This service manuals covers the 1989-1999 Yamaha Ovation

CS340/CS340E Series.
Please understand that this is an older manual, some pictures may be darker than most of my
manuals.

Some models may need supplemental manuals which have blue titles. Use the base
manual for everything not contained in the supplement if your model or year requires
a supplement.
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search on any word.
 

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ILLUSTRATED SYMBOLS
CD ®
(Refer to the illustration)

INFO I~
GEN INSP
ADJ ~ Illustrated symbols CD to ® are designed as
thumb tabs to indicate the chapter's number and
® ® content.

ICOOll)C I
ENG
'"
•• CD General information
® Periodic inspection and adjustment
® Engine
® Cooling system
® Carburetion
® Power train
(j) Chassis
® Electrical
(j) ® ® Appendices

ICHASI..:! II---El-EC~I.---'-1
Illustrated symbols @ to @ are used to iden

@~
® tify the specifications appearing.

@ Filling fluid
QD Lubricant
@Special tool
@Tightening
@ Wear limit, clearance
@ Engine speed
@Q,V,A

@ Illustrated symbols @ to ® in the exploded

i i diagram indicate grade of lubricant and location

a
of lubrication point.

tTl @ Apply engine oil

@ Apply gear oil
® @ Apply molybdenum disulfide oil
® Apply wheel bearing grease
~ @ Apply lightweight lithium-soap base grease
@ Apply molybdenum disulfide grease
® Apply locking agent (LOCTITE®)
®
1
IT)
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INDEX
GENERAL INFORMATION

PERIODIC INSPECTIONS
AND ADJUSTMENTS

ENGINE OVERHAUL
ENG

CARBURETION 1-----
•
POWER TRAIN

CHASSIS

ElEen

APPENDICES
APPX

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GEN
INFO
CHAPTER 1.
GENERAL INFORMATION

MACHINE IDENTIFICATION ...... . ................ . ............ 1-1

FRAME SERIAL NUMBER .. . .... . ................. . .......... 1-1
ENGINE SERIAL NUMBER .... .. ................... . .. . .... . . 1-1

STORAGE . . .............. . .. . ............. . ...... . ........... 1-2

PRE-SEASON PREPARATION ....... . .............. . ... . ......... 1-2

IMPORTANT INFORMATION . ... .. .... . ......................... 1-3

PREPARATION FOR REMOVAL AND DISASSEMBLY . . .. . ........ 1-3
ALL REPLACEMENT PARTS ........ . ..... . ................... 1-4
GASKETS, OIL SEALS, AND O-RINGS . . ... . . . ..... . ............ 1-4
LOCK WASHERS/PLATES AND COTTER PINS ................... 1-4
BEARINGS AND OIL SEALS ................... .. . . ...... . .... 1-4
CIRCLIPS . . ........... . ... . . . ... . . . ..... .. . . ...... ;-.. . . . .. 1-5

SPECIAL TOOLS ..... ... ... . . .. .... . ...... . .. .. . . .. . ........... 1-5

FOR TUNE UP ................ . ...... ..... .... . ... . ........ 1·5
FOR ENGINE SERVICE ...... . . . . . . . .. . ......... . ........ .. .. 1-6
FOR POWER TRAIN SERVICE ........ .. . . ....... . . . .......... 1-6
FOR ELECTRICAL SERVICE ....................... . . . ....... 1-7

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GEN
MACHINE IDENTIFICATION INFO-
GENERAL
INFORMATION
MACHINE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number CD is located on the
right-hand side of the frame (just below the
front of the seat).

ENGINE SERIAL NUMBER

The engine serial number CD is located on the
right-hand side of the crankcase.
NOTE: ________________________

The first three digits of these numbers are for

model identifications; the remaining digits are
the unit production number.

Starting Serial Number:

For U.S.A. and CANADA:
CS340N .....85L-000101
CS340EN ...85N-000101
For EUROPE:
CS340 ......85M-000101

NOTE: _________________________

Designs and specifications are subject to change

without notice.

,-,
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GEN
STORAGE/PRE-SEASON PREPARATION IN FO
.......,;;...,;;,..;....~L-- _ _...1

STORAGE
If a snowmobile will not be used for several
months, it should be stored in a proper place so
that both the engine and the track are not
damaged .
• Completely drain the fuel tank, and disconnect
the fuel line from the carburetor .
• With the engine running at idle, squirt oil into
the carburetor until the engine dies. This will
distribute oil evenly throughout the engine,
and protect it against rust.
• Disassemble the suspension, clean and grease
all parts, and reassemble the suspension.
• Lightly coat all shafts and axles with grease.
• Oil all fittings and cable 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.

PRE-SEASON PREPARATION
Perform the predelivery service as described in
the predelivery check list before operating any
snowmobile that has been stored for several
months. (Refer to CHAPTER 2. "PERIODIC
MAINTENANCE TAB LE" section.)

1-2
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GEN
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DIS-

ASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassembly.
While cleaning, take care to protect the
electrical parts, such as relays, switches,
motor, resistors, controllers, etc., from
high pressure water splashes.
2. Use proper tools and cleaning equipment.
Refer to "SPECIAL TOOLS".

3. When disassembling the machine, keep

mated parts together. This includes gears,
cylinders, pistons, and other mated parts
that have been "mated" through normal
wear. Mated parts must be reused as an
assembly or replaced.

4. During the machines disassembly, clean all

parts and place them in trays in the order of
disassembly. This will speed up assembly
time and help assure that all parts are
correctly reinstalled.
5. Keep away from fire.

6. Be sure to keep to tightening torque specifi-

cations. When tightening bolts, nuts, and
screws, start with a larger-diameter one and
from an inner-positioned one to an outer-
positioned one in a criss-cross pattern.

1-3
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IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine parts
for all replacements. Use oil and/or grease
recommended by Yamaha for assembly and
adjustment.

GASKETS, OIL SEALS, AND O-RINGS

1. All gaskets, seals, and a-rings should be re-
placed when an engine is overhauled. All
gasket surfaces, oil seal lips, and a-rings
must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.

LOCK WASHERS/PLATES AND COTTER

PINS
1. All lock washers/plates CD and cotter pins
must be replaced when they are removed.
Lo~k tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been pro-
perly tightened.

300-000

BEARINGS AND OIL SEALS

1. Install the bearing(s) CD and oil seal(s) ®
with their manufacturer's marks or numbers
facing outward. (In other words, the
stamped letters must be on the side exposed
to view.) When installing oil seal(s), apply a
light coating of light-weight lithium base
grease to the seal lip(s). Oil the bearings libe-
300-002
rally when installing.

Do not use compressed air to spin the bearings

dry. This causes damage to the bearing surfaces.

300-003

1-4
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GEN
SPECIAL TOOLS
CIRCLIPS
_---
.....INFO ......__....
1. All circlips should be inspected carefully be-
fore reassembly. Always replace piston pin
clips after one use. Replace distorted cir-
clips. When installing a circlip CD , make sure
that the sharp edged corner ® is positioned
opposite to the thrust @ it receives. See the
sectional view.
300-001
@Shaft

SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or impro-
vised techniques.

FOR TUNE UP
1. Sheave Gauge
PIN YS-91047

This gauge is used for sheave distance and offset

adjustment.

2. Inductive Tachometer
PIN YU-08036, 90890-03113

This tool is used for ignition timing checking.

3. Timing Light
PIN YU-08037, 90890-03109

This tool is used for ignition timing checking.

1-5
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GEN
SPECIAL TOOLS INFO
L..";,,;;"';;;";;""";;;;;...,,A.._ __

FOR ENGINE SERVICE

1. Piston Pin Puller
PIN YU-01304, 90890-01304

This tool is used to remove piston pin.

2. Universal Clutch Holder

PIN YM-91042, 90890-04086

This tool is used to hold starter pulley.

3. Rotor Puller
PIN YU-33270, 90890-01362

This tool is used to remove COl magneto.

4. Dial Gauge
PIN YU-03097, 90890-03097

This gauge is used for crankshaft runout measure-

ment.

FOR POWER TRAIN SERVICE

1. Primary Sheave Holder
PIN YS-01880, 90890-01701

This tool is used to hold primary sheave.

1-6
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GEN
SPECIAL TOOLS INFO
2. Primary Sheave Puller
PIN YS-01882-A, 90890-01898

This tool is used for removing primary sheave.

3. Sheave Compressor
PIN YS-28891, 90890-01712

This tool is used for disassembling and assembl-

ing sheave.

4. Clutch Spider Separator

PIN YS-28890-A,90890-01711

These tools are used for disassembling and

assembling primary sheave.

5. Clutch Separator Adapter

PIN YS-34480

This tool is used for disassembling arid assembl-

ing primary sheave.

FOR ELECTRICAL SERVICE

1. Pocket Tester
PIN YU-03112, 90890-03112

This instrument is necessary for checking the

electrical components.

1-7
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SPECIAL TOOLS

2. Dynamic Spark Tester

PIN YM-34487, 90890-03144

This tester is necessary for checking the ignition

system components.

1-8
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CHAPTER 2.
PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION .............................................. 2-1

PERIODIC MAINTENANCE TABLE ............................... 2-1

LUBRICATION INTERVALS ..................................... 2-3

SHROUD, COWLS, SEAT, COVER AND HANDLEBAR ................ 2-4

SHROUD OPENING ................... ;- ..................... 2-4
SIDE COWLS ............................................... 2-4
SEAT ..................................................... 2-4
HANDLEBAR .............................................. 2-5
CENTER COVER ........................................... 2-7
HEADLIGHT AND METER ASSEMBLY ......................... 2-8

ENGINE ..................................................... 2-10

ENGINE OIL LEVEL INSPECTION ............................ 2-10
FUEL LINE INSPECTION .................................... 2-10
ENGINE OIL LINE INSPECTION .............................. 2-10
ENGINE IDLE SPEED ADJUSTMENT .......................... 2-11
THROTTLE CABLE FREE PLAY ADJUSTMENT ................. 2-11
STARTER CABLE FREE PLAY ADJUSTMENT ................... 2-12
OIL PUMP CABLE FREE PLAY ADJUSTMENT .................. 2-13
OIL PUMP STROKE ADJUSTMENT ............................ 2-14
OIL PUMP AIR BLEEDING .................................. 2-18
OIL FILTER INSPECTION ................................... 2-19
FUEL FILTER INSPECTION ................................. 2-20
FUEL PUMP OPERATION CHECK ............................. 2-21

POWER TRAIN ............................................... 2-23

DRIVE V-BELT INSPECTION ................................ 2-23
SHEAVE DISTANCE AND OFFSET ADJUSTMENT ............... 2-24
DRIVE CHAIN HOUSING OIL LEVEL INSPECTION .............. 2-25
DRIVE CHAIN HOUSING OIL REPLACEMENT .................. 2-26
DRIVE CHAIN SLACK ADJUSTMENT ......................... 2-27
BRAKE PAD INSPECTION ................................... 2-29
BRAKE ADJUSTMENT ...................................... 2-30
TRACK TENSION ADJUSTMENT ............................. 2-32

CHASSIS .................................................... 2-35

SKI ADJUSTMENT ......................................... 2-35
BRAKE CABLE END LUBRICATION .......................... 2-36
SLIDE RUNNER INSPECTION ................................ 2-37

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ELECTRICAL . ............................................... 2-38

SPARK PLUG INSPECTION .................................. 2-38
IGNITION TIMING CHECK .................................. 2-39
BATTERY INSPECTION (FOR CS340EN) ....................... 2-40
HEADLIGHT BULB REPLACEMENT .......................... 2-41
HEADLIGHT BEAM ADJUSTMENT ........................... 2-42
TIAL/BRAKE LIGHT REPLACEMENT ......................... 2-42

TUNING .................................................... 2-43

CARBURETOR TUNING .................................... 2-43
CLUTCH TUNING .......................................... 2-51
GEARING SELECTION ..................................... 2-52
SLIDE RAIL SUSPENSION TUNING ........................... 2-54
HIGH ALTITUDE TUNING .................................. 2-56

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INTRODUCTION/PERIODIC MAINTENANCE TABLE

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and
a longer service life. The need for costly overhaul work will be greatly reduced. This information
applies to vehicles already in service as well as new vehicles that are being prepared for sale. All service
technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE TABLE
Every
Check point 20 hrs. or 40 hrs. or 80 hrs. or When
Seasonally
400km 800km 1,600 km necessary
(250 mi) (500 mi) (1,000 mi)
ENGINE:
Tightness of bolts and nuts 0 0
Bends, cracks and wear 0 0
Abnormal noise 0 0
Loose connection and breaks of fuel and pulse pipes 0 0
Loose connection and breaks of oil pipes 0 0
Loose connection and breaks of oil delivery pipe 0 0
Manual rope starter system 0 0
CARBURETOR:
• Operation of starter jet 0 0
• Mixing adjuster (pilot screw) 0 0
• Idling speed adjustment 0 0
Operation and adjustment of oil pump 0 0
Ignition timing 0
Engine compression 0 0
Cylinder head/exhaust pipe decarbonization 0
Spark plug condition, gap and cleaning 0 0
Tightening of the cylinder head** 0
DRIVE:
Tightness of bolts and nuts 0 0
Wear on slide runners 0 0
Primary drive system 0 0
V-belt 0 0
Secondary drive system 0 0
Sheave distance 0 0
Sheave offset 0 0
Brake pad wear 0 0
Brake operation and adjustment 0 0
Guide wheel rubber 0 0
Initial 100
km (SOmil & 0
Wear of drive track wheel sprocket 0
300 km
(200 mil
Drive track adjustment 0 0
Breaks in drive track 0 0
Bends in front and rear axles 0 0
Checking of lock washers 0 0
Drive chain adjustment 0 0
Drive chain oil level 0 0
2-1
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PERIODIC MAINTENANCE TABLE Ir8f IQ I

Every
20 hrs. or 40 hrs. or 80 hrs. or When
Check point Seasonally
400km 800km 1,600 km necessary
(250 mi) (500 mi) (1,000 mi)
BODY:
Tightness of bolts and nuts 0 0
Bends and cracks 0 0
Welded/riveted, joints 0 0
Ski adjustment 0 0
Ski runner wear 0 0
Breaks in fuel tank 0 0
Cleaning of fuel tank 0
Fuel filter 0
Loose connection and breaks in fuel pipe 0 0
Breaks in oil tank 0 0
Oil filter 0
ELECTRICAL:
Wear, breakage of wire covering 0 0
Breaks in high-tension cord 0 0
Voltage regulator working voltage 0
Operation of engine stop switch 0 0
Operation of throttle override system 0 0
Headlight 0 - 0
Taillight 0 0
Brake light 0 0
** Retighten every 10 hours from the first use.

2-2
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LUBRICATION INTERVALS
LUBRICATION INTERVALS

Every
Check point 20 hrs. or 40 hrs. or 80 hrs. or When Oil/Grease
Seasonally
400 km 800 km 1,600 km necessary Brand name
(250mi) (500mi) (1,000 mil
ENGINE:
Starter case 0
Aeroshell grease #7 A or
Oil pump control box 0 0 Esso Beacon 325 grease
Pump drive cover 0 0
For U.S.A. and CANADk
YAMALUBE 2-cycle oil
Oil in the oil tank 0 or equivalent
For EUROPE:
Yamaha Oil 2T or Air
cooled 2 stroke engine oil

DRIVE:
Primary sheave weight Molybdenum disulfide
and roller pins
0 0 snowmobile grease
Secondary shaft and Molybdenum disulfide
sliding sheave
0 0 snowmobile grease
Front axle housing 0 0
Shaft 1 and shaft 2 Light all-purpose grease
(Slide rail)
0 0
Drive chain oil Gear oil API GL-3
replacement 0 0 SAE #75 or #80

BODY:
Steering column lower
0 0 Light all-purpose grease
bearing
Steering column upper Motor oil
bearing
0 0
Steering links 0 0 Light all-purpose grease
Brake wire and stopper
and brake lever
0 0 Esso Beacon 325 grease

Telescopic strut
0 Esso Beacon 325 grease
suspension

2-3
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SHROUD OPENING/SIDE COWLS/SEAT

SHROUD, COWLS, SEAT, COVER
AND HANDLEBAR
SHROUD OPENING
When the engine requires a check or service,
the shroud can be opened forward.
1. Unhook:
- Shroud latches CD (Left and right)
2. Should be slowly raised until shroud stops.

SIDE COWLS
Removal
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
- Side cowls CD (Left and right)

Installation
Reverse the "Removal" procedure.
Note the following points.
1. Install:
-Side cowls
Screw (Side Cowl):
3 Nm (0.3 m - kg, 2.2 ft- Ib)
Bolt (Side Cowl):
3 Nm (0.3 m - kg, 2.2 ft- Ib)

SEAT
Removal
1. Remove:
-Seat

2-4
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HANDLEBAR
2. Disconnect:
-Tail/Brake light lead coupler

Installation
Reverse the "Removal" procedure.
Note the following points.
1. Install:
-Seat
Screw (Seat - Front):
3 Nm (0.3 m· kg, 2.2 ft· Ib)
~-~ Nut (Seat - Rear):
9 Nm (0.9 m· kg, 6.5 ft·lb)

HANDLEBAR
Removal
1. Remove:
_ Handlebar covers (Front CD and rear @ )

2. Remove:
- Throttle cable CD
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Before removing the throttle cable, remove the
clip@ .

2-5
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HANDLEBAR
3. Remove:
• Brake cable(s) CD
Removal steps:
• Loosen the locknut(s) ® .
• Turn the adjuster(s) @ clockwise.
• Remove the brake cable(s) CD from the
brake lever pivot(s).
NOTE: __________________________

Right hand brake is Europe only.

4. Disconnect:
• Leads and coupler
5. Remove:
• Band CD

6. Remove:
• Handlebar CD
• Handlebar holder (Upper)
• Handlebar holder (Lower)

Installation
Reverse the "Removal" procedure.
Note the following points.
1. Install:
• Handlebar
• Handlebar holder (Lower)
• Handlebar holders (Upper)

Bolts (Handlebar holder):

15 Nm (1.5 m- kg, 11 ft-Ib)

2-6
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CENTER COVER
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
• The upper handlebar holder should be installed
with the punch mark CD forward.
• Align the punch marks ® with the handlebar
holder gaps respectively.
• Tighten the bolts to specification so that
U--_.....J-.l b the front clearance "a" is smaller than rear
T clearance "b".

First tighten the bolts on the front side of the

handlebar holder, and then tighten the bolts
on the rear side.

2. Adjust:
• Brake
Refer to "BRAKE ADJUSTMENT" sec-
tion.

CENTER COVER
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
.Handlebar cover
• Handlebar
Refer to the "HANDLEBAR" section.
3. Remove:
• Side cowls (R ight and left)
Refer to "SIDE COWLS" section.
4. Remove:
• Starter cable CD
• Center cover ®

NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Remove the center cover then disconnect the
fuel level hose ® , oil level hose @ , main
switch coupler ® and grip warmer leads ® .

2·7
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HEADLIGHT AND METER ASSEMBLY

Installation
Reverse the "Removal" procedure.
Note the following points.
1. Install:
• Center cover
2. Install:
• Handlebar
• Handlebar cover
Refer to the "HANDLEBAR" section.

HEADLIGHT AND METER ASSEMBLY

Removal
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Disconnect:
• Headlight lead CD
3. Remove:
.Clips ®

4. Remove:
• Headlight CD

5. Disconnect:
• Meter light leads CD
• Speedometer cable ®

6. Remove:
• Meter assembly CD

2-8
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HEADLIGHT AND METER ASSEMBLY

Installation
Reverse the "Removal" procedure.
Note the following points.
1. Install:
• Meter assembly
• Headlight

Screw (Meter Assembly) :

2 Nm (0.2 m - kg, 1.4 ft-Ib)

2. Adjust:
• Headlight beam
Refer to the "HEADLIGHT BEAM
ADJUSTMENT" section.

2·9
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_E_N_G_I_N_E_O_I_L_L_EV_EL_IN_S_P_EC_T_I_O_N_/F_U_E_L_L_I_N_E_IN_S_P_E_cr_I_O_N_/IIANDSJPI~1
ENGINE OIL LINE INSPECTION . . ~.
ENGINE
ENGINE OIL LEVEL INSPECTION
1. Place the machine on a level place.
2. Inspect:
• Engine oil level
Oil level low -+ Add sufficient oil.

CD "F" (Full) level mark

® "E" (Empty) level mark
3. Open the shroud.
Refer to the "SHROUD OPENING" section.
4. Add the engine oil until the oil level reaches
"F" level mark.

Recommended oil:
For U.S.A. and CANADA:
Y AMALUBE "2" or equivalent
For EUROPE:
Yamaha Oil 2T or Air cooled
2 stroke engine oil

CD Oil tank cap

Always use the same type of engine oil; mixing

oils may result in a hurmful chemical reaction
and lead to poor performance.

FUEL LINE INSPECTION

1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Inspect:
• Fuel hose
Crack/Damage -+ Replace.

ENGINE OIL LINE INSPECTION

1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Inspect:
• Engine oil hose
Crack/Damage -+ Replace.

2·10
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ENGINE IDLE SPEED ADJUSTMENT/
THROTTLE CABLE FREE PLAY ADJUSTMENT
ENGINE IDLE SPEED ADJUSTMENT
1. Open the shroud.
Refer to the "SH ROUD OPEN I NG" section.
2. Adjust:
• Pi lot screws CD
Adjustment steps:
• Turn in the both pilot screw until they are
lightly seated.
• Turn out the both pilot screw to specifica-
tion.

Pilot Screw:
1-3/4 turns out

3. Start the engine and let it warm up.

4. Adjust:
• Engine idle speed

Adjustment steps:
• Turn the throttle stop screw CD in or out
until the specified engine speed is obtained.

Turn in Idle speed becomes higher.

Turn out Idle speed becomes lower.

C\ Engine Idle Speed:

1,800 r/min

NOTE:
After adjusting the engine idle speed, the
throttle cable free play should be adjusted.

THROTTLE CABLE FREE PLAY ADJUST-

MENT
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.

2-11
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STARTER CABLE FREE PLAY ADJUSTMENT

1. Measure:
• Free play (Throttle cable) ®
Out of specification -+ Adjust.

Free Play (Throttle Cable):

0.5 - 1.0 mm (0.02 - 0.04 in)

2. Adjust:
• Free play (Throttle cable)

Adjustment steps:
• Open the shroud.
Refer to the "SHROUD OPENING" section.
• Loosen the locknut CD .
• Turn the adjuster ® in or out until the
specified free play is obtained.

Turn in Free play is increased.

Turn out Free play is decreased.

• Tighten the locknut.

• Close the shroud.

STARTER CABLE FREE PLAY ADJUST-

MENT
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
• Rubber cap CD
3. Pull the outer tube of starter cable upward.
4. Measure:
• Free play (Starter cable) ®
Out of specification -+ Adjust.

Free Play (Starter Cable):

0.5 - 1.5 mm (0.02 - 0.06 in)

1-'+---+ ®

2-12
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OIL PUMP CABLE FREE PLAY ADJUSTMENT

5. Adjust:
• Free play (Starter cable)

Adjustment steps:
• Loosen the locknut CD .
• Turn the adjuster ® in or out until the
specified free play is obtained.

Turn in Free play is increased.

Turn out Free play is decreased.

.Tighten the locknut and install the rubber

cap.

6. Close the shroud.

OIL PUMP CABLE FREE PLAY ADJUST-

MENT
NOTE: __________- -______________
Before adjusting the oil pump cable free play,
the throttle cable free play should be adjusted.

1. Open the shroud.

Refer to the "SHROUD OPENING"
section.

2. Pull:
• Outer tube (Oil pump cable)
3. Measure:
• Free play (Oil pump cable) ®
Out of specification ~ Adjust.

Free Play (Oil Pump Cable):

24 - 26 mm (0.94 ~ 1.02 in)

4. Adjust:
• Free play (Oil pump cable)

Adjustment steps:
• Loosen the locknut CD .
• Turn the adjuster ® in or out until the
specified free play is obtained.

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01 L PUMP STROKE ADJUSTMENT

Turn in Free play is increased.

Turn out Free play is decreased .

• Tighten the locknut and install the rubber

cap.

5. Close the shroud.

OIL PUMP STROKE ADJUSTMENT

1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
.Side cowl (Left)
• Drive V -belt guard
• Drive V -belt
• Primary sheave
Refer to the CHAPTER 5. "PRIMARY
SHEAVE AND DRIVE V-BELT" section.
3. Disconnect:
• Oil pump cable
(from carburetor)
·Oil hose CD
• Oil delivery hose ®
NOTE: __________________________

Plug the oil hose and oil delivery hose so that

oil does not run out.

4. Remove:
.Oil pump assembly CD with drive gear
housing ®

5. Remove:
• Oil pump assembly CD
NOTE: _________________________

Place a rug under the oil pump assembly.

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01 L PUMP STROKE ADJUSTMENT

6. Remove:
• Oil pump cover <D
7. Wipe off the grease from the plunger top.

8. Measure:

@~®
• Minimum pump stroke ®
Out of specification ~ Adjust.

® 5 Minimum Pump Stroke:

0.20 - 0.25 mm (O.OOS - 0.010 in)

Minimum pump stroke measurement steps:

• Turn the pump worm gear <D with your
fingers, until the plunger top @ is at its
maximum distance from the pump body
mating surface ® of the pump cover.
• Using a Feeler Gauge, measure the minimum
pump stroke ® between the adjusting plate
@ and the raised boss @ on the adjusting
pulley .
• If minimum pump stroke is not within the
specjfied limits, perform the adjustment
steps.

9. Measure:
• Maximum pump stroke @
Out of specification ~ Adjust.

Maximum Pump Stroke:

1.65 - 1.S7 mm (0.065 - 0.074 in)

Maximum pump stroke measurement steps:

• Pu II the oi I pu mp cable <D out of its sheather
as far as it will go. The cable must be held in
this taut position when measuring the
maximum pump stroke.
NOTE: ________________________

It may be helpful to securely warp duct tape

@ around the cable where it enters the
sheath.

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OIL PUMP STROKE ADJUSTMENT

eTurn the pump worm gear @ with your
fingers, until the plunger top @ is at its
maximum distance from the pump body @.
e Using a Feeler Gauge, measure the maxi-
mum pump stroke @ .
elf maximum pump stroke is not within the
specified limits, perform the adjustment
steps.

10. Adjust:
eOil pump stroke

Adjustment steps:
e Remove the locknut CD , spring washer @
and adjusting plate @ .
eAdjust the pump stroke by adding or remov-
ing a shim.
@"Shims
Add shim Pump stroke is increased.
Remove shim Pump stroke is decreased.

e Reinstall the adjusting plate, spring washer

and locknut.

!~
Locknut:
7 Nm (0.7 m·kg, 5.1 ft·lb)

e Recheck the minimum and maximum pump

stroke.
If out of specification limits, perform the
above steps again.

11. Apply:
e Lithium soap base grease
(to out side of pump pulley)

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01 L PUMP STROKE ADJUSTMENT

12. Install:
• Oil pump cover CD
NOTE: _________________________

Apply the Yamabond No. 5® (ACC-11001-31-

00) to the mating surface of the oil pump
cover.

Screw (Oil Pump Cover):

2 Nm (0.2 m· kg, 1.4 ft·lb)

13. Inspect:
• Gasket (Oil pump)
Damage -+ Replace.
14. Install:
• Oil pump assembly CD

Bolt (Oil pump assembly):

4 Nm (0.4 m' kg, 2.9 ft·lb)
NOTE: _________________________

After installing the oil pump assembly, the oil

pump, oil hose and oil delivery hose should be
bleed.
Refer to the "OIL PUMP AIR BLEEDING"
section.

15. Install:
• Drive gear housing CD with oil pump
assembly ®

16. Connect:
.Oil hose
• Oil delivery hose
• Oil pump cable
17. Install:
• Primary sheave
• Drive V-belt
• Drive V-belt guard
• Side cowl (Left)

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OIL PUMP AIR BLEEDING

18. Adjust:
• Oil pump cable

Free Play (Oil Pump Cable):

24.0 ~ 26.0 mm (0.94 ~ 1.02 in)

Refer to the "OIL PUMP CABLE FREE

PLAY ADJUSTMENT" section.
19. Close the shroud.

01 L PUMP AIR BLEEDING

The oil pump and delivery line must be bled on

the following occasions:
• Any portion of the oil system has been dis-
connected.
• The machine has been turned on its side.
• Whenever the oil tank has been run empty.
• During predelivery.

1. Open the shroud.

Refer to the "SH ROU D OPEN I NG" section.
2. Remove:
• Air duct (Outlet) CD

3. Disconnect:
• Oil delivery hose CD

4. Fill:
.Oil tank

Recommended Oil:
For U.S.A. and CANADA:
Y AMALUBE "2" or equivalent
For EUROPE:
Yamaha Oil 2T or Air cooled
2 stroke engine oil

5. Place a rug under the oil pump assembly.

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01 L FI L TER INSPECTION
6. Put oil into the oil delivery hose for complete
air bleeding. Then, connect them with the
oil pump.

7. Remove:
• Bleed screw CD
8. Inspect:
• Gasket (Bleed screw)
Damage ~ Replace.
9. Keep the oil running out until air bubbles
disappear.
10. Install:
• Gasket (Bleed screw)
• Bleed screw
• Air duct (Outlet)
11. Close the shroud.

OIL FILTER I~SPECTION

1. Open the shroud.
Refer to the "SHROUD OPENING" sec-
tion.
2. Remove:
• Carburetor
Refer to the CHAPTER 4. "CARBURE-
TOR - REMOVAL" section.
NOTE: _________________________

The throttle cable, starter cable and carburetor

switch leads do not need removing.

3. Remove:
.Oil filter CD
NOTE: __________________________

Plug the oil hoses so that the oil will not run
out of the oil tank and oil pump.

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_~~~~~~~~_IIANDSJPI_I
FUEL FI L TER INSPECTION _ _ _ ~

4. Inspect:
- Oil filter CD
Contamination -+ Replace.

5. Install:
- Oil filter
- Carburetor
6. Close the shroud.

FUEL FILTER INSPECTION

1. Remove the seat.
Refer to "SEAT" section.
2. Remove:
-Springs CD

3. Remove:
-Cap CD
- Fuel filter ®
4. Inspect:
- Fuel filter
Contamination -+ Replace.

5. Install:
- Fuel filter
-Cap
-Springs
-Seat

Screw (Seat - Front):

3 Nm (0.3 m - kg, 2.2 ft- Ib)
Nut (Seat - Rear):
9 Nm (0.9 m- kg, 6.5 ft-Ib)

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FUEL PUMP OPERATION CHECK

FUEL PUMP OPERATION CHECK
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
·Oil tank CD

3. Disconnect:
• Oil hose CD
• Oi I level hose ®
NOTE: __________________________

Plug the oil hose and oil level hose so that oil
does not run out.

4. Disconnect:
• Pu Iser hose CD
(from the crankcase)

5. Disconnect:
• Fuel hoses
(from carburetor CD and junction ® )

6. Remove:
• Fuel pump CD

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FUEL PUMP OPERATION CHECK

7. Inspect:
• Fuel hoses CD
• Pulser hose ®
Clog/Damage ~ Replace.

8. Check:
• Fuel pump operation

Operation checking steps:

• Connect a hand-operated vacuum pump
(such as Mighty - Vac®) to the pulser hose
CD .
• When operating a hand-operated vacuum
pump, fuel flows out the fuel hose ® .
• If fuel does not flow out, replace the fuel
pump.

9. Install:
• Fuel pump
NOTE: _________________________

Position the left side hole of the fuel pump to

the projection on the frame.

10. Connect:
• Pulser hose
• Fuel hoses
• Oil hose
• Oil level hose
11. Install:
• Oil tank

Bolt (Oil Tank - Upper):

4 Nm (0.4 m o kg, 2.9 ft·.lb)
Bolt (Oil Tank - Lower):
5 Nm (0.5 m· kg, 3.6 ft· Ib)

12. Close the shroud.

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DRIVE V-BELT INSPECTION

POWER TRAIN
DRIVE V-BELT INSPECTION
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
• Side cowl (Left)
• Drive V-belt guard CD
• Drive V -belt

Drive V-belt removal steps:

• Turn the secondary sliding sheave ® clock-
wise and push it towards the engine .
• While holding the secondary sliding sheave
in this compressed position, remove the
drive V·belt ® from the secondary sheave .
• Then, remove the drive V-belt from the
primary sheave.

3. Inspect:
• Drive V·belt
Crack/Wear/Damage ~ Replace.
Oil or grease adhered to the V-belt ~ Check
the primary and secondary sheaves.

4. Inspect:
• Primary sheave
• Secondary sheave
Oil or grease adhered to the primary and
secondary sheaves ~ Remove the oil or
grease using a rug soaked in lacquer thinner
or solvent.

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SHEAVE DISTANCE AND OFFSET ADJUSTMENT

5. Measure:
• Drive V-belt width ®
Out of specification -+ Replace.

New Belt Width:

31.6 mm (1.24 in)
1---'" Belt Wear Limit:
28.0 mm (1.10 in)

6. Measure:
• Drive V -belt length ®
Out of specification -+ Replace.

Drive V-belt Length:

1,099 mm (43.4 in)

7. Install:
• Drive V-belt
• Drive V -belt guard
• Side cowl (Left)
8. Close the shroud.

SHEAVE DISTANCE AND OFFSET ADJUST-

MENT
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
• Side cowl (Left)
• Drive V-belt guard CD
Refer to the "DRIVE V-BELT INSPEC-
TION" section.

3. Measure:
• Sheave distance ®
Use the Sheave Gauge.
Out of specification -+ Adjust.

Sheave Distance:
Approx. 268.5 mm (10.57 in)

Il'j Sheave Gauge:

YS-91047

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DRIVE CHAIN HOUSING OIL LEVEL INSPECTION

4. Measure:
• Sheave offset ®
Use the Sheave Gauge.
Out of specification ~ Replace.

Sheave Offset:
Approx. 11.0 mm (0.433 in)

Sheave Gauge:
YS-91 047

5. Adjust:
• Sheave distance and offset

Adjustment steps:
• Check the engine mounting bracket, dam-
pers and frame of bend, crack and weather-
ing. Replace as required.
• Loosen the engine mounting nuts.
• Adjust the position of the engine so that
the sheave distance and offset are within the
specification.
• Tighten the engine mounting nuts.

Ix Mounting Nut
53 Nm (5.3
Mounting Nut
(Front):
m· kg, 38 ft· Ib)
(Rear):
30 Nm (3.0 m· kg, 22 ft ·Ib)

6. Install:
• Drive V -belt
• Drive V-belt guard
• Side cowl (Left)
7. Close the shroud.

DRIVE CHAIN HOUSING 01 L LEVEL

INSPECTION
1. Place the machine on a level place and open
the shroud.
Refer to the "SHROUD OPENING" section.
NOTE: _________________________

Be sure the machine is positioned straight up

when inspecting the oil level.
2. Remove:
• Side cowl (Left)
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DRIVE CHAIN HOUSING OIL REPLACEMENT

3. Place a rug under the checking bolt CD .
4. Remove:
- Checking bolt

5. Inspect:
-Oil level
Oil flows out ~ Oil level is correct.
Oil does not flow out ~ Oil level is low.
Add oil until oil flows out.

Recommended Oil:
Gear oil API GL-3 SAE #75
or# 80

6. Inspect:
- Gasket (Checking bolt)
Damage ~ Replace.
7. Install:
- Gasket (Checking bolt)
- Checking bolt
-Side cowl (Right)

Checking Bolt:
7 Nm (0.7 m· kg, 5.1 ft· Ib)
8. Close the shroud.
DRIVE CHAIN HOUSING OIL REPLACE-
MENT
1. Open the shroud.
Refer to the "SHROUD OPENING"
section.
2. Remove:
-Side cowl (Right)
- Stay (Side cowl)
-Muffler CD

3. Place some rugs under the drive chain

housing.
4. Remove the chain housing cover CD and
drain the oil.

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DRIVE CHAIN SLACK ADJUSTMENT

5. Replace:
• Gasket (Chain housing cover)
Use new one.
6. Install:
• Gasket (Chain housing cover)
• Chain housing cover)

Be sure no foreign material enters the chain

housing case.

Bolt (Chain Housing Cover):

6 Nm (0.6 m' kg, 4.3 ft·lb)

7. Fill:
• Drive chain housing

Recommended Oil:
Gear oil API GL-3 SAE #75
or #80
Oil Quantity:
250 cm 3 (8.8 Imp OZ, 8.5 US oz)
8. Inspect:
• Drive chain housing oil level
Refer to the "DRIVE CHAIN HOUSING
OIL LEVEL INSPECTION" section.
9. Install:
• Muffler
• Stay (Side cowl)
.Side cowl (Right)

Bolt (Muffler):
19 Nm (1.9 m' kg, 14 ft·lb)

10. Close the shroud.

DRIVE CHAIN SLACK ADJUSTMENT

1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
• Side cowl (R ight)
·Stay (Side cowl)
• Muffler CD

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DRIVE CHAIN SLACK ADJUSTMENT I~gr I~ I

3. Place some rugs under the chain housing.
4. Remove:
.Chain housing cover CD
Drain the oil.

5. Check:
• Drive chain slack ®
Out of specification -.. Adjust.

Drive Chain Slack:

8 ~ 15 mm (0.31 ~ 0.59 in)

6. Adjust:
• Drive chain slack

Drive chain slack Adjustment steps:

• Loosen the locknut CD .
• Turn the adjuster ® in or out until the
specified slack is obtained.

Turn in Slack is decreased.

Turn out Slack is increased.

• Tighten the locknut.

7. Replace:
• Gasket (Chain housing cover)
Use new one.
8. Install:
• Gasket (Chain housing cover)
.Chain housing cover

Be sure no foreign material enters the chain

housing case.

Bolt (Chain Housing Cover):

6 Nm (0.6 m·kg, 4.3 ft·lb)

2-28
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_~~~~~~~~_IIANDSJPlel
BRAKE PAD INSPECTION _ _ _ ~

9. Fill:
• Drive chain housing

Recommended Oil:
Gear oil API GL-3 SAE #75
or #80
Oil Quantity:
250 cm 3 (8.8 Imp OZ, 8.5 US oz)

10. Inspect:
• Drive chain housing oil level
Refer to "DRIVE CHAIN HOUSING OIL
LEVEL INSPECTION" section.
11. Install:
• Muffler
• Stay (Side cowl)
• Side cowl (R ight)
Bolt (Muffler):
19 Nm (1.9 m- kg, 14 ft·lb)

12. Close the shroud.

BRAKE PAD INSPECTION

1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
• Bracket CD
• Brake caliper ®

3. Remove:
• Brake pads
4. Measure:
• Brake pad thickness ®
Out of specification ~ Replace.

r~
Al
Wear Limit:
9.5 mm (0.37 in)
NOTE: __________________________
I
Replace the brake pad as a set.
5. Install:
• Brake caliper
• Bracket
Bolt (Brake Caliper):
48 Nm (4.8 m· kg, 35 ft·lb)
Nut (Bracket):
24 Nm (2.4 m· kg, 17 ft·lb)
Bolt (Oil Tank - Upper):
4 Nm (0.4 m· kg, 2.9 ft·lb)
2-29
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BRAKE ADJUSTMENT
6. Adjust:
e Brake system
Refer to the "BRAKE ADJUSTMENT"
section.
7. Close the shroud.

BRAKE ADJUSTMENT
NOTE: _________________________

Adjust brake every 40 hours of operation, or

whenever the brake lever becomes loose during
operation.

1. Open the shroud.

2. Measure:
e Distance "L"
Out of specification -+ Adjust.

~ Distance "L":
[6J 57 mm (2.24 in)

3. Adjust:
e Distance" L"

Distance ilL" adjustment steps:

First steps:
e Loosen the locknuts CD .
e Turn in the adjuster (Right hand side) to
give enough play in the wire.
eTurn the adjuster ® (Left hand side) in or
out until specified distance is obtained.

Turn in Distance ilL" is increased.

Turn out Distance ilL" is decreased.

eTighten the locknut (Left hand side only).

Second steps:

NOTE:
Right hand side is Europe only.

eTurn out the adjuster (Right hand side) until

the same distance "L" as the other one is
obtained.
eTighten the locknut (Right hand side).

2-30
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BRAKE ADJUSTMENT
4. Measure:
• Clearance (Brake pad) ®
Out of specification -+ Adjust.

Clearance (Brake Pad):

0.15 ~ 0.30 mm (0.006 ~ 0.012 in)

5. Adjust:
• Clearance (Brake pad)

Adjustment steps:
• Loosen the locknut CD and adjuster ® .
• Insert a 0.15 mm (0.006 in) feeler gauge @
between the brake pad and brake disc.
• Turn the adjuster in until it is seated lightly.
• Tighten the locknut.
• Remove the feeler gauge and recheck the
brake pad clearance.

6. Measure:
• Free play (Brake lever) ®
Out of specification -+ Adjust.

Free Play (Brake Lever):

5.0 ~ 8.0 mm (0.20 ~ 0.31 in)

7. Adjust:
• Free play (Brake lever)

Adjustment steps:
First steps:
• Loosen the locknuts CD .
• Turn in the adjuster (Right hand side) to
give enough play in the wire.
• Turn the adjuster ® (Left hand side) in or
out until specified free play is obtained.
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TRACK TENSION ADJUSTM ENT

Turn in Free play is increased.

Turn out Free play is decreased.

- Tighten the locknut (Left hand side on IV).

Second steps:

NOTE:
Right hand side is Europe onlV.

-Turn out the adjuster (Right hand side) until

the same free plav as the other one is
obtained.
- Tighten the locknut (R ight hand side).

8. Close the shroud.

TRACK TENSION ADJUSTMENT

& WARNING:
A broken track, track fittings, or debris thrown
by the track could be dangerous to an operator
or bystanders. Observe the following pre-
cautions.
1. Do not allow anYOlle to stand directly
behind the snowmobile when starting
forward.
2. When the engine is running and the track
is engaged with the snowmobile on its side,
do not allow anyone to stand behind or
on the track side of the snowmobile. The
operator must stay near on the seat front.
3. Never lift the rear of the snowmobile to
allow the track to turn while the engine
is running. Stop the engine and prop up
the rear with a suitable stand. Never stand
behind a machine when the track is spinning.
4. Never install studs (cleats) closer than three
inches from the edge of the track.
5. Replace any track that is damaged to the
depth where fabric reinforcement material
is visible. Inspect track condition frequently.

2-32
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TRACK TENSION ADJUSTMENT

1. Turn the track by running the engine.
2. Measure:
10 kg (22 Ib) • Track tension ®
Pull at the track center window by a force
of 10 kg (22 Ib) using a spring scale.
Out of specification -+ Adjust.

Track Tension:
25 ~ 30 mm/10 kg
(1.0"" 1.2 in/22Ib)

3. Adjust:
• Track tension

Track tension adjustment steps:

• Loosen the both rear axle locknut CD .
NOTE:
Track tension adjustment is possible without
removing the cotter pin.

• Turn the both adjuster ® in or out using a

box wrench until the specified track tension
is obtained.

Turn in Tension becomes higher.

Turn out Tension becomes lower.

• Be sure that the track ® and slide rail @

are correctly aligned as shown in figure lAl .
If they are misaligned as indicated in the
figure rnJ and ~ , correct as follows.

2-33
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TRACK TENSION ADJUSTMENT

B 1) lID (when shifted to the right)
Tighten the right track adjuster, and
loosen the left track adjuster.
2) [g (when shifted to the left)
Tighten the left track adjuster and loosen
the right track adjuster.
• By repeating the above procedures the track
should be brought in alignment with correct
tension .
• After making sure all adjustments are cor-
c rect, tighten the rear axle lock nuts.

I".AI) Rear Axle Locknut:

" 75 Nm (7.5 mokg, 54 ftolb)

@ Track metal
[Q) GAP BETWEEN SLIDE RUNNER AND EDGE
OF TRACK WINDOW.

2-34
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SKI ADJUSTMENT
CHASSIS
SKI ADJUSTMENT
1. Remove:
• Engine assembly
Refer to the CHAPTER 3. "ENGINE RE-
MOVAL" section.
2. Place the machine on a level place and elevate
the skis.
3. Hold the handlebars straight, and check to
see that the skis at right angles to the handle-
bars. If not, adjust the skis.
4. Adjust:
.Skis

Adjustment steps:
• Loosen the locknut CD and ®.
• Direct the skis in parallel to the moving
direction .
• With the skis thus, turn the relay rod @
either way to adjust the handlebars to from
the right angles with the moving direction.

Turn the relay rod The handlebars move to

to@way. @)way.
Turn the relay rod The handlebars move to
to@way. @way.
o

• Tighten the locknuts (Steering relay rod).

:X
NOTE:
Locknut (Steering Relay Rod):
25 Nm (2.5 m· kg, 18 ft·lb)

Apply thread-locking compound such as

LOCTITE® to the locknuts.

S. Install:
• Engine assembly
Refer to the CHAPTER 3. "ENGINE
ASSEMBLY AND INSTALLATION"
section.

Mounting Nut (Front):

53 Nm (S.3 m·kg, 38 ft·lb)
Mounting Nut (Rear):
30 Nm (3.0 m· kg, 22 ft·lb)

2-35
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BRAKE CABLE END LUBRICATION

6. Check:
• Ski toe - Out
Direct the skis in parallel to the moving
direction.
Out of specification -+ Adjust.

Ski Toe - Out (®-@):

0.0 - 15.0 mm (0.0 - 0.6 in)
SkiWidth@:
870 mm (34.3 in)

7. Adjust:
• Ski toe - Out

Ski toe - Out adjustment steps:

• Open the shroud.
• Loosen the locknuts (Tie-rod) CD and ® .
• Remove the side cowl (Right), stay (Side
cowl) and muffler.
• Turn the tie-rod ® in or out until the
specified toe - out is obtained.
• Tighten the locknuts (Tie-rod).

~
Locknut (Tie-rod):
25 Nm (2.5 m- kg, 18 ftolb)

NOTE:
Apply thread - locking compound such as
LOCTITE® to the locknuts.

.Install the muffler, stay (Side cowl) and

side cowl (Right).

I~
Bolt (Muffler):
19 Nm (1.9 mokg, 14 ftolb)

• Close the shroud.

BRAKE CABLE END LUBRICATION

1. Apply:
• Low temperature grease
To the brake cable end.

Recommended Grease:
Esso Beacon 325 Grease or
Aeroshell Grease #7A.

2-36
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SLIDE RUNNER INSPECTION

~ WARNING:

Do not apply a grease between the outer cable

and inner cable.

SLIDE RUNNER INSPECTION

1. Inspect:
• Slide runner CD
Cracks/Damage/Wear -+ Replace.
2. Measure:
®
• Slide runner thickness
Out of specification -+ Replace.
Refer to the CHAPTER 5. "SLIDE RAI L
SUSPENSION" section.

Slide Runner Thickness:

15 mm (0.59 in)
Wear Limit:
10 mm (0.39 in)
r
®

® Wear indicator

2-37
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SPARK PLUG INSPECTION

ELECTRICAL
SPARK PLUG INSPECTION
1. Open the shroud and remove the spark plugs.
2. Inspect:
- Spark plug type
Incorrect -+ Replace.

Standard Spark Plug:

BR9ES (NGK)

3. Inspect:
- Electrode CD

-
.
Wear/Damage -+ Replace .
-Insulator color @
Normal condition is a medium to light tan
color.
Distinctly different color -+ Check the
engine condition.
4. Clean:
-Spark plug
Clean the spark plug with a spark plug
cleaner or wire brush.
5. Measure:
-Spark plug gap ®
Out of specification -+ Regap.
Use a wire gauge.

Spark Plug Gap:

0.7'" 0.8 mm (0.028 - 0.031 in)

6. Tighten:
-Spark plug
NOTE: __________________________

Before installing a spark plug, clean the gasket

surface and plug surface.

Spark Plug:
28 Nm (2.8 m· kg, 20 ft·lb)
NOTE: __________________________

If a torque wrench is not available when you are

installing a spark plug, a good estimate of the
correct torque is 1/4 to 1/2 turns part finger
tight. Have the spark plug torqued to the correct
value as soon as possible with a torque wrench.

7. Close the shroud.

2·38
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IGNITION TIMING CHECK

IGNITION TIMING CHECK
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Remove:
-Side cowl (Right)
- Stay (Side cowl)
-Muffler
3. Check:
-Ignition timing
Out of firing point ~ Check pickup as-
sembly.

Checking steps:
- Disconnect the spark plug leads.
- Remove the air duct (Inlet) CD .
- Connect the spark plug leads.
-Connect the Timing Light and Inductive
Tachometer to spark plug lead (Right hand).

Timing Light:
YU-08037,90890-03109
Inductive Tachometer:
YU-08036,90890-03113

-Start the engine and accele to aligne engine

speed at 7,000 r/min.
- Check if the firing marke ® on the cooling
fan and allow mark ® on the cooling fan
cover matches.
- Disconnect the Timing Light and Inductive
Tachometer.
-Install the air duct (Inlet).

4. Install:
-Muffler
-Stay (Side cowl)
-Side cowl (Right)

Bolt (Muffler):
19 Nm (1.9 m·kg, 14 ft·lb)

5. Close the shroud.

2-39
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BATTERY INSPECTION (FOR CS340EN)

BATTERY INSPECTION (FOR CS340EN)
1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Inspect:
Fluid level should be between upper CD
and lower ® level marks.
Incorrect -+ Refill.

Refill with distilled water only; tap water

contains minerals harmful to a battery.

----l> 3. Check:
• Specific gravity
Less than 1.280 -+ Recharge battery.

Charging Current:
1.4 amps/1 0 hs
Specific Gravity:
1.280 at 20°C (68° F)

Replace the battery if:

• Battery voltage will not rise to a specific
value or bubbles fail to rise even after many
hours of charging.
• Sulfation of one or more cells occurs, as
indicated by the plates turning white, or
an accumulation of material exists in the
bottom of the cell.
• Specific gravity readings after a long, slow
charge indicate one cell to be lower than
the rest .
• Warpage or buckling of plates or insulators
is evident.

Always charge a new battery before using it to

ensure maximum performance.

L'h WARNING:
Battery electrolyte is dangerous; it contains
su Ifu ric acid and is therefore poisonous and
highly caustic.
Always follow these precautionary measures:
• Avoid bodily contact with electrolyte as it can
cause severe burns or permanent eye injury.
• Wear protective eye gear when handling or
367-009
working near batteries.
2-40
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HEADLIGHT BULB REPLACEMENT

Antidote (EXTERNAL):
.SKIN - Flush with water.
• EYES - Flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk, follow
with milk of magnesia, beaten egg, or vegetable
oil. Get immediate medical attention.
Batteries also generate explosive hydrogen gas.
Therefore you should always follow these
precautionary measures:
• Charge batteries in a well·ventilated area.
• Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment, lighted
cigarettes, etc.)
• DO NOT SMOKE When charging or handling
batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.

HEADLIGHT BULB REPLACEMENT

1. Open the shroud.
Refer to the "SHROUD OPENING" section.
2. Disconnect:
• Headlight lead CD
I 3. Remove:
• Headlight bulb cover ®

4. Turn the bulb holder CD counterclockwise

and remove the defective bulb.

to WARNING:

Keep flammable products or your hands away

from the bulb while it is on, it will be hot. Do
not touch the bulb until it cools down.

5. Install:
• Bulb (New)
6. Reinstall by reversing the removal procedure.
Adjust the headlight beam if necessary.

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2·41
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HEADLIGHT BEAM ADJUSTMENT/
TAIL/BRAKE LIGHT REPLACEMENT
HEADLIGHT BEAM ADJUSTMENT
1. Place the machine on a level place.
2. Inspect:
e Headlight beam direction
The high beam should be directed down-
ward at an angle of 1/2 0 to the horizontal
line. If not, adjust the direction.

L 3.0 m (10 ft) 7.6 m (25 ft)

H 26 mm (1.0 in) 66 mm (2.6 in)

3. Adjust:
e Headlight beam direction
Adjust the headlight beam by tightening or
loosening the adjusters CD .

TAIL/BRAKE LIGHT REPLACEMENT

1. Remove:
e Tail/Brake light lens CD

2. Remove:
eBulb CD
Turn it counterclockwise.
3. Install:
eBulb (New)
eTail/Brake light lens

2-42
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CARBURETOR TUNING
TUNING
CARBURETOR TUNING
The carburetor is set at the factory to run at
temperatures of O°C- _20° C (32° F '" _4° F) at
sea level. If the machine has to be operated
under conditions other than specified above, the
carburetor must be reset as required. Special
care should be taken in carburetor setting so
that the piston will not be damaged or seized.

In this model, the engine oil is mixed with the

fuel just before the fuel enters the fuel pump, so
it is not always possible to supply the optimum
mixture depending on the throttle opening.
Therefore, after the carburetor is tuned up or
maintained, or after the float chamber is re-
moved for cleaning or jet replacement, be sure
to idle the engine for about three minutes in
order to avoid engine trouble.

Before performing the carburetor tuning, make

sure that the following items are in correct con-
dition.
- Starter cable adjustment
- Throttle cable adjustment
- Oil pump cable adjustment
-Idle mixture setting
-Idle speed adjustment

Carburetor Tuning Data

1. Standard specifications
Model Y30W-2A
Manufacture TEIKEI
85LOO
1.0. Mark
85MOO (For Europe)
Main jet L: # 128 R: # 132
Pilot jet #72
Pilot screw 1~3/4 turns out
30.0 '" 32.0 mm
Float height
(1.18'" 1.26 in)
Idle speed 1,800 r/min

2-43
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CARBURETOR TUNING
2. High altitude tuning
A guide to main jet according to variations
in elevation and temperature.

With Standard Air I ntake System

~ Altitude
-30o e
(_22°F)
I

r- MJ L: :130 ...
-20o e
(_4°F)

I
I
I
I
_1O o
(14°FI
I
MJ L: l128
e oOe
(32°F)
i
I
I
i ...
10
(50°F)
i
I
0e

I MJ L: :124
200e
(68°F)
iI

Sea level R: 134 R: 132 I R: 128

I
I
! iPJ #72
t
t I :
I I I

-I-
I I I
I I I
0~600 m MJ L: :128 I
I MJ L: :124
I R: 132 I
I R: 128 I
(0 ~ 2,000 tt) PJ #72
: I
I
I I
I
MJ L: :124
I
I I I
MJ L: :122
I
600 ~ 1,200 m I
I
I
-I-
R: 128 I R: 126 I
(2,000 ~ 4,000 tt) I PJ #72 I I
I I I

1 ,200 '" 1,800 m

: I
I
t
MJ L: $122
I
I
I
I
I
I
I I R: 126 I
I
I
(4,000'" 6,000 ttl PJ #72 I I
PJ #70
I I I i
I t I I
I
1,800 ~ 2,400 m i MJ L: 1122 I
I .1. MJ L: 1120 I

(6,000 ~ 8,000 ttl i R: 126

PJ 72
t
I I
I
R: 124
PJI 68
I
t
t
I
I
it I
I
I

I t I I
2,400 ~ 3,000 m MJ L: 1120 t .11 .. MJ L: 1118
t R: 124 I t R: 122 I
(8,000 ~ 10,000 ttl PJ 72 I I
PJ 68
I
I I I
:
With Fresh Air Intake System (See page 2-45)

~ Altitude

0~600 m
oOe
(32°FI
I
,I ..
10
(50°FI
0e 20 0e
(68°FI
I
I

MJ L: 1118
I R: 120
(0 '" 2,000 ttl I· PJ 72
I
I

600 ~ 1,200 m
(2 ,000 ~ 4,000 ttl
:.
I
MJ L: 1114
R: 118
1 ..
I
PJ 72
I
I
I
1,200 '" 1 ,800 m MJ L: 1114
(4,000 ~ 6,000 ttl '.
'II
I
I
PJ
R: 118
70
I
I

1 ,800 ~ 2,400 m I
i· MJ L:f16
I R: 118
(6,000 ~ 8,000 ttl I- PJ 68
I I
I
I
2,400'" 3,000 m I. MJ L: 1114
I R: 116
(8,000 ~ 10,000 ttl I- PJ 66
I

2-44
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CARBURETOR TUNING

CD Main jet (MJ)

® Pilot jet (PJ)

How to use the Fresh Air Intake

It is recommended that the fresh air intake be
used under the following conditions.

Conditions:
- Free air temperature is above 5°C (41 ° F).
-When climbing mountains or hills at a time.

CD Air intake elbow

2-45
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CARBURETOR TUNING
Low Speed Tuning
The carburetor is built so that low speed tuning
can be done by adjusting the pilot screws CD and
throttle stop screw ® .

The engine should never be run without the air

intake silencer and air chamber installed; severe
engine damage may result.

1. Tighten the pilot screws CD lightly, and back

it out from its lightly seated position.

Standard Tuning Out:

1-3/4

2. Start the engine, and allow it to warm up for

a few minutes. The warm-up is complete
when the engine responds normally to the
throttle opening.

h WARNING:

Do not move the throttle lever more than nece-

ssary so that the engine will not run faster than
the following revolutions at which the snowmo-
biles starts to more off.

Engine Revolutions: 3,000 r/min

3. Adjust the throttle stop screw until the en-

gine speed at 2,000 - 2,500 r/min.

4. Slowly loosen the pilot screw. As the pilot

screw is loosened, the mixture will become
leaner, and engine speed will increase. Adjust
the pilot screw to attain the highest possible
engine speed.

2-46
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CARBURETOR TUNING
5. Finally, set the engine idle speed by tuning
the throttle stop screw in (to increase engine
speed) or out (to decrease engine speed).

Standard Idle Speed:

1,800 r/min

6. If the engine still shows poor performance in

high elevations or in an extremely cold area
or when it is suddenly accelerated or run at
low speed, replace the pilot jets.
NOTE: __________________________

In this case, set the carburetor on the richer side;

use a larger number pilot jet.

Standard Pilot Jet: #72

7. By repeating steps 1 to 5 above, adjust the

idle speed.

Middle-Range and High Speed Tuning

No adjustment is normally required, but adjust-
ment is sometimes necessary depending on tem-
peratures and/or altitude.
Middle-range speed and high speed tuning (from
1/4 to full-throttle) can be done by adjusting the
main jet.

The engine should never be run without the air

intake silencer and air chamber installed; severe
engine damage may result.

2-47
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CARBURETOR TUNING
1. Start the engine, and run the engine at high
speed, Make sure the engine operates smoo-
thly.
2. Stop the engine, and remove the spark plug.
Then, check the spark plug color.
NOTE: ___________________________

Check the spark plug color using the CHAPTE R

8. "APPENDICES, Spark Plug Color Chart"
section.

3. The main jet should be adjusted on the basis

of the following chart.

Standard Main Jet: L: # 128 R: # 132

'6WARNING:

Never remove the main jet cover while the en-

gine is hot. Fuel will flow out of the float cham-
ber 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
sprend. Place the main jet cover in a clean place.
Keep it away from fire. After assembling the car-
buretor, firmly tighten the intake silencer joint
clamps and intake manifold clamps. Make sure
the throttle cable is in place, and the throttle
cable smoothly. Clean the carburetor, and allow
it to dry.

Main jet selection chart

Spark plug
Checkup Remedy
color
Good (Carburetor is tuned
No.1
properly.)
No.2 Bad (Mixture is too rich.) Replace main jet with one-step small one.
No.3 Bad (Mixture is too lean.) Replace main jet with one-step larger one.
Replace the piston and spark plug.
Bad (Due to too lean a mixture,
No.4 Tune the carburetor again, starting with
piston is damaged or seized.)
low-speed tuning.
Check the piston for holes or seizure.
Check the cooling system, gasoline octane
Bad (Due to too lean a mixture, the
No.5 rating and ignition timing. After replacing
engine knocks.)
the spark plug, tune the carburetor again,
starting with low-speed tuning.
Check the piston for holes or seizure.
Check the cooling system, gasoline octane
Bad (Due to lean a mixture, the rating and ignition timing. After replacing
No.6
spark plug melts.) the spark plug with colder type, tune the
carburetor again starting with low-speed
tuning.
2-48
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CARBURETOR TUNING
Troubleshooting

Trouble Check point Remedy Adjustment

Hard starting I nsufficient fuel Add gasoline
Excessive use of starter Clean spark plug Return starter lever to its
(Excessively opened seated position.
choke)
Fuel passage is clogged Clean Parts other than carburetor
or frozen • Clogged fuel tank air vent,
clogged fuel filter, or clog-
ged fuel passage
Carburetor
• Clogged or frozen air vent
clogged valve.
.If water collects if float
chamger, clean.
(Also check for ice).
Overflow Correct
Poor idling Improper idling speed Tighten pilot screw lightly,
adjustment and check throttle opening.
(Relative troubles) .Pilot screw Adjust idling speed If incorrect, back it out spe-
• Poor performance cification. Start the engine
at low speeds and turn pilot screw in and
• Poor acceleration out 1/4 turn each time. When
• Slow response to the engine runs faster, back
throttle out throttle stop screw so the
• Engine tends to engine idles at specified
stall speed.
• Throttle stop screw Adjust Tightened to much - Engine
speed is higher.
Backed out too much -
Engine does not idle.
Damaged pilot screw Replace pilot screw
Clogged bypass hole Clean
Clogged or loose pilot Clean and retighten Remove pilot jet, and blow it
jet out with compressed air.
Air leaking into carbu- Retighten band screw
retor joint
Defective starter valve Clean or replace
seat
Overflow Correct
Poor performance at Clogged or loose pilot Clean and retighten Remove pilot jet, and blow it
mid-range speeds jet out with compressed air.
(Relative troubles)
• Momentary slow
response to throttle
• Poor acceleration Lean mixtures Overhaul carburetor
Poor performance at Clogged air vent pipe Clean Remove the air vent pipe,
norma I speeds and clean.
(Relative troubles) Clean and retighten Remove main jet, and blow it
Clogged or loose main
• Excess fuel con- out with compressed air.
jet
sumption
• Poor acceleration Overflow Check float and float
valve and clean
2-49
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CARBURETOR TUNING Irgr IQ I

Trouble Check point Remedy Adjustment
Poor performance at Starter valve is left Fully close valve Return starter lever to its
high speeds open home position.
(Relative troubles) Clogged air vent Remove and clean
• Power loss
• Poor acceleration Clogged or loose main Clean and retighten Remove main jet, and clean
jet with compressed air, then
install.
Clogged fuel pipe Clean or replace
Dirty fuel tank Clean fuel tank
Air leaking into fuel Check joint and re-
line tighten
Low fuel pump perfor- Repair pump or re-
mance place
Clogged fuel filter Replace
Clogged intake Check for ice, and
remove
Abnorma I combution Lean mixtures Clean carburetor and
(Mainly backfire) adjust
Dirty carburetor Clean carburetor
Dirty or clogged fuel Clean or replace fuel
pipe pipe
Overflow Clogged air vent Clean
(Relative troubles) Clogged float valve Disassemble and clean Clean while taking care not
• Power idling to scratch valve seat.
• Poor performance
at low, mid-range, Scrached or unevenly Clean or replace float Valve seat is press-fitted to
and high speeds worn float valve or valve and valve seat body.
• Excessive fuel con- valve seat So body must be replaced if
sumption seat is damaged.
• Hard starting Broken float Replace float
• Power loss Incorrect float level If not within the spe-
• Poor acceleration cified range, check
the following parts
and replace any de-
fective part .
• Worn float tang • Replace float Replace float assembly.
.Worn pin • Replace arm pin
• Deformed float arm • Replace float

2-50
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CLUTCH TUNING
CLUTCH TUNING
The clutch may require tuning depending upon
the area of operation and desired handling cha-
racteristics. The clutch can be tuned by changing
engagement and shifting speed. Clutch engage-
ment speed is defined as the engine speed where
the machine first begins to move from a comp-
lete stop.
Shifting speed is the engine speed when the ma-
chine passes a point 200 '" 300 m (650'" 1,000
ft) from the starting position after the machine
has been started at full-throttle from a dead stop.
Normally, when a machine reaches shift speed,
the vehicle speed increases but the engine speed
remains nearly constant. Under unfavorable
conditions (Wet snow, icy snow, hills, or rough
terrain) however engine speed may decrease
after the engine speed has reached shifting speed.

Engine speed
Engine speed
t
t Good condition Bad condition

Clutch Clutch shifting speed

shifting speed

Clutch engagement Clutch engagement

speed speed

-
r--_____--lr-_ _ Travelled distance Travelled distance
t - t
Starting position #200'" 300 m (650'" 1,000 ftl Starting position #200'" 300 m (650'" 1,000 ftl

2-51
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GEARING SELECTION
High Altitude Tuning
High altitude specifications should be applied to
operation at an altitude of more than 1,800
meters (6,000 ft).

Clutch Setting Data

High altitude spec.

Item Standard spec. 600- 1,800 m 1,800 - 3,000 m
(2,000 - 6,000 ft) (6,000 - 10,000 ft)
Engagement speed Approx 3,500 r/min Approx 3,600 r/min +-

Shifting speed Approx 6,600 r/min Approx 6,700 r/min +-

Weight Part No. 85L-17632-00 85L-17632-00 85 L-17632-90

Part No. 90501-520A9 90501-55485 90501-554F6
Set weight 25 kg (55Ib) 25 kg (55Ib) 30 kg (66 Ib)
Primary spring Spring rate 21 N/mm 25 N/mm 30 N/mm
(2.1 kg/mm, 118 Ib/in) (2.5 kg/mm, 140 Ib/in) (3.0 kg/mm, 168 Ib/in)
Color Gold Brown - White Sky blue - Orange
Part No. 90508-45763 +- +-

Secondary spring Twist angle 50° (A, B, C) 80° (D) +-

Color Red +- +-

GEARING SELECTION
The reduction ratio of driven gear to drive gear
must be set according to the snow condition. If
many rough surfaces or unfavorable snow condi.
tions, drive/drive gear ratio should be made lar-
ger. Few rough surface or better snow condi-
tions; the ratio should be made smaller.

Gear Ratio Chart

The following drive and drive gears and chains
are available as options. The figures in upper
lines represent the driven and drive gear ratios,
while those in lower lines represent the number
of chain links.
NOTE: _ _ _ _ _ _ _ _ _ _ _ __

Do not set the gearing to any of the indicated

(X) settings.

2-52
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GEARING SELECTION

~Driven gear

22
10

2.200
11

2.000
12

1.833
48 48 48

24 2.400 2.182 2.000

48 48 48

Drive gear options Driven gear options

Part No. Teeth Part No. Teeth
802-17682-10 10 * 85T-47548-20 22
802-17682-20 11 85T-47548-40 24
* 806-17682-20 12
Drive chain
Part No. No. of links

* 94880-01 048 48

* Standard
High Altitude Tuning
High altitude specifications should be applied
to operation at an altitude of more than 600 m
(2,000 ftl.

Gearing Setting Data

~
High altitude spec.
Standard spec. 600- 1,800 m 1,800 - 3,000 m
(2,000 - 6,000 ft) (6,000 - 10,000 ft)
Secondary gear ratio 12/22 (1.833) 11/24 (2.182) 10/24 (2.400)
Part No. 806-17682-20 802-17682-20 802-17682-10
Drive gear
Teeth 12 11 10
Part No. 85T-47548-20 85T-47548-40 +-
Driven gear
Teeth 22 24 24

2-53
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SLIDE RAI L SUSPENSION TUNING

SLIDE RAIL SUSPENSION TUNING
The setting of suspension greatly affects the sta-
bility and steering of the machine. Therefore, it
is necessary to adjust the suspension setting ac-
cording to course conditions and rider's driving
technique.

Stopper Band Setting

The height (L) of the front suspension can be
properly adjusted by changing the length of the
stopper band.

Standard Setting:
Front: No.2 hole
Rear: No. 2 hole

CD Front stopper band

® Rear stopper band

Nut (Stopper Band):

4 Nm (0.4 m· kg, 2.9 ft·lb)

This adjustment will affect the stability and

maneuverability of the machine.

Front

Performance Performance
Hole Maneu-
of straight of starting
No. verability
running acceleration
No.1 Less Less Better

No.5
I I Better
!
Better
I
Less

Rear

Hole No. Riding comfort Stability

No.1 Normal Normal
:
No.5
t
Less
t
Better

2-54
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SLIDE RAIL SUSPENSION TUNING ~r 141.1

1
Spring Preload
The spring preload is determining factor in ma-
chine stability.
Consider the course condition and the rider's
weight when setting spring preload. The suspen-
sion should be set as soft as possible without im-
paring the stability of the machine.

Standard Hard Soft

2 3 1

CD Rear spring preload adjuster

2-55
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HIGH ALTITUDE TUNING

HIGH ALTITUDE TUNING Ir9f Itill
To attain the best performance in high altitude conditions, carefully tune the snowmobiles as outlined
below.

Confirm STD. settings

• Carburetor (Page 2-43)
• Ignition timing (Page 2-39)
• Spark plug (Page 2-38)

+
Adjust main jet size according to the chart

I
(Page 2-44)

Test main jet size

I-NotOK" Adjust main jet size .......
(Performance & plug color)

I
OK
•
t OK Not OK
~__T_e_s~t_lo_w__sp_e_e_d_s_et_trin_g__________~I~---------r-_-:.-:.-_-:.-:.-:.-:.-:.-:.-::I__________________~
I
Not OK L..-----OK-----,..

OK NotOK

Not OK L..-----OK------.---~ Adjust gearing as required

(Page 2-52)

OK NotOK
and adjust accordingly

NotOK ~-------OK------~ Check engagement speed and

sh ift performance

OK High altitude
tuning OK

Adjust primary clutch as required

(Page 2-51) OK

NotOK NotOK

Adjust secondary clutch as required

OK
(Page 2-51)

2-56
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HIGH ALTITUDE TUNING

NOTE: _________________________
• It is recommended that the three plates as
shown be removed at an ambient temperature
of 5°C (41.5° F) or higher .
• Louver plates are installed at the factory.

CD Louver plate
® Bolt

2-57
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CHAPTER 3.
ENGINE OVERHAUL

ENGINE REMOVAL ............................................ 3-1

SHROUD AND COWLS ....................................... 3-1
BATTERY (FOR CS340EN) ................................... 3-1
MUFFLER ................................................. 3-1
PRIMARY SHEAVE ......................................... 3-2
CARBURETOR ............................................. 3-2
AIR SHROUD .............................................. 3-2
LEADS AND HOSES ......................................... 3-3
ENGINE REMOVAL ......................................... 3-3

ENGINE DISASSEMBLY ........................................ 3-4

INTAKE AND EXHAUST MANIFOLD ........................... 3-4
01 L PUMP ................................................. 3-4
STARTER MOOR (FOR CS340EN) ............................. 3-4
CYLINDER HEAD, CYLINDER AND PISTON .................... 3-5
CDI MAGNETO ............................................. 3-6
CRANKCASE AND CRANKSHAFT ............................. 3-7

INSPECTION AND REPAIR ...................................... 3-8

CYLINDER HEAD .......................................... 3-8
CYLINDER AND PISTON ..................................... 3-9
PISTON RINGS ............................................ 3-11
PISTON PIN AND BEARING ................................. 3-12
CRANKSHAFT ............................................ 3-13
CRANKCASE ............................................. 3-14
OIL PUMP DRIVE GEARS ................................... 3-14

ENGINE ASSEMBLY AND INSTALLATION ........................ 3-16

CRANKCASE AND CRANKSHAFT ............................ 3-16
CDI MAGNETO ............................................ 3-17
PISTON, CYLINDER AND CYLINDER HEAD ................... 3-19
STARTER MOTOR (FOR CS340EN) ........................... 3-22
01 L PUMP ................................................ 3-22
INTAKE AND EXHAUST MANIFOLD .......................... 3-22
REMOUNTING ENGINE ..................................... 3-22

RECOIL STARTER ............................................ 3-24

REMOVAL ............................................... 3-25
DISASSEMBLY ............................................ 3-25
INSPECTION .............................................. 3-26
ASSEMBLY AND INSTALLATION ............................ 3-27

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ENGINE REMOVAL ENGI.~I

.....

'ENGINE OVERHAUL
ENGINE REMOVAL
NOTE: _________________________

It is not necessary to remove the engine in order

to remove the following components:
- Cylinder head
-Cylinder
- Piston and piston ring
- Recoil starter
- Cooling fan assembly
- CD I magneto
-Oil pump
- Starter motor

SHROUD AND COWLS

1. Open:
-Shroud
Refer to the CHAPTER 2. "SHROUD
OPENING" section.
2. Remove:
- Side cowls (Left and right)
Refer to the CHAPTE R 2. "SI DE COWLS"
section.

BATTERY (FOR CS340EN)

1. Disconnect:
- Battery negative lead CD

MUFFLER
1. Remove:
-Stay (Side cowl) CD
-Muffler ®

3·1
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_~~~~~~~~_I~GI~I
ENGINE REMOVAL . . ....
PRIMARY SHEAVE
1. Remove:
• Drive V-belt guard CD with air duct (Outlet)
• Drive V-belt
• Primary sheave
Refer to the CHAPTER 5. "PRIMARY
SHEAVE AND DRIVE V-BELT -
REMOVAL" section.

CARBURETOR
1. Remove:
• Carburetor
Refer to the CHAPTER 4. "CARBURE-
TOR - REMOVAL" section.
NOTE: __________________________

The throttle cable, starter cable and carburetor

switch leads do not need removing.

AIR SHROUD
1. Disconnect:
• Spark plug leads
2. Remove:
• Air duct (I nlet) CD

3. Disconnect:
• Ignition coil leads
4. Remove:
• Cooling fan cover CD

5. Remove:
• Cylinder air shroud (Rear) CD
• Cylinder air shroud (Front) ®

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3·2
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______________ EN_G_I_N_E_R_E_M_O_V_A_L_
ENG
~I
LEADS AND HOSES
1. Disconnect:
• CD I magneto leads

2. Disconnect:
.Starter motor leads (for CS340EN)

3. Disconnect:
• Oil hose CD
• Oil delivery hose ®
NOTE: _ _ _ _ _ _ _ _ _ _ _ ___
Plug the oil hose and oil delivery hose so that
oil does not run out.

4. Disconnect:
• Pulser hose CD

ENGINE REMOVAL
1. Remove:
• Nuts (Engine mounting bracket)
• Engine assembly

3-3
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ENGINE DISASSEMBLY
ENGINE DISASSEMBLY
ENG 1'-1
INTAKE AND EXHAUST MANIFOLD
1. Remove:
-Intake manifold CD
- Gaskets (Intake manifold)

2. Remove:
- Exhaust manifold CD
- Gaskets (Exhaust manifold)

OIL PUMP
1. Remove:
-Oil pump with drive gear housing CD

STARTER MOTOR (FOR CS340EN)

NOTE: __________________________

With the engine mounted, the starter motor

can be maintained by removing the following
parts.
- Side cowl (Right)
-Muffler
- Air duct (I nlet)
- Cooling fan cover

1. Remove:
- Starter motor CD

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3-4
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ENGINE DISASSEMBLY ENG

CYLINDER HEAD, CYLINDER AND PISTON
1'-1
NOTE: __________________________

With the engine mounted, the cylinder head,

cylinder and piston can be maintained by remov-
ing the following parts.
• Side cowl (Right)
• Muffler
• Carburetor
• Air duct (Inlet)
• Cooling fan cover
• Cylinder air shroud
1. Remove:
• Cylinder heads CD
• Gaskets (Cylinder head)
NOTE: _________________________

• Before removing the cylinder head, loosen the

spark plug ® .
• The cylinder head nuts should be loosened 1/2
turn each time, and remove.

2. Remove:
.Cylinders CD
• Gaskets (Cyl inder)

3. Remove:
• Piston pin clip CD
NOTE: __________________________

Before removing the piston pin clip, cover the

crankcase with a clean rag so you will not
accidentally drop the clip into the crankcase.

4. Remove:
• Piston pin CD
• Piston ®
• Small end bearing
NOTE: _________________________

Before removing the piston pin, deburr the

clip groove and pin hole area. If the piston pin
groove is deburred and piston pin is still difficult
to remove, use Piston Pin Puller.

3-5
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ENGINE DISASSEMBLY I 1"-1

ENG
Piston Pin Puller:
YU-01304, 90890-01304

Do not use a hammer to drive the piston pin out.

COl MAGNETO
NOTE: __________________________

With the engine mounted, the COl magneto

can be maintained by removing the following
parts.
-Side cowl (Right)
-Muffler
-Air duct (Inlet)
- Cooling fan cover

1. Remove:
- Starter pulley CD
NOTE: ___________________________

Hold the starter pulley to loosen the nut (COl

magneto) <V by the Universal Clutch Holder @ .

Universal Clutch Holder:

YM-91042,90890-04086

2. Remove:
- Rotor CD
NOTE: _________________________

When removing the rotor, use the Rotor Puller

<V.
Rotor Puller:
YU-33270, 90890-01362

3. Remove:
- Stator assembly CD
- Woodruff key <V

3-6
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ENG 1N E 01 SASSEMB LY
CRANKCASE AND CRANKSHAFT
ENG 1'-1
1. Remove:
• Engine brackets (Front <D and rear ®)

2. Remove:
• Crankcase (Lower)
NOTE: _________________________
• Remove the bolts starting with the highest
numbered one.
• Loosen the each bolt 114 turn, and remove
them after all bolts are loosened .
• If they are tightly stuck together, tap lightly
the crankcase indicated points with a soft-head
hammer.

3. Remove:
• Crankshaft <D
• Crankcase (Upper) ®
• Knock pins @

3-7
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INSPECTION AND REPAIR

INSPECTION AND REPAIR
IENG 1'-1
CYLINDER HEAD
1. Eliminate:
• Carbon deposits
Use a rounded scraper CD.
NOTE: __________________________

Take care to avoid damaging the spark plug

threads. Do not use a sharp instrument. Avoid
scratching the aluminum.

2. Measure:
.Cylinder head warpage
Out of specification ~ Resurface.

Warpage Limit:
0.03 mm (0.0012 in)

Warpage measurement and resurfacement

steps:
• Attach a straight edge and a thickness gauge
on the cylinder head.
• Measure the warpage .
• If the warpage is out of specification, resur-
face the cylinder head.
• Place a 400 ,.., 600 grit wet sandpaper on the
surface plate, and resurface the head using
a figure-eight sanding pattern.
NOTE: _________________________
Rotate the head several times to avoid re-
moving too much material from on side.

3-8
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INSPECTION AND REPAI R

CYLINDER AND PISTON
ENG 1'-1
1. Eliminate:
• Carbon deposits
Use a rounded scraper.

NOTE:
Do not use a sharp instrument and avoid damag-
ing or scratching.

2. Inspect:
• Cylinder wall
Wear/Scratches -+ Rebore or replace.

3. Eliminate:
• Carbon deposits
(from piston crown and ring grooves)
4. Inspect:
• Piston crown
Burrs/Nicks/Damage -+ Replace.

5. Eliminate:
• Score marks and lacquer deposits
(from piston wall)
Use a 600'" 800 grit wet sandpaper.
NOTE: _________________________

Sand in a crisscross pattern. Do not sand

excessively.

6. Inspect:
• Piston wall
Wear/Scratches/Damage -+ Replace.

3-9
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INSPECTION AND REPAI R

7. Measure:
ENG 1'-1
- Piston-to-cylinder clearance

Measurement steps:
First step:
- Measure the cylinder bore I'C" with a
Cylinder Bore Gauge.

/
-
~
-- ... ---DJ- -
D4
.....
\
NOTE:
Measure the cylinder bore "C" in parallel to
, .... ~ /
and at right angles to the crankshaft. Then,
..... -----..,.,. find the average of the measurements.

~Cylinder
Standard Wear Limit

60.00 - 60.02 mm
Bore "c" (2.362 - 2.363 in)
-
0.05 mm
Taper "T" - (0.0019 in)
Out of 0.01 mm
Round "R"
- (0.0004 in)

C = Maximum 0
T = (Maximum 0) or O 2 ) -
(Maximum Os or 0 6 )
R= (Maximum 0) r 0 3 or Os) -
(Minimum O 2 r 0 4 or 0 6 )

-If out of specification, reb ore or replace

cylinder, and replace piston and piston rings
as a set.
2nd step:
- Measure the piston skirt diameter "P" with
a micrometer.
® 10.0 mm (0.40 in) from the piston bottom edge

~ Piston Size P

59.94 - 60.00 mm
Standard
307-0()()
(2.360 - 2.362 in)
Oversize 1 60.25 mm (2.372 in)
Oversize 2 60.50 mm (2.382 in)

-If out of specification, replace piston and

piston rings as a set.
3rd step:
- Calculate the piston-to-cylinder clearance
with following formula:

3-10
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INSPECTION AND REPAI R ENG 1'-1

Piston-to-cylinder Clearance =
Cylinder Bore "c" -
Piston Skirt Diameter lip"

-If out of specification, rebore or replace

cylinder, and replace piston and piston rings
as a set.

~
Piston-to-cylinder Clearance:
0.040 - 0.045 mm
(0.0016 - 0.0018 in)
Limit: 0.1 mm (0.004 in)

PISTON RINGS
1. Measure:
-Side clearance
Out of specification """* Replace piston and/
or rings.
Use a Feeler Gauge CD .

0.020 ~ 0.060 mm
307-005
Top (0.0008 ~ 0.0024 in)
Clearance 0.020 - 0.060 mm
2nd (0.0008 ~ 0.0024 in)

2. Install:
- Piston ring
(into cylinder)
Push the ring with the piston crown.
3. Measure:
- End gap
Out of specification """* Replace rings as a
set.
307-027 Use a Feeler Gauge CD .

3-11
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INSPECTION AND REPAI R ENG 1'-1

0.35 - 0.55 mm
Top
(0.014 - 0.022 in)
....._~ End Gap
2nd 0.35 - 0.55 mm
(0.014 - 0.022 in)

Oversize Piston Ring

Oversize 1 25
Oversize 2 50

PISTON PIN AND BEARING

1. Inspect:
• Piston pin
Blue discoloration/Groove ~ Replace, then
inspect lubrication system.
2. Measure:
• Outside diameter ® (piston pin)
Out of specification ~ Replace.
307-018
Outside Diameter (Piston Pin):
15.95 - 16.00 mm
(0.628 - 0.630 in)

3. Measure:
• Piston pin-to-piston clearance
Out of specification -+ Replace piston.

Piston Pin-to-Piston Clearance =

Bore Size (Piston Pin) @ -
307-019
Outside Diameter (Piston Pin) @

Piston Pin-to-Piston Clearance =

0.004 - 0.065 mm
(0.0002 - 0.0026 in)
< Limit: 0.07 mm (0.003 in) >
4. Inspect:
• Bearing (Piston pin)
Pitting/Damage ~ Replace.

3-12
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INSPECTION AND REPAI R ENG I'-a I

CRANKSHAFT
1. Measure:
• Runout
Use a V-Blocks and Dial Gauge.
Out of specification ~ Replace or repair.

Dial Gauge:
YU-03097,90890-03097

Runout Limit:
C1 0.03 mm (0.0012 in)
C2 , C3 0.04 mm (0.0016 in)
C4 : 0.05 mm (0.0020 in)

IV 60 mm (2.36 in)
@ 83 mm (3.27 in)

2. Measure:
• Sma II end free play
Use a Dial Gauge.
Out of specification ~ Replace the defective
parts.

Small End Free Play:

2.0 mm (0.079 in)

3. Measure:
• Big end radial clearance
Use a Dial Gauge.
Out of specification ~ Replace the defective
parts.

Big End Radial Clearance:

0.013 - 0.027 mm
(0.0005 - 0.0011 in)

4. Measure:
• Big end side clearance
Use a feeler gauge.
Out of specification ~ Replace the defective
parts.

Big End Side Clearance:

0.25 - 0.75 mm
(0.01 - 0.03 in)

3-13
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INSPECTION AND REPAIR

5. Inspect:
ENG 1'-1
• Crankshaft bearing
Pitting/Damage ~ Replace.
NOTE: __________________________

Lubricate the bearing immediately after examing

them to prevent rust.

6. Inspect:
• Stopper ring
Bend/Damage ~ Replace.
• Crankshaft oil seals
Wear/Damage ~ Replace.

CRANKCASE
1. Thoroughly wash the case halves in mild
solvent.
2. Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly.
3. Inspect:
• Crankcase
Cracks/Damage ~ Replace.
• Oi I delivery passages
Clog ~ Blowout with compressed air.
OIL PUMP DRIVE GEARS
1. Remove:
• Oil pump assembly CD
NOTE: _________________________

Place a rug under the oil pump assembly.

2. Remove:
• Drive gear housing cover CD

3-14
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___________
N_S_PE_C_T_
O_N_A~N~D~R~E~~~I~RIENGI~I
3. Remove:
.Circlip CD
• Plain washer ®
• Wave washer @
• Driven gear @
• Securing pin @
• Worm shaft ®

4. Inspect:
• Drive gear teeth CD
Pitting/Cracks/Wear/Damage -+- Replace.

5. Inspect:
• Driven gear CD
Pitting/Galling/Wear -+- Replace.
• Worm shaft ®
Bend/Pitting/Wear -+- Replace.

6. Inspect:
• Oil seal (Drive gear housing)

3-15
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ENGINE ASSEMBLY AND INSTALLATION

-~---------CD--'" ENGINE ASSEMBLY
1 1"'-1
ENG
AND
VMJ INSTALLATION
CRANKCASE AND CRANKSHAFT
1. Install:
• Stopper ring CD
Onto the crankshaft bearing @ (Primary
sheave side) as shown.
@Knockpin
[A] Lower case
[ID Upper case
2. Install:
• Crankshaft assembly
(to the upper crankcase)
NOTE: _________________________

Set the knock pins CD on the bearings and

labyrinth seal into the pin holes @ of the
upper crankcase by turning the bearings and
labyrinth seal. At the same time, align the
bearing and seal punch marks @ with the
crankcase mating surface @.

The oil seal lip must fit into the crankcase

groove.

3. Apply:
• Yamabond No. 5®
(to the mating surfaces of both case halves)
4. Install:
• Knock pins CD

5. Install:
• Lower crankcase CD
Onto the upper crankcase @ , then tap
lightly on the case with a soft-head ham-
mer.

Before installing and torquing the crankcase

bolts, be sure to check whether the crankshaft
is turning smoothly.
3-16
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ENGINE ASSEMBLY AND INSTALLATION

6. Tighten:
ENG 1'-1
e Bolts (Crankcase)
NOTE: _________________________
eThe embossed numbers in the lower crankcase
designate the crankcase tightening sequence.
e Tighten the bolts in two stages.

Bolt (Crankcase):
First:
13 Nm (1.3 m· kg, 9.4 ft:lb)
Final:
23 Nm (2.3 m· kg, 17 ft.lb)

7. Install:
e Engine brackets (Front CD and rear ® )

8. Apply:
e2-stroke engine oil
To the crankpin, bearing and each crank-
shaft bearing oil delivery hole.

CDIMAGNETO
1. Pass the magneto leads CD throught the hole,
and install the grommet ® to the crankcase.

2. Install:
e Stator assembly CD
NOTE: _________________________

Align the pry points on the stator with the

cutout on the crankcase.

3-17
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~~~~~~_E_N_G_I_N_E_A_S_S_EM~B_LY~A_N_D_I_N_S_TA~LL_A_T_I_O_N IENGI~I
CRANKCASE AND CRANKSHAFT
CD Upper crankcase @Crank
®Oil seal @ Labyrinth seal
@Bearing @Crank
@Piston @Crank
®Woodruff key @ Stopper ring Recommended Grease:
@Crank @Oil pump drive gear Esso Beacon 325 grease
<l)Crank pin @Knock pin or Aeroshell grease #7A
@ Connecting rod @ Lower crankcase
® Big end bearing

A RUNOUT LIMIT:
C1 : 0.03 mm (0.0012 in)
C2 ,C3 : 0.04 mm (0.0016 in)
C4 : 0.05 mm (0.0020 in)
BIG END SIDE CLEARANCE @:
0.25 - 0.75 mm (0.010 - 0.030 in)
SMALL END FREE PLAY ®:
2.0 mm (0.079 in)
BIG END RADIAL CLEARANCE CD : D USE NEW ONE
0.013 - 0.027 mm (0.0005 - 0.0011 in)

First:

~ C APPLVVAMABONDNo.5
13 Nm (1.3 m· kg, 9.4 ft·lb)
Final:
23 Nm (2.3 m· kg, 17 ft .Ib)

3-18
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E_N_G_
N_E_A_~_E_M_B_L_Y_A_N_D_IN_S_T_A_L_L_A_T_lo_N_I~GI~1
_______
3. Install:
e Woodruff key CD
NOTE: __________________________

When installing the COl magneto, make sure the

woodruff key is properly seated in the key way
of the crankshaft. Apply a light coating of
lighium soap base grease to the tapered portion
of the crankshaft end.

4. Install:
Starter pulley CD
NOTE: __________________________

Hold the starter pulley to tighten the nut (COl

magneto) ® by the Universal Clutch Holder ® .

Universal Clutch Holder:

YM-91042,90890-04086

Nut (COl Magneto):

85 Nm (8.5 m· kg, 61 ft·lb)

PISTON, CYLINDER AND CYLINDER HEAD

1. Apply:
e2-stroke engine oil
To the piston pin, bearing, piston ring
grooves and piston skirt areas.

2. Install:
eSmall end bearingCD
ePiston®
e Piston pin ®
ePiston pin clip (New)@)
NOTE: _________________________

eThe arrow ® on the piston must point to the

front of the engine.
e Before installing the piston pin clip, cover the
crankcase with a clean rag so you will not
accidentally drop the pin clip and material
into the crankcase.

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3-19
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CYLINDER AND CYLINDER HEAD

ENGINE ASSEMBLY AND INSTALLATION ENG 1'-1
CD Cylinder head
® Gasket (Cylinder head)
® Cylinder
® Gasket (Cylinder)

28 Nm (2.8 m kg, 20 ft olb)

0
CYLINDER HEAD WARPAGE LIMIT:
A
0.03 mm (0.0012 in)
25 Nm (2.5 m kg, 18 ft olb)
0
CYLINDER BORE:
B 60.00 - 60.02 mm
(2.362 - 2.363 in)

USE NEW ONE

3-20
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ENGINE ASSEMBLY AND INSTALLATION

3. Install:
1 ENG I\.I
• Gaskets (Cylinder - New)
NOTE: _________________________
.Make sure ring ends CD are properly fitted
around ring locating pins in piston grooves.
• Be sure to check the manufacture's marks or
numbers stamped on the rings are on the top
side of the rings.
• Before installing the cylinder, apply a liberal
coating of 2-stroke engine oil to the piston
rings.

4. Install:
• Cylinder
NOTE: _________________________
Install the cylinder with one hand while com-
pressing the piston rings with the other hand.

5. Install:
• Gaskets (Cylinder head - New)
• Cylinder head
NOTE: __________________________
• Tighten nuts in crisscross pattern.
• Finger-tighten the spark plug before tighten-
ing to specification.

Nut (Cylinder Head):

25 Nm (2.5 m· kg, 18 ft· Ib)
Spark Plug:
28 Nm (2.8 m· kg, 20 ft·lb)

3·21
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ENGINE ASSEMBLY AND INSTALLATION

.. ~
1 1"'-1
STARTER MOTOR (FOR CS340EN)
ENG
1. Install:
e Starter motor CD

Bolt (Starter Motor) :

23 Nm (2.3 m - kg, 17 ft- Ib)

OIL PUMP
1. Install:
e Oil pump with drive gear housing CD

INTAKE AND EXHAUST MANIFOLD

1. Install:
eGaskets (Intake manifold - New)
elntake manifold CD
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Apply LOCTITE® to the holding bolts.

2. Install:
e Gaskets (Exhaust manifold - New)
e Exhaust manifold CD

REMOUNTING ENGINE
Reverse the "ENGINE REMOVAL" procedure.
Note the following points.
1. Temporarily tighten the nuts (Engine
mounting bracket).

3-22
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~~~~~~_E_N_G_I_N_E_A_S_S_EM~B_LY~A_N_D_I_N_n_A~LL_A_T_I_O_N IENGI~I
2. Install:
• Primary sheave
Refer to the CHAPTER 5. "PRIMARY
SHEAVE AND DRIVE V-BELT - IN-
STALLATION" section.

3. Adjust:
• Sheave distance and offset
Refer to the CHAPTER 2. "SHEAVE
DISTANCE AND OFFSET ADJUS-
MENT" section.

4. Tighten:
• Nuts (Engine mounting bracket)

Nuts (Engine Mounting Bracket):

Front:
53 Nm (5.3 m' kg, 38 ft.lb)
Rear:
30 Nm (3.0 m· kg, 22 ft.lb)

5. Air bleed:
.Oil pump
Refer to the CHAPTE R 2. "01 L PUMP
AIR BLEEDING" section.

6. Adjust:
• Free play (Oil pump cable) ®
Refer to the CHAPTER 2. "01 L PUMP
CABLE FREE PLAY ADJUSTMENT"
section.

Free Play (Oil Pump Cable):

24 ~ 26 mm (0.94 ~ 1.02 in)

3-23
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RECOIL STARTER
RECOILSTARTER I 1'\.1
ENG
CD Air duct (Inlet)
® Recoil starter case
@ Starter rope
@ Starter handle
@ Starter spring
® Sheave drum
(j) Drive pawl
® Drive plate
® Starter pulley

3-24
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RECOIL STARTER
REMOVAL
ENG 1'-1
1. Open the shroud.
Refer to the CHAPTER 2. "SHROUD
OPEN I NG" section.
2. Remove:
- Side cowl (R ight)
- Stay (Side cowl)
-Muffler
-Air duct (Inlet)

3. Remove:
- Starter handle CD
Loosen the knot ® of the starter rope.
NOTE: __________________________

After removing the starter handle, knot @ the

rope so it will not be pulled into the recoil
starter case @ .

4. Remove:
- Recoil starter

DISASSEMBL Y
1. Remove:
-Nut CD
-Spring washer ®
- Plain washer @
- Specia I washer @
- Drive plate ®
- Spri ng seat ®
- Drive plate spring (j)

3-25
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RECOIL STARTER ENG

NOTE: _________________________
I\.I
There is a drive plate spring (J) under the drive
plate. Care should be taken so that it will not
be lost.

2. Remove:
• Return spring CD
• Drive pawl ®
NOTE: __________________________

Care should be taken so that the return spring

CD will not be lost.

3. Remove:
• Sheave drum CD

There is a starter spring under the sheave drum.

Care should be taken so that it will not spring
out.

4. Undo the knot on one end of the starter

rope. Then, pull it out from the starter case.
5. Remove:
• Starter spring CD

INSPECTION
1. Inspect:
• Drive plate CD
Cracks/Bends/Damage -+ Replace.
• Drive plate spring ®
Fatigue/Damage -+ Replace.

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3-26
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ENG 1"-1
1
RECOIL STARTER _ _ ~_
--------------------------------------------
2. Inspect:
• Starter rope
Wear/Breaks/Damage -+ Replace.

3. Inspect:
• Starter spri ng
Cracks/Bends/Damage -+ Replace.

4. Inspect:
• Sheave drum CD
Cracks/Damage -+ Replace.
• Drive pawl ®
Wear/Cracks/Damage -+ Replace.

ASSEMBLY AND INSTALLATION

1. Hook the starter spring around the post
in the starter case. Carefully wind the spring
counterclockwise, and fit the spring into
the case.
NOTE: _________________________
After installing the spring thoroughly apply
the low-temperature grease.

2. Feed the starter rope into the sheave drum,

and knot the rope end. Then fit the knot
into the cutout in the sheave drum.

3-27
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RECOllSTARTER
3. Wind:
1 1'-1
ENG
• Starter rope (2 turns counterclockwise)
(to the sheave drum)

4. Install:
• Sheave drum
(in the starter case)
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Be sure the inner hook on the starter spring
hooks around the post on the sheave drum.

5. Lubricate:
• Grease (Lightly)
(to the pivot point of the drive pawl CD )
Low-Temperature Lithium Soap
Base Grease

6. Install:
• Drive pawl CD
• Return spring @
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Hook the return spring end to the drive pawl CD.
Then, hook other end of the return spring to
the post on the sheave drum @ .

7. Install:
• Drive plate spring
• Spri ng seat
• Drive plate
• Specia I washer
• Plain washer
• Spri ng washer
.Nut
NOTE: ______________
Be sure the cutout in the drive plate fits over
the post on the drive pawl.

3-28
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RECOIL STARTER ENG 1'-1

8. Pull about four inches of starter rope from
out of the cutout in the sheave drum, and
rotate the sheave drum five times counter-
clockwise to preload the starter spring.

9. Install:
• Starter handle

10. Install:
• Recoil starter
NOTE: ________________________

Apply LOCTITE® to the holding bolts.

11. Check the starter for smooth operation. If it

does not operate smoothly, repair it.
12. Install:
• Air duct (I nlet)
• Muffler
• Stay (Side cowl)
• Side cowl (R ight)

Bolt (Muffler):
19 Nm (1.9 m· kg, 14 ft·lb)

13. Close the shroud.

3-29
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_________ ICARBI.I
CHAPTER 4.
CARBURETION

CARBURETOR ................................................ 4-1

REMOVAL ................................................ 4-2
DISASSEMB L Y ....... .. .................................... 4-3
INSPECTION .............. . ................................ 4-4
ASSEMB L Y .............. .. ... .. ........................... 4-5
INSTALLATION ............................................ 4-6

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----------------------------------------
CARBURETOR ICARBI • I
CARBURETION
CARBURETOR
SPECIFICATIONS
CD Starter plunger (J) Float
® Top cover ® Float pin Main Jet (M.J.) L: #128 R: #132
® Pilot screw ® Float chamber cover Pilot Jet (P.J.) #72
® Main jet ® Carburetor switch Pilot Screw (P.S.) 1-3/4 turns out
@ Needle valve (for U.S.A. and Canada) Starter Jet (G.S.) <I> 1.3
® Pilot jet @ Throttle stop screw Fuel Level (F.L.) 40.0 - 42.0 mm
(1.57 - 1.65 in)
Float Height (F .H.) 30.0 - 32.0 mm
(1.18-1.26 in)
Engine Idle Speed 1,800 r/min

4·1
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_____________________________
C_A_RB_U_R_E_T_O__
R ICARSI ~ I
REMOVAL
NOTE: _________________________

The following parts can be cleaned and inspected

without disassembly.
• Starter plunger
• Pilot screw
• Main jet

1. Open the shroud.

Refer to the CHAPTER 2. "SHROUD
OPENING" section.
2. Remove:
• Air duct (Outlet) CD

3. Remove:
• Bolts (I ntake silencer)

4. Loosen:
• Screws (Carburetor joints)

5. Disconnect:
• Carburetor switch leads (Except for
Europe) CD
(Black/Yellow, Black)

4·2
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_____________________________
CA__ RB_U_R_E_T_O_R_lcARBI ~ I
6. Remove:
• Starter cable CD

Take care so that the rubber caps, coil springs,

starter cable adjusters and starter plungers do
not fall off or are not lost. Also use special care
not to scratch the starter plunger surface.

7. Disconnect:
• Fuel hose CD
NOTE: __________________________

Plug the fuel hoses so that fuel does not run out.

8. Remove:
• Cover (Carburetor switch)
9. Disconnect:
• Throttle cable CD
.Oil pump cable ®

10. Remove:
• Carburetor assembly
11. Drain:
.Fuel

DISASSEMBL Y
1. Remove:
• Float chamber cover CD

4-3
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____________________________
CA_R_B_U_R_ET_O_R_lcARBI ~ I

2. Remove:
• Float CD
• Needle valve ®
.Main jets (Right and left) ®
• Pi lot jets (R ight and left) @

3. Remove:
• Pilot screws CD
• Top cover (Carburetor) ®

4. Remove:
• Carburetor switch (Except for Europe)
CD (With spring)
• Throttle stop screw ®
NOTE: __________________________
Before removing the carburetor switch, remove
the holding plate ® of it. Then keep turning the
throttle stop screw clockwise unti I the carburetor
stop switch removes.

INSPECTION
1. Inspect:
• Carburetor body
• Float chamber cover
• Fuel passage
Contamination ~ Clean.
NOTE: __________________________
• Use a petroleum based solvent for cleaning .
• Blowout all passages and jets with compressed
air.
4-4
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_______________~_R_B_U_R_E_T_O_RI~R~.I
2. Inspect:
• Float
Damage -+ Replace.

3. Inspect:
• Needle valve CD
• Pi lot screw ®
Wear/Damage -+ Replace.

4. Inspect:
• Main jet CD
• Pilot jet ®
Contamination -+ Clean.
NOTE: __________________________
Use a petroleum based solvent for cleaning.
Blowout all passages and jets with compressed
air.

5. Inspect:
• Throttle valve
Wear/Damage -+ Replace.
6. Check:
• Valve free movement
Stick -+ Replace carburetor assembly.

ASSEMBLY
Reverse the "DISASSEMBLY" procedure. Note
the following points.
NOTE: __________________________
• Before reassembling, wash all parts use a
petroleum based solvent .
• Always use a new gasket.

4-5
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_____________________________C_A_R_BU_R_E_T_O__
R ICARBI ~ I
1. Install:
• Throttle stop screw CD
• Carburetor switch (Except for Europe)
@
• Holding plate (Carburetor switch) ®
NOTE: __________________________

Do not forget to install springs of the throttle

stop screw and carburetor switch.

2. Measure:
• Float height ®
Out of specification ~ Adjust.

Float Height:
30.0 - 32.0 mm (1.18 ~ 1.26 in)

Measurement and adjustment steps:

• Hold the carburetor in an upside down posi-
tion.
• Measure the distance from the carburetor
body to the top of the float.
NOTE: _________________________
• Before measurement, remove the gasket
between the carburetor body and float
chamber.
• The float arm should be resting on the
needle valve, but not compressing the
needle valve.

• If the float height is not within specification,

inspect the valve seat and needle valve.
• If either is worn, replace them both.
• If both are fine, adjust the float arm height
by bending the float tang CD on the float.
• Recheck the float height.

INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Adjust:
• Engine idle speed
Refer to the CHAPTER 2. "ENGINE IDLE
SPEED ADJUSTMENT" section.

4-6
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______________C_A_R_B_U_R_E_TO_R_lcARBI • I
~ Engine Idle Speed:
V }: 1,800 r/min

2. Adjust:
• Throttle cable free play
Refer to the CHAPTER 2. "THROTTLE
CABLE FREE PLAY ADJUSTMENT" sec-
tion.

Throttle Cable Free Play:

0.5 - 1.0 mm (0.02 - 0.04 in)

3. Adjust:
• Starter cable free play
Refer to the CHAPTER 2. "STARTER
CABLE ADJUSTMENT" section.

Starter Cable Free Play:

0.5 - 1.5 mm (0.02 - 0.06 in)

4. Adjust:
.Oil pump cable free play
Refer to the CHAPTER 2. "01 L PUMP
CABLE FREE PLAY ADJUSTMENT"
section.

Oil Pump Cable Free Play:

24 - 26 mm (0.94 - 1.02 in)

4-7
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CHAPTER 5.
POWER TRAIN

PRIMARY SHEAVE AND DRIVE V-BELT . . .. . .. . ....... . ... . ...... 5-1

REMOVAL .............................. . ................. 5-2
DISASSEMBLY ..................................... . ... . ... 5-2
INSPECTION ...... . . . .................... . ............. . ... 5-4
ASSEMBLY . ................................ . .............. 5-5
INSTALLATION ..... . ................. . ............ . ....... 5-8

SECONDARY SHEAVE .................. . ........... . .... . ..... 5-10

REMOVAL .... .. . . ................................ . ... . .. 5-11
INSPECTION ... . .. . . .. ..... . ............... . ........ . ... . . 5-12
INSTALLATION . ........................... . .............. 5-12

DRIVE CHAIN HOUSING ....... . .... . ........ . .......... . ...... 5-14

REMOVAL ... . .... . ... . .................................. 5-15
INSPECTION ................... . .......................... 5-16
INSTALLATION .... . ... . .................................. 5-18

BRAKE .............. . ...................................... 5-20

REMOVAL . . . .... . ...... . .... .. ........ .. .... .. . . . . . . .... 5-21
INSPECTION ........ . ..................................... 5-21
INSTALLATION .................................... . ...... 5-22

SLIDE RAIL SUSPENSION . . .... . . . .... . . .. .... . ...... .. .... . ... 5-23
REMOVAL ... . .... . ........... . .......................... 5-25
DISASSEMBLY ................ .. ........ . .......... . ...... 5-26
INSPECTION .............................................. 5-28
ASSEMB L Y ............. . ............ . .............. . .... . 5-29
INSTALLATION .... . .... . ................... . ...... . ...... 5-31

DRIVE ................ . ......... . ........................... 5-32

REMOVAL .. . .. . .................................. . ...... 5-33
INSPECTION ........ . ...... . ............... . ....... . . .. ... 5-34
INSTALLATION ......................... . .......... . ...... 5-34

rJl....
sa.lles@m
www. lm ldwe:s tmanua s. colm
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_ _ _ _ _ _ _ _ _ _ IPatNTRRIA
UUlf I_
PRIMARY SHEAVE AND DRIVE V-BELT _ _
REMOVAL
1. Open the shroud.
Refer to the CHAPTER 2. "SHROUD
OPENING" section.

2. Remove:
.Side cowl (Left)
• Drive V-belt guard
• Drive V -belt CD
Refer to the CHAPTER 2. "DRIVE
V-BELT INSPECTION" section.

3. Remove:
• Bolt (Primary sheave) CD
NOTE: ___________________________________________________________

Hold the primary sheave to loosen the bolt

(Primary sheave) by the Primary Sheave Holder
®.
Primary Sheave Holder:
YS-01880, 90890-01701

4. Remove:
• Primary sheave CD
NOTE: _____________________________________________________________

When removing the primary sheave, use the

Primary Sheave Puller ® .

Primary Sheave Puller:

YS-01882-A,90890-01898

DISASSEMBL Y
1. Remove:
• Primary sheave cap CD
NOTE: ___________________________

When removing the bolts (Primary sheave cap),

use the Sheave Compressor ® .
Make sure to press the primary sheave spring.

5-2
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PRIMARY SHEAVE AND DRIVE V-BELT ~41

Sheave Compressor:
YS-28891,90890-01712

2. Remove:
- Primary sheave spring CD

3. Remove:
-Weight CD
- Roller 00
-Slider @

4. Remove:
-Spider CD
NOTE: _________________________

For assembling the spider and fixed sheave, the

special tools and LOCTITE® #548 are
necessary. If there are unavailable, avoid dis-
assembling.

Removal steps:
-Immerse the primary sheave assembly in
approximately 80° - 100°C (176° - 212°F)
water for several minutes.
- Hold the lower piece of the Clutch Spider
Separator CD on a rigid table using a suitable
mounting bolts.
Then, install the Clutch Separator Adapter
00 onto the Separator.
5-3
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PRIMARY SHEAVE AND DRIVE V-BELT I~ 41

Clutch Spider Separator:
YS-28890-A,90890-01711
Clutch Separator Adapter:
YS-34480

- Fit the primary sheave assembly onto the

Adapter, and secure the supporting plates.
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Securely fit the projections of the Adapter
into the fixed sheave holes.
-Set the special tool onto the spider and
turn the special tool clockwise to loosen
the spider.

Spider has a left-hand thread.

~ WARNING:
To loosen the spider, high torque is required
so be sure that the spider, fixed sheave and
special tool are placed securely. Loosen the
spider carefully to prevent cracks and/or
damage to the sheaves and spider.

- Remove the fixed sheave, fixed sheave

stopper, and sliding sheave from the spider.

INSPECTION
1. Inspection:
-Spider (Tapered portion)
Crack/Damage ~ Replace.

2. Measure:
- Bush clearance
Out of specification ~ Replace abushing.

Bush Clearance (Primar sheave cap):

0.25 mm (0.01 in)
Bush clearance (Sliding sheave):
0.25 mm (0.01 in)

CD Feeler gauge
5-4
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_~~~~~~~~_I~TRRI~I
PRIMARY SHEAVE AND DRIVE V-BELT _ _VUH _
3. Measure:
- Drive V-belt width ®
Out of specification ~ Replace.

Drive V-belt width:

New:
31.6 mm (1.24 in)
Wear Limit:
28.0 mm (1.10 in)

4. Inspect:
-Weight CD
- Roller ®
-Bushing @
-Slider @
Wear/Damage ~ Replace.

5. Inspect:
- Primary sheave spring CD
Damage ~ Replace.
- Drive V-belt ®
Cracks/Damage ~ Replace.

ASSEMBLY
Reverse the "DISASSEMBLY" procedure.
Note the following points.
1. Install:
-Spider
To the sliding sheave.
NOTE: _ _ _ _ _ _ _ _ _ _ _ __

Be sure the sliding sheave match mark (X) is

aligned with the spider match mark (X).

2. Install:
- Fixed sheave
Onto the spider.
NOTE: _ _ _ _ _ _ _ _ _ _ _ __

Apply the LOCTITE® # 548 CD to the top 4

threads ® of the spider.

5-5
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PRIMARY SHEAVE AND DRIVE V-BELT I~ 41

i_, WARNING:
LOCTITE® should be applied only to the area
specified. Never apply to the bushings and
other areas.

3. Install:
• Fixed sheave stoppers CD
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Stopper tapered portion should face fixed
sheave.

4. Tighten:
.Spider

Tightening steps:
• Finger-tighten the spider until it stopped
by fixed sheave stopper.
• Hold the fixed sheave with the Clutch
Spider Separator CD.
NOTE: _ _ _ _ _ _ _ _ _ _ __

Securely fit the projections of the Adapter

® into the fixed sheave holes.
• Tighten the spider to specification using the
Special Tool @ .

Clutch Spider Separator:

YS-28890-A,90890-01711
Clutch Separator Adapter:
YS-34480

Spider:
200 Nm (20 m'kg, 145 ft·lb)

Spider has a left-hand thread.

5-6
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_ _ _ _PRIMARY
__ _AND
SHEAVE _ _
DRIVE _ IPOTWRRI
V-BELT _
A
_VUH I_

&WARNING:
- Do not use the primary sheave until the
LOCTITE® has completely cured. Wait 24
hours before using primary sheave.
- Since tightening torque is high, make sure
the spider, fixed sheave, and special tool
are placed securely. Tighten the spider care-
fully to prevent cracks and/or damage to
the sheaves and spider.

5. Install:
-Weight CD
-Pin ®
-Shims ®
-Slider

6. Install:
- Roller CD
-Bushing ®
- Plain washers ®
-Conical spring washers ®
-Bolt
-Nut

I~ NU~:Nm (0.5 m' kg, 3.6 ft·lb) I

& WARNING:

To maintain the balance of the primary sheave,

the roller bolts must be installed with their
threaded portions pointing in a clockwise
direction; see illustration.

5-7
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PRIMARY SHEAVE AND DRIVE V-BELT 1~141

7. Apply:
• Molybdenum disulfide grease to the
weights.

JIll

8. Install:
• Primary sheave cap
NOTE: ________________________

Be sure the sheave cap match mark (X) is

aligned with the spider match mark (X).

9. Tighten:
• Bolts (Primary sheave cap)

.'
I
NOTE: _________________________

When tightening the bolts (Primary sheave cap),

use the Sheave Compressor.
Make sure to press the primary sheave spring.

Sheave Compressor:
YS-28891,90890-01712

Bolt (Primary Sheave Cap):

14 Nm (1.4 m- kg, 10 ft-Ib)

INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Install:
• Primary sheave assembly

Be sure to remove any oil and/or grease from

the tapered portion of the crankshaft and
spider with a thinner_
5-8
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PRIMARY SHEAVE AND DRIVE V-BELT

2. Apply:
r'W 141 R

-YAMALUBE "2" or equivalent

(to the threads of the bolt)

3. Tighten:
- Bolt CD (Primary sheave)

Tightening steps:
-Tighten the bolt to the specification.

NOTE:
Hold the primary sheave to tighten the bolt
(Primary sheave) by the Primary Sheave
Holder ®.

~
Primary Sheave Holder:
YS-01880, 90890-01701

Ix Bolt (Primary Sheave):

Initial Tightening:
120 Nm (12 m· kg, 85 ft·lb)

- Loosen the bolt completely.

- Retighten the bolt to the specification.

X Bolt (Primary Sheave) :

Final Tightening:
58 Nm (5.8 m· kg, 42 ft ·Ib)

4. Install:
- Drive V -belt
NOTE: __________________________

Before installing the V-belt, clean the oil off the

fixed sheaves and sliding sheaves using a locquer
thinner.

5-9
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SECONDARY SHEAVE 1~141

~ECONDARY SHEAVE
1 Jackshaft
® Straight key
@ Bearing holder
@Bearing
@Spring seat
@Spring
(VSliding sheave
® Fixed sheave

i
~'~
~
./
\

@~)t
ow
\ -~ :~INGTWI~//

SP~'"NG HOLE POSITIO "

Position "A" , "B" or "e"1\1

C OSPR,'NG HOLE POSITION"

n yone "

D Recommended Grease"
E
Asso Beacon 325 grease" or
eroshell grease #7 A

5-10
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_~~~~~~~~_I~TRRI~I
SECONDARY SHEAVE _ _UUlf .
REMOVAL
1. Open the shroud.
Refer to the CHAPTER 2. "SHROUD
OPENING" section.

2. Remove:
.Side cowl (Left)
• Drive V-belt guard
• Drive V -beltcD
Refer to the CHAPTER 2. "DRIVE
V-BELT INSPECTION" section.

3. Remove:
• Secondary sheave CD
Removal steps:
• Apply the parking brake.
• Loosen the nut (Secondary sheave) ® com-
pletely.
• Pull the fixed sheave by the Rotor Puller.

Ifb Rotor Puller:

YU-33270, 90890-01362

NOTE:
When attaching the Rotor Puller, use the
6 mm bolts @ and nuts @ .

• Remove the nut, washer, fixed sheave and

straight key.
• Remove the sliding sheave ® and spring @ .

5-11
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_ ______ __
SECONDARY _ IPOWTRRI.A
SHEAVE _ _VUlf I
_
INSPECTION
1. Inspect:
- Sliding sheave CD
- Fixed sheave ®
-Spring ®
Cracks/Damage -+ Replace.

2. Inspect:
- Spring seat CD
Cracks/Damage -+ Replace.

INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Apply:
- Low temperature grease
(to inside of the sliding sheave)

Recommended Grease:
Esso Beacon 325 grease or
Aeroshell grease # 7 A

2. Install:
- Secondary sheave spring CD
NOTE: _________________________

Hook the end of the secondary sheave spring

onto the spring hole in the spring seat.

Spring Position:
Either of A, Band C

3. Install:
- Secondary sheave

Installation steps:
-Install the sliding sheave.
-Turn the sliding sheave the specified degrees,
in the clockwise direction.
Holding the sliding sheave and fixed sheave
in the position.

5-12
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SECONOARY SHEAVE 1~141

Standard twist angle:
50°

-Install the straight key and fixed sheave CD .

- Tighten the nut @

X Nut (Secondary Sheave):

40 Nm (4.0 m - kg, 29 ft-Ib)

4. Install:
- Drive V -belt
NOTE: _________________________

Before installing the V -belt, clean the oil off

the fixed sheaves and sliding sheaves using a
lacquer thinner.

5-13
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DRIVE CHAIN HOUSING I~R141

DRI~E CHAIN HOUSING
CD Drive sprocket @G"kot -
® Bearing @ Driven sprocket
®
'4' .
Drive chain hou smg
. @ Drive chain
\!.I 011
seal @Bearing
@Oil seal
® Chain tensioner
(J) Adjuster
® Chain housing cover

40 Nm (40
. m·kg, 29 ft·lb) DRIVE CHAIN OIL'
RECOMMENDED OIL
Gear oil API GL-3
SAE #75 or #80
OIL QUANTITY
250 cm 3 (88
. Imp oz ,85
. US oz)

23 Nm (23
. m·kg,17 ft·lb)

6NmIO_6m_kg'4_3ft-'bl~~ !

5-14
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DRIVE CHAIN HOUSING umr I

IPOTWRRI~
---------------------------------------------------------
REMOVAL
1. Open the shroud.
Refer to the CHAPTER 2. "SHROUD
OPENING" section.
2. Remove:
-Side cowl (Right)
- Stay (Side cowl)
-Muffler CD

3. Place some rugs under the drive chain

housing.
4. Remove:
- Chain housing cover CD

5. Apply the parking brake.

6. Loosen:
- Nut CD (Drive sprocket)
- Bolt ® (Driven sprocket)
- Adjuster @ (Chain tensioner)

7. Remove:
- Drive sprocket CD
- Driven sprocket ®
- Drive chain @
- Chain tensioner ®

8. Remove:
-Collars CD

5-15
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DRIVE CHAIN HOUSING 1~141

9. Remove:
• Nut (Oil tank stay) CD
• Bolts (Brake caliper) ®
• Brake caliper
• Brake pads

10. Loosen:
.Axle nut CD
• Adjusters (Track tention) ®
NOTE: _________________________

Axle nut loosening is possible without removing

the cotter pin.

11. Remove:
• Drive chain housing CD

INSPECTION
1. Inspect:
• Bearings
Pitting/Damage ~ Replace.

Bearing replacement steps:

• Remove the bearing using a general bearing
puller .
• Install the new bearing.

5-16
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DRIVE CHAIN HOUSING

--------------------------------------------------
I R
POTWRI.A
uw.r I
NOTE: _________________________

Use a socket CD that matches the outside

diameter of the race of the bearing.

Do not strike the inner race of balls of the

bearing. Contact should be made only with
the outer race.

2. Inspect:
• Oil seal lips
Damage/Wear ~ Replace.

3. Inspect:
• Drive gear teeth CD
• Driven gear teeth ®
Pitting/Wear/Damage ~ Replace.

4. Inspect:
• Drive chain
Wear/Damage ~ Replace.
Stiff ~ Lubricate or replace.

5. Inspect:
• Chain tensioner CD
Pitting/Wear/Damage ~ Replace.

5-17
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_ _ _ _ _ _ _ _ _ _ IPOTWRRI~
VUH I
_
DRIVE CHAIN HOUSING _ _
INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Apply:
• Low temperature lithium soap base grease
(to oil seal lips.)

2. Install:
• Drive chain housing CD

Bolt (Drive Chain Housing):

23 Nm (2.3 m· kg, 17 ft·lb)

3. Install:
.Brake caliper
NOTE: _________________________

Before installing the brake caliper, clean the

oil/grease off the brake disc using a locquer
thinner.

Bolt (Brake Caliper) :

48 Nm (4.8 m' kg, 35 ft·lb)
Nut (Bracket):
24 Nm (2.4 m· kg, 17 ft·lb)

4. Adjust:
• Brake
Refer to the CHAPTER 2. "BRAKE
ADJUSTMENT" section.

5. Apply the parking brake.

6. Install:
• Driven sprocket
• Drive sprocket

Nut (Drive Sprocket):

40 Nm (4.0 m' kg, 29 ft·lb)

5·18
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_~~~~~~~~_I~TRRIAI
DRIVE CHAIN HOUSING _ _U1W' _
7. Install:
• Cotter pin

~t~ WARNING:
Always use a new cotter pin.

8. Adjust:
• Drive chain slack

Drive Chain Slack:

8 ~ 15 mm (0.31 ~ 0.59 in)

Refer to the CHAPTER 2. "DRIVE

CHAI N SLACK ADJUSTMENT" section.
9. Install:
• Gasket (Chain housing)
Use a new one.
10. Install:
• Chain housing cover

Bolts (Chain Housing Cover):

6 Nm (0.6 m· kg, 4.3 ft·lb)

11. Fill:
• Drive chain housing

Recommended Oil:
Gear oil API GL-3 SAE #75 or #80
Oil Quantity:
250 cm 3 (8.8 Imp OZ, 8.5 US oz)

12. Adjust:
• Track tension

Track Tension:
25 ~ 30 mm/10 kg
(1.0 ~ 1.2 in/22Ib)

Refer to the CHAPTER 2. "TRACK

TENSION ADJUSTMENT" section.

13. Tighten:
.Axle nut

Axle Nut:
75 Nm (7.5 m· kg, 54 ft·lb)

5-19
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BRAKE ~141
------------------------------
BRAKE
CD Brake caliper ®Brake disc
®Cam screw @Key
@Spring
@ Brake cam lever
@Adjuster
® Back up plate
(j) Brake pad
® Brake pad

I
I

BRAKE PAD THICKNESS:

13.5 mm (0.53 in)
A <WEAR LIMIT>
9.5 mm (0.37 in)

PAD TO DISC CLEARANCE:

B 0.15 ~ 0.30 mm (0.006 ~ 0.012 in)

5-20
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__________BR_AK_E~141
REMOVAL
1. Remove:
• Drive chain housing
Refer to the "DRIVE CHAIN HOUSING
- REMOVAL" section.

2. Remove:
• Brake caliper
(from brake cable(s))
• Brake disc

INSPECTION
1. Measure:
• Brake pad thickness
Out of specification -+ Replace as a set.

Brake Pad Thickness:

New@:
13.5 mm (0.53 in)
Wear Limit ® :
9.5 mm (0.37 in)

2. Inspect:
• Brake disc
Cracks/Damage -+ Replace.

3. Inspect:
.Cam screw
Crack/Damage -+ Replace.

5-21
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_ _ _ _ _ _ _ _ _ _B_R_AK_E I~R141
INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Apply:
- Low temperature lithium soap base grease
(to the back up plate shaft and cam screw)

2. Install:
-Cam screw
NOTE: _________________________

When installing the cam screw, make sure that

the lever is positioned upward, then align the
screw mount and start screw in.

3. Install:
- Drive chain housing
Refer to the "DRIVE CHAIN HOUSING
- INSTALLATION" section.

5·22
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SLIDE RAIL SUSPENSION 1~141

SLIDE RAIL SUSP
ill Rear axle ENSION
®Guide wheel
cr Suspension wheel
~ Suspension wheel
5 Suspension wheel
®
6 Front axle
CVTrack assembly

A USE NEW ONE

92 Nm (92
. mokg • 67 f tolb)

5-23
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CD Rear pivot arm

@R~d
® (Fmnt)
sLice
9 Slid Ing fram
RA
IL SUSPENSION _
IP~RRI ~ I
--_;..;:......J_~UUH:..J:!y[,J_
®
@ BRear sh oc k absorber
f"i\ racket @ Slide runner e
~R
@ F ear stopper band @Frontt
@R . spring
orslon
ront pivot arm ear torsion spring
® Front sh
(J) Front st ock absorber
opper band

A SLIDE RUNNER
10 mm (0.4 in) WEAR LIMIT:

4 Nm (04
. m • kg, 2.9 ft ·Ib)

4 Nm (0.4 m • kg , 2 .9 ft ·Ib)

3 Nm (03
. m • kg, 2.2 ft ·Ib)

5-24
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__ _ _ _ _ _ _ _ _ IPOWTRRI~
VUH I_
SLIDE RAil SUSPENSION _ _
REMOVAL
1. Remove:
• Cotter pins (Rear axle and suspension
wheel) CD

2. Loosen:
·Axle nut CD
• Adjusters (Track tention) ®

3. Loosen:
• Bolts (Torsion spring guide) CD
NOTE: _________________________
Loosen the both right and left bolts at the
same time.

4. Unhook:
• Torsion spring ®

5. Remove:
• Suspension mounting bolts CD

5·25
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SLIDE RAIL SUSPENSION 1~141

6. Turn the machine on its right or left side.

NOTE: _________________________
Seal the carburetor so fuel will not spill when
you turn the machine.

7. Remove:
• Slide rail suspension CD

DISASSEMBL Y
1. Remove:
• Front stopper band CD
• Rear stopper band ®

2. Remove:
• Holders (front torsion spring) CD

3. Remove:
• Rod (Front) CD

5-26
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4. Remove:
• Front shock absorber CD
• Suspension wheels ®
• Front torsion springs ®

5. Remove:
• Front pivot arm CD

6. Remove:
• Rear shock absorber CD

7. Remove:
• Rear pivot arm CD
.Suspension wheels (Rear) ®
• Guide wheels ®

8. Remove:
• Slide runner CD

5-27
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SLIDE RAI L SUSPENSION

-------------------------------------------------------------
A
IPOTWRRI_uwr I_
INSPECTION
1. Measure:
• Slide runner thickness ®
Out of specification -+ Replace.
®
Slide Runner Wear Limit:
10 mm (0.4 in)
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Replace the right and left slide runners as a set.

2. Inspect:
• Suspension wheel
e Guide wheel
Cracks/Damage -+ Replace.
eWheel bearing
Wheel turns roughly -+ Replace.

Wheel and/or wheel bearing replacement

steps:
e Remove the circJip CD .
e Remove the wheel using a general bearing
puller.
e Remove the circJip ® .
e Remove the wheel bearing using a general
bearing puller.
elnstall the wheel bearing into the wheel.
NOTE: _ _ _ _ _ _ _ _ _ _ __
Use a socket that matches the outside diameter
of the race of the bearing.

Do not strike the inner race of balls of the

bearing. Contact should be made only with
the outer race.

elnstall the circlip.

elnstall the wheel to the shaft.
NOTE: _ _ _ _ _ _ _ _ _ _ _ _ ____

Use a socket that matches the inside diameter

of the race of the wheel bearing.

Do not strike the outer race of balls of the

wheel bearing. Contact should be made only
with the inner race.

elnstall the circlip.

5-28
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SLIDE RAIL SUSPENSION _vmr I

IPOWTRRI~
-------------------------------------------------
3. Inspect:
• Stopper band CD
Frayed/Damage ~ Replace.
• Torsion spring ®
Fatigue/Cracks/Damage ~ Replace.

4. Inspect:
• Shock absorber CD
Oil leaks/Damage ~ Replace.

5. Inspect:
.Sliding frame
• Front pivot arm
• Rear pivot arm
Cracks/Damage ~ Replace.

ASSEMBLY
Reverse the "DISASSEMBLY" procedure.
Note the following points.
1. Install:
• Slide runner

Screw (Slide Runner):

3 Nm (0.3 m' kg, 2.2 ft· Ib)

5·29
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SLIDE RAIL SUSPENSION 1~141

2. Apply:
• Low temperature lithium soap base grease
to the "Gil mark points in the illustration.
3. Tighten:
• Bolts
• Nuts

Bolt CD :
69 Nm (6.9 m' kg, 50 ft·lb)
Nut ®:
92 Nm (9.2 m' kg, 67 ft·lb)
Bolt®:
69 Nm (6.9 m 'kg, 50 ft·lb)
Nut @:
75 Nm (7.5 m· kg, 54 ft·lb)

4. Install:
• Stopper bands (Front and rear)

Bolt (Stopper Band):

4 Nm (0.4 m· kg, 2.9 ft·lb)

5. Install:
• Cotter pins

Ji WARNING:
Always use a new cotter pin.

5-30
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SLIDE RAIL SUSPENSION 1~41

INSTALLATION
Reverse the "R EMOVAL" procedure.
Note the following points.
1. Place the slide rail suspension CD into the
track, and fit the front pivot arm holding
bolts. Then fit the rear pivot arm bracket
mounting bolts.
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Do not tighten the bolts at this point. Finger-
tighten the bolts.

2. Tighten:
• Suspension mounting bolts

Suspension Mounting Bolts:

Front
69 Nm (6.9 m'kg, 50 ft·lb)
Rear
69 Nm (6.9 m'kg, 50 ft·lb)

3. Adjust:
• Track tension

Track tension:
25 - 30 mm/10 kg
(1.0 - 1.2 in/22 Ib)

Refer to the CHAPTE R 2. "TRACK

TENSION ADJUSTMENT" section.

5-31
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~~lR~~V~II;~--------------------------~D~RI~V~E I~I~I
® Sprocket wheel
® Front axle
@Bearing
® Bearing holder

2 90 Nm (90
. m· kg, 65 ft ·Ib)

5-32
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___________DR_'V_E IpW~41
REMOVAL
1. Open the shroud.
Refer to the CHAPTER 2. "SHROUD
OPENING" section.
2. Remove:
.Side cowl (Right and left)
• Stay (Side cowl - Right)
• Muffler CD

3. Remove:
• Speedometer gear assembly CD
• Bearing holder

4. Apply the parking brake.

5. Remove:
• Nut (Front axle) CD
• Plain washer
• Bearing

6. Remove:
• Chain housing cover
• Drive sprocket
• Driven sprocket
• Drive chain
Refer to the "DRIVE CHAIN HOUSING-
REMOVAL" section.
7. Remove:
.Slide rail suspension
Refer to the "SLI DE RAI L SUSPENSION
- REMOVAL" section.
8. Remove:
• Front axle assembly
• Track assembly

5-33
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___________DR_IV_E 1~141
INSPECTION
1. Inspect:
-Track CD
- Slide metal ®
Wear/Cracks/Damage -+ Replace.

2. Inspect:
-Sprocket wheel CD
Wear/Break/Damage -+ Replace.
- Front axle ®
Bent/Scratched (excessively)/Damage-+ Re-
place.
- Spli nes/Threads
Damage -+ Replace.

3. Inspect:
- Front axle bearing
Pitting/Damage -+ Replace.

INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Place the track in the chassis.
NOTE: __________________________
Be sure it is positioned as shown in the illustra-
tion.

[A] TURNING DIRECTION

2. Install the front axle CD ,

push up the
splined end toward the chain housing, and
install the threaded end into the speed-
ometer gear housing side.
NOTE: _________________________

Be sure the lugs correctly engage the track.

5-34
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___________DR_IV_E 1P<ftr141
3. Install:
• Drive chain
• Driven sprocket
• Drive sprocket
• Chain housing cover
Refer to the "DRIVE CHAIN HOUSING-
INSTALLATION" section.

4. Apply the parking brake.

5. Install:
• Nut (Front axle)
• Speedometer gear assembly

Nut (Front Axle):

90 Nm (9.0 m· kg, 65 ft ·Ib)

6. Install:
• Slide rail suspension
Refer to the "SLI DE RAI L SUSPENSION
- INSTALLATION" section.

5-35
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__________________ ICHASI..#
CHAPTER 6.
CHASSIS

STEERING ................................................... 6-1

REMOVAL .................................. . ............. 6-2
INSPECTION ............................................... 6-4
INSTALLATION ..................... . ...................... 6-4

SKI . ......................................................... 6-7

REMOVAL ................................................ 6-8
INSPECTION ............................................... 6-8
INSTALLATION ............................................ 6-9

FRONT SUSPENSION . ......................................... 6-10

REMOVAL ............................................... 6-11
INSPECTION ....................... , .. " .................. 6-13
INSTALLATION .......................... . ................ 6-14

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STEERING ICHASI..!# I
CHASSIS
STEERING
Q) Handlebar
® Steering column
@Bearing
® Relay rod
@Tie-rod
* For Europe

A USE NEW ONE

_ (2.2 m.kg ,ft·lb)

22 Nm 16

, 61
T'"®~, "/
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I@

A~
, ® ~I i 25Nm(25 --
. m.kg, 18 -
ft·lb)

~C-.¢I
-j

6-1
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I
STEERING _CHAS -
--------------------------------------------------------
I---1
REMOVAL
1. Remove:
• Handlebar
Refer tothe CHAPTER 2. "HANDLEBAR"
section.
2. Remove:
• Center cover
Refer to the CHAPTER 2. "CENTER
COVER" section.
3. Remove:
• Carburetor
Refer to the CHAPTER 4. "CARBURE-
TOR - REMOVAL" section.
4. Remove:
• Engine assembly
Refer to the CHAPTER 3. "ENGINE
REMOVAL" section.

5. Remove:
• I ntake silencer CD

6. Straighten:
• Lock washer tabs (Upper CD and lower ® )
7. Remove:
• Cotter pin ®

6-2
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________________S_T_E_E_R_IN_G_lcHASI-.!!f
8. Remove:
- Steering column CD
NOTE: __________________________
When removing the relay rod from the steering
column, the relay rod end ® needs to be held
fixed in order to facilitate the lock nut removal.

9. Remove:
- Cotter pins CD

[Al Right side

[ID Left side

10. Remove:
- Relay rod CD
-Tie-rod ®

6-3
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STEERING ICHASI..# I
INSPECTION
1. Inspect:
• Handlebar CD
• Steering column ®
Bends/Cracks/Damage ~ Replace.

~ WARNING:

Do not attempt to straighten a bent column,

this may dangerously weaken the column.

2. Inspect:
• Bearings (Steering column ® ) CD
Wear/Damage ~ Replace.
• Bearing and steering column contact sur-
faces.
Scratches/Wear/Damage ~ Replace.

3. Inspect:
• Relay rod CD
·Tie-rod ®
Bends/Cracks/Damage ~ Replace.

J. WARNING:
Do not attempt to straighten a bent rod, this
may dangerously weaken the rod.

INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Tighten:
• Nuts (Tie-rod end)

Nuts (Tie-rod End):

25 Nm (2.5 m· kg, 18 ft·lb)

6-4
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STEERING ICHASI...J'
-------------------------------------------------
2. Install:
• Cotter pins

it WARNING:
Always use a new cotter pin.

3. Lubricate:
• Low temperature lithium soap base grease
(to the bearing inner surface)

4. Install:
• Lock washers

it WARNING:
Always use a new lock washer.

5. Tighten:
• Nuts (Steering Column)
• Bolts (Steering Column)

Nut (Steering Column)

22 Nm (2.2 m' kg. 16 ft·lb)
.....- . ; ; 1 Bolt (Steering Column):
27 Nm (2.7 m· kg. 20 ft·lb)

6. Bend:
• Lock washer tab
NOTE: _________________________
Bend the lockwasher tab along the nut or bolt
flats.

7. Install:
• Engine assembly
Refer to the CHAPTER 3. "ENGINE
ASSEMBLY AND INSTALLATION
REMOUNTING ENGINE" section.

6·5
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________________S_T_E_E_R_IN_G_lcHASI..,#
8. Install:
- Carburetor
Refer to the CHAPTER 4. "CARBURE-
TOR - INSTALLATION" section.
9. Install:
- Center cover
Refer to the CHAPTER 2. "CENTER
COVER" section.
10. Install:
- Handlebar
Refer tothe CHAPTER 2. "HANDLEBAR"
section.
11. Adjust:
-Ski
Refer to the CHAPTER 2. "SKI ADJUST-
MENT" section.

6-6
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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_K_' ICHASI"""
SKI
CDSki stopper
®Ski
® Ski runner

Recommended Grease:
ESSO Beacon 325 grease or
Aeroshell grease # 7 A

43 Nm (4.3 mokg, 31 ftolb)

Be careful not to reverse the mounting posi-

tions of the left and right ski assembly.

6-7
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_________________SK_I_~~IJI
REMOVAL
1. Elevate the ski by placing a suitable stand
under the chassis.
2. Remove:
- Cotter pin CD

3. Remove:
-Ski CD
-Collar

4. Remove:
- Ski stopper CD
-Ski runner

INSPECTION
1. Inspect:
-Ski CD
- Ski runner ®
Wear/Cracks/Damage ~ Replace.

6-8
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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_K_' ICHASIJ
2. Inspect:
• Mounting bolt
• Collar
Wear/Damage ~ Replace.

INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Install:
.Ski runner

Nut (Ski runner):

19 Nm (1.9 m-kg, 13 ft-Ib)

2. Install:
• Ski stopper CD
NOTE: _ _ _ _ _ _ _ _ _ _ _ _ ___

• Fit the stopper with its raised portion posi-

tioned in front .
• Be careful not to reverse the mounting posi-
tions of the left and right ski assemblies.

3. Install:
.Ski
4. Lubricate:
• Grease
To the collar CD and mounting bolt ® .
Recommended Grease:
ESSO Beacon 325 grease or
Aeroshell grease #7 A

5. Tighten:
• Mounting bolt (Ski)

Mounting Bolt (Ski):

43 Nm (4.3 m-kg, 31 ft-Ib)

6. Install:
• Cotter pin
ill, WARNING:

Always use a new cotter pin.

6-9
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FRONT SUSPENSION ICHASI..=f I

FRONT SUSPENSION
CD Rear arm (Upper)(j) Suspension bracket (Upper)
@ Rear arm (Lower) ® Suspension bracket (Lower)
@ Absorber holder ® Holding plate
@)Spring
@ Shock absorber
@Outertube
Recommended Grease:
ESSO Beacon 325 grease or
Aeroshell grease # 7 A

16 Nm (1.6 m.kg,
11 ft·lb)

13 Nm (1.3 m· kg, 9.4 ft .Ib)

43 Nm (4.3 m • kg,
31 ft ·Ib)

43 Nm (4.3 m· kg, 31 ft·lb)

23 Nm (2.3 m·kg,17 ft·lb)

6-10
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FRONT SUSPENSION
--------------------------------------------------------
ICHASI----'
~

REMOVAL
1. Open the shroud.
Refer to the CHAPTER 2. "SHROUD
OPENING" section.
2. Remove:
·Side cowl

3. Remove:
·Ski
Refer to the "SKI - REMOVAL" section.

4. Remove:
• Cotter pin ill
• Tie-rod end ®
(from the suspension bracket)

5. Remove:
• Cotter pins ill

6. Remove:
• Rear arm (Upper) <D
• Rear arm (Lower) ®

6-11
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FRONT SUSPENSION ICHASI..# I

7. Remove:
• Absorber holder CD

8. Remove:
.Spring CD
• Shock absorber ®

9. Remove:
• Holding plate (Suspension bracket) CD

10. Loosen:
• Pinch bolts CD

11. Remove:
• Suspension bracket (Lower) CD

6-12
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FRONT SUSPENSION ICHASI...::f

12. Remove:
- Outer tube (Shock absorber) CD

13. Remove:
-Circlip CD
-Washer
- Suspension bracket (Upper) ®

INSPECTION
1. Inspect:
- Shock absorber
Oil leaks/Bend/Damage -+ Replace.

2. Inspect:
- Suspension brackets
- Rear arms
Cracks/Damage -+ Replace.

3. Measure:
- Spring free length®
Out of specification -+ Replace.

Spring free length:

464 mm (18.27 in)
< Limit>
450 mm (17.72 in)

6-13
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FRONT SUSPENSION
4. Inspect:
ICHASI...:f I
• Spring
Cracks/Damage -+- Replace.
5. Inspect:
.Oil seals
Damage -+- Replace.

INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Lubricate:
• Grease
(to inside of the suspension supporting
frame, suspension bracket (Upper) and oil
seal lips)

Recommended Grease:
ESSO Beacon 325 grease or
Aeroshell grease # 7 A

2. Install:
• Suspension bracket (Lower)

Pinch Bolt:
23 Nm (2.3 m- kg, 17 ft-Ib)

3. Install:
• Absorber holder

Bolts (Absorber Holder):

13 Nm (1.3 m- kg, 9.4 ft-Ib)
~-~ Nut CD (Shock Absorber):
5 Nm (0.5 m - kg, 3.6 ft-Ib)
Nut ® (Shock Absorber):
16 Nm (1.6 m - kg, 11 ft- Ib)

6-14
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FRONT SUSPENSION
---------------------------------------------------------
IC HASI---1 -
4. Lubricate:
- Grease
To the collor (Front arm)

Recommended Grease:
ESSO Beacon 325 grease or
Aeroshell grease # 7 A

5. Install:
- Rear arms

Bolt:
43 Nm (4.3 m- kg, 31 ft-Ib)
Apply LOCTITE@

6. Install:
- Cotter pins

& WARNING:
Always use a new cotter pin.

7. Install:
- Tie-rod end

Nut (Tie-rod End):

25 Nm (2.5 m - kg, 18 ft - Ib)

8. Install:
- Cotter pin

&WARNING:
Always use a new cotter pin.

9. Install:
-Ski
Refer to the "SKI - INSTALLATION"
section.

6-15
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CHAPTER 7.
ELECTRICAL
CS340(N)/E(N) CIRCUIT DIAGRAM (FOR U.S.A. AND CANADA) ....... 7-1

CS340 CIRCUIT DIAGRAM (FOR EUROPE) ......................... 7-3

ELECTRICAL COMPONENTS ..................................... 7-5

CHECKING OF CONNECTIONS ................................... 7-7

CHECKING OF SWITCHES ....................................... 7-8

SWITCH CONNECTION AS SHOWN IN MANUAL .................. 7-8
CHECKING SWITCH FOR TERMINAL CONNECTION .............. 7-8

CHECKING OF BULBS (FOR HEADLIGHT, TAIL/BRAKE LIGHT,

METER LIGHT, ETC.) ......................................... 7-11
KINDS OF BULBS .......................................... 7-11
CHECKING BULB CONDITION ............................... 7-11

IGNITION SYSTEM ............................................ 7-13

CIRCUIT DIAGRAM ........................................ 7-13
DESCRIPTION ............................................. 7-17
TROUBLESHOOTING ....................................... 7-18

ELECTRICAL STARTING SYSTEM (FOR CS340EN) ................. 7-27

CIRCUIT DIAGRAM ........................................ 7-27
TROUBLESHOOTING ....................................... 7-29
STARTER MOTOR ......................................... 7-33

CHARGING SYSTEM (FOR CS340EN) ............................. 7-41

CIRCUIT DIAGRAM ........................................ 7-41
TROUBLESHOOTING ....................................... 7-43

LIGHTING SYSTEM ........................................... 7-47

CIRCUIT DIAGRAM ........................................ 7-47
TROUBLESHOOTING ....................................... 7-51

SIGNAL SYSTEM .............................................. 7-61

CIRCUIT DIAGRAM ........................................ 7-61
TROUBLESHOOTING ....................................... 7-65

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________________________C_I_R_C_UI_T_D_IA_G_R_A_M_IELECI Iii 1
ELECTRICAL
CS340N/EN CIRCUIT DIAGRAM (FOR U.S.A. AND CANADA)

..,
c:J
[A]
.----- ---------
: CD I ® @
: B/W B R/W R Br I
I
I OFF i
I

i ON/LIGHT :
II START I
I
B/W B
WIR
r·
L
L _____ B/W B R/W R Br I ~ I
101 '.L.= '-- - - - - - - - - - - - - - - J
~---------~I
CD I
I
I
OFF I
I
ON/LIGHT I R
I
B/W B I R
~ I I I
______~I
_ _ ...J I
B I
L...-_--(,.....,,-.-Q_....j-J I
rID
1-------1 J. r-------
I
_J

I-L T I
L ___ _ __ _
I
._ _ _ _ _ _ _ _ _ _ _ .JI , - - - - . . . . J
: G :
I
IL ______ .JI

I _ _ -lI
1...

L
L G Br
W/R
®
~-R
B/Y

B/Y B B
Y G G/Y B
-!- o:b l
[A]
~------ 1
a
I
I
I
I
r----.J
B
[A]
r--- ---, .!.
I
_ _ _ .JI

I
L :

B
<MB I
B
B
~
~ 1 :
- __ JI
L": .l. ----'

7-1
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________________________C_I_R_CU_I_T_D_IA_G_R_A_M_IELECI iii 1
CD Main switch @ Grip warmer (Right)
® "ENGINE STOP" switch (jJ) Grip warmer (Left)
@ Rectifier/regulator @Throttle switch
@ Starter relay @Carburetor switch
® Starter motor ® Brake light switch
® Battery @Tail/brake light
(j) Fuse @) Meterlight
@CDI unit ® Headlight beam switch
® COl magneto @Headlight
® Spark plug [A] For CS340EN
@ Ignition coil (ID For CS340N
@ Grip warmer switch

COLOR CODE
B . . . . . . . Black W .." ...White
L . . . . . . . Blue B/Y ..... BlacklYeliow
G . . . . . . . Green B/W ..... BlacklWhite
Y . . . . . . . Yellow Y/B ..... Yellow/Black
O . . . . . . .Orange GIY ..... Green/Yellow
R . . . . . . . Red RIW ..... Red/White
Br. . . . . . . Brown W/R .... .white/Red

7-2
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________________________C_I_R_CU_I_T_D_IA_G_R_A_M_IELECI Iii 1
CS340 CIRCUIT DIAGRAM (FOR EUROPE)

CD ® ® @

Q
B!W B

=
OFF OFF
ON/LIGHT ON
B!W B W L B!W B
~ -1-

B/W

L G G Y W Br
W!R

~-R

Y G G!Y GIY B
B
l
*'
L

9@ <ij@
L G!Y L

B B B
=
1 1 1

7-3
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_________________________C_I_RC_U_I_T_D_IA_G_R_A_M_IELECI
® Brake light switch (Right)
iii I
CD Main switch
® "ENGINE STOP" switch ® Brake light switch (Left)
@ Rectifier/regulator ® Tail/brake light
@ Tether switch @ Meterlight
® CDI unit @ Headlight beam switch
® CD I magneto ® Headlight
(j) Spark plug
® Ignition coil

COLOR CODE
B . . . . . . . Black Br. . . . . . . Brown
L . . . . . . . Blue W . . . . . . .white
G . . . . . . . Green B/W . . . . . BlacklWhite
Y . . . . . . . Yellow Y/B . . . . . Yellow/Black
O . . . . . . . Orange G/Y . . . . . Green/Yellow
R . . . . . . . Red W/R . . . . . White/Red

7·4
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ELECTRICAL COM ELECTRICAL COMPONENTS IElECI ~ I

CD M.;n ",;toh PONENTS - - - -
® Tether
's'
. switch (Fo r E urope)
\fY WIreharness
® Fuse *
®
Ignition coil
@ Grip warmer * ® COl unit
@ Rectifier/regulator * For CS340EN
® Battery *
(j) Starter relay *

7-5
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___________________E_L_E_CT_R_I_CA_L__
co_M_P_o_N_E_NT_s_IELEcl Iii 1
CD Handlebar switch assembly (Right) ®Source coil
@ Handlebar switch assembly (Left) ® Lighting coil (2)
@ High beam switch @ Starter motor
@Brake switch @Brake switch (Right)
@COI magneto [K] For Europe
@ Stator assembly rn:J For CS340EN
CDPick-up coil
® Lighting coil (1)

L __________ _

7-6
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CHECKING OF CONNECTIONS IElECI iiiill

CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
• Connector
2. Dry each terminal by an air blower.

3. Connect and disconnect the connector two

or three times.
4. Pu II the lead to check that it wi II not come
off.
5. If the terminal comes off, bend up the pin
CD and reinsert the terminal into connector.

6. Connect:
• Connector
7. Check for continuity by a tester.
NOTE: _________________________
• If there is no continuity, clean the terminals.
• Be sure to perform the above steps 1 to 7 when
checking the wireharness.
• When replacing the CD I unit, be sure to check
its' connector.
• For a field remedy, use a contact revitalizer
available on the market.
• Use the tester on the connector as shown.

7-7
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CHECKING OF CONNECTIONS IELECI iiii I

CHECKING OF SWITCHES
Check the switches for the continuity between
the terminals to determine correct connection.

Read the following for switch inspection.

SWITCH CONNECTION AS SHOWN IN

MANUAL
The manual contains a connection chart as shown
left showing the terminal connections of the
switches (e.g., main switch, handlebar switch,
brake switch, lighting switch, etc.)

-----
OFF
ON/LIGHT
B B/W The extreme left column indicates the switch po-
sitions and the top line indicates the colors of
leads connected with the terminals in the switch
component.

"0--0" indicates the terminals between which

there is a continuity of electricity; i.e., a dosed
circuit at the respective switch positions.

In this chart:
"B and B/W" is continuous with the "OFF"
switch position.

CHECKING SWITCH FOR TERMINAL

CONNECTION
Before checking the switch, refer to the connec-
tion chart as shown above and check for the cor-
rect terminal connection (closed circuit) by the
color combination.

To explain how to check the switch, the main

switch is taken for example in the following.

7-8
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CHECKING OF SWITCHES IELECIIiiiii I

1. Disconnect the main switch coupler from the
wireharness.

Never disconnect the main switch coupler

by pulling the leads. Otherwise, leads may
be pulled off the terminals inside the coupler.

2. Inspect whether any lead is off the terminal

inside the coupler. If it is, repair it.

NOTE: _________________________
If the coupler is clogged with mud or dust, blow
it off by compressed air.

3. Use the connection chart to check the color

combination for continuity (a closed circuit).
In this example, the continuity is as follows.

"8 and 8/W" is continuous with the "OFF"

switch position.

Please note that there is no continuity (an

B BIW open circuit) at all for the color combinations
OFF other than the above ..
ON/LIGHT

4. Check the switch component for the continui-

ty between "R and 8r".

Checking steps:
- Turn the switch key to the "OF F" and
"ON/L I GHT" several times.
- Set the pocket tester selector to the "Q x 1".
-Connect the tester (+) lead to the "8" lead
terminal in the coupler and the (-) lead to
the "8/W" lead terminal.
7·9
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CHECKING OF SWITCHES IELECIIliilI

NOTE: ________________________
Use thin probes for checking the continuity.
Otherwise, the probes may contact other ter-
m~nals inside the coupler.

"n x 1" -Check the continuity between "B" and

"B/W" at the respective switch positions of
"OFF" CD .
There must be continuity (the tester indicat-
ing "0") at the "OFF" switch position, and
there must be no continuity (the tester
indicating "00") at "ON/L1GHT". There
is something wrong between "B" and
"B/W" if there is no continuity at the
"a F F" position or if there is some conti-
nuity either at the "ON/L1GHT".
NOTE: ________________________
Check the switch for continuity several times.

5. If there is something wrong with anyone of

the combinations, replace the switch com-
ponent.

CD ON/LIGHT
(V OFF

7-10
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CHECKING OF BULBS IELECI iiiiii I

CHECKING OF BULBS (FOR HEAD-
LIGHT, TAl L/BRAKE LIGHT, METER
LIGHT, ETC.)
Check the bulb terminal continuity for the condi-
tion of the bulb.

KINDS OF BULBS
The bulbs used in the motorcycle are classified
as shown left by the shape of the bulb socket.

®
® and @ are mainly used for the headlight.

© is mainly used for the tail/brake light.

@ and ® are mainly used for the meter light and

other indicator lights.

CHECKING BULB CONDITION

1. Remove the bulb.
NOTE: ________________________

-Bulbs of the ® and @type uses a bulb holder.

© Remove the bulb holder before removing the
bulb itself. Most of the bulb holders for this type
can be removed by turning them counter-
clockwise.
-Most of the bulbs of © and @ type can be re-
moved from tj1e bulb sockets by pushing and
turning them counterclockwise.
-Bulbs of the ® type can be removed from the
bulb sockets by simply pulling them out.

Be sure to hold the socket firmly when

removing the bulb. Never pull the lead.
Otherwise, the lead may be pulled off the ter-
minal in the coupler.

cL WARNING:
Keep flammable products or your hands
away from the headlight bulb while it is on.
It will be hot. Do not touch the bulb until it
cools down.

7-11
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CHECKING OF BULBS IELECI iii I

2. Check the bulb terminals for continuity.

Checking steps:
- Set the pocket tester selector to the "n x 1".
-Connect the tester leads to the respective bulb
terminals. Take for example a 3-terminal bulb
as shown left. First check the continuity be-
tween the CD and ® terminals by connect-
ing the tester ( + ) lead to the CD terminal and
the tester ( - ) lead to the ® terminal. Then
check the continuity between the CD and ®
terminals by connecting the tester ( +) lead
still to the CD terminal and the tester ( - ) lead
to the ® terminal. If the tester shows "00"
in either case, replace the bulb.

3. Check the bulb socket by installing a proven

bulb to it. As in the checking of bulbs, con-
nect the pocket tester leads to the respective
leads of the socket and check for continuity
in the same manner as mentioned above.

7-12
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_________________________IG_N_I_T_IO_N_S_Y_ST_E_M_IELECI Iii 1
IGNITION SYSTEM
CIRCUIT DIAGRAM (FOR U.S.A. AND CANADA)

I
I
I
I
I
81J
I
I
J ___ --J
L I

7-'3
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_________________________IG_N_I_T_IO_N_S_Y_ST_E_M_IELECI Iii I
Aforementioned circuit diagram shows ignition circuit in circuit diagram.
NOTE: ____________________________________________________________
For the color codes, see page 7-2.

CD Main switch [A] For CS340EN

®"ENGINE STOP" switch [aJ For CS340N
@CDI unit
®CD I magneto
®Spark plug
(j})lgnition coil
@Throttle switch
@Carburetor switch

7-14
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IGNITION SYSTEM IELECIIliii I

CIRCUIT DIAGRAM (FOR EUROPE)

• - - 7-15
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IGNITION SYSTEM IELECIIlliiiii I

Aforementioned circuit diagram shows ignition circuit in circuit diagram.
NOTE: ____________________________________________________________
For the color codes, see page 7-4.

CD Main switch
® "ENGINE STOP" switch
@Tetherswitch
<IDCOI unit
®COI magneto
CVSpark plug
® Ignition coil

7-16
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IGNITION SYSTEM IELECI iiiiiIiIl

DESCRIPTION (FOR U.S.A. AND CANADA)
This model is equipped with a throttle override
system consisting of the following parts.

<DCDI unit
® Throttle switch
@Carburetor switch

The throttle switch is interlocked with the car-

buretor switch with the following switching
function.

~Switch
Carburetor
Idle or starting Run

ON OFF
switch
Throttle
OFF ON
switch

@To ignition coil

@From COl magneto

A [A] Idle or starting

rm Run

ON
n

OFF
n

7-17
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TROUBLESHOOTI NG
IGNITION SYSTEM IELECIIlliiiii I
NO SPARK OR WEAR SPARK

Procedure
Check;
1. Spark plug 7. Tether switch (For Europe)
2. Ignition spark gap 8. Throttle switch (For U.S.A. and CAN)
3. Spark plug cap resistance 9. Carburetor switch (For U.S.A. and CAN)
4. Ignition coil resistance 10. Source coil resistance
5. Main switch 11. Pickup coil resistance
6. "ENGINE STOP" switch 12. Wiring connection
NOTE: ____________________________________________________________

• Remove the following parts before troubleshooting.

1 )Shroud
2) Handlebar cover
3) Center cover
• Use the following special tools in this troubleshooting.

Pocket Tester: Dynamic Coil Tester:

YU-03112,90890-03112 YM-34487,90890-03144

1 . Spark plug
.Check the spark plug condition .
• Check the spark plug gap.
Refer to the CHAPTER 2. "SPARK PLUG
INSPECTION" section.

INCORRECT
Standard Spark Plug:
BR9ES (NGK)

Spark Plug Gap:

0.7 '" 0.8 mm (0.028'" 0.031 in) IRepair or replace spark plug.

~CORRECT

7·18
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IGNITION SYSTEM I ElECI iii I

2. Ignition spark gap
• Disconnect the spark plug cap from the
spark plug.
• Connect the Dynamic Spark Tester CD to
the spark plug and spark plug cap ® , and
set the specified spark gap.

SPARK

• Turn the main switch to "ON" and IIgnition circuit is good.

"ENGINE STOP" switch to "RUN" .
• Start the engine.
• Check the ignition spark cond ition.

Minimum Spark Gap:

6 mm (0.24 in)
+- OUT OF SPECIFICATION
3. Spark plug cap resistance
• Remove the spark plug cap.
• Connect the Pocket Tester (n x 1 k) to the
spark plug cap.

G:J
-@+(
--.=/\
-I l<f
J

• Check the spark plug cap for specificated OUT OF SPECIFICATION

resistance.

~
Spark Plug Cap Resistance:
3.8'" 5.8 kn at 20°C (68° F)
4.7'" 6.9 kn at 20°C (68° F)
I Replace spark p lug cap.
(For CAN)
n MEETS
~ SPECIFICATION

* 7·19
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IGNITION SYSTEM IELECIIiiiii I

4. Ignition coil resistance
- Disconnect the ignition coil lead (Orange)
from the wireharness.
-Connect the Pocket Tester (n x 1) to the
ignition coil.

Tester (+) Lead --7 Orange CD Terminal

Tester (-) Lead --7 Ignition Coil Base

,
CD
(@\'P
I'--~ c:J
-f ©+<j)
'1 L
- Measure the primary coil resistance.

~
Primary Coil Resistance:
o@ ~ 0.16'" 0.24n at 20°C (68°F)
- Connect the Pocket Tester (n x 1) to the
ignition coil.

Tester (+) Lead --7 Spark Plug Lead CD

Tester (-) Lead --7 Ignition Coil Base

~ I Qx1k I
~@~ OUT OF SPECIFICATION

~~
~ --------------~

- Measure the Secondary coil resistance.

I Replace ignition coil.

~
Secondary Coil Resistance:
o@ ~ 3.9'" 5.9 kn at 20°C (68° F)

n BOTH MEET
-<.7 SPECIFICATIONS
*
7-20
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_________________________IG_N_I_T_lo_N_S_V_ST_E_M_IELECI Iii 1

5. Main switch
• Disconnect the main switch coupler CD from
the wireharness.
• Connect the Pocket Tester (n x 1) to the

main
LIGHT" and "START"*.
• Check the main switch for continuity.
*For CS340EN
BAD CONDITION
Switch Good
Bad condition
position condition

I
Replace main switch.

6. "ENGINE STOP" switch

.Disconnect the "ENGINE STOP" switch
coupler CD from the wirehi3rness.
• Connect the Pocket Tester (n x 1) to the
"ENGINE STOP" switch.
Tester (+) Lead -+ Black/White Terminal
Tester (-) Laed -+ Black @ Terminal
For Europe:

7-21
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_________________________IG_N_I_T_IO_N_S_Y_ST_E_M_IELECI iii I
• Turn the "ENGI NE STOP" switch to "OFF"
and "RUN" .
• Check the "ENGINE STOP" switch for con-
tinuity.

BAD CONDITION
Switch Good
Bad condition
position
RUN
OFF
condition
X
0
0
X
X
X
0
0
i
0: Continuity X: Nocontinuity IReplace handlebar switch.
I
n GOOD
~ CONDITION

7. Tether switch (For Europe)

• Disconnect the tether switch coupler CD
from the wireharness.
• Connect the Pocket Tester (n xl) to the
tether switch.

Tester (+) Lead -+ Black/White ® Terminal

Tester (-) Laed -+ Black @ Terminal

• Operate the tether switch to "PUSH" and

"FREE" .
• Check the tether switch for continuity.
BAD CONDITION
Switch Good
position
PUSH
FREE
condition
o
X
X
X
Bad condition

X
0
o
o
l
IReplace tether switch.
0: Continuity X: Nocontinuity

~
n GOOD
CONDITION

7-22
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IGNITION SYSTEM IELECI iiiiii I

8. Throttle switch (For U.S.A. and CAN)

- Disconnect the throttle switch coupler CD
from the wireharness.
-Connect the Pocket Tester (n x 1) to the
throttle switch.

Tester (+) Lead -+ Black/Yellow ® Terminal

Tester (-) Lead -+ Black ® Terminal

- Operate the throttle lever "OPEN" and

"CLOSE".
- Check the throttle switch for continuity.
BAD CONDITION
Throttle Good

1
Bad condition
operation condition
OPEN o x x 0
CLOSE
0: Continuity
x x
X: Nocontinuity
o 0 IReplace handlebar switch.

n GOOD
~CONDITION

9. Carburetor switch (For U.S.A. and CAN)

- Disconnect the carburetor switch leads CD
from the wireharness.
-Connect the Pocket Tester (n x 1) to the
carburetor switch.

Tester (+) Lead -+ Yellow/Black ® Lead

Tester (-) Lead -+ Black ® Lead

B Y/B
I I
....- - - - - -.... 7-23
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__________________________IG_N_IT_I_O_N_S_V_ST_E_M_IELECI iii I
-Operate the throttle lever "OPEN" and
"CLOSE". BAD CONDITION
-Check the carburetor switch for continuity.

~--------,
Throttle
operation
Good
condition
X
Bad condition
I Replace carburetor switch.
OPEN X 0 0
CLOSE 0 X X 0
0: Continuity X: Noconti nu ity
n GOOD
~CONDITION

10. Source coil resistance

- Disconnect the COl magneto coupler and
leads CD from the wireharness.
- Connect the Pocket Tester (n x 100) to
the COl magneto.

Tester (+) Lead ~ Brown ® Lead

Tester (-) Lead ~ Black ® Terminal

OUT OF SPECIFICATION

- Measure the source coil resistance.

Source Coil Resistance: I

i
Replace source coi I.
220 - 330n at 20°C (68° F)
n MEETS
"'(7 SPECIFICATION
11. Pickup coil resistance
- Disconnect the COl magneto coupler CD
from the wireharness.
-Connect the Pocket Tester (n x 10) to the
COl magneto.

Tester (+) Lead ~ White/Red ® Terminal

Tester (-) Lead ~ Black ® Terminal

7-24
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_________________________IG_N_I_T_IO_N_S_y_ST_E_M_IELEcl Iii 1

OUT OF SPECIFICATION
- Measure the pickup coil resistance.

Pickup Coil Resistance:

16'" 24n at 20°C (68° F)

n
MEETS
I Replace pickup coil.

~ SPECIFICATION
12. Wiring connection POOR CONNECTION

1------...,
-Check the entire ignition system for con-
nections.
Refer to the "WI RING D I AG RAM" section.

~ CORRECT
ICorrect.

I
Replace CDI unit.

7·25
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IGNITION SYSTEM IELECI iii I

-MEMO-

7-26
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_________________E_L_EC_T_R_I_CA_L_S_T_A_R_T_IN_G__
SY_S_T_E__
M IELEcl Iii 1
ELECTRICAL STARTING SYSTEM (FOR CS340EN)
CIRCUIT DIAGRAM

7-27
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ELECTRICAL STARTING SYSTEM IELECI iiiiii I

Aforementioned circuit diagram shows electrical starting circuit in circuit diagram.
NOTE: __________________________________________________________

For the color codes, see page 7-2.

CD Main switch [AJ For CS340EN

®"ENGINE STOP" switch ffil For CS340N
@Starter relay
®Starter motor
®Battery
0Fuse

7-28
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_________________E_LE_C_T_R_IC_A_L_S_T_A_RT_I_N_G_S_Y_ST_E_M_IElEcl iii 1
TROUBLESHOOTI NG

STARTER MOTOR DOES NOT OPERATE

Procedure
Check;
1. Fuse 6. Starter relay
2. Battery 7. Wiring connection
3. Main switch
4. "ENGINE STOP" switch
5. Starter motor
NOTE: __________________________________________________________

- Remove the following parts before troubleshooting.

1 )Shroud
2) Handlebar cover
3) Center cover
4) Side cowl (Left)
-Use the following special tools in this troubleshooting.

Pocket Tester:
YU-03112,90890-03112

1. Fuse
_ Remove the fuse. NOCONTINUITY

l -----......,
_Connect the Pocket Tester (n x 1) to the
fuse.
-Check the fuse for continuity.
IReplace fuse.
~ CONTINUITY

2. Battery
-Check the battery condition. INCORRECT

•
Refer to the CHAPTER 2. "BATTERY
INSPECTION" section.
-------------.,
- Refill battery fluid
Specific Gravity:
1.280 at 20°C (68° F) -Clean battery term ina Is.

~ CORRECT - Recharge or replace battery.

7·29
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_________ EL_E_C_T_R_IC_A_L_S_T_A_R_T_IN_G_S_V_S_T_E_MIEUCI~1

3. Main switch
• Disconnect the main switch coupler CD from
the wireharness .
• Connect the Pocket Tester (n xl) to the
main switch.
Tester (+) Lead -+ Red ® Terminal
Tester (-) Lead -+ Red/White @ Terminal

.Turn the main switch to "OFF", "ON/

LIGHT" and "START" .
• Check the main switch for continuity.

Switch Good BAD CONDITION

Bad condition
position condition
OFF
ON/LIGHT
START
X
X
0
X
X
X
0
X
X
0
0
0 I
1
Replace main switch.
0: Continuity X: Nocontinuity

~ GOOD CONDITION

4. "ENGI NE STOP" switch

• 0 iscon nect the "E N GIN E STOP" switch
coupler CD from the wireharness .
• Connect the Pocket Tester (n xl) to the
"ENGINE STOP" switch.
Tester (+) Lead -+ Black/White ® Terminal
Tester (-) Laed -+ Black @ Terminal

7-30
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ELECTRICAL STARTING SYSTEM IELECI iiiii I

• Turn the "ENGINE STOP" switch to "OFF"
and "RUN" .
• Check the "ENGINE STOP" switch for con-
tinuity.
BAD CONDITION
Switch Good
Bad condition
position condition
RUN X 0 X 0
OFF
0: Continuity
0 X
X: Nocontinuity
X 0 IReplace handlebar switch.

n GOOD
~ CONDITION
* ~ WARNING:
5. Starter motor
A wire for the jumper lead must have
.Connect the battery positive terminal CD
the equivalent capacity as that of the
and starter motor lead ® using the jumper
battery lead or more, otherwise it may
lead @*.
cause the jumper lead to be burned.
• Check the starter motor operation.
This check is likely to produce sparks,
so be sure that no flammable gas or
fluid is in the vicinity.

DOES NOT OPERATE

IRepair and/or replace starter motor.

~ OPERATES
6. Starter relay
• Disconnect the starter relay coupler.
• Connect the battery positive terminal CD
and starter relay terminal (Red/White) ®
using jumper lead @ .
• Connect the battery negative terminal @
and starter relay terminal (Blue/White)
® using the jumper lead @ .
• Check the starter motor operation.

DOES NOT OPERATE

l
IReplace starter relay.
~OPERATES

* 7-31
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ELECTRICAL STARTING SYSTEM IElEClliiil1

7. Wiring connection
• Check the entire starting system for con-
nections.
Refer to the "WIRING DIAGRAM" section.

7-32
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_________________E_L_E_CT_R_I_C_A_L_ST_A_R_T_IN_G
__Sy_S_T_E_M_IELECI Iii 1
STARTER MOTOR
<D Starter motor assembly @Yoke
® Clip @ Armature coil
@ Pinion stopper @ Brush plate
@ Return spring @ Brush
@ Pinion gear @ Brush spring
® Plain washer @ a-ring
(j) Front cover (j]) Washer
® a-ring @ Rear cover
® Washer

23 Nm (2.3 m-kg, 17 ft-Ib)

ARMATURE COIL RESISTANCE:
A
0.013 - 0.015Q
BRUSH WEAR LIMIT:
B
8.5 mm (0.33 in)
COMMUTATOR WEAR LIMIT:
C
27 mm (1.06 in)
MICA UNDERCUT:
D
0.4 - 0.8 mm (0.016 - 0.031 in)

E USE NEW ONE

7-33
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_________________
EL_E_C_T_R_IC_A_L_S_TA
__RT_I_N_G_S_YS_T_E_M_IElECI Iii I
Removal
1. Remove:
• Starter motor
Refer to "ENGINE REMOVAL", section.

Disassembly
1. Remove:
• Rear cover securing bolts CD
• Rear cover <V
• Brush holder assembly @
.Voke @

A 2. Remove:
• Pinion gear
Pinion gear removal steps:
00:
• Fit the open-end wrench CD (19 mm (3/4 in))
on the pinion stopper <V , and tap lightly
the wrench with a hammer @ .
[ID:
B • Hold the clip @ with a vise-grip plier ® ,
and open the clip @ , with a slotted head
screwdriver ®.
NOTE: _________________________

Take care not to scratch the armature shaft

0 .
• Clip @ will come out when vise-grip plier
® is taken out.
WARNING:
Support the pinion stopper <V so that the
loosened pinion stopper <V and return spring
® will not fall out.
c ~:
• Remove the pinion gear ® .
If not removed pinion gear ® , remove
the bu rr ® from the groove @ of the
armature shaft 0 using a oil stone.

7-34
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_________________E_L_E_C_T_RI_C_A_L_S_TA_R_T_I_N_G_S_Y_ST_E_M_IELECI iii 1
3. Remove:
• Front cover CD
2
From the armature ®.

@ Armature

Inspection
1. Inspect:
• Pinion gear teeth CD
Cracks/Wear/Damage ~ Replace.
• Return spring ®
Fatigue/Damage ~ Replace.

2. Clean the interior of the yoke and brackets

with compressed air.
3. Inspect:
.Outer surface (Front, rear cover and yoke.)
Cracks/Damage ~ Replace.

4. Inspect:
• Bearings (front CD and rear ®)
Pitting/Damage ~ Replace.

5. Inspect:
• a-rings (front CD and rear ®)
Damage ~ Replace.
2

7-35
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_________________
E_LE_C_T_R_IC_A_L_S_T_A_RT_I_N_G_S_YS_T_E_M_IELEcl Iii 1
6. Inspect:
• Commutator (Outer surface)
Dirty ~ Clean it with #600 grit sandpaper
CD.
Hold the armature in a vise ® and copper
or aluminium plate @ .
NOTE: __________________________
Lightly grip the armature with a vise.

7. Measure:
.Commutator (Diameter)
Measure the diameter ® of the commuta-
tor at which the brush contacts.
Out of specification ~ Replace.

Commutator Wear Limit ® :

27.0 mm (1.06 in)

A 8. Measure:
• Mica CD
(I nsu lation depth)
(between commutator segments)
Out of specification ~ Scrape mica to
proper limits.
Use a hacksaw blade ® that is ground to
fit.

Mica Undercut @ :
Limit: 0.4 mm (0.016 in)
B NOTE: __________________________
• The mica insu lation of the commutator must
be undercut to ensure proper operation of the
commutator .
• Carefully clean between the segments after the
above steps.

[A] CORRECT
rn:J INCORRECT

7-36
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ELECTRICAL STARTING SYSTEM IELEclliil1

9. Measure:
• Armature coil resistance
, (insu lation/continu ity)
~,
: !-Q) Defect(s) -+ Replace starter motor.
~~ nx 1 0
By the following inspecting steps.
""
Armature coil inspecting steps:
• Connect the Pocket Tester for continuity
check CD and insulation check ®.

!JIb Pocket Tester:

YU-03112,90890-03112

• Measure the armature coil resistances.

~
Armautre Coil Resistance:
Continuity Check CD :
0.013'" 0.015n at 20°C (68° F)
Insulation Check ® :
More than 0.5Mn at 20°C (68° F)

.If the resistance is incorrect, replace the

starter motor.

1O. Measu re:

• Brush length ®
Out of specification -+ Replace.
Brush Length Limit ® :
8.5 mm (0.33 in)

11. Measure:
• Brush spring pressure
Fatigue/Out of specification -+ Replace as a
set.

Brush Spring Pressure:

650 '" 950 g (22.9 '" 33.5 oz)

Assembly
Reverse the "Disassembly" procedure.
Note the following points.
1. Before installing the front and rear covers,
apply the bearing grease to the bearings of
the front and rear covers.
2. Make sure the rear cover and front cover are
fitted with the O-rings.

7-37
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ELECTRICAL STARTING SYSTEM IELECIIliii I

3. Before installing the pinion gear, apply the
grease to the worm gear portion of the
armature shaft.

4. Install:
• Pinion gear CD
• Return spring ®
• Pinion stopper ®
5. Open the end of the new clip @ about
9 - 10 mm (0.35 - 0.40 in).

6. Install the clip CD to the groove of the

armature shaft ® , and press fit the clip
CD to the groove with a plier ® .

7. Install the clip CD into the pinion stopper

® with a screwdriver ® and open-end
wrench @.

NOTE:--------------___________
• Take care not to scratch the pinion gear CD
• Make sure the clip ® fits tightly into the
pinion stopper ® .

@ Armature shaft
@ Return spring
7-38
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ELECTRICAL STARTING SYSTEM IELECIIiiiii

8. When installing the rear cover assembly,
I
take care not to scratch the brushes.
9. Install:
-Securing bolts (Starter motor)
NOTE: ___________________________

Align the match marks CD on the bracket with

the match marks ® on the yoke.

Installation
Reverse the "Removal" procedure.
Note the following points.
1. Install:
- Starter motor

Bolt (Starter Motor):

23 Nm (2.3 m'kg, 17 ft·lb)

7-39
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ELECTRICAL STARTING SYSTEM IELECI iiill

-MEMO-

7-40
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CHARGING SYSTEM IELECIIiii I

CHARGING SYSTEM (FOR CS340EN)
CI RCUIT DIAGRAM

- 7-41
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CHARGING SYSTEM IELEcl1iii I

Aforementioned circuit diagram shows charging circuit in circuit diagram.
NOTE: ____________________________________________________________
For the color codes, see page 7 -2.

@ Rectifier/regulator IAl For CS340EN

@Battery lID For CS340N
CVFuse
®CDI magneto

7-42
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________________________C_H_A_R_G_IN_G_S_V_ST_E_M_IELECI iii I
TROUBLESHOOTI NG

BATTERY IS NOT CHARGED

Procedure
Check;
1. Fuse
2. Battery
3. Main switch
4. Charging coil resistance
5. Wiring connection
NOTE: ______________________________________________________________

• Remove the following parts before troubleshooting.

1) Shroud
2) Side cowl (Left)
• Use the following special tools in this troubleshooting.

Pocket Tester: Inductive Tachometer:

YU-03112,90890-03112 YU-08036, 90890-03113

1. Fuse
NOCONTINUITY
• Remove the fuse .
• Connect the Pocket Tester (n x 1) to the
fuse.
• Check the fuse for continuity.

~ CONTINUITY
I Replace fuse.

2. Battery
INCORRECT
• Check the battery condition.
Refer to the CHAPTER 2. "BATTERY
INSPECTION" section.

Specific Gravity: • Refill battery fluid

1.280 at 20° C (68° F) .Clean battery term inals .
• Recharge or replace battery.
~CORRECT
*

7-43
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CHARGING SYSTEM IELECIIiiiii I

*
3. Charging voltage
• Connect the Engine Tachometer to spark
plug lead.
• Connect the Pocket Tester (DC20V) to the
battery.

Tester (+) Lead ~ Battery (+) Terminal

Tester (-) Lead ~ Battery (-) Terminal

• Start the engine and accelerate to about MEETS SPECIFICATION

5,000 r/min.
• Measure the charging voltage.

Charging Voltage:
14'"" 15V at 5,000 r/min
I Replace battery.

OUTOF
SPECIFICATION

4. Charging coil resistance

• Disconnect the COl magneto coupler and
leads CD from the wireharness .
• Connect the Pocket Tester (n x 1) to the
charging coil.

Tester (+) Lead ~ White ® Lead

Tester (-) Lead ~ Black @ Lead

7-44
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CHARGING SYSTEM IELECIIiiiiiilI

• Measure the charging coil resistance.
OUT OF SPECIFICATION

~
Charging Coil Resistance:
0.30 ~ O.46n at 20°C (68° F)

I
l
MEETS
SPECIFICATION
Replace stator assembly. I
~~
5. Wiring connection POOR CONNECTION

• Check the entire charging system for conne-

tions.
I
l
Refer to the "WI RING DIAGRAM" section.
Correct.
I
~ CORRECT
I
Replace rectifier/regulator.

7-45
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CHARGING SYSTEM IElECl1ii I

-MEMO-

~ ........ , ............................................................................................................................................................., .... .

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

7-46
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LIGHTING SYSTEM IELEcl1lIiEi I

LIGHTING SYSTEM
CI RCUIT DIAGRAM (FOR U.S.A. AND CANADA)

~-- - - - -- - --- ---,

I
I
I
I
®

c:J
I I
I I
I I
I I
I I
I t
I I WilL
I I
L.._____ •
[I]
·-----'--~-'-i
------------------1---------------+4
..
I .. I I
I I I
I
I
I
I
II
I I I
I I I
I I I
I I I
I I I
I1.. _ _ _ _ _ _ _ _ ...JI I
I
----, I
I
,....------
I
I-L T : I __
L..
I
I.---_.....J
:
I
I1.. ______
G
..1I
: --------------..1

Y G

@------
I I
I I
I I
I I
I r----.1
I I
: @!
I I
I I @
I I
: I
I
I
@II
I I
I B I
B B :+ II
~
I
1 1..----1

7-47
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_________________________L_I_G_HT_I_N_G_S_VS_T_E_M_IELECI
Aforementioned circuit diagram shows lighting circuit in circuit diagram.
iii I
NOTE: ______________________________________________________________
For the color codes, see page 7-2.

® Rectifier/regulator [A] For CS340EN

@CDI magneto [ID For CS340N
@Tail/brake light
(j]) Meter light
® Headlight beam switch
@Headlight

7-48
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_________________________L_I_G_HT_I_N_G_S_YS_T_E_M_IELECI Iii 1
CIRCUIT DIAGRAM (FOR EUROPE)

••••••••••••••••• •.® . . . .

II
II
••• •
••• •
II
••• •

•
••
L

@
~@ .
'.-
~

B B

1 1 ·1
1111
•• • •0. •
II II II
w~1Il
111111111111
11111111111111
7-49
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_________________________Ll_G_H_T_IN_G_S_V_ST_E_M_IELECI
Aforementioned circuit diagram shows lighting circuit in circuit diagram.
Iii I
NOTE: ____________________________________________________________

For the color codes, see page 7 -4.

@Rectifier/regulator
®CDI magneto
@Tail/brake light
@Meter light
@Headlight beam switch
@Headlight

7·50
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LIGHTING SYSTEM IELECIIiiiii I

TROUBLESHOOTI NG

HEADLIGHT DOES NOT COME ON

Procedure
Check;
1. Headlight bulb
2. Headlight bulb socket
3. Headlight beam switch
4. Lighting voltage
5. Lighting coil resistance
6. Wiring connection
NOTE: ____________________________________________________________

- Remove the following parts before troubleshooting.

1)Shroud
2) Handlebar cover
- Use the following special tool in this troubleshooting.

Pocket Tester: Inductive Tachometer:

YU-03112,90890-03112 YU-08036,90890-03113

1. Headlight bulb
- Remove the bulb.
Refer to the CHAPTER 2. "HEADLIGHT
BULB REPLACEMENT" section.
-Connect the Pocket Tester (n x 1) to the
bulb terminals.

Tester (+) Lead ~ Terminal CD

Tester (-) Lead ~ Terminal ®
Tester (+) Lead ~ Terminal CD
Tester (-) Lead ~ Terminal ®

NOCONTINUITY

-Check the bulb for continuity.

~ CONTINUITY I Replace bulb.

*
7-51
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LIGHTING SYSTEM IELECIIlliiii I

2. Headlight bulb socket
- Disconnect the headlight lead coupler CD
from the wireharness.
-Install the bulb to the bulb socket.
-Connect the Pocket Tester (n xl) to the
bulb socket leads.

Tester (+) Lead -+ Yellow ® Lead

Tester (-) Lead -+ Black @ Lead

Tester (+) Lead -+ Green @ Lead

Tester (-) Lead -+ Black @ Lead

NOCONTINUITY

I
1
Replace bulb socket.
-Check the bulb socket for continuity.

~ CONTINUITY

3. Headlight beam switch

- Disconnect the headlight beam switch
coupler CD from the wireharness.
-Connect the Pocket Tester (n x 1) to the
headlight beam switch.

When pressing beam switch to "HI":

Tester (+) Lead -+ Yellow ® Terminal
Tester (-) Lead -+ Blue @ Terminal

When pressing beam switch to "LO":

Tester (+) Lead -+ Green @ Terminal
Tester (-) Lead -+ Blue @ Terminal

7-52
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_________________________L_IG_H_T_IN_G_S_Y_S_TE_M_IElECI iii I
- Press the beam switch to "HI" and "LO".
- Check the beam switch for continuity.

Switch Good BAD CONDITION

Bad condition
position condition
HI
LO
0
0
X
0
0
X
X
X
I
1
0: Continuity X: Nocontinuity Replace headlight beam switch.
I
~ GOOD CONDITION

4. Lighting voltage
- Press the beam switch to LO".
II

- Connect the Pocket Tester (AC20V DC20V I

(For CS340EN)) to the headlight coupler

CD.
Tester (+) Lead -+ Green ® Terminal
Tester (-) Lead -+ Black @ Terminal

-Connect the Inductive Tachometer to the

spark plug lead.
-Start the engine and check the lighting
voltage.

Do not run the engine in neutral above 6,000 MEETS SPECI FICATION
r/min for more than 1 or 2 seconds.

Lighting Voltage:
11.5"" 13.0V at 2,500 r/min ILighting system is good.

• OUT OF
. . SPECIFICATION

7-53
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LIGHTING SYSTEM IElECllIIiiiiiiI1

5. Lighting coil resistance
• Disconnect the COl magneto coupler CD
from the wireharness.
• Connect the Pocket Tester (n x 1) to the
lighting coil coupler.

Tester (+) Lead -+ Yellow ® Terminal

Tester (-) Lead -+ Black ® Terminal

OUT OF SPECIFICATION
• Measutre the lighting coil resistance.

Lighting Coil Resistance:

0.24 - 0.36n at 20°C (68° F) I
l
Replace stator assembly.

n MEETS
"<j SPECIFICATION
6. Wiring connection
• Check the entire lighting system for connec-
tions. POOR CONNECTION
Refer to the "WI RING DIAGRAM" section.

~CORRECT
ICorrect.
l
Rectifier/Regulator is faulty, replace it.

7-54
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LIGHTING SYSTEM

TAILLIGHT DOES NOT COME ON

Procedure
Check;
1. Tail/brake light bulb
2. Tail/brake light bulb socket
3. Lighting voltage
4. Lighting coil resistance
5. Wiring connection
NOTE: __________________________________________________________

• Remove the following parts before troubleshooting.

1) Shroud
2) Seat
• Use the following special tool in this troubleshooting.

Pocket Tester: Inductive Tachometer:

YU-03112,90890-03112 YU-08036,90890-03113

1. Tail/brake light bulb

• Remove the bulb .
• Connect the Pocket Tester (n xl) to the
bulb terminals.

Tester (+) Lead ~ Terminal CD

Tester (-) Lead ~ Terminal 00
Tester (+) Lead ~ Terminal CD
Tester (-) Lead ~ Terminal @

-@+
NOCONTINUITY

• Check the bulb for continuity. I Replace bu lb .

1
~ CONTINUITY

7-55
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_________________________L_I_G_HT_I_N_G_S_YS_T_E_M_IElECI Iii 1

2. Tail/brake light bulb socket

- Disconnect the bulb socket coupler CD from
the wireharness.
_Install the bulb to the bulb socket.
_ Connect the Pocket Tester (Q x 1) to the
bulb socket coupler.

Tester (+) Lead ~ Blue ® Terminal

Tester (-) Lead ~ Black @ Terminal

NOCONTINUITY

-Check the bulb socket for continuity. IReplace bulb socket.

~ CONTINUITY

3. Lighting voltage
_ Connect the Pocket Tester (AC20V, DC20V
(For CS340EN)) to the tail/brake light
coupler CD.

Tester (+) Lead ~ Blue ® Terminal

Tester (-) Lead ~ Black @ Terminal

- Connect the Inductive Tachometer to the

spark plug lead.
- Start the engine and check the lighting
voltage.

7-56
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LIGHTING SYSTEM IELECIIiiii I

Do not run the engine in neutral above 6.000
MEETS SPECIFICATION
r/min for more than 1 or 2 seconds.

Lighting Voltage:
11.5"'" 13.0V at 2.500 r/min ILighting system is good.
• OUTOF
..... SPECITIFCATION

4. Lighting coil resistance

• Disconnect the COl magneto coupler CD
from the wireharness.
• Connect the Pocket Tester (n xl) to the
lighting coil coupler.

Tester (+) Lead ~ Yellow ® Terminal

Tester (-) Lead ~ Black ® Terminal

OUT OF SPECIFICATION
• Measure the lighting coil resistance.

Lighting Coil Resistance:

0.24,.." 0.36n at 20°C (68° F)
i
IReplace stator assembly.
n MEETS
~ SPECIFICATION

5. Wiring connection
• Check the entire lighting system for connec-
tions. POOR CONNECTION

1
Refer to the "WI RING DIAGRAM" section.

~ CORRECT

Rectifier/Regulator is faulty, replace it.

I
Correct.

7-57
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LIGHTING SYSTEM IELECIIlii I

METER LIGHT DOES NOT COME ON (EXCEPT FOR CS340N) I
Procedure
Check;
1. Meter light bulb
2. Meter light bulb socket
3. Lighting voltage
4. Lighting coil resistance
5. Wiring connection
NOTE: __________________________________________________________

• Remove the following parts before troubleshooting.

1 ) Shroud
• Use the following special tool in this troubleshooting.

Pocket Tester: Inductive Tachometer:

YU-03112,90890-03112 YU-08036,90890-03113

1. Meter light bulb

• Remove the bulb.
• Connect the Pocket Tester (n x 1) to the
bulb terminals.

Tester (+) Lead -+ Terminal CD

Tester (-) Lead -+ Terminal ®

@
I,~I ~
~@t
~9f NOCONTINUITY

I
l
.Check the bulb for continuity. Replace bulb.
I
~ CONTINUITY

2. Meter light bulb socket

• Disconnect the bulb socket leads CD from
the wireharness .
• Install the bulb to the bulb socket .
• Connect the Pocket Tester (n x 1) to the
bulb socket lead and coupler.

7-58
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LIGHTING SYSTEM IELECrliiii I

Tester (+) Lead ~ Blue ® Lead
Tester (-) Lead ~ Black @ Terminal

NOCONTINUITY

B L
I I
• Check the bulb socket for continuity. Replace bulb socket.

~ CONTINUITY

3. Lighting voltage
• Connect the Pocket Tester (AC20V, DC20V
(For CS340EN)) to the meter light leads CD.

B L
I I
• Connect the I nductive Tachometer to the
spark plug lead.
• Start the engine and check the lighting
voltage.

MEETS SPECIFICATION
Do not run the engine in neutral above 6,000
r/min for more than 1 or 2 seconds.

Lighting Voltage:
11.5....., 13.0V at 2,500 r/min
ILighting system is good.

• OUT OF
..... SPECIFICATION

7-59
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LIGHTING SYSTEM IELECIIiii I

• *
4. Lighting coil resistance
• Disconnect the COl magneto coupler CD
from the wireharness.
• Connect the Pocket Tester (n x 1) to the
lighting coil coupler.

Tester (+) Lead -+ Yellow ® Terminal

Tester (-) Lead -+ Black @ Terminal

OUT OF SPECIFICATION
• Measure the lighting coil resistance.

Lighting Coil Resistance:

0.24 ~ 0.36n at 20°C (68° F) IReplace stator assembly.
n MEETS
~ SPECIFICATION

5. Wiring connection
POOR CONNECTION
.Check the entire lighting system for connec-
tions.
Refer to the "WI RI NG DIAG RAM" section.

~CORRECT ICorrect.
1
Rectifier/Regulator is faulty, replace it.

7-60
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SIGNAL SYSTEM IELECIIiiiii I

SIGNAL SYSTEM
CIRCUIT DIAGRAM (U.S.A. AND CANADA)

,
I
I
I
J
I
I
I
I
I
f
I I

-
L_ ........ ..J

7-61
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__________________________S_IG_N_A_L_S_Y_ST_E_M_IELECI
Aforementioned circuit diagram shows signal circuit in circuit diagram.
iii I
NOTE: __________________________________________________________

For the color codes, see page 7-2.

CD Main switch (For CS340EN) [A] For CS340EN

@ Rectifier/regulator [6] For CS340N
® Battery (For CS340EN)
(j) Fuse (For CS340EN)
@CDI magneto
@Brake light switch
@Trail/brake light

7-62
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SIGNAL SYSTEM IElEClliiiiI1

CIRCUIT DIAGRAM (FOR EUROPE)

7-63
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__________________________S_.lG_N_A_L_S_y_S_TE_M_IELEcl iii 1
Aforementioned circuit diagram shows signal circuit in circuit diagram.
NOTE: ________________________________________________________

For the color codes, see page 7-4.

@ Rectifier/regulator
® CD I magneto
® Brake light switch (Left)
@Brake light switch (Right)
@Tail/brake light

7·64
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__________________________S_IG_N_A_L_S_Y_S_TE_M_IElECI iii 1
TROUBLESHOOTING

BRAKE LIGHT DOES NOT COME ON

Procedure
Check;
1. Tail/brake light bulb 6. Brake switch(es)
2. Tail/brake light bulb socket 7. Wiring connection
3. Fuse (For CS340EN)
4. Battery (For CS340EN)
5. Main switch (For CS340EN)
NOTE: ___________________________________________________________

• Remove the following parts before troubleshooting.

1)Shroud
2) Handlebar cover
3) Side cowl (Left)*
4) Center cover*
5)Seat
* For CS340EN
• Use the following special tool in this troubleshooting.

Pocket Tester:
YU-03112,90890-03112

1. Bulb
• Remove the bulb.
• Connect the Pocket Tester (n x 1) to the
bulb.

Tester (+) Lead -+ Terminal CD

Tester (-) Lead -+ Terminal ®
Tester (+) Lead -+ Terminal CD
Tester (-) Lead -+ Terminal @

NOCONTINUITY
• Check the bulb for continuity.

~ CONTINUITY
I Replace bulb.
*
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SIGNAL SYSTEM IELECI iii I

2. Bulb socket
_ Disconnect the bulb socket coupler CD from
the wire harness.
_Install the bulb to the bulb socket.
-Connect the Pocket Tester (Q x 1) to the
bu Ib socket leads.

Tester (+) Lead -+ Green/Yellow ® Terminal

Tester (-) Lead -+ Black @ Terminal

NOCONTINUITY

-Check the bulb socket for continuity. I

1
Replace bulb socket.

~ CONTINUITY

3. Fuse (For CS340EN) NOCONTINUITY

- Remove the fuse.
-Connect the Pocket Tester (Q x 1) to the
fuse.
-Check the fuse for continuity. IReplace fuse.
1
~ CONTINUITY

4. Battery (For CS340EN) INCORRECT

-Check the battery condition.
Refer to the CHAPTE R 2. "BATTERY
INSPECTION" section.
1
- Refill battery fluid.
Specific Gravity: -Clean battery terminals.
1.280 at 20°C (68° F) - Recharge or replace battery.

~ CORRECT

7-66
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__________________________S_IG_N_A_L_S_Y_ST_E_M_IELEcl Iii 1

5. Main switch (For CS340EN)

• Disconnect the main switch coupler CD from
the wireharness.
• Connect the Pocket Tester (n xl) to the
main switch.

Tester (+) Lead ~ Red ® Terminal

Tester (-) Lead ~ Brown ® Terminal

• Turn the main switch to "OFF", "ON/

LIGHT" and "START" .
• Check the main switch for continuity.
BAD CONDITION
Switch Good
Bad condition
position condition
OFF x x o 0
ON/LIGHT o x x 0 IReplace main switch.
START 0 X X 0
0: Continuity X: Nocontinuity

~ GOOD CONDITION

6. "Brake switch(es)
• Disconnect the brake switch coupler CD
from the wireharness.
• Connect the Pocket Tester (n xl) to the
brake switch coupler.

NOTE:
Right hand side is Europe only.

Tester (+) Lead ~ Green ® Terminal

Tester (-) Laed ~ Green/Yellow ® Terminal

7-67
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SIGNAL SYSTEM IELECIIiiiii I

-Check the brake switch(es) for continuity.

Good
Bad condition BAD CONDITION
condition
Apply
the brake
Do not apply
the brake
0

X
0

0
X

0
X

X
1
IReplace rear brake switch.
0: Continuity X: Nocontinuity

n GOOD
~ CONDITION

7. Wiring connection
_Check the entire signal system for connec-
tions.
Refer to the "WI RING DIAGRAM" section.

7-68
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-----------------------------------------------
IAPpxl~'1
CHAPTER 8.
APPENDICES

GENERAL SPECIFICATIONS .................................... 8-1

MAINTENANCE SPECIFICATIONS ................................ 8-3

ENGINE ................................................... 8-3
POWER TRAIN ............................................. 8-7
CHASSIS ................................................. 8-11
ELECTRICAL ............................................. 8-13

GENERAL TORQUE SPECIFICATIONS ........................... 8-15

DEFINITION OF UNITS ........................................ 8-15

CABLE ROUTING ............................................. 8-16

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___________________ G_E_N_E_R_A_L_S_PE_C_IF_IC_A_T_IO_N_S_IAPPXI .~I

APPENDICES

GENERAL SPECIFICATIONS
Model CS340(N)/CS340EN
CS340N CS340EN CS340
Model Code Number 85L 85N 85M (For Europe)
Frame Starting Number 85 L-0001 01 85N-000101 85M-000101
Engine Starting Number 85L-000101 85N-000101 85M-000101
Dimensions:
avera II Length 2,545 mm (100.2 in)
avera II Width 1,015 mm (40.0 in)
Overall Height 1,140 mm (44.9 in)
Weight:
Dry Weight (without fuel and oil) 167 kg (368 Ib) 177 kg (390 Ib) 172 kg (379 Ib)
Minimum Turning Radius:
Clockwise 3.9m (12.8 tt)
Counterclockwise 3.7 m (12.1 ft)
Engine:
Engine Type Fan cooled 2-stroke, 5-port
Induction System Piston valve
Cylinder Arrangement Forward Inclined Paralled 2-cylinder
Displacement 337 cm 3
Bore x Stroke 60 x 59.6 mm (2.362 x 2.346 in)
Compression Ratio 6.5 : 1
Starting System CS340, CS340N: Recoil Hand Starter
CS340EN: Electric and Recoil Hand Starter
Lubrication System Separate Lubrication (YAMAHA AUTOLUBE)
Engine Oil:
Type YAMALUBE 2 or Equivalent
Yamaha Oil 2T or Air cooled 2-stroke
engine oil (For Europe)
Tank Capacity 2.2 L (1.9 Imp qt, 2.3 US qt)

Drive Chain Housing Oil:

Type Gear oil API "GL-3" SAE #75 - #80
Quantity: 250 cm 3 (8.8 Imp OZ, 8.5 US oz)
Fuel:
Type Regular gasoline
Tank Capacity 30.6 L (26.9 Imp qt, 32.3 US qt)
Carburetor:
Type x Quantity Y30W-2 x 1
Manufacturer TEIKEI
Spark Plug:
Type BR9ES
Manufacturer NGK
Gap 0.7 - 0.8 mm (0.028 - 0.031 in)
Transm ission:
Primary Reduction System V-Belt
Primary Reduction Ratio 3.5 : 1 - 1 : 1
Clutch Type Automatic centrifugal engagement
Secondary Reduction System Chain
Secondary Reduction Ratio 22/12 (1.833 : 1)

8-1
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GENERAL SPECIFICATIONS IAPPXI. 'I

Model CS340(N)/CS340EN
Chassis:
Frame Type Monocock
Caster 22.5°
Ski Stance 870 mm (34.3 in)
Suspension:
Front Suspension Type Telescopic Strut Suspension
Rear Suspension Type Slide Rail
Track:
Track Type Internal Drive Type
Track Width 381 mm (15 in)
Length on Ground 676 mm (26.6 in)
Track Deflection 25 - 30 mm/l0 kg (0.98 - 1.18 in/22 Ib)
Brake:
Brake Type Caliper type disc brake
Operation Method Handle lever, left hand operated
Both left and right hands operated (For Europe)
Electrical:
Ignition System/Manufacturer COl/YAMAHA
Generator System Flywheel magneto
Bulb Wattage (Quantity):
Headlight 12V 60W/60W, 60W/55W (For Europe)
Tail/Brake Light 12V 8W/23W
Meter Light 12V 3.4W (For CS340EN)

8-2
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_________________M_A_I_N_TE_N_A_N_C_E_S_P_EC_I_F_IC_A_T_IO_N__
S IAPPXI~~1
MAINTENANCE SPECIFICATIONS
ENGINE

Model CS340(N)/CS340EN
Cylinder Head:
Volume (with spark plug) * 21.0- 21.6cm 3
< Warp Limit > < 0.03 mm (0.0012 in) >
* Lines indicate straightedge measurement.

Cylinder:
Material Aluminum alloy with cast iron sleeve
Bore Size 60.00 - 60.02 mm (2.362 - 2.363 in)
< Taper Limit> <0.05 mm (0.002 in) >
< Out-of-Round Limit> <0.01 mm (0.0004 in) >
Piston:
Piston Size (D) 59.94 - 60.00 mm (2.360 - 2.362 in)
~
Measuring Point ® 10.0 mm (0.39 in)
o J ®
7~~
D
Piston Off-Set 1.0 mm (0.039 in)
Off-Set Direction Exhaust side
Piston-to-Cyl inder Clearance 0.040 - 0.045 mm (0.0016 - 0.0018 in)
< Limit> < 0.1 mm (0.004 in) >
Piston Pin Bore Inside Diameter 16.004 - 16.015 mm (0.6301 - 0.6305 in)
Over Size: 1st 60.25 mm (2.372 in)
2nd 60.50 mm (2.382 in)
Piston Pin:
Piston Pin Outside Diameter 15.95 - 16.00 mm (0.628 - 0.630 in)
Piston Pin Length 46.97 - 47.00 mm (1.849 - 1.850 in)
Piston Ring:
Sectiona I Sketch Top Ring Keystone
B = 1.2 mm (0.047 in)
T = 2.6 mm (0.102 in)
2nd Ring Keystone
B = 1.2 mm (0.047 in)
T = 2.6 mm (0.102 in)
End Gap (Installed): Top Ring 0.35 - 0.55 mm (0.014 - 0.022 in)
2nd Ring 0.35 - 0.55 mm (0.014 - 0.022 in)
Side Clearance Top Ring 0.02 - 0.06 mm (0.0008 - 0.0024 in)
2nd Ring 0.02 - 0.06 mm (0.0008 - 0.0024 in)
Coating Top Ring Chrome plated
2nd Ring Chrome plated

8·3
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MAINTENANCE SPECIFICATIONS IAPPXI ~ "I

Model CS340(N)/CS340EN
Crankshaft:
Crank Width" A" 51.95 ~ 52.00 mm (2.045 ~ 2.047 in)
Connecting Rod Small End Free Play "F" 2.0 mm (0.079 in)
Connecting Rod Big End Side Clearance "0" 0.25 ~ 0.75 mm (0.01 0 ~ 0.030 in)
Crankshaft Deflection "C": C 1 Below 0.03 mm (0.0012 in)
C2, C3 Below 0.04 mm (0.0016 in)
C4 Below 0.05 mm (0.0020 in)
Measuring Points: 1 60 mm (2.36 in)
2 83 mm (3.27 in)
Crank Width "B" 159.90 ~ 160.20 mm (6.295 ~ 6.307 in)
Big End Radial Clearance "E" 0.013 ~ 0.027 mm (0.0005 ~ 0.0011 in)

F
D -
... @® Q

B
A-:j'J ,]
Big End Bearing:
Type Needle bearing
Small End Bearing:
Type Needle bearing
Crank Pin:
Crank Pin Outside Diameter 21.991 ~ 22.000 mm (0.8658 - 0.8661 in)
Connecting Rod:
< Parallel Limit> < 0.05 mm (0.002 in) >
Carburetor:
Type/Quantity Y30W-2A/l
Manufacture TEIKEI
1.0. Mark 85LOO
85MOO (For Europe)
Main Jet (M.J.) L:#128 R:#132
Main Air Jet (M.A.J.) if> 1.9
Pilot Jet (P.J.) #72
Pilot Air Jet (P.A.J.) if> 1.1
Pilot Outlet (P.O.) if> 0.9
Bypass 1 (B.P. 1) L:if>0.6x3 R:if>0.6x3
Pilot Screw (P.S.) 1-3/4 turns out
Throttle Valve (C.A.) 13°
Valve Seat Size (V.S.) if> 1.4
Starter Jet (G.S.) if> 1.3
Fuel Level (F.L.) 40.0 ~ 42.0 mm (1.57 ~ 1.65 in)
Float Height (F.H.) 30.0 ~ 32.0 mm (1.18 ~ 1.26 in)
Engine Idle Speed 1,800 r/min

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8-4
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MAINTENANCE SPECIFICATIONS IAPPXI. "I

Model CS340(N)/CS340EN
Fuel Pump:
Type Y4D-1A
Manufacturer TEIKEI
Oil Pump:
Color Code Green
Plunger Diameter 5.5 mm (0.22 in)
Worm Gear Ratio 1/25 x 47/59 (0.0319)
Minimum Stroke 0.20 ~ 0.25 mm (0.008 ~ 0.010 in)
Maximum Stroke 1.65 ~ 1.87 mm (0.065 ~ 0.074 in)
Minimum Output 0.950 ~ 1.188 cm 3 / 200 stroke
Maximum Output 7 .840 ~ 8.886 cm 3 / 200 stroke
Pump Cable Free Play 24.0 ~ 26.0 mm (0.94 ~ 1.02 in)
High Altitude Setting:
With Standard Air Intake System

~
Altitude
-30oe
(-22°F)
-20oe
(_4°F)
-lOoe
(14°F)
____ MJ L: #130 . . . I MJ L: # 128
oOe
(32°F)
I ...
100 e
(50°f)
200 e
(68°F)
I MJ L: #124
R: # 134 1 R: # 132 1 1 R: #128
Sea level

.,..
I I I I I I
PJ #72 I
I 1
I I I
I MJ L: # 1'28 I I : MJ L:#124
0~600m 1 1

,,
1 R: # 132 I 1 R:#1?8
(0 ~ 2,000 ft) 1

.'
I
PJ #72
600 ~ 1,200 m
1 MJ L: # 124 , I MJ L: #122
(2,000 ~ 4,000 ft)
,
I
R: # 128 I
1
i
1..
1
1
R: #126
1
PJ #72
1 1 MJ L: #122, 1 ,
1,200~ 1,800m , ,
(4,000 ~ 6,000 ft)
PJ #72 i
1
1
1
R: #126:
.. , . 1
1
,1
PJ #70

1,800 ~ 2,400 m
I
,
MJ L: #120 ,, .. : .. : MJ L: #120
(6,000 ~ 8,000 ft) I
R: #124
PJ #72 i
I
, 1
.1 ..
,
I
R: #124
I
PJ #68
1
MJ L: #120 1 I MJ L: #118
2,400 ~ 3,000 m ,
I

R: #124
I

,
1 .1....
1 R: #122
(8,000 ~ 10,000 ft) 1
PJ #72 i 1
..
1
.1..
1
1
I
PJ#68
With Fresh Air Intake System

~ oOe lOoe 200 e

I.:
Altitude (32°F) (50°F) (68°F)
MJ L: #118
0~600m
1 : R: #120
(0 ~ 2,000 ft) I .. 1 PJ #72 ~

600 ~ 1,200 m I.
1

I
MJ
:
L: #114
R:#11?
(2,000 ~ 4,000 ft)
I"
I
IPJ #72
MJ L: #114
1,200 ~ 1,800 m
(4,000 ~ 6,000 ft)
I"
I
1
1
R: #118
1
I.. I PJ #70

1,800 ~ 2,400 m ;
1
.. MJ L: #116
I
I R:#118
(6,000 ~ 8,000 ft) :.. I PJ #68
I

2,400 ~ 3,000 m :... MJ L: #114

1
1 , R:#11?
(8,000 ~ 10,000 ft) !.. : PJ #66 1

8-5
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MAINTENANCE SPECIFICATIONS IAPPXI ~ "I

TIGHTENING TORQUE:
Tightening torque
Parts to be tightened Remarks
Nm m· kg ft· Ib
Crankcase (First) 13 1.3 9.4 Tighten the bolts
(Final) 23 2.3 17 in two stages.
Engine Bracket and Crankcase 30 3.0 22
Cooling Fan 9 0.9 6.5
Cooling Fan Cover 5 0.5 3.6
Cylinder Head
Nut 25 2.5 18
Spark Plug 28 2.8 20
Starter Pu lIey 85 8.5 61
Starter Motor (85N) 23 2.3 17
Starter Motor Lead Terminal 5 0.5 3.6
Air Shroud 4 0.4 2.9
Recoil Starter 6 0.6 4.3
Engine Mounting Nut
Front 53 5.3 38
Rear 30 3.0 22
Muffler and Frame 19 1.9 14

8-6
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MAINTENANCE SPECIFICATIONS IAPPXI. "I

POWER TRAIN

Model CS340(N)/CS340EN
Transmission:
Type V -belt Automatic
Range of Ratio 3.5 : 1 - 1 : 1
Engagement RPM Approx. 3,500 r/min
Shift RPM Approx. 6,600 r/min
Sheave Center Distance" A" Approx. 268.5 mm (10.57 in)
Sheave Offset "B" Approx. 11.0 mm (0.433 in)

----
~~
--- J J - '::'
.10: I;;;a.
,8

c 0
~ ~ If
~ ~A ~ r-
V-Belt:
Part Number 820-17641-00
Outside Circumference 1,099 mm (43.3 in)
Width "A" 31.6 mm (1.24 in)
< Wear Limit "B" > < 28.0 mm (1.10 in) >

A
8
I I
,, ,,,
,,
,, ,
,, ,,,
,,
, ,,

Primary Sheave Spring:

Part Number 90501-520A9
Color Code Gold
Outside Diameter 55.0 mm (2.17 in)
Wire Diameter 5.2 mm (0.20 in)
Pre-load/Set Length 25 kg/61.5 mm (55 Ib/2.42 in)
Spring Rate 21 N/mm (2.1 kg/mm, 118Ib/in)
Number of Coils 4.82
Free Length 73.4 mm (2.89 in)
Primary Sheave Weight Arm:
Part Number 85L-17632-09
Secondary Sheave Spring:
Part Number 90508-45763
Color Code Red
Outside Diameter 50.0 mm (1.97 in)
Wire Diameter 4.5 mm (0.18 in)
Pre-load/Twist Angle 416 kg (917 Ib)/50°

8-7
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MAINTENANCE SPECIFICATIONS IAPPXI. 'I

Model CS340(N)/CS340EN
Hole Position:
Sheave Side * Only one
Spring Seat Side ** A, B or C
* -------
0

o
Spring Rate 8.32 kg-mm/deg (0.722 inolb/deg)
Number of Coils 6.2
Free Length 83.0 mm (3.27 in)
Color Code Red
Torque Cam Angle 46°
Drive Chain:
Type #40K-2
Number of Links 48
Free Play 8.0 - 15.0 mm (0.31 - 0.59 in)
Chain Tensioner:
Pad Thickness 42.7 mm (1.68 in)
< Wear Limit> < 10.0 mm (0.39 in) >
Optional Sprocket:
Drive Sprocket lOT, llT, 12T
Driven Sprocket 22T,24T
Track:
Part Number 8J6-47110-00
Width 381.0 mm (15.0 in)
Length 2,759 mm (108.6 in)
Pitch 83.6 mm (3.29 in)
Number of Links 33
Thickness" A" 5.0 mm (0.20 in)
Height "B" 16.0 mm (0.63 in)
A a <=>
B-t-_=-vLF
Deflection at 10 kg (22 Ib) 25 - 30 mm (1.0 - 1.2 in)
Slide Rail Suspension:
Front Travel 96.4 mm (3.80 in)
Rear Travel 154.9 mm (6.10 in)
Suspension Spring Rate
Front 82.5 kgomm/deg (7.16Ib oin/deg)
Rear 107.6 kg·mm/deg (9.34 Ib oin/deg)
Suspension Spring Wire Diameter
Front 8.0 mm (0.31 in)
Rear 9.5 mm (0.37 in)

8-8
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MAINTENANCE SPECIFICATIONS IAPPXI.'I

Model CS340( N )/CS340E N
Suspension Setting Position:
Stopper Band Hole Position
Front* No.2
Rear* * No.2

* ~No.5 * * \\ a i""" No.5

o .¥' No.4 ¥ No.4

Q ~No.3 ~ aa ¥No.3
No.2
(J ~No. 2 ¥
() ¥No.1
() ~
o
~(1 ~ Or"'/
NO.'~~Y
Shock Absorber:
Damping Foce (Extension)
Front 123 kg/0.3 m/s
Rear 76 kg/0.3 m/s
Damping Foce (Compression)
Front 31 kg/0.3 m/s
Rear 38 kg/0.3 m/s
Slide Runner:
Thickness 15 mm (0.59 in)
< Wear Limit> < 10 mm (0.39 in) >
Track Sprocket Wheel:
Material Polyethylene
Number of Teeth llT
Rear Guide Wheel:
Material Aluminum with Rubber
Outside Diameter 178 mm (7.0 in)
Brake:
Pad Thickness 13.5 mm (0.53 in)
< Wear Limit> < 9.5 mm (0.37 in) >
Pad to Disc Clearance 0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
Disc Outside Diameter 155 mm (6.10 in)
Disc Thickness 4.0 mm (0.16 in)
Brake Lever Free Play 5.0 ~ 8.0 mm (0.20 ~ 0.31 in)
High Altitude Setting:
Clutch Engagement RPM: Approx 3,600 r/min
Shift RPM: Approx 6,700 r/min
Primary Sheave Spring:
Part Number (Color Code) 90501-55485 (Brown - White)
90501-554F6 (Sky blue - Orange)
Pre-load/Set Length 25 kg/ 61.5 mm (55 Ib/2.42 in)
30 kg/61.5 mm (66 Ib/2.42 in)
Spring Rate 25 N/mm (2.5 kg/mm, 140 Ib/in)
30 N/mm (3.0 kg/mm, 168 Ib/in)
Number of Coils 4.51
Free Length 71.5 mm (2.81 in)

8-9
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MAINTENANCE SPECIFICATIONS IAPPXI. "I

Model CS340(N)/CS340EN
Secondary Sheave Spring:
Part Number 90508-45763
Color Code Red
Pre-load/Twist Angle 665.6 kg (1,468Ib)/80°
Hole Position
Sheave Side Only one
Spring Seat Side D

TIGHTENING TORQUE
Tightening torque
Parts to be tightened Remarks
Nm m· kg ft.lb
Primary Sheave 120 12.0 85 Tighten the bolts in
58 5.8 42 two stages. See NOTE
Spider and Sliding Sheave 200 20.0 145 Left-hand thread.
Apply LOCTITE®
Primary Sheave Cap and Sliding Sheave 14 1.4 10
Roller (Primary Sheave) 5 0_5 3.6
Secondary Sheave 40 4.0 29
Drive Sprocket 40 4.0 29
Front Axle 90 9.0 65
Adjusting Bolt (Suspension Stopper Band) 4 0.4 2.9
Rear Axle 75 7.5 54
Suspension Wheel 92 9.2 67
Sliding Frame and Slide Runner 3 0.3 2.2
Slide Rail Suspension Mounting Bolt 69 6.9 50
Brake Caliper Body and Oil Tank Bracket 24 2.4 17
NOTE: ____________________________________________________________

Tightening steps:
1. Tighten the bolt. 120 Nm (12 m· kg, 85 ft.lb).
2. Loosen it completely.
3. Retighten it. 58 N m (5.8 m' kg, 42 ft· Ib)

8-10
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MAINTENANCE SPECIFICATIONS IAPPXI ~ "I

CHASSIS

Model CS340(N)/CS340EN
Frame:
Frame Material Aluminum and steel
Seat Height 565 mm (22.2 in)
Laggage Box Location Not Equipped (85L)
Front Left Side of Engine Room (85M)
Rear of Seat (85N)
Steering:
Steering Angle (Left) 52°
(Right) 52°
Ski Alignment Toe-out
Toe-out Size o - 15 mm (0 - 0.6 in)
Distance" A" 1,620 mm

Ski:
Ski Material Steel
Length 1,067.5 mm (42.03 in)
Width 145 mm (5.71 in)
Thickness 34.5 mm (1.36 in)
Ski Ground Length 514.8 mm (20.27 in)
Ski Suspension:
Type T.S.S.
Travel 140 mm (5.51 in)
Spring Type Coil Spring
Spring Rate 16 - 20 N/mm (1.6 - 2.0 kg/mm, 90 - 112 Ib/in)
Wire Diameter 6.5 mm (0.26 in)
Shock Absorber:
Damping Force (Extension) 30 kg/0.3 m/s
(Compression) 25 kg/0.3 m/s

8-11
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MAINTENANCE SPECIFICATIONS IAPPXI' 'I

TIGHTENING TORQUE:
Tightening torque
Parts to be tightened Remarks
Nm m- kg ft- Ib
Handlebar Holder (Upper) and Steering Column 15 1.5 11
Steering Relay and Inside Arm 43 4.3 31
Relay Rod End and Outside Arm 25 2.5 18
Relay Rod Adjustment Nut 25 2.5 18
Steering Column (Nut) 22 2.2 16
(Bolt) 27 2.7 20
Ski 43 4.3 31
Pinch Bolt (Suspension Bracket) 23 2.3 17
Absorber Holder 13 1.3 9.4
Mounting Nut (Shock Absorber) 5 0.5 3.6
Locknut (Shock Absorber) 16 1.6 11
Suspension Bracket and Rear Arm (Lower) 43 4.3 31 ~
Suspension Bracket and Rear Arm (Upper) 43 4.3 31 ~
Rear Arm (Upper) and Rear Arm (Lower) 43 4.3 31 ~
Fuel Tank (Rear) and Frame 10 1.0 7.2
Seat and Frame (Nut) 9 0.9 6.5
(Screw) 3 0.3 2.2
Oil Tank and Bracket 4 0.4 2.9
Oil Tank and Frame 5 0.5 3.6
Hood 3 0.3 2.2
Starter Lever 4 0.4 2.9
Main Switch 4 0.4 2.9

8-12
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MAINTENANCE SPECIFICATIONS IAPPXI ~ "I

ELECTRICAL
Model CS340(N)/CS340EN
Voltage: 12V
Ignition System:
Ignition Timing (B.T.D.C.) 17° /7 ,000 r/min

-c.i
cl 30
...:
-c
III
Cl
20
E
i=
c
0
:-ec
Cl
10
-
0 2 3 4 5 6 7 8 9

Engine Speed (x 103 r/min)

COl:
Magneto Model/Manufacturer F82H/YAMAHA (85L)
F81 L/YAMAHA (85M)
F85N/YAMAHA (85N)
Pickup Coil Resistance 16 ~ 24n at 20°C (68° F)
(Color Code) (White/Red - Black)
Source Coil Resistance 220 ~ 330n at 20°C (68° F)
(Color Code) (Brown - Black)
COl Unit Model/Manufacturer 81E-MO/YAMAHA (U.S.A., CAN)
81 L-MO/YAMAHA (Europe)
Ignition Coil:
Model/Manufacturer 85T-00/Y AMAHA
Primary Coil Resistance 0.16 ~ 0.24n at 20°C (68°F)
Secondary Coil Resistance 3.9 ~ 5.9 kn at 20°C (68°F)
Spark Plug Cap:
Type Resin Type
Noise-Supressor Type (CAN)
Model/Manufacturer L.05EL/NGK
ASCC21/NIPPON DENSO (CAN)
Resistance 3.75 ~ 5.75k n at 20° C (68° F)
4.68 ~ 6.88kn at 20°C (68° F) (CAN)
Charging System:
Type Flywheel Magneto

8-13
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MAINTENANCE SPECIFICATIONS IAPPXI ~ "I

Model CS340(N)/CS340EN
Flywheel Magneto:
Model/Manufacturer F82H/Y AMAHA (85L)
F81 L!YAMAHA (85M)
F85N/Y AMAHA (85N)
Charging Current - Day (Minimum) 0.6A at 3,000 r/min
Charging Current - Day (Maximum) 2.0A at 8,000 r/min
Charging Coil Resistance 0.30 - 0.46n at 20°C (68° F)
(Color Code) (White - Black)
Lighting Voltage (Minimum) 6.2V at 1,200 r/min
(Maximum) 15.0V at 8,000 r/min
Lighting Coil Resistance 0.24 - 0.36n at 20°C (68° F)
(Color Code) (Yellow - Black)

30
2:
Q>
C)
co
~

"0
> 20

-
C)
c
.';:;
.c
C) ~
:.J 10
..--- ".....
.,-
----
0 2 4 6 8
Engine Speed (x 103 r/min)

Color Resistance for Grip Warmer 0.64 - 0.96n at 20°C (68° F)

(Color Code) (Red - Black)
Voltage Regulator:
Type Short Circuit Type
Model/Manufacturer 22J-60/STAN LEY
No Load Regulated Voltage 13.5 - 14.5V
Rectifier:
Model/Manufacturer 22J-60 /STANLEY
Capacity 4A
Battery (F or CS340 EN):
Model/Manufacturer YB14L-A2/YUASA
Capacity 14.0AH
Specific Gravity 1.280
Electric Starter System (For CS340EN):
Type Bendix type
Starter Motor (For CS340EN):
Model/Manufacturer 7KY-00/NIPPON DENSO
Output 0.6kW
Armature Coil Resistance 0.013 - 0.015n at 20°C (68°F)
Brush: Overall Length 12 mm (0.48 in)
< Wear Limit> 8.5 mm (0.33 in)
Spring Force 650 - 950 g (22.9 - 33.5 oz)
Commutator Diameter 28 mm (1.10 in)
< Wear Limit> < 27 mm (1.06 in) >
Mica Undercut 0.4 - 0.8 mm (0.016 - 0.031 in)

8-14
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GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS _
IAPP'VI.l ~I
A. " _

GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasteners
General torque
with standard 1.5.0. pitch threads. Torque speci- A B specifications
fications for special components or assemblies (Nut) (Bolt)
are included in the applicable sections of this Nm m·kg ft·lb
book. To avoid warpage, tighten multifastener 10mm 6mm 6 0.6 4.3
assemblies in a crisscross fashion, in progressive 12mm 8mm 15 1.5 11
stages, until full torque is reached. Unless other-
14mm 10mm 30 3.0 22
wise specified, torque specifications call for
clean, dry threads. Components should be at 17mm 12mm 55 5.5 40
room temperature. 19mm 14mm 85 8.5 61
22mm 16mm 130 13.0 94

I
A
L~_

A: Distance across flats

B: Outside thread diameter

DEFINITION OF UNITS

Unit Read Definition Measure

mm millimeter 10-3 meter Length

cm centimeter 10-2 meter Length
kg kilogram 103 gram Weight
N Newton 1kg x m/sec2 Force
Nm Newton meter Nxm Torque
m·kg Meter ki logram m x kg Torque
Pa Pascal N/m 2 Pressure
N/mn Newton per millimeter N/mn Spring rate
L Liter
- Volume or Capacity
cm 3 Cubic centimeter
r/min Rotation per minute - Engine Speed

8·15
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CABLE ROUTING IAPPXI ~ "I

CABLE ROUTING
FOR U.S.A. AND CANADA
CD Brake cable ® Fuel level hose @Ignition coil
®"ENGINE STOP" switch @Oillevel hose @Fuel pump
@Crip @Voltage regulator @CDI unit
@Band @Oil filter @Fuel cock
@Throttle cable @Speedometer cable* @Main switch
@Gripwarmer lead @Clamp* @ Grip warmer switch*
CD "LIGHTS" (Dimmer) switch @Spark plug lead @ Breather hose
® Brake switch lead @Battery* *For CS34QEN only
@Starter cable @Meter light lead

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8-16
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CABLE ROUTING IAPPXI ~ " I

FOR U.S.A. AND CANADA
CD Speedometer cable*
® Meter light lead *
® Headlight lead
@Clamp
*For CS340EN only

8-17
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CABLE ROUTING IAPPXI ~ "I

FOR EUROPE
CD Brake cable @Starter cable @Meter light lead
® "ENGINE STOP" switch ® Fuel level hose @Ignition coil
@Crip @Oil level hose @Fuel pump
@Band @Voltage regulator @JCDI unit
@Throttle cable @Oil filter @Fuel cock
@Grip warmer lead @Speedometer cable @Main switch
CV"LlGHTS" (Dimmer) switch @Clamp @Tether switch
® Brake switch lead @Spark plug lead @Breather hose

--------~~-

8-18
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CABLE ROUTING IAPPXI ~ "I

FOR EUROPE
(j)Speedometer cable
® Meter light lead
® Headlight lead
@Clamp

8-19
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CABLE ROUTING IAPPXI ~ \J

CD Fuel tank cap
® Fuel level hose
~ Fuel breather hose
4 Fuel delivery hose
@Fuel hose
@Fuel cock
(Vail tank cap
®Oil tank

~-1
~-- \-
\

8-20
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CD Tail/Brake light lead

CABLE ROUTING IAPPXI' " I
® Speedometer cable*
*Except for CS340N

8-21
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 Meter light

Fuse
~ Battery
Grip warmer
switch
1 L:-J R~7f Et" 0

M~~
B L B L
B
R
HCJ=Eeadlight ~~L Y/tl

E15=~ ~
G G BL LB Y
I Tail/brake'light

n
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Y G G Y

111 G~ 1 ~
"ENGINE STOP" ~B/Y
~w Br I
In:..1 1X ~ Ir
B/Y
I II I
--. I I IGjTI\
switch B G Y L I B/W W/R I
B o
I I R I
o
y.

Throttle switch
Spark plug

~
L R VV
COLOR CODE

~rrN~
8 B--D<J---B- W
B ....... Black
Carburetor switch ?C R
Ignition coil L ....... Blue
BIY B/Y-C>D--B/Y IIII B
G ....... Green
Y ....... Yellow
O ....... Orange

~Hrl ~L- J
COl magneto COl unit
~ R ....... Red

fX: g: d)b-~-
Headlight Br....... Brown
beam switch
W .......White
B/Y ..... Black/Yellow
Rectifier/
regulator B/W ..... BlacklWhite
Y/B ..... Yellow/Black

~I ~
OFF ON
G/Y ..... Green/Yellow
Brake light
switch
k :81 t---Br
IL--G/Y J -= -=
RIW ..... Red/White
W/R .....White/Red
 CS340N WIRING DIAGRAM

Carburetor switch
I"::: I B IBIYI
ON

B B/Y

99~9

H():Eeadlight
B L B L

~~L
II
B Y/B
B B/Y

EillE~ ~
G G BL LB Y Tail/brake light

~
Y G G Y .r. I

;yH
L

l~
,
~ IIII (;
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G/Y
B
---
"ENGINE STOP"
switch I -:-1 1 (l) L-., B G Y L I BAv
r---B/W

IBI
i;;
1
= .r I.
G/Y I B/Y
I I-- R III 1 B o

l
~
~

y I I I I I I ~ R
o

~~
Throttle switch
Spark plug
B

~
B L W
o COLOR CODE
Br W
Main switch B- - - - i I s 1 I s 1 - B - R B ....... Black
Ignition coil
1'>/¥v1 v I rB/w~ ~B/W I I I I L ....... Blue
G ....... Green
Y ....... Yellow

~
O ....... Orange

m~181 fB,~~=-
COl unit
Headlight R ....... Red
beam switch Br ....... Brown
W ...... .white
COl magneto B/Y ..... Black/Yellow
Rectifier/
regulator B/W ..... Black/White
Y/B ..... Yellow/Black
Brake light
switch ~frNI
G!i :8; ~r.1-G-
~IY-
:GIY -=- -=-
G/Y ..... Green/Yellow
R/W ..... Red/White
W/R .... .white/Red