Yamaha JT1 Series Assembly Manual Download | Manualshive

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Summary of Contents for JT1 Series

Page 1: ...JT1 JT2 SERIES ASSEMBLY MANUAL LIT 11662 88 72 ...

Page 2: ...to future sales and service business On the other hand a poorly prepared machine is sure to result in a dissat1sf1ed customer and possibly extra work due to the need for subsequent re doing of portions of the Job Follow the procedures in this manual rn the order in which they are presented Don t skip around and perform them out of sequence and don t omit any of them They are all essential to a wel...

Page 3: ...le Control 12 Section 111 Adjusting Components A Adjusting the Front Brake 13 B Adjusting the Clutch 14 C Adjusting the Chain 15 D Adjusting the Rear Brake 16 E Bleeding the Autolube Pump 16 F Checking Autolube Pump Minimum Stroke 18 G Adjusting the Carburetor 18 H Checking Ignition Timing 19 Section IV Making Preliminary Checks A Filling Fuel Tank 22 B Checking Transmission Oil Level 23 C Checkin...

Page 4: ...aution Don t cut too deeply when removing the masking tape You might damage components directly be neath the tape COMPONENT TRAY MASKING TAPE FIBER TAPE 2 Open the flaps of the car ton and Iift out the tray of components Set the tray aside Caution Don t try to lift the tray by the wooden frame around it Lift the tray itself 1 ...

Page 5: ...t to the Warranty Department of Yahama International Corporation for credit Mark the form DAMAGED IN SHIP MENT 2 Section 11 Assembling the Motorcycle Note The following proce dures apply to either of the two motorcycles in the carton A Installing the Handlebars 1 Lift the front wheel out of the carton and set it aside 2 Using a 10 mm wrench remove the four bolts that secure the two handlebar retai...

Page 6: ...otorcycle from the wooden frame This is a job for two men Place a support under the engine to hold the motorcycle upright 4 Using a 10 mm wrench remove the three front fender mounting bolts and washers from the frame 5 Position the front fender on the yoke Secure it with the three mounting bolts and washers BUSHING LOCK AXLE C Installing the Front Wheel 1 Using a 17 mm wrench remove the axle from ...

Page 7: ... 30ft lbs D Installing the Footrests 1 Remove the footrest pin and cotter pin from the plastic bag in the compo nent tray Note The following steps apply to either footrest 2 Slide the footrest into the frame bracket Hold the footrest vertical with the cover tread forward 3 Slide the pin head for ward into the bracket and footrest Slide the cotter pin into the pin hole and bend up the ends CHANGE P...

Page 8: ...cable collar back and pull the cable around through the long slot in the lever bracket Release the collar 3 Secure the front brake cable to the lever at the right handgrip in the same manner H Installing the Rear Brake Rod 1 Remove the brake rod as sembly return spring large washer and cotter pin from the component tray The spring washer and cotter pin are in the plastic bag 2 Hook the elbow of th...

Page 9: ...o yellow blue to blue by pushing them into the teminals NOTE See JT2 Supple ment for instaIlation in structions 1972 to i11ights P 32 J Connecting Wiring 1 Remove the Phillips head screw at the left side of the headlight housing Carefully pull out the head light and rim 2 There is a loose grommet inside the headlight hous ing Install this grommet in the hole in the left side of the housing 3 Inser...

Page 10: ...ulder of the nylon sleeve against the lower surface of the upper cap Secure the upper and lower caps together with the two Phillips head screws 12 STOP BUTTON Note Rotate the handgrip as sembly so that the engine stop button is horizontal before tightening the screws Section 111 Adjusting Components A Adjusting the Front Brake 1 Lightly squeeze the lever at the right handgrip The lever should move...

Page 11: ...play with a rider in position Total move ment at the center of the lower section of the chain should be about inch 20 mm If it is not con tinue with step 2 2 Using a 25 mm socket wrench loosen the rear wheel nut 3 Adjust the play in the chain by turning the ad justing nut on each side of the wheel Turn both nuts the same amount Note Turning the nuts in de creases free play 4 Check that the wheel i...

Page 12: ...iller plug 2 Fill the Autolube tank with YAMALUBE The tank holds 1 1 US quarts 1 03 liters Note In temperatures below 25 F thinner oil 1s re quired Refer to SER VICE NEWS BULLETIN 157 3 Push in the filler plug and install the seat 4 Pull the spring and lift the rubber cover from around the cover plate Remove the cover plate 5 Remove the bleeder bolt Place a cloth under the hole to absorb oil spill...

Page 13: ...e later with the en gine running J H Checking Ignition Timing 1 Remove the generator cover from the left side of the crankcase 2 Pull the wire lead cap assembly off the spark plug Using a 21 mm socket wrench remove the spark plug 3 Turn the magneto rotor by hand until the points close 4 Dip a thin strip of card board such as a business card in lacquer thinner 5 Pry the points open with your finger...

Page 14: ...e equals 1 mm of piston travel Therefore when the needle moves back 2 revolutions then for ward to 20 it means the piston is at a final position of 1 8 mm be low Top Dead Center Overshooting and re turning to 20 is done to take up any slack in gears and bearings 13 If the point checker nee dle moved as the piston was brought to the 1 8 mm point t iming and point gap is correct Go to step 16 If it ...

Page 15: ...il Level 1 Remove the dipstick and check that there is oil on it The actual oil level is unimportant since it can only be accurately checked after the engine is warm 2 If there is not oil at all on the dipstick fill the trans mission with break in oil The transmIssIon holds 0 64 US quart 0 6 liter Note Refer to SERVICE NEWS BULLETIN 169 for more information on add ing transmission oil 5 4 ADD I C ...

Page 16: ... Starting the Engine 1 Turn the fuel petcock lever to 0 2 Pull the starter lever up 3 Kick down on the kick pedal quickly and smooth ly Keep the accelerator grip closed while you do this 4 When the engine is run ning push in the starter lever l__ B Checking the Trans mission Oil 1 Let the engine idle for about 10 minutes then turn it off 2 Unscrew the dipstick and wipe it clean Check the oil level...

Page 17: ...tep 7 If not continue with step 6 26 THROTTLE STOP SCREW THROTTLE CABLE I 1 64 TO 1 32 LOCK NUT 6 Turn the throttle cable adjusting screw at the handgrip until play is 1 8 4 to 3 inch Tighten the lock nut against the adjusting screw 7 Turn the accelerator handgrip slightly to re move free play from the throttle cable 8 With free play removed turn the pump cable ad justing screw until the mark on t...

Page 18: ...ransmis sion shifts easily and makes no unusual noises 4 Check that acceleration is typical of the average JT1 L Caution Avoid using high engine or road speeds at this time Remember that easy running during break in is necessary for maximum engine life and customer satisfaction 5 Check that handling qual ities and stability are sat isfactory Poor handling and instability may be caused by improper ...

Page 19: ...L JT2M SUPPLEMENT Contents Charging Battery 31 Ins ta11 ing TaiII ight 32 Installing Ignition Switch 33 Installing Speedometer Cable 33 Connecting Wiring 34 JTl L JT2 L Connection Diagrams 35 Torque Specifications 36 ...

Page 20: ...r venting is tak ing place 2 Fi II each ce II to the top level line with fresh elec trolyte 3 Charge the battery at O 2 A MAX until specific gravity is 1 260 1 280 4 lnstal I the battery in the frame and connect the lead wires 5 Make sure the battery ground strap is con tacting clean metal at the frame mounting point 31 ...

Page 21: ...ure the taillight ound strap is situated with good metal to metal contact between the bolt and bracket Secure both bolts 4 Install reflectors 2 32 D Ignition Switch Installation JT2 L 1972 1 Place the ignition switch on the mounting bracket Install the lock washer over the Phi IIips screw Insert the screw in the mounting bracket hole and secure with the lock nut E Speedometer Cable Installation JT...

Page 22: ...d per their wiring color codes 5 Connect the speedometer running and indicator lamp male leads to the appropriately color coded wires 6 Route the turn signo1 1iigh low beam switch sub lead into the head lamp shell in the same manner as numbers 2 3 foregoing Connect these leads to their appropriate color coded wires Note See JT2 L schematic for color codes and connection points 34 7 Route to ill ig...

Page 23: ...Torquing should always be done to the nut never the bolt head A TORQUE SPECIFICATIONS A B Nut T stud Kg m Ft lbs In lbs 13mm 8mm 2 0 15 180 i 14mm 300 350 17mm 10mm 3 5 4 0 20 29 12 r4 0 4 5 19mm 29 33 350 400 22mm 14mm1 4 5 5 0 33 37 400 450 500 600 26mm 17m 5 8 7 0 40 50 27mm 18mm 5 8 7 0 40 50 500 600 600 700 30mm 20mm 7 0 8 3 50 60 NOTE Certa in items with other than standard thread pitches ma...

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