Yamaha ET340ED Manual

LIT -12618-00-25
• YAMAHA
81MMDBIlE
SUPPLEMENTARY
SERVICE l
[Frame serial number: 8J9-040101
~ 8J9-049999 ]
Engine serial number: E338-040101
~ E338-049999
8J9-28197-10

CONTENTS
1. NEW SERVICE PROCEDURE ........... .... .... ........ .. .. .. . .. ...............................
2.
MAINTENANCE INTERVALS .. ....................... .. ........................................ 2
3. SPECiFiCATIONS
... .. .......... .. ... ... .... . .. ............... .... . .... . .. .......... ..... ........... .... 4
4. SPECIAL TOOLS..............................................
.. .......... .. ........................ ..... 10
5. WI RING DIAGRAM .... ........... .. ........................ .... ........... ... .. ............ .... ... .... 11
6. WI RE AND PIPE ROUTING DIAGRAM .. .. ...... .. ............ .. " ........... .. ......... 12
1. NEW SERVICE PROCEDURE
(New service procedure applied to the 1980 ET340ED)
Carburetor
1. To achieve the precise fitting of the
main nozzle,
the main nozzle is press-
fitted to the mixing chamber body, and
accordingly the main nozzle cannot be
removed.
1980 ET340ED
2. For better performance, th e recom-
mended
type of the main jet which is
more effective at
altitudes is changed.
[M ain jet setting chart]
~
- 30 °C -20 °C -10 °C ooe
1Q oe
20 °C
( -22 ° F) (- 4° F) (14° F) (32° F)
(50 ° F) (68° F)
Altitude
I I I I I I
..
#220
# 240
Sea level
..
(Std)
..
#2 50
..
..
# 220
~ 600m ( 2000 ft)
# 240
(Std)
..
.
#220
..
~ 1 200m (4000 ft)
r-.- #240
# 210
.. ..
(Std) *
.
#210
..
~ 1800m (6000 ft)
* #200_
#220
..
..
*
..
# 200
~ 2400m (8000 ft)
#210
-
--#190
~ 3000m (10000 ft) --
#190
or more
#200
..
* Newly changed specification.
- 1 -

1980 ET340ED
2. MAINTENANCE INTERVALS
[PERIOorc MAINTENANCE]
Check point
20 hrs. or
400km
(250 mi)
ENGINE
Tightness
of bolts and nuts a
Bends. cracks and wear
a
Abnormal noise a
Loose connection and breaks of fuel and pulse pipes a
Loose connection and breaks of oil pipes a
Loose connact ion and breaks of oil delivery pipe a
Manual rope starter system
Carburetor
•
Operation of starter jet
•
Mixing adjuster (pilot scr ew)
•
Idling speed adjustment
Operation and adjus tm ent of oil pump
I gnition timing
Cylinder comp ressions
Cylin der head/exhaus t pipe decarbonize
Spark plug co n ditio n. gap and cleaning a
Tightening of the cylinder head--
DRIVE:
Tightness of bolts and nuts a
We ar on slide runners a
Pr imary drive system
V-belt a
Secondary drive system
Sheave distance
Sheave offset
Brake pad wear
Brake operation and adjustment
Guide wheel rubber
Wear of drive track wheel sprocket
Drive track
adjustment
Breaks in drive track
Bends in front and rear axles
Checking of lock washers
Drive chain adjustment
Drive chain oil level
BODY:
Tightness of bolts and nuts
a
Bends and cracks a
Welded riveted. joints
a
Ski adjust ment
Ski runner wear
a
Breaks in fuel tank
Cleaning of fuel tank
Fuel filter
Loose connection and breaks in fuel pipe
Breaks in oil tank
Oil filter
-2-
Every
40 hrs. or 80 hrs or
When
Seasonally
800 km 1600 km
necessary
(500mi) (1000 mi)
a
a
a
a
a
a
a a
a a
a a
a a
a a
a
a a
a
a
a
a
a
a a
a
a a
a a
a a
a a
a a
a a
a a
a a
a a
a a
a a
a 0
a a
a
a
a
a a
a
a a
a
a
a a
a a
a

1980 ET340ED
Every
Check point
20 hrs. or 40 hrs. or
80 hrs or
When
Seasonally
400 km
800 km 1600 km necessary
1250 mil 1500 md
11000 mr)
ELECTRICAL
Wear. breakage of wire cover ing
0 0
Breaks;n high - tension cord 0 0
Voltage regulator working voltage
0
Operation of engine stop sWitch 0 0
Operation of tether switch
()
0
Headlight
(,
0
Taillight
( , 0
Brake light
( 0
Battery fluid top up/specific gravity and breather pipe
0 0
•• R etighten every 10 hours from the first use.
[LUBRICATION INTERVALS]
Every
Lubrication point
20 hrs. or 40 hrs. or BO hrs or
When
Seasonally
O,l/Greilse
400 km BOO km 1600 km necessary Brand
name
1250 mil 1500 mil 11000 mil
ENGINE
Starter case 0
a,l pump control box 0 0
Aeroshell grease ;1 7A or
Esso Beacon
325 grease
P
ump drive cover 0 0
all In the 011 tank
C
YAMALUBE 2-cycle 011
DRIVE
Primary sheave weight
0 0
Molybdenum disulfide
and roller pins
snowmobile grease
Secondary shaft and 0 0 Molybdenum disulfide
sliding sheave snowmobile grease
Front axle
housing
0 0
Shaft 1 and shaft 2 0
ISlide rail! 0 Light all-
purpose grease
Drive
chain oil Gear oil API
"GL-3"
repla cement
0 0 SAE
#75 or #80
BODY:
Steering column lower
0 0 Light all- purpose grease
bearing
Steering column uppe r 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
Brake wire end stopper
0 0 Esso Beacon 325 grease
and brake lever
-3-

1980 ET340ED
3. SPECIFICATIONS
NOTE : * .... New specification
General (Compared
with 1979 ET340EC)
Model
ET340 ED
Model:
Model (I.B.M. No.) * ET340ED (8J9)
Frame 1.0. & starting number
* 8J9-040101
Engine 1.0. & starting number
*
E338 - 040101
Dimension:
Overall length
* 2.555 mm (100.6 in)
Overall width (std)
970 mm (38 .2 in)
Overall height (w/windshield) 1.040 mm (40.9 in)
Engine
Description:
Engine type
Fan cooled two-stroke 5-port. twin cylinders
Engine model E338
Displacement
338 cc (2 0.6 cu.in)
Bore X
Stroke 60 X 59 .6 mm (2.36 X 2.35 in)
Effective
compression ratio
6.5: 1
Starting system Recoil hand
starter and electric starter
Ignition system C.D.I.
Lubrication system "Autolube" oil inspection
Cylinder head:
Combustion chamber volume (with spark plug)
21.3 cc (1.30 cu.in)
Compression chamber type
Dome + Squish
Head gasket thickness 0.5 mm (0.02 in)
Cylinder:
Material
Cast iron sleeves aluminum
Bore size 60 mm (2.362 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 piston skirt end)
Piston over size 1st 60.25 mm (2. 372 in)
2nd 60.50 mm (2.382 in)
3rd 60.75 mm (2. 392 in)
4th 61.00 mm (2.402 in)
Piston pin outside diamet er X length
¢16 X 47 mm (¢0.630 X 1. 85 in)
Piston ring:
Piston ring design (Top) Keystone
Piston 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 bearing
Big end bearing:
Type Needle bearing
Crankshaft:
Crankshaft assembly
width (A)
160 ±0.1 mm (6.30 ± 0.004 in)
-4-

1980 ET340EO
Crankshaft assembly width (F)
52 ~g05mm (2.047 ~ g002 in)
Crankshaft deflection (0) 0.03 mm (0-1) 0.04 mm (0 - 2)
0.04 mm (0 -3) 0.03 mm (0 -4)
Connecting rod large end side clearance (C) 025~0.35 mm (0.01O~0 . 014 in)
Connect ing rod small end deflection (P)
2.0 mm (0.079 in)
.
---P
Q
0-1
D-4
I
:J
E~ A~ 6
Crank pin outside diameter X l ength ¢2 2 X 51 mm (¢0.866 X 2.008 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
#6 206 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 /q uantity 838 - 34 MIKUNI X 1 pc.
I.D. Mark
8J600
Main jet (MJ.)
#240
Pilot jet (PJ.)
#75
Pil ot screw (P.S.)
1.0 turns out
Throttle valve (ThV)
#190
Valve seat (V .S. ) ¢ 1.5
mm (0.059 in)
Float height
25 ± 1 mm (0. 98 ± 0.04 i n)
I dling engine speed
1700 r/min
Main jet sett ing chart
~
- 30 ' C - 20 ' C -
10 ' C O°C 10 °C
20 °C
Altitude
1-2 2° FI
1- 4°FI 114° FI 1
32 °FI ISO ° FI 168°FI
I I I I I I
. #
220
#2 40
Sea level IStdl
f---#2S0 - --
# 22 0
-
600m 12000 It I #
240
IStdl
#
220
- · 1200m 1 400 0 Itl
c- 1~~~ -- -
# 210
.
# 210
- 1 800m 16000 It l •
_#2 .00 _
#
220
# 200
- 2400m 1 8000 It I #
210
- #1 90
- 3000m 110000 ItI #
190
or more #
200
• Newly changed specification.
-5-

1980 ET34GED
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 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
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
Brake pad wear limit
Gap between pad and disc
White
0.20~. 0.25 mm (00079 ~ 0.0098 in)
1.67 ~ 1.87 mm (0.0657 ~ 0. 0736 in)
1/
32
0.50 ~ 0.63 cc (0.016 9 ~ 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 (25 US.qt)
YAMAlUBE 2-cycle
V-belt automat ic 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/1 0 kg (0.98 ~ 1.18 in/22 Ib)
760 mm (29 .9 in)
* Polyethylene 11 T
186.5 mm (7.34 in) (1 st hole from the bottom)
Chain (#40K -2)
22/13 (1.692)
12.7 mm (0.5 in) X 60l
+ 5 + 0.2 .
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 (0008 ~ 0.039 in)
-6 -

1980 E T340ED
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 (386 x 4.7 x 0.06 in)
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
c Fuel tank:
Capacity
22 .7 liter (6 US. gal)
Fuel grade Regular
gasoline
Electrical
Ignition system
Type- flywheel magneto (C.D.I. Type)
M
odel/ ma nufactu rer F3T352 / MITSUBISHI
Voltage
12V
r Pulser coil resistance
9.0n at 20 °C (68 ° F) (White /Red-Black)
Charging coil resistance
350n at 20 °C (68 ° F) (Brown-Black)
Charging coil resistance 15.0n 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 a nufacturer
CM62 - 20/HITACHI
Spark gap 9
mm (04 in)/ 300 r/ min
11 mm (0.6 in)/ 3.000 r/ min
Primary winding resistance 0.
15n at 20 °C (68 ° F)
Secondary winding resistance 3.
6kn at 20 °C (68 ° F)
Diode (Yes or No)
No
Spark plug :
Type & quantity
*
NGK BR-9ES x 2 pcs .
Spark
plug gap 0.7~0 . 8 mm (0.028~0.031 in)
Spark plug cap:
Type Rubber
type with noise suppressor
r Noise suppressor resistance
5kn at 20 °C (68 ° F)
C.D.I. unit
Model/Manufacturer
8H4-20/MITSUBISHI
Starter motor type: *
HITACHI S108 - 73
Armature coil resistance * 0.
014nat20°C(68°F)
Field coil resistance * 0.
008n at 20 °C (68 ° F)
Brush length : standard *
13 .5 mm (0.53 in)
minimum
* 9.5
mm (0.37 in)
Brush spring pressure *
700 g (24 .7 oz)
c
Armature mica undercut
* 0.2
mm (0. 008 in)
- 7-

1980 ET340ED
Battery type: *
YUASA YB-14L -2A
Charging rate * 1.4
Amps for 10 Hours
Spec
ific gravity
1.28/20 °C (68 ° F)
Charging system
Type Flywheel
magneto
* Charging coil resistance
0.22n at 20 °C (68 ° F) (White-Black)
Starter relay switch:
Hitachi A 104 - 61
Cut -in voltage
6.5V
Winding resistance 3.0n at 20 °C (68 ° F)
Rectifier:
Type
l-element type (Half wave)
Model/manufacturer D E5404/ST AN LEY
Capacity
6A
With stand voltage
400V
Light ing system:
Lighting output
*
12V-ll0W
Lighting coil resis tance 0.19n at 20 °C (68 ° F) (Yellow -Black)
H ea d 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
TRIZ-24B/H ITACHI or S85 16 B/ TOSHI BA
Voltage
13.8 ± 0.5V
Tightening torque
Part to be tightened
Thread size
Tightening torque
Remarks
Engine:
Spark plug
M14
Pl.25
2.8 m-kg
(20 ft -Ib)
Cylinder head
M8
Pl.25
2.5 m-kg
(18 ft -Ib)
Flywheel
magneto
M16
Pl.0
7.3 m-kg
(53 ft-Ib)
Crankcase upper and low er
M8
P1.25
First 1.0 m-kg (7.5 ft -Ib)
Fin
al 2.0 m-kg (15 ft-Ib)
T ightening sequence
rr
-
/
-$ 6 3
$$ 2
7~t--
_.
~
-$5
1$ $4
8$
\v
Starter pulley
M8 Pl.25
1.6 m-kg
(11.5ft -lb)
Crankcase and Engine
bracket
Ml0 Pl.25
3.0 m-kg
(21.5 ft -Ib)
-8 -

1980 ET340ED
Drive and track suspension
Primary sliding sheave and Cap
M6
Pl.0
1.1 m-kg (8
ft -Ib)
Installation of primary sheave
UNF1/2"
Initial Use Motor oil
12 m-kg
(88 ft-Ib)
Loosen once and
retighten:
6.0 m-kg
(43.5 ft-Ib)
Installation of drive chain sprocket M12 Pl.25
4.0 m-kg
(29 ft-Ib) Use
cotter pin
Installation of driven chain sprocket
Ml0
Pl .25 3.5 m-kg
( 25 ft -Ib)
Chain housing and Frame
M8 Pl.25 2.5 m-kg
(1 8 ft - Ib)
Chain housing cap
M8 Pl.25 1.6 m-kg
(11.5 ft-Ib)
Chain tensioner
lock nut
Ml0 Pl.25 3.3 m-kg
(24 ft-Ib)
Installation of front axle R.H . M20
Pl.0 9.0 m-kg
(65 ft-Ib)
Front axle housing and Frame M8 Pl.25 2.5 m-kg
(1 8 ft-Ib)
Wheel sprocket and Front axle
0.5 m-kg
(3.5 ft -Ib)
Shaft 1 and Frame Ml0
Pl.25 5.5 m-kg
(40 ft -Ib) Use LOCK-TITE
Shaft 2 and Rear bracket Ml0
Pl.25 5.5 m-kg
(40 ft-Ib) Use LOCK-TITE
Rear bracket and Frame M8
Pl.25 2.5 m-kg
(18 ft-Ib) Use
LO CK-TITE
Bracket 2 and Frame sliding 1
M6 Pl .0 1.2
m-kg
(9 ft -I b)
Installation of suspension wheel
M6 Pl .0
1.1 m-kg
(8 ft- Ib)
Installation of rear guide wheel
M8
Pl.25 2.5 m-kg
(18 ft-Ib) Use LOCK-TITE
Installation of runner sliding 1 M6
Pl .0 0.25 m-kg
(2 ft -I b) Use LOCK-TITE
Installation of runner sliding 2
M6 Pl.0
0.6 m-kg
(4 ft-Ib) Use LOCK-TITE
Pivot 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 P l.0 1.3 m-kg
(9 5 ft-Ib) Use LaC K-TITE
Frame sliding 1 and 2 & 3 M8 Pl.25 2.5 m-kg (18 ft-Ib)
Installation of stopper 1 M6 Pl.0 0. 35 m-kg
(2.5 ft -Ib)
Chassis:
Engine mounting bolt Ml0 Pl.25 3.0 m-kg
(22 ft-Ib)
Ski runner M8 P1.25
I1.4
m-kg
(10 ft -I b)
Use plain washer and
LOCK-TITE
Steering column and Gate
M8 Pl.25 2.0 m-kg
(14.5 ft-Ib) Use lock
washer
Steer ing relay rod adjusting nut
Ml0 Pl.25 2.5 m-kg
(18 ft-Ib)
Out side arm and Ski column
Ml0
Pl.25
3.0 m-kg (
22 ft -I b) Use lock washer and
wave washer
Steering l ower bracket
M8 Pl.25 2.0 m-kg
(145ft-lb)
Use lock washer and
LOCK-TITE
Installation of steering column 1,2
M8 Pl.25 1.45 m-kg (10 5ft- lb) Use lock
washer
Steering relay ass'y
Ml0
Pl.25
3.0 m-kg
(22 ft-Ib) Use
cotter pin
Universal
joint
Ml0 Pl.25 2.5 m-kg
(18 ft -I b)
S teering gate
M8 P1.25 1.4 m-kg
(10 ft -Ib)
- 9-