YAMAHA SERVICE MANUAL alae Tre) Ei yalFOREWORD This manual was written by the Yamaha Motor Company primarily foruse by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's edu- cation into one manual, so itis assumed that persons using this book to perform mainte- nance and repairs on Yamaha water pumps have a basic understanding of the mechani: cal precepts and procedures inherent to gen- erator repair technology. Without such knowl- edge, attempted repairs or service to this model may render it unfit for use and/or unsafe. Yamaha Motor Company Ltd. is continually striving to further prove all models manu- factured by Yamaha. Modifications and sig- nificant changes in specifications or proce- dures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. NOTE: This Service Manual contains information regarding periodic maintenance to the emis- sion control system. Please read this material carefully. YP20G/YP30G SERVICE MANUAL ©1996 by Yamaha Motor Co., Ltd. 1st Edition, March 1996 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the follow. ing notation ‘The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN- VOLVED! RTE Failure to follow WARNING instructions could result in severe injury or death to the ma- chine operator, a bystander, or a person in- specting or repairing the machine. ACAUTION icates special precautions that must be taken to avoid damage to the ma- chine. NOTE: ‘A NOTE provides key information to make procedures easier or clearer. MANUAL FORMAT The procedures in this manual are organized in a sequential, step-by-step format. The in- formation has been compiled to provide the mechanic with an easy to read, handy refer ‘ence that contains comprehensive explana- tions of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty componentwill precede an arrow sym- bol and the course of action required will follow the symbol, €.g., * Bearings Pitting/Damage —> Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying the correct disassembly and as- sembly procedures.ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols @ thru Mare designedas thumb tabs to indicate the chapter's number and content. @ General information @ Periodic inspections and adjustments © Pump @ Engine © Carburetion © Electrical © Specifications Illustrated symbols ® thru @ are used to identify the specific tools and test equip- ment. © Filling fluid @® Lubricant © Special tool © Tightening @ Wear limit, clearance 4 Engine speed @2,V,A lustrated symbols @ thru @in the exploded diagram indicate the grades of lubricant and the locations of the lubrication points. ® Apply engine oll © Apply gear oil ® Apply molybdenum disulfide oil ® Apply wheel bearing grease Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease @ Apply locking agent (LOCTITE®) @ Apply Yamaha bond € Use new oneINDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS CARBURETION ELECTRICAL SPECIFICATIONS : = le) arCHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION... ENGINE SERIAL NUMBER. IMPORTANT INFORMATION.... PREPARATION FOR REMOVAL AND DISASSEMBLY NOTES ON SERVICE ALL REPLACEMENT PART! GASKETS, OIL SEALS, AND O-RINGS BEARINGS AND OIL SEALS ....sasasee 12 12 14 SPECIAL TOOLS AND TESTERS .. CHAPTER 2 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ... MAINTENANCE INTERVALS CHART. PERIODIC MAINTENANCE/LUBRICATION INTERVALS .... AIR FILTER, FUEL TANK JOB INSTRUCTION CHART MUFFLER ... i JOB INSTRUCTION ENGINE . ENGINE OIL. FUEL LINE INSPECTION . FUEL PETCOCK.. AIR FILTER .. MUFFLER ... VALVE CLEARANCE ADJUSTMENT. COMPRESSION PRESSURE MEASUREMEN’ CYLINDER HEAD DECARBONIZATION GOVERNOR ADJUSTMENT ENGINE SPEED ADJUSTMENT. T.C.L. AIR GAP... BREATHER HOSE INSPECTION SPARK PLUG ..... a CRANKSHAFT SIDE CLEARANCE ADJUSTMENT PUMP... 2 IMPELLER GAP ADJUSTMENT ..CHAPTER 3 PUMP PUMP JOB INSTRUCTION CHART CHECK VALVE INSPECTION VOLUTE CASE/IMPELLER MECHANICAL SEAL SET FIXED SEAL SET INSTALLATION CHAPTER 4 ENGINE CYLINDER HEAD COVER, CYLINDER HEAD . JOB INSTRUCTION CHART CYLINDER HEAD INSPECTION PUSH LOD INSPECTION . CYLINDER HEAD INSTALLATION .. VALVE JOB INSTRUCTION CHART VALVE REMOVAL... VALVE INSPECTION VALVE SEAT INSPECTION .. PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT ... JOB INSTRUCTION CHART CAMSHAFT REMOVAL CAMSHAFT AND VALVE LIFTER INSPECTION .. CRANKCASE INSPECTION .. PISTON, PISTON PIN AND CRANKSHAFT INSPECTION .... FLYWEIGHT SHAFT (GOVERNOR) GEAR INSPECTION ae 13 CRANKCASE COVER INSPECTION PISTON RING AND PISTON INSTALLATION .. CONNECTING ROD INSTALLATION CAMSHAFT INSTALLATION CRANKCASE COVER INSTALLATION .. RECOIL STARTER JOB INSTRUCTION CHART RECOIL STARTER REMOVAL .. RECOIL STARTER INSPECTION ...... RECOIL STARTER INSTALLATIONFLYWHEEL JOB INSTRUCTION CHART FLYWHEEL REMOVAL, FLYWHEEL INSTALLATI GOVERNOR .... JOB INSTRUCTION CHART CHAPTER 5 CARBURETION CARBURETOR... JOB INSTRUCTION CHART FLOAT HEIGHT INSPECTION FUEL PASSAGE INSPECTION VALVE SEAT INSPECTION .. CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS CIRCUIT DIAGRAM... COLOR CODE TROUBLESHOOTING CHART. CHAPTER 7 SPECIFICATIONS GENERAL SPECIFICATIONS .... MAINTENANCE SPECIFICATIONS ENGINE ELECTRICAL TIGHTENING TORQUE... GENERAL TORQUE SPECIFICATIONS .. DEFINITION OF UNITS..... CABLE ROUTING.MACHINE IDENTIFICATION [BEN GENERAL INFORMATION MACHINE IDENTIFICATION ENGINE SERIAL NUMBER The engine serial number @ is located into the fan case. NOTE: —————____ The first three digits of these numbers are for engine identifications; the remaining digits are the ui Starting serial numbe YP20G 7RN-0100101~ YP30G_7RP-0100101~ NOT Designs and specifications are subject to change without notice. WIMPORTANT INFORMATION IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY NOTES ON SERVICE 1.Fire prevention When servicing the engine, always keep the engine and yourself away from fire. 2.Correct tools To guard against damage, be sure to use the correct special tool for the specific job. 3.0il, grease and sealers Be sure to use genuine Yamahaoils, grease and sealers, or the equivalents. 4.Expendable parts When servicing the engine, always replace the gaskets, O-rings, cotter pins andcirclips with new parts. 12GEN IMPORTANT INFORMATION lReS (ee) 5. Tightening torque Be sure to follow torque specifications. When tightening bolts, nuts orscrews, start with the largest-diameter fastener and work from an inner position to an outer position in a crisscross pattern, 6.Notes on disassembly and assembly a.After disassembly, parts should be cleaned in solvent and biown dry with compressed air. Solvent b.When reassembling moving parts oil their contact surfaces Make sure that parts move smoothly after each section of the machine is assembled. 13IMPORTANT INFORMATION 14 ALL REPLACEMENT PARTS. 1, We recommend theuse of genuine Yamaha parts for all replacements. Use Oil and/or grease, recommended by Yamaha, for as- sembly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 1,All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2.Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. BEARINGS AND OIL SEALS 1.Install the bearing(s) @ and oil seal(s) © with their manufacture’s marks or num- bers facing outward. (In other words, the stamped letters must be on the side ex- posed to view.) When installing oil seal(s), apply alight coating of light-weight lithium base grease to the seal lip(s). Oil the bear- ings liberally when installing. (CATION Do not use compressed air to spin the bear- ings dry. This causes damage to the bearing surfaces.SPECIAL TOOLS AND TESTERS Es fis 15 GEN INFO SPECIAL TOOLS AND TESTERS The proper special tools are necessary for complete and accurate tune-up and assem- bly. Using the correct special too! will help to prevent the damage caused by the use of improper tools or improvised techniques. 1.Piston ring compressor PIN. YU-33294 (90890-05158) This tool is used to compress the piston rings when installing the piston. 2.Valve spring compressor P/N. YM-01253 (90890-01253) This tool is used to remove the valve spring, 3.Cylinder gauge P/N 90890-03017 YU-03017 (90890-03017) ‘This instrument is used for checking cylinder bore size and condition. 4. Inductive tachometer P/N. YU-8036-A Tachometer [5] P/N. 90793-80008 This instrument is used for reading engine rpm.SPECIAL TOOLS AND TESTERS 5.Compression gauge set PIN. YU-33223 (90890-03081) Adapter PIN. YU-38223-3 (90890-04082) This gauge is for checking engine compres- sion. 6.Piston pin puller P/N. YU-01304 (90890-01304) This tool is used to remove the piston pin. 7.Pocket tester PIN. YU-03112 (90890-03112) This instrumentis necessary for checking the electrical system. 8.Dynamic spark tester [A PIN. YM-34487 Ignition checker PIN. 90890-06754 This instruments necessary for checking the ignition system components. 16INTRODUCTION/MAINTENANCE INTERVALS CHART/ [INSP PERIODIC MAINTENANCE/LUBRICATION INTERVALS | ApJ Q PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as tonew machines that are being prepared for sale. All service technicians should be familiar with this entire chapter. MAINTENANCE INTERVALS CHART Proper periodic maintenance is important: Especially important are the maintenance services related to emissions control. These controls not only function to ensure cleaner air but are also vital to proper engine operation and maximum performance. In the following maintenance tables, the services related to emission controls are indicated as “**” in the chart. PERIODIC MAINTENANCE/LUBRICATION INTERVALS Pro-Opora: Every Remarks tion check 6 months. (daily) | or 20 He 0r 100 Hr a Check condition, adjust Spark plug gep and clean. e Roplace it necessary. Chock oil lovel. Replace. Clean. Replace if necessary. Clean fuel petcock and Fuel filter fuol tank fitter. Replace if necessary. ‘Check and adjust when engine is cold. Check fuel hose for Fuel line cracks or damage. Replace itnecessery. a * Check for leakage Exhaust system | Retighten orreplacegas- ket if necessary. Check choke (Control lover) operation, Cooling system __| Check for fan damage, Check recoil starter. Operation, Engine oil Ric fiter Valve clearance Carburetor Starting system Bocarbonization | More often ifnecessary. Chock for leakage. Water pump Retighten or replace O- ting andior gasket. Check all fitting and fas- Fitting/Fasteners | teners. Correct if neces- sary. “Itis recommended that these items be serviced by a Yamaha dealer. 24AIR FILTER, FUEL TANK AIR FILTER, FUEL TANK Nm (0.7 m+ kg, 5.1 ft Ib) JOB INSTRUCTION CHART ‘Job name/Parts name ilter and fuel tank Air filter cover Air filter element Nut Plate Bolt Air filter case Gasket Fuel hose Bolt Fuel tank 22 Remarks Remove the parts in the order below. Turn the fuel petcock “OFF”, Reverse the removal procedure for installation.MUFFLER INSP Q | MUFFLER JOB INSTRUCTION CHART ‘Job name/Parts name Y Remarks Removal of muffler Remove the parts in the order below. Bolt Nut Muffler assembly Metal gasket Screw Retainer band Muffler cup Washer (except for USA) Muffler screen Spark arrester (for USA) Screw Muffler cover 7 2 3 4 5 6 7 8 9 10 Wu 2 Reverse the removal procedure for installation. 28[AJSAE #30 or 10W-30 ‘or 10-40. ENGINE OIL INSF Q ENGINE ENGINE OIL Recommended oil: [A] SAE #30. or 10W-30 or 10W-40 [6] SAE #20 or 10W-30 or 10W-40 SAE 10W or 10W-30 or 10W-40 Above 35°C (95°F): SAE #40 Engine oil quantity: 0.6L (0.53 Imp at, 0.63 US qt) NOTE: Recommended engine oil classification: API Service “SE” or "SF" if not available, "Sp" il level measurement 1.Check: * Oil level Oil level measurement steps: * Place the engine on level ground. * Warm up the engine for a few minutes. © Stop the engine. © Make sure the engine oil is between the upper and lower levels, Add oil asneces- sary. Q Upper level ® Lower level Oil replacement 1.Warm up the engine for several minutes. 2.Place a receptacle under the engine. 3.Remove: * Oil filler capENGINE OIL/FUEL LINE INSPECTION/FUEL PETCOCK [SEQ] 25 4.Remove: © Drain plug @ Drain the engine oil 5.Tighten ® Drain plug @ Oil drain plug: 17 Nm (1.7 m+ kg, 12 ft + Ib) 6.Fill: © Crankcase Recommended engine oil: 0.6 L (0.53 Imp qt, 0.63 US qt) Do not allow foreign material to enter the crankcase. 3] 2? [a] FUEL LINE INSPECTION 1.Inspect: © Fuel hose © Cracks/Damage — Replace. Poor connection ~» Correct. FUEL PETCOCK Removal and inspection 1.Tum the fuel petcock lever to “OFF” 2.Inspect: * Fuel petcock cup ® Contamination — Clean. ‘* Rubber gasket © Cracks/Damage — Replace. * Metal screen @ Contamination > Clean. NOTE: Clean the cup with solvent and dry it off. Fuol petcock cup: 1.5 Nm (0.15 m «kg, 1.1 ft + Ib)AIR FILTER/MUFFLER 26 AIR FILTER 1.Remove: * Bolt © * Air filter cover ® * Air filter element © 2.Inspect: © Element Clogging — Wash the element in solvent and dry. Oil the element and squeeze out excess oil. Damage — Replace. Recommended oil: Foam-air-filter oil or SAE #20 motor oil 3.Install: © Air filter element filter cover NOTE: ——___ Do not wring out the element; this could cause it to tear. ‘The engine should never be run without the element; excessive piston and/or cylinder wear may result. MUFFLER 1.Remove: * Muffler Refer to “MUFFLER” section. 2.Remove: * Retainer band @ * Muffler screen @ * Spark arrester @ (for USA)INSP MUFFLER/VALVE CLEARANCE ADJUSTMENT | ADJ Q 27 2.Decarbonize: © Muffler Tap on the muffler, in the area shown in the illustration, to loosen carbon buildup. Then, shake the carbon pieces out of the end of the muffler. Cony Do not use a wire to clean the inside the mufiler or the noise damping material may come out, reducing the damping effect. 3.Decarbonize: © Muffler screen © Spark arrester (for USA) 4.Anstall: © Metal gasket VALVE CLEARANCE ADJUSTMENT 1.Remove: © Breather hose © * Cylinder head cover ® © Spark plug © * Recoil starter 2.Turm the crankshaft clockwise until the line @ on the fan is parallel with the stationary dot ®. The piston is then at TDC. 3.Measure: © Valve clearance Out of specification > Adjust. $4 intake val Exhaust valve (Cold) (Right) | (Cold) (Left) O.1mm 1mm (0.004 in} (0.004 in)VALVE CLEARANCE ADJUSTMENT/ [NSP COMPRESSION PRESSURE MEASUREMENT | ADJ No © When measuring the valve clearance, be sure that the piston is at Top Dead Center (TDC) on the compression stroke. * Valve clearance must be measured when the engine is cool to the touch. Valve clearance adjustment 1. Turn the crankshaft until the piston reaches top dead center (T.D.C.) 2.Loosen the locknut @ and insert the 0.1 mm (0.004 in) feeler gauge between the rocker arm and the valve tip. 3.Tum in or out the adjuster © to obtain the proper valve clearance. Move the feeler gauge up and downto check for the proper resistance. Valve clearance Decrease Increase Adjuster [Tum in| increase [um out | Decrease | 4.Tighten the locknut @. Adjuster locknut: 10 Nm (1.0 m - kg, 7.2 ft « Ib) COMPRESSION PRESSURE MEASUREMENT Insufficient compression pressure will result, in performance loss and may indicate leaking valves or worn or damaged piston rings. 1.Measure: ¢ Valve clearance 2.Warm up the engine for several minutes, then stop the engine. 3.Remove: * Spark plug 4.Connect: + Compression gauge @ * Adapter @ Compression gauge: YU-33223, 90890-03081 Adapter: YU-33223-3, 90890-04082 28COMPRESSION PRESSURE MEASUREMENT/ ||NSP CYLINDER HEAD DECARBONIZATION | ADJ Q 5.Measure: * Compression To measure compression, pull the recoil starter until the needle stops rising on the compression gauge. 4 standard compression pressure: 450 ~ 550 kPa (45 ~5.5 kg/cm’, 64 ~ 78.2 psi) When cranking the engine, ground the spark plug wire to prevent spa Compression test steps (below minimum levels): * Squirta few drops of oil into the cylinder. * Measure compression again. Diagnosis Ifhigher than © Worn cylinder, without oil piston and piston ring if the same as, * Defective piston, without oil ring(s), valve(s) and cylinder head gasket ‘* Improper valve ‘timing and valve clearance Compression test steps (above maximum levels): * Check cylinder head, valve surfaces, or piston crown for carbon deposits, CYLINDER HEAD DECARBONIZATION 1.Remove: * Carbon deposits Refer to “CYLINDER HEAD INSPECTION” section in CHAPTER 4. 29GOVERNOR ADJUSTMENT/ [INSP ENGINE SPEED ADJUSTMENT | ADJ ADJ GOVERNOR ADJUSTMENT 1.Remove: © Fuel tank 2.Adjust: * Governor Governor adjustment steps: 1.Loosen the bolt ®. 2.Turn the governor arm@ clockwise until it stops. 3.Tum the governor shaft @ clockwise until it stops. 4.Tighten the bolt. 3.Adjust: * Engine speed Refer to “ENGINE SPEED ADJUSTMENT” section. ENGINE SPEED ADJUSTMENT 1.Adjust Engine speed (with no load) Engine speed adjustment steps: ‘1.Install the tachometer onto the spark plug lead. ¢Z.| Inductive tachometer: F YU-8036-A, 90793-80008 2.Warmup the engine for several minutes. 3.Loosen the throttle stop screw @. 4.Adjust the high speed engine idle by turing the throttle lever ®. 4,000 + 50 r/min 5. Tighten the throttle stop screw © until it stops. 6.Turn the throttle lever @ clockwise until it stops. 7.Adjust the low speed engine idle by turn- ing the throttle stop screw @, on the carburetor. ee Low speed engine idle: 2,000 + 100 r/minBREATHER HOSE INSPECTION/SPARK PLUG | ADJ an T.C.I. AIR GAP/ [INSP Q| T.C.. AIR GAP 1.Remove: © Fuel tank © Air filter © Carburetor ¢ Recoil starter * Fan cover 2,Measure: © T.CA. air gap Use feeler gauge @. Incorrect -» Adjust. T.C.L. air gap adjustment steps: 1.Loosen the bolts ®. 2.Adjust the T.C. air gap between the T.C.L. pulser and the flywheel by moving the T.C.I. unit up or down, 3.Tighten the bolts, 10 Nm (1.0 m+ kg, 7.2 ft + Ib} $4 7.0.1. air gap: 0.5 mm (0.0197 in) BREATHER HOSE INSPECTION 1.Inspect: * Breather hose Cracks/Damage -» Replace. Poor connection ~» Correct. SPARK PLUG 1.Remove: © Spark plug | CAUTION: | Before removing the spark plug, use com- pressed air to clean the cylinder head coverCRANKSHAFT SIDE CLEARANCE ADJUSTMENT 242 SPARK PLUG/ 2.Inspect: * Electrode @ Wear/Damage — Replace. * Insulator color @ 3.Measure: © Plug gap @ Use a wire gauge or feeler gauge. Out of specification + Regap. q | Spark plug gap: 0,7 ~ 0.8 mm (0.028 ~ 0.031 in) Ifnecessary, clean the spark plug witha spark plug cleaner. ‘Standard spark plug: ‘Spark plug (without resistor): BPR4ES| Before installing a spark plug, clean the gas- ket surface and plug surface. 4.Tighten: © Spark plug Sp | Spark plug: 4] 18 Nm (1.8 m+ kg, 13 ft + tb) NOTE: Finger tighten © the spark plug before torqu- ing @, to prevent thread damage. CRANKSHAFT SIDE CLEARANCE ADJUSTMENT 1.Remove: * Pump assembly 2,Measure: + Crankshaft side clearance Use dial gauge. Incorrect — Adjust $4 standard crankshaft side clearance: 0 ~ 0.2 mm (0 ~ 0.0079 in}CRANKSHAFT SIDE CLEARANCE ADJUSTMENT/ IMPELLER GAP ADJUSTMENT Crankshaft side clearance adjustment steps: 1.Remove the crankcase cover ©. 2.Add or subtract the shim ©. 0.7 mm (0.0039 in) Shim size 0.2 mm (0.0079 in) 0.3 mm (0.0118 in) 3.Install the crankcase cover. Crankease cover bolts: ‘YP20G/30G 22 Nm (2.2 m- kg, 16 ft « Ib} 4. Recheck the crankshaft side clearance. PUMP IMPELLER GAP ADJUSTMENT 1,Remove: Pump case 2,Measure: ¢ Impeller gap Use feeler gauge ©. Incorrect -» Adjust gap. ‘a A Standard impeller gap: 0.3 ~ 0.5 mm renee (0.012 ~ 0.02 in) Impeller gap adjustment steps: 1.Remove volute casing ® and impeller ® 2.Add or subtract the adjusting washer ©. 3. Install the impeller and volute casing. NOTE: Be sure to securely tighten the impeller. 4,Recheck the impeller gap ©.PUMP pump |PUMP & [SoNm (3 m+ kg, 21.7 ft Ib) YP20G: 7 Nm (0.7 m+ kg, 5.1 ft Ib) YP30G: 10 Nm (1 m- kg, 7.2 ft Ib) JOB INSTRUCTION CHART Job name/Parts name Removal of the pump Delivery bend Suction cover Check valve Pump case 1 Volute case Impeller Adjusting washer Spring Rotating seal Pump case 2 Fixed seal set ft Ib) Remarks Remove the parts in the order below. Mesh the pump case projection with the volute case slot. ‘Turn the impelter counterclockwise by tapping the outer edge of the impeller with a plastic hammer. The rotating seal collar must be removed prior to the rotating seal, The cut-out section of pump case 2 faces down. Reverse the removal procedure for installation.PUMP CHECK VALVE INSPECTION ‘Inspect: * Check valve Cracks/Wear/Damage ~» Replace VOLUTE CASE/IMPELLER ‘Inspect: * Volute case D * Impeller ® * O-ring © Cracks/Wear/Damage — Replace MECHANICAL SEAL SET ‘1L.Inspect: * Spring © # Inner circumference of rubber lip @ * Friction surface @ * Outer circumference of buffer rubber @ Cracks/Wear/Damage — Replace FIXED SEAL SET ‘inspect: * Seal * Damper rubber © * O-ring @ Cracks/Wear/Damage -» Replace INSTALLATION 1.Adjust: © Impeller gap Refer to the "IMPELLER GAP ADJUST- MENT” section in CHAPTER 2. a2CYLINDER HEAD COVER, CYLINDER HEAD [enc | si | ee CYLINDER HEAD COVER, CYLINDER HEAD JOB INSTRUCTION CHART Job name/Parts name Removal of cylinder head cover and Remove the parts in the order below. cylinder head Air filter, carburetor Refer to "AIR FILTER, CARBURETOR” section. Muffler Refer to “MUFFLER” section. Breather hose Bolt Cylinder head cover Gasket Bolt Air shroud Bolt Cylinder head Gasket Dowel pin Push rod Reverse the removal procedure for installation. aCYLINDER HEAD COVER, CYLINDER HEAD | ENG CYLINDER HEAD INSPECTION 1.Remove: * Carbon deposits Use rounded scraper. 2.Measure: * Cylinder head warpage Exceeds allowable limit» Re-surface. 5 Warpage limit: 0.1. mm (0.004 in) PUSH LOD INSPECTION Zi 1.Measure: © Push rod runout Roll on V-block Exceeds runout limit — Replace. 0 Runout limit: 0.5 mm (0.02 in} CYLINDER HEAD INSTALLATION ‘Install: © Gasket * Cylinder head assembly NOTE: Follow proper tightening sequence. Cylinder head bolt: 20 Nm (2.0 m- kg, 14 ft Ib) 2.Adjust: * Valve clearance Referto the “VALVE CLEARANCE ADJUST- MENT” section in CHAPTER 2. 42JOB INSTRUCTION CHART 1 2 3 4 5 6 7 8 9 ‘Job name/Parts name Removal of valve Cylinder head Locknut Adjuster Rocker arm Valve cotter Valve spring retainer Valve spring Push rod guide Exhaust valve Intake valve 43 vatve | ENG | gy Remarks Remove the parts in the order below. Refer to “CYLINDER HEAD” section. Reverse the removal procedure for installation.vatve | ENG | gag VALVE REMOVAL 1.Remove: * Valve cotter ® * Valve spring retainer ® * Valve spring @ * Valve @ Use a valve spring compressor ©. £25) Valve spring compressor: 7 YM-01253, 90890-01253 VALVE INSPECTION 1.Inspect: * Valve length @ © Valve face diameter ©) $Y Valve length: Intake | :YP20G 645mm (2.54 in} :¥P30G_ «65.9 mm (2.59 in} Exhaust :¥P20G 64.5 mm (2.54 in} :YP30G 659mm (2.59 in} Valve face diameter: Intake :YP20G 21.0 mm (0.83 in) :YP30G 24.0 mm (0.94 in) Exhaust :YP20G —19.0mm (0.75 in) YP30G 22.0 mm (0.87 in) 2.Inspect: * Valve stem diameter @ Valve stem diameter: ‘Standard 5 mm (0.22 in) 5 mm (0.22 in) Out of specification + Replace. 3.Measure: © Valve stem runout 3 Valve stem runout limit ‘mm (0.0004 in) Out of specification + Replace. at45 vatve | ENG VALVE SEAT INSPECTION 1.Measure: * Valve seat width @ Poor seating > Lap Out of specification ~» Replace. Valve seat width: Standard: 0.7 mm (0.03 in} Limit: 1.7 mm (0.067 in) Valve/Valve seat assembly lapping 1.Apply: * Coarse lapping compound (small amount to the valve face) 2.Position: * Valve {in cylinder head) 3.Rotate: * Valve Turn until valve and valve seat are evenly polished, then clean off compound. 4.Repeat the above steps with a fine com- pound and continue lapping until the valve face has a completely smooth surface. 5.Remove: * Compound (from valve face) 6.Apply: * Mechanic's bluing dye (dykem) @ (to valve face and seat) 7.Rotate: * Valve Valve must make fullseat contact indicated by grey surface all around the valve face where the bluing was removed. 8.Apply: * Solvent (into each intake and exhaust port) Leakage past valve seat —> Repeat valve lapping until seal is complete. NOTE: Pour solvent into intake and exhaust ports only after completion of all valve work and assembly of head parts.Valve spring measurement 1.Measure: * Vaive spring free length © Out of specification > Replace. {Valve spring free length: 26.5 mm {1.04 in) Limit 25.0 mm (0.98 in) 2.Measure: * Valve spring tilt @ Use a square, Out of specification Replace. Tilt limit: 0 mm (0, )PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT 1 22. Nm (2.2 m-kg, 16 ft Ib) Tightening sequenPISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT JOB INSTRUCTION CHART Job name/Parts name Remarks Removal of piston, camshaft crankcase Remove the parts in the order below. and crankshaft Refer to the “CYLINDER HEAD COVER, Cylinder head CYLINDER HEAD" section, Flywheel Refer to the “FLYWHEEL” section. Bolt NOTE: Follow proper tightening sequence. Crankcase cover Gasket Dowel pin Camshaft Be sure to align the ‘camshaft gear mark with the crankshaft gear mark. Valve lifter Bolt Connecting rod cap Be sure the connecting rod mark is aligned with the cap mark. Connecting rod Be sure the “YAMAHA” mark on the connecting rod faces to the crankcase cover side. Piston pin circlip Piston pin Be sure the “V” mark on the piston head faces to the push rod side. Piston ring Be sure to install the rings so that manufacturer's marks face to the piston head. Be sure each piston ring end is positioned as in the illustration. Crankshaft Drain plug Gasket Bolt Oil level switch Reverse the removal procedure for installation. Piston pin wear limit | 15.95 mm (0.63 in) cam lobe i Crankpin wear limit | _ 27.9 mm (1.098 in) length 2668 mm 0.04 mm (0.0016 in) 48PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT | ENG CAMSHAFT REMOVAL 1.Remove: * Camshaft NOTE: ————___ Remove the camshaft when the camshaft gear mark and the crankshaft gear mark are aligned, 2.Remove: * Intake valve lifter © Exhaust valve lifter @ Mark the intake and the exhaust valve lifters 0 as not to confuse them during reassem- bly. CAMSHAFT AND VALVE LIFTER INSPECTION 1.Measure: * Cam lobes length © and ® Use a micrometer. Out of specification -> Replace. Cam lobe length @: Intake : 26.9 + 0.05 mm (1.06 + 0,002 in) Exhaust : 26.68 + 0.05 mm (1.05 + 0.002 in} Cam lobe length ©: Intake : 22.0 + 0.05 mm (0.87 + 0.002 in) Exhaust : 22.0 + 0.05 mm (0.87 + 0.002 in) 2.Inspect: * Camshaft © * Decompressor ® © Valve lifter @ Damage/Wear —> Replace. 49PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT | ENG 410 3.Measure: * Camshaft diameter Out of specification > Replace. Camshaft diameter (li 14.95 mm (0.589 in) it): CRANKCASE INSPECTION 1.Inspect: © Cylinder walls Vertical scratches — Rebore or replace cyl- inder. 2.Measure: * Cylinder inside diameter “D” NOTE: ———___ Take side to side and front to back measure- ments at each of the 3 locations {total of 6 measurements). Then, find the average of the measurements. Outof specification Reborecylinder, and replace piston and piston rings. 4 “qT Standara 56.15 mm (2.21 in) 66.18 mm (2.604 in) 0.05 mm (0.002 in) 0.05 mm (0.002 in) D-Maximum A, B, C laximum A-Minimum C 3.Inspect: © Crankease Damage -» Replace. * Bearing Roughness ~+ Replace bearing.PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT PISTON, PISTON PIN AND PISTON RING INSPECTION 1. Measure: @ Piston skirt diameter “P” @=5 mm (0.2 in) from the piston bottom edge. Standard piston size P: ‘YP20G: 56.0 mm (2.205 in) YP30G: 66.0 mm (2.60 in) Piston wear limit: YP20G: 55.9 mm (2.2001 in) YP30G: 65.9 mm (2.59 in} 2.Measure: © Piston clearance Piston clearance= Cylinder inside diameter “D“ — Piston skirt diameter “P” Out of specification +» Rebore cylinder and replace piston and piston rings. {| Piston clearance: 0.015, 040 mm {0.0006 ~ 0.0016 in) 3. Measure: ¢ Piston pin diameter @ Use a micrometer. Out of specification -> Replace. Standard piston pin diameter 15.995 ~ 16.00 mm (0.6297 ~ 0.6299 in} Piston pin wear limit: 1.95 mm (0.627 in) anPISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT [ENG 4,Measure © Piston ring end gap Use a feeler gauge. Out of specification + Replace. Piston ring end gap: Top ring: 2nd ring: 0.2 ~ 0.4 mm (0.008 ~ 0.016 in} 0.2 ~ 0.4 mm (0.008 ~ 0.016 in) Piston ring end ga 0.9 mm (0.035 5. Measure: * Piston ring side clearance Use a feeler gauge Out of specification -+ Replace. NOTE: Clean carbon from piston ring grooves and rings before measuring the side clearance. Piston ring side clearance: Top ring: 0.04 ~ 0.08 mm {0.0016 ~ 0.003 in) 2nd ring: 0.02 ~ 0.06 mm {0.0008 ~ 0.002 in) Piston ring side clearance limit: 0.1 mm (0.004 in) CRANKSHAFT INSPECTION 1.Measure: © Crankshaft runout Use a dial gauge. Out of specification > Replace. 4 Crankshaft runout limit: 04 mm (0.0016 in)PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT [ enc | 2,Measur * Crankpin outside diameter Use a micrometer. Out of specification — Replace. Crankpin outside diameter: 27.969 ~ 27.984 mm {1.1011 ~ 1.1017 in) Crankpin outside diameter limit: 27.9 mm (1.088 in} 3. Measure: © Oil clearance Use plastigauge®. Out of specification +» Replace connecting rod. $4 oil clearance: 0.016 ~ 0.046 mm (0.0006 ~ 0.0018 in} Oil clearance limi 0.1 mm {0.004 in) Oil clearance measuring steps: 1.Clean all parts thoroughly. 2.Place plastigauge® onto crankpin 3.Install the connecting rod and cap onto the crankcase. 4.Torque both cap bolts evenly. Nyy Connecting rod cap bolt: Ay| 12 Nm (1.2 m+ kg. 8.7 ft - Ib) 5.Remove the connecting rod and mea- sure the plastigauge® width. NOTE: Donot move the crankshaft until the oil clear- ance measurement has been completed. FLYWEIGHT SHAFT (GOVERNOR) GEAR INSPECTION 1.Inspect: * Collar ‘+ Washer * Flyweight gear Damage/Wear -» Replace. 4g.PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT | ENG | gy CRANKCASE COVER INSPECTION 1.Inspect: © Crankcase cover * Bearing Damage/Roughness > Replace. PISTON RING AND PISTON INSTALLATION install: * Piston rings “CAUTION: Be sure to install the second ring so that the manufacturers mark @ faces towards the piston head. * Be sure that each end of the piston ring is ed, as in the illustration. Top ring 2nd ring Oil ring 2.\nstall: * Piston pin © Piston pin circlips 3.Install: © Piston Use a piston ring compressor ©. £2 Piston ring compressor: I YU-33294, 90890-05158PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT Eo (ieAUTION? © Be sure the “YAMAHA” mark on the con- necting rod faces to the crankcase cover side. © Be sure the “V" mark on the piston head faces to the push rod sid CONNECTING ROD INSTALLATION ‘Install: * Conneeting rod cap Be sure theconnecting rod mark @is aligned with the cap mark Q. yy | Connecting rod cap bolt: 12. Nm (1.2m kg, 8.7 ft Ib) CAMSHAFT INSTALLATION 1.Install: © Camshaft Be sure to align the camshaft gear mark with the crankshaft gear mark. CRANKCASE COVER INSTALLATION 1.Install: © Crankcase cover Crankcase cover bolt: 22 Nm (2.2 m- kg, 16 ft - Ib) Follow proper tightening sequence. 2.Adjust: © Crankshaft side clearance Refer to the “CRANKSHAFT SIDE CLEAR- ANCE” section in CHAPTER 2.RECOIL STARTER | ENG RECOIL STARTER 6.5 Nm (0.65 m= kg, 4.7 ft Ib) JOB INSTRUCTION CHART | Order | Removal of recoil starter Remove the parts in the order below. Bolt Recoil starter Starter handle Bolt Drive plate Clip Drive paw! Spring Drum sheave Starter spring Starter case Starter rope Reverse the removal procedure for installation. 41647 RECOIL STARTER | ENG | gy RECOIL STARTER REMOVAL 1.Remove: ® Starter handle @ NOTE: ———__ Before untying the knot @ above the starter handle, make a knot @on the rope so thatthe rope is not pulled into the case. CAUTION: Release the spring pre-load before removing the sheave drum bolt. Hook the rope into the sheave drum slot @ and turn the sheave drum assembly clockwise. 2.Remove: * Drum shave @ * Starter spring @ Be sure to press down on the drum sheave, because the spring will spread out suddenly it is removed from the sheave drum. RECOIL STARTER INSPECTION 1.Inspect: * Starter rope Damage/Wear — Replace. © Starter spring Contamination — Clean and apply grease. Damage/Wear — Replace. 2.Inspect: * Drive pawl © Damage/WVear ~ Replace. * Starter case @ Cracks/Damage —> Replace.RECOIL STARTER [enc] das | RECOIL STARTER INSTALLATION Install: * Starter spring @ © Sheave drum @ @enuriOns Engage the springhook @ with thedrumslit, then wind the spring counterclockwise into the drum from larger to smaller diameter. 2.Install: * Starter rope Engage the spring hook @ with the starter case hook ©. 3.Install * Springs ® * Drive pawls © 4.Install: * Clip * Drive plate @ S.Install: * Bolt @ Tur the drum sheave counterclockwise 4 turns to give spring preload.FLYWHEEL 65 Nm (6.5 m+ kg, 47 ft Ib) JOB INSTRUCTION CHART Job name/Parts name Removal of flywheel Air filter Carburetor Recoil starter Nut Washer Starter pulley Flywheel Key 419 Remarks Remove the parts in the order below, Refer to the “AIR FILTER" section in the CHAPTER 2. Refer to the “CARBURETOR” section. Refer to the "RECOIL STARTER" section. Reverse the removal procedure for installation,FLYWHEEL FLYWHEEL REMOVAL 1,.Remove: * Flywheel © Use a bearing puller (General tool) FLYWHEEL INSTALLATION install: * Flywheel : Flywheel nut: 65 Nm (6.5 m - kg, 47 ft « Ib) 4] T.c4. air gap: 0.5 mm (0.0197 in) Refer to the “T.C.l. AIR GAP” section in the CHAPTER 2.Governor | ENG GOVERNOR 8Nm (0.8 m-kg, 5.8 ft = Ib) JOB INSTRUCTION CHART Job name/Parts name Remarks Removal of governor Remove the parts in the order below. Fuel tank Refer to “FUEL TANK” section. Water pump assembly Refer to “PUMP” section in CHAPTER 3. Crankcase cover Refer to “CRANKCASE" section. Spring Link rod Spring Bolt Nut Governor arm Flyweight shaft assembly NOTE: Lightly tap the shaft from ‘tho outside of the crankcase cover. Clip Governor shaft Throttle lever assembly Reverse the removal procedure for installation. 421Throttle lever assembly Install: “Install: © Throttle lever assembly ® NOTE: Push the throttle lever assembly @ towards the fuel tank stay ® until the side of the throttle lever assembly is against the fuel tank stay ©. Then tighten the bolt @. 2. Adjust: * Governor * Engine speed Refer to the “GOVERNOR ADJUSTMENT” and “ENGINE SPEED ADJUSTMENT” sec- tion in CHAPTER 2. 422CARBURETOR |CARB; CARBURETION CARBURETOR YP206 Type BVi8 1.D. Mark TNMI0 Float height_[16 mm (0.63 in) JOB INSTRUCTION CHART ‘Job name/Parts name Removal of carburetor Remove the parts in the order below. Air fitter Refer to the “AIR FILTER” section in the CHAPTER 2. Nut Plate Air filter case Gasket Carburetor assembly Bolt Gasket Float chamber body Gasket Float pin Float Needle assembly Screw Reverse the removal procedure for installation, BtZ 52 CARBURETOR FLOAT HEIGHT INSPECTION 1. Measure: * Float height NOTE: Place the carburetor in an inverted position for measurement. Liftup the floatso thatthe tip ofthe floatvalve lightly contacts the float arm, and measure the float height. (This measurement should be made with the gasket removed.) °@ Float height: 16 mm (0.63 in} FUEL PASSAGE INSPECTION ‘Inspect: © Carburetor body * Fuel passage Contamination > Clean as indicated Carburetor cleaning steps: ‘* Wash the carburetor in petroleum based solvent. (Do notuse any caustic carbure- tor cleaning solution.) * Blow outall passages and jets with com- pressed air. Never use a wire. VALVE SEAT INSPECTION ‘.Inspect: * Valve seat Damage/Wear — Replace. Contamination > Clean. @ Grooved wear @ DustELECTRICAL COMPONENTS |ELE ELECTRICAL ELECTRICAL COMPONENTS. @ Engine stop switch @ Oil level warning light @ TCA. unit @ Spark plug © Oil warning unit *: This illustration may differ from the actual engine. 61CIRCUIT DIAGRAM CIRCUIT DIAGRAM @ Engine stop switch COLOR CODE QTC. unit B @ Spark plug @ Oil warning unit © Oil level switch © Oil level warning light 62IGNITION SYSTEM ELEC| TROUBLESHOOTING CHART NO SPARK OR WEAK SPARK NOTE: * Remove the following parts before troubleshooting. 1) Spark plug * Use the following special tools) in this troubleshooting. Pocket tester: ic spark tester ‘YU-03112, 90890-03112 checker): |-34487, 90890-06754 © Check the spark plug condition. Refer to the “SPARK PLUG” section in the CHAPTER 2. © Disconnect the spark plug cap @ from the spark plug, ¢ Connecttheignitionchecker@asshown. Spark plug cap > Ignition checker Ignition checker lead > Spark plug © ‘ Turn the crank and measure the ignition spark gap @. Minimum spark gap: 6 mm (0.24 in) OUT OF SPECIFICATION % ORO SPARK Ignition system is good. 63IGNITION SYSTEM 3.Spark plug cap resistance ‘¢ Remove the spark plug cap. © Connect the pocket tester ({2x1k) to the spark plug cap. * Check the spark plug cap for resistance. Co is [oJ ji] Spark plug cap resistance: 0 5 kQ220% at 20°C (68°F) MEETS: SPECIFICATION 4.T.C.l. unit coil resistance OUT OF SPECIFICATION Replace the spark plug cap. ‘* Remove the T.C.l. unit © Connect the pocket tester (€2x1k) to the T.C.I, unit. [ Tester (+) lead > Orange terminal _| (+) lead [ Tester (+) lead > Orange terminal _| terminal @ T.C.L. unit coil resistance: eal 11.7 kQ+10% MEETS SPECIFICATIONIGNITION SYSTEM * Disconnect the engine stop switch leads. * Connect the pocket tester (Qx1) to the engine stop switch. © Turn the engine stop switch to “ON” and check the engine stop switch for continu- ity. tb NO CONTINUITY * Tum the engine stop switch to “OFF” and check the engine stop switch for continuity. CONTINUITY NO CONTINUITY © Drain the engine oil. Refer to the “ENGINE OIL” section in CHAPTER 2. * Remove the oil level switch. Refer to the “CRANKCASE” section in CHAPTER 4. * Connect the pocket tester as shown. CONTINUITY NO CONTINUITY Replace the oil level s\ 65IGNITION SYSTEM |ELEC * Tighten the oil level switch bolts. 10 Nm (1.0 m+ kg, 7.2 ft Ib) 7.Wiring connections POOR CONNECTION * Check the connections on the entire igni- tion system. tL CORRECT Properly connect the ignition system. 66GENERAL SPECIFICATIONS |SPEC) O* SPECIFICATIONS GENERAL SPECIFICATIONS YP20G YP30G MODEL CODE NUMBER TAN 7RP DIMENSIONS Overall length in 391 (15.4) 397 (15.6) Overall width i 502 (19.8) 518 (20.4) Overall height i 454 (17.8) 466 (18.3) Dry weight 27 (59.5) 30 (66.1) ENGINE Engine type 4-stroke OHV forced air cooled Cylinder arrangement 1 « Displacement 0.123 0.171 Bore x Stroke 56 x 50 (2.20 x 1.97) 66 x 50 (2.60 x 1.97) Compression ratio 8. 85:1 Rated output kw (PS\/3,600 r/min 2.0 (2.8) 3.3(4.5) Fuel Unleaded regular gasoline Fuel tank capacity _L (Imp gal, US gal) 4.5 (2.64, 3.17) Engine oil capacity L (imp gt, US at) 0.6 (0.53, 0.63) Engine oil grade ‘stroke engine oll API service classification SE or SF if not available, SD ee isa tow ‘or 10-30 IGNITION SYSTEM. Ignition timing Spark plug type BPRAES (NGK) Gap 0.70.8 (0.028-0.031) m”MAINTENANCE SPECIFICATIONS, MAINTENANCE SPECIFICATIONS ENGINE YP206. YP30G PISTON Piston clearance |0.015~0.04 (0.0006~0.0016) « Piston size "D” 55.975 ~55.990 65.975~65.990 (2.2037~2.2043) (2,597~2.598) 55.9 (2.20) 65.9 (2.60) Measuring point “H" 5 (0.2) © Oversize 1st 56.25 (2.21) 66.25 (2.61) 2nd 56.50 (2.22) 66.50 (2.62) PISTON PIN Piston pin dia 15,995~16.000 « (0.6297~0.6299) Limit 15.95 (0.63) e PISTON RING Top ring Type Barvel face < Dimensions 1.5 x 2.4 (0.059 x 0.094) | 1.5 x 2.7 (0.059 x 0.106) End gap 0.2-0.4 (0.008-0.016) 0.9 (0.0354) Side clearance |0.04~0.08 (0.0016~0.003) 0.1 (0.0039) 2nd ring Type Taper < Dimensions - 1.5 x 2.4 (0.059 x 0.094) | 1.5 x 2.7 (0.059 x 0.106) End gap 0.2-0.4 (0.008-0.016) 0.9 (0.0354) Side clearance 0.02~0.06 (0.0008-0.0024) 0.1 {0.0039) Oil ring Type Solid Dimensions 2.5 x 2.4 (0.098 x 0.094) End gap 0.2-0.4 (0.008-0.016) 0.9 (0.0354) CYLINDER HEAD. Warp limit 0.1 (0.004) CYLINDER Bore size 56.005~56.015 66.005~66,015 (2.2049--2.2053) (2.5986~-2.5990) CRANKSHAFT Big end side clearanc 0.2~0.6 (0.008~0.024) 0.8 (0.03) Runout “B” 0.02 (0.0008) 0.04 (0.0016) Crank pin dia “C” 27.969-27.984 (9.1011~1.1017) 27.9 (1.098)MAINTENANCE SPECIFICATIONS YP20G CONNECTING ROD ‘Small end dia “A” 16.006~16.020 (0.6301~0.6307) Oil clearance 0.006~0.025 Big end dia “B” Oil clearance 0.016~0.046 {0.0006~0.0018) 0.1 (0.004) CAMSHAFT Camshaft outside dia. Cam dimension IN EX “A 26.9 (1.06) |26.68 (1.05) “3” 22.0 (0.87) | 22.0 (0.87) Camshaft journal 14,973~14,989 7 (0.5895~0.5901) 14.95 (0.589) VALVE Valve dimension Head dia “A” 21.0 (0.83) 24.0 (0.94) 19.0 (0.75) 22.0 (0.87) Stem dia “B" 5.5 (0.22) 5.5 (0.22) Length “C” 64.5 (2.54) 65.9 64.5 (2.54) 66.2 Seat width “D” 0.7 (0.03) 0.7. (0.03) 1.7 (0.067) ng" 90° ttttsptt Valve guide Guide inside dia 5.5 (0.22) 5.5 (0.22) Stem to guide clearance 10.04~-0.06 (0.0016~0.002) 0.06~0.08 (0,002~-0.003) Valve clearance 0.1 (0.004) 0.1 {0.004) TTT ttt PUSH ROD Runout limit 0.5 (0.02) 73MAINTENANCE SPECIFICATIONS Unit YP20G VALVE SPRING Free length Set length Set force Tilt limit mm (in) IN EX IN EX IN 26.5 (1.04) 26.5 (1.04) 21.6 (0.85) 18.9 (0.74) 4.5 kg (9.9 Ib) 7.0 kg (15.4 Ib) 1.0 (0.04) TTT CARBURETOR Type/Manufacturer Bore size Main jet Pilot jet Pilot screw Valve seat size Float height ELECTRICAL mm {in} Gh, BV18-11/MIKUNI 918/11 #75.0 #388 24 91.5 (0.06) 16 (0.63) YP20G BV20-15/MIKUNI 620/15 491.3 #42.5 1-3/4 91.8 (0.07) « ELECTRICAL Ignition system Coil resistance TCI. 11.7KO+10% rHTIGHTENING TORQUE SPEC) o= TIGHTENING TORQUE Item YP206, Thread size YP30G, Torque Nm (m+ kg, ft Ib) Thread size Torque Nm im +kg, ft+ tb) Cylinder head M8x 1.25 20 (2.0, 14.5) M8x1.25 20 (2.0, 14.5) Cylinder head cover M6x1.0 10 (1.0, 7.2) M6x1.0 10 (1.0, 7.2) Crankcase cover ‘Spark plug M8x 1.25 M 14x 1.25 22 (2.2, 16.9) M8x 1.25 22 (2.2, 15.9) 18(1.8, 13) M14 1.25 18.(1.8, 13) Fan case M6x1.0 710.7, 5.0) M6x1.0 710.7, 5.0) Connecting rod M7x1.0 | 1217.2, 8.7) M7x1.0 12(1.2, 8.7) Flywheel magneto M 14x15 65 (65, 47.0) M 14x16 65 (6.5, 47.0) Governor arm. Oil level switch’ M6x1.0 M6x1.0 8 (0.8, 5.8) M6x10 8 (0.8, 5.8) 10(1.0, 7.2) M6x1.0 10 (1.0, 7.2) TCL unit M6x1.0 10 (1.0, 7.2) M6x1.0 10 (1.0, 7.2) Oil drain plug M 10x 1.25 47(1.7, 12.3) M10 x 1.25 WAVT, 12.3) [Rocker arm lock nut M6x05 10 (1.0, 7.2) M6x05 10 (1.0, 7.2) Push rod guide M 6x 1.0 10 (1.0, 7.2) M6x10 10.(1.0, 7.2)GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fas- teners with standard I.S.0. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multifastener assemblies in a criss- cross fashion, in progressive stages, until full torque is reached. Unless otherwise speci- fied, torque specifications call for clean, dry threads. Components shouldbe at room tem- perature. DEFINITION OF UNITS. Read SPEC Tightening torque Thread size M4 MS M6 M7 Ms M10 M12 Definition Measure Millimeter Centimeter Kilogram Newton 10° meter 10? meter 10? gram, ‘kg x m/sec? Length Length Weight Force Newton meter m-kg Meter kilogram Pa Pascal N/mm Newton per millimeter Nxm mxkg Nim? Nimm Torque Torque Pressure Spring rate L Liter om? Cubic centimeter Volume or capacity r/min Engine speed 16CABLE ROUTING @ Engine stop switch lead © Engine stop switch @ Oil level warning light © Oil warning unit CABLE ROUTING SPECMEL) Sea creo Cen Peni arat) Hae bance)