivot pin, and pull the pivot pin downward and out.

4-16

B. Inspection 1. Check the pads for damage and wear. If the thickness is less than specified below, replace pads as a set. Wear limit: (Thinnest) 1 mm (0.04 in)

Apply a small amount of antifreeze grease to the contact areas of the brake wire with brake lever stopper surface.

1. Wear limit:

1 mm (0.04 in)

2.

3.

If the brake lever will not return smoothly to the rest position because of a fatigued return spring, replace the return spring. Inspect the brake disc. Place it on a surface plate and check around the edges with a feeler gauge. If the gap is uneven, the disc is bent and must be replaced.

c. Assembly
NOTE: __

D. Adjustment Adjust the gap between the brake pad and the brake disc 0.2 - 1 mm (0.008 - 0.04 in). 1. The outer brake pad should be adjusted by the adjusting screw attached to the chain case. Loosen the adjusting bolt locknut. Unscrewing the bolt makes the gap larger. Screwing the bolt in makes the gap smaller. 2. The inner brake pad should be adjusted by the adjusting screw attached to the makes the gap larger, while loosening makes the gap smaller.

The brake system must be installed to the chain case before installing the chain case to the frame. 1. 2. 3. Install the outer pad and spring to chain case. Install the secondary sheave assembly to chain case. Install the inner pad to chain case and push pin into holes in calipers and in chain case from below, install return spring, washer, and cotter pin. Install the chain case assembly to frame. (See chain case section) Install brake wire to the calipers and brake leverl.

4. 5.

Inner pad adjusting screw 3. Inner pad adjusting screw locknut

4-17

4-8. SLIDE RAIL SUSPENSION

Rear pivot arm

End cap

Front shaft

Front pivot arm

A. Removal 1. 2. Loosen the track. Seal the carburetor (Refer tor.") to so fuel will not spill when you turn the machine on its side. 1-6, C "Sealing the Carbure-

3. 4.

Remove the battery (EC340). Remove two front bolts and four mounting bolts. pivot shaft mounting rear pivot shaft bracket

4-18

NOTE:

_
10 ~ 15 mm (0.4 ~0.6 in) 2 ~3 mm (0.08 ~0.12 in)

It is advisable to loosen the track adjusting screws and unhook rear spring before removing the mounting bolts.

WARNING: Wear eye protection to prevent eye damage

from escaping gas and/or metal chips. 5. Remove slide rail suspension. B. Inspection 1. WARNING: This shock absorber contains highly presInspect the hyfax. Replace them if they are worn beyond the wear limit. Torque the screws to specification. Wear limit: torque: 10 mm (0.4 in)

surized nitrogen gas. Read and understand the following manufacturer information before handling the shock absorber. The cannot be held responsible for property damaged or personal injury thet may result from improper handling. 1. 2. Do not tamper with or attempt to open the cyl inder assembly. I njury may result. Do not subject shock absorber to an open flame or other high heat. This may cause the unit to explode due to excessive gas pressure. 3. Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. 4. Gas pressure must be released before disposing of the shock absorber. To do so, drill a 2 ~ 3 mm (0.08 ~ 0.12 in) hole through the cylinder wall at a point 10 ~ 15 mm (0.4 ~ 0.6 in) above the bottom of the cylinder.
1. Wear limit: 10 mm (0.4 in) 2. New: 13.5 mm (0.5 in)

Slide runner securing screw tightening 3.5 Nm (0.35 m· kg,2.5 ft·lb)

~ l11
@
--

2.

Inspect the suspension wheels; replace as necessary. Apply a thread-locking compound to the securing bolts, and torque the bolts to specification. Tightening torque: 14 Nm (1.4

rn- kg, 10 ft-lb)

wheels; replace as com-

3.

Inspect

the

guide

necessary. Apply tion.

a thread-locking

pound and torque the bolt to specifica-

4-19

Tightening torque: 23 Nm (2.3 m· kg, 17 ft-Ib) 4. 5. Replace any fatigued springs. Inspect the front stopper bands. Repalce if either is frayed or damaged. L (Std.) = 186.5 mm (7.34 in) Standard setting: 1st hole from the bottom Tightening torque: 3.8 Nm (0.38 m -kq, 2.75 ft·lb) This adjustment will greatly affect the stability and handling of the machine as well as the side slip of the track while turning a corner.
Handle-

0 0 0 0, -. 0
Track side slip running Increase Decrease L

"<,

Std

Performance of straight pitching Poor Good

Bumping and More Less

Riding comfort Poor Good

-inq
Esay Hard

Lower Higher (Std.)

6.

Insepct the rear springs. The rear speings are a determining factor in machine stability. Consider the race course condition and the rider's weight when setting rear springs. The suspension should be set as soft as possible, unless it impairs the stability of the machine.

Course

Oval course riding (more gap) Upper

Rear spring set position

c.

Adjustment:

1. Remove the rear spri ngs from the hooks. 2. Remove the rear spring hook securing clips and washers. 3. Set rear spring pins to specified set position.

4-20

Must be set both the right and left springs to the same height. 4. 5. Install the washers and new clips. Install the rear springs to the hooks.

D. Installation 1. Grease the suspension where indicated in the illustration.

Fully loosen the drive track adjusting screws. 3. Thoroughly grease the axle in the front pivot arm. Tape the end caps in place. This will hold the axle within the pivot arm during installation of the suspension.

2.

NOTE:

__

Install bolts finger-tight. Bolts will be tightened to proper torque when slide rail installation is complete.

4-21

4.

Fit the rear pivot shaft ot the frame. The rear pivot shaft is being forced toward the rear by the shock absorber. To assist in rear shaft installation keep the shaft forward by using an iron bar.

1. Iron bar

NOTE: When installation

__ of slide rail is complete,

tighten front and rear bolts to proper torque.

Tightening torque: Front pivot shaft mounting bolts. 55 Nm (5.5 m· kg, 40 ft·lb) Rear pivot shaft bracket mounting bolts. 25 Nm (2.5 m· kg, 18 ft·lb) Rear pivot shaft mounting bolts. 55 Nm (5.5 m· kg, 40 ft·lb) 5. After installing the slide rail suspension

assembly on the frame, hook the right and left torsion springs in place. Adjust the track tension by turning adjusting to "00-0 Track adjustment". the track refer screws. For adjustment,

4-22

4-9. DRIVE

Drive sprocket

A. Removal 1. Place an oil pan beneath the chain case, and remove the chain case cover. Let the oil drain into the oil pan. 2. Remove the axle nut and washer; remove the bearing cage. NOTE: Lock the front axle by applying the brake. __

3. 4. 5.

Remove the driven sprocket. Remove the suspension. (Refer to 4-8, A " Removal." ) Place the machine on its right side. Remove the axle by pushing it down and out of the chain case, then out of the track.

6.

Remove the track.

4-23

B. Inspection 1. Check the track and clips for cracks, damage, or wear. Replace the track or clips as required. 2. Inspect the sprockets. If the lugs are excessively worn, replace the sprockets. 3. Inspect the axle. If it is bent, excessively scratched, or if the splines or threads are damaged, replace the axle. 4. When pressing the sprockets onto the axle, be sure the lugs on each sprocket are opposite one another as shown in the photograph. Locate each sprocket on the axle where shown in the illustration. After positioning, tighten the band.

182mm (7.2 in)-----+---123

mm (4.8 --i---in)

140.5 mm (5.5 in)-l

1------149

mm (5.9 in)---.,

c. Assembly
1. Place the track in the chassis. Be sure it is positioned as shown in the illustration.

2.

Install the axle then install the splined end into the chain case. Be sure the lugs correctly engage the track. Insert the left hand side of the front ax Ie into the chain case through drive track. Tighten the front axle with chain drive sprocket. Refer to 4-6 chian case assembly. Tightening torque: 35 Nm (3.5 m· kg, 25 ft·lb)

Turning direction

4-24

Track deflection 25 ~ 30 mm/l0 (ET340TG): 40 ~ 50 mm/l0

(EC340G): kg

(0.98 ~ 1.18 in/22 Ib) kg

(1.57 ~ 1.97 in/22 Ib)

3.

Install the bearingcage and the bearing onto the drive axle. Torque the three bolts to specification. Tightening toruqe: 23 Nm (2.3 m- kg, 17 ft·lb)

4.

Insta II the

washer and the ax Ie nut.

1 Track deflection

Torque the nut to specification. Tightening torque: 80 Nm (8.0 5.

1. Turn the track by running the engine. 2. Loosen the lock nuts, and turn both the right and left track adjusting bolts until the track is aligned with the slide rail as illustrated.

rn- kg, 58 ft-Ib]

Install the meter gear unit.

1. Lock nut

2. Adjusting bolt

6. 7.

Install the slide rail suspension. (Refer to 0-0, C "Installation.") Reassemble the chain case, and fill (Refer to 0-0,60 "Assembly.") oil.

D. Track Adjustment The track tension should be adjusted so that tarck deflection 10 kg (22Ib). will equal specification when the track is pulled at the middle by a force of

4-25

No good Slide runner Track

Good Slide runner

No good SIide runner Track

Track metal

Track metal

Forward

Gap between slide runner and edge of ta

Forward

Forward

Gap between slide runner and edge of track window.

When shifted to right: Tighten the right track adjusting bolt, and loosen the left track adjustinb

When shifted to right: Tighten the right track adjusting bolt, and loosen the left track adjusting bolt.

3.

Check the track

deflection.

It should

equal the specified value.

4. If it does not, repeat the above procedures until tion. deflection equals specifica-

5. Tighten the track adjusting lock nuts.

Torque to specification. Tightening torque:

35 Nm (3.5 rn- kg, 25 ft-Ib)

4-26

CHAPTER 5.
5-1. ST E E R I N G '

CHASSIS
5-1 5-2

A. Assembly B. Adjustment
5-2. SKiS

5-3
5-4 5-4 5-5

A. Inspection B. Assembly 5-3. OIL TANK

5-4. FUEL TANK

5-6
5-7

51

CHASSIS
5-1. STEERING

Tire rod

Outside arm

Ski column

5-'

A. Assembly

3. on the frame. the skis so that they are parallel

Install

the

steering the

column

onto

the

1. Grease the ski column

Position to each other.

frame. Grease the upper and lower bearings. Torque bolts to specification and bend the lock tab.

Place the outside arms on skis (L on left ski, R on right ski). Be sure to install Tighten the wave washer betmounting nuts ween outside arm and frame. the ski column and outside arm pinch bolts. After tightening washer tab. Tightening Nut: the nuts, bend the lock

torque:

30 Nm (3.0 rn- kg, 22 ft·lb)

Pinch bolt:

20 Nm (2.0 rn- kg, 15 ft· Ib)

4. Connect
steering
1. Nut 2. Pinchbolt

the steering column.

relay

rods to the

Torque

the flange nut

to specification pin. Tightening to the outside

and install a new cotter

2. Secure the steering relay rods (with the

universal joint attached) arm. Torque the flange nut to specifica-

torque:

tion and install a new cotter pin. Tightening torque;

25 Nm(2.5 rn- kg, 18 ft· lb)

30 Nm (3.0 rn- kg, 22 ft· lb)

5-2

B. Adjustment
1. Straighten the handlebars and check to see that the skis are parallel. tie rod lock nut If not, and the loosen the

steering relay-rod

lock nut. By turning to specification.

the tie rod and the steering relay rod, adjust the ski toe-out Torque the lock nut to specification. Ski stance: Ski toe-out: 850 mm (33.3 in) 0 ~ 6 mm (0 ~ 0.24 in)
1. Clamp 2. Handlebar

Front

CD

1. Ski spindle center A-C=O-Smm (0-0.24 in) B. Ski stance

Tightening torque: 25 Nm (2.5

rn- kg, 18 ft·lb)

2.

The

height

of the

handlebars can be

adjusted to suit the rider's preference. After adjusting the handlebars, alternately tighten the four securing bolts. Maintain the specified gap in the steering clamps. Torque the bolts to specification.

Tightening torque: 14 Nm (1.4 m·kg, 10 ft·lb)

5·3

5-2. SKIS

A. Inspection
1. Check the ski runner. excessively worn. specificaiton. Tightening torque: 14 Nm (1.4 m-kq, 10 ft-Ib) Replace it if it is the nuts to Torque

2.

Inspect the leaf spring and the spring retaining pins. If the spring is fatigued or if a pin is worn, replace them as necessary. Torque the securing nut to specification and install a new cotter pin. Tightening torque: Spring nut: 14 Nm (1.4 rn-kq, 10 ft-Ib)

5-4

3. Check the wear plate. Replace it if it is worn. B. Assembly 1. After assembling the ski, thoroughly greasethe wear plate and all retaining pins.

2. Carefully install the ski onto the ski column. tighten the securing bolt until it is tight, then back it out 114 turn. Tighten the slotted nut, and install a new cotter pin. 3. When installing the ski shock, securethe bottom end to the ski then secure the top end to the ski column. All collars should be greased, and securing nuts should be torqued.

Be sure to install the shock with the word "YAMAHA" facing upward. Tightening torque: 14.5 Nm (1.45 rn- kg, 10.5 ft·lb)

5-5

5-3. OIL TANK

Oil gauge line

1.

Check the oil line from pump. tions sary. and should not

the tank to the be pinched or

It should be free from all obstrucin any way. Replace as neces-

damaged

5-6

5-4. FUEL TANK

Fuel gauge line

Fuel lin~~-<;>

Fuel tank vent pipe

1.

Check crimped, them.

all

lines.

If

any

are

cracked,

or damaged in any way, replace

2. 3.

Be sure all lines are secured in place by a retaining in the routed clip. Cable The so that Routing breather Diagram pipe in the must be Be sure that all lines are routed as shown appendix. operation.

no fuel will

leak during of

4.

The fuel filter fuel tank. It is advisable If the filter flow ment), or

is located in the cottom that the fuel filter (obstructing be replaced

be rethe fuel

paced with a new one each season. is faulty having it should a breakage in the eleas an as-

sembly unit.

5·7

CHAPTER 6.

ELECTRICAL
6-1 6-2 6-3 6-4 6-4 6-5 6-6 6-6 6-7 6-7 6-7 6-8 6-10 6-10 6-11 6-12 6-12 6-14 6-14

6-1. IGNITIONSYSTEM A. Troubleshooting...................................... B. Ignition Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. C. Spark Gap Test D. Ignition Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. E. Spark Plug F. Pickup and C.D.I. Charging Coil Test G. C.D.I. Unit : . . . . . . . . . . . .. 6-2. LIGHTING SYSTEM A. Headlight Beam Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . .. B. Lighting Coil Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. C. Voltage Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-3 CHARGING SYSTEM (For EC340G) A. Charging Circuit Test B. Checking Silicon Rectifier 6-4. ELECTRIC STARTING SYSTEM (For EC340G) A. Starter Motor B. Starter Relay Switch C. Battery

ELECTRICAL
6-1. IGNITION SYSTEM Circuit Diagram

6-1

A. Troubleshooting No spark is produced or weak .

. . . . . . . . . .Check leadwire connections for short circuits.

OK

Faulty

Correct.

S""k

.Jt

1················

.S" 6-1, E "Spark G,P T

Spark

No spark

..

"t."
Plug is faulty.

OK

FauIty------

Replace.

..............

Measure coil resistance. (See6-1, G "Pick up and C.D.I. ChargeCoil.")

Faulty-------_Replace

L-

__

-.

. . . . . . . . . . . . .Ignition coil test (See6-1, E "Ignition Coil.")

OK

Faulty-----_

Replace.

CD.I. tLn_it_I_._._._._._._. _._._._._._._ .._._._s_ee_6-1,"C.D.1. Unit." H. Faulty ---------_.

Replace.

The engine starts but will not pick up speed.

OK

OK .......... (See6-1, C "Ignition Timing.")

~---.-----~

L-----------------------.Faulty------_

Replace.

6-2

B. Ignition Timing Use of dial gauge 1. Remove the starter from the engine. 2. Remove the spark plug, and screw the dial gauge stand into the spark plug hole (right). Dail gauge stand: YU-01256-1 90890-01195-00

3.

Insert the dial gaugewith the needle into the stand. Dial gauge: Dial gage YU-03097 90890-03097 -00 YU-01256-2 90890-03098-00

8.

Loosen both coil plate screws.

9.

Rotate the coil plate by using a screwdriver at the pry points. Align the marks on the coil plate with the mark on the flywheel. Tighten the screws and torque them to specification.

Rotate the flywheel magneto until the piston is at top-dead-center (T.D.C.). Set the dial gauge at zero. Tighten the set screw on the dial gauge satnd to secure the dial gauge assembly. Rotate the flywheel back and forth to be sure that the indicator needle does not go past zero. 5. Starting from T.D.C., rotate the flywheel counterclockwise until the dial gauge reads 3-112 needle revolutions before top-dead-center. 6. Slowly turn the flywheel clockwise until the dial gauge indicates the specified ignition timing. 10. Ignition timing (B.T.D.C.): 1.6 mm (0.062 in) 7. The marks on the coil plate should align with the timing mark on the magneto. If not, adjust the timing.
6-3

4.

Tightening torque: 6.5 Nm (0.65 m· kg, 5 ft·lb) Remove the dial gauge stands. Reinstall the starter and the spark plug. Torque the plug to specification. Tightening torque: 28 Nm (2.8 m· kg, 20 ft·lb)

Use of timing light 1. 2. 3. Attach the timing light. Start the engine and keep it running at idling speed. Check the marks on fan and crankcase for alignment. If not aligned, remove starter assembly and loosen the base set screw and turn base assembly. Tighten base set screws and replace
1. Electro- Tester 2. Plug wire from coil 3. Spark plug

starter assembly.

3.

Start the engine, and increase the spark gap until misfire occurs.

Minimum spark gap: 9 mm (0.35 in)

D. Ignition Coil 1. Coil spark gap test a. Remove the ignition coil from the frame.

4. Repeat steps 2 and 3 until alignment is

acheved. NOTE: When removing just the ignition the fan from timing flywheel, _ ad-

b. Connect the Electro Tester as shown. c. Connect tester. d. Turn on the spark gap switch, and increase the gap until misfire occurs. a fully charged battery to the

at the step 1 (use of Minimum spark gap: 9 mm (0.35 in)

dial gauge) and check the marks on fan and crankcase for alignment.

C. Spark Gap Test The entire ignition system can be checked for system will fire across system is tests misfire and weak spark by using the Electro Tester. If the ignition good. If it will a specified gap, the entire ignition

not fire across the gap, pro-

ceed with the individual component until the problem is located. Electro tester: YU-03021 90890-03021-00

1. Thoroughly

warm up the engine so that

all electrical components are at operating temperature. 2. Stop the engine, and connect the tester as shown.
1. Battery

2. 9 mm (0.35 in)

6-4

2.

Coil winding resistance tests Use a pocket tester to determine resistance and continuity of the primary and secondary coil windings.
No.1 No.2 Secondary coil resistance 3.5 kQ ± 20% at 20°C (68°F) 4.0 kQ ± 20% at 20°C (68°F) No.4 No.3

Spark plug color Good (Carburetor is tuned properly.)

Bad (Mixture is too rich.) Replace main jet with one-step small one. Bad (Mixture is too lean.) Replace main jet with one-step larger one. Bad (Due to too lean a mixture, piston is damaged or seized.) Replace the piston and spark plug. Tune the carburetor again, starting with low-speed tuning. Bad (Due to too lean a mixture, the en· gine knocks.) Check the piston for holes or seizure. Check the cooling system, gasoline octane rating and ignition timing. After replacing the spark plug, tune the carburetor starting with low-speed tuning. again,

Manufacturer HITACHI CM62-21 TOYODENSO YW-1

Primary coil resistance 0.15Q±10% at 20°C (68°F) 0.12Q ± 10% at 20°C (68°F)

No.5

_Primary coil rasistance ----_Secondary coil rasistance

No.6

E. Spark Plug
The life of a spark plug and its condition vary according to the habits of the rider. You can learn a great deal about the operating condition of an engine by studying the spark plug. Examine the spark plug how cold at each periodic long and how fast and recommend a plug to accordingly. change the will remain inspection, and replace it with a suitable plug. Ask the customer hot, standard, your or he rides his snowmobile, Encourage

Bad (Due to lean a mixture, the spark plug melts.) Check the piston for holes or seizure. Check the cooling system, gasoline octane rating and ignition timing. After replacing the spark plug with colder type, tune the carburetor again starting with low-speed tuning.

customers

spark plug regularily. low. 1.

Their snowmobiles will

run better, and fuel consumption

How to "read" spark plug (condition) (The spark plug color samples are at the end of this manual)

6-5

Inspection Instruct the rider to: 1. Inspect the clean the spark plug every 400 km (250 mil or 20 hours. 2. Clean the electrodes of carbon and adjust the electrode gap. 3. Be sure to use the proper reach plug to avoid overheating, fouling, or piston damage. Spark plug type: NGK BR9ES

F. Pick up and C.D.I. Charge Coil Test Check the resistance of each coil as shown in the illustration. If the resistance is not within specification, the coil is not working. Check the connections. If the connections are good, the coil is damaged internally; it should be replaced. Pocket tester: YU-03112 90890-03112-00

Spark plug gap (use wire gap gauge): 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Spark plug torque: 28 Nm (2.8 rn- kg, 20 ft·lb)

C.D.I. Charging coil resistance: Black to Brown leads: 590n ± 10% at 20°C (68° F) Pick up coil resistance: Black to White/Red leads: 15.1n ± 10% at 20° C (68° F)

Pickup coil------C.D.I.charge coil--(Pickup coil)

r;:::==::;;----Pocket

tester (Charge coil)

590n

Settesterat "RX 1" position

Flywheel agneto m

G. C.D.I. Unit If the ignition system malfunctions and all of the above components are working properly, then the C.D.I. unit is faulty; replace it.

6-6

6-2. LIGHTING SYSTEM

A. Headlight Beam 1. Inspection Check the headlight beam direction. The high beam must be directed downward at an angle of 1/2 to the horizontal line.
0

Q h

3.0 m (0 tt) 26 mm (1.0 in)

7.6 m (25

ttl

66 mm (2.6 in)

2. Adjustment
When necessary, adjust the headlight beam by tightening or loosing the four headlight mounting screws. B. Lighting Coil Check the resistance between the yellow lead and ground. If the resistance is not within specification, the coil is not working. Check the connections. If the connections are good, the coil is broken internally; it should be replaced. Lighting coil resistance: Black & Yellow: .19n ± 10% at 20 C (68 F)

~---------Q----------~
Horizontal line

6·7

0.19,Q± 20% Yellow Set tester at .. RX 1" position

Flywheel magneto

C. Voltage Regulator

Instruments required for inspection: • Voltage Regulator Tester: 90890-03090-00 • Two 12V batteries • One jumper Connect the tester, batteries, and the voltage regulator as shown in the illustration.

Voltage regulator

Tester

~-------24V------~~

Battery +

6-8

Inspection 1. Check the battery voltage. Set the left and right switches to "VOLT" and "12V". If the checker needle reads 20volts or more, battery voltage is sufficient.
6V [JJ;J 12V REG YAMAHA ~

0
@

REGULATOR

em

VOLT

~
~

CHECKER

Replace the regulator

Light
YAMAHA

6V[JJ;J12V

REG [JJ;J VOLT

~ CHECKER

e
2.

REGULATOR

Check the tester. Set the right switch to "REG". If the lamp lights up, there is contibuity in the tester. Proceed with the tester. 3. Test the regulator. Slowly turn the tester knob clockwise; the needle will move with the knob. If the needle quickly returns to zero the moment it enters the black area on the scale, then the working voltage of the thyristor is good; the voltage regulator is working properly. If the needle swings into the black area of the scale but will not return to zero, the regulator is faulty and should be replaced.

Thyristor working voltage: 13.8 ± 0.5 volts at 5,000 r/min

Light is out
6V [JJ;J 12V YAMAHA ~

REG

GlIJ

VOLT

@
CHECKER

0 e

REGULATOR

Regulator is good

6-9

6-3. CHARGING SYSTEM

A. Charging Circuit Test 1. Charging output test a. Connect tester as shown.

b. Start engine, and amperage readings.

Voltage (Battery voltage) Amperage (Current)

note

voltage

and

i",iC'~J
CD
@

11.8Vor

more/3,aaa r/min r/min

a.6A/3,aaa

~~'
L_

.. "'"
~@

1(1£]1I ®
(lJ

.. : 0
0
0

c. If the indicated voltage and amperage cannot be reached, perform the tests in step 2. 2. Charging coil resistance test Check the resistance between terminal and ground. If resistance is out of specification, check the coil connections. If the coil connections are good, then the coil is broken inside, and it should be replaced.

J .'~.
.,j,.

oso

1. Rectifier 2. Fuse

..

3. Battery 4. Set the tester in "DC VOLTAGE" position

6·10

r====-r--0.19n±20%
r-

Pocket tester

~o ~ / /l---I-----5et tester at "R x 1" position

Y~e~I~lo~w~~~

Flywheel magneto

Charging coil resistance: Ground to white leads: 0.22n ± 10% at 20°C (68°F)
Nonnal connection

Good

Replace

Replace

B. Checking Silicon Rectifier 1. Normal connection: connect the tester's red lead (+) to the silicon rectifier's red point, and connect the tester's black lead (-) to the rectifier's white point. 2. Check with reversed connections: reverse the tester leads.

§J §

Reversed connection

§J §

The silicon rectifier can be damaged if subjected overcharging. Special care should be taken to avoid a short circuit and/or reversed connections of the positive and negative leads at the battery. Never connect the rectifier directly to the battery to make a continuity check.
5et tester at "R x 100" position --Normal connection Reversed connection

NOTE:

This rectifier test must be checked with both normal and reversed connections.

6-11

6-4. ELECTRIC STARTING SYSTEM

A. STARTE R MOTOR Removal 1. See Chapter 2. "ENGINE DISASSEMBL Y". Inspection and Repair 1. Check the outer surfaceof the commutator. If its surface is dirty, clean it with #600 grit sandpaper. 2. The mica insulation between the commutator segments should be 0.4 ~ 0.8 mm (0.02 ~ 0.03 in) below the segment level. If not, scrape the mica to proper limits with an appropriately shapedtool. (A hacksaw blade can be ground to fit.)

1. 0.4 '""0.8 mm (0.02 ~ 0.03 in)

3. The starter's armature and field coil should be checked with an ohm meter for insulation breakdown (shorting to each other or to ground) and for continuity. Coil resistance: Armature coil: 0.014n ± 6% at 20°C (68°F)

NOTE:

The mica insulation of the commutator must be under-cut to ensure proper operation of commutator.

6·12

Armature coil

Continuity test

Insulation test

4. Check the ratchet teeth on the pinion gear and the ring gear. The mating edges should fit flush against each other. If there is severe rounding off, replace asa set. 5. Check to see that the pinion gear spins freely on the armature shaft. If not, replace either or both as required. Replace if any signsof galling arefound. 6. Check the pinion gear return spring. If excessivelyfatigued, replace.

7. Check the front and rear cover bearings for damage. If damaged, the starter assembly must be replaced.

8. Check the brush length. Replace the brush if at, or near, limits. Minimum brush length: 12 mm (0.5 in)

9. Check brush spring pressure. Compare it with a new spring. Replacethe old spring if it is weak.
6·13

B. Starter Relay Switch Inspection 1. Disconnect starter relay leads at the relay. 2. Connect pocket tester leads to the relay terminals (ohms x 1 scale). 3. Turn ignition to "Obl" position. 4. Push the starter button. The relay should click once and the scale should read zero. If not, the relay must be replaced.

C. Battery If the battery shows the following defects, it should be replaced: 1. The battery voltage will not rise to a specific value or no bubbles rise in any cell even after may hours of charging. 2. Sulfation of one or more cells is indicated by the plates turning white or an accumulation of material in the bottom of the cell. 3. Specific gravity readings after a long, slow charge indicate a cell to be lower than any others. 4. Warpage or buckling of plates or insulators is evident. WARNING: Battery fluid is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with the skin, eyes, or clothing. Antidote: EXTERNAL - Flush with water. INTERNAL - Drink large quantities of water or milk. Follow with of magnesia, beaten eggs, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes, and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

5.

If the relay does not click, check the wires fromthe starter button and from the battery (RedlWhite, BluelWhite). Turn the ignition off. Use (ohms x 1) scale on tester. The resistance between these wires should be no more than 3.0 ohms. If there is more resistance, the relay should be replaced.

The service life of a battery is usually two to three years. Lack of care, as described below, will shorten the life of the battery.

6-14

• • • • • •

Negligence in keeping battery topped off with distilled water. Battery left discharged. Over-charging with heavy charge. Freezing Filling with tap water containing impurities. or sulfuric acid

Improper charging voltage or current on new battery.

If the machine is not to be used for a long time, remove the battery The 1. 2. 3. following served. Recharge the battery periodically. Store the battery in a cool, dry place. Recharge the battery tion.
Battery Electrolyte Initial charging current Recharging current Refill fluid YB14L Specific gravity: 1.280

and have it stored. should be ob-

instructions

before

reinstalla-

1.4 amp for 10 hours (new battery) 10 hours (or until speficic gravity reaches 1.280) Distilled water (to maximum level line) Check once per month (or more often as required)

Refill period

6-15

CHAPTER 7. APPENDIX
7-1. SPECIFICATIONS 7-2. TIGHTENING 7-3. CONVERSION 7-4. EXPLODED Flywheel Oil Pump Top End Bottom Intake Primary Sheave Secondary Chain Case Slide Rail Suspension Drive Axle Steeri ng Ski 7-5. WI RING DIAG RAM 7-6. WI RE AND CABLE ROUTING Sheave End Carburetor TORQUE TABLES DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Magneto 7-1 7-7 7-8 7-9 7-9 7-10 7-11 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21 7-22 7-23 7-24

Recoil Starter.

71
x

APPENDIX
7-1. SPECIFICATIONS
General
Model Model: Model (I.B.M. No.) Frame I.D. & starting number Engine I. D. & starting number Dimension: Overall length Overall width (std) Overall height (w/windshield) 8T7 8T7-121101 E388-121101 2,555 mm (100.6 in) 970 mm (38.2 in) 1,040 mm (40.9 in) EC340G 8T9 8T9·111101 E388·111101 2,895 mm (114 in) 940 mm (37 in) 1,090 mm (42.9 in) ET340TG

Engine
Model Description: Engine type Engine model Displacement Bore x stroke Effective compression ratio Starting system Ignition system Lubrication system Cylinder head: Combustion chamber volume (with spark plug) Compression chamber type Head gasket thickness Cylinder: Material Bore size Taper limit Out of round limit Piston: Piston skirt clearance (Measuring point) EC340G Fan cooled two-stroke twin cylinders E338 338 cm ' (20.6 cu.in) 60 x 59.6 mm (2.36 x 2.35 in) 6.5: 1 Recoil hand starter and electric starter C.D.1. "Autolube" oil inspection 21.3
+-s-

ET340TG 5·port,
+++++-

6: 1 Recoil hand starter

--

crrr'

(1.30 cu.in)

+++-

Dome + Squish 0.5 mm (0.02 in) Cast iron sleeves aluminum 60 mm (2.362 in) 0.05 mm (0.0020 in) 0,01 mm (0.0004 in) 0.040 ~ 0.045 mm (0.0016 ~ 0.0018 in) (10 mm (0.4 in) from piston skirt end) 1st 60.25 mm (2.372 in) 2nd 60.50 mm (2.382 in)

++++-

++++++-

Piston oversize 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) (2nd)

1> 16 x 47 mm (1) 0.630 x 1.85 in)

Keystone Keystone 0.35 ~ 0.55 mm (0.014 ~ 0.022 in) 0.35 ~ 0.55 mm (0.014 ~ 0.022 in) 7·1

++++-

Model Small end bearing: Type Big end bearing: Type Crankshaft: Crankshaft assembly width (A) Crankshaft assembly width Crankshaft deflection (D) (F)

EC340G Needle bearing Needle bearing 160

+-

ET340TG

+-

0.1 mm (6.30

0.004 in)

++++++-

52 _ g.05 mm (2.047 _ g.OO2in) 0.03 mm (D-l) 0.04 mm (D-2) 0.04 mm (D-3) 0.03 mm (D-4) 0.25 ~ 0.75 mm (0.010 ~ 0.014 in) 2.0 mm (0.079 in)

Connecting rod large end side clearance (C) Connecting rod small end deflection (P) (Limit)

ir--P

D-l

D-4

ZSt~J Lj'~
A--I Crank pin outside diameter x

rp 22 x

51 mm

(rp 0.866 x

2.008 in)

++++++++-

x length
Crank pin type Crank Crank q'ty Crank q'ty Crank Crank q'ty Crank q'ty bearing type (Left) x q'ty bearing type (Center) x bearing type (Right) x oil seal type (Left) x q'ty oil seal type (Center) x oil seal type (Right) x Solid shaft assembly type with serration # 6306 special 1 pc, # 6205 special x 2 pcs. # 6305 special x 1 pc. FPJ-30 72 8 2TS x 1 pc. Labyrinth seal x 1 pc. FPJ-2548 8TS x 1 pc.

Carburetor: Type & manufacturer/quantity I.D. Mark Main jet (M.J.) Pilot jet (P.J.) Pilot screw (P.S.) Throttle valve (Th.V.) Valve seat (V.S.) Float height Idling engine speed

B38-34 MIKUNI 8J600 #240 #75 1.0 turns out

x 1 pc.

+++++++++-

rp

#190 1.5 mm (0.059 in) 25 ± 1 mm (0.98 ± 0.04 in) 1,700 r/min

7-2

Model Main jet setting chart

EC340G

ET340TG

~::>~'~~:
e -30Oe (_22°F) _20Oe (_4°F) Sea level -#250~ - 600 m (2,000 It) #240 (Std.) - 1,200 m (4,000 ft) _# - 1,sao m (6,000 tt) #220 240 (Std.)~

_10Oe (14° F)

oOe
(32°F)

lOOe
(50°F) #220

200e (6SoF)

#240
(Std.]

#220

#210---#220 #210 1-----# #200 - 2,400 m (S,OOO tt) #210 # 190 - 3,000 m (10,000 tt] or more #200 1-# 190200-

~-

Lubrication: Autolube pump: Color code Minimum stroke Maximum stroke Reduction ratio Output Min./200

White 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) 1.65 ~ 1.87 mm (0,0657 ~ 0.0736 in) strokes 1/32 0.50 ~ 0.63 crrr' (0.0176 ~ 0.0222 Imp OZ, 0.0169 ~ 0.0213 US oz) 4.15 ~ 4.70 ern" (0.146 ~ 0.166 Imp OZ, 0.1403 ~ 0.1589 US oz) 25 ± 1 mm (0.98 ± 0.04 in) at idle 2.4 L (2.11 Imp qt, 2.5 US qt) YAMALUBE 2-cycle

~ ~ ~ ~ ~ ~

Output Max./200 strokes

Autolube pump wire free play Oil tank capacity Oil grade

~ ~ ~

Drive and track suspension

Model Transm ission: Type Drive ratio Engagement rpm Primary spring: Part No. Color code Secondary spring: Park No. Color code Secondary spring pre-load (twist) Sheave distance Sheave off-set V-belt width and outer line length V-belt wear limit EC340G V-belt automatic centrifugal engagement 3.5 : 1 ~ 1 : 1 3,000 ± 100 r/min 90501-50500 Red 90508-40080 No painted 160 266 ± 2 mm (10.47 ± 0.08 in) 11 ± 3 mm (0.43 ± 0.12 in) 31.6 x 1,099 mm (1.24 x 43.3 in) 26 mm (1.02 in) 7-3
0

ET340TG

~ ~
3,300 ± 200 r/min

~ ~ ~ ~ ~ ~ ~ ~ ~

Model Track suspension: Type Damper type Spring color code (Front) Spring color code (Rear) Slide runner wear limit Track width Trade deflection Length on ground Wheel sprocket material and number of teeth Stopper band length (Front) Secondary drive: Type Reduction ratio Chain pitch x Number of links Free play Chain housing oil quantity Chain housing oil grade Brake: Type Brake pad thickness Brake pad wear limit Gap between pad and disc

EC340G Slide rail suspension Oil and gasdamper Red No painted 10 mm (0.394 in) 380 mm (15 in) 25 ~ 30 mm/1O kg (0.98 ~ 1.18 in/22 Ib) 760 mm (29.9 in) Polyethylene 11T 186.5 mm (7.34 in) (2nd hole from the bottom) Chain (#40K-2) 22/13 (1.692) 12.7 mm (0.5 in) x 60 L +5 + 0.2 . 10 _ 2 mm (0.4 _ 0.08 In) 400cm3 (14.1Impoz, Gear oil API "GL3" (SAE # 75 or 85) 13.5USoz)

ET340TG

40 ~ 50 mm/10 kg (1.57~ 1.97 in/22Ib) 1,100 mm (43.7 in)

23/12 (1.916)

Disc brake 7.3 mm (0.287 in) 1.0 mm (0.04 in) 0.2 ~ 1.0 mm (0.008 ~ 0.04 in)

Chassis
Model Frame: Material Steeri ng system: Caster (ski column) Camber Ski length x width x thickness Ski stance Ski toe-out Steering linkage type Lock to lock angle (Ski) Lock to lock angle (Steering column) Front suspension: Type Damper type Fuel tank: Capacity Fuel grade EC340G Aluminum + Steel
+--

ET340TG

25°
0° 980 x 120 x 1.6 mm (38.6 x 4.7 x 0.06 in) 850 mm (33.5 in) o ~ 6 mm (0 ~ 0.23 in) Tie-rod Right ski, L: 27.6° L: 24.8° Left ski, Right: 54.3° Left: R: 24.8° R: 27.6°

+-+-+-+-+-+-+-+-+-+--

56.3°

Leaf spring Oil damper 22.7 L (5 Imp gal, 6 US gal) Regular gasoline

+-+--

+-+--

7-4

Electrical
Model Ignition system: Type Model/manufacturer Voltage Pick up coil resistance C.D.1. charging coil resistance Ignition timing: B.T.D.C. EC340G flywheel magneto (C.D.1. Type) F3T352/MITSUBISHI 12V 15.1 .Q ± 10% at 20°C (68° F) (White/Red - Black) 590.Q ± 10% at 20°C (68°F) (Brown - Black) 1.6 ± 0.1 mm (0.06 ± 0.004 in),
+-+-+-+-+-+-+--

ET340TG

+-+--

17° /7 ,000 r/min

19 18
Q)

""0

c co >

17 16 15

,/

T 0
Ignition coil: Model/manufactu Spark gap rer CM62-20/ HITACHI 9 mm (0.4 in)/ 300 r/min 11 mm (0.6 in)/ 3,000 r/min 0.15.Q±10%at 20°C (68°F) 3.5 k.Q ± 20% at 20°C (68°F) No

Engine speed ( x 10 r/min)

YW51/ TOYO DENSO

+-+-+-+--

+-+-+-+-+-+-+-+-+-+-+--

Primary winding resistance Secondary winding resistance Diode Spark plug: Type x quantity Spark plug gap Spark plug cap: Type Noise suppressor resistance C.D.1. unit: Model/manufacturer Starter motor: Type Armature coil resistance Brush length: Standard Minimum Brush spring pressure Armature mica undercut

0.12.Q±10%at 20°C (68°F)

+-+-+--

NGK BR-9ES x 2 pes, 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Rubber type with noise suppressor 5.5 k.Q ± 20% at 20°C (68°F) 8N4-20/MITSUBISHI NIPPONDENSO 028000-7180 0.014.Q ± 6% at 20°C (68°F) 12 mm (0.47 in) 8.5 mm (0.33 in) 7.85 N/mm (0.8 kg/mm,44.8Ib/in) 0.6 ± 0.2 mm (0.023 ± 0.0078 in)

+-+--

+-+--

+--

7-5