Yamaha SL338D Service Manual Download

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Summary of Contents for SL338D

Page 1: ... I I I _ 71 72 73 MODEL SPE CIFICATIONS and H R 9 J_ j 0 A ...

Page 2: ... of the requisite basic product knowledge Other inforn1ation is produced by the U S distributor Yamaha international Corporation and is necessary to provide total technical coverage regarding the product The Research Engineering and Service Departments of Yamaha are continually striving to further improve all models manufactured by the company Modifications are tt 1ere fcre inevitable and changes ...

Page 3: ...dels 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 having twin cylinders ranging from 338 c c to 433 c c It also includes specifica tions of 1971 to 1973 models for convenience of Yamaha service technicians YAMAHA MOTOR CO LTD SERVICE DEPARTMENT ...

Page 4: ... I I I l I I I j I I I I t I l I __ I ...

Page 5: ...ange EL433B SW433C GP433B EW433C Chain Case and Front Axle Removal Front Axle Installation I Bogie Wheel s Rear Axle Removal Track Removal I CHAPTER 4 STEERING SKIS AND CHASSIS 4 1 4 2 4 3 4 4 4 5 Steering Skis Chassis and Shroud Seat I Luggage Box CHAPTER 5 TIGHTENING BOLTS AND NUTS ELECTRICAL CHAPTER 6 6 1 Ignition System Lighting System 6 2 6 3 Wiring Circuit CHAPTER 7 7 1 ENGi NE MAINTENANCE I...

Page 6: ...imary Sheaves 97 8 2 Secondary Sheaves 97 8 3 or 1ve Belt 97 97 8 4 Primary Sheave and Secondary Sheave Alignment 8 5 Chain and Chain Case 101 8 6 Brakes 101 8 7 Track 102 8 8 8 9 Adjusting the Track 102 Sk IS 102 APPENDIX 1 INSPECTION AND MAINTENANCE 104 APPENDIX 2 CONVERSION TABLE 105 J I ...

Page 7: ...etor These carburetors incorporate an internal metering device which always meters the _correct air fuel mixture to the engine regardless of vibration or machine position 5 Superior Braking A new design in the track sprocket V belt and caliper disc brake has greatly improved the braking efficiency and safety of the Yamaha snowmobile 6 Tilt up Engine Shroud The attract ive fiberglass engine shround...

Page 8: ...ed 15 in 380 mm 50 in 1 270 mm 12 rubber wheel 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 oil bath 25 13 1 923 1 Fabricated steel Reinforced fiberglass removable Yes Removable Fiberglass reinforced in the engine room 5 0 US gal 19 0 Q 2 1 US qt 2 0 Q Chromed tubular steel Chr...

Page 9: ... 60W Hi Lo beam 12V 8W rectangular 12V 23W incorporated in taillight 4 position on dash Disc brake Handle lever left hand operated Handle lever right hand pperated Yes Yes 3 GENER h Specifications GP338 12V 60 60W Hi Lo beam Ii 12V 8W rectangular 12V 23W incorporated in taillight 4 position on dash I Disc brake Handle lever left hand operated Handle lever right hand operated _ Yes Yes ...

Page 10: ... 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 oil bath Hi 25 14 1 786 1 Lo 25 14 x 1 6 2 855 1 Fabricated steel Reinforced fiberglass removable Yes Removable Fiberglass reinforced in the engine room 6 0 US gal 23 0 Q 2 1 US qt 2 0 Q Chromed tubular steel Chromed t...

Page 11: ... Lo beam 12V SW rectangular 12V 23W incorporated in taillight 4 position on dash Disc brake Handle lever left hand operated Handle lever right hand operated Yes Yes 5 GENERAL Specifications SL433B I 12V 60 60W Hi Lo beam I1 I1 12V SW rectangular I1 12V 23W incorporated in tai11ight 4 position on dash 1l Disc brake 1 Handle lever left hand operated I Handle lever right hand operated I I I I Yes Yes...

Page 12: ...6 kg Air cooled two stroke 5 port induction Cast iron sleeves Alu1ninum cylinders 2 cylinders parallel 2 677 in x 2 346 in 68 mrn x 59 6 mm 30 H P 5 500 r p m KEIHIN CD42 38 x 1 Autolube oil injection Flywheel magneto 12V 70W 3 000 r p m B 7HS N G K Electric starter Manual recoil starter w ith add I emergency rope starter Molded rubber steel reinforced 18 in 457 mm 50 in 1 270 mm 12 rubber wl1eels...

Page 13: ...V SW rectangular 12V SW rectangular 12V SW rectangular Stop Iight 12V 23W 12V 23W 12V 23W incorporated in tai ll ight incorporated in taillight incorporated in tailllight Ignition key switch 4 position on dash 4 position on dash 4 position on dash Brake Type Disc brake Disc brake Disc brake Control Handle lever left hand Handle lever left hand Handle lever left hand operated operated operated I Th...

Page 14: ...80mm 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 oil bath 25 13 1 923 1 Fabricated steel Reinforced fiberglass removable Yes Removable Fabricated steel located behind backrest 4 0 Gal 15 02 2 1 Ot 2 0 Q Chromed tubular steel Chromed tubular stee...

Page 15: ...ht 12V lOW incorporated in tai11ight Ignition key switch 4 position on dash 4 position on dash Brake Type Disc brake Disc brake Control Handle lever left hand operated Handle lever left hand operated I1 Throttle Type Handle lever right hand operated Handle lever right hand operated Accessories Emergency starter rope Yes Yes Tool kit Yes Yes Seat spring upper No Yes Spark plug Yes B7Hz Yes 87Hz I 9...

Page 16: ...reinforced 18 in 457 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 oil bath 25 13 1 923 1 Fabricated steel Reinforced fiberglass removable Removable Fabricated steel located behind backrest 2 1 Ot 2 0 2 Chromed tubular steel Chromed tubular ste...

Page 17: ... m at 6 2V Brake Type Disc brake Disc brake Control Handle lever left hand operated Handle lever left hand operated Throttle Type Handle lever left hand operated Handle lever right hand operated Accessory Emergency starter rope Yes Yes Tool kit Yes Yes Spark plug B 7Hz 2 Yes B 7Hz 2 Seat spring upper Yes 2 I 11 ...

Page 18: ...ingle polyurethane 9 teeth Single polyurethane 9 teeth Automatic centrifugal engagement infinitely variable 3 5 1 1 1 Duplex roller chain enclosed in oil bath 25 13 1 923 1 Fabricated steel Reinforced fiberglass removable Removable Front part of the seat 4 0 Gal 15 0 Q SR433 99 in 2 515 mm 32 in 815 mm 38 in 965 mm 275 lbs 125 kg Natural Air cooled two stroke 5 port induction Chrome plated Aluminu...

Page 19: ...brake Disc brake Control Handle lever left hand operated Handle lever left hand operated Throttle Type Handle lever right hand operated Handle lever right hand operated Accessory Emergency starter rope Yes Yes Tool kit Yes Yes Spark plug No N2G 2 I I I I I 13 ...

Page 20: ...mm 50 in 1 270 mm 12 rubber wheels bearing mounted Single polyurethane 9 teeth Single polyurethane 9 teetl1 Automatic centrifugal engagement infinitely variable 3 5 1 1 1 Duplex roller chain enclosed in oil bath 25 13 1 923 1 i Fabricated steel Reinforced fiberglass removable Yes Removable Fiberglass reinforced in the engine room 4 0 Gal 15 0 Q 2 1 Ot 2 0 Q Chromed tubular steel Chromed tubular st...

Page 21: ...ndle lever left hand operated Throttle Type Handle lever right hand operated Handle lever right hand operated I Accessories Emergency starter rope Yes Yes Sef 1ice tool Yes Yes I Optional Accessories Electric starter Electric starter Speedometer Speedometer 1 1 Tachometer Tachometer I High windshield High windshield 15 ...

Page 22: ...gle polyurethane 9 teeth Automatic centrifugal engagement infinitely variable 3 5 1 1 1 Duplex roller chain enclosed in oil bath Hi 25 14 1 786 1 Lo 25 14 x 1 6 2 875 1 Fabricated steel Reinforced fiberglass removable Yes Removable Fiberglass reinforced in the engine room 5 0 Gal 19 0 Q 2 1 Gt 2 0 Q Chromed tubular steel Chromed tubular steel 12V 60 60W Hi Lo beam 12V 5W rectangular 12V 10W incorp...

Page 23: ...I Th rattle Type Handle lever right hand operated Handle lever right hand operated Electric Starter Maximum output 0 51 kW Maximum torque 0 54 kg m 3 90 ft lbs at 6 2V I Speedometer Light bulb 12V 2W Tachometer Light bulb 12V 2W Accessories Emergency starter rope Yes Yes i I Service tool Yes Yes i Optional Accessories High windshield High windshield 1 17 ...

Page 24: ...eels bearing mounted Single polyurethane 9 t eeth Single polyurethane 9 teeth Automatic centrifugal engagement infinitely variable 3 5 1 1 1 Duplex roller chain enclosed in oil bath 23 13 1 770 1 Fabricated steel Reinforced fiberglass removable Removable Racing seat 4 0 Gal 15 0 Q 2 1 Ot 2 0 Q Chromed tubular steel 12V 35 35W Hi Lo beam 12V 5W rectangular 12V 1OW with twin reflector 4 position on ...

Page 25: ...operated Tachometer Right hand side of t he instrument panel Right hand side of the instrument panel Speedometer Left hand side of the instrument panel Left hand side of the instrument panel Accessories Emergency starter rope Yes Yes Service tool Yes Yes Optional equipment parts Expansion muffler SS kit SR kit 19 ...

Page 26: ...8 ir1 2 625 n1m 37 5 8 in 925 mrn 40 3 4 in 1 035 mm 485 lbs 220 kg Forced air cooled two stroke 5 port induction Al uminum cylinders 2 cylinders parallel 3 01 x 2 76 in 76 5 x 70 111m each 39 2 cu in 643 c c 41 H P 5 500 r p m One diaphragm type KEIHIN Autolube oil injection Flywheel magneto 12V 75W 3 000 r p m B 7ES N G K Electric starter witl1 manual Molded rubber steel reinforced 18 in 457 mm ...

Page 27: ...ft hand operated Th rattle Type Handle lever right hand operated I Electric starter Starting method Button type Left hand side of the instrument panel I I Speedometer Light bulb 12V 3W Tachometer Light bulb 12V 3W Accessories Service tool Yes Optional Accessories High windshield 21 ...

Page 28: ...in width Special reinforced rubber track deep pattern Bogie type torsion spring 12 rubber wheel Aluminum Fiberglass reinforced plastic 3 2gal 12 0Q 2 1 qt 2 0 Q Yes Aluminum Yes Aluminum Floating pad disc brake Handle lever right hand operated Yes Right hand side of the instrument panel Yes Left hand side of the instrument panel Service tool Spark plug Champion N 2G x 2 22 SR643 99 3 4 in 2 535 mr...

Page 29: ...90 02203 3 d Screw 8 mm L 80 l Support plates 90890 02204 3 e Screw 6 mm L 160 1 f Wedge 90890 02205 4 Ignition timing setting tool 1 g Stops 56 mm 90890 0221 5 4 a Dial gauge stand 1 2 Ring nu t removal tool 4 b Dial gauge stand 2 2 a Bearing nut wrench 90890 01812 5 Socket end wrench 2 Gauge 5 2 1 3 6 4 W _ 0 I c e ort 7 Fig 1 2 1 Thickness gauge 4 Cylinder gauge 2 Dial gauge 5 Vernier caliper 3...

Page 30: ... Open end wrench 6 8 x 7 mm Open end wrench I 1 2 14 15 2 3 4 5 4 16 11 13 17 Fig 1 3 7 Circlip pliers RT type 8 Needle nose pliers 9 Pliers 10 Philips heac t screwdriver 11 Philips head screw driver large 12 Philips heac t screw driver medium 5 6 Fig 1 4 7 13 x 21 mm Plug wrench 8 Screwdriver handle t 1 8 13 Philip s head screw driver small 14 Slot head r crew driver medium 15 Slot head r c rew d...

Page 31: ...rburetor choke lever Return to its original position when the engine will revolve smoothly c PulI the starter Firmly grasp the starter handle and pull slowly until engagement of the mechanism can be felt Then pull briskly but be careful not to pull the cable so far out that it bottoms This will result in longer cable Iife Sometimes an engir1e wi 11 start better at a certain throttle opening A litt...

Page 32: ...ss y 11 Removing the drive belt V belt 12 Removing engine mounting bolts 2 1 1 Removing the Double Seat The double seat is bolted at its front and rear ends The rear end is fastened with two 13 mm nuts while the front end is secured with a 10 mm bolt together with the engine cowl Note The 10 mm bolt means that its distance across flats of the hexagon head is 10 mm Note Before removing the double s...

Page 33: ... the lid to the left and separate it from the engine v n 0 Fig 2 4 I v O o cit r I I I Fig 2 5 Fig 2 6 ENGINE Engine Removal 2 1 3 Removing the Engine Cowl SW433C EW433C EL4338 SL4338 and SI 3380 First remove the pipe gauge from the oil tank Then remove the two 1O mm bolts on the instrument panel On a 15 in track model remove the two panhead screws c Fig 2 7 C a Fig 2 8 Q 0 I 0 1 I I f J Fig 2 9 2...

Page 34: ...he throttle wire from the carburetor Loosen the screw and disconnect the choke wire from the carburetor Note Both throttle wire and choke wire should be bent at their ends after installed I Choke w i re 2 1 8 Removing the Tachometer Cable Remove tl1e tachometer cable f rom the oil pump by turning the ring nut EL4338 EW433C and GP model I I I Fig 2 13 2 1 9 Disconnecting the Flywheel Magneto Leads ...

Page 35: ...rew and remove the sliencer 2 o I iiinjectio11 I Fig 2 18 I I ENGINE Engine Ret11oval Remove the six panhead screws and remove the silenc er 1 Fig 2 19 2 1 12 Removing the Drive Guard Loosen the knob on the drive guard end by turning to the left By turning the latch on the drive guard to the left unlock the lock Then pull out the drive guard toward you I Fig 2 20 Fig 2 21 29 ...

Page 36: ...emoval Fig 2 22 2 1 13 Disconnecting the Fuel Pipe and Oil Pipe Pull out the fuel pipe from the carburetor Pull out the oil pipe from the oil pump Note When installing they should be tightly held at the joints with circlips Fig 2 23 l Fig 2 24 30 ...

Page 37: ...1 GASKET 1 2 12 GASKET 3 I 2 2 JOINT 2 13 JOINT 1 3 GASKET 2 2 14 SPACER I 2 4 JOINT manifold 1 15 NUT 2 5 WASHER plain 4 16 WASHER spring 2 l I 6 WASHER spring 4 17 PLATE 1 7 I BOLT 2 18 SCREW panhead 3 8 0 RING 1 9 6 8 2 19 WASHER spring 3 9 BOLT I 2 20 SPRING 1 t I 10 NOZZLE 21 CLAMP throttle l 2 11 I I STUD 2 _ 31 ...

Page 38: ...2 1 14 Drive Belt V belt Removal Push the secondary sliding sheave to the other side while turning to the right and pull the drive belt upward at the center of its upper section Then remove it by pulling toward the sliding sheave 7 Fig 2 26 J y Q 0 I Fig 2 27 Fig 2 28 2 1 15 Engine Mounting Bolt Removal Loosen the four 17 mm bolts securing the engine lower bracket to the frame Fig 2 29 32 I I I I ...

Page 39: ...NUT 10 WASHER spring I L 11 BOLT engine mounting ENGINE Engine Ret11oval 0 I I I I I I I I I I I I 10 16 17 8 Fig 2 30 Q ty Ref No 1 12 4 13 4 14 4 15 1 16 I 1 17 2 18 2 19 4 20 4 21 1 22 33 I I I 5 Description WASHER 1 BOLT engine mounting 2 WASHER 2 BRACKET guard drive GUARD drive ARM fitting Cl RCLIP E 6 KNOB SPRING 1 WASHER PIN spring 15 a iv 1 3 3 I 1 I 1 11 1 1 i 1 I 1 I iI ...

Page 40: ...D MAGNETO REMOVAL 2 2 1 Remove the four bolts that hold the manual starter assembly to the engine The manual starter assembly will now slide off YAMAHA Fig 2 32 34 2 2 2 This illustration shows the inside of the starter assembly before it is disassembled Removal of the nut and washers located in the middle makes it possible to dismantle the rest o f the starter assembly parts Fig 2 33 2 2 3 Fig 2 ...

Page 41: ... be necessary to completely disassemble the starter assembly to correct the mistake preload the starter spring with 1 3 2 3 of a turn for positive return F i 2 35 I Fig 2 36 ENGINE Starter and Magneto Removal 2 2 5 Once the starter assembly has been completely reassembled it should be checked for proper starter action Follow the example as shown in the picture and pull the starter rope out approxi...

Page 42: ...e plate SPRING return SPRING return PLATE drive WASHER flat WASHER spring NUT ROPE iIii 15 14 f9 5 6 8 20 9 22 23 Fig 2 38 Q ty Ref No 14 1 15 1 16 1 17 3 18 1 19 1 20 3 21 1 22 1 23 I 1 I 24 1 25 1 26 1 36 10 I I 12 o a 21 I 16 17 Deseription HANDLE starter CONNECTOR COVER sheave SCREW panhead WASHER spring KNOB stopper ring SH IM drive plate 8 0 11 5 0 6 PULLEY starter BOLT WASHER spring BOLT WA...

Page 43: ...ing sheave from the crankshaft Now the primary spring can be removed Fig 2 40 ENGINE Removal of Primary ShecMS 2 3 3 This illustration shows the primary sheave cap after it has been removed and taken apart The parts in relation to each other as they have been removed Fig 2 41 2 3 4 The bearing nut must be removed in order to continue disassembly The special bearing ring nut removal tool is used as...

Page 44: ...ice in the picture a wrench is used to hold the special tool so that it will not turn as the T handle is saewed in Fig 2 43 2 4 REMOVING THE OIL PUMP 2 4 1 Remove the two oil delivery pipe from the oil pump a Fig 2 44 2 4 2 Remove the four 10 mm bolts and one hexagon bolt and remove the oil pump drive gear cover The oil pump can be removed together with the oil pump drive gear cover Fig 2 45 0 Fig...

Page 45: ...g the idle gear and drive gear 2 coat them with anti freeze grease Beacon 325 or Aero ShelI 7A Fig 2 50 Fig 2 51 ENGINE Removing the Oil Pump I I I When greasing without demounting the engine it is necessary to remove the panhead screw indicated by the arrow 2 4 6 To remove the idle gear first remove the circl ip from the outside of oil pump drive cover 2 0 0 0 Fig 2 52 Idle Gear Fig 2 53 39 ...

Page 46: ...e the circlip on the worm shaft end When installing drive gear 2 be sure to install the dowel pin in the worm shaft 0 Drive gear 2 0 Fig 2 54 c Fig 2 55 2 4 8 For installation reverse the procedure for disassembly 2 4 9 The ring gear is attached to the reverse side of the primary fixed sheave When installing coat the ring gear with anti freeze grease Beacon 325 or Aero Shell 7A oa 0 o_ Fig 2 56 40...

Page 47: ...emoving the Oil Pump When the tachometer option is installed this blind cap 17 should be removed and the driven gear should be installed instead 10 5 6 7 8 9 I I 23 15 t 22 16 21 20 L 19 21 20 18 Fig 2 57 O ty Ref No Description 1 15 COVER pump drive 2 1 16 Cl RCLIP R 26 1 17 PIN dowel 1 18 BOLT 1 19 BOLT I 20 WASHER spring 21 WASHER plain 22 SCREW flathead 1 23 BOLT 1 24 SCREW panhead 1 25 GASKET...

Page 48: ...T 3 WASHER lock 4 WAS HE A 10 2 28 3 2 5 CIRCLIP S 30 6 COLLAR 7 PRIMARY SLIDING SHEAVE COMP 6 5 I I I I Fig 2 58 O ty Ref No 1 8 1 9 1 10 1 11 1 12 2 13 1 14 42 1 4 3 o 7 14 I Description SPA ING primary NUT bearing WASHER 28 36 2 SEAT spring BEARING 6205 PRIMARY FIXED SHEAVE COMP V BELT 2 Q ty 1 1 1 1 1 1 1 I ...

Page 49: ...to can now be removed This requires the use of special puller that you will find in our special tool kit Be sure to use the three short screws that oome with the puller when removing the flywheel Note Immediately after the flywheel is removed take the woodruff key off the shaft and in same satisfactory W 1f attach it to the flywheel so that it is not lost 1 I Fig 2 61 2 5 4 All parts of the magnet...

Page 50: ...g I 6 CONTACT BREAKER ASS Y I 7 SCREW panhead 4 12 I i 8 WASHER spring 9 WASHER plain II 10 CONDENSER 11 LUBRICATOR 12 SCREW panhead 4 10 I Q 7 12 8 13 9 I I 10 5 18 8 12 13 I I 20 16 14 Fig 2 63 O ty Ref No Descript ion Q ty 1 13 WASHER spring 2 1 14 LEAD WI RE ASS Y 1 1 15 CLAMP lead 1 1 16 SCREW panhead 4 8 1 4 17 WASHER spring 1 4 18 PLATE timing 1 2 19 ROTOR ASS Y 1 2 20 SCREW panhead 4 2 21 ...

Page 51: ...the 3 phillips head screws that secure it L2 1 L_ __J_ _ I J I I f 1 _ I I I Fig 2 65 45 ENGINE Removal of Fancase and Air Shroud 2 6 3 Straighten the bent positions of lock washers 1 and 2 and remove the bolts The fancases 1 and 2 can be removed out of the crankcase Note that a packing agent gasket is applied to the mating surfaces of the fancases 1 and 2 Fig 2 66 ...

Page 52: ...A I J _ t r J r t I t o I r 1 J 1 J v l JJ f t I _ Description CASE fan 1 CASE fan 2 PIN dowel B 4 13 8 PLATE SCREW panhead BOLT WASHER lock 1 SCREW panhead 12 9 10 Fig 2 67 Q ty Ref No 1 9 1 10 2 11 1 12 2 13 5 14 5 15 I 6 16 I 46 15 14 Description Al R SHROUD cylinder 1 Al R SHROUD cylinder 2 SCREW panhead WASHER spring WASHER plain DUCT FASTNER EMBLEM O ty 1 1 10 I 10 I 10 1 3 1 I I ...

Page 53: ...to slip a clean rag beneath the piston This wi ll stop any carbon broken parts or other contaminations from falling into the engine Do not use a hammer to drive the pin out oOo I_ i r r _1 _ L l ENGINE Removal of Top End 2 7 3 The piston assembly is removed at this time Use a needle nose pliers to remove the piston pin clip Use a soft drift pin to push the piston pin out to allow a pair of pliers ...

Page 54: ...crank 2 PIN dowel A 9 8 12 16 BOLT BOLli BOLT WASHER plain BOLT cylinder holding GASKET cylinder CYLINDER left O ty 1 1 1 2 4 5 3 12 8 2 1 The lower crankcase has two drain saews These drain saews are used to empty the crankcase before the engine is s tored away for a long time When installing these screws 48 Ref No l 1 12 13 14 15 16 17 18 19 20 21 Description CYLINDER right GASKET cylinder left ...

Page 55: ...lost before the engine is assembled again 0 ooo 0 Fig 2 73 ENGINE Top End Reassembling Crankshaft Assembly 2 8 3 After removal of the crankshaft wear of the connecting rod big end crank pin and bearing should be checked Excessive wear of the connecting rod big end is checked by measuring the axial play of the connecting rod small end when it is moved from side to side with your fingers The axial p...

Page 56: ...aligning marks offset 90 from the lock pin hole The aligning marks should be matched with the sealing surface of the upper crankcase half so as to insure correct matching of the knock pin in the knock pin hole Should the crankshaft be assembled in the cases with the bearings misaligned the knock pin wi ll be pushed into the body of the crankcase and the bearing will not be properly secured after t...

Page 57: ... CRANK 2 left CRANK 2 right ROD connecting SEARi NG con rod big end WASHER crank pin 24 2 38 1 PIN crank BEARING B6206C3 special SEAL labyrinth BEARING 86306C3 special BEAAING con rod smalI end I I I I I I I I 8 Fig 2 80 O ty Ref No 1 13 1 1 1 1 14 1 1 2 15 2 16 4 17 2 18 3 19 1 20 1 21 2 5 21 18 Description PISTON 59 96 mm STD PISTON 59 98 mm STD PISTON 60 25 mm 1st 0 S PISTON 60 50 mm 2nd O S RI...

Page 58: ... done by removing the nut and spring washer the brake disc itself and on some machines the shims immediately behind it You will notice in the picture that the shims are situated in front of the brake disc This is merely for purpose of identification as they actually are located behind the brake disc Fig 3 2 3 1 3 Once the brake disc has been removed the two bolts holding the left and right hand se...

Page 59: ... sheave assem bly removed and assembled on the bench Normally this should be the extent of disassembly but if a problem arises in the secondary sheaves themselves then additional break dov in wi ll be required Th is will be accomplished by first remov ing the roll pin at the right hand end of the shaft The spring seat will slip off the end of the shaft once the roll pin has been removed The spring...

Page 60: ...l P OWERTRAIN Disc Brakes and Secondary Sheaves When instalIing the secondary sliding sheave feed the shelI alvania grease 2 or 3 between the sheave and the secondary shaft t t Fig 3 10 shell ALV NIA grease 2 or t3 l Secondary shaft I y Secondary sliding sheave 54 I ...

Page 61: ... SECONDARY FIXED SHEAVE COMP SECONDARY SLIDING SHEAVE COMP SHAFT secondary PlN spring POWER TiRAIN Disc Brakes and Secondary Sheaves If I 2 4 I I lri 0 Fig 3 11 O ty Ref No Description 1 5 SPRING secondary 1 6 SEAT spring 1 7 SHOE lamp 1 55 Q ty t 1 3 I ...

Page 62: ...m slipping and fast wear 12 17 18 3 28 21 22 I 23 Fig 3 12 Ref No Description O ty Ref No Description O ty 1 AXLE counter 1 21 GEAR 1 19T 1 2 GEAR 2 18T 1 22 BEARING needle 1 3 COLLAR distance 2 1 23 SH IM 17 2 28 0 9 1 4 SHIM 17 2 25 0 2 24 BAR sh ift fork guide 1 SHIM 17 2 25 0 3 U R 25 Pl N spring 1 SHIM 17 2 25 0 5 26 FORK shaft 1 5 Cl RCLI P S 32 1 27 0 RING 1 6 COLLAR 2 28 LEVER 1 7 GEAR 3 1...

Page 63: ...plined to the secondary shaft As the change knob is shifted to High the dog clutch meshes with the drive chain sprocket On the contrary when the change knob is in Low the dog clutch meshes with gear 1 JI I M J I D ff fll r 1 1 1 D Dog 1LI al I Drive Chain Sprocket I I I I I r II 3 2 3 Power Transmission A High Position In case of SW433C When the change knob is in High engine power is carried to th...

Page 64: ...ngine power is carried to the drive chain sprocket That is the engine speed is increased from gear 1 19 teeth to gear 2 18 teeth and then reduced from gear 3 14 LJ _ I n u Gear 1 I 19 1 eP L g _ I Dog n I I teeth to gear 4 24 teeth Accordingly the gear ratio of the secondary transmission is 18 gear 2 x 24 gear 4 19 gear 1 x 14 gear 3 After reduced by the quick change the engine RPM is further redu...

Page 65: ...ration shows the transmission in the secondary housing after the left secondary shaft housing is removed A B and C indicate the shift fork guide bar secondary shaft and counter axle respectively Note that a shim is attached to the secondary shaft c 8 Fig 3 18 C 4 6 After removing the left secondary shaft housing remove the bolt as illustrated and remove the spring and shift pin from the inside of ...

Page 66: ...ass y from the secondary housing follow the procedures given in the SL4338 Care should be taken not to drop the drive chain sprocket and gear 4 into the chain housing Note that there is a shim between gear 4 and right secondary shaft C 4 11 When installing the secondary sheave ass y be sure to feed Shell ALVAN IA grease 2 or 3 into each needle bearing C 4 12 Avoid operating the quick change system...

Page 67: ...e the four 13 mm bolts holding the chain case cover On an 18 in track model the chain case top is held to the steering gate through the bracket Remove the 13 mm bolts and remove the bracket Fig 3 26 Fig 3 27 P OWER TRAIN Chain Case and Front Axle Removal 3 3 4 Position yourself at the right side of the snowmobile for this next step Pry off the rubber cap in the center of the axle housing On a mode...

Page 68: ...n case the front axle should be shifted to the right as much as possible for easy removal Lock washer Fig 3 32 J Fig 3 33 62 3 3 6 At th is time it will be necessary to tip the snowmobile on its right side in order to allow the axle to be removed 0 0 Fig 3 34 3 3 7 Reach underneath the snowmobile and grab hold of the axle Lift up on the axle as far as possible so that the tip of the axle will exte...

Page 69: ... should be inserted into the chain housing With the collar sprocket and journal instal led on the chain housing insert the front axle end into the chain housing Fig 3 36 OWER JiRAIN Front Axle Installation Fig 3 37 For the subsequent operation reverse the procedure for installation 63 ...

Page 70: ...cription 1 FRONT AXLE COMP 2 WHEEL sprocket 1 3 COLLAR I 4 RIM sprocket wheel 2 I 5 I BOLT I 6 WASHER lock 11 I 7 GUIDE WHEEL COMP I I 8 PLATE 9 PIN spring I 10 Oil SEAL SD 25 34 7 11 14 16 15 12 19 I I 13 10 8 7 15 8 6 9 3 2 4 8 7 8 Fig 3 38 O ty Ref No Description Q ty 1 11 BEARING B6004 special 1 1 12 Cl RCL IP R 44 1 4 13 HOUSING front axle 1 1 14 BOLT 3 4 15 WASHER spring 3 I 2 16 WASHER 1 2 ...

Page 71: ... BOLT WASHER 30 I 34 21 35 I 22 20 4 5 25 19 9 10 I I Fig 3 39 O ty Ref No 1 19 1 20 1 21 1 22 2 23 2 24 1 25 26 U R 27 1 28 1 29 1 30 U R 31 1 32 1 33 1 34 1 35 1 36 1 37 6 38 6 65 POWER TRAIN Front Axle Installation 14 23 I J2 29 24 I I I 18 17 I I 13 15 16 Description BOLT WASHER spring WASHER plain CAP2 BEARING 86303 01 L SEAL SD 22 32 5 0 RING 3 1 113 HOUSING secondary shaft left SEARi NG B62...

Page 72: ...ry Note If the snowmobile is immobile or stored for more than a week the rear of the machine should be raised and placed on blocks Th is witI prevent the rubber bogie wheels from flattening under the weight of the machine Bogie wheel Suspension spring Fig 3 41 After the installation bend the four spring end stoppers Fig 3 42 3 6 REAR AXLE REMOVAL 3 6 1 Remove the track adjusting screw pivot rear s...

Page 73: ...le Removal Sprocket Fig 3 48 3 6 3 Rear Axle Installation Before installing the rear axle the bogie wheels must be installed on the frame As illustrated install the pivot rear arm on the rear axle with the rear axle positioned on the inside of the track In this case the rear arm pivot should be positioned outside of the track Install the collar on the rear arm _ I t_ I Fig 3 49 Insert the pivot re...

Page 74: ... on the front hook to raise the rear of the machine b To increase traction the rear spring should be hung on the rear hook to lower the rear of the machine Fig 3 53 68 Install the inside washer and plain washer and secure the rear pivot screw with the nut After tightening the nut lock the nut with the cotter pin 11 I I Fig 3 54 3 7 TRACK REMOVAL 3 7 1 The front axle rear axle and bogie wheel assem...

Page 75: ... portion outside the track Install the two bolts in the B through the A and C jigs and tighten them Then tighten the center bolt 5 r 12 I 33 f 1 I v l l I v 120 30 I I f I I I I f I 40 I I I 2 l I I _i I I I v 1 5 I L 13 I l 3G I I 5 v 160 ll I 1 I 0 33 52 I 15 T r I I 15 5 28 A I 35 ri i t l I 110 _ f 1 20 i l I Link plate I I 20 52 I 15 1 Link plate B I f 2 _J 0 85 Drive track Fig 3 56 69 I I I ...

Page 76: ...inkage system is very important in controlling parallelism of the skis while the snowmobile is in motion Skis are supported on 5 leaf springs that are pivotted at the rear of the ski and free to expand and contract on a wear plate at the front part of the ski This wear plate should be greased often to reduce friction between the spring and Near plate 2 Ski Parallelism Parallelism of the skis is ch...

Page 77: ...t The shround is painted f iberglass and should require little maintenance Checking for cracking will insure it from serious damage The windshield is dear PVC and shou ld require no maintenance When it is cleaned you shouId attempt to wash off any d irt or mud first and then wipe it off This will keep scratches to a minimum 71 4 4 SEAT The seat is a single unit of foam chips covered with vinyl If ...

Page 78: ... t j i I I I I I TIGHtrENING BOLTS NUTS CHAPTER 5 TIGHTENING BOLTS AND NUTS The snowmobile tends to bounce up and down on rough snow covered terrain causing bolts and nuts to loosen Head light rim bind screw Steering relay rod lock nut In particular the bolts and nuts as illustrated below should be carefuIly tightened and locked with a bond when the machine is serveced Rear bumper bind screw Oil t...

Page 79: ...current is generated in a similar manner by the lighting coil located on the point plate The lighting system is of a balanced output type design for the headIight and taillight Overloading of the lighting system by adding on Iighting equipment is not recommended Because the lighting system is of a balanced output type burning out of either the headlight or taillight can result in a heavy surge of ...

Page 80: ...V2W Low Tachometer 12V 2W c 0 CJ Rigt1t l1and ignition coi l CJ CJ t J f Spark plug I 0 0 0 0 Left l1and ignition coil 0 0 r 0 Kill SW B B Y Battery 12V 30AH 12V 60W 12V 60W 1 OFF 1 2 3 Fig 6 2 Speedometer 12V2W Tachometer 12V 2W Gy 0 0 x x x G Br R Y L Br x 0 x x x x 0 x High 12V 60W Low 12V 60W 1 B B t t i t 4 Y __ I Stop lamp Tail lamp L L 12V 23W 12V8W G Gy R WGy 0 Gy 0 0 R W Gy 0 y 8 Gy Right...

Page 81: ...en be drawn from between the points to remove residue Repeat this procedure until the points are clean 0 Fig 7 1 b Remove the spark plugs and install the dial indicator and adaptor into the right hand cylinder head Fig 7 2 c Remove the connector from the four lead wires gray orange black and green of the flywheel magneto and connect the point checker s red lead wire to the flywheel magneto s gray ...

Page 82: ...points are just opening at 1 8 mm BTDC 1 I Fig 7 6 g Tighten the securing screws and recheck the timing h Repeat the above procedure for the left hand cyli nder and left hand set of points The lef t hand primary ignition w ire is orange in color i There is only one point adjustment on the AC magneto when the timing has been adjusted correctly the point gap wil l also be correct When the mark on th...

Page 83: ...ing the pump fuel pressure constant by reducing or increasing it in order to deliver a proper air fuel mixture according to engine speed The regulator of the diaphragm type c arburetor plays a role similar to the float of the float type carburetor The fuel level in the float chamber is likened to the regulator internal pressure Accordingly the regu later internal pressure must be kept at a constan...

Page 84: ...t and the fuel is fed to the engine At low speed the fuel is drawn into the engine through the idle discharge port alone With 1 4 throttle or more the fuel is drawn through the main discharge port and fully atomized in the primary venturi being supplied to the engine The fuel is controlled by the slow adjusting screw at low speed and by the main adjusting screw at high speed at a proper rate accor...

Page 85: ...screw should be turned out from a lightly seated position according to the following table Number of turns to be backed off See following table Slow Adjusting Screw Main Adjusting Screw SW433C SL4338 1 1 3 8 EL433B 1 1 3 8 EW433C 7 8 1 1 8 GP4338 SL338D GP338 7 2 3 Fuel Level Adjustment The Keihin carburetor is provided with a level pipe which is used for fuel level adjustment When adjusting the f...

Page 86: ...rting to acceleration in the range of low and medium speeds Turn in or out the slow adjusting screw and when t he engine speed reaches its maximum back out the screw 1 8 80 t ur n to enrich the mixture a little The final adjustment of idling speed is made by the throttle stop screw idle speed screw The t hrottle stop screw is closely related to tl1e slow adjust ing screw in the adjust ment of idli...

Page 87: ...est the engine quickl y bring the throttle shutter to fu II open from idling position and acceleration the snowmobile Then watch the performance of engine operation 4 After running at high speed check the spark plug for coloration for an indication of carburetor mixture 5 Run the snowmobile at high speed and test if the engine wi 11 pick up speed smoothly Repeat the adjustments as specified in 1 2...

Page 88: ...t is below the scale center tighten the throttle syncl1ronizing screw Tl1en turn the knob in the center of the balancer so that the float will move to the scale center I I _ Fig 7 26 6 After the adjustment set the th rattle stop screw so that the engine idles at a specified speed ____ Fig 7 27 7 2 8 Main Adjusting Screw and Slow Adjusting Screw On a twin carburetor both main adjusting screw and sl...

Page 89: ...g screw is used to adjust the air fuel mixture when the snowmobile runs at high speed Adjustment should be made so that the mixture becomes as rich as possible provided that the engine still runs smoothly This is necessary to prevent engine overheating ENGINE MAINTENANCE Carburetion and Fuel System For adjustment follow the following steps 1 First back out the main adjusting screw as specified 2 T...

Page 90: ...osition When assembling the check valve ensure all the outer lip of the check valve fit in the hollow of the pump body and also ensure the valve seat of the pump body and six ports of the check valve coincide completely If not the pump may not actuate or show poor performance Secure firm ly Secure firmly Do not damage the tip of the taper When the tip is worn or damaged replace with by assembly De...

Page 91: ...0 0 Ml 0 0 0 0 0 0 When assembling 1 care should be taken AlI the fuel passages must coincide Confirm the correct position When assembling the check valve ensure all the outer lip of the check valve fit in the hollow of the pump body and also ensure the valve seat of the pump body 11 Deformed spring may result poor per and six ports of the check valve coincide d formance completely If not the pump...

Page 92: ...ol lever end is incorrect in height o Fuel pump operation is not smooth o Both carburetors do not synchronize 86 Re111edy Remove inlet valve and clean it Replace i11let control valve When replacing it make sure the seat SL1rface is free of scratcl1es 1 Repl ace irilet control lever 2 Reinstall inlet control lever correctly Adjust the end of lever to the position as sl1ovvn in Fig 7 34 Rei nstal I ...

Page 93: ... place For cleaning gasoline should be used Solutions incl uding alcohol acetone lacquer thinner benzol etc should not be used as cleaning agents for they will damage the synthetic rubber in the carburetor 87 Air is in fuel pump Remove plug screw and bleed air at idling speed Fig 7 35 Overhaul carburetor 2 When the primer pump is used for the diaphragm type carburetor it should not be squeezed mor...

Page 94: ...main diaphragm I I 21 SEAT spring I 36 I 4 1 0 0 0 Q 16 6 9 t f J I 19 1 12 14 13 15 20 0 21 22___ 25 Fig 7 36 _ r 23 a 24 O ty Ref No 1 22 2 23 1 24 1 25 1 26 1 27 1 28 1 29 1 30 1 31 1 32 1 33 1 34 2 35 1 36 1 37 1 38 1 39 1 40 1 41 I 1 42 1 I 88 I Description BODY pump 3 NUT lock SCREW stop SCREW panhead 0 RING WASHER plain SPRING slow adjuster SCREW slow adjuster 0 RING WASHER plain SPRING mai...

Page 95: ...ol lever so that it is set to the match mark on the oil pump Adjust ca be made by turning the pump control rod nuts 3 After adjustment fully tighten the nuts by holding bottom nut while tightening top nut When fully open the carburetor mold as shown in Fig 7 38 and adjust to the marking Fig 7 38 Pump control lever r Full throttle At maximum stroke of the pump d ismounted from the snowmobile I 0 I ...

Page 96: ...r to the disassembl ing so that both gear st1aft and control lever may be correctly reassembled 2 The adjusting pulley cover if once removed from the adjusting pulley shou ld be reinstalled and the gear timing must be set These two gears should be meshed so that the markings match Note 90 When the pump control lever reaches the maximum working range the center Iine of the lever and the marking on ...

Page 97: ...NJO deliver pipe CL P delivery pipe 23 16 4 5 6 2 Fig 7 41 Q ty Ref No 1 18 1 19 1 20 2 21 1 22 1 23 1 24 1 25 1 26 1 27 1 28 2 29 2 30 1 31 1 32 1 33 4 34 4 35 4 36 91 ENGINE MAINJ EN NCE Autolube I I 13 r BOLT banjo 1 12 I I 10 Description PIPE 6 3 120 7 PIPE delivery right 3 170 SCREW bind GASKET breather 4 2 8 5 0 5 BOLT banjo 2 GASKET banjo bolt 6 1 3 0 5 COVER adjust pulley SCREW panhead SCR...

Page 98: ...should be done if this tolerance is exceeded Taper of the cylinder bore is measured by moving the micrometer from the top to the bottom of the cylinder being careful to miss the port openings The difference in these measurements between top and bottom should not exceed 0 002 0 05 mm If upon inspection of the cylinder bore scoring of the cylinder wall is observed hone or rebore until these scores d...

Page 99: ... grooves and replace the piston ring gap be aligned with the knock pin in the ring groove as shown in the illustration Th is is especially critical when installing the cylinder over the piston I I Fig 7 48 1 I ENGINE MAINifEN NCE Top End Maintenance 7 The up and down play of the piston rings in the piston ring groove should be checked with a feeler gauge Tolerance should be 0 001 _ 0 0027 0 03 _ 0...

Page 100: ...ing against tl1e cylinder wal l This action is considerably slower than that of the keystone ty pe ring and w ill allow more blow by With blow by heat cannot be dissipated from the piston ring t o the cy linder w all and as was mentioned earlier excessive combustion heat w ill cause the oil film to break down creating additional gum deposits The keystone ring allows for much better heat transferen...

Page 101: ...sure the ring end gap with a feeler gauge If the gap measured is in the range of 0 0012 to 0 002 0 3 to 0 5 mm the ring is in satisfactory condi tion If more than 0 002 0 5 mm the ring face is excessively worn Remove the ring from the cylinder and keep it in a free position Then measure the ring end gap If the gap measured is less than 0 0012 0 3 mm the ring is con sidered to be fatigued with heat...

Page 102: ...e may easily occur and in the worst case serious engine troubles may result 4 When a good seal between the piston ring bottom and the ring groove bottom is noticed the piston ring is considered to smoothly slide in and out on the ring groove bottom in a correct manner 7 5 4 Before replacing the piston ring remove carbon accumula tions from the gap between the ring and the groove The piston ring mu...

Page 103: ... SECONDARY SHEAVES After appro ximately 40 hours riding time sliding secondary sheave should be rernoved and the secondary shaft greased Th is wi ll keep the sheave from bind ing LIP from lack of lubrication 8 3 DRIVE BELT Tension of the drive belt is adjusted by maintaining a pre determined distance between the centers of the primary and seconclary sheaves Il sl10L1 id be 10 8 270 mm Adjustment i...

Page 104: ...ce between centers of sheaves The distance between the centers of the sheaves can be set by moving the engine back and forth to move the engine the four engine lower bracket mounting bolts should be loosened F W D Fig 8 4 j 111111 1 111 111111 1 Fig 8 5 4 How to set the off set between sheaves The sheave off set can be set by moving the engi ne sideways To move the engine the four engine upper bra...

Page 105: ...heave off set Remove the V belt and al low the secondary sliding sheave to contact the secondary fi xed sheave Then as illustrated place the sheave gauge against inner sheave surfaces If the sheaves are paral lei the gauge w ill touch at all four spots See arrows b Fig 8 8 Sheave off set Fig 8 9 99 I 1 l I ...

Page 106: ...secondary sliding sheave Then measure the distance be tween the primary shaft and the secondary shaft by placing the 9 2 in 233 0 1 mm scale side of the sheave gauge between the shafts If both sheave shafts contact the sheave gauge at the positions indicated by arrows the distance is correct I Secondary shatt i i ru t I 0 Fig 8 10 Sheave distance Fig 8 11 100 Sheave gauge Bearing Primary shaf t I ...

Page 107: ...final tension check Fig 8 12 2 The cover located at tl1e bo ttom of tl1e chain case has a window in it lo cl1eck for proper oil level The oil level should be topped up fill througli the rubber oil filler tube to maintain the oil level near the top of the window Never let the oil level drop below the wi ndow bottom If the chain case oil rs emptized completely then refill with 500 c c 17 oz of 10W 3...

Page 108: ...g rna nner B Rear arrn Rear arm When shifted to left I D B N G A B Properly tighten the left track adjust screw and loosen the right track adjust screw 0 012 3 mm _J A 8 Good A B D J 0 012 3 mm A D r A 8 N G A B When shifted to righ l Properly tighten the right track adjust screw and loosen the left track adjust screw Fig 8 17 5 After the track tension is adjusted correctly the clearance between t...

Page 109: ...djusting the tie rod length Correct center to center distance of the skis is24 1 6 13 mm Fig 8 18 A i i 1 1 I I w B I A B o 394 10 mm DRIVE TRAIN CHASSIS MAINTENANCE Skis Note 103 Measure the distance between the skis center to center at the front ends and at the rear ends respectively If the difference of the value measured exceeds 0 4 10 mm adjustment is required ...

Page 110: ...nes or 3 a quality detergent automot ive 1OW 30 oil in that ord er of preference 2 The factory recommends Aeroshell Grease 7 which is a synthelic aircraft lubricant having a useful temperature range to 100 F 3 The factory recommends a molybdenum disulf ide grease Shell Lithal MOS Grease and Aeroshell Grease 17 conform roughly to these specifications 4 1OW 30 detergent automotive motor o ii 5 The f...

Page 111: ... L 1 lers Q I j r l O cr1s g 31 0 I I J ci r r r I 2 205 0 4536 0 061 16 387 0 264 3 785 1 2 4 546 Pounds Kilograms Grams q Ounces oz VOLUMES Cubic inches Imperial galIons c c Liters Q Gallons U S Ouants qt Liters Cubic centimeters c c Imperial gals Fluid ounces fl oz Liters 0 03527 28 35 77 26 1 057 0 946 0 0339 29 57 Ounces Grams cu in Quarts Liters Fluid ounces cc _ _ OTHE RS j i l Iv l t I I r...

Page 112: ... I I I I t JL t I SINCE 1 887 I cl I I I r I t t t I f _ R Cll l D HAMAM Arsu JAPAN PRINTED IN AP AN 5 1 X 1 G 72 7 ...

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Yamaha SL338D, Service Manual

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