CHAPTER 7. APPENDICES

7-1 . GENERAL SPECIFICATIONS 7-2 A. General 7-2 B. Engine 7-2 C. Chassis 7-4 D. Electrical 7-5 E. Tightening Torque 7-6

7-2. CABLE ROUTING 7-7 7-3. WIRING DIAGRAM 7-11

7-1. GENERALSPECIFICATIONS A. General

Model: Model (I.B.M. No.) Frame I.D. & Starting Number Engine I D . & Starting Number

Dimension: Overall Length Overall Width (standard) Overall Keight (standard) Seat Height Wheelbase Minimum Ground Clearance

Weight: Net Weight

Performance: Minimum Turning Radius

3L8 3L5-700101 3L5-700101

1,550 mm (61.0 in) 670 mm (26.4 in) 965 mm (38.0 in) 705 mm (27.8 in)

1,050 mm (41.3 in) 120 mm ( 4.7 in)

43 kg (95 lb)

1,500 mm (59.1 in)

B. Engine

Description: Engine Type Engine Model Displacement Bore x Stroke Compression Ratio Starting System Ignition System Lubrication System

Air cooled 2-stroke, Gasoline, Reed valve 3L5 49 cc (3.0 cu.in) 40.0 mm x 39.2 mm (1.575 in x 1.543 in) 6 . 0 : 1 Kick C.D.I. Separate lubrication (Yamaha Autolube)

Cylinder head: Volume (with spark plug) 7.0 cc (0.43 cu.in)

Cylinder: Material Bore Size Taper Limit Out of Round Limit

Special cast iron 40 mm (1.57 in) 0.05 mm (0.002 in) 0.01 mm (0.0004 in)

Piston: Piston Clearance Piston Over Size

0.035 ~ 0.047 mm ( 0 . 0 0 1 4 - 0.0019 in) 40.25 mm, 40.50 mm (1.585 in. 1.594 in)

Piston Ring: Piston Ring Design (Top) Piston Ring Design (2nd) Ring End Gap (Installed) (Top) Ring End Gap (Installed) (2nd) Ring Groove Side Clearance (Top) Ring Groove Side Clearance (2nd)

Keystone ring Keystone ring 0.15 ~ 0.35 mm (0.006 ~ 0.014 in) 0.1 5 ~ 0.35 mm (0.006 ~ 0.014 in) 0.03 ~ 0.05 mm (0.001 ~ 0.002 in) 0.03 ~ 0.05 mm (0.001 ~ 0.002 in)

Small End Bearing: Type Needle bearing

Big End Bearing: Type Needle bearing

7-2

Crankshaft:

Crankshaft Assembly Width (F)

Crankshaft Deflection (A) Connecting Rod Big End Side Clearance (C) Connecting Rod Small End Deflection (S)

•

1

Crank Bearing Crank Bearing Crank Oil Sea

S

fjfflfo 1̂ IT p I *

U -c

Type (Left) Type (Right) Type (Left)

Crank Oil Seal Type (Right)

Clutch: Clutch Type Primary Reduction Ratio & Method Clutch Shoe — Thickness Clutch Shoe Spring — Free Length Clutch Shoe Spring — Set Weight Clutch-in Revolution Clutch-stall Revolution

Transmission: Secondary Reduction Ratio & Method Transmission Gear Oil Quantity & Type

Reduction Ratio & Method

Kick Starter: Type

Intake: • 1 Air Cleaner Type Reed Valve

Bending Limit Valve Lift Tightening Torque

Carburetor: Type & Manufacturer I.D. Mark Main Jet (M.J.) Air Jet Jet Needle-cli Needle Jet Cutaway Pilot Jet Air Screw (tur Starter Jet Fuel Level

(A.J.) p Position (J.N.)

(N.J.) (C.A.) (PJ.)

nsout) (A.S.) (G.S.) (F.L.)

Engine Idling Speed

38 _ 0 0 5 mm (1.50 _0.002 in)

0.03 mm (0.0012 in) 0 3 5 ~ 0.55 mm ( 0 . 0 1 4 ~ 0.021 in) 0 . 4 ~ 0.8 mm (0.016 ~ 0.031 in)

6203-C3

6203-C3

SD17—35—7 SD23—35—7

Wet. Centrifugal automatic 63 /33 (1.909), gear 1.0 mm (0.040 in) 34.5 mm (1.36 in) 3.6 kg (7.94 lb) 2.700 r/min 3.500 r/min

19/1 5 (1.266), bevel wheel gear Exchange: 300 cc (0.32 US.qt) Total: 350 cc (0.37 US.qt) Yamalube 4-cycle oil or SAE 10W/30 motor oil 57 /10 (5.700), bevel wheel gear

Ratchet type

Oiled foam rubber

0.8 mm (0.031 in) 4.8 ± 0 . 2 mm (0.19 ± 0.008 in) 0.08 m-kg (0.6 ft-lb)

VM12SC, MIKUNI 3L500 (3L501) ( ): Air cleaner type No #75 (#70) 2.5 3Q3-3 (3T3-2) E-0 1.0 (4.0) #45 (#40) 1-3/4(1-1/2) #35 22.0 mm ± 1.0 mm (0.87 ± 0.04 in) 1,700 r/min

3L5-702401

Lubrication,: Autolube Pump-Color Code Autolube Pump-Minimum Stroke Autolubd Pump-Maximum Stroke Oil Tank Capacity Oil Grade!

Yellow 0.20 ~ 0.25 mm (0.008 ~ 0.010 in) 0.95 ~ 1.10 mm (0.037 ~ 0.043 in) 0.8 lit (0.8 U.S.qt) Yamalube 2-cycle oil or equivalent

C. Chassis

Frame: Frame Design

Steering System: Caster Trail Number & Size of Balls in Steering Head

Upper Rape Lower Race

Lock to Look Angle Front Suspension:

Type Damper Type Front Fork Cushion Travel Front Fork S

Free Lengt Spring Cor Wire Diam

pring

stant ster x Winding Outside Diameter

Inner Tube Outside Diameter Rear Suspension:

Type Damper Type Rear Shock Absorber Travel Rear Wheel ijravel Rear Shock Absorber Spring

Free Length Set Length Spring Constant Wire Diameter x Winding Outside Diameter

Fuel Tank: Capacity Fuel Grade

Wheel: | Tire Size (Front)

(Rear! Tire Pressure (ffront)

(Rear) Rim Size (Fronw

(Rear) Rim Run Out Liinit (Front/Rear)

Vertical Lateral

Drive Shaft Lubricating Grease: Grade

1 Quantity 1 1 — !*h

Steel tube underbone

25° 7.5 mm (2.95 in)

26 pes 5/32 in 26 pes 5/32 in 100°

Telescopic fork Coil spring 45 mm (1.77 in)

78.0 mm (3.86 in) ki = 0.55 kg/mm 03.2 mm (0.13 in) x 026.8 mm (1.06 022.2 mm (0.87 in)

Unit swing Coil spring, Oil damper 30 mm (1.18 in) 50 mm (1.97 in)

150.5 mm (5.93 in) 145.5 mm (5.73 in) ki = 6.32 kg/mm 06.4 mm (0.25 in) x 039.0 mm (1.54

2.3 lit (0.6 U.S.gal) Regular leaded gasoline

2.00—14—4PR 2.25—14—4PR 1.25 kg/cm2 (18 psi) 2.00 kg/cm2 (28 psi) 1.20x14 1.20x14

0.7 mm (0.028 in) 1.3 mm (0.051 in)

Lithium base wheel bearing grease (EX. SHELL LETHINAX A) 10g(0.4oz)

in)

in)

7-4

Brake: Front Brakfe

Type Drum Diameter (Limit) Shoe Dialmeter x Width Lining Thickness/Wear Limit Shoe Spiling Free Length

Rear Brake Type , Drum Diameter Shoe Diameter x Width Lining Thickness/Wear Limit Shoe Spring Free Length

Drum brake 080 mm (3.15 in) 080 x 17 mm (3.1 5 x 0.67 in) 3.5 mm/2 mm (0.138 in/0.079 in) 44.5 mm (1.75 in)

Drum brake 080 mm (3.15 in) 080 x 17 mm (3.15 x 0.67 in) 3.5 mm/2 mm (0.138 in/0.079 in) 44.5 mm (1.75 in)

D. Electrical

Ignition System Model/Manufacturer Voltage Pulser Coil Charge Coif

Ignition Timing

Resistance (White/Red-Black) Resistance (Black/Red-Black)

Ignition Coil: Model/Mahufacturer Spark Gap Primary Winding Resistance Secondary Winding Resistance Diode Spark Plug

Type/Mar ufa cture Spark Pluij Gap

C.D.I. Unit: Model/Manufacturer

C.D.I. Magneto: Model/Me nufacturer

Charging Systor Flywheel Magneto Charging Output

Charge Coil Resistance (Black-White) Lighting Oijtput

Lighting Cojl Resistance (Black-Blue) Rectifier Type Capacity Withstand Voltage Rating

Battery Model/Manufacture Capacity Charging Specific Gravity

Rate

F3L6/Yamaha 6V 20f l± 10%at20°C(68°F) 295f i± 10%at20°C(68°F) 0.94 mm (0.037 in) (Not adjustable)

C2T4/Yamaha 7 mm (0.28 in) 1.6fi± 10%at20°C(68°F) 6.6kQ ± 20% at 20°C (68° F) No

BP4HS(N.G.K.)

0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

2E9-MO/Yamaha

F3L6/Yamaha

1.0 ± 0.5A/5.000 r/min 1.7 ± 0.5A/8.000 r/min 0.38Q± 10%at20°C(68°F) 6.5V or more/4,000 r/min 7.7V or less/8,000 r/min 0.28fl± 10%at20°C(68°F)

DE4504, S5108 4A 400V Silicon

6N4-2A-2/GS, F U R U u ^ A , YUASA 6V-4AH 0.4Ax 10 hours 1.26at20°C(68°F)

! 1

Lighting System: Headlight Type Bulb Wattajge/Q'ty

HeadlightjWattage Tail/Stop Light Wattage Flasher Lijjht Wattage Flasher Pilot Light Wattage Meter Ligltit Wattage High Beam Indicator Light Wattage Oil Warninjg Light Wattage

Semi-Sealed beam

6V, 20W/20W 6V. 5.3W/25W 6V, 17W 6V. 3W 6V,3W 6V.3W 3V.3W

Horn: Model Maximum Almperage

GF-6 1.5A

Flasher Relay: Model Type Flasher Frequency

FR9T11 Heat-Ribbon type 90 cycle/min

Fuse: Rating/Q'ty 10A/1 pc

E. Tightening Torque

Spark plug M14 2.0 m-kg (14 ft-lb Oil pump M5 0.4 m-kg ( 3 ft-lb Primary drivejgear M10 3.0 m-kg (22 ft-lb Kick crank M6 1.0 m-kg ( 7 ft-lb Reed valve—Manifold M6 0.9 m-kg ( 6.5 ft- b) Generator (Rqtor) M12 4.0 m-kg (30 ft-lb Generator (Stator) M6 0.9 m-kg ( 6.5 ft- b) Exhaust pipe M6 1.0 m-kg ( 7 ft-lb Cover plate (Iv ain axle) M6 1.0 m-kg ( 7 ft-lb Screw (Middle driven pinion) M45 6.0 m-kg (43 ft-lb Cover plate (R ng gear) M6 1.0 m-kg ( 7 ft-lb Screw (Drive r. inion) M35 5.0 m-kg (36 ft-lb

Chassis: Front wheell slhaft nut M10 4.0 m-kg (30 ft-lb, Rear wheel shaft nut M12 6.0 m-kg (43 ft-lb Rear cushion-} Upper M8 2.3 m-kg (17 ft-lb Rear cushion-4Lower M8 2.3 m-kg (17 ft-lb Footrest (Front M8 2.0 m-kg (14 ft-lb Footrest (Rear) M8 2.0 m-kg (14 ft-lb Meter ass'y—Fjandle comp. M5 0.4 m-kg ( 3 ft-lb Rear arm—Engine M8 2.5 m-kg (18 ft-lb Rear arm—Hoipsing M8 2.5 m-kg (18 ft-lb Bracket main stand M6 1.0 m-kg ( 7 ft-lb Engine mounting bolt M10 5.0 m-kg (36 ft-lb

7-6

7-2. CABLE ROUTIIMG

Starter wire

Rear brake wire

Wire harness

u

ftl

Stop switch lead wire.

Stop switch lead wire.

Wire harness ass'y (Headlight)

Wire harness ass'y (Main switch)

Route wire harness behind horn.

Headlight unit

7-8

Starter wire

Wire harness ass'y

Battery lead wire ( —

)

-Battery

After connecting wires, put coupler, lead

wires and rectifier inside side cover 3 so

that wires are not pinched by cover.

Housing

Oil delivery pipe

fmm

mBm

mm

mm

wm

sm^w^m

^^r

,%..

Switch cord band

Clam

p wire to upper part of front carrier so

that it is not pulled when handlebars are

turned fully to left.

Wire harness ass'y

High tension lead w

ire

FRO

NT STO

P S

WITC

H

FRO

NT

FLASHER

LIGH

T (R)

(6V17W

)

REAR FLASH

ER LIG

HT(R

)(6V17W

)

OIL W

AR

NIN

G

LIGH

T Q

J FLA

SHER

IND

ICA

TOR LIG

HT

G>

-| H

IGH B

EAM

IND

ICA

TOR LIG

HT

QT-^

SPEEDO

METER

LIGH

T Cp

J 1

TAIL/S

TOP

LIGH

T (6V25W

)

FRO

NT FLA

SHER

LIGH

T(L)(6V17W

)

REA

R STO

P S

WITC

H

REAR FLASH

ER LIG

HT(L)

(6V17W

)

i CO

m

2 Q

D > O

>

FLASH

ER ^r

SW

ITCH

HO

RN

SWITC

H C

.D.I. M

AG

NE

TO

CO

LOR C

OD

E R

Red

L Blue

B Black

P Pink

Y Yellow

G

Green

0 O

range W

W

hite

Dg Dark green

Ch Dark brow

n G

y G

ray Br

Brown

G/Y

Green/Yellow

B/R Black/R

ed W

/R....:.

White/R

ed B

r/W

Brown/W

hite L/W

Blue/W

hite