Yamaha YT175J 1982 Manuel utilisateur

CONTENTS

GENERAL

INFORMATION

PERIODIC INSPECTIONS

AND

ADJUSTMENTS

ENGINE

OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

APPENDICES

CHAPTER

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

the steering head pipe.

1. Frame serial number

NOTE:

______________________

The first three digits

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

the right rear section

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

improper tools or improvised techniques.

Fortune-up

Timing light

Tachometer

For

engine

service

Dial gauge

PIN 90890-03002-00

Dial gauge stand

PIN 90890-01256-00

Dial gauge needle

PIN 90890-03099-00

1-2

Tools

and 3

are

use

set the ignition

timing.

Crankcase separation tool

PIN 90890-01135-00

This tool is use

split the crankcase

well

remove the crankshaft from either case.

Crank installer

pot

PIN 90890-01275-00

Crank installer bolt

PIN 90890-01275-00

7. Spacer

90890-01288-00

8. Crank installer bolt adapter

90890-01278-00

Tools

7, and 8 are

use

install the

crankshaft.

Flywheel puller

90890-01189-00

This tool

use

remove the flywheel

magneto.

1-3

10.

Flywheel holding tool

90890-01235-00

Use

this tool

hold the flywheel magneto

while removing or tightening the flywheel

magneto securing nut.

For

chassis

service

Steering

nut

wrench

90890-01051-00

Use

this wrench

put the proper tension on

the steering head bearing.

2. Front-fork-cylinder holder

90890-01300-00

This tool is used

loosen and tighten the

front fork cylinder holding bolt.

For

electrical

components

The

use

these tools

are

described in

Chapter

1. Pocket tester

90890-03104-00

2. Electro tester

90890-03021-00

1-4

Additional

tool

and

supplies

Thickness gauge set

2. Torque wrench

Tire pressure gauge

4. Fluid mesuring cup

Micrometer

6. Slide caliper

7. Cylinder gauge

8. Magnetic stand

Grease gun

10.

Yamalube 4-cycle oil

11.

Yamalube 2-cycle oil

12. Yamabond

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

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

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

a guide

general maintenance and lubrica-

tion intervals. You must take into consideration

~hat

weather, terrain, geographical location, and

a variety

individual uses. This time schedule should be altered

match individual owner's re-

quirements.

For

example, if the machine

continually operated

area

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 Year

Cylinder head/Exhaust

system/

Decarbonize 0 0 0

Spark arrester

Spark plug Inspect/Cleaning

replace

required 0 0 0 0

Air

filter

Wet

type-

Must be washed and damped

with

0 0 0

Yamalube 2-cycle

Oil

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

required-Repair

required 0 0 0 3

Months

Drive chain Check/Adjust

required/Replace

required 0 0 0 1

Month

Steering bearings Check/Adjust

required/Replace

required 0 0

'Wheels

and tires Chack pressure/Wear/Balance/

Run

out

0 0 0 0

Fuel cock Clean/Flush tank

required 0 0 0 0

"Lights

Check operation/Replace

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

Year

"Transmission oil Replace/Warm engine Yamalube 4-cycle oir

SAE 0 Check 0 0

before draining 1

OW30

type

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

0 0 1

specifications SAE 10W30type

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

...

grease

" Indicatespre-operation checkItems.

2-2

ENGINE

Spark

plug

Check electrode condition and wear, in-

sulator color, and electrode gap.

Clean the spark plug

with

spark plug

cleaner

necessary.

Use

a wire gauge

adjust the plug gap

the specifica-

tion.

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

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

necessary.

Over

flow

chamber

If gasoline begin

show

up in the pipe

loosen the three screws from over

flow

chamber and completely drain gasoline from

the pipe

and chamber.

Idle

speed

Turn the pilot air screw until

lightly

seats, then back

out

specification.

This adjustment can be made

with

engine stopped.

2-3

Air screw (Turns out): 1and

1/4

Startthe engine and let

warm up.

Throttle stop screw

Turn throttle stop screw in or

out

achieve smooth engine operation at

specified idle speed.

Idling speed: 1,600 ±

r/min

NOTE:

______________________

The pilot air and throttle stop screws

are

separate adjustments

but

they must be ad-

justed at the same time

achieve optimum

operating condition at engine idle speeds.

Throttle stop screw

Pilot air screw

Throttle

cable

Loosen cable adjuster lock

nut

(at

top

car-

buretor) and turn cable adjuster until

specified free play is obtained. Retighten lock

nut.

Free

play: 1

-1.5

(0.04 -0.06 in)

Adjuster

Lock

nut

Ce manuel convient aux modèles suivants

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