Yamaha ET300E Manual

LlT-12618-00-33
• YAMAHA
SNOWMOBILE
. SUPPLEMENTARY
SERVICE MANUAL
8L3-28197-10

FOREWORD
This supplementary service manual for ET300E has been published to sup-
plement the ET300D supplementary service manual (8KO- 28197 -10) .
For
complete information on service procedures, it is necessary to use this
Supplementary service Manua l together with the following manuals.
ET300C Service Manual (8H9-28197-10)
ET300D Supplementary Service Manual (8 KO - 28197 -10)
NOTE: ---- ------------ -------- ------------ ------------
The Research and Engineering Department of Yamaha are continually
striving to further perfect all models . Improvements are modifications are
therefore
inevitable .
In light of this fact all specifications wi thin this manual are subject to
change without notice. Information regarding changes is forwarded to all
Authorized Yamaha Dealers as soon as available.
SERVICE DEPT.
INTERNATIONAL DIVISION
YAMAHA CO., LTD.
Particularly important information is distinguished in this manual by the
following notations:
NOTE:
A NOTE provides key information to make procedures easier or clearer.
YAMAHA
ET300E
SUPPLEMENTARY SERVICE MANUAL
1st Edition, APRIL,I980
ALL RIGHTS RESERVED BY YAMAHA
MOTOR COMPANY,LTD ., JAPAN
PRINTED IN JAPAN
lIT-12618 - 00 - 33
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CONTENTS
1. NEW SERVICE PROCEDU RE . .. ... ........ ... . ... ..........-. .. .... .... ...... .... . .. . .... .. .... .. ... 1
2. SPECIFICATIONS .. ... .. ............ ... . .. ... .... ........ ... .. .. ... .. .. .. ...... ....... .... . .... . .... . ... .. 2
3.
WIRE ROUTING DIAGRAM .... .. ..... .... . .. .... . .... ... ...... .......... .. . .. ....... ... .......... 6
c
C 1. NEW SERVICE PROCEDURE
c
c
c
f
'-
(New service procedure applied to the 1981
ET300E.)
A . Piston ring inspection
As a result of the recent change in the piston
ring, item 10, page 2-8 of the ET300C
service manual (8H9-28197 - 10) should be
read as fo l lows :
10. Piston ring ins pect ion
a. Check rings for scoring. If any severe
scratches are noticed, replace ring set.
b.
Measure ring end gap in free position. If
beyond tolerance, replace ring set.
Ring end gap, free
Top Approx.
6.5 mm (026 in)
Second
Approx . 7.5 mm (0. 30 in)
-1 -
c. Push the ring into the bore and check
end gap clearance with a feeler gauge .
If beyond tolerance, replace ring set.
Ring end gap, installed
Minimum
Maxim um
Top
0.30 mm 0.50 mm
(0012 in) (0020 in)
Second
0.30 mm
0.50 mm
(0012 in) (0020 in)

2. SPECIFICATIONS
NOTE: * ..... New specification
(Compared with 1980 ET300D)
General )
Model ET300E
Model (IB.M No.) * ET300E
(8L3)
Frame 10. & starting number
*
8L3-020101
Engine 10. & starting number
* E2
94 - 020 101
Dimension:
Overall length
2,385 mm (939 in)
Overall width (std)
935 mm (36 .8 in)
Overall height (w/windshield)
965 mm (380 in)
Engine
Description:
Engine
type
Fan cooled two-stroke 5-port. twin cylinders
Engine model
E294
Displacement
294 cc (17.94 cu.in)
Bore X Stroke
56 X 59 .6 mm ( 2.2 1 X 2.35 in) )
Effective compression ratio 6.5 : 1
Starting system Recoil hand
starter
Ignition system C.D.I
Lubrication system
"Autolub e" oil inj ection
Cylinder head
Combustion chamber volume
18.3 cc (1 . 12 cu.in) with spark plug
Compression chamber type
Dome + Squish
Head gasket thickness 0.5
mm (0.02 in)
Cylinder:
Material
Cast iron sleeves aluminum
Bore size
56 mm (2.21 in)
Taper
limit
0. 05 mm (0. 0020 in)
Out of round limit
0.01 mm (0.0004 in)
Piston:
Piston
skirt clearance (Measuring point)
0 . 040~ 0. 045 mm (0 . 0016~ 0. 0018 in)
(10 mm from pis ton skirt end)
Piston oversize 1st
56.25 mm (2213 in)
2nd
56.50 mm (2224 in)
3rd
56. 75 mm ( 223 4 in)
4th 57 . 00 mm (2244 in)
Piston pin
out side diameter X length
¢16 X 47 mm (¢0.630 X 1 .85 in)
Piston ring:
Piston ring design (Top) Keystone
Piston ring design (2nd) Plane
Ring end gap (installed) (Top) * 0.1 5
~ 0. 35 mm (0. 006 ~ 0. 014
Ring end gap (installed) (2nd) 0.
30 ~ 0.50 mm (0.012 ~ 0.0 20 in)
* Ring groove side clearance (2nd) 0.
02 ~ 0.06 mm (00008 ~ 0 .00 24 in)
Sma ll end bearing:
Type Needle b
ea ring
Big end bearing:
Type Needle bearing
-2 -

Crankshaft:
c Crankshaft
assembly width (A)
160 ±0 1 mm (630 ± 0.004 in)
Crankshaft assembly width (F)
+0 +0 .
52 - 0.05 mm (2.047 - 0002 In)
Crankshaft deflection (D) 0.
03 mm (D-1) 0.04 mm (D-2)
0.04 mm (0 -3) 0.03 mm (0 -4)
Connecting rod big end side clearance (C)
0.25 ~ 0.35 mm (001 0 ~ 0.014 in)
Connecting rod small end deflection (P)
2.0 mm (0079 in)
-- H --p
Q
D- 1 D-4
I J
c
11: ~ J A~ I,'\
Crank pin outs ide diameter X length ¢
22 X 51 mm (¢0866 X 2008 in)
Crank pin type
Solid shaft assembly type with serration
Crank bearing type (Left) X q'ty #6306 special 1 pc.
Crank bearing type (Center) X q'ty
#6206 special X 2 pcs.
Crank bearing type (Right) X q'ty #6305 special X 1 pc.
Crank oil seal type (Left) X q'ty
FPJ - 30 72 8 2TS X 1 pc.
Crank oil seal type (Center) X q'ty
Labyrinth seal X 1 pc.
Crank oil seal
type (Right) X q'ty
FPJ - 25 48 8TS X 1 pc.
Carburetor:
Type & manufacturer/quantity
B38-32 MIKUNI X 1 pc.
I.D. Mark
8H901
Main jet (MJ)
#210
Pilot jet (PJ)
#90
Pilot screw (PS)
1- 1/2 turns out
Throttle valve (ThV)
#185
r Valve seat (V.S.) ¢1 .5
mm (0059 in)
Float height 25 ± 1 mm (098 ± 0.04 in)
Idling engine speed 1600 r/ min
Main jet setting chart :
~
- 30
ve -
20 "C -
10 e ooe 10 e 20 e
Altitude
1- 22 ' FI
1_ 4 ' FI
1 14 ' FI 1
32 FI 1 50 FI
1 68 'FI
#200
Sea level #
210
1-- #220 - - IStd.1
#200
- 600m 12000 ftl
# 210
IStd.)
#190
- 1200m 14000 ftl
#200
-#2 10- -
IStd l -
-- #180 -
- 1800m 16000 h) #190
#200
- 2400m 18000 ftl
#190
Ii180
#200
c
#180
- 3000m 110000 hi or more #190
-3-

Lubrication:
Autolube pump -Color code
Autolube pump -Minimum stroke
Autolube pump - Maximum stroke
Autolube pump -Reduction ratio
Autolube pump - Output Min/200 strokes
Autolube pump - Output Max/200 strokes
Autolube pump wire free play
Oil tank capacity
Oil grade
Drive and track suspension
Transmission:
Type
Drive ratio
Engagement rpm
Primary spring:
Part No.
Color code
Secondary spring:
Part No.
Color code
Secondary spring pre-load
(twist)
Sheave di::;tance
Sheave off-set
V-belt width and outer line length
V-belt wear limit
Track suspension:
Type
Damper type
Spring
color code (Rear)
Slide runner wear limit
Track width
Track deflection
Length on ground
Wheel sprocket material and number of teeth
Stopper band length
Se condary drive:
Type
Reduction ratio
Chain pitch X Number of links
Free play
Chain housing oil
quantity
Chain housing oil grade
Brake:
Type
Brake pad thickness
B
ra ke pad wear limit
Gap between pad and disc
Blue
0.20 rv 0.25 mm (0.0079 rv 0.0098 in)
1.65 rv 1.87 mm (00650 rv 0.0736 in)
1/36
0.50 rv 0.63 cc (0.0169 rv 0.0213 oz)
4.15 rv 4.70 cc (0.1403 rv 0.1589 oz)
25 ± 1 mm (098 ± 0.04 in) at idle
2.4 liter (25 us. qt)
YAMALUBE 2-cycle
V-belt automatic centrifugal engagement
3.5 : 1 rv 1 1
* 3100 rv 3300 r/min
90501-55345
Red-Red
90508-40080
No. painted
160
0
266 ±2 mm (10.47 ± 0.08 in)
11 ± 1 mm (0.43 ± 0.04 in)
31.6 X 1,099 mm (1.24 X 43.3 in)
26 mm (1.02 in)
Slide rail suspension
Oil and gas damper
No. painted
10 mm (0394 in)
380 mm (15 in)
25 rv 30 mm/l 0 kg (098 rv 1.18 in/22 Ib)
650 mm (256 in)
Polyethylene 11 T
210 mm (827 in)
Chain (#40K-l)
22/13 (1 692)
12.7 mm (05 in) X 60L
+5 +0.2 .
10 - 2 mm (0.4 - 008 In)
450 cc (15.2 oz)
Gear oil API
"GL3" (SAE #75 or 85)
Disc brake
7.3 mm (0.287 in)
1.0 mm (004 in)
0.2 rv 1.0 mm (0008 rv 0.039 in)
-4 -
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Chassis
c Frame: Material
Aluminum + Steel I
Steering system'
Caster (ski
column)
25 °
Camber 0°
r S
ki length X width X thick ne ss
980 X 120 X 1.6 mm (38.6 X 4.7 X 0.06 in)
S
ki stance
800 mm (31.5 in)
Ski
toe - out
O~ 6 mm (O~ 0. 23 in)
Steering linkage type Tie-rod
Lock
to lock angle (ski) Right ski,
L: 27.6 °
R: 24.8 °
Left ski,
L:
248 °
R: 27. 6°
Lock
to lock angle (steering column)
Right: 54.3 °
Left: 56.3 °
Front suspension:
Type Leaf spring
Damper type
Oil damper
Fuel tank :
Capacity
22.7 liter (6 U S.
gal)
Fuel grade Regular gasoline
Electrical
Ignition system:
Type- flywheel magenta (C .D. 1.
type)
Model/m a nuf act ur er
F3T352 / MITSUBI SHI
Voltage
12V
Pulser coil resistance
9.00 at 20 °C (68 ° F) (Whit e /Red -Black)
C harging coil resistance
350n at 20 °C ( 68 ° F) (Bro wn -Black)
Charging coil resistance
15.00 at 20 °C (68° F) (Blue-Black)
Ignition timing:
B.T.D.C. 1.4 ± 0.1
mm (0.055 ± 0 .00 4 in)
Ignition coil:
Model: Manu facturer
CM62 -2 0 HITACHI or * YW- 51 TOYO DENSO
Spark
gap
9 mm (0.4 in)/ 300 r/min +--
11 mm (0.6 in)/3,000 r/ min +--
Pr ima ry winding resistance 0.150 at 20 °C (68 ° F)
* 0.120at20 °C (68 ° F)
S eco ndary winding resistance
3.6k O at 20 °C ( 68 ° F)
* 40kO at 20 °C (68 ° F)
Di ode (Yes or No) No
+--
Spark plug:
Type & quantity
NGK BR-9ES X 2 pcs.
Spark
plug gap
O. 7 ~ 0.8 mm (0. 028 ~ 0.031 in)
Spark
plug cap:
Type Rubber
type with noise suppressor
c Noise suppressor resistance 5kO at
20 °C (68 °F)
C.D.
1. unit:
Model/Manufacturer
8H4-20 /MI TSUBISHI
Lighting system:
Lighting output
12V-l00W
Lighting coil resistance
0.190 at 20 °C (68 ° F) (Yellow-Black)
c H
eadlight type
Semi shield
Bu lb wattage/q'ty 12V -60 / 60W X 1 pc.
Tail/stop light wattage
12 - 8W / 23W
A.c. regulator:
Model/manufactur er TRIZ-24B/HITACHI or S8516B /TO SHIBA
Voltage
1 3.8 ± 0.5V
-5 -

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