Yamaha 1991-1993 Exciter II - 570 User manual

CD
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ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols CD to ® are designed as
thumb tabs to indicatethe chapter's number and
content.
CD General information
® Periodic inspection and adjustment
@ Chassis
® Power train
@ Cooling system
® Engine
(j) Carburetion
® Electrical
® Appendices
Illustratedsymbols ® to @ are usedto identify
the specifications
which appear.
® Filling fluid
([D Lubricant
@ Tightening
@ Wear limit, clearance
@ Engine speed
@ n,V,A
Illustrated symbols @ to @ in the exploded
diagram indicate grade of lubricant and location
of lubrication point.
@ Apply locking agent (LOCTITEIl!»
@ Apply engine oil
@ Apply gear oil
@ Apply molybdenum disulfide oil
® Apply wheel bearing grease
® Apply low-temperature lithium-soap base grease
@ Apply molybdenum disulfide grease
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INDEX
GENERAL INFORMATION
PERIODIC INSPECTION
AND ADJUSTMENT
CHASSIS
POWER TRAIN
ENGINE OVERHAUL
COOLING SYSTEM
CARBURETION
ELECTRICAL
APPENDICES
\,.
ENG
X
COOL
•
CARB
iii
ELEC
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APPX
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CONTENTS
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ............................. 1-1
FRAME SERIAL NUMBER ......................... 1-1
ENGINE SERIAL NUMBER ........................ 1-1
IMPORTANT INFORMATION ...........................1-2
PREPARATION FOR REMOVAL
AND DISASSEMBLY ................................1-2
ALL REPLACEMENT PARTS ......................1-3
GASKETS, OIL SEALS, AND O-RINGS ..... 1-3
LOCK WASHERS/PLATES AND
COTTER PINS ...........................................1-3
BEARINGS AND OIL SEALS ......................1-3
CIRCLIPS .....................................................1-4
SPECIAL TOOLS ................................................1-4
FOR TUNE UP.............................................1-4
FOR ENGINESERVICE ................................1-5
FOR POWER TRAIN SERVECE ................... 1-6
FOR ELECTRICAL SERVICE ........................1-7
CHAPTER 2.
PERIODIC INSPECTIONS AND
ADJUSTMETS
INTRODUCTION .............................................. 2-1
PERIODIC MAINTENANCE TABLE ................. 2-1
SIDE COWLING...........................................2-3
ENGINE ..............................................................2-3
SPARK PLUG ...............................................2-3
OIL PUMP ....................................................2-4
ENGINE OIL LINE INSPECTION .................2-6
OIL FILTER INSPECTION ............................2-6
FUEL LINE INSPECTION .............................2-6
FUEL FILTER INSPECTION .........................2-7
COOLING SYSTEM .....................................2-7
ENGINE IDLE SPEED ADJUTMENT .........2-12
THROTTLE CABLE ADJUSTMENT ..........2-13
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THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK ....................................2-14
STARTER CABLE ADJUSTMENT ............2-14
EXHAUST SYSTEM ..................................2-15
POWER TRAIN ................................................2-15
DRIVE V-BELT ......................................,.... 2-15
ENGAGEMENT SPEED CHECK................2-17
BRAKE PAD INSPECTION ........................2-18
BRAKE ADJUSTMENT .............................2-18
DRIVE CHAIN ............................................2-18
TRACK TENSION ADJUSTMENT ............ 2-21
SLIDE RUNNER INSPECTION ..................2-22
CHASSIS ..........................................................2-23
SKI/SKI RUNNER ......................................2-23
STEERING SYSTEM .................................2-23
LUBRICATION ...........................................2-24
ELECTRICAL ...................................................2-25
HEADLIGHT
AND METER LIGHT
BULB REPLACEMENT............................2-25
HEADLIGHT BEAM
ADJUSTMENT .........2-27
TAIL/BRAKE LIGHT BULB
REPLACEMENT ......................................2-27
BATTERY INSPECTION
(FOR EX570ER) .......................................2-28
FUSE INSPECTION
(FOR EX570ER) .......................................2-30
TUNING .......................................................... 2-31
CARBURETOR TUNING ........................... 2-31
CLUTCH TUNING .....................................2-40
GEARING SELECTION ..............................
2-41
SLIDE RAIL SUSPENSION TUNING ........2-43
ENGINE ROOM PLATES ..........................2-44
HIGH ALTITUDE TUNING ........................2-45
CHAPTER 3.
CHASSIS
STEERING ......................................................... 3-1
REMOVAL ...................................................3-2
INSPECTION ...............................................3-4
INSTALLATION ...........................................3-5
SKI ......................................................................3-8
REMOVAL ...................................................3-9
INSPECTION ...............................................3-9
INSTALLATION ...........................................3-9
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FRONT SUSPENSION .................................... 3-11
REMOVAL .................................................3-12
INSPECTION .............................................3-14
INSTALLATION .........................................3-15
CHAPTER 4.
POWER TRAIN
PRIMARY SHEAVE AND DRIVE V-BELT ......... 4-1
REMOVAL ...................................................4-2
DISASSEMBLY ........................................... 4-2
INSPECTION ...............................................4-4
ASSEMBLY .................................................4-6
INSTALLATION ...........................................4-9
SECONDARY SHEAVE ...................................4-10
REMOVAL..................................................
4-11
DISASSEMBLY.......................................... 4-11
INSPECTION ..............................................4-12
ASSEMBLY................................................4-13
INSTALLATION .........................................4-14
SHEAVE DISTANCE AND OFFSET
ADJUSTMENT ........................................4-15
DRIVE CHAIN HOUSING AND
JACKS HAFT ..................................................4-18
REMOVAL .................................................4-19
INSPECTION ............................................. 4-21
INSTALLATION .........................................4-22
BRAKE .............................................................4-23
REMOVAL .................................................4-24
DISASSEMBLY .........................................4-24
INSPECTION .............................................4-25
ASSEMBLY AND INSTALLATION ...........4-26
SLIDE RAIL SUSPENSION .............................4-29
REMOVAL.................................................. 4-31
DISASSEMBLY.......................................... 4-31
INSPECTION ..............................................4-33
ASSEMBLY................................................4-35
INSTALLATION .........................................4-36
FRONT AXLE AND TRACK .............................4-37
REMOVAL .................................................4-38
INSPECTION .............................................4-38
INSTALLATION .........................................4-39
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CHAPTER 5.
ENGINE OVERHAUL
ENGINE REMOVAL .......................................... 5-1
BATIERY LEADS ........................................ 5-1
HOSES ......................................................... 5-1
CABLE AND LEADS ....................................5-2
OIL TANK ....................................................5-2
STARTER MOTOR ......................................5-2
RECOIL STARTER .......................................5-3
ENGINE REMOVAL.....................................5-3
DISASSEMBLY .................................................5-3
OIL PUMP ....................................................5-3
WATER
PUMP .............................................5-3
COl MAGNETO ...........................................5-3
CYLINDER HEAD
AND CYLINDER.............5-4
PISTON ........................................................5-5
CRANKCASE
AND CRANKSHAFT.............5-6
INSPECTION AND REPAIR ...............................5-6
CYLINDER HEAD ........................................5-6
CYLINDER
AND PISTON ............................5-7
PISTON RINGS ...........................................5-9
PISTON PIN AND BEARING.....................5-10
CRANKSHAFT...........................................
5-11
CRANKCASE .............................................5-12
OIL PUMP STROKE ADJUSTMEr:-JT ........5-12
ENGINE ASSEMBLY AND ADJUSTMENT ...5-15
CRANKCASE
AND CRANKSHAFT...........5-15
PISTON ......................................................5-19
CYLINDER
AND CYLINDER HEAD...........5-19
CDI MAGNETO .........................................5-20
WATER
PUMP ...........................................5-22
OIL PUMP ..................................................5-22
REMOUNTING ENGINE ...........................5-22
RECOIL STERTER ...........................................5-23
REMOVAL .................................................5-24
DISASSEMBLY .........................................5-24
INSPECTION .............................................5-25
ASSEMBLY AND INSTALLATION ...........5-25
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CHAPTER 6.
COOLING SYSTEM
COOLANT FLOW .............................................. 6-1
COOLING LINE ..................................................6-2
COOLING SYSTEM ...........................................6-3
REMOVAL ...................................................6-3
INSPECTION ...............................................6-5
INSTALLATION ...........................................6-6
CHAPTER 7.
CARBURETION
CARBURETOR ................................................... 7-1
REMOVAL....................................................7-2
DISASSEMBLY............................................7-3
INSPECTION ................................................7-4
ASSEMBLY..................................................7-5
INSTALLATION ...........................................7-6
FUEL LEVEL ADJUSTMENT .......................7-6
FUEL PUMP .......................................................7-7
OPERATION CHECK....................................7-7
CHAPTER 8.
ELECTRICAL
CIRCUIT DIAGRAM ........................................... 8-1
ELECTRICAL COMPONENTS ...........................8-3
ELECTRICAL STARTING SYSTEM
(FOR EX570ER) .................................................8-5
CIRCUIT DIAGRAM.....................................8-5
TROUBLESHOOTING .................................8-7
MAIN SWITCH (FOR EX570ER) .................8-8
RECTIFIER ...................................................8-8
STARTER MOTOR ......................................8-9
CHARGING SYSTEM (FOR EX570ER) ...........8-15
CIRCUIT DIAGRAM...................................8-15
TROUBLESHOOTING ...............................8-17
BATTERY...................................................8-18
CHARGING COIL .......................................8-19
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IGNITION SYSTEM ......................................... 8-21
CIRCUIT DIAGRAM ................................... 8-21
TROUBLESHOOTING ...............................8-23
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) ...................................................8-25
SOURCE COIL AND PICKUP COIL ...........8-26
HANDLEBAR SWITCH (RIGHT) ...............8-27
CARBURETOR SWITCH ...........................8-27
MAIN SWITCH (FOR EX570R) .................8-28
LIGHTING SYSTEM ........................................8-29
CIRCUIT DIAGRAM ....................................8-29
TROUBLESHOOTING ................................ 8-31
HEADLIGHT BEAM SWITCH .....................8-32
LIGHTING COIL ..........................................8-32
SIGNAL SYSTEM .............................................8-33
CIRCUIT DIAGRAM ....................................8-33
TROUBLESHOOTING ................................8-35
BRAKE LIGHT SWITCH .............................8-37
THERMO SYSTEM .....................................8-37
GRIP WARMER SYSTEM ......•.............••..•........8-39
CIRCUIT DIAGRAM ....................................8-39
TROUBLE SHOOTING ............................... 8-41
GRIP WARMER SWITCH INSPECTION ....8-42
GRIP WARMER COIL INSPECTION ..........8-42
CHAPTER 9.
APPENDIX
SPECIFICATIONS .............................................. 9-1
GENERAL SPECIFICATIONS ...................... 9-1
MAINTENANCE SPECIFICATIONS ............9-3
GENERAL TORQUE SPECIFICATIONS .........9-15
DEFINITION OF UNITS ...................................9-15
CABLE ROUTING ............................................9-16
EX570R WIRING DIAGRAM
EX570ER WIRING DIAGRAM
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MACHINE IDENTIFICATION 1 ~EF~ 1"1
GENERAL
1-1
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 identification;the remaining digits are the
unit production number.
Starting Serial Number
EX570R ........................88R-0001 01
EX570ER ......................88S-0001 01
NOTE: ______________________ __
Designs and specifications are subject to change
without notice.
D
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D
I
GI NEFNO I<4wI
IMPORTANT INFORMATION ~
--------------------------------------------------------
'-2
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 parts that have
been
"mated" through normal wear. Mated
parts
must be reused as an assembly or
replaced.
4. During disassembly of the machine, 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
reinstalled correctly.
5. Keep away from fire.
6.
Be sure to keep to tightening torque specifi-
cations. When tightening bolts, nuts, and
screws, start
with larger-diameterpieces, and
proceed
from an inner-positioned one to an
outer-positioned one in a criss-cross pattern.
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IMPORTANT INFORMATION I~EF~I-:kl
ALL REPLACEMENT PARTS
300-000
300-002
300-003
'-3
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.
Lock tab(s) should be bent along the bolt
or
nut flat(s) after the bolt or nut has been
properlytightened.
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
liberally
when installing.
Do
not use compressed air to spin the bearings
dry. This causes damage
to the surface of the
bearings.
D
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300-001
1-4
SPECIAL TOOLS I ~ EF~ ~ I
CIRCLIPS
1. All circlips should be inspected carefully be-
fore reassembly. Always replace piston pin
clips after one use. Replace misshapen
circlips. When installing a circlip
CD , make
sure that the sharp edged corner ® is
positioned opposite
to the thrust ® it
receives. See the sectional view.
@ Shaft
SPECIAL TOOLS
The some special tools are necessary for
complete accurate tune-up and assembly. Using
the correct special
tool will help prevent damage
thet can be caused by the use of improper tools
or improvised techniques.
NOTE: ______________________ ___
Be sure to use the correct part number when
ordering the tool, since the part
number differs
according
to the area as shown below. The first
part
number is for Europe, and the last part is for
the U.S.A. and Canada.
e.g. 90890 - *****, YU- *****
FORTUNE UP
1. Vacuum Gauge
PIN -, YS-33275
Thisgaugeis used
for carburetorsynchronization.
2. Sheave Gauge
PIN -, YS-91047 CD
PIN - , YS-33274 ®
This gauge is used to measure sheave distance
and
for offset adjustment.
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1-5
3. Fuel Level Gauge
PIN 90890-01312, YM-01312-A
This gauge is used
to measurethe fuel level inthe
float chamber.
FOR ENGINE SERVICE
1. Universal Clutch Holder
PIN 90890-04086, YM-91042
This
tool is used to hold the starter pulley.
2. Piston Pin Puller
PIN 90890-01304, YU-01304
This
tool is used to remove the piston pin.
3. Universal Rotor Holder
PIN 90890-01235, YU-01235
This
tool is used to hold the COl magneto.
4. Rotor Puller
PIN 90890-01362, YU-33270
This
tool is used to remove the magneto rotor.
u
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1-7
SPECIAL TOOLS I ~EF~IJMI
5. Clutch Separator Adapter
PIN - , YS-34480
This tool is used when disassembling and
assembling the primary sheave.
6. Track Clip Installer
PIN -, YS-91045
This tool is used for installing the track clip.
FOR ELECTRICAL SERVICE
1. Pocket Tester
PIN 90890-03112, YU-03112
This
instrument is necessaryforcheckingtheelec-
trical components.
2. Electro Tester
PIN 90890-03021, YU-33260
This
instrument is invaluable for checking the
electrical system.
D
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INTRODUCTION! IINSP I Ml.1
PERIODIC MAINTENANCE TABLE ADJ.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapterincludesall information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures,
if followed, will ensure more reliable machine operation and
a longer service life.
In addition, the need for costly overhaul work will be greatly reduced. This
information applies
to machines alreadyin service as well as new machines that are being prepared for
sale. All service technicians should be familiar with t!lis entire chapter.
PERIODIC MAINTENANCE TABLE
Initial
Pre-operation 1 Month
Item Remarks
or
check (Daily) 800 km
(500 Mi) (40 hr)
Spark Plug: Check condition adjust the gap and clean.
Replace if necessary.
Check oil level. •
Engine Oil:
... Air bleed the oil pump if necessary.
... Oil Filter: Check condition.
Replace if necessary.
- ~
Fuel: Check fuel level. •
... Fuel Filter: Check condition.
Replace
if necessary.
... Fuel Line: Check fuel hose for cracks or damage.
Replace
if necessary.
... Oil Line: Check oil hose for cracks
or damage.
Replace
if necessary.
Check coolant level. •
Engine Coolant
... Air bleed the cooling system if necessary.
Check throttle lever operation. •
Carburetor Whenever operating condition
... Adjust the jets., (elevation/temperature)
is changed.
... Water Pump Belt Check wear and damage. Replace if necessary.
Adjust water pump belt if necessary.
Manual Starter: Check operation and rope damage. •
... Replace if necessary.
Engine Stop Switch: Check operation •
... Repair if necessary.
Throttle Override System: Check operation. •
... Repair if necessary.
Throttle Lever: Check operation. •
... Repair if necessary.
... Exhaust System: Check for leakage.
Retighten
or replace gasket if necessary.
... Decarbonization: More frequently if necessary.
Drive V-belt Guard: Check cracks, bends
or damage. •
... Replace if necessary.
Drive V-belt: Check wear and damage. Replace if necessary. •
Drive Track/Idler Wheels: Check deflection, wear and damage.
.......
... Adjust/replace if necessary.
Slide Runner Check wear and damage. •
... Replace if necessary.
... : It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
...... :Perform after 1 Month or 50 km (31 Mi) (2hr) and every 1 Month or 400 km (250 Mi)(20 hr).
2-1
Every
Seasonally
or
3,200 km
(2,000 Mi)
(160 hr)
•
•
•
•
•
•
•
•
•
•
•
•
•
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-
PERIODIC MAINTENANCE TABLE I rgf I till
Initial Every
Pre-operation 1 Month Seasonally
Item Remarks or
or
check (Daily) 800 km 3,200
km
(500 Mi) (40 hr) (2,000 Mi)
(160 hr)
Check operation. •
Brake/ Adjust free play and/or replace pads if neces-
Parking Brake * sary. •
Check oil level. •
*Drive Chain Oil Replace. •
Check deflection.
**.
*Drive Chain: Adjust if necessary.
Ski/ Check wear and damage. •
Ski Runner * Replace if necessary. •
Check operation. •
Steering System * Adjust toe-out if necessary. •
Lights: Check operation. •
Replace bulbs if necessary.
Check fluid level. •
Battery * Check specific gravity and breather pipe
operation. •
Charge/Correct if necessary.
Check engagement and shift speed. •
Adjust if necessary. Whenever operating elevation is changed.
*Primary Sheave Check wear and damage.
Replace
if necessary. •
Lubricate with specified grease. •
Lubricate with specified grease. •
*Secondary Sheave Adjust
if necessary. Whenever operating elevation
is changed.
*Steering Column Bearing: Lubricate with specified grease. •
*Ski and Front Suspension: Lubricate with specified grease. •
•Suspention Component: Lubric~te with specified grease. •
* Brake Cable End and Lubricate with specified grease. •
Lever End! Throttle Check cable damage.
Cable End Replace
if necessary. •
Shroud Latches: Make sure the shroud latches are hooked. •
Fittings/Fasteners: Check tightness. •
* Repair if necessary.
Service Tools/Spare Parts: Check proper placement. •
*: It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
**: Perform after 1 Month or 50 km (31 Mi) (2hr) and every 1 Month or 400 km (250 Mi)(20 hr).
2-2
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SIDE COWLING/SPARK PLUG I rgf I Q.I
377-000
2-3
SIDE COWLING
Removal
1. Open the shroud.
2. Remove:
• Screws CD
3. Remove:
• Side cowlings (left and right) CD
Pull it forward [AI •
Installation
Reverse the uRemoval" procedure.
ENGINE
SPARK PLUG
1. Remove:
• Spark plug
2. Inspect:
• Electrode
CD
Wear/Damage~Replace.
• Insulator color ®
3. Measure:
• Plug gap @
Out of specification~Regap.
Use Wire Thickness Gauge.
Spark Plug Gap:
0.7 ..0.8 mm (0.028 .. 0.032 in)
Clean the plug with a spark plug cleaner if
necessary.
Standard spark plug:
BR9ES (NGK)
Before installing a spark plug, clean the
gasket surface and plug surface.
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________________________ O_IL_PU_M_plrgfl4Gl1
(' tN..-----.Y1l
377-004
2-4
4.Tighten:
• Spark plug
Spark Plug:
28
Nm (2.8 mokg, 20 ftolb)
NOTE: ___________ _
Finger-tightenCDthe spark plug before torquing ®
to specification.
OIL PUMP
Air Bleeding
The oil
pump and delivery line must be bled on
the following occasions:
• When any portion of the oil system has been
disconnected.
• When the machine hasbeen turned on its side.
• Whenever the oil tank has been run empty.
• During pre delivery.
1.Remove:
• Drive V-belt guard (See page 2-16)
• Carburetors (See page 7-2)
2.Fill:
• Oil tank CD
Oil tank capacity
3.0 L (2.6 Imp qt, 3.2 US qt)
Recommended oil:
Vamalube 2-cycle oil
3. Place a rag under the oil pump assembly to
catch oil.
4. Disconnect:
• Oil hoses CD
5. Keep the oil running out until air bubbles
disappear from the oil hoses CD
6. Connect:
• Oil hoses CD
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________________________ O_IL_PU_M_plr&sl4il1
3
2-5
7. Disconnect:
• Oil delivery hoses CD
8. Feed the "Yamalube 2-cycle oil" into the oil
deliveryhosesCDusing aoil
can®forcomplete
air bleeding.
9. Connect:
• Oil delivery hoses CD
10. Remove:
• Bleed screw CD
• Gasket (bleed screw)
11. Keep the
oil running out until air bubbles
disappear from bleed hole.
12. Inspect:
• Gasket (bleed screw)
CD
Wear/Damage ~ Replace.
13. Install:
• Gasket (bleed screw)
• Bleed screw ®
Cable Adjustment
NOTE: ______________________ __
Before adjusting the oil pump cable, the throttle
cable free play should
be adjusted.
1. Pull back the adjuster cover CD .
2. Adjust:
Oil pump cable
Adjusting steps:
• Loosen the locknut CD .
• Hold the throttle leverat full-throttle position.
• Turn the adjuster® in or out untilthe adjust-
ment
mark@is aligned with the end @ofthe
adjuster.
• Tightenthelocknutand installthe rubbercaps
from both sides.
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ENGINE OIL LINE INSPECTION/ IINSP I ~.I
OIL FILTER INSPECTION/FUEL LINE INSPECTION ADJ.
2-6
ENGINE OIL LINE INSPECTION
1.Inspect:
• Oil hoses
CD
• Oil delivery hoses ®
Crack/Damage-+Replace.
OIL FILTER INSPECTION
1. Remove:
• Cover (oil tank-right) CD
• Oil tank stay ®
2. Disconnect:
• Oil hoses
NOTE: ______________________ __
Plug theoil hoses so thatthe oil will not run out of
the oil tank and oil pump.
3. Inspect:
• Oil
filter CD
Contamination-+Replace.
Recommended replacement interval:
Every season
4. Reverse the removal procedure.
FUEL LINE INSPECTION
1. Inspect:
• Fuel hoses
• Fuel delivery hoses
Crack/Damage-+Replace.
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