Yamaha Sl292c 1971 User manual

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NOTICE

This manual has been written by Yamaha Motor Company fer use

by

Authorized Yamaha

Dealers and their qualified mechanics.

In

light of this purpose

it

l1as

been

asst.1n1ed

tt·iat certain

basic mechanical precepts and procedures inherent

to

our p:-oduct are already !<

!1ovvn

and

understood by the reader.

Without such basic knowledge, repairs or service

to

this

rr1odel

may re11dcr

the

rn~c:!1i11e

l

r~s

cife,

and

for

th

is

reason we

must

advise

that

al

I repairs and/l)r

s~r·Jic.e

be pe:-forrn8d b\' ari

Authorized Yamaha delaer

who

is

in

possession

of

the requisite

bas

~

c

prod~

st

l<j;0v'Jl

e

d

~

~e

.

Other

information

is

produced by the U.S. distributor, Y

am~ha

:1

1·i:e:

r.;Jt::(.ii :;;;;

Cc

.rpo

:-a

tion,

?.

i1C1

is

necessary

to

provide total technical coverage regarding the

prod

i.. I

C~.

* * * * * * * * * * * * * * * * * * * * *

-II

*

+.

*

~

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·

~

¥

.._

;;

_.

+

~

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>

·

~

+:·

The Research, Engineering, and Service Departments

of

'r'

amah.:t

or

•::

r;•

)t

:!..

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i

!~

1

~

I~

\·

str

!v;

rig

to

further

improve

all

models manufactured by the compan\'. !1

/:>

)

di

fie:

:~ic·r

.

~

~:

re

t i:

<::

rc

!.

'J:-P.

inevitable and changes

in

specifications or procedures will be

fvr'i~ct•

·:.l\1

(~

to

~I!

/\

1

;1t

·

.ari

zec:!

Yamaha Delaers

and

will, where applicable, appear

in

future editic:ns

of

!.!1

:

'.l

rn

&

i':t

1::;:

.

YAMAHA

SL292C/GP292B SERVICE

MANUAL

1

1st

Edition

JUNE 1972

•

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ENGINEERING

& SERVICE

DEPARTMENT

YAMAHA

MOTOR

COMPANY

HAMAMATSU,

JAPAN

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FOREWORD

Tl1e

Service Manual for

tl1is

year's Yamaha snowmobiles is divided into two

volumes for single-c;1/inder models and twin-cylinder models. These two

books

will be used

as

the

basic service manuals

for

this year's

models

.

This manual contains service information

for

standard

and

GP

models ·

equipped with a 292-c.

c.

cylinder.

It

al.so

includes specifications

of

1971 to

19

73 models

for

convenie11ce

of

Yamaha service technicians.

YAMAHA

MOTOR

CO.,

LTD.

ENGINEERING

& SERVICE

DEPARTMENT

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CONTENTS

CHAPTER 1.

GENERAL

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

1-1

Features • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

1-2

Specifications • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

1-3

Tools

......

. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

1-4

Operation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

ENGINE I

'•

I

....\. • • • • •

CHAPTER 2. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

2-1

2-2

2- 3

2- 4

2-5

2-6

2- 7

2- 8

Engine Removal • • • • • • • •

Starter and Magneto Removal

Removal of Primary Sheave

Removing the

Oil

Pump • • •

• • • • • • • •

• • • • • • •

• • • • • • • •

• • • • • • • • • • • • • • • • • •

• \

• • • •

It

••

•

•• •

• • •

• • • • •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

•

Removal

of

Flywheel Magneto

Removal

of

Fancase and Air Shroud

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Removal • • • • • • • •

Top End

Crankshaft Ass'y Removal • • •

• • • •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

CHAPTER 3. REASSEMBLING • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

3-1

3- 2

Crankshaft Ass'y

As

sembling

the

Crankcase

• • •

• • • • • •

• • •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

CHAPTER 4.

POWER

TRAIN

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

4- 1

4-2

4-3

4- 4

4- 5

Disc

Brakes and Secondary Sheaves .

Chain Case and Front Axle Removal

Bog

ie Wheels

Removing

the

Track Removal

• • • • • • •

Rear Axle

• • • • • •

• • • • • • • •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

CHAPTER 5. STEERING (SKIS)

AND

CHASSIS • • • • • • • • • •• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

5- 1

5- 2

5- 3

5-4

5- 5

Steering

Skis

..

•

• • •

• • • • • •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Chassis and Shroud • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Seat • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Luggage

Box • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

CHAPTER 6. TIGHTENING BOLTS

AND

NUTS • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

•

CHAPTER 7.

ELECTRICAL

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

7-1

7-2

7-3

Ignition System

Lighting System

Wiring Circuit •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

.,. .

. ..... . ...... .... ............

..

...... ... .......... ..... .. . . ...

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

CHAPTER

8.

ENGINE

MAINTENANCE

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

8-1

8-2

8-3

8-4

8-5

Ignition Timing

........

. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

••

Carburetion and Fuel System • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Autolube • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Top

End Maintenance • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Piston

and

Piston Ring Maintenance (GP292B) .................

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.... ...... ..... ........

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1

2

8

10

11

~8

21

23

27

29

31

33

35

36

37

41

46

48

50

51

52

53

55

57

65

69

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CHAPTER

9.

DRl~E

TRAIN

AND

CHASSIS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74

9-1

Primary Sheaves . . . . . . . . . . . . . . . . . .

..

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9-2

Secondary

Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9-3

Drive-

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9-4

Primary Sheave

and

Secondary

Sheave Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9-5

Chain

and

Chain Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

9-6

Breakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

9-7

Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79

9-8

Adjusting

the

Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79

9-9

Skis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

..

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

APPENDIX 1. INSPECTION

AND

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81

APPENDIX 2. CONVERSION

TABLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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GENERAL

-Features

CHAPTER

1.

GENERAL

1-1

FEATURES

1.

Optimum

Engine Performance

The new, exclusive, five-port

cyli

nder design

is

being

used

in this year's model

to

insure

optimum

performance. The

five-port system innovated

by

the Yamaha engineers

has

already proven itself in many fields

of

competition.

2. Increased Engine

Reliability

and

Economy

As another f

ir

st in the indust

ry

Yamaha

ha

s introduced

it

s already proven

Autolube

oil

injection system in Yamaha

snowmobile engin

es.

The

Auto

lube system

wil

l

ins

ure long engine

life

and also res

ult

in a dec

rease

in

operational and

•

maintenance costs.

3. Smooth and Positive Clutch System

4.

5.

Yamaha snowmobiles h

ave

an

improved

automatic

centrifugal

clutc

h

and

power

train

system. The new

clutch

allows the

engine

to

ach

i

eve

the most usable r.p.m. under all operati

ng

conditions. The drive ratio

will

vary

from

3.5:

1 - 1 : 1 thus

giving

maximum

acceleration and climbing abil

it

y.

Diaphragm Carburetor

The Yamaha snowmobiles have one diaphragm-type carburetor. This carburetor incorporates

an

internal metering device

whi

ch a

lw

ays meters the

cor

r

ec

t air/fuel

mixture

to

the engine regardless

of

vibration

or

machine position.

Superior Braking

A new

des

i

gn

in the track,

sp

rocket, V-be

lt

and

ca

liper disc brake hasgreatly improved the braking

efficiency

and safety

of

the Yamaha snowmobile.

6.

Tilt-up

Engine Shroud

7.

The attractive fiberglass engine shroud

has

been designed

to

ti

lt

up

and away

from

the engine.

Thi

s

functional

feature

al

lows

for

easy

refueling and engine maintenance.

Superior

Comfort

The suspension system

of

the main track rides on

individually

mounted

torsion spring bogie wheels. The adjustable

torsion springs

of

the r

ea

r

pivot

arm

of

the track, in

combination

with

the attractive and durable seat, assure tireless

comfort

even on the longest trips.

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GENERAL

·Specifications

1-2

SPECIFICATIONS

•

---

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,, MODEL

Dimensions and Weight:

I Length (W/Skis)

.I Width

I

111 Height (W/Windshield)

(approx

.)

Weight

Engine:

I

111

Type

I:

I I1

I No.

of

cylinders

,,, Bore and stroke

, 1 Displacement

' 1 Max. Horse

power

1 Carburetor

I ;

''

Lubrication

system

1

Ignition

method

~

Magneto

output

Spark plug

Starting System:

Track and Suspension:

Track

1:

' I•

Width

I1

,1 Length

on

ground

Suspension wheels

Drive

sprocket

I

~

.

,.

VVheel

sprocket

'

' 1

1 Transmission:

l

-

Type

Drive

Reduction

1 Frame:

Type

--

, Cowl:

,

Type

Seat:

Storage

Box:

-- -..

Fuel

Tank:

, 'i Capacity

Oil

Tank:

,L

Capacity

(

'

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Front Bumper:

-

Rear

Bumper:

- -

·-

.,.

--

-~

..

-

.

--

---- -

-.

-

-~

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--

•

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'73

Models

SL292C

105.5

in. (2,

680

mm)

34.7

in. (

880

mm)

40.6

in. (1,030

mm)

337

lbs. {

15

3 kg)

Air

c

ool

ed

two

-s

troke

5-

port

indu

c

ti

on

Cast

iron

sleeve a

luminu

m cylinder

1

cylinder

2.874

in.

x

2.75

6

in

.

(7

3

mm

x 70 mm)

17.82 c

u.

in. (292 c.c.)

20

H.P

. @5,

500

r.p.m.

KEIHIN

CD38-32 x 1

''

Autol

ube'' o

il

injec

ti

on

Flywhe

el magneto

12V

-70W @3,000 r.p.m.

N.G.K. B-7ES

Manual recoil s

tarter

with

add'I emergen

cy

rope st

art

er

Mold

ed rubber, ste

el

reinf

orced

15in.

(

38

1

mm)

50

in. (1,270

mm

)

12

rubber

wh

ee

ls

bearing mo

unt

ed

Single, polyurethane,9 t

ee

th

Single, po

lyure

thane, 9 tee

th

Automati

c c

entr

ifugal e

ng

ag

ement,

infini

te

ly

variable

3.5

: 1 - 1 : 1

Duple

x

roller

chain encl

ose

d in

oi

l bath

25/13

=

1.923

: 1

Fabricated

st

eel

Reinfor

ced

fib

erglass (removable)

Removable

Fiberglass

reinfor

c

ed

in

the engine room

5.0 U.S gal. (19.0

Q)

2.1 U.S.

qt

(2.0

Q)

Chromed

tubular

steel

Chromed

tubular

steel

·-

-- - -

--

-

~

--

-2-

1

05

.5 in.

34.7 in.

39

.0 iII .

337 lbs.

GP292B

(2,680 mrn)

(

880

r11m)

(

990

r

nrn)

(

153

kg)

Air

cooled

two

-st

roke

5-port in

duct

ion

Cast

iron

sl

eeve

alu111inum

cylinder

1 cylinder

2.

874

in. x 2.7

56

in. {73 mrn x 70 mm)

1

7.82

cu.i

n.

(292 c.c.)

27 H.P. @6,000 r

.p.n1

.

KE

IHIN C

04

2-38 x 1

''

Auto

Iube''

oi

I injection

Flywheel magneto

1

2V

-70W @3,000 r.p.m.

Champion N-3G

Man

ua

l recoiI starter wi

th

a

dd'

I emergency

rope starter

Molded rubber, steel reinforced

15 in. ( 381 mm)

50 in. (1,270 mm)

12 rubber wheels bearing mo

unt

ed

Si

ngle, pol

yur

ethane, 9 teeth

Si

ngl

e,

polyurethane, 9 teeth

A

ut

omatic

centrifugal

en

gagement,

inf

initely

variable 3.5 : 1 - 1 : 1

Duplex roller chain enclosed in oiI bath

25/

13 =1.

923

: 1

Fa

bricated steel

Rein

fo

r

ce

d fiberglass (removabl

e)

Remova

bl

e

Fibergl

ass

reinforced in the engine room

5.0 U.S. gal. (1

9.

0

Q)

2.1 U

.S

ga

l (2.0 Q) .

Chromed tu

bul

ar steel

Chr

omed

tubular

steel

I

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MODEL

El

ect

rical:

HeadI

ight

Taillight

Ignition

key s

wit

ch

Brake:

T

yp

e

Co

ntro

l

T

hr

ott

le:

Type

Accessori

es

:

Emer

ge

ncy sta

rter

rop

e

Tool

kit

SL292C

12V 60/60W

12V

8W

12V

23W

Oi

se

brak

e

Handle lever,

left-hand

operated

Handle leve

r,

right

-

hand

operated

Yes

-3-

GENERAL

-Specifications

--- - - i

GP292B --

-- -

12V

60/60W

12V8W

• I

12V

23W I

•.

-

I

Disc

brake

I(

Handle

lever,

left-hand

operated

,,

I

•

-I I •

Handle lever, right-hand operated I ·

-'

Yes

•

'

Yes

I '

I

-- -

•

}t

l

I

t • J

. I

I I

••

•

r

I

GENER~l

-·Specifications

. -

o I ' --'

p

' l1

11

•

I '

r

I '

I:

I II

11

I IT

'

11

- -

-

.-

.....

---

1I

M<:>DEL

Dimensions and Weight:

Length (W/Skis)

Width

Height (W/Windshield)

Weight (approx.)

Engine:

Type

No.

of

cylinders

Bore and stroke

Displacement

Max. Horse power

Carburetor

Front

Bumper:

-- -

Rear Bumper: ----

-

ElectriGal:

-

Headlight

Taillight

Ignition

key

switch

•

·-

-

·-

'

' -

-

·--

- - ·-

-··

- - .

·-

·~

·-

-- ---- -~- -- -

•

I '

'71

Models

99-1 /2 in.

32 in.

38

in.

310

lbs.

(2,526 mm)

(

815mm)

(

965

mn1)

(

141

kg)

Air

cooled two-cycle

5-

port

induction

SL292

Cast

iron

sleeve alurninum

cylinder

1

cylinder

73

x

70

mm

(2.87 x

2.76

in.)

292

c.c. (17.6 cu.in.)

20

BHP @5,500 r.p.m.

One (diaphragm-type) M

iku

ni

''Autolube''

o

il

injection

Flywheel magneto

12V

-40W @3,000 r.p.m.

N.G.K. B-7ES

Manual recoil starter

with

add'I eme

rgen

cy rope starter

Molded rubber, steel reinforced

15 in. (

38

1 mm)

50

in

. (1,270

mm)

12 rubber wheels bearing

mount

ed

Single, polyurethane,9 teeth

Single, polyurethane, 9 teeth

Automatic

centrifugal engagement,

infini

te

ly

variable 3.5 : 1 - 1 : 1

Duplex

roller

chain enclosed in

oil

bath

25/13

=

1.923

: 1

Fabricated steel

Reinforced fiberglass (removable)

Removable

Fabricated steel, located behind backrest

4.0 gal. (15.0

Q)

2.1

qt.

(2

.0

Q)

Chromed

tubular

steel

Chromed

tubular

steel

12V

-

35/35W

Hi-Lo

beam

12V

-5W (rectangular)

4

position

on

dash

- - --

-·-

-4-

I

•

I

'

I

•

I

.

I

!

I

'

I

Brake:

Type

Cont

rol

Th

rott

le:

Type

Accessories:

MODEL

Emergen

cy

st

arter

rope

Tool

kit

Seat

sp

ri

ng

upper

Spark plug

SL292

Disc

brake

Handle lever, le

ft-hand

operated

Handle lever, right-hand operated

Yes

No

Yes (B7Hz)

•

-5-

GENERAL

-Specifications •

•

l

I

l •' .

l·fl

:

I •

•• •

•

f

'·

t '

••

•

GENERAL

-Specifications

-

' I; MODEL

Dimensions and Weight:

11 Length (W/Skis)

Width

Height (W/Windshield}

Weight (approx.)

Engine:

,.

Type

I '

I1

No.

of

cylinders

Bore and

stroke

Displacement

,, Max. Horse

power

I

Carburetor

"

I '

Lubrication

system

Ii

"

Ignition

method

Ii Magneto

output

Spark plug

Starting System:

.

Track

and Suspension:

Track

i!

Width

11 Length

on

ground

, Suspension wheels

Drive

sprocket

Wheel

sprocket

Transmission:

I ,l

,

Type

I

''

Drive

I!

·

Reduction

ratio

Frame:

d l

Type

-- -

-.

Cowl:

I•

Type

It

I

Ignition

timing

-

Seat: -

Storage

Box:

- --

!!Fuel

Tank:

:1

Capacity

--

Oil

Tank:

I

Capacit¥

I1 -

·-

Front

Bumper:

--

Rear

Bumper:

----

~

--

·--

..

-.- -

- -

.

·- --

'72

Models

103-3/8

in.

33-1

/2

in.

38

in.

320

lbs.

SL292B

(2,625

mm)

(

850

mm)

(

965

mm)

(

145

kg)

Air

cooled

two

-s

troke

5-port

induction

Cast

iron

sleeve a

luminum

cylinder

1

cylinder

2.87

x

2.

76

in.

(73

x

70

mm)

17.6

cu.in

. (292 c.c.)

20

BHP

@5,500 r.p.m.

One (diaphragm-type)

Mikuni

BN38-34

''

Autolube''

oil

inje

ct

ion

FI

ywheel magneto

12V

-

40W

@3,000 r.p.m.

N.G.K

B-7ES

Manual recoil starter

with

add'I emergency

rope

starter

Molded

rubber,

steel re

inforced

15

in.

(381

mm)

50

in. (1;270

mm)

12

rubber

wheels bearing

mounted

Single,

polyurethane,

9 teeth

Single,

polyurethane,

9 teeth

Automatic

centrifugal engagement,

infinitely

variable

3.5

: 1 - 1 : 1

Duplex

roller

chain enclosed

in

oi

I

bath

25/13

=

1.923

: 1

Fabricated steel

Reinforced

fiberglass (removable)

0.102

in.

(2.6

mm) B.T.D.C.

Removable

Fabricated steel, located

behind

backrest

4.0 gal. (15.0

Q}

2.1

qt.

(2.0

Q)

Chromed

tubular

steel

Chromed

tubular

steel

- -

- - -

·-

-" - - --

•

-6-

•

I •

l

03-3/8

ir1.

33

-1

/2 in.

38

i11.

320

lb

s.

GP292

(2,625

m111)

(

850

n1

r1

1)

(

965

n1n1)

(

145kg)

Air

cool

ed

two

-stroke

5-p

ort

indu

ctio

n

Cast

ir

on sleeve alur

11inur11

c

ylind

er

1

cy

lind

er

2.87 x 2.

76

in

. (73 x 70 mn

1)

17.8 cu.in. (292 c.c.)

27 H.

P.

@6,000 r.p.m.

One

(d

iaphragn

1-

type)

''Autolube''

oil injectio

r1

Flywheel magneto

1

2V

-40W @3,000 r.p.m.

Champion N-2G

Manual recoil starter witt1 a

dd'

I

e111e

rg

ency

rop

e starter

Molded rubber, steel reinforc

ed

15 in. (

38

1 mrn )

50

in. (1,270

mm)

12 r

ubber

wh

ee

ls bearing

mounte

d

Single, polyurethane, 9 t

ee

th

Single,

polyureth

an

e,9 t

ee

th

Aut

oma

tic

centrifugal e

ngag

ement, in"fini tely

variable 3.5 : 1 - 1 : 1

Duplex

roller chain

en

closed in

oil

bath

25/

13 =

1.923

: 1

Fabri

ca

ted steel

Reinforced

fibe

rg

l

ass

(removable)

0.090

in. (2.3

mm)

B.

T.D.

C.

Removable (Racing seat)

4.0 gal. (15.0

Q}

2.1

qt.

(2.0

Q)

Chromed

tubular

steel

Chromed

tubular

steel

-

•

j

•

I

•

1

l

I

.

,,

I

•

,

r

I

•

I

•

.

GENERAi!.

-Specifications

-- -

-- --

MODEL

SL292B GP292

• I I

--

Electrical: ' I

I

Headlight

12V

-35/35W

Hi-Lo

beam

12V

-35/35W

Hi-Lo

beam I

Tai

11

ight

12V

-

5W

(rectangular)

12V

-5W (rectangular) I

Stop

light

12V

-lOW

12v~1ow

with

twin

reflector

Ignition

key

switch

4

position

on

dash 4

position

on

dash I

. --

Brake: -- -Il

Type

Disc brake Disc brake 11

Control

Handle lever, left-hand operated Handle lever, left-hand operated

Throttle

:

Type

Handle lever, right-hand operated Handle lever, right-hand operated

Tachometer: Center

of

the

steering handle

bar

Left-hand side

of

the

instrument

panel :

Speedometer: I I

• I

·-

-,

A

cces

sories: I

Emergency

starter

rope Yes Yes

I•

•

Ser

vice

tool

Yes Yes I

Opt

io

nal

equipment

parts:

Electric

starter

Expansion

muffler

(SS

kit)

I

Speedometer

SR

kit

Tachometer I

'

High

windshield

I

--I

--- - -

--

Note:

The research and engineering departments

of

Yamaha are

continually

str1v1ng

to

further

perfect

the

Snowmobile.

Improvements and

modifications

are

therefore

inevitable

.

Information

regarding changes

will

be

forwarded

to

all

Authorized

Yamaha

Snowmobile

Dealers are soon

as

it

is available.

.. •

- 7 -

•

••

,

..

••

I I

t •

• t

• • •

GENERAL

-

Tools

1-3

lOOLS

1. Special Tools

2-f

2-b 0

2-e

3-a

J.b

4-a

4-b

1. Bearing

nut

wrench

(For

primary

sheave)

2.

Flywheel/Primary

sheave

puller

2-a

Body,

magneto

puller

2-b Screw,

magneto

pu

Iler

2-c

Screw,8

mm

L:

80

mm

(For

flywheel

magneto)

2-d Screw, 6

mm

L :

160

mm

(For

primary

sheave)

2-e

Handle

2-f

Attachment,

magneto

puller

3. Crankcase disassembling

tool

3-a

Crankcasedisassembling

tool

3-b

Bolt

2.

Gauges

1 2

4

6-b

6-c 6

-a

2-d

6-d

I 6-e

5 •

l

4-c .-.....-

..

90890-01812

4.

90890-01802

90890

-

01804

90890-01806

5.

90890-01816

6.

90890-018

l 7

90890-01804

90890-01011

90890-01819

7.

Fig. 1-1

3

7

Crankshaft setting t

oo

l

4-a Spacer

90890-0

1818

4-b Crank setting

bolt

90890-0

1020

4-c Crank setting

tool

(Boss)

90890

-

010

19

Ign

ition

tim

i

ng

setting

tool

D

ia

l gauge stand assembly

90890-0

1825

Crankshaft

as

s

emb

ly

disassembli

ng

and reassembling jigs

6-a Crank j

ig

6-b

Press

b

ox

6-c Press

pi

n

6-d

Support

plat

es

6-e

Stops

Socket and

wren

ch

5

{)

00

Cl

0

90890

-

023

00

90890

-

02202

908

90-02203

90890

-02204

90890

-02215

90890-0

1813

9

10

7 6 8

1.

Thicknessgauge

6.

Torqu

e

wren

ch

2.

Dial

gauge

7.

Point

checker

3.

Micrometer

8.

Coil

tester •

.

9.

Tape measure

4.

Cy

I

inder

gauge

5.

Vernier

caliper

Fig. 1-2 10. Scale

-8-

I

3.

General Tools

3

2

6

..

•

8 7

14

11

10

15

1. Pl

ug

wren

ch

2. Set

of

open

-e

nd wrenches

3. Set

of

socket wrenches

4. So

ft

-faced hammer

5. Steel hammer

6. C

ir

clip

pli

ers

(ST

typ

e)

7.

Cir

clip pliers

(R

T

type)

8. Needle nose pliers

9. Pliers

4. Standard

Tool

Kit

It 1

•

4

I 3

('

-

1. 13 x

21

mm

Plug

wrench

2.

29 x

22

mm

Special

wrench

3.

21

x 19

mm

Open-end wrench

4. 17 x 13

mm

Open-end wrench

5.

12

x

10

mm

Open-end

wrench

6.

8x

7

mm

Open-end

wrench

GENERAL

·Tools

5 4

16

18

•

13

17

10.

Ph

iiips-head screw

driver

11. Philips-head screw

driver

(large)

12

. Philips-head screw

dr

iver

(medium)

13. Philips-head screw

driver

(small)

14. Slot-head screw

driver

(medium)

15. Slot-head screw

driver

(small)

16

. T-

type

socket

wrench

17. L

-type

socket wrench

18.

Torque

wrench and sockets

Fig. 1-3

4

4V--~

5

e:;-----?

:;::---_...,~

6

7.

Screw

driver

handle

t11

:l 7

c•

==:='Cit:=~·

8

-9

10

•

11

8.

9.

Combination

slotted

and

philips

type

screw drivers

Philips

type

screw

driver

10. Pliers

11.

Point

wrench

and feeler gauge

•

Fig. 1-4

-9-

•

.

•

GENERAL

-Operation

1~

OPrERATION

1. Warm-up and Break-in Procedures

Each

time

the engine

is

started

it

should be allowed

to

reach normal operating temperature before

bei119

use

d.

When

the

unit

is

new,

full

speed

or

laboriou

s

operat

ion

in

wet

snow should be avoided.

After

10

t10L1r

s

of

oper

atio

n,

break-in

is

usually complete, and

the

unit

will

run

both

better

and cooler.

At

the

end

of

the

10

hour

break-in

period,

it

would

be advisable

to

throughly

check nuts,

bo

lts, and

sc

rews

for

tightness.

Loose hardware

can

cause excessive

vibration

and lead

to

damage

of

the

engine

or

chassis.

2.

Pre-Operational Checks

Before operating

the

snowmobile, make

it

a

habit

to

check:

a. Fuel -When

fueling,

use straight

gas.

Check

amount

before starting out.

Tt1e

fuel tank

hold

s

approximately

f

ive

galIons and

is

located in

the

shroLJd.

b. Oil -Check level

of

oil

in

autolube

tank.

c.

Controls -Check

to

make sure

the

brake and

throttle

operate correc

tly.

d.

Lighting -Make sure

al

I Iighti

ng

equipment

is operable.

e.

Drive-belt -Inspect the drive

belt

for

damage and adjustment.

f. Track -Check

the

track

for

cracks.

If

necessary, adjust the tension of the track and align the track

so

that

it

is

brought

to

a centered

position

.

• ••

"

3.

Sequence

of

Operations

'

•

a.

Turn

switch

on

by

inserting key and

turning

clockwise.

b. Depress

carburetor

c

hoke

lever -

(Return

to

its original

position

when the engine

wi

ll rev

sm

oothly).

c.

Pull

the

starter -

Firmly

gra

sp

the starter handle and

pull

slo\r..i

ly

until

engagement

of

th

e mechanism

can

be

felt.

Then,

pull

briskly,

but

be careful

not

to

pull

the cable

so

far

out

that

it

''bottoms''.

This

will

r

esu

lt

in longer

ca

ble

I

ife.

Sometimes an engine

will

start

better

at

a certain

throttle

opening. A

little

practice wilI insure in1mediate-starting.

d.

Warm up

the

engine -Once the engine is running cleanly, movement of the

throttl

e lever \Nill increase engine r.p.m.

and cause engagement

of

the

drive

system.

e.

Regulate

the

speed

of

the

snowmobile

with

various

throttle

positions.

Si

nee

the

throttl

e is

sp

ring loaded, the

snowmobile

will

stop and

the

engine

will

re

turn

to

an

idle any

time

the hand is remov

ed

fro

m the lever.

f.

The disc brake can be used

to

stop

the

snowmobile

.

It

brakes the entire

dr

ive mechani

sm

.

It

is

ac

tuated by the lever

mounted

on the

left

side

of

the

handle lever.

4.

Service and Spare Parts

;?H a. Always check

your

machine

periodically

to

prevent damage

to

parts be

ca

use

of

improper

adjustments

or

wear

of

it

II

other

parts.

b. Carry

tools

with

you

at all times

so

that

minor

maintenance can be done when required. The

se

tools should include:

1.

Tool

kit

2. Flashlight 3.

Vinyl

tape 4. Steel

wire

5.

Tow

rope

c. Spare parts recommended

as

a safety measure.

1. Drive

belt

2.

Light

bulbs 3. Spark plugs 4. Emergency starter ro

pe

d.

Fuel -When

making

long

trips,

extra

fuel and

oil

should be carried.

-

•

'

•

-10-

ENGINE

-Engine

Removal

CHAPTER 2. ENGINE

2-1 E

ngien

Removal

Note:

For engine removal

only,

it

is

not

necessary

to

remove

ll1e

magneto assembly

or

primary

s

heave

assembly.

However, crankshaft maintenance does require,

their

removal. Maintenance

of

the magneto assembly and

primary

sheaves

can be done w

ith

the engine in the

s

nowmobile

frame.

2-1-1

Removing the Double Seat

The do

ub

le seat

is

bolted

at its

front

a

nd

r

ea

r ends. The

re

ar end

is

fastened

with

two

13

mm

nuts located beneath

the seat.

As for the

fr

o

nt

end, the SL292C

doub

le seat

is

secu

red

wi

th

a panh

ea

d screw, and the GP2928

with

a 10

mm

bolt.

Not

e:

T

he

10

mm

bolt

means

that

its distance across flats of

the

h

ex

agon head

is

10 mm.

Note:

Before removing the

double

seat, disconnect

th

e sto

p/

ta

ii la

mp

connec

tor

at the

front

of

the

daub

le

seat.

Fig. 2-1

)

Fig. 2-2

I

f

p

,,

'I

I

"

•

I

'

)

•

II

t/

,,

~

I

,

0

I

,,

II

,,

)

I

'

f

)

'

I

'

I

0

I

~

~@

0

I

( )

I

I\

I

I I I

\

I

1r

"'

.

L--

.-...-

....

-------,!)

I

--

-

---

I ---

- - -

---

~==.=

~·~''~~-t

• ---

-

--

-

--

\

..J

'=========-•·--

--

~.---

--

1

"'

--

-

Fig. 2-3

2-1-2

Removing

the

Silencer Cover

Remove the four panhead screws, and remove the oil gauge

from

the silencer cover.

-

I I

I

..

-

Fig. 2-4

Fig. 2-5

\

\..

II

-

-I

/,

__.,,,

• .\

-11

-

f.

'

,

~

·

: t I •

•

ENGINE

-

Engine

Removal

2-1-3

Removing the Silencer

Remove the five panhead screws

indi

cated by

ar

r

ow

s.

On

the GP292B, a lock washer

is

used

at

th

e

ca

rburetor

inta

ke

,

and therefore,

it

should be bent flat.

'

0

( . -

+-

~

--

\ /

...

~.

1

·:

Fig.2-6

••

I '

•

\._;_

-

...

~

...._

_

----

I

f

~

Fig. 2-7

•

-12-

•

~--~

-

~

--8

I

.-'

IT

/

•

/ --

-'

•

..

'"

·t .

t I • • •

c ••

I ' •

••

•

, :' i •

'••

. .

~

..

~ f • •

•• •

·r • 1 I

..

.

~

••

• •

!,._

~

• • I '

~

f , •

•

ENGINE

-Engine Removal

2-1-4

Disconnecting

the

Oil Pump Control Rod

Loosen

the

6

mm

double

nut,

and disconnect

the

oil

pump

control

rod

from

the c.arburetor

throttle

link.

0

_\

~-

0

,

__

Fig. 2-9

2-1-5

Disconnecting

the

Throttle

Wire

Loosen the screw, and remove the

throttle

wi

re

fr

om

the

carburetor.

Note:

After

installing the

throttle

wire,

be

s

ur

e to bend the

wire

end.

-I

-n

l1

\ '

I

Fig. 2-10

•

2-1-6

Disconnecting the Decompression Cable

Remove the air s

hr

oud, and remove tl

1e

decompression

cable.

I

.

Fig.

2-1

1

---

-

Fig.

2-

12

2-1-7

Removing

the

Tachometer Cable

Remove t

he

tachometer

cab

le

from

the oil pump

by

tu

rn

i

ng

the

ca

bl

e.

(GP292B)

---

-

~\

Fig. 2-

13

•

-14-

Yamaha SL292C 1971 User manual

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