Yamaha ET340D Manual

• YAMAHA
SNOWMOBILE
[Frame serial number: 8J6-025101
~ 8J6-039999 ]
Engine serial number: E338-025101
~ E338-039999
LIT -12618-00-24
8J6-28197-10

c
c
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CONTENTS
1. NEW SERVICE PROCEDURE .............................................................. .... .
2.
MAINTENANCE INTERVALS .... ...... .... .................................. .... .. ............. 2
3. SPECiFiCATIONS.
... .. . .. ..... .... ....... ... .. ..................................... .... ..... . ..... . .... 4
4. SPECIAL TOOLS.......................
.. ............ ..... ... ............ ... ............................. 9
5.
WIRING DIAGRAM ............................................ .... .... .... .......................... .. 10
6. WIRE AND PIPE ROUTING DIAGRAM ...... .................. .. .. ...................... 11
1. NEW SERVICE PROCEDURE
(New service procedure applied to the 1980 ET340D)
CARBURETOR
1. To achieve the precise fitting of the
main nozzl
e, the main nozzle is press-
fitted to the mixing chamber body, and
accordingly the main nozzle cannot be
removed.
1980 ET340D
2. For better performance, the recom-
mended
type of the main jet which is
more effective at alititudes is changed.
[Main jet setting chart]
~
-3 0°C -
20 °C - 10°C
ooe
10 °C
20 °C
Altitude
(-22 ° F)
(-4 ° F)
(14 ° F) (32° F)
(50 ° F) (68° F)
I I I I I I
..
#220
#240
Sea level
..
(Std) .
# 250
..
..
#220
~ 600m (2000 ft)
#240
(Std)
..
..
# 220
.-
~ 1200m (4000 ft)
-#24
# 210
. ..
*
.
#210
.
~ 1800m (6000 ft) *
#200_
#2 20
..
..
*
..
#200
~ 2400m (8000 ft)
#210
..
--#190
~ 3000m (10000 ft)
f--
-
#190
or more
#200
..
* Newly changed specification.
-1 -

1980 ET340D
2. MAINTENANCE INTERVALS
[PERIODIC MAINTENANCE]
Every
Check point
20 hrs. or
40 hrs. or 80 hrs or When Seasonally
400 km 800km
1600 km necessary
(250 mil
(500mi) (1000mi)
ENGINE:
Tightness of bolts and nuts a a
Bends. cracks and wear
a a
Abnormal noise a a
Loose connection and breaks of fuel and pulse pipes a a
Loose connection and breaks of oil pipes a a
Loose connection and breaks of oil delivery pipe a a
Manual rope starter system a a
Carburetor
•Operation
of starter jet a a
•
Mixing adjuster (pilot screw) a a
•Idling speed adjustment a a
Operation and adjustment of oil pump
a a
Ignition timing
a
Cylinder compressions a a
Cylinder head/exhaust pipe decarbonize a
Spark plug condition. gap and cleaning a a
Tightening of the cylinder head**
a
DRIVE:
Tightness of bolts and nuts a a
Wear on slide runners a a
Primary drive system a a
V-belt a a
Secondary drive system a a
Sheave distance a a
Sheave offset a a
Brake pad wear a a
Brake operation and adjustment a a
Guide wheel rubber a a
Wear of drive track wheel sprocket a a
Drive track adjustment a a
Breaks in drive track a a
Bends in front and rear axles a a
Checking of lock washers a a
Drive chain adjustment
a a
Drive chain oil level a a
BODY:
Tightness of bolts and nuts a a
Bends and cracks a a
Welded riveted. joints
a a
Ski adjustment a a )
Ski runner wear a a
Breaks in fuel tank a a
Cleaning of fuel tank a
Fuel filter a
Loose connection and breaks in fuel pipe a a
Breaks in oil tank a a
Oil filter a
-2 -

1980 ET340D
Every
Check point
20 hrs. or 40 hrs. or 80 hrs or
When
Seasonally
400 km 800 km 1600 km
necessary
(250 mil
(500mi) (1000mi)
ELECTRICAL:
Wear. breakage of wire covering 0 0
Breaks in high-tension cord 0 0
Voltage r egulato r working voltage 0
Operation of engine stop switch 0 0
Operation of tether switch 0 0
Headlight 0 0
Taillight 0 0
Brake light
0 0
•• Retighten every 10 hours from the first use.
[LUBRICATION INTERVALS]
Every
Lubrication
point
20 hrs. or 40 hrs. or 80 hrs or
When
Seasonally
Oi l/ Grease
400 km 800 km 1600 km necessary Brand name
(2
50 mil
( 500mi)
(1000 mil
ENGINE:
Starter case 0
Oil pump control box 0 0 Aeroshell grease #7A
or
Esso Beac on 325 grease
Pump drive cover 0 0
Oil in the oil tank 0 YAM.A.LUBE 2-cycle oil
DRIVE:
Primary sheave weight
0 0
Molybdenum disulfide
and roller
pins
snowmobile grease
Secondar y shaft and 0 0 Molybdenum disulfide
sliding sheave
snowmobi le grease
Front axle
housing
0 0
Shaft 1 and shaft 2 0
(Slide rail) 0 Light all-purpose grease
Drive chain oil Gear oil API
"GL -3"
replacement
0 0 SAE #
75 or #BO
BODY:
Steering column lower
0 0
Light all-purpose grease
bearing
Steering
column up per
0 0
Motor oil
bearing
Steering links 0 0
Ski column 0 0
Ski wear plate 0 Light
all-purpose grease
0
Ski retaining pin 0 0
8rake wire end stopper
0 0 Esso Beacon 325 grease
and brake lever
- 3 -

1980 E T340D
3. SPECIFICATIONS
NOT E: * ..... New specification
General (Compared
with 1979 ET340C)
Model ET340D
Model :
Model (I.B.M. No.) *
ET340D (8J6)
Frame I.D. &
starting number * 8J6-025101
Engine I.D. & starting number
*
E338-0251 01
Dimension:
Overall length * 2,
555 mm (100 .6 in)
Overall width (std)
970 mm (38.2 in)
Overall height (w/wind shield) 1,040 mm (40.9 in)
Engine
Descripti0 n:
Engine type
Fa n cooled two -stroke 5- port twin cylinders
Engine
model
E338
Displacement
338 cc ( 20 .6 cu.in)
Bore X Stroke
60 X 59 .6 mm (2 .36 X 2.35 in)
Effective compression ratio
6.5: 1
S
tarting system Recoil hand starter
Ignition sys tem
C .D.1.
Lubrication system "Autolube" oil inspection
Cylinder hea d:
Combustion chamber volume (with spark plug) 2
1. 3 cc (1. 30 cu.in)
Compress
ion chamber type
Dome + Squish
Head gasket thickne ss
0.5 mm (0. 02 in)
Cylinder:
Material
Cast iron sleeves a lu minum
Bore size 60 mm (2 .36 2 in)
Taper
limit
0.05 mm (0. 0020 in)
Out of round limit
0.01 mm (0 .0004 in)
Piston:
Piston sk
irt clearance (Measuring point) 0. 040 ~ 0.045 mm (0.001 6 ~ 0.0018 in)
(10 mm from piston s kirt end)
Pi s ton oversize 1st 60.25 mm ( 2.372 in)
2nd 60.50 mm (2 .38 2 in)
3rd 60 . 75 mm ( 2.392 in)
4th 61.00 mm (2. 402 in)
Pi st on pin outside diameter X length
¢16 X 47 mm (¢0.6 30 X 1.85 in)
Piston ring:
Piston ring design (Top) Keys
ton e
Pi s ton ring design ( 2nd ) Keystone
Ring end gap (installed) (Top)
0.35~ 0.55 mm (0 . 014~ 0.022 in)
Ring end gap (installed) (2nd) 0.
35 ~ 0. 55 mm (0.014 ~ 0.022 in)
Small end bearing:
Type Needle b
ea ring
Big end bearing:
Type Needle b
ea ring
Crankshaft:
Crankshaft asse
mbly width (A)
160 ±0.1 mm (6.30 ± 0.004 in)
-4 -

1980 ET 3 400
Crankshaft assemb ly width (F)
52 ~ g05 mm (204 7 ~ g002 in)
Cranksha ft deflection (0)
0.03 mm (0 -1) 0.04 mm (0-2)
0.04 mm (0 -3) 0.03 mm (0-4)
Con necting rod large end side clearance (C) 0 . 25~0 . 35 mm (0.01 0~O.014 in)
Connecting rod small end deflec tion (P) 2.0 mm (0. 079 in)
---P
Q 0 -4
I
.:J
l U A ~ ~
Crank pin outside diameter X length
rjJ 22 X 51 mm (rjJ0866 X 2008 in)
Crank pin type So lid shaft assembly type with serration
Cra nk bearing type (L ef t) X q' ty
#6306 special 1 pc.
Crank bearing type (Center) X q'ty
# 6206 special X 2 pcs.
Crank be aring 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 ( Ce nt er) X q'ty
La byrinth seal X 1 pc.
Crank oil seal
type (Right) X q'ty
FPJ -25 48 8T S X 1 pc.
Carburetor :
Type & manufacturer / quant ity 838-34 MIKUNI X 1 pc.
I. D. Mark
8J600
Main jet (MJ.)
# 240
Pi lot jet (PJ)
# 75
Pilot screw (P. S .)
1.0 turns out
Throttle va lve (ThV)
#1 90
Valve seat (V. S. )
rjJl .5 mm (0. 059 in)
Fl oat height
25 ± 1 mm ( 0.98 ± 0.04 in)
I dling engine speed
1700 r/ min
Main jet sett ing chart
~
- 30 °C - 20 °C - 10 °C O°C
10 °C 20 °C
(-
22 ° F) (- 4 ° F) ( 14 °F) (32° F)
(50 °F) (68° F)
Altitude
~
I I I L I
#2 20
# 240
Sea level (Std)
- #2
50 -- -
#
220
~ 600m (2 000 It)
# 240
(Std)
#
220
~ 1200m ( 4000 It)
r----# 2 40 -- -#
210
.
# 210
~ 1800m (6000 It)
•
_#2. 00 _
# 220
# 200
~ 2400m ( 8000 It) #
210 - # 190
~ 3000m (1000 0 It)
#190
or more #
200
• New ly changed specificati on .
- 5 -

1980 ET340D
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.
Col or code
Secondary spring pre-load
(twist)
Sheave distance
Sheave off-set
V-belt width and outer line length
V-belt wear limit
Track suspension:
Type
Damper type
Spring color code (Front)
Spring color code (Rear)
Slide runner wear limit
Track width
Trade deflection
Length on ground
Wheel sprocket material and number of teeth
Stopper band length
Secondary drive:
Type
Reduction
ratio
Chain pitch X Number of link s
Free play
Chain
housing oil quantity
Chain housing oil grade
Brake:
Type
Brake pad thickness
Brake pad
wear limit
Gap between pad and disc
White
0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in)
1.67 ~ 1.87 mm (0.0657 ~ 0.0736 in)
1/32
0.50 ~ 0.63 cc (0.0169 ~ 0.0213 oz)
4.1 5
~ 4. 70 cc (0 1403 ~ 0.1589 oz)
25 ± 1 mm (0.98 ± 0.04 in) at idle
2.4 Liter (2.5 US.qt)
YAMALUBE 2-cycle
V-belt automatic centrifugal engagement
3.5: 1 ~ 1 : 1
3000 r/min
90501-50500
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
Red
No painted
10 mm (0. 394 in)
380 mm (15 in)
25 ~ 30 mm/l 0 kg (0. 98 ~ 1.18 in/22 Ib)
760 mm (29.9 in)
* Polyethylene 11 T
186.5 mm (7.34 in) (1st hole from the bottom)
Chain (#40K-2)
22 /1 3 (1 . 692)
12.7 mm (0.5 in) X 60L
+5 + 02 .
10 - 2 mm (0.4 - 0.08 In)
400 cc (13.5 oz)
Gear oil API
"GL3" (SAE #75 or 85)
Disc brake
7.3
mm (0. 287 in)
1.0 mm (0.04 in)
0.2 ~ 1.0 mm (0.008 ~ 0.039 in)
-6-

1980 ET340D
Chassis
Frame:
Material
Aluminum + Steel
Steering system:
Caster (ski
column)
25 °
Camber 0°
Ski length X
width X thickness
980 x 120 x 1.6 mm (38.6 x 4.7 x 0.06 i n)
Ski stance
850 mm (33.5 in)
Ski toe - out o ~ 6 mm (0 ~ 0.23 mm)
Steering linkage type Tie-rod
Lock
to lock angle (Ski) Right ski.
L:
27.6 ° R: 24.8 °
Left ski.
L:
24.8 ° 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 US. gal)
Fuel grade Regular gasoline
Electrical
Ignition system:
Type- flywheel magneto (C.D.1. Type)
Model/manufacturer
F3T352/MITSUBISHI
Voltage
12V
Pulser coil resistance
9.00 at 20 °C (68 ° F) (White/Red-Black)
Charging coil resistance
3500 at 20 °C (68 ° F) (Brown-Black)
Charging coil resistance
15.00 at 20 °C (68 ° F) (Blue-Black)
Ignition timing:
B.T.D.C. 1.6 ± 0.1 mm (0.06 ± 0.004 in)
Ignition coil:
M odel/M an ufacturer CM62 - 20 /H ITACHI
Spark gap 9
mm (0.4 in)/ 300 r/ min
11 mm (0.6 in)/3,000 r/ min
Primary winding resistance 0.150 at 20 °C (68°F)
Secondary winding resis tance 3.6kO at 20 °C (68 ° F)
Diode (Yes or No)
No
Spark plug:
Type & quantity * NGKBR-9ESx2pcs.
Spark plug gap *
0 . 7~0.8 mm (0.028~0.031 in)
Spark plug cap:
Type Rubber type
with noise suppressor
Noise suppres
sor resistance 5kQ
at 20 °C (68 ° F)
C.D.1. unit:
I
Model/Manufacturer
8H4-20 / MITSUBISHI
Lighting system:
12V - l00W I
Lighting output
Lighting coil resistance
0.190 at 20 °C (68 ° F) (Yellow -Bla cK)
Head light type Semi shield \
Bulb wattage/q'ty
12V-60/60W X 1 pc.
Tail/brake light wattage
12V-8W/23W
A.C. regulator:
Model/Manufacturer
TR IZ -2 4B/H ITACHI 0< 8B51 6B/ TO 81 'BA
Voltage
13 .8 ± 0.5V
-7-

1980 ET340D
Tightening torque
Part to be tightened
Thread size
Tighten ing torque Remarks
Engine:
Spark plug
M14 P1.25
2.8 m-kg
( 20 ft -Ibl
Cylinder head
M8 P1.25
2.5 m-kg
(1 8 ft-Ib l
Flywheel magneto
M1 6 P1.0
7.3 m-kg (53 ft-Ib l
Crankcase upper and lo wer
M8
P1.25
Fi rst: 1.0 m-kg ( 7.5 ft-Ibl
Final: 2.0 m-kg (1 5 ft -Ibl
Tightening sequence
rr-
-
/
~ 6
3 $$ 2
7 ~t- -
_.
f--
$ 5
1$$ 4 8$
I
~
S tarter pulley
I M8
P1.25
1.6 m-kg (11.5 ft- I b)
Crankcase and E ngine bracket
I M10
P1.25
3.0 m-kg (2 1.5 ft -Ib)
Drive and
track su~penslOn
Pr imary sliding sheave and Cap
M6
P1.0
11m -kg (8 ft-Ibl
Installation of primary sheave UNF1/ 2" Initial Use
Motor od
12 m-kg
( 88 ft-Ib)
Loosen once and
retighten ·
6.0 m-kg
( 435 ft-Ibl
I nstallation of drive chain sprocket
M1 2
P1 . 25
40 m- kg
( 29 ft-Ibl Use cotte r pin
Installation of dnven chain sprocket
M10
P1 . 25
3.5 m-kg
( 25 ft -Ib)
Chain housing and Frame
M8
P1 .25
2.5 m- kg
( 18 ft-Ibl
Chain housing cap
M8 P1. 25
1.6 m-kg (
11 .5 ft-Ib)
Chain tensioner lock nut
M10 P1 .25 3.3
m-kg
( 24 ft-Ibl
In stallation of front axle R .H
M20 P1 .0 9.0
m-kg
( 65 ft-Ibl
Front axle housing and Frame M8
P125
2.5 m-kg
(1 8 ft-Ibl
Wheel sprocket and Fr ont axle
0.5 m-kg
( 35 ft-Ibi
Sh aft 1 and Fra me
M10
P1.25 5.5 m-kg
( 40 ft-Ib) Use LOCK-TI TE
S haft 2 and Rear bracket
M10
P1 . 25 5.5 m-kg
( 40 ft-Ibl Use LOCK-TITE
Rear bracket and Fra me
M8
P1.25
2.5 m-kg (1 8 ft-Ibl Use LOCK-TITE
Bracket 2 and Frame sliding 1
M6
P1.0 1.2 m-kg (9
ft -Ib)
Installation of suspension wheel
M6
P1 .0
1.1 m- kg
(8 ft-Ibl
Installation of rear guide wheel
M8
P1.25
2.5 m- kg
(18 ft-Ibl Use LOCK- TI TE
Installation of runner sliding 1 M6 P1.0 0.
25 m-kg (2 ft-Ibl
Use LOCK-TITE
Installation of runner sliding 2
M6 P1 .0 0.6 m-
kg
(4 ft -Ibl Use LOCK-TITE
P ivot arm 1 and Bracket 2
M6 P1 .0 5.0 m-kg (
36 ft-Ib) Use LOCK-TITE
Pivot 5 & 6 and Frame sliding 1
M6 P1 .0 1.3 m-kg (9 5 ft-Ib) Use LOCK-
TI TE
Frame sliding 1 and 2 & 3 M8 P1 . 25 2.5 m-kg (18 ft -Ibl
Installation of stopper 1 M6 P1 .0 0.35 m-kg (2 5 ft-Ibl
Chassis.
Engine mounting bolt
M10 P 1. 25 3.0 m- kg ( 22 ft-Ib l
Ski runner
M8 P1.25 1.4 m-kg (10 ft-Ibl Use plain washer and
LOCK-TITE
- 8 -

1980 ET340D
St eering co lum n and Gate M8
P1 . 25
2.0 m-kg (
14 5 ft -Ib) 1 Use lock washer
St eering relay rod adjusting nut
M10 P1 . 25
2.5 m-kg (
18 ft -Ib\ i
Out side arm and Ski co lumn M10
P1 25 3.0 m-kg (
22 ft -I b) I Use
lock washer and
!
wave washer
Steerrng lo wer bracket
M8 P1 .2 5 2.0 m-kg (
14 .5 ft-Ib) Use
lock washer and
LO CK-TI TE
Installati on of steering column 1. 2 M8
P1 . 25
1.45 m-kg (
105 ft-Ib) Use lock
washer
S tee ring relay ass'y M10
P1 . 25 3.0 m-kg
( 22 ft -Ib) Use co
tter pin
Universal jOint M10
P1 . 25
2.5 m-kg (
18 ft-Ib )
Ste e ri ng gate
M8
P1 . 25 1.4 m-kg
( 10 ft -Ib)
4. SPEC IAL TOOLS
1. 4-a.
10.
6.
No. Description Tool No.
1 Di
al gauge
90890-03097
2 Dial gauge stand No.2
90890-01195
3 Dial gauge needle
(56 mm)
90890 - 03098
4-a Flywheel puller bolt
90890 - 01803
4-b Flywheel puller attachment
90890 - 01804
7.
4-c Flywheel puller screw
90890 -01806
4-d Drive handle
90890 -01 81 7
4-e Flywheel puller
body
9 0890-01848
5 Rotor holding
tool
90890 -0 12 35
6 Primary fixed sheave puller
90890-01859
7 Sheave sub-assembly tool
90890 - 01858
8 Bushing
tool
90890-01877
9 Sheave gauge
90890 - 01875
10
Main switch ring nut tool
90890-0185 7
11
Pocket tester
90890-03 1 04
12 Electro tes ter 90890 - 03021
13
A.C. Regulator checker 90890-03090
- 9 -