1981 Ex440d Supplementary Service Manual

• YAMAHA
SNOWMORlll
SUPPlEMENTARY
SERVICE
UAl
Frame serial number: 8J7-036101 ~ 8J7-049999
[ Engine serial number : S5433-036101 ~ SS433-049999
LIT-12618-00-26
J
8J7-28197-10
1980 EX440C
CONTENTS
1. NEW SERV ICE PROCEDURE .... .. .. .. .... .. .. .... .. .. ........ .... .... .. .... .. .. ...... .... .. ..... 2
2. MAINTENANCE INTERVALS ...... .. .. ........ .......... ...... .... ...... .. ........ .. .. .......... . 3
3. SPECIFICATIONS ............ .............. .. ............ .. ...... ...................... .. ................. 5
4. SPEC IAL TOOLS ............ .. ...... .. .. .. ........ .... .. .... .. .. .. ...... .. .... ........................ .. ... 11
5. WIRING DIAGRAM .................... ............................ ...... .. .......... .. ................ .. 12
6. WIRE AND PIPE ROUTING DIAGRAM ...... .. .. .......................................... 13
(
)
- 1-
1980 EX440D
1. NEW SERVICE PROCEDURE
(New service procedure applied to the 1980
EX440D)
7. Chec k the marks on flywhee l and pu lser
for ali gnment.
A. Ignition timing
1. Remove t he reco il starter assembly.
2. Remove the right side spark plug and
screw dia l gauge stand into spark plu g
ho le.
Too l name
Dial gauge stand
(
)
Tool No.
90890-0 1195
2 . In sert dia l gage w ith needle into stand .
Tool name
Too l No.
Dial gauge
90890-01252
Dial gauge needle
90890-03098
If not al igned, adjust ignition t iming as
follows:
a. Loosen the pulser set screws and turn
the pu lser unti l mark alignment is
achieved.
4 . Rotate magneto f lywheel unti l piston is
at top -dead-center (T.D.C.)
Set the zero on dial gauge face to line
up exactly with a dial gauge needle .
Tighten set screw on dial gauge stand
to secure dial gauge assembly . Rotate
flywhee l back and forth to be sure that
indicator need le does not go past zero.
5 . Starting at T.D.C ., rotate flywhee l
counterclockwise until dial gauge
reads approx imate ly 3-1 / 2 need le re volutions
before-top - dead -cente r
(B .T.D .C.) .
6 . Slowly turn flywheel clockwise until
dial gauge reads specified ign iti on t im-
\
...&.
\
~,
NOTE: ------------------------If the marks can not be aligned by this ad justment. remove the flywheel roto r and
turn the base (stator) assemb ly.
ing.
Ign ition timing (B.T.D .C.)
1.6 ± 0 .1 mm (0.060 ± 0.004 in)
- 2-
l )
1980 EX440D
NOTE: -------------------------
b. Tig hten the pulse r set screws.
The tim ing light shou ld be used to check if
the marks on the rotor and base are aligned
when both are rep laced with new ones . The
marks shou ld a li gn at any specified timing .
Remove the dial gauge and stand. Replace the spark plu g and recoil starter.
8.
Tightening torq ue
Spark plug : 2.8 m-kg (20 ft- Ib)
Sta rter assemb ly : 0.7 m- kg (5 ft-Ib)
2. MAINTENANCE INTERVAL
[PERIODIC MAINTENANCE]
(
Every
Check point
2 0 hrs. or
400 km
(250 mil
40 hrs. or
800 km
(500mi)
80 hrs. or
1.600 km
(1.000mi)
When
necessary
Seasona lly
ENGINE:
Tightness of bolts and nuts
0
0
8ends. cracks and wear
0
0
Abnorma l no ise
0
0
Loose connection and breaks of fuel and pulse pipes
0
0
Loose con nection and breaks of oil pipes
0
0
Loose connection and breaks of oil delivery pipe
0
0
0
Manua l rope starter syst em
0
Carbu retor
•
Operation of starter jet
•
Idli ng speed adjust me nt
•
0
0
0
Mixing adjuster (pilot sc rew)
0
0
Operation and adjustment of oi l pump
0
a
0
0
M uffler joints
0
0
0
Ign ition ti ming
Cylinder comp ressions
0
0
Cylinde r head/ exhaust pipe decarbonize
0
Spark plug cond ition. gap and cleaning
0
0
Tig htening of the cy linde r head"
DR IVE:
Tightness of bolts and nuts
0
Wea r on slide runners
0
0
0
0
Primary drive system
0
0
V-be lt
0
Secondary drive system
0
0
Sheave distance
0
0
Sheave offset
0
0
Brake pad wear
0
0
Brake ope rat ion and ad justment
0
0
Guide whee l rubber
0
0
Wea r of drive track w hee l sprocket
0
0
Drive track ad justmen t
0
0
Breaks in drive track
0
0
Be nds in fro nt and rear axles
0
0
Checking of lock washe rs
0
0
Drive cha in adjustment
0
0
Drive chain oil level
0
0
-3-
1980 EX440D
Every
20 hrs. or
400 km
(250 mil
Check point
40 hrs. or
800 km
(500mi)
80 hrs. or
1.600 km
(1.000mi)
When
necessary
Seasonally
BODY :
Tightness of bolts and nuts
0
0
Bends and cracks
0
0
Welded riveted. joints
0
0
Ski adjustment
Ski runner wear
0
0
0
0
0
0
Breaks in fue l tank
Cleaning of fuel tank
0
Fuel filter
0
Loose con nection and breaks in fuel pipe
0
0
Breaks in oi l tank
0
0
(
0
Oil filter
ELECTRICAL:
0
Wear. breakage of wire covering
0
0
Breaks in high-tension cord
0
0
Voltage regulator working voltage
**
Operation of engine stop switch
0
Operation of tether switch
0
0
0
Headlight
0
0
Taillight
0
0
Brake light
0
0
Retighten every 10 hours from the first use.
[LUBRICATION INTERVALS]
Every
Lubricat ion point
20 hrs. or
400 km
(250 mil
40 hrs. or
800 km
(500mi)
80 hrs. or
1.600 km
(1.000m i)
When
necessary
Oil/Grease
Brand name
Seasonally
ENGINE :
Starter case
0
Oi l pump control box
0
Pump drive cove r
0
Oi l in the oil tank
0
Aeroshell grease #7 A or
Esso Beacon 325 grease
0
YAMALUBE 2-cycle oil
0
DRIVE:
Primary sheave weight
and roller pins
0
0
Secondary shaft and
sliding sheave
0
0
Front axle housing
0
Shaft 1 and shaft 2
(S li de rail)
Molybdenum disulfide
snowmobile grease
0
0
O·
Light all-purpose grease
0
0
Gear oil API " GL-3"
SAE #75 or #80
Steering column lower
bearing
0
0
Light all-purpose grease
Steering colum n upper
bearing
0
0
Motor oil
Steering links
0
0
Ski co lumn
0
0
Ski wear plate
0
0
Ski retaini ng pin
0
0
Brake wire and stopper
and brake lever
0
0
Drive chain oil
replacement
BODY:
-4-
Light all-purpose grease
Esso Beacon 325 grease
l
1980 EX440D
3. SPECIFICATIONS
(
NOTE:
* "". New specification
(Compared with 1979 EX440C)
General
Model:
Mode l (I.B.M. No.)
Frame 1.0. & starting number
Eng ine 1.0. & starting number
*
*
*
Dimension:
Overa ll length
Overall width (std)
Overall height (w/ w indsh ield)
2 ,520 'mm (99.2 in)
980 mm (38.6 in)
995 mm (39.2 in)
EX440D (8J7)
8J7-036101
SS433-036101
Engine
Desc ription:
Eng ine type
Fan coo led two-stroke 7 -port torque
induction, twin cylinders
SS433
433 cc (26.42 cu.in)
68 X 59 .6 mm (2.68 X 2.35 in)
7.0: 1
Recoi l hand starter
C.D.I.
"Auto lu be" oi l injection
Eng ine model
Displacement
Bore X Stroke
Effective compress ion ratio
Starti ng system
Ignition system
Lubrication system
Cylinder head:
Combustion chamber volume (with spark plug)
Compression chamber type
Head gasket thickness
24.6 cc (1 .50 cu .in)
Dome + Squ ish
0.5 mm (0.02 in)
Cylinder:
Material
Bore size
Taper lim it
Out of rou nd limit
Cast iron sleeves aluminum
68 mm (2.677 in)
0.05 mm (0.0020 in)
0.01 mm (0.0004 in)
Piston:
Piston skirt clearance (Measuring point)
l
Piston oversize
Piston pin outside diameter
X length
0.045 ~ 0.050 mm (0.00 18 ~ 0 .0020 in)
(20 mm from piston skirt end)
1st 68.25 mm (2.687 in)
2nd 68.50 mm (2.697 in)
3rd 68.75 mm (2.707 in)
4th 69.00 mm (2 .717 in)
r/l18 X 55 mm (r/l0 .709 X 2.17 in)
Piston ring:
Piston ring design (Top)
(2nd)
Ring end gap (insta ll ed) (Top)
(installed) (2nd)
Keystone
Keystone
0.35 ~ 0.55 mm (0.0 14 ~ 0.022 in)
0 .35 ~ 0.55 mm (0.014 ~ 0.022 in)
Smal l end bearing:
Type
Needle bearing
Big end bearing:
Type
Needle bearing
Cra nkshaft:
Crankshaft assembly width (A)
174 ± 0.1 mm (6.85
(F)
Crankshaft deflection (D)
± 0.004 in)
+0
+0
56 -0,05 mm (2.205 -0.002
0.03 mm (0-1) 0 .04 mm (0-2)
0 .04 mm (0-3) 0.05 mm (0-4)
-5-
in)
1980 EX440D
0.25 ~ 0.75 mm (0.010 '" 0.030 in)
2 .0 mm (0.079 in)
Connecting rod large end side clearance (C)
Connecting rod smal l end deflection (P)
--H--
p
Q
D-l
CI
D-4
K~A~~
Crank pin outside dia meter X length
Crank pin type
Crank bearing type (Left) X q'ty
(Center) X q'ty
(Right) X q'ty
Crank oi l seal t ype (Left) X q'ty
(Center) X q'ty
(Right) X q'ty
I
24 X 55 mm (0.94 5 X 2 .165 in)
Solid shaft assembly type w it h serration
#6306 special X 2 pcs.
#6206 special X 2 pcs.
#6206 specia l X 1 pc.
FWJ-32 78 9.5 X 1 pc .
Labyrinth sea l X 1 pc .
FWJ-32 48 10 X 1 pc .
Carburetor :
Type & manufa cturer/ quant ity
I.D . Mark
(M .J .)
Main jet
(MAJ.)
Main air jet
(Pw.J.)
Power jet
(PwAJ.)
Power air jet
(S.J.)
Slow jet
(SAJ .)
Slow air jet
(P.S.)
Pi lot screw
(StJ.)
Starter jet
BD44 X 38 KEIHIN
8H600
#1 45
# 180
#150
#200
#90
#100
1-5/8
#160
X 1 pc.
15 +2 mm (0.59 + 0.08 in)
- 0 .12
-3
1,500 r/min
Float height
Idling engine speed
Main jet setti ng chart :
~
Altitude
- 30 °C
1- 22 ° FI
- lO OC
114 ° FI
- 20 °C
1- 4 ° FI
O° C
132 ° FI
10' C
150 ° FI
# 140
Sea level
# 145
- 600m 12000 ttl
- 1200m 14000 ttl
- 1800m 16000 tt l
- 2400m 18000 ttl
.
#140
·
·
#135
·
#1 45
#130
# 140
.
# 135
#130
.
# 125·
# 120·
- 3000m 110000 tt l or more
# 125·
• Change the starter jet to #95 or # 100.
- 6-
20 ° C
168 ° FI
1980 EX440D
(
Intake reed va lve:
Type
Bending lim it
Valve lift
Tightening torque
V type
0.3 mm (0.012 in)
10.4 mm (0.409 in)
8.0 cm -kg (6.9 in-Ib)
lubrication:
Autol ube pump - Color code
- M inimum stroke
- Maximum stroke
- Reduction ratio
- Out put M in./200 strokes
- Output Max./200 strokes
Autolube pump wire free play
Oi l tank capacity
Oil grade
Da rk blue
0.20 ~ 0 .25 mm (0.0079 ~ 0.0098 in)
1.65 ~ 1.87 mm (0.0650 ~ 0.0736 in)
1/44
0.95 ~ 1.19 cc (0.032 1 ,....., 0 .0402 oz)
7.84 ,....., 8.89 cc (0.2651 ,....., 0 .3006 oz)
25 ± 1 mm (0 .98 ± 0.04 in) at idle
2 .8 Liter (3 US.qt)
YAMAlUBE 2 -cycle
Drive and track suspension
(
Transmission:
Type
Dri ve ratio
Engagement rpm
Primary spring:
Part No.
Color code
Secondary spring:
Pa rt No.
Color code
Secondary spring pre- load (tw ist)
V-belt automatic centrifugal engagement
3 .5 : 1 ,....., 1 : 1
2.900 ~ 3 .300 r/min
9050 1-45534
Blue/Green
90508-45286
Yellow
150 ° (Hole No. 1)
:g.12 in)
Sheave distance
270 : ~ mm (10.6
Sheave off-set
V-belt w idt h and outer line length
V-belt wea r limit
5.5 ± 0 .5 mm (0.22 ± 0.02 in)
31.6 x 1.099 mm (1.24 x 43 .3 in)
26 mm (1.02 in)
Track suspe nsion :
Type
Damper type
Spring color code
Sl ide run ner wea r limit
Track w idth
Track deflection
l negth on ground
W heel sprocket mate ri al and number of teeth
Stopper band length
Slide rail suspe nsion
Oil and gas damper
No. painted
10 mm (0.4 in)
380 mm (15 in)
25 ~ 30 mm/1 0 kg (0 .984 ~ 1.18 in/22 Ib)
850 mm (33 .5 in)
Polyethylene 8T
2 14 mm (8.4 in) (3rd hole from the bottom)
Secondary drive:
Type
Reduction ratio
Chai n pitch X Number of links
Chain (#35-3)
29/ 17 (1 .706)
9.525 mm (0 .375 in)
X 68l
Free play
2
10 -+ 25 mm (0 .4 -+ 0.
0 .08
Chain housing oil quantity
Cha in housing oil grade
320 cc (10.82 oz)
Gear oi l AP I "Gl3" (SAE #75 or 80)
Brake :
Type
Brake pad th ickness
Bra ke pad wear lim it
Gap between pad and disc
.)
In
Floating pad type disc brake
13 .5 mm (0.53 in )
9.5 mm (0.37 in)
0.15 mm (0.006 in)
- 7-
1980 EX440D
Chassis
Frame:
Frame design & materia l
Steering system:
Caster (ski column)
Camber
Ski length X w idth X thickness
Ski sta nce
Ski Toe-ou t
Steering linkage type
Lock to lock ang le (ski)
Lock to lock angle (steering column)
+
Alum inum
Stee l
25 °
0°
980 X 140 X 2.6 mm (38.6 X 5.5
800 mm (31.5 in)
O~ 6 mm (O~ 0.23 in )
Tie-rod
Right ski, L: 20.2 °
R: 27.6 °
R:20.2 °
Left ski. L: 27.6 °
Right: 46.5 °
Left: 46.5 °
Front suspension:
Type
damper type
Leaf spring
Oil damper
Fue l tank:
Capac ity
Fue l grade
30 Liter (9.0 US.gal)
Regular gasoline
X 0.10 in)
(
(
Electrical
Ignition system:
Type - flywhee l magneto (C .D.I. Type)
Model/man ufacturer
Voltage
Pulse r co il res istance
Charg in g coi l resistance
Ignit ion timi ng:
B.T.D.C.
Ignition:
Model/Manufacturer
Spa rk gap
Primary winding resistance
Secondary winding resistance
Diode (Yes or No)
Spark plug:
Type & Quantity
Spa rk plug gap
...
F280-78/HITACHI
12V
... 780 at 20 ° C (68 ° F) (Wh ite/Red - Black)
... 1130 at 20 ° C (68 ° F) (Brown - Black)
... 290 at 20 ° C (68 ° F) (Blue - Black)
1.6
± 0.1
mm (0 .060
± 0.004 in)
CM62-20/H ITACH I
9 mm (0.35 in)/300 r/min
11 mm (0.43 in)/3,000 r/ min
0.150 at 20 ° C (68 °F)
3.6kO at 20 ° C (68 ° F)
No
... NGK B-9ES X 2 pcs.
... 0.7
~
0.8 mm (0.028
~
0.031 in)
Spark plug cap:
Type
Noise suppressor resistance
Rubber type w ith noise suppressor
5kO at 20 ° C (68 ° F)
C.D .I. un it:
Model/Man ufactu rer
... TIA01-30/HITACH I
Lighti ng system:
Lighting output
Lighting coil resistance
Head lig ht type
Bulb wattage/q'ty
Ta il/brake light wattage
Meter light wattage
12V/100W
... 0.220 at 20 ° C (68 °F) (Yellow Sem i shie ld
1 2V 60/60W X 1 pc.
12V 8W/23W
12V 3 .4W
-8-
Black)
1980 EX440D
A.C. regulator:
Model/M anufacturer
Voltage
TR IZ-24B/ HITACH I or S8516B/ TOSH IBA
13.8 ± 0.5V
Tightening Torque
Part to be tightened
Thread size
Eng in e:
Spark plug
Cylinder head
Cylinder head
Flywheel magneto
Crankcase upper and lower
M14
M8
M8
M16
M8
Tightening torque
P1.25
P1.25
P1.25
P1.0
P1.25
Tighten ing sequence
2.8 m-kg (20 ft-Ib)
2.5 m-kg (18 ft- Ib)
2.5 m-kg (18 ft- Ib)
7.3 m-kg (53 ft- Ib)
First: 1.0 m-kg (7.5 ft-Ib )
Final: 2.0 m-kg (15 ft-Ib)
Remarks
Special nut-Stud bolt
Nut-Stud bo lt
,.....
W~
7 6
(
-
0
0
2
3
0"6
14 10
t--- . - - - - - -
8 5
00
11
0
Starter pulley
Crankcase and engine b racket
Cy li nder and exhaust pipe
Dri ve and track suspension:
Primary sli ding sheave and cap
Insta llation of primary sheave
Installation of secondary sheave
Bearing housing
Secondary shaft and Bearing collar
Brake cal iper and Housing chai n
Installation of drive chain sprocket
Installation of driven chain sp rocket
Chain housing and Frame
Instal lation of front ax le L.H.
Front axle housing and Frame
Shaft 1 and Frame
Shaft 2 and Rear bracket
Rear bracket and Frame
Installation of suspension wheel
Insta llation of rear gu ide wheel
Insta llation of runner sl iding 1
Installation of runner sliding 2
Pivot arm and Frame sl iding 1
Bracket 5 & 6 and Frame sliding 1
Frame sl iding 1 and 2 & 3
Installation of stopper 1
1
4
°
0
°
a/'
9
13
"-
M8 P1.25
M10 P1.25
M8 P1.25
1.1 m-kg (8 ft-Ib)
4.0 m-kg (29 ft-Ib)
2.0 m-kg (15 ft-Ib)
M6 P1.0
UNF 1/ 2"
1.1 m-kg (8 ft- Ib)
Initia l:
12 m-kg (87 ft -Ib)
Loosen once and
retighten:
6.0 m-kg (43.5 ft-Ib)
5.0 m-kg (36 ft-Ib)
6.5 m-kg (47 ft-Ib)
0.6 m-kg (4 ft- Ib)
5.0 m-kg (36 ft- Ib)
6.0 m-kg (43.5 ft- Ib)
5.0 m-kg (36 ft- Ib)
2.5 m-kg (18 ft-Ib)
8 .5 m-kg (6 1.5 ft-Ib)
2.5 m-kg (18 ft-Ib)
6.5 m-kg (47 ft-Ib)
6.5 m-kg (47 ft-Ib)
3.0 m-kg (21.5 ft- Ib)
1.0 m-kg (7 ft-Ib)
2.5 m-kg (18 ft-Ib)
0.3 m-kg (2 ft-Ib)
1.0 m-kg (7 ft- Ib)
1.3 m-kg (10 ft-Ib)
1.3 m-kg (10 ft-Ib)
2.5 m-kg (18 ft- Ib)
0.4 m-kg (3 ft- Ib)
M10 P1.25
M10 P1.25
Socket screw
M10 P1.25
M14 P1.5
M10 P1.25
M8 P1.25
M22 P1.0
M8 P1.25
M10 P1.25
M10 P1.25
M8 P1.25
M6 P1.0
M8 P1.25
M6 P1.0
M6 P1.0
M6 P1.0
M6 P1.0
M8 P1.25
M6 P1.0
-9-
Specia l nut-Stud bo lt
Use motor oil
Nut
Bolt
Use LOCK-TI TE
Use LOCK-TITE
Use LOCK-TITE
Use
Use
Use
Use
Use
LOCK-TITE
LOCK-TITE
LOCK-TITE
LOCK-TITE
LOCK-T ITE
1980 EX440D
Part to be tightened
Chass is:
Eng ine mounting bolt
Ski runner
Th read size
Tighte ning torque
M10 P1.25
MB P1.25
3.B m-kg (27 .5 ft-Ib)
1.45 m-kg( 10 ft-Ib)
Steering colum n and Gate
Steering relay rod adjusting nut
Outside arm and Ski co lumn
M6 P1.0
M10 P1.25
M10 P1.25
0.9 m-kg (6 .5 ft-Ib)
2.5 m-kg (1B ft-Ib)
4.0 m-kg (29 ft- Ib)
Stee ring lower bracket
MB
P1 .25
1.5 m- kg (11 ft- Ib)
Installation of steering column 1. 2
Steering relay ass 'y
Level gauge securing bolt
Screw to install the front of seat
Nut to install the rear of seat
Brake level holder
Throttle lever
M6
M10
M6
M6
MB
M5
M6
P1.0
P1.25
P1.0
P1.0
P1.25
PO .S
P1.0
0.9 m-kg (6.5 ft-Ib)
3 .0 m-kg (22 ft-Ib)
0.25 m-kg( 1 .B ft- Ib)
0.5 m-kg (3 .5 ft- Ib)
0.9 m-kg (6.5 ft -Ib)
0.4 m-kg (3.0 ft-I b)
0.35 m-kg(2.5 ft-Ib)
- 10-
Remarks
Nylon nut
Use plain washer and
LOCK-TITE
Use lock washer and
wave washer
Use lock washer and
LOCK-TITE
Use lock washer
Use cotter pin
1980 EX440[
4. SPECIAL TOOLS
\
1.
4·c.
7.
2.
4·d.
8.
13.
)
\
3.
')
..
4·a.
~_3
~
6.
11.
I
["
(
A
No.
Description
Tool No.
1
Dial gauge
90890-03097
2
Dial gauge stand No.2
90890-01195
3
Dial gauge needle (56 mm)
90890-03098
4-a
Flywheel puller bo lt
90890-01803
4-b
Flywheel puller attachment
90890-0 1804
4-c
Flywhee l puller screw
90890-01806
4-d
Drive hand le
90890-0 1817
4-e
Flywheel puller body
90890-01848
5
Rotor ho lding tool
90890-01235
6
Primary fixed sheave puller
90890-01859
7
Sheave sub-assembly tool
90890-0 1858
8
Bushing tool
90890-0 1877
9
Sheave gauge
90890-01875
10
Eccentric bearing installer
90890-0185 1
11
Ma in switch ring nut tool
90890-01857
12
Pocket tester
90890-03104
13
Electro tester
90890-03021
14
A.C. Regulator checker
90890-03090
- 11 -
-0·.
co
CO
o
m
X
~
~
Speedometer light
(12V 3.4W)
Tachometer light
(12V3.4W)
~
mJ
C1I
~
-2::xJ
8
Head light (12V 60W/60W)
G)
-l>C
~ll
G)
::xJ
l>
S
Engine stop switc h
G:
I
I I I I I I II
Tit
I
0'"
~
N
I
Spark plug
Tether switch
81 qGl'1118t.v
~IRUNIOFF
Gy
Gy
~
I I 16~
0
0
Loo l
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~
8
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L
~
_8--+-1_
GI y
, oW
8I
..I~~~'U
G/Y
Main switch
R
LI 8d
IW/R Iy
.::::::::::::::::~-
<:>
Headlight beam switch
~\~
C.D.I. unit
G/'f
o
y
<>
<>
<>
Ignition coil
'"
o
-L
1
C.D.I. magneto
Brake light switch
~
Color code
G .. ........ .... Green
B ................ Black
Y ............ .... Yeliow
L ..... ....... .... Blue
o ................ Orange
~
G;
Br . ... .......... Brown
Gy .............. Gray
Voltage
regulator
W/ R .. .. .....White/ Red
G/ Y ........... Green/ Yellow
T
B/ W .......... Black!White
-
.-
-
~
o
o
6. WIRE AND PIPE ROUTING DIAGRAM
1. Main switch
2. Tether switch
3. Wire harness 2
4. Fuel tank breather pipe
5. Fuel pipe
6. Clip
7. Hose
8 . C.D. I. unit
9 . W ire harness 1
@
10. To taillight
11. Starter w ire
12. Fuel level pipe
13. Oil level pipe
14. Oil ta nk breather pipe
15. Voltage reg ulator
16. Speedometer cable
17. Tachometer cable
18. Oil pipe
19. To carburetor
20. To engine cra nkcase
21 . To oil pump
22. To tac hometer gear unit
23. To carburetor
24. Clamp
25. Clamp
26. Head light lead wire
27. Speedometer cable (G ray)
28. Tachometer cable (Black)
29. Spring
30. Shro ud stopper
31 . Sta rter w ire
r------@
32. Brake wire
33. Throttle wire
34. Pump wire
35. Clamp
36. To tachometer gear unit
37. To speedometer
38. To tachometer
}--{~~u
I \V ++ \
~
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1/\ \
8
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Tank
NOTE~
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//
~
Tip of clip should be
positioned on the opposite
side of the tank .
@--------~
@
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r
r r
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rr
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r r
II
@
@
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........
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"
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Bumper
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II
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