Yamaha EX440D User manual

LIT -12618-00-26
• YAMAHA
SNOWMORlll
SUPPlEMENTARY
SERVICE UAl
[Frame serial number: 8J7-036101
~ 8J7-049999 J
Engine serial number: S5433-036101 ~ SS433-049999
8J7-28197-10

1980 EX440C
CONTENTS
1. NEW SERVI CE PROCEDURE .... .... .. .... .... .... .. .. ........ .... .... .. .... .... ...... .... .. ..... 2
2. MAINTENANCE INTERVALS
...... .. .. .................. ...... .... ...... .. ........ .. .. ........... 3
3. SPECIFICATIONS .......................... .. ............ .. .... .. ...................... .. ................. 5
4. SPEC I AL TOOLS............ .. ...... .. .. .. ........ .... .. .... .. .. .. ...... .. .... ........................ .. ... 11
5. WIRING DIAGRAM .............................................. .. ...... .. .......... .. ................ .. 12
6. WIRE AND PIPE ROUTING DIAGRAM ...... .. .. .......................................... 13
( )
- 1-

1980 EX440D
1. NEW SERVICE PROCEDURE
(New service procedure applied to the 1980
EX440D)
A. Ignition timing
1. Remove the recoil starter assembly.
2. Remove the ri
ght side spark plug and
screw dial gauge stand i
nto spark plug
hol e.
Tool name Tool No.
Dial gauge stand
90890-0 1195
2. In sert dial gage with needle i nto stand.
Tool name T
oo l No.
Dial gauge
90890-01252
Dial gauge needle
90890-03098
4. Rotate magneto flywheel unti l piston is
at
top -dead-center (T.D.C.)
Set the zero on dial gauge face
to line
up exactly
with a dial gauge needle.
Tighten set
screw on dial gauge stand
to secure dial gauge assembly. Rotate
flywheel back and forth
to be sure that
indicator needle does not go past zero.
5. Starting
at T.D.C., rotate flywheel
counterclockw i se unt il dial gauge
reads approximately 3-1/ 2 needle
re -
volutions before-top - dead -cente r
(B .T.D. C.) .
6.
Slowly turn fl ywheel clockwise until
dial gauge reads specifi
ed ignition tim-
ing.
Ignition timing (B.T.D.C.)
1.6 ±0
.1 mm (0.060 ± 0.004 in)
- 2-
7. Check the marks on flywheel and pulser
for a
li gnment.
If not al igned, ad just i gnit ion timing as
follows:
a. Loosen the pulser set screws and turn
the pulser until mark alignment is
achieved.
\
...&. \ ~,
NOTE: -- -- ---- -------- ---- -- ---
If the marks can not be aligned by this ad -
justment. remove the flywheel rotor and
turn the base (stator) assembly.
( )
l )

(
b. Tight en the pulser set screws.
8. Remove the dial gauge and stand. Re-
place the spark p lu g and recoil starter.
Tightening torque
Spark plug: 2.8 m-kg (20 ft-I b)
Sta rt er assemb ly : 0.7 m-kg (5 ft-Ib)
2. MAINTENANCE INTERVAL
[ PERIODIC MAINTENANCE]
1980 EX440D
NOTE: -------------------------
The timing light should be u sed to check if
the marks
on the rotor and base are aligned
when both are replaced with n ew ones. The
marks should a
li gn at any specified timing .
Every
Check point 20 hrs. or
40 hrs. or 80 hrs. or When Seasonally
400 km 800 km 1 .600 km
necessary
(250 mil
(500m i) (1 .000m i)
ENGINE:
Tightness of bolts a nd nuts 0 0
8ends. cracks and wear 0 0
Abnormal noi se 0 0
Loose connection a nd breaks of fuel and pulse pipes 0 0
Loose connection and breaks of oil pip es 0 0
Loose connection and breaks of oil delivery pipe 0 0
Manual rope starter system 0 0
Carburetor
• Operation of starter jet 0 0
•
Mix ing adjuster (p il ot sc rew) 0 0
• Idling speed adjustment 0 0
Operation and adjustment of oil pump 0 0
Ignition ti ming 0
Cylinder compressions 0 a
M uf fler join ts 0 0
Cylinder head/exhaust pipe decarboni ze
0
Spark plug conditio n. gap and cleaning 0 0
Tightening of the cylinder he ad"
0
DR I VE:
Tightness of bolts and nuts 0 0
Wear on s li de runners 0 0
Pr imary drive system 0 0
V-belt 0 0
Secondary dr i ve system 0 0
Sheave distance 0 0
Sheave offset 0 0
Brake pad wear 0 0
Brake operation and ad justment 0 0
Guide wheel rubber 0 0
Wear of drive track wh ee l sprocket 0 0
Drive track adjustment 0 0
Breaks in drive track 0 0
Be nds in front and rear axl es 0 0
Che cking of lock washe rs
0 0
Drive cha in adjus tm ent 0 0
Dri ve chain oil lev el 0 0
-3-

1980 EX440D
Every
Check point
20 hrs. or
40 hrs. or
80 h rs. or When Seasonally
400 km
800 km 1. 600 km necessary
(250 mil
(500mi) (1.000mi)
BODY:
Tightness of bolts and nuts 0 0
Bends and cracks 0 0
Welded riveted. joints
0 0
Ski adjustment 0 0
Ski runner wear 0 0
Breaks in fuel tank 0 0
Cleaning of fuel tank 0 (
Fuel filter 0
Loose connection and breaks in fuel pipe 0 0
Breaks in oil tank 0 0
Oil filter 0
ELECTRICAL:
Wear. breakage of wire covering 0 0
Breaks in high-tension cord 0 0
Vo ltage regulator 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 O
il/ Grease
400 km 800 km 1.600 km necessary Brand name
(250 mil
(500mi) (1.0 00m i)
ENGINE:
Starter case 0
Oi l pump control box
0 0 Aeroshell grease #7A or
Esso Beacon 325 grease
Pump drive cover 0 0
Oi l in the oil tank 0 YAMALUBE 2-cycle oil l
DRIVE:
Pr imary sheave weight
0 0
and roller pins
Mo lybdenum disulfide
Secondary shaft and 0 0 snowmobile grease
sliding sheave
Front axle housing 0 0
Shaft 1 and sha ft 2 0
O·
Light all-purpose grease
(S li de rail)
Dri
ve chain oil 0 0 Gear oil API "
GL-3"
replacement SAE
#75 or #80
BODY:
Steering column
lower
0 0 Light all-purpose grease
bearing
Steering column upper 0 0
Motor oil
bearing
Steering links 0 0
Ski co lumn 0 0
Ski wear plate 0 0 Light all-purpose grease
Ski retaining pin 0 0
Brake wire and stopper 0 0
Esso Beacon 325 grease
and brake lever
-4-

1980 EX440D
3. SPECIFICATIONS
NOTE: * "". New specification
( General (Compared
with 1979 EX440C)
Model:
Model (I.B.M. No.) * EX440D (8J7)
Frame 1.0. & starting number *
8J7-036101
Eng i ne 1.0. & starting number *
SS433-036101
Dimension:
Overa ll length 2,
520 'mm (99.2 in)
Overall width (std) 980 mm (38.6 in)
Overall height (w / windshield) 995 mm (39.2 in)
Engine
Description:
Eng i ne type Fan cool ed two-stroke 7-port torque
induction, twin cylinders
Eng i ne model
SS433
Displacement 433 cc (26.42 cu.in)
Bo re X Stroke
68 X 59 .6 mm (2.68 X 2.35 in)
Effective compression ratio
7.0: 1
Starting system Recoil hand starter
Ignition system C.D.I.
Lubrication system "Auto lu be" oil injection
Cylinder head:
Combustion chamber volume (with spark plug) 24.6 cc (1 . 50 cu .in)
Compression chamber type Dome + Squi
sh
Head gasket thickness 0.5 mm (0.02 in)
Cylinder:
Material Cast iron sleeves aluminum
Bore si ze
68 mm (2.677 i n)
Taper lim it 0.05 mm (0.0020 in)
Out of round li mit 0.01 mm (0.0004 in)
Piston:
Piston
skirt clearance (Measuring point) 0.045 ~ 0.050 mm (0.00 18 ~ 0. 0020 in)
l (20
mm from piston skirt end)
Piston oversize 1st
68.25 mm (2.687 i n)
2nd 68.50 mm (2.697 in)
3rd 68.75 mm (2.707 in)
4th 69.00 mm (2. 717 in)
Piston pin outside diameter X length r/l18 X
55 mm (r/l0 .709 X 2.17 in)
Piston ring:
Piston ring design (Top) Keystone
(2nd) Keystone
Ring end gap (installed) (Top)
0.35 ~ 0.55 mm (0.0 14 ~ 0.022 in)
(installed) (2nd) 0.
35 ~ 0.55 mm (0.014 ~ 0.022 in)
Small end bearing:
Type Needle bearing
Big end bearing:
Type Needle bearing
C
ra nkshaft:
Crankshaft assembly
width (A) 174 ±0.1 mm (6.85 ± 0.004 in)
(F)
+ 0
56 -0,05
+ 0
mm (2.205 -0.002
in)
Crankshaft deflection (D)
0.03 mm (0-1) 0 .04 mm (0-2)
0 .04 mm (0-3) 0.05 mm (0-4)
-5-

1980 EX440D
Connecting rod large end side clearance (C) 0.25 ~ 0.75 mm (0.010 '" 0.030 in)
Connecting rod small end deflection
(P)
2.0 mm (0.079 in)
-- H -- p
Q
D -l
D-4
CI
I
K ~A ~~
Crank pin outside d ia meter X length 24 X 55 mm (0.94 5 X 2. 165 i n)
Crank pin type Solid shaft assembly type with serration
Crank bearing type (Left) X q'ty
#6306 special X 2 pcs.
(Cen ter) X q 't y
#6206 special X 2 pcs.
(R ight) X q'ty
#6206 special X 1 pc.
Crank oi l seal type (Left) X q' ty FWJ-32 78 9.5 X 1 pc.
(Cen ter) X q'ty Labyrinth sea l X 1 pc .
(Right) X q'ty FWJ-32 48 10 X 1 pc.
Carburetor:
Type & manu
fa cturer/quantity
BD44 X 38 KEIHIN X 1 pc.
I.D. Mark
8H600
Main jet (M.J.)
#1 45
Main air jet
(MAJ.)
# 180
Power jet (Pw.J.)
#150
Power air jet
(PwAJ.)
#200
Slow jet (S.J.) #
90
Slow air jet
(SAJ .)
#100
Pi l ot screw (P.S.) 1 -5/8
Starter jet
(StJ.)
#160
Float height
15 +2
mm (0.59 +
0.08
in)
-3
- 0.12
Idling engine speed 1,500 r/ min
Main jet setting chart:
~
- 30 °C - 20 °C -lOOC O°C 10 ' C 20 °C
Alt i tu de
1- 22 °FI
1- 4°FI 114°FI 1
32 °FI 1 50 ° FI 1 68 °FI
Sea level # 1
40
#1 45
· #
14 0
-
600m 1 2000 ttl
#1 45
· #1
35
- 1200m 1 4000 ttl
#140
.
·
#130
- 1800m 16000 ttl
#135
- 2 40 0m 18 000 ttl
#130
#1 25·
.
. #1
20·
- 3000m 1 10000 ttl or more #
125 ·
•
Ch ange the starte r jet to # 95 or #1 00 .
- 6 -

(
(
Intake reed va lve:
Type
Bending lim it
Valve li ft
Tightening to rque
lub rication:
Autol ube pump - Co lor code
- Mini
mum stroke
-Maxi
mum stroke
-Reduction ratio
-
Ou tput Mi n./200 strokes
-Output
Max./200 strokes
Auto lu be pump wire free play
Oi l tank capaci ty
Oil grade
Drive and track suspension
Transmission:
Type
D
ri ve ratio
Engagement rpm
Pr imary spring:
Part
No .
Co lor code
Secondary spring:
Pa rt 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
Sl ide runner wear limit
Track wi dth
Track defl ect ion
lnegth on ground
Wheel sprocket mate ri al and number of teeth
Stopper band length
Secondary drive:
Type
Reduction ratio
Chain pi tch X Number of links
Fr ee play
Chain housing oil quanti
ty
Cha in housing oil grade
Brake:
Type
Brake pad thickn
ess
Bra ke pad wear limit
Gap between pad and disc
V type
0.3 mm (0.012 i n)
10 .4 mm (0.409 in)
8.0 cm-kg (6.9 in-Ib)
Da rk blue
0.20 ~ 0. 25 mm (0.0079 ~ 0.0098 i n)
1. 65 ~ 1. 87 mm (0.0650 ~ 0.0736 in)
1
/44
0.95 ~ 1.19 cc (0.032 1 ,....., 0. 0402 oz)
7.84 ,....., 8.89 cc (0.2651 ,....., 0. 3006 oz)
25 ± 1 mm (0. 98 ± 0.04 in) at idle
2.8 Liter (3 US.qt)
YAMAlUBE 2-cyc le
V-belt automatic centrifugal engagement
3.5 : 1
,....., 1 : 1
2.900 ~ 3. 300 r/ min
9050 1- 45534
Blue/Green
90508 - 45286
Yellow
1 50 ° (Hole No. 1)
270 : ~ mm (10.6 : g. 12i n)
5.5 ±0.5 mm (0.22 ± 0.02 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 (0.4 in)
380 mm (15 i n)
25 ~ 30 mm/1 0 kg (0. 984 ~ 1.18 in /22 I b)
850 mm (33.5 i n)
Polyethylene 8T
214
mm (8.4 i n) (3rd hole fr om the bottom)
Chain (#35 -3)
29/ 17 (1 . 706)
9.525 mm (0. 375 i n) X 68l
10 +5 (0 4 +0.2
.)
- 2 mm . - 0.08 In
320 cc (10 . 82 oz)
Gear oil API "Gl3" (SAE #75 or 80)
Floating pad type disc brake
13.5
mm (0.53 in)
9.5 mm (0.37 i n)
0.15 mm (0.006 i n)
- 7 -
1980 EX440D

1 98 0 EX440D
Chassis
Frame:
Frame design & material
Alum inum + Steel
Steering system:
Caster (ski column)
25 °
Camber 0 °
Ski length X wi dth X thick ness 980 X 1 40 X 2.6 mm (38.6 X 5.5 X 0.10 i n)
Ski stan ce
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: 20.2 °
R: 27.6 °
Left ski. L:
27.6 ° R:20.2 °
Lock to lock angle (steering column) Right: 46.5 °
Left: 46.5 °
Front suspension:
Type Leaf spring
damper type Oil damper
Fue l tank: (
Capaci ty
30 Liter (9.0 US.gal)
Fuel grade Regular gasoline
Electrical
Ignition system:
Type - flywhee l magneto (C .D .I. Type)
Model/ m an ufacturer
...
F280-78/HITACHI
Voltage 12V
Pulser coil resistance ... 780 at 20 °C (68° F) (White/Red - Black)
Charg
in g coil resistance
...
1130 at 20 °C (68° F) (Brown - Black)
... 290 at 20 °C (68° F) (Blue -Black)
Ignition
timi n g:
B.T.D.C. 1.6 ±0.1
mm (0. 060 ± 0.004 in)
Ignition:
Model/Manufacturer
CM62-20/H ITACHI
Spark gap 9 mm (0.35 in)/300 r/min
11 mm (0.43 in)/3,000 r/ min
Primary
winding resistance 0.150 at 20 °C (68 °F )
Secondary winding resistance 3.6kO at 20 °C (68° F)
Diode (Yes or No) No
Spark plug:
Type & Quantity
...
NGK B-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
Noise suppressor resistance
5kO at 20 °C (68° F)
C.D .I. unit:
Model/Man ufacturer
... TI A01-30/HITACH I
Lighting system:
L
ighting output 12V/100W
Lighting coil resistance ... 0.220 at 20 °C (68°F) (Yellow -Black)
Headlight type Semi shield
Bulb wattage/q'ty
1 2V 60/60W X 1 pc.
Ta il/brake light wattage 12V 8W/23W
Meter light wattage 1 2V 3. 4W
-8-

(
A.C. regulator:
Model/M anufacturer
Voltage
Tightening Torque
Par t to be tightened
Eng in e:
Spark plug
Cylinder head
Cylinder head
Flywheel magneto
Crankcase upper and l ower
Tighteni ng sequence
W~
0
7 6 3
Thread size
M14 P1.25
M8 P1.25
M8 P1.25
M16 P1.0
M8 P1.25
,.....
0
0"6
2
14 10
TR IZ-24B / H IT ACH I or S8516B /TOSH IBA
13.8 ± 0.5V
Tightening torque Remarks
2.8 m-kg (20 ft-Ib)
1980
EX440D
2.5 m-kg (18 ft-I b)
Special nut-Stud bolt
2.5 m-kg (18 ft-I b)
Nut-Stud bolt
7.3 m-kg (53 ft- Ib)
First: 1.0 m-kg (7.5 ft-Ib)
Final: 2.0 m-kg (15 ft-Ib)
-
t--- .------
8 5 1 4 9
00
11
° 0 13 °
0
a/'
"-
Starter pulley
M8 P1.25 1.1 m-kg (8 ft-Ib)
Crankcase and engine bracket
M10 P1.25 4.0 m-kg (29 ft-Ib) Special nut
-Stud bo lt
Cy li nder and exhaust pi pe
M8
P1.25 2.0 m-kg (15 ft-Ib)
D ri ve and track suspension:
Primary s li ding sheave and cap
M6 P1.0 1.1 m-kg (8 ft-I b)
Installation of primary sheave UNF 1/
2" Init ia l:
Use motor oil
12 m-kg (87 ft -Ib)
Loosen once and
retighten:
6.0 m-kg (43.5 ft-Ib)
Installation
of secondary sheave
M10 P1.25 5.0 m-kg (36 ft-Ib)
Bearing housing
M10
P1.25 6.5 m-kg (47 ft-Ib)
Secondary shaft and Bearing collar Socket screw 0.6 m-kg (4 ft-I
b)
Brake caliper and Housing ch ai n
M10 P1.25 5.0 m-kg (36 ft- I b)
Installation of dri ve chain sprocket
M14 P1.5 6.0 m-kg (43.5 ft-I b)
Nut
Installation of driven chain sp rocket
M10 P1.25 5.0 m-kg (36 ft- I b)
Bolt
Chain housing and Frame
M8
P1.25 2.5 m-kg (18 ft-Ib)
Installation
of front ax le L.H.
M22
P1.0 8.5 m-kg (6 1.5 ft-Ib)
Front axle housing and Frame
M8 P1.25 2.5 m-kg (18 ft-Ib)
Shaft 1 and Frame
M10 P1.25 6.5 m-kg (47 ft-Ib)
Use LOCK-TI TE
Shaft 2 and Rear bracket
M10 P1.25 6.5 m-kg (47 ft-Ib)
Use LOCK-TITE
Rear bracket and Frame
M8 P1.25 3.0 m-kg (21.5 ft-I
b)
Use LOCK-TITE
Installation of suspension wheel
M6 P1.0 1.0 m-kg
(7 ft-Ib)
Installation
of rear gu ide wheel
M8 P1.25 2.5 m-kg (18 ft-Ib)
Use LOCK-TITE
Installation
of runner sl iding 1
M6 P1.0 0.3 m-kg
(2 ft-Ib)
Use LOCK-TITE
Installation
of runner sliding 2
M6 P1.0 1.0 m-kg (7 ft- Ib)
Use LOCK-TITE
Pi
vot arm and Frame sl iding 1
M6 P1.0 1
.3 m-kg (10 ft-Ib)
Use LOCK-TITE
Bracket 5 & 6 and Frame sliding 1
M6 P1.0 1
.3 m-kg (10 ft-Ib)
Use LOCK-T IT E
Frame sl i ding 1 and 2 & 3
M8 P1.25 2.5 m-kg (18 ft-
Ib)
Installation of stopper 1
M6 P1.0
0.4 m-kg (3 ft-I b)
-9-

1 980 EX440D
Part to be tightened Th read si ze Tightening torque Remarks
Chassi
s:
Eng i ne mounting bolt M10 P1.25 3.B m-kg (27.5 ft-Ib) Nylon
nu t
Ski runner MB P1.
25
1.45 m-kg(10 ft-Ib) Use plain washer and
LOCK-TI TE
Steering column and Gate
M6 P1.0 0.9 m-kg
(6 .5 ft-Ib)
Steering relay rod ad justing nut M10 P1.25 2.5 m-kg (1B ft-Ib)
Outside arm and Ski co lumn M10 P1.25 4.0 m-kg (29 ft-
Ib)
Use lock washer and
wave washer
Steering lower bracket MB
P1 . 25 1.5 m- kg
( 11 ft-I b)
Use lock washer and
LOCK-T ITE
Installation of steering column 1. 2 M6 P1.0 0.9 m-kg (6.5 ft-Ib) Use lock washer
Steering
re lay ass 'y M10 P1.25 3.0 m-kg (22 ft-Ib) Use cotter pin
Level gauge securing bolt
M6 P1.0
0.25 m-kg(1 .B ft-I b)
Screw to install the front of seat
M6
P1.0 0.5 m-kg (3 .5 ft-I b)
Nut to install the rear of seat MB P
1. 25 0.9 m-kg (6.5 ft - Ib)
Brake level holder M5 PO .S 0.4 m- kg (3.0 ft -I b)
Throttle lever
M6 P1.0 0.35 m-kg(2.5 ft-Ib)
-10-

\ )
\
')
~
I
["
(
A
4. SPECIAL TOOLS
1.
4·c.
2.
4·d.
3.
4·a.
6.
No. Description
1 Dial gauge
2 Dial gauge stand
No.2
3 Dial gauge needle (56 mm)
4-a Flywheel puller
bo lt
4-b
Flywheel puller attachment
4-c Flywheel puller screw
4-d
Drive handle
4-e Flywheel puller body
5 Rotor holding
too l
6 Pr imary fixed sheave puller
7 Sheave sub-assembly tool
8 Bushing
tool
9 Sheave gauge
10 Eccentric beari ng installer
11 Main switch ring nut tool
12 Pocket tester
13 Electro tester
14 A.C. Regulator checker
1980 EX440[
7.
8. 13.
~_3 ... -0· ..
11.
Tool No.
90890-03097
90890-01195
90890-03098
90890-01803
90890-0 1 804
90890-01806
90890-0 1 817
90890-01848
90890-01235
90890-01859
90890-0 1 858
90890-0 1 877
90890-01875
90890-0185 1
90890-01857
90890-03104
90890-03021
90890-03090
- 11 -

I
~
N
I
Head light (12V 60W/60W)
~ll
Engine stop switc h
Speedometer light
(12V 3.4W)
~
Tachometer light
(12V3.4W)
mJ
8
G: I I I I I I II Tit 0'" I
Tether switch
~IRUNIOFF
81 qGl'1118t.v
I0 I 16~ 0 L oo I III 8 ~
l I, _It~
Gy
~
Gy
GI y
Main switch
Headlight beam switch
G/'f
~\~ y 1
Brake light switch
~ ~ G;
L
~ _8 --+- 1_
G/Y
o
Voltage
regulator
T
.. I~~~'U
R
C.D.I. unit
o
-
8 I LI 8d IW/R Iy
, oW
<:>
<>
<>
<>
'"
-L
C.D.I. magneto
.- -
Spark plug
"
C1I
~
::xJ
-
2
G)
C
-
l>
G)
::xJ
l>
S
.::::::::::::::::~-
Ignition coil
~
Color code
G .. .......... .. Green
B ................Black
Y ............
.... Yeliow
L .. ... ......... .. Blue
o ...... . ......... Orange
Br . .
.. .......... Brown
Gy ..............Gray
W/R .. .. .....White/ Red
G/ Y ...........Green/ Yellow
B/ W .......... Black!White
co
CO
o
m
X
~
~
o
o

t:7
6. WIRE AND PIPE ROUTING DIAGRAM
1. Main sw i tch
2. Tet her switch
3. Wire harness 2
4. Fuel
tank breather pipe
5. Fuel pipe
6. C li p
7. Hose
8. C.D.I. un it
9. W i re harness 1
10. To taillight
11. Starter wire
12. Fuel level pipe
13. Oil level pipe
14 . Oi l tank breather pipe
15. Vo ltage regulator
16. Speedometer cable
17. Tach ometer cable
18. Oil pipe
19. To carburetor
20. To engine crankcase
21 . To o il pump
22. To tachometer gear unit
23. To carburetor
24. Clamp
25. Cl amp
26. Head light lead wire
27. Speedometer cable (G ray)
28. Tachometer cable (Black)
29. Spri ng
30. Shroud stopper
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31 . Starter wire
32. Brake wire
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33. Throttle wire
34. Pump wire
35. Clamp
36. To tachometer gear unit
37. To speedometer
38. To tachometer
Tank
NOTE~
Tip of clip should be
positioned on the opposite
side
of the tank .
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