Yamaha GP 338F, Servise Manual

Page 1: ...VA AHA 8101108111 GP 338F GPK433F SIRVICIMAIUAI ...

Page 2: ...ation GPX338F 2 5 6 Adjustments GPX338F 2 5 7 Disassembly GPX433F 20 2 5 8 Cleaning and Inspection GPX433F 20 2 5 9 Assembly GPX433F 21 2 5 10 Installation GPX433F 2 5 11 Adjustments GPX433F 2 5 12 Carburetor with Accelerator Pump GPX433F 21 21 23 2 6 Oil Pump 24 2 7 Engine 2 7 1 Disassembly CHAPTER 3 POWER TRAIN 3 1 Secondary Sheave 3 1 1 Removal 3 1 2 3 1 3 3 1 4 Cleaning and Inspection Assembly...

Page 3: ...Sliding Suspension 43 CHAPTER 4 STEERING SKI AND CHASSIS 4 5 4 1 Frame 4 6 4 2 Engine M ount 4 3 Oil and Fuel 4 4 Ski Steering Control W ires 48 48 48 48 48 4 5 4 6 4 7 Shroud 48 CHAPTER 5 ELECTRICAL SYSTEM 49 CHAPTER 6 TIGHTENING TORQUE 57 ...

Page 4: ...octane Fuel tank capacity 6 0 US gal 23 0 lits 6 0 US gal 23 0 lits Carburetor Diaphragm type Diaphragm type MIKUNI BN38 34SH x 2 KEIHIN CDX42 38 x 2 Ignition and Electrical Systems Ignition system Flywheel magneto CD I Flywheel magneto CDI Headlight 12V 60 60W High Low beams 12V 60 60W High Low beams Taillight 12V 8W 12V 8W Stoplight 12V 23W 12V 23W Meter lamp 12V 3W 12V 3W Frame Fabricated alumi...

Page 5: ...ow altitudes 1 3 _ Tools To service the snowmobile the following tools are re quired o Special tools o Gauges Measuring instruments 1 Special Tools 2 b o General tools o Standard tools GPX433F 7 0 1 2 500 r p m Champion N 2G KEIHIN CDX42 38 x 2 87900 L R L R 65 45 1 118 1 3 8 0 059 in dia 1 5 mm 29 5 ins 750 mm 0 69 0 71 in 17 5 5 mm 0 20 0 25 mm 1 60 1 78 mm 1 a Crankshaft separator 1 b Crankshaf...

Page 6: ...ad screwdriver large 2 Set of open end wrenches 12 Phillips head screwdriver medium 3 Set of socket wrenches 13 Slotted head screwdriver medium 4 Soft faced hammer 14 Slotted head screwdriver large 5 Steel hammer 15 Slotted head screwdriver small 6 Circlip pliers ST type 16 T handle socket wrench 7 Circlip pliers RT type 17 L handle socket wrench 8 Needle nose pliers 18 Torque w rench and sockets ...

Page 7: ... open end wrench 5 12x10mm open end wrench 6 10 x 8 mm open end wrench 7 13 mm special wrench Fig 1 4 4 8 S 10 11 12 13 14 6 8 9 10 Point w rench and feeler gauge 13 x 21 mm plug wrench Screwdriver handle 11 13 Combination slotted and Phillips head screwdriver Phillips head screw driver Allen wrench Tool bag ...

Page 8: ...hen remove the two exhaust chambers Next remove the starter handle from the starter handle holder 2 Remove the throttle wires R L and choke wires from the carburetor assembly 3 Remove the two spring assemblies from the silencer and remove silencer 1 Fig 2 1 Fig 2 1 4 Remove the six bolts from the carburetor using the 10 mm open end wrench and remove the silencer plate Next remove the tachometer ca...

Page 9: ...9 20 I 13 1 2 3 4 5 6 7 8 9 10 Starter case Sheave drum Starter spring Drive paw l Thrust washer Drive plate spring Return spring Return spring Drive plate Thrust washer 3 2 11 11 Spring washer 12 Nut 13 Rope Q 1820 14 Handle 15 Connector 16 Starter pulley 17 Bolt 18 Spring washer 19 Bolt 20 Spri ng washer Fig 2 4 6 ...

Page 10: ...move the four bolts holding the starter and remove it from the crankcase cover Fig 2 5 Fig 2 5 2 3 Primary Sheave 1 Primary fixed sheave complete 6 Cam 2 Bushing 7 Primary sheave cap complete 3 Spring seat 8 Lock washer 4 Compression spring 9 Bolt 5 Primary sliding sheave complete 10 V Belt Fig 2 6 7 ENGINE Primary Sheave ...

Page 11: ...el hamm er Fig 2 7 Fig 2 7 2 Install primary sheave holder 1 special tool on the edges of primary sliding sheave and primary fixed sheave so that the primary sliding sheave is not forced by the spring Fig 2 8 Fig 2 8 3 Using the 22 mm socket wrench remove the prima ry sheave assembly securing bolt and remove the primary sheave cap Fig 2 9 Fig 2 9 4 With primary sheave installer remover 1 being in ...

Page 12: ...the weight pivot points 1 Primary fixed sheave complete 2 Bushing 3 Spring seat ENGINE Primarly Sheave 5 If the sliding sheave spline is excessively worn re place 6 Check the sheave for bends If bent replace 7 If the V belt width is worn to 26 mm or less or if cracked it should be replaced It is advisable to replace the V belt if the machine is used for a race 2 3 3 Assembly 1 Place the V belt aro...

Page 13: ...installer remover 1 on the primary fixed sheave and primary sliding sheave Fig 2 13 Fig 213 4 With primary sheave installer remover 1 being in stalled remove primary sheave 2 and primary sheave assembly securing bolt Then tighten the primary sheave cap with the primary sheave assembly secur ing bolt Next remove primary sheave installer remover 1 and bend the lock washer Fig 2 14 Fig 2 14 Tightenin...

Page 14: ...6 Spring washer 7 Pulser 8 9 10 11 12 13 14 ENGINE C D I Magneto 19 mm open end wrench Flywheel magnet puller Special tool Impact screwdriver Phillips large Steel head hammer Fig 2 16 Panhead screw 15 Spring washer Spring washer 16 Rotor assembly Pla in washer 17 Pan head screw Lead wire assembly 18 Hole cover Lead clamp 19 Crank shaft nut Lead clamp 20 Spring washer Panhead screw 21 Washer Fig 2 ...

Page 15: ... Fig 2 19 4 The flywheel magneto can now be removed This requires the use of special puller that you will find in our special tool kit Be sure to use the three short screws that come with the puller when removing the flywheel Note Immediately after the flywheel is removed take the woodruff key off the shaft and attach it to the flywheel so that it is not lost Fig 2 20 Fig 2 20 5 All parts of the m...

Page 16: ...2 Lighting coil 1 3 Lighting coil 2 4 Spacer 5 Pan head screw 6 SJ lring washer 7 Pulser 8 Pan head screw Fig 2 22 13 ENGINE C D I Magneto pulser coil holding screws two each per pulser coil Then remove the pulser coils from the coil plate 9 Spring washer 10 Plain washer 11 Lead wire assembly 12 Lead clamp 13 Lead clamp 14 Pan head screw 15 Spring washer 16 Pan head screw ...

Page 17: ...te 7 Spring washer 8 Pan heed screw 9 Diaphragm arm 48 10 Diaphragm spring t 11 Lever pin 12 Oval head screw f30 13 Main diaphragm 14 Body gasket 1 15 Body 1 29 16 Pump diaphragm 17 Body 2 18 Body gasket 2 19 Check valve r 20 Body 3 21 Gasket 22 Cover 23 Screw 24 Spring washer 25 Pan head screw 26 starter plunger 27 Cable assembly 28 Plunger spring 29 Plunger cap 30 Cap 31 Washer 13 32 Spring 33 W...

Page 18: ...oil pump control rod and remove the four nuts using the 13 mm open end w rench Then remove the carburetor from the cylinder Be careful not to lose the spacer between the ca r buretor flange and the stud bold Fig 2 2 5 Fig 2 25 15 ENGINE Carburetor 48 Main adjuster screw 49 Spring 50 Adjust screw 51 Gear 52 Main adju ster screw 53 Stay plate 54 Link shaft 55 Coliar 56 Spring pin 57 Compression spri...

Page 19: ...sassembly GPX338F 1 Loosen the screw and remove the cover and gasket rubber Loosen the four screws and remove body 3 check valve body 2 gasket body 2 body 1 gas ket body 1 and main diaphragm Fig 2 28 1 2 3 4 5 3 2 4 2 5 6 7 9 10 i 11 Main diaphragm 6 Body gasket 2 10 Body gasket 1 7 Check valve 11 Body 1 8 Body 3 12 Pump diaphragm 9 Gasket 13 Body 2 Cover Screw Spring washer Pan head screw Fig 2 2...

Page 20: ...2 mm open end wrench loosen the plunger cap and remove the cable assembly plunger spring and starter plunger Straighten the lock washer and loosen the lock nut using the 10 mm open end wrench Then loosen the primary venturi holding screw and remove the primary venturi and secondary venturi from inside Fig 2 30 2 5 3 Cleaning and Inspection GPX338F 1 Cleaning Clean the carburetor with carburetor cl...

Page 21: ...e it should not be disassembled or adjusted unnecessari ly However according to operating conditions or geo graphical conditions weather altitude etc it may require readjustment cleaning and inspection In this case the following parts must be readjusted 1 The slow adjusting screw to control the mixture when the engine idles 2 The throttle stop screw to control the idling speed 3 The main adjusting...

Page 22: ...t the engine runs smoothly with the richest possible mixture This is very important in order to prevent the engine from overheating 1 Procedure for adjustment a Back o ut the main adjusting screw as specified Turns out 1 1 8 b Perform a running test To test accelerate the snowmobile by quickly pulling the throttle lever to full throttle position from idling position c Perform a high speed runn ing...

Page 23: ...rtial jet 7 Remove the pan head screw and remove the stay plate Using the 13 mm T handle wrench remove the bolt and remove the throttle bracket 8 Remove t he throttle stop screw and stop screw spring 9 Never disassemble the choke butterfly throttle but te rfly and th rottle shaft 10 The right hand carburetor has a link shaft and two gears for easy adjustment of the main adjusting screw Remove the ...

Page 24: ...factory and therefore it should not be disassembled or adjusted unnecessari Iy However according to operating conditions or geo graphical conditions weather altitude etc it may require readjustment cleaning and inspection In this case the following parts must be readjusted 1 Adjusting screw to control the pressure fuel level in the regulator cha mber 2 The pilot screw to control the mixture when t...

Page 25: ...Set the pilot screw and the main adjusting screw to specification at the same time Settings at factory Settings at factory GPX433F Pilot screw L R 1 3 8 Slow jet 45 Partial jet 65 Main adjuster screw L R 1 1 8 b Turn the pilot screw in or out 1 8 turn each time until the engine idles fast c Back out the pilot screw aditional 1 8 1 4 turn to provide enough fuel for proper acceleration d Perform a r...

Page 26: ...iscoloration Adjust the main adjuster screw so the spark plug porcelain has a tan color at maximum high speed load e Keep the snowmobile running at high speed and test the engine operating condition Repeat the operations 2 to 5 above and set the main adjuster screw in the best position to achieve good spark plug color Note If the factory setting is improper making the mixture too rich or too lean ...

Page 27: ...late 5 Spring wash 6 Nut er 7 Oil seal 8 Starter plate 9 Cotter pin 10 Pan head screw 11 PIain washer 17 21 24 16 8 7 12 B reather bolt 13 Ball 5 32 gasket 14 Inch 23 Check ball Pan head s 15 N 24 W 16 25 an head screw Delivery Pum 17 D I pipe left 3 160 26 P control lever e Ivery Plain washer D pipe left 3 80 2 18 ehvery 7 Spr 2 w Delivery 8 Pan head 20 PO 011 W 21 om oo ol 30 0m 0 Adjust pulley ...

Page 28: ...nstall the oil pump delivery pipe Never attempt to change the pipe length by cutting or use a longer pipe for installation Fig 2 46 ENGINE Oil Pump 2 1 Guide pin 2 6Mark Fig 2 45 2 Delivery pipe left 276 13161 00 L 160 mm to the right side of carburetor 2 Delivery pipe left 395 13161 00 L 80 mm to the left side of carburetor Fig 2 46 3 The oil pump control rod adjustment should be made with the th...

Page 29: ...Cylinder gauge Micrometer Feeler gauge Vernier calipers V blocks Dial gauge Dial gauge stand Surface plate Copper head hammer Steel head hammer 25 rr 9 _Gpx3 8f _ 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Crank case 1 Crank case 2 Dowel pin 9 8 12 16 Bolt Bolt Bolt Plain washer Cylinder holding bolt Cylinder gasket Left cylinder Right cylinder Cylinder head gasket ...

Page 30: ... rod bearing Crank pin washer 7 9 Crank pin ENGINE Engine Piston pin clip 18 19 Circlip 10 Bearing 20 Oil seal Labyrinth seal I 11 21 Oil sea 12 Bearing 22 Washer 13 Bearing I d bearing 23 Dowel pin Con rod smal en Woodruff key 1 2 15 Piston 16 Piston ring 17 Piston pin Fig 2 49 27 ...

Page 31: ... pattern A 16 6 19 5 ft Ibs 2 3 2 7 m kgs B 14 5 16 6 ft Ibs 20 2 3 m kgs Fig 2 51 Fig 2 51 2 When installing both right and left cylinders the in take port flanges must be lush with each other If not the throttle valve and choke valve will not oper ate smoothly Fig 2 52 Fig 2 52 3 Crankshaft run out can be checked by placing the crankshaft ends in V blocks By using a dial indicator the deflection...

Page 32: ... 6 Pan head screw 7 Secondary spring 8 Secondary spring seat 9 Ramp shoe 10 Shim 11 12 13 14 15 16 17 18 19 20 Circlip Primary sheave installer remover 1 Primary sheave installer remover 2 17 mm open end wrench 17 mm open end wrench Circlip pliers Chisel Primary fixed sheave puller bolt 21 Chain drive sprocket Distance coliar 1 22 Plate washer Bearing housing 23 Nut Bearing 24 Cotter pin Circiip 2...

Page 33: ... ary spring plate 2 and secondary sliding sheave complete Fig 3 4 3 5 Fig 3 4 Fig 3 5 3 1 2 Cleaning and Inspection 1 Cleaning All parts should be washed in solvent and blow with compressed air 2 Inspection 1 Check the sliding sheave and fixed sheave for burrs which may damage the V belt Also check for bends Burrs should be removed by sandpaper 2 Check the secondary spring for fatigue If fatigued ...

Page 34: ...ave Compress the compression spring using primary sheave installer remover 2 and install primary sheave installer remover 1 Figs 3 8 3 9 Fig 3 8 POWER TRAI N Secondary Sheave Fig 3 9 3 Remove primary sheave installer remover 1 and 2 and install the cam primary sheave cap complete and lock washer Tighten the bolt using the 22 mm open end wrench or off set wrench Tightening torque First tighten to 4...

Page 35: ...9 1n T 11 1 Primary fixed sheave complete 7 Ramp shoe 2 Primary sliding sheave complete 8 Secondary shaft 3 Primary sheave cap complete 9 Bolt 4 Hexagon bolt 10 Bearing housing 5 Secondary fixed sheave complete 11 Bolt 6 Plate 2 12 Pan head screw Fig 3 10 32 ...

Page 36: ...ft and if the other end of the gauge contacts the primary shaft the distance from center to center of the sheaves is correct If not an adjustment is needed by moving the engine back and forth Correct distance 10 6 0 04 ins 270 1 mm 10 6 0 04 ins 270 1 mm If the center to center distance between the primary sheave and the secondary sheave is incorrect or if the offset between both two sheaves is im...

Page 37: ... sliding sheave and the primary fixed sheave at four places at the same time the offset is correct If not adjust by shifting the engine sideways The sheave gauge is designed to make three differ ent offset measurements 0 24 in 0 43 in and 0 63 in 6 mm 11 mm and 16 mm Correct offset 0 48 in 11 mm Fig 3 10 Fig 3 14 10 6 0 04 ins 270 1 mm l 0 48 in 11 mm l iffiHH ft Fig 3 15 34 ...

Page 38: ...Caliper body 1 3 Caliper pad 4 Back up plate 5 Cam 6 Brake lever 7 Plain washer Fig 3 16 35 POW ER TRAIN Disc Brake Primary sheave installer remover 1 and 2 17 mm open end wrench 10 mm open end wrench 22 mm open end wrench 8 Nut 9 Screw 10 Starter handle holder 11 Bolt 12 Spring washer 13 Compression spring ...

Page 39: ...ning pad complete 5 Nut 2 Disk brake 6 Brake wire 3 Back screw 7 Lock nut 4 Back up plate 8 Adjusting bolt Fig 3 19 2 Check the brake disc for bends If bent replace If the brake disc has severe scratches it should be replaced because fast wear will result on the brake pads 3 If the brake lever will not return smoothly to the rest position because of a fatigued return spring replace the return spri...

Page 40: ...wire adjust the play of the brake wire 6 at the brake lever end to 0 21 in 5 mm after the adjustment and tighten the lock nut 7 6 7 3 Lining pad complete 5 Nut Disc brake 6 Brake wire Back screw 7 Lock nut Back up plate 8 Adjusting bolt Fig 3 20 37 POWER TRAIN Disc Brake Fig 3 21 Replace any broken gasket Next secure the hous ing cap with eight bolts and tighten the track adjust ing screw Next sec...

Page 41: ...ps head screwdriver medium Pliers 4 1 Chain housing 12 Flat head screw 23 Pan head screw 2 Bearing 13 Tensioner 24 Screw gasket 3 Circlip 14 Wheel 25 Housing cap 4 Oil seal 15 Bearing 26 Gasket 5 Oil seal 16 Washer 27 Bolt 6 Chain driven sprocKet 17 Circlip 28 Plain washer 7 Chain 18 Bolt 29 Cap 2 8 Washer 19 Washer 30 Bolt 9 Spring washer 20 Clip 31 Spring washer 10 Bolt 21 Spring pin 32 Plain wa...

Page 42: ... track adjusting screw so the front axle becomes loose Remove the four bolts mounting the chain housing and remove the chain housing Fig 3 25 3 26 POWER TRAIN Chain Housing Fig 3 25 Fig 3 26 3 3 2 Cleaning and Inspection 1 Cleaning 1 Wash the oil seal in a denatured alcohol solution Never use a mineral oil 2 As for the other parts clean them in solvent and blow with compressed air 2 Inspection 1 C...

Page 43: ...e 2 3 4 13 14 1 Paddler pleat 2 Screw 3 Nut 4 Disk brake 5 Chain driven sprocket 6 Chain 7 Cap housing Tightening torque Drive sprocket Driven sprocket Adjust the chain 0 7 0 8 ft Ibs 5 0 6 0 m kgs 0 6 0 7 ft Ibs 4 5 5 5 m kgs By screwing the bolt A in or out adjust the deflection of the chain to 0 4 in 10 mm as illustrated in Figs 3 27 3 28 11 6 o Note Tolerance for sprocket wheel 1 position in a...

Page 44: ...wrench 13 mm open end wrench 6 1 Front axle complete 2 Sprocket wheel 1 3 Sprocket wheel rim 2 4 Bolt 5 Nut 6 Guide wheel complete 7 12 7 8 9 10 11 12 3 Collar Screw Oil seal 10 mm open end wrench Punch Steel head hammer Chisel 13 14 Bearing Circiip 15 Washer Front axle housing 16 Nut Spring washer 17 Cap Bdlt Fig 3 29 41 4 r o ...

Page 45: ...ith the screw 3 5 Rear Axle Tools Required 13 mm socket wrench 13 mm open end wrench Punch 11 10 8 and the collar 7 The removal sequence for other parts are the same as other models Screw 8 tightening torque 7 95 ft Ibs 1 1 m kgs Apply Shell Alvania grease 2 or 3 to the contact sur face of the guide wheel with the front axle oil seal 9 and bearing 13 Note Retighten bolts and nuts and grease moving...

Page 46: ...er 12 Hook 1 13 Roller 1 illill 14 Cotter pin 15 Spring pi n 16 Shaft 1 17 Washer 18 Bellevile spring 19 Bolt 20 Bracket 1 21 Stopper 1 22 Stopper 2 23 Sliding runner 2 24 Roller 2 25 Pin with hole 26 Clip Fig 3 31 43 27 28 29 30 31 32 33 34 35 36 37 38 39 POWER TRAIN Rear Axle Sliding Suspension Soft faced hammer Phillips head screwdriver medium and large Pliers 17 19 mm open end wrench Rear brac...

Page 47: ...ghtening 0 mm h the track IS pulled at 1 2 the end 35 mm Irom d sliding runner After installe d that w en n IS hould be so adJuste the total dellectlo Track tension s I 235 Ibs 10 kgs 3 fo 0 ItS center Y I the track 069 In 17 5 mm to a cleat at the center odes 01 the track balance n both Sl Hook up a spring n should be the same 0 F 3 32 amount 01 dellectlo Ig 44 d 1 38 ins 2 should be clinche ...

Page 48: ...t 4 Bolt 12 Spring w asher 5 Steering pad 13 Plain w ashe r 6 Clamp 14 Steering relay rod 7 Band 15 Nut 1 17 18 19 20 21 22 23 8 Steering lower bracket 16 Nut 2 Fig 4 1 45 checked every 80 hours of operation If the machine is new bolts and nuts should be re tightened as instructed separately For tightening torque refer to the torque chart Joint 24 Plate washer Universal joint 25 Wave washer Plain ...

Page 49: ...Spring washer 15 Clamp 23 Flap stopper 8 Plain washer Fi g 4 2 4 1 Frame 1 Check the front bumper screws and retighten as required The front bumper also serves as a rein forcement of the frame If front bumper mounting screws are loose the frame may be cracked 2 Check the secondary shaft bearing housing bolts The bearing housing is constantly under the pressure from the V belt If the bearing housin...

Page 50: ...o mount the rear bumper be sure to install two washers 1 and 2 If not the frame may be bent when the rear bumper is raised Fig 4 5 1 Washer 1 2 Washer 2 Fig 4 5 STEERING SKI AND CHASSIS Frame 6 Be sure to install the foot rest If the machine is used without the foot rest for a long time frame step tends to bend down Fig 4 6 Fig 4 6 7 Check the suspension bolts six and if loose retigh ten If bolts ...

Page 51: ... offered as options a Carbide runner b Shock absorber c Spring assembly 4 5 Steering 1 Avoid turning the steering handle more than speci fied If it is turned excessively the outside arm con tacts the stopper attached to the frame reinforce ment rib Take care particulary when the machine is stopped or runs at low speeds Fig 4 10 Fig 4 11 2 Check lock washers Bolts and nuts tend to come loose becaus...

Page 52: ...tronger quicker primary current pulse This improves ignition performance particularly at higher r p m s Additionally the stronger pulse inhibits misfire due to oil fouling and bridging The following diagrams show a comparison of ignition performance between the contact breaker system and the C D I system 2 1 Voltage 2 Milliseconds 3 Ignition voltage curve Fig 5 1 49 3 2 ___ _ 1 Voltage 2 Milliseco...

Page 53: ... Thyristor Fig 5 4 Ignition Capacitor Charging When the mark on the rotor aligns with the mark on the pulse coil see Figure 5 5 a trigger pulse is sent to the thyristor gate This pulse allows the thyristor to conduct and the current stored in the ignition capacitor will quickly flow through the pri mary winding of the ignition coil This induces a high voltage in the ignition coil secondary winding...

Page 54: ...r testers with a battery of large capac ity Model External rotation F280 51 Parts to be Charging coil Pulser mesured Brown B White red D IWhite black C Lead wires Blue E Black A Black A Resistance n 190 85 A B c D E 51 ELECTRICAL SYSTEM b The C D I unit and ignition coil should be installed in the specified positions If position is to be changed a dry and airy place should be selected Keep free fr...

Page 55: ...und Black 1 5 7 7 400 00 400 00 Brown 7 170 200 400 00 400 00 Charging coi l Blue 7 170 200 400 00 400 00 White 150 80 100 100 400 00 400 00 red Pulser White BO 150 100 100 400 00 400 00 black Grey 700 1 000 1 000 2 000 1 000 2 000 1 000 2 000 2 000 00 Ignition Orange 700 1 000 1 000 2 000 1 000 2 000 1 000 2 000 2 000 00 Notes C D 1 unit 1 The figures in the above chart show tester readings when ...

Page 56: ...ll the dial gauge and dial gauge stand 2 in the plug hole of the cylinder head 2 Turn the flywheel magneto to bring the piston to top dead center and set the dial gauge to zero ELECTRICAL SYSTEM Fig 5 12 3 Turn the flywheel magnet counter clockwise and set the ignition timing at 0 063 in 1 6 mm B T D C This adjustment This adjustment can be done by turning the pulser Loosen the two pan head screws...

Page 57: ...f spark is advanced or not White red Black I No con ti nui ty NO W YES t Ignition system Igni t ion coi l w t Continui ty test CD I unit t Black Core Continuity test in Table 6 0 7n 10 High tension wire Core t 6kn 20 Spark pi ug t J CO I unit Continui ty test Insulation between electrodes Resistance 1Mn or more Continuity tests Spark pi ug Igni tion system Continuity test Insul ation between elect...

Page 58: ...ing coil flywheel magneto C D I unit stoplight switch and stoplight If anyone of the lights should burn out replace it immediately otherwise the other lights will soon burn out 1 Headlight beam angle adjustment The headlight beam angle can be adjusted by loosen ing and tightning the four screws mounting the lens assembly Fig 5 14 55 ELECTRICAL SYSTEM The engi ne tends to kick back Magneto Check fo...

Page 59: ...Meter bulb 12V 3W 6 Meter damper 3 Meter socket 7 Fitting plate 4 Nut B Speedometer cable assembly Fig 5 16 c Tail stoplight Remove the four mounting screws and remove the lens Remove the light bulb from the socket and replace 1 Tail stoplight unit assembly 6 Pan head screw 2 Tail stoplight base 7 Damper 3 Tail stoplight bulb 8 Coliar 4 Base seat 9 Special washer 5 Tail stoplight lens 10 Spring wa...

Page 60: ...and retighten 12 mm 28 9 ft Ibs 4 0 m kgs Secondary sheave mounting nut 0 4 in 21 6 32 5 ft Ibs 10 mm 3 0 4 5 m kgs Bearing housing mounting nut 0 4 in 36 1 43 3 ft Ibs 10 mm 5 0 6 0 m kgs Chain drive sprocket mounting nut 0 55 in 36 1 43 3 ft Ibs 14 mm 5 0 6 0 m kgs Chain driven sprocket mounting bolt 0 4 in 36 1 43 3 ff Ibs 10 mm 5 0 6 0 m kgs Chain housing cap mounting bolt 0 24 in 2 8 5 0 ft I...

Page 61: ...nting bolt Panel instrument rear mounting nut Note Tightening torque tolerance is 20 10 Size Tightening torque 0 3 in 8 mm 10 8 ft Ibs 1 5 m kgs 0 4 in 10 mm 21 7 ft Ibs 3 0 m kgs 0 24 in 6 mm 3 6 ft Ibs 0 5 m kg 0 3 in 8 mm 10 8 ft Ibs 1 5 m kgs 0 24 in 6 mm 7 2 ft kgs 1 0 m kg 0 24 in 6 mm 3 6 ft Ibs 0 5 m kg 0 24 in 6 mm 7 2 ft Ibs 1 0 m kg 0 4 in 10 mm 18 ft Ibs 2 5 m kgs 0 4 in 10 mm 18 ft Ib...

Page 62: ...e Clamp hose 90460 11002 Cover connector 878 82599 00 Pipe clip 2 806 24357 00 Clamp 90465 06013 jrl iJ1 Hose 90446 11032 Wire clip 183 26278 00 C O I unit assembly _ 1 _ _ ___j Hose 90446 09067 Clamp 90465 06013 _ l l Wire clip 83 26278 00 jr r Clip 90467 11009 ___ Clip 90467 09005 Pipe clip 1 810 24356 00 Housing bearing Wire clip2 810 2435 Clamp 90465 06012 224 26278 00 Hose 90446 09062 Band 81...

Page 63: ... Clip 90467 09005 Pipe clip 810 24356 00 Pipe joint YA AHA External appearance of steering pad with wiring completed Wire clip 878 26391 00 Clamp 90465 05024 Clip 90467 09005 Pipe clip 810 24356 00 Hose 90446 09088 Clamp 90465 06011 167 26278 00 olt Be sure to pass pipes 1 and 2 under pipe 3 Note Speedometer unit is optionally installed so speedometer cable and the clamp for it are optional parts ...