Yamaha YT175J 1982 Manuel utilisateur
CONTENTS
GENERAL
INFORMATION
PERIODIC INSPECTIONS
AND
ADJUSTMENTS
ENGINE
OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
APPENDICES
CHAPTER
1.
GENERAL INFORMATION
MACHINE
IDENTIFICATION
..............................................
1-1
Frame serial
number
..................................................
1-1
Engine
serial
number
.................................................
1-1
(
SPECIAL
TOOLS
........................................................
1-2
For
tune-up
.........................................................
1-2
For
engine
service
.....................•..............................
1-2
For
chassis
service
...................................................
1-3
For
electrical
components
.............................................
1-4
Additional
tools
and
supplies
..........................................
1-4
GENERAL
INFORMATION
MACHINE
IDENTIFICATION
Frame serial
number
The frame serial number is stamped into the
right-sde
of
the steering head pipe.
1. Frame serial number
NOTE:
______________________
__
The first three digits
of
these numbers are
for
model identification; the remaining digits are
the unit production number.
Starting Serial Number:
YT175J
................
5V7-000101
1-1
Engine serial
number
The engine serial number is stamped into the
elevated part
of
the right rear section
of
the
engine.
SPECIAL TOOLS
The proper special tools
are
necessary
for
complete and accurate
tune-up
and
assembly. Using the correct special tool will
help prevent damage caused by the
use
of
improper tools or improvised techniques.
Fortune-up
1.
Timing light
2.
Tachometer
For
engine
service
1.
Dial gauge
PIN 90890-03002-00
2.
Dial gauge stand
PIN 90890-01256-00
3.
Dial gauge needle
PIN 90890-03099-00
1-2
Tools
1,
2,
and 3
are
use
to
set the ignition
timing.
4.
Crankcase separation tool
PIN 90890-01135-00
This tool is use
to
split the crankcase
as
well
as
remove the crankshaft from either case.
5.
Crank installer
pot
PIN 90890-01275-00
6.
Crank installer bolt
PIN 90890-01275-00
7. Spacer
PIN
90890-01288-00
8. Crank installer bolt adapter
PIN
90890-01278-00
Tools
5,
6,
7, and 8 are
use
to
install the
crankshaft.
9.
Flywheel puller
PIN
90890-01189-00
This tool
is
use
to
remove the flywheel
magneto.
1-3
10.
Flywheel holding tool
PIN
90890-01235-00
Use
this tool
to
hold the flywheel magneto
while removing or tightening the flywheel
magneto securing nut.
For
chassis
service
1.
Steering
nut
wrench
PIN
90890-01051-00
Use
this wrench
to
put the proper tension on
the steering head bearing.
2. Front-fork-cylinder holder
PIN
90890-01300-00
This tool is used
to
loosen and tighten the
front fork cylinder holding bolt.
For
electrical
components
The
use
of
these tools
are
described in
Chapter
6.
1. Pocket tester
PIN
90890-03104-00
2. Electro tester
PIN
90890-03021-00
1-4
Additional
tool
and
supplies
1.
Thickness gauge set
2. Torque wrench
3.
Tire pressure gauge
4. Fluid mesuring cup
5.
Micrometer
6. Slide caliper
7. Cylinder gauge
8. Magnetic stand
9.
Grease gun
10.
Yamalube 4-cycle oil
11.
Yamalube 2-cycle oil
12. Yamabond
#4
13. Yamaha chain and cable lube or SAE
10W30
motor
oil
14. Medium
weight
wheel bearing grease
15. Locktit stud N'bearing mount (Red)
CHAPTER
2.
PERIODIC INSPECTIONS
AND
ADJUSTMENTS
INTRODUCTION
.........................................................
2-1
MAINTENANCE
INTERVALS
CHART
......................................
2-1
ENGINE
................................................................
2-3
Spark
plug
..........................................................
2-3
Fuel
line
............................................................
2-3
Over
flow
chamber
...................................................
2-3
Idle
speed
..........................................................
2-3
Throttle
cable
........................................................
2-3
Throttle
lever
........................................................
2-4
Autolube
pump
cable
adjustment
......................................
2-4
Minimum
pump
stroke
check
and
adjustment
............................
2-4
Air
bleeding
.........................................................
2-5
Engine
oil
....................................
'.'
.....................
2-6
Checking
the
water
release
valve
.......................................
2-6
Transmission
oil
.....................................................
2-6
Checking
ignition
timing
..............................................
2-7
CHASSIS
...............................................................
2-8
Air
cleaner
..........................................................
2-8
Front
brake
shoe
inspection
...........................................
2-8
Rear
brake
pad
inspection
.............................................
2-8
Brake
adjustment
....................................................
2-9
Drive
chain
tension
check
............................................
2-11
Drive
chain
tension
adjustment
........................................
2-11
Drive
chain
cleaning
and
lubrication
...................................
2-11
Steering
head
adjustment
............................................
2-11
Wheel
bearings
.....................................................
2-12
Fuel
cock
..........................................................
2-13
Tires
..............................................................
2-13
Cable
inspection
and
lubrication
......................................
2-14
Brake
and
change
pedals/front
and
rear
brake
levers
.....................
2-14
ELECTRICAL
...........................................................
2-15
Headlight
bulb
replacement
..........................................
2-15
Headlight
beam
adjustment
..........................................
2-15
PERIODIC INSPECTIONS
AND
ADJUSTMENTS
INTRODUCTION
This chapter includes
all
information necessary to perform recommended inspections and ad-
justments. These preventive maintenance procedures, if followed, will ensure more reliable vehi-
cle operation and a longer service life. The need for costly overhaul work will be greatly reduced.
This information applies to vehicles already
in
service and to
new
vehicles that are being
prepared for sale. All service technicians should be familiar with this entire chapter.
MAINTENANCE
INTERVALS CHARTS
The following charts should be considered strictly
as
a guide
to
general maintenance and lubrica-
tion intervals. You must take into consideration
~hat
weather, terrain, geographical location, and
a variety
of
individual uses. This time schedule should be altered
to
match individual owner's re-
quirements.
For
example, if the machine
is
continually operated
in
an
area
of
high humidity, then
all
parts must be lubricated much more frequently that shown on the chart to avoid damage
caused by water to metal parts.
PERIODIC
MAINTENANCE
Initial Thereafter every
Item Remarks 1 3 6 6 1
Month
Months
Months
Months Year
Cylinder head/Exhaust
system/
Decarbonize 0 0 0
Spark arrester
Spark plug Inspect/Cleaning
or
replace
as
required 0 0 0 0
Air
filter
Wet
type-
Must be washed and damped
with
0 0 0
Yamalube 2-cycle
Oil
or
SAE 10W30
motor
oil
Water
release valve Check operation/Foreign materials 0 0 0 1
Month
Check operation/Fittings 0 0 0
Carburetor Clean/Refit/Adjust 0
Autolube
pump
Check/
Adjust/
Air
bleeding 0 0 0 0
'Brake
system (complete) Check/Adjust
as
required-Repair
as
required 0 0 0 3
Months
Drive chain Check/Adjust
as
required/Replace
as
required 0 0 0 1
Month
Steering bearings Check/Adjust
as
required/Replace
as
required 0 0
'Wheels
and tires Chack pressure/Wear/Balance/
Run
out
0 0 0 0
Fuel cock Clean/Flush tank
as
required 0 0 0 0
"Lights
Check operation/Replace
as
required 0 0 0 0
'Fittings/
Fasteners Tighten before each
trip
and/or
... 0 0 0 0
• Indicatespre-operation check Items.
2-1
LUBRICATION INTERVALS
Initial Thereafter every
Item Remarks Type 1 3 6 6 1
Month
Months
Months
Months
Year
"Transmission oil Replace/Warm engine Yamalube 4-cycle oir
or
SAE 0 Check 0 0
before draining 1
OW30
type
SE
motor
oil
Throttle lever and Apply lightly Lithium base grease 0 0
housing
Brake lever
Apply
lightly Lithium base grease 0 0 0
Brake cam shaft
Apply
lightly
Lithium base grease 0 0 0
Drive chain Lubricate chain thoroughly
Motor
oil SAE30 -50 0 0 0 1
Month
Front forks Drain
completely-check
Yamaha
fork
oil10wt
or
0 0 1
specifications SAE 10W30type
SE
motor
oil Year
Steering bearings Inspect
thoroughly/pack
Medium-weightwheel bearing Check 2
moderately grease Years
Wheel bearings Do
not
over-pack Medium-weightwheel bearing 0
yearly
or
...
grease
" Indicatespre-operation checkItems.
2-2
ENGINE
Spark
plug
1.
Check electrode condition and wear, in-
sulator color, and electrode gap.
2.
Clean the spark plug
with
spark plug
cleaner
if
necessary.
Use
a wire gauge
to
adjust the plug gap
to
the specifica-
tion.
3.
If
the electrode becomes
too
worn,
replace the spark plug.
4. When installing the plug, always clean
the gasket surface, wipe
off
any grime
that might be rresent on the surface
of
the spark plug, and torque the spark
plug properly.
Standard spark plug: NGK
BP7ES
Spark plug gap:
0.7 -0.8 mm (0.028 -
0.031
in)
Spark plug tightening torque:
20Nm(2.0m·kg,14.5ft·lb)
Fuel
line
Check the fuel hoses and vacuum lines for
cracks or damage; replace
if
necessary.
Over
flow
chamber
If gasoline begin
to
show
up in the pipe
II
A"
,
loosen the three screws from over
flow
chamber and completely drain gasoline from
the pipe
II
A"
and chamber.
Idle
speed
1.
Turn the pilot air screw until
it
lightly
seats, then back
it
out
to
specification.
This adjustment can be made
with
engine stopped.
2-3
Air screw (Turns out): 1and
1/4
2.
Startthe engine and let
it
warm up.
3.
Throttle stop screw
Turn throttle stop screw in or
out
to
achieve smooth engine operation at
specified idle speed.
Idling speed: 1,600 ±
50
r/min
NOTE:
______________________
__
The pilot air and throttle stop screws
are
separate adjustments
but
they must be ad-
justed at the same time
to
achieve optimum
operating condition at engine idle speeds.
1.
Throttle stop screw
2.
Pilot air screw
Throttle
cable
Loosen cable adjuster lock
nut
(at
top
of
car-
buretor) and turn cable adjuster until
specified free play is obtained. Retighten lock
nut.
Free
play: 1
-1.5
mm
(0.04 -0.06 in)
1.
Adjuster
2.
Lock
nut
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