Yamaha Jt1 series User manual

JT1-JT2

SERIES

ASSEMBLY

MANUAL

LIT

11662

-

88

-

72

Introduction

The

individu

I

who

pr

p r s Y m h

motorcycl

for d liv ry ha

th

responsibility

of

b irn. n

import

nt

link

b

tw,

,n

th

factory

nd

th

custom

r.

Th

tI f

t1on

that

th

cu tornr:ir

will

r c

iv

from

hi

Yamaha

.

both

1n1ti

II

nd ov r

th

l1f

of

th"

rn

chin

, is v ry

much

dep

nd

nt

on

th

c r

with

which

th

s t-up

proc

~ctur

i p rforrn d.

As

the

on

doing

the

work

. you hould b

owur

of

this r

sponsibility

.

Th

degr

of

car

that

you

t,1k

in

doing

th

\

job

will

rcfl

ct

on you.

the

deal

r.

and

th

factory

A properly s t up

Yamaha

will

give

many

miles

of

satisfaction

to

th

owner

and

1s

important

to

future

sales and

service

business On the

other

hand. a

poorly

prepared

machine

is sure

to

result

in

a dissat1sf1ed

customer

and possibly extra

work

due

to

the

need

for

subsequent

re

doing

of

portions

of

the

Job

Follow

the

procedures

in

this

manual

rn

the

order

in

which

they

are

presented

Don

't

skip around and

perform

them

out

of

sequence, and

don't

omit

any

of

them

. They are all essential

to

a

well

done

Job

Remember

,

this

initial

set

up

Is

the

most

important

servicing

the

motorcycle

will

ever

receive.

Service Department

Yamaha International Corporation

Buena

Park,

California 90620

JT

1/ JT2

SERI

ES

ASSEMBLY

MANUAL

1st

Printing

July,

1972

Copyright

©

1972

Yamaha

International

Corp.

All

Rights

Reserved

Yamoho

Int'

I.

Corp.,

Buena

Pork,

Calif.

JTt

/

JT2

SRS

ASSY

MNL

P N

LIT

11662-88-72

Table

of

Contents

Section

I -

Unpacking

The

Motorcycle

Page

A.

Opening

the

Carton

................................

.

B.

Checking

for

Damage

and

Shortages

.................

.

Section

II -

Assembling

The

Motorcycle

1

2

A.

Installing

the

Handlebars

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

B.

Installing

the

Front

Fender . . . . . . . . . . . . . . . . . . . . . . . . . . 4

C.

Installing

the

Front

Wheel

. . . . . . . . . . . . . . . . . . . . . . . . . . . 5

D.

Installing

the

Footrests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

E.

Installing

the

Transmission

Change Pedal . . . . . . . . . . . . . . 7

F.

Attaching

the

Brake Cable

to

the

Front Brake . . . . . . . . . . 8

G.

Secur

i

ng

Clutch

and

Brake

Cables

to

the

Levers . . . . . . . . 8

H.

Installing

the

Rear Brake Rod . . . . . . . . . . . . . . . . . . . . . . . . . 9

I.

Installing

the

Tail

Light

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

J .

Connecting

Wiring

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

K.

Connecting

the

Throttle

Control

. . . . . . . . . . . . . . . . . . . . . . .

12

Section

111

-

Adjusting

Components

A.

Adjusting

the

Front Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

B.

Adjusting

the

Clutch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

C.

Adjusting

the

Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

D.

Adjusting

the

Rear Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

E.

Bleeding

the

Autolube

Pump

......

...

....

...

.

.....

....

16

F.

Checking

Autolube

Pump

Minimum

Stroke . . . . . . . . . . . . . .

18

G.

Adjusting

the

Carburetor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

H.

Checking

Ignition

Timing

......

.....

..

...

............

.

19

Section

IV

-

Making

Preliminary

Checks

A. Filling Fuel

Tank

....

..

...

.

..

........

.

.....

.

.......

22

B.

Checking

Transmission

Oil Level

....

...

.

...

....

.. ..

23

C.

Checking

for

Loose

Nuts

and

Bolts

..

...........

.

.......

23

D.

Checking

Tire

Pressure

...

. .

...

....

.........

. .

...

• .

24

Section

V -

Making

Running Checks

A.

Start

i

ng

the

Engine

.. ..

....

• • • • • • • • · · · · · · · · · · · · · · · · · ·

25

B.

Checking

the

Transmission

Oil . . . . . . . . . . . . . . . . . . . . . . . .

25

c.

Adjusting

Carburetor

and

Autolube

Cable

....

...

.

..

....

26

D.

Checking

Lights

.......

......

· . · · · · · · · · · · · · · · · · · · · · · ·

27

E. Road

Testing

.............

. . • • • • •• • • • •• • • •• • •· • • • · • · ·

28

Section

VI

-

JT2

Supplement

A.

Miscellaneous

Section

VII

-Service Data

Page

. . . . .

31

A.

Torque Specificotions . . . . . . . . . . . . . . . . . . . . . . . . .

36

Section I - Unpacking

the

Motorcycle

A. Opening

the

Carton

1. Using scissors

or

a pen-

knife.

cut

the

tape

from

around

the

carton.

Caution

Don't

cut

too

deeply

when

removing

the

masking

tape. You

might

damage

components

directly

be-

neath

the

tape

.

COMPONENT

TRAY

MASKING

TAPE

FIBER

TAPE

2. Open

the

flaps

of

the

car-

ton

and I

ift

out

the

tray

of

components

.

Set

the

tray

·

aside.

Caution

Don't

try

to

lift

the

tray

by

the

wooden

frame

around

it. Lift

the

tray

itself.

1

3.

Lift

the

sides

of

the

carton

straight

up

.

exposing

the

motorcycles

B.

Checking

for

Damage

and

Shortages

1.

If

shipping

damage

has

occurred

, record

the

num-

bers

of

the

engine

.

frame

,

crate

, and

damaged

part

.

2.

Shipping

damage

should

be

corrected

by

the

dealer

. Replace

parts

that

are

missing

or

dam-

aged

in

shipment

from

your

parts

stock,

or

order

them

from

the

Yahama

Parts

Department

.

Sub-

mit

a

Standard

Warranty

Claim

Form

and

the

ship-

per

's

damage

inspection

report

to

the

Warranty

Department

of

Yahama

International

Corporation

for

credit

. Mark

the

form

"DAMAGED

IN

SHIP-

MENT"

.

2

Section

11

-Assembling

the

Motorcycle

Note

The

following

proce-

dures

apply

to

either

of

the

two

motorcycles

in

the

carton

.

A.

Installing

the

Handlebars

1. L

ift

the

front

wheel

out

of

the

carton

and

set

it

aside.

2. Using a

10

mm

wrench

.

remove

the

four

bolts

that

secure the

two

handlebar

retaining

clamps

. Re-

move the

clamps

.

3.

Remove

the

handlebars

from the

tray

and

ins

taII

them on the handle crown.

Secure the

retaining

clamps

(handle holders)

with

the

bolts

(4)

and

lock

washers

(4)

provided.

Tighten

grad-

ually

and

in

pattern, ,

until

secure.

RETAINING

CLAMP

3

8 .

Installing

the

Front

Fender

4

Untie the rope

that

se

-

cures the front fender

to

the rear wheel. Remove

the fender and unwrap

the paper

that

covers it.

FRO

NT FE

ND

ER

2. Remove

the

two

nails

holding the plastic

block

that

secures

the

front

of

the

motorcycle

to

the

wooden

frame

.

3. Lift

the

motorcycle from

the

wooden

frame

. This

is a

job

for

two

men.

Place a

support

under

the

engine

to

hold

the

motorcycle

upright

.

4. Using a

10

mm

wrench

.

remove

the

three

front

fender

mounting

bolts

and washers

from

the

frame..

5. Position

the

front

fender

on

the

yoke. Secure

it

with

the

three

mounting

bolts and washers.

BUSHING

~LOCK

AXLE

C. Installing

the

Front

Wheel

1. Using a

17

mm

wrench

.

remove

the

axle

from

the

front

fork

assembly. Dis-

card

the

plastic

block

.

Re

-

move

the

bushing

from

the

axle.

6

2. Remove

the

brake

assem-

'

bly

from

the

component

tray

.

Slide

it

into

the

front

wheel

hub

from

the

right

side

.

3.

Slide

the

bushing

in

the

left

side

of

the

wheel

hub

.

RIGHT

TUBE

6

BUSHING

LEFT

SIDE

4. Position

the

front

wheel

between

the

fork

tubes

.

Fit

the

locating

lug

on

the

right

tube

into

the

slot

in

the

hub.

5. Put a

light

coat

of

oil

or

light

grease

on

the

axle.

This

will

help

to

prevent

it

from

rusting.

6. Slide

the

axle in

from

the

left

side

through

the

left

tube. bushing,

wheel

, and

right

tube

.

Using

the

17

mm

wrench,

install

and

tighten

the

axle

nut

.

Proper

tightening

torque

is

: 25-30ft/lbs.

D.

Installing

the

Footrests

1. Remove

the

footrest

.

and

cotter

from

the

plastic

bag

in

the

compo

-

nent

tray

.

Note

The

following

steps

apply

to

either

footrest

.

2. Slide

the

footrest

into

the

frame

bracket

. Hold

the

footrest

vertical.

with

the

cover

tread

forward

.

3. Slide

the

(head

for

-

ward)

into

the

bracket and

footrest

. Slide

the

cotter

into

the

hole

and

bend

up

the

ends.

CHANGE

PEDAL

E.

Installing

the

Transmission

Change

Pedal

1.

Remove

the

change

pedal

from

the

component

tray

.

2.

Using

a

10

mm

wrench

.

remove

the

bolt

from

the

pedal

and

set

it aside.

3. Push

the

pedal

on

the

splined

stud

with

the

arm

facing

forward

.

Note

You

might

have

to

pry

the

pedal

jaws

apart

slightly

with

a

screwdriver

to

al-

low

it

to

slip

all

the

way

on

the

stud

.

4.

Install

and

tighten

the

bolt

.

7

F.

Attaching

the

Brake

Cable

to

the

Front

Brake

1.

Using

a

10

mm

wrench

.

turn

the

adjusting

nut

against

the

head

of

the

adjusting

bolt.

2.

Turn

the

adjusting

bolt

all

the

way

in.

3 Back

off

the

adjusting

bolt

enough

to

align

the

slots

in

the

bolt.

nut

and

mount

i

ng

lug

.

4. Pull

the

rubber

boot

away

from

the

fitting

at

the

end

of

the

cable

.

Insert

the

fi

tt

i

ng

i

nto

the

sl

ot

at

the

end

of

the

actuating

lever.

5 Pull

the

rubber

boot

agai

nst

the

actuat

i

ng

lever.

Insert

the

exposed

cable

i

nto

the

slot

in

the

adjust

-

i

ng

bolt

.

8

ADJUSTING

RUBBER

BOLT

BOOT

~

...........

,:

II

A

ENO

FITT~~G

'-..,._

ADJUSTING

,/,

~

---'

'--...,

NUT

:.

:J

~

1/

6. Back

off

on

the

bolt

to

lock

the

cable in

position

.

Turn

the

nut

down

against

the

lug.

7. Slide

the

boot

over

the

ex-

posed cable.

G. Securing Clutch

and Brake Cables.

to

the

Levers

,. Slip

the

head

of

the

clutch

cable end

fitting

into

the

crosswise

slot

in

the

lever

at

the

left

handgrip.

2. Pull

the

cable

collar

back

and

pull

the

cable around

through

the

long

slot

in

the

lever bracket. Release

the

collar

.

3. Secure

the

front

brake

cable

to

the

lever

at

the

right

handgrip

in

the

same

manner

.

H. Installing the

Rear

Brake

Rod

1. Remove

the

brake rod as-

sembly

,

return

spring,

large

washer

, and

cotter

from

the

component

tray

. The spring, washer,

and

cotter

are in

the

plastic

bag.

2.

Hook

the

elbow

of

the

re-

turn

spring

into

the

frame

hole

at

the

left

of

the

pivot

shaft

. Hook

the

stop

light

actuating

spring

to

the

rod assembly.

3. Put a

light

coat

of

grease

on

the

pivot

shaft

. Slide

the

rod assembly

on

the

shaft

.

4. Pull

the

right

side

of

the

return spring

down

and

slip

it

under

the

pedal

arm

.

5. Slide

the

washer

on

the

pi

vot

shaft

. Install

the

cot

-

te

r

through

the

hole

in

the

shaft

and bend

up

the

ends

.

6.

Remove

the

nut

and cl

ev

is

from

the

end

of

the

rod

assembly

.

7.

Insert

the

clevis

thru

the

ho

l

es

in

the

rear brake

actuating

lever

.

Insert

the

brake

rod

between

the

jaws

of

the

lever and

th

ru

the

hole

in

the

clevis

pin.

8.

Install

the

nut

on

the

end

of

the

rod.

9

I. Installing

the

Tail Light

1. Remove

the

seat

by

pull

-

ing

the

black

knob

under

the

right

rear

corner

of

the

seat

and

pulling

the

seat

straight

back

.

2

Remove

the

tail

light

as-

sembly

and

the

three

at

-

taching

bolts

.

lockwash

-

ers

. and

nuts

from

the

component

tray

. The

fasteners are in

the

plastic

bag

.

3. Feed

the

wires

of

the

ta,I li

ght

assembly

through

the

large

hole

at

the

rear

of

the

rear

fender

. Bring

them

out

the

hole

at

the

top

of

the

fender

.

4. Line

up

the

three

holes in

the

tail

light

bracket

with

the

three

holes

at

the

bot

-

tom

of

the

fender

. Install

the

three

bolts

.

5. Install

the

lockwashers

and

nuts

from

the

under

-

side

of

the

fender.

Using

a

10

mm

wrench

.

tighten

the

nuts

.

6.

Obtain

two

split

rubber

grommets

from

the

plastic

bag in

the

component

tray

.

Place one in each

of

the

two

large

fender

holes.

10

WIRES

7. Connect

the

tail

light

wires

to

those

at

the

front

of

the

rear

fender

(yellow

to

yellow

. blue

to

blue)

by

pushing

them

into

the

teminals

.

NOTE:

See

JT2

Supple-

ment for

ins

taIla

ti

on

in-

structions,

1972

toi

11

ights.

(P.

32)

J. Connecting Wiring

1.

Remove

the

Phillips-head

screw

at

the

left

side

of

the

headlight

housing

.

Carefully pull

out

the

head-

light

and

rim

.

2. There is a loose

grommet

inside the

headlight

hous-

ing. Install

this

grommet

in

the

hole in

the

left

side

of

the housing.

3. Insert

the

wire

pack

that

runs

from

the

left

hand

grip

through

the

hole in

the

housing.

4. Connect the

four

color-

coded wires

to

the

corres-

ponding

wires

from

the

headlight and brake

light

wire

bundles by pushing

them

into

the

terminals

.

5.

Align

the hole in

the

tab

on the rim

with

the

screw

hole in the

headlight

hous-

ing

and

insert

the

head-

light

and

rim

.

Install

the

headlight

and

rim

.

6.

Connect

the

blue/white

wire

from

the

engine

stop

switch

at

the

right

handgrip

to

the

black

wire

at

the

coil.

To

find

the

coil

wire.

trace

the

spark

plug

wire

up

under

the

fuel

tank

.

The

coil

wire

is

the

plug

wire

at

that

point

.

Note

Keep

this

connection

in

mind

.

It

will

be used

later

in

timing

the

en-

gine

.

11

NOTE

:

See

JT2L Supplement for

installation

instructions

-

ignition

switch

and speedometer.

Also

,

wiring

differences,

battery

charg-

ing

in

struct

ions.

K.

Connecting

the

Throttle

Control

1

Remove

the

two

Phillips-

head

screws

from

the

cap

the

right

handgrip

.

Lift

off

the

upper

cap.

2

Insert

the

end

of

the

throttle

cable

through

the

hole

in

the

upper

cap

.

3

Slip

the

fitting

at

the

end

of

the

cable

into

the

lower

groove

of

the

white

nylon

sleeve

on

the

handlebar.

Lock

it

in

place

by

pulling

the

cable

up

into

the

long

groove

.

4. Place

the

shoulder

of

the

nylon

sleeve

against

the

lower

surface

of

the

upper

cap

.

Secure

the

upper

and

lower

caps

together

with

the

two

Phillips-head

screws.

12

STOP

BUTTON

Note

Rotate

the

handgrip

as-

sembly

so

that

the

engine

stop

button

is

horizontal

before

tightening

the

·

screws

.

Section

111

-Adjusting

Components

A.

Adjusting

the

Front

Brake

1.

Lightly

squeeze

the

lever

at

the

right

handgrip

. The

lever

should

move

3/

18

to

5/,

6

inch

(5

to

8

mm)

before you feel resistance.

If

it

doesn

·t.

continue

with

step

2.

Using

a

10

mm

wrench

.

loosen

the

adjusting

nut

at

the

wheel.

Turn

the

adjusting

bolt

until

you

get

the

proper

free

play

at

the

lever

.

Note

Turning

the

bolt

out

de-

creases free

play

.

3.

Tighten

the

adjusting

nut

against

the

mounting

lug

.

3/16

..

TO

5/16

'

13

8 . Adjusting

the

Clutch

Lightly

squeeze

the

lever

at

the

left

ha

nd

g

rip

. The

lever

shoul

d m

ov

e

1/

,6

to

1·8

inch

(2

to 3 mm) be-

fore

you

feel resis

tan

ce.

If

It

doesn

't.

con

t

inue

wi

th

step

2.

2

Using

a 10

mm

wrench.

loosen

the

locknut

at

th

e

cable

f

itting

above

the

left

engin

e

co

ve

r.

T

urn

the l

ong

ad1usting

nu

t

un

til

you

ge

t

th

e

prop

er

free

play

at t he

lever

.

Note

Tu

rning

the

nut

up

de

-

cre

a

ses

fr

ee

play

.

3 T

igh

ten the lock nut

aga

ins

t

th

e ad

jus

ting

nu

t.

14

1/

16

TO

1/8

ADJUSTING

NUT

/

...

FWD

/(-

~

C. Adjusting

the

Chain

1.

Check

the

chain

for

prop

-

er

free

play

with

a

rider

in

position

.

Total

move-

ment

at

the

center

of

the

lower

section

of

the

chain

should

be

about

¾ i

nch

(20

mm)

.

If

it

is

not.

con

-

tinue

with

step

2.

Using

a

25

mm

socket

wrench

.

loosen

the

rear

wheel

nut

.

3.

Adjust

the

play

in

the

chain

by

turn

i

ng

the

ad-

justing

nut

on

each

side

of

the

whe

e

l.

Turn

both

nuts

the

s

ame

amount

.

Note

Turning

the

nuts

in

de

-

creases free

play

.

4.

Check

that

the

wheel

is

aligned

properly

by

mak

-

ing

sure

that

the

match

mark

on

the

chain

adjust

-

er

is

aligned

with

the

same

swing

arm

mark

on

each

side

of

the

wheel.

Ad

-

just

the

nuts

individually

if

necessary.

5.

When

chain

play

and

wheel

alignment

are

good

.

tighten

the

wheel

nut

.

6.

Check

the

rear

brake

ad-

justment

.

It

may

have

changed

due

to

the

chain

adj

ustment

.

15

D.

Adjusting

the

Rear

Brake

Check

the

free

play

of

th

e

rear

brake

pedal

by

de

-

pressing

1t

with

your

hand

.

It

should

move

about

1

inch

(25

mm)

before

you

feel

resistance

.

If

it

do

esn·t.

continue

with

step

2

Using

a 13

mm

wrench

.

turn

the

adJusting

nut

at

the

ac

tuating

lever

a

half

-

turn

at

a

time

until

you

get

the

proper

free

play

at

the

pedal

Holding

the

lever

forward

will

make

1t

easier

to

turn

the

nut

16

Note

Turning

the

nut

creases

free

play

\

in

de

-

J~

......

_--

~UT

E.

Bleeding

the

Autolube

Pump

1. Remove the Autolube tank

filler

plug.

2. Fill

the

Autolube

tank

with

YAMALUBE

. The

tank

holds 1.1 US

quarts

(1.

03

liters).

Note

In

temperatures

b

elo

w

25°F

.

thinner

oil

1s

re-

quired. Refer

to

SER-

VICE

NEWS

BULLETIN

#

157

.

3. Push in

the

filler

plug

and

install

the

seat

.

4. Pull

the

spring

and

lift

the

rubber

cover

from

around

the

cover

plate

. Remove

the

cover

plate

.

5.

Remove

the

bleeder

bolt

.

Place a

cloth

under

the

hole

to

absorb oil spillage.

6.

Rotate

the

starter

plate

with

your

thumb

in

the

direction

of

the

arrow

marked

on

the

plate

.

Cont

inue

until

no

air

bub

-

bles

come

out

with

the

oil.

Note

Bleedi

ng

can

be

done

more

rapid

ly

if

you

open

the

throttle

w

ith

the

hand

grip

while

rotating

the

plate

.

7.

When

bleeding

1s

com

-

plete

.

install

the

bleeder

bolt

.

17

F.

Checking

Autolube

Pump

Minimum

Stroke

Set

the

gap

between

the

adIustment

pulley

and the

ad1ustment

plate

as

wide

as

possible

Do

this

by

rotating

the

starter

plate

w i

th

your

thumb

in

the

di

-

rec

t

ion

of

the

arrow

.

2 Try

to

insert

a O

007

inch

(0

15

mm)

feeler

gage

in-

to

the

gap

.

If It

fi

ts

.

the

stroke

Is

sufficient.

3.

If

the

gage

cannot

enter

the

gap

.

remove

the

lock

nut

and

adIustment

plate

.

Install

O 1

mm

brass ad-

justment

shims

until.

with

plate

and

locknut

installed

.

a 0.

008

inch

(0.

20

mm

)

18

feeler gauge

can

enter

.

but

c 0.01

inch

(0

.

25

mm)

gau;:ie

cannot

.

( JT2L -JT2M)

.011" - .013"

G. Adjusting

the

Carburetor

The

only

carburetor

adjust

-

ment

to

be

made

this

time

is

to

lightly

tighten

the

throttle

stop

screw

and

back

it

off

1½

turns

.

All

other

adjustments

are made

later

.

with

the

en-

gine

running

.

'J

H.

Checking

Ignition

Timing

1.

Remove

the

generator

cover

from

the

left

side

of

the

crankcase.

2. Pull

the

wire

lead

cap

assembly

off

the

spark

plug

. Using a 21

mm

socket

wrench

.

remove

the

spark

plug

.

3.

Turn

the

magneto

rotor

by

hand

until

the

points

close.

4.

Dip

a

thin

strip

of

card-

board.

such

as a business

card. in

lacquer

thinner

.

----

5. Pry

the

points

open

with

your

fingers

.

Then

let

the

points

snap

shut

on

the

wet

cardboard

.

Slowly

withdraw

the

cardboard

.

Repeat

until

the

points

are

clean

.

6.

Obtain

a

Yamaha

point

checker

(ohmmeter).

Turn

the

toggle

switch

to

ON

.

Make

sure

the

wire

leads are

not

touching

.

then

set

the

needle

at

infinity

(oo)

by

turning

the

ADJ

knob

.

When

the

needle

is

set

.

turn

the

toggle

switch

to

OFF

.

7.

Connect

the

red

lead

of

the

point

checker

to

the

black

coil

wire. (See

page

11.

step

J.6

.)

Connect

the

black

lead

to

a

good

ground

.

such

as a

gener-

ator

cover

mounting

screw

hole

or

a

cylinder

head

cooling

fin

.

19

8

Obtain

a

dial

indicator

and

adapter

Insert

the

dial

indicator

into

the

adapter

Secure

It

by

tightening

the

setscrew

at

the

side

of

the

adapt

-

er

finger

tight.

9

Screw

the

adapter

in

to

the

spark

plug

hole

.

10

Turn

the

magneto

rotor

to

the

point

where

the

dial

indicator

hesitates

Just

before

reversing

d1

-

rectIon

This

,s

Top

Dead

Center

- where

the

piston

,s at ,ts

high

-

est

poin

t in

the

cylinder

.

M

ove

the

rotor

back

and

forth

several

times

to

make

sure

you

are ex-

actly

at

this

point

.

11

When

the

piston

Is

at

Top

Dead

Center

.

line

up

the

0

on

the

face

of

the

dial

indica

t

or

w

ith

th

e

needle

by

rotating

the

dial

face

Turn

the

po

int

checker

togg

le sw

itch

to

ON

12

Turn

the

rotor

cloc

kw

ise

(back

ward) until t

he

dial

indicator

need

le

makes

2

full

revolutions

of

the

dial

Then. w

hile

w

atch

-

ing

the

point

checker

.

rotate

the

rotor

counter

-

clock

wise

(forward)

un-

til

the

point

checker

needle

moves

At

this

point

.

the

dial

indica

t

or

20

_)

DIAL

INDICATOR

needle

should

be

at

20

.

(Tolerance is 3

marks

on ei

ther

side

of

20

.)

Note

One c

omplete

revolutio

n

of

the

needle

equals

1

mm

of

pi

ston

trave

l.

Therefore.

when

the

needle

moves

back

2

revolut

ions.

then

for

-

ward

to

20

.

it

means

the

pi

ston

is

at

a final

posi

tion

of

1.8

mm

be-

low

Top

Dead

Center

.

Ove

rshooting

, and

re

-

turning

to

20

is

done

to

t

ak

e up any

slack

in

gears

and

bear

i

ng

s.

13. If

the

po

i

nt

checker nee-

dle

mov

ed as

the

pis

ton

wa

s

brought

to th

e 1.8

mm

p

oint

. ti

min

g and

p

oint

gap

is

corr

ect. Go

to

step

16

.

If

it

doe

sn't.

the

po

i

nts

must

be ad-

jus

ted

to

open

at

1.8

mm

.

Continue

with

step

14

.

14

.

Make

sure

piston

is

at

1.8

mm

(20

on

the

dial

indicator)

.

15

.

Adjust

the

points

by

loosening

the

point

se-

curing

screw

and

mov

-

ing

the

plate

with

a

screwdriver

.

When

the

point

checker

needle

moves

.

it

mea

ns

the

points

are

just

beginn

i

ng

to

open

.

At

this

po

i

nt

.

adjustment

is

correct

.

Ti

ghten

the

secur

i

ng

screw

.

16

. Repeat

step

12

and

13

to

check

your

work

. Re-

adjust

the

po

i

nts

if

ne

c-

essary.

17.

Turn

the

point

checker

to

OFF and

disconnect

the

leads.

Remove

the

dial i

ndicato

r

and

adapt

-

er

fro

m

th

e

spa

rk

plu

g

hol

e.

18

.

Us

i

ng

a

wi

re

type

feele

r

gage

, c

heck

that

the

spark

plug

gap

is 0 .

020

to

0.

024

inch

(0.5

to

0.6

mm

).

Ad

just

it

if

ne

cessary.

19

.

Insta

ll

the

spark

pl

ug

and

tor

qu

e it to

20

to

25

lb

-

ft

.

Snap

t

he

wire

lead c

ap

assembly

on

the

spa

rk

plug

.

20

. I

nstall

th

e

generator

cove

r.

21

Section

IV

-

Making

Preliminary Checks

A. Filling

the

Fuel

Tank

If

the

cover

at

the

right

side

of

the

engine

is in-

stalled. remove

it

.

2 Turn

the

fuel

petcock

lever

to

"R"

.

3 Squeeze

the

wire

and

disconnect

the fuel line

at

the

carburetor

.

Allow

any

gas

or

impurities

to

drain.

Reinstall

the

line

.

4. Turn

the

fuel

petcock

lever

to

''S''

.

22

5. Fill

the

tank

with

a

good

grade

of

fresh regular gas-

oline. preferably

low

-lead.

The

tank

holds

1.1

US

gallons

(4.

15

liters).

8.

Checking Trans-

mission Oil Level

1.

Remove

the

dipstick

and

check

that

there

is oil

on

it

.

The

actual oil level is

unimportant.

since

it

can

only

be

accurately

checked

after

the

engine

is

warm

.

2.

If

there

is

not

oil

at

all

on

the

dipstick

. fill the

trans-

mission

with

break-in

oil.

The transmIssIon

holds

0.

64

US

quart

(0

.6

liter)

.

Note

Refer

to

SERVICE

NEWS

BULLETIN

#

169

for

more

information

on

add-

ing

transmission

oil.

5 4

ADD

I

[~

C.

Checking

for Loose

Nuts

and

Bolts

Check

all

fitt

i

ngs

for

ti

ght

-

ness

. Pay

particular

atten

-

tion

to

the

follow

i

ng

:

1.

Front

fork

nuts

2.

Fender

mounting

bolts

3.

Front

axle

nut

4.

Carburetor

clamp

screw

(behind

rubber

plug)

5.

All

{a

ir

cleaner)

securing

screws

6 .

Headlight

switch

screw

23

7 Exhaust system

bolt

8. Rear cushion nuts

9 Chain adJust

bolt

lock

-

nuts

10

Axle

nut

11

Crankcase cover screws

12

Engine mounting

bolts

24

7

D.

Checking

Tire

Pressure

8

Check

both

front

and

rear

tires

for

proper

air

pressure

with

an

accurate

tire

gauge.

The

front

tire

should

be be-

tween

22

and

23

psi. The

rear

tire

should

be

at

28

psi.

Add

or

bleed

air

as neces-

sary.

.iection V -

Making

Running

Checks

A.

Starting

the

Engine

1.

Turn

the

fuel

petcock

lever

to

0.

2. Pull

the

starter

lever

up

.

3. Kick

down

on

the

kick

pedal

quickly

and

smooth

-

ly

. Keep

the

accelerator

grip

closed

wh

ile you

do

this

.

4.

When

the

engine

is run-

ning. push

in

the

starter

lever.

l

__

B.

Checking

the

Trans-

mission

Oil

1.

Let

the

engine

idle

for

about

10

minutes

.

then

turn

it

off

.

2.

Unscrew

the

dipstick

and

wipe

it

clean

.

Check

the

oil

level.

If

it

is

not

be

-

tween

the

two

marks

. add

or

drain

oil

as

necessary

.

Note

When

checking

the

oil

level.

don't

screw

the

dip

-

stick

in.

Just

press

it

against

the

filler

hole

boss

.

3.

Screw

in

the

dipstick

.

25

C. Adjusting

Carburetor and

Autolube

Cable

If

the

cover

on

the

right

side

of

the

engine

1s

in-

stalled remove

1t

2 Start

the

engine and

let

1t

warm

up

With

the

engine running.

turn

the

throttle

stop

screw

until

engine speed

is

1.

200

to

1

400

rpm

3 Pull

up

the

throttle

cable

sheath

of

the

carburetor

and check

for

1/

32

inch

{1 0

mm)

free play

If

play

1s

good.

go

to

step

5 If

not

.

continue

with

step 4

Note

Free play Is all

taken

up

when

engine speed

starts

to

increase.

4

Using

an 8

mm

wrench

.

turn

the

throttle

cable

ad1usting

screw

until

free play

1s

•1

32

inch

.

Tighten

the

lock

nut

against

the

adJusting

screw

5 Pull

the

throttle

cable

sheath

at

the

handgnp

and

check

for

1/

84

to

~

32

inch

(0

5

to

1.0

mm)

free

play

If

play is

good

go

to

step

7

If

not

continue

with

step

6

26

THROTTLE

STOP

SCREW

THROTTLE

CABLE

I

1/64'TO

1/32

"

LOCK

NUT

6.

Turn

the

throttle

cable

adjusting

screw

at

the

handgrip

until

play

is

1/

8 4

to

'/3,

inch

.

Tighten

the

lock

nut

against

the

adjusting

screw

.

7.

Turn

the

accelerator

handgrip

slightly

to

re

-

move

free

play

from

the

throttle

cable

.

8.

With

free play

removed

.

turn

the

pump

cable

ad-

justing

screw

until

the

mark

on

the

pulley

is in

line

with

the

guide

Tighten

the

locknut

against

the

adjusting

screw

.

9.

Shut

off

the

engine.

10

. Rotate

the

accelerator

hand

grip

to

full

throttle

.

Check

that

the

guide

does

not

strike

the

raised

boss

at

the

end

of

the

pump pully.

11 . Install

the

engine

cover.

D.

Checking

Lights

1.

With

the

engine

running

,

move

the

on

-

off

switch

back

and

forth

several

times

.

Check

that

the

headli

ght

and

tail

light

turn

on

and

off

w i

th

the

switch

.

Move

the

di

mmer

switch

on

and

off

and

check

that

the

headlight

brightens

and

dims

.

27

2 Push on

the

rear brake

pedal and check

that

the

stop

light

comes

on

Just

after the pedal

free

play

1s

taken up

If

1t

doesn't,

or

1f

1t

comes

on

too

soon

or

too

late. the

stop

light

switch

must

be

adjusted

.

The

switch

is

loca

ted

be-

neath the

Autolube

tank

.

3 To ad1ust the

switch.

loosen

the

two

lock

nuts

.

Use a

17

mm

and a 21

mm

wrench

.

Move

the

switch

up

or

down

as re-

quired

to

make

the

stop

light

come

on

at

the

prop-

er

time

.

4

With

the

switch

pos1-

t1oned properly.

tighten

the

lock

nuts

against

the

mounting

bracket

. E.

Road

Testing

1.

Check

that

the

clutch

en-

gages

smoothly

and

pro

-

gressively

as

the

l

ever

is

released.

2.

Check

that

the

brakes

have

adequate

stopping

power

.

Caution

Do

not

apply

severe pres-

sure

to

the

brakes.

New

brakes

require

"

breaking

in"

just

as a

new

engine

does

.

Customer

satis-

faction

w

ith

brake

life

and

performance

will

greatly

depend

on

easy use

at

thi

s

time

.

3.

Check

that

the

transmis

-

sion

shifts

easily

and

makes

no

unusual

noises

.

4.

Check

that

acceleration

is

typical

of

the

average

JT1 -L.

Caution

Avoid

using

high

engine

or

road

speeds

at

this

time

.

Remember

that

easy

running

·

during

break-in is necessary

for

maximum

engine

life

and

customer

satisfaction

.

5.

Check

that

handling

qual

-

ities

and

stability

are

sat-

isfactory

.

Poor

handling

and

instability

may

be

caused

by

improper

tire

pressures

.

loose

nuts

and

bolts

.

or

loose

spokes

6.

When

testing

is

complete

,

check

that

no

fittings

have

loosened

due

to

vibra

-

tions

.

Refer

to

Section

IV,

step

C.

Remember

-

The

rider

is

the

customer

.

Make

sure

he

gets

a

safe,

road-worthy

ma-

chine

.

The

motorcycle

is

now

fully

assembled

,

adjusted

.

and

otherwise

mechanically

prepared

.

There

is

one

more

step

to

be

perfo

r

med

before

p

utting

it

on

display

or

in

the

hands

of

a

buyer

.

That

is

to

make

sure

that

i

ts

appearance is as

sharp

as

its

mechanical

condition

.

Remove all

traces

of

dirt

or

oil

film

that

may

have

accumulated

during

road

testing

.

particularly

around

the

wheel

hubs

.

Polish

the

pa

i

nted

sur

-

faces -

the

tanks

.

the

fenders.

and

so

forth

.

29

Section

VI

JT2L-JT2M

SUPPLEMENT

Contents

Chargi

ng

Battery . . . . . . . . . . . . . . . . . . . . . .

31

In

sta

11

ing Tai

II

ight . . . . . . . . . . . . . . . . . . . . . 32

Installing Ignition Switch

..........

.

......

33

Installing Speedometer & Cable .

..

.

.....

.

...

33

Connecting Wiring . . . . . . . . . . . . . . . . . . . . . 34

JTl-L

& JT2-L Connection Diagrams . . . . . . . .

35

Torque Specifications .

...

..

.

..

.

..

...

36

A.

Charging Battery

1. Remove

the

vent

tube and

filler

caps.

Blow

gently through the

vent

and vent tube to make

sure proper

venting

is

tak-

ing

place.

2.

Fi

II each ce

II

to the top

level

line

with

fresh

elec-

trolyte.

3.

Charge the battery

at

O.

2

A(MAX.)

until

specific

gravity

is

1,260

.:..

1,280.

4.

lnstal

I the battery

in

the

frame, and

connect

the

lead

wires

.

5. Make sure the

battery

ground

(-)

strap

is

con-

tacting

clean

metal at the

frame mounting

point.

31

Yamaha JT1 Series User manual

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