YAMAHA SERVICE MANUAL DTIE pT2 DT3 RTIB — RT2~= RT3 250cc THRU360cc ENDUROS (1971-1973)FOREWORD to acquaint both the This Service Manual for the Yamaha Enduro DT, RT Series are direc ‘owner and mechanic with the operation, servies, and maintenance of his machine iduros ara Yamaha's first fully strat logal, large Displacernant motorcycle designed 10 Those fanabla the owner to ride it on the street, use it for trail riding, or convert it with factory ‘available parts into a competition-reedy scrambler or motocrosser. This manusl and the technical and service information enclosed should be closely followed to insure continuous good performance, long life, and to enable you to properly maintala the machini YAMAHA MOTOR CG., LTD. Engineering & Service Department.CONTENTS CONTENTS Chapter 1 12 13 14 Chapter 2 22 23 Chapter 34 32 38 a4 35 36 a7 38 39 3410 3-11 3412 343 314 315 316 347 318 39 3:20 CONTENTS 1. General... Profiles... +++ Specifications .... ++ Performance Curves «+. « pee eeeee 2 Tools and Instruments for Shop S 2. Yamaha Autolube . . Whot Is Yomcha Autolube . . . Features of Yamaha Autolube 16 seen 16 +16 Handling the Oil Pump .- +--+ Seve ont ges eum ys ower ees 17 3. Engine 20s eee seeeee Engine Removal... + Cylinder Head . Cylinde Reed Valve Construction and Handling . Piston Pin... e esse ee Piston Ring Piston Flywheel Magneto. Crankease Cover (RH) see ee eee eeee renee Clutch ove. Primary Drive Gear... 40 Kick Storter Mechanism « Shift Mechanism Drive Sprocket « « « Crankease Transmission Assombly . Crankshaft. . Bearings and Oil Seals . « a Carburetors oes eee eee Air Cleaner... -2-Chapter 4. Chassis... Chapter 5. Electrical Equipment ........ CONTENTS CONTENTS 4-1 Front Wheel. - 42 Rear Wheel 43 Reor Wheel Sprocket... 4-4 Tires and Tubes. « . 4:5 Front Forks 4-6 Rear Shocks 4-7 Gos Tonk 4-8 Rear Swing Arm . . 4-9. Steering Head vet ee ees 4:10 Oil Tank, Battery Box ond Tool Box. 4-11 Frame. 4-12 Handlebars . 4:13 Miscellaneous ........ 5:1 Deseription . see dee 5:2 Table of Component Parts... sss e 00s 5-3 Connection Diagram . . « Sed Ignition System — Function and Service 5-5. Ignition Timing .....+ 56 Ignition Coil . 57 Condenser... cceceeeen eee a 5-8 Charging System bev eee 2 59 Bottery .. sees -% 5-10 Checking the Main Switch .% Sl Spork Plugs... re) 5-12 Lighting and Signal System. . 7 WIRING DIAGRAM 4 eo 0 SES SHIR Wa ¥ eR cee eeee 18 ateGENERAL - Profiles 1-1 Profiles oTi-€ CHAPTER 1. GENERAL ateRTI-B =—s5- GENERAL - ProfilerGENERAL = Specifications 1-2. Specifications MODEL DT1-E 1. MODEL DTI-E 2._HORSEPOWER © RPM Be 7,000 T_TORQUE # RPM 17.5 6,500 @_BORE & STROKE (om) 70 x64 5. ENGINE DISPLACEMENT ‘bcc 50 cu. in $6. NET WEIGHT (Appr.) 245 Ibs. 7. COMPRESSION RATIO. 6.421 8. IGNITION TIMING B.T.D.C. (wm) Retarded = ‘Advanced Zamm =. 9. CONTACT BREAKER POINT GAP SETTING (wn) (inch) || .30--4Omm 012.015" 10, SPARK PLUG AND GAP (mm) B-BES .5-.6mm IL, VOLT. REG, ADJ. (Volts @ vam =ne load) MAGETO 12, CUTOUT RELAY ADJ. (Cut in voltege) 13, CONDENSER CAPACITY Wicroforad) 20 14, PISTON SKIRT CLEARANCE (rm) (Inch) -040-.045mm .0016-.0018" 15. CARBURETOR TYPE & MANUFACTURER ‘VM26SH_ Mikuni MAIN JET. HJ.) 160 AIR JET (A) = NEEDLE JET Wd) 02 JET NEEDLE - clip povition (JN. SDI: ‘CUTAWAY (Ay 25 PILOT JET, (Ped) #35, ‘AIR SCREW (Turns oui) _(A.S.) A STARTER JET (5.3) 60) FLOAT LEVEL (om) (FL) 15. Tm 16._AIR FILTER TYPE Wet foam rubber 17. PRIMARY REDUCTION RATIO & METHOD 65/21 3.095 gear 18._SECONDARY REDUCTION RATIO & METHOD 19. TRANS. GEAR RATIOS Is (Internal) (No. teeth) (Overall) 4414 3.144 chain, St ad 1.789_34/19_17.41 ied 1.304 30/2 1269 ath 1.000 26/26 9.73 sth 767 D/0 7.46 720,_TRANS, OIL CAPACITY (Q1) 1.06 [21 Oi TANK OR ENGINE SUNP CAPACITY (O77 V7 72 FUEL TANK CAPACITY (U5. Gal.) 25 23._ FRONT FORK OIL CAPACITY 5.9 oz W75ee 24,_TIRE SIZE (Front) 33-19 (Rest 4,00-18 25,_TIRE PRESSURE (Lbs) (Fron) 13 (Reon 16 7s._DRIVE CHAIN TENSION (Up & down Trevpley) 20mm 26752" 27. OIL FUMP STROKE ADJUSTMENT HIN. (am) 20-.25mm MAX. (rem) 1.85-2.050m [ia AUTOUUBE CABLE AOTUSTMENT (Thats poeTTonT Ar idle |["a9. VALVE CLEARANCE INTAKE = EXHAUST =MODEL DT? GENERAL - Specifications 1. MODEL (IBM 1.D. NUMBER) pT2 31 Z HORSEPOWER RPM 24 7000, 3_TORQUE @ APH 18.36 6000 4_BORE & STROKE (WN (ND. OF CYLINDERS) 703641 ENGINE DISPLACEMENT - INDUCTION SYSTEM 2tsce 1507010 Tor. dh NET WEIGHT (APPROX), 2s Ls. 7._CONPRESSION RATIO. eat &_1GNITION TIMING 8.1.0.6. Ol) RETARDED @ ADVANCED c= isan 3. CONTACT BREAKER POINT GAP SETTING (wo (INCH) 35 + 05mm a 10. SPARK PLUG AND GAP (MN (INCH) NGK BES 5.5 00-028 TL. STARTING ENGINE NUMBER DTiFA05101 B GASOLINE TANK COLOR Peatl/Yellow Gold PISTON SKIRT CLEARANCE (i) (INCH) 040-085 0016-0018 He RNC GROOVE SEGA THIN (WARY 07 Wax. 15. RING END GAP (WIN) (MAX) Anat 16. CARBURETOR TYPE & MANUFACTURER nese Wika WAN JET Ww) 60 AIR JET I) Drill 2 Sam NEEDLE JET (WI) ue JET NEEDLE-CLIP POSITION U.N.) ‘spPT3 ‘CUTANAY (GA) 15 PILOT JET a) fe ‘IR SOREW (TURNS OUT) _—_—_(A5.) MK STARTER JET ($3) 60 FLT 151m 17 AIR FILTER TYPE 18. PRIMARY REDUCTION RATIO & METHOD [Wet Foam Rubber AL 2085 19. SECONDARY REDUCTION RATIO & METHOD HAL_2.2 Chan oy OS 19T (INTERNAL) (NO. TEETH) (OVERALL) [2933 38/5 26H | 2ND 178 _ W718 17.407 IRD, Tat 0782589 mH Toot 2753.78 | STH ‘0766 B/N 1A | 7L_TRANS. OIL CAPACITY (CO) (TYPE) 000+ Boce SAEIOWSD [OIL TANK OR ENGINE SUMP CAPACITY (QT) (TYPE) | L 1,_FUEL TANK CAPACITY (US. GAL) (OCTANE RATING) 23 24 FRONT FORK OIL CAPACITY see 25._TIRE SIZE (FRONT) (TYPE TREAD) 325-19 TPR TREARY (TYPE TREAD) 0018 IPR TIRE PRESSURE (LBS. (FRONT) 4 REAR 17 | T7_DRIVE CHAIN TENSION (UP & DOWN FREEPLAY) ane EOL PUMP STROKE ADJUSTMENT MIN. OM) Za WAX. Las 20 _AUTOLUBE CABLE ADJUSTMENT (THROTTLE POSITION) At Tale -T-GENERAL - Specifications MODEL DT3 MODEL — IBM 1.D. NUNBER wend] DT3 a ‘STARTING ENGINE7FRAWE NUW 7 E/E No | OTIEDEIOL BANIO COLOR (FUEL TANK) Color “Competition Green NET WEIGHT Wetant [254 vs. ENGINE (TvP6) (INDUETION SvsTEM) Engine_|~ 2stoke, T-port, sigle/eed valve BORE /STROKE/CYLINDERS/DISPLACEWENT Disol. | roxeex) t4sce 16.01 61D HORSEPOWER/TORQUE-FT_LB’. P/Tare |"2a@ TOC) __1a.2@ 6000 COMPRESSION RATIO/NOMINAL PRESSURE Compr. | 6.81 6 PISTON SKIRT CLEARANCE (WOWIVAL) (WAX. ALCOWABLE) [Skin CL] _0W-04Gam 102 (00 RING END GAP (TOP) (2NO) (RO) End G29 | 24m (ANT RING GROOVE CLEARANCE (TO) (AND) (3RD) Groove | 7mm (AD) VALVE CLEARANCE (ENG. COLD) NTARE/ERHATST vain |e CARBURETOR (WFR) (TYPE) (1-0. NUNBER) car, | Want Wud AEP “RAN TET Wau NEEDLE TET Ad pW TET NEEDLE7OLP PORTION iN, s0Pra CUT ANY cA [1s SPiLOT JET FLL wap ART ALT STARTER JET Soom AURSOREW (TURNS OUT) as FLOAT LEVEL FL | Bien AiR FILTER (TYPET ToUANTTTD Filer Wetton aba DRIVE - PAWARY_(T¥ee) (TEETH) (RATION Pinay_[ Ger w/ cn SECONDARY (TYPE) (TEETH) (aTio) Seed | Chip wit sue TRANSMISSION RATIOS IST (reETH) (RATIO) TK) Tat Gea 25 ase 2ND and 1.789) 1.407 380 ad 1308 1288 wri 7 ate 3m oH 3h 0766 Lae oth 3 on CAPACITIES — THaNsulsIoN (QUANTITY) (TYPE Tars._[ nine ce AE In SE" na HL TANK OR ENGINE SUMP (QUANTITY) CTYPE) Faking). ats Yani FUEL TANK (QUANTITY) (wINTWM OCTANE) Foor Tonk 25 els. FRONT FORKS (QUANTIFY) TYE ots _[1rSee tA iva TIRES FRONT/REAR (SIZE) (NOMINAL PRESSUR@) Tines | 3.0021 PRIGPSI 400-18 PR/ATPR ELECTRICAL ~ CHARGING SYSTEM (MFR) (TYPE) Gen, | MUSubISNT —Fipwhval Wapnalo THO LOAD VOLTAGE ADJUSTWENT wattage MAXIMUM OUTPUT Gust |e FIELD COIL (and/or) CHARGING COIL RESIETANCE Fiala_| BATTERY (WFR) (MODEL) (RATING) aly (WL ae AVA HEADLIGHT/TAILLIGHT RATINGS Linsls_| sv357060 __6vs.3/7w ‘ TGNITION COWL SPARK GAP (ain)7PRI, RES./SEC. RES. Ser] ihe 30 SKY yl ‘CONDENSER CAP AOITY Bonds. | 0.50 POINT GAP (NOMINAL) /SPARK PLUG (TYPE) (AP) Pont | -36:0§an/NGKS-4E9 5: Gaa/.0a0"009", THN Timing [3.0 Siw 3700GENERAL - Specifications MODEL RTI-B 1. MODEL RTVB 2._HORSEPOWER © RPM 30.@ 6,000 E_TORQUE RPM 5.0 5,500 BORE & STROKE (om) 80 x70 3._ENGINE DISPLACEMENT ‘35lec 214 wv. in ._NET WEIGHT (Apox.) 258 Ibs. 7._COWPRESSION RATIO 6 IGNITION TIMING 8.1.0.6. (nm) Retarded = Advanced Zonm 1 9. CONTACT BREAKER POINT GAP SETTING (mm) (inch) ll 30. dOmm OIDOIS™ 10. SPARK PLUG AND GAP (nm) BES 5.6mm I1,_VOLT. REG. ADJ, (Volie 9 rpm -na lod) a 12, CUTOUT RELAY ADJ. (Cut In valtege) 13, CONDENSER CAPACITY (Microfarsd) uF 14. PISTON SKIRT CLEARANCE (nm) (inch) (055; 060mm .0020-.0024"" 1S. CARBURETOR TYPE & MANUFACTURER ‘VM32SH_Mikuni MAIN JET Wd)" #240 AIR JET, At) 7 NEEDLE JET way Ot JET NEEDLE - clip position (J.N.) 6CFI-2 (CUTAWAY, (Cad 15 PILOT JET (Pd) #30 ‘AIR SCREW (Turns oul) (A.8.] 1% STARTER JET (5.3) #60 FLOAT LEVEL (mm) (FL) ‘8.5mm 1é,_AIR FILTER TYPE Wet foam rubber 17, PRIMARY REDUCTION RATIO & METHOD’ 5/21_3.095 gear 18, SECONDARY REDUCTION RATIO & METHOD 39/15 2.600 chain 2.533 38/15 20.38 19. TRANS. GEAR RATIOS 1st (Internal) (No. teeth) (Overall) 7 1.789 34/19 14.40 3d 1.304 30/2 10.49 oy 1.000 26/25 8.0: She 767 B/0 6.1 20, TRANS. OIL CAPACITY (ai) 1.06 [2101 TANK OR ENGINE SUWP CAPACITY (Oh 17 32. FUEL TANK CAPACITY (US, Gal} oe 23._FRONT FORK OIL CAPACITY 5.9 on. Vice 24, TIRE SIZE (Front) 325-15 (Rear 4.00-18 25, TIRE PRESSURE (Lbs) (Front 13 (Ree) 16 26,_DRIVE CHAIN TENSION (Up & down Freeploy) 20mm 2572" (27. O1L PUMP STROKE ADJUSTHENT HIN. (nn) -20-, Tamm 5 WAX (on) 1.85-2.05m [Re AUTOLUSE CABLE ADIUSTHENT (Throne pasiToay Aridie 29. VALVE CLEARANCE INTAKE EXHAUST,GENERAL - Specifications MODEL RT2 1, MODEL (IBM 1.D, NUMBER) RT2 308 Z_ HORSEPOWER @ RPUL eo s000 TORQUE @ RP 27.7 5500 BORE. & STROKE (WD (NO.OF CYLINDERS) | 0x7Ox1. %._ENGINE DISPLACEMENT - INDUCTION SYSTEM 354¢e 21.4C1D Tora. ind 6. NET WEIGHT (APPROX). 262 Lis. T._CONPRESSION RATIO 6a1 {IGNITION TIMING B.T.0.C. (Wi) RETARDED a ADVANCED 252 150m 3, CONTACT BREAKER POINT GAP SETTING (i (INCH) 35 050m 3 T0._SPARK PLUG AND GAP (i (INCH) NGK BES 5.6.02.08 TL. STARTING ENGINE NUNBER RTI-IOOIOL 12_GASOLINE TANK COLOR sine 13. PISTON SKIRT CLEARANCE (Wil) (INCH) (045-050 __O018- 0020 TERING GROOVE SIDE GAP (MIN) (WAX) 7mm -0- 15. RING END GAP (IN) (WAX) 2.0m 16. CARBURETOR TYPE & NANUFACTURER Wu32sH Mant MAIN JET wy #230 AIRJET (AS) 20 NEEDLE JET WJ) Po JET NEEOLE-OLIP POSITION C.K.) DHE CUTAWAY (CA) 3.0 PILOT JET 2) 45 AUR SCREW (TURNS OUT) —_(AS.) i STARTER JET. (SJ) +60" FLOAT LEVEL (Op (FLT 450m TZ. AR FILTER TYPE Wet Foam Rubber 18. PRIMARY REDUCTION RATIO & METHOD 65/21 3.095 1B. SECONDARY REDUCTION RATIO & METHOD BAS_LeO0 [Zl TRANS. GEAR RATIOS IST (INTERNAL) (NO. TEETH) (OVERALL) BS IND 179 _ 4/19 SRD EOE 10/8 TH L000 26726, STH. 07662470 72i,_TRANS. OIL CAPACITY (CO) (TYPE) Ted0 = Soce SAE 10ND 22,_O1L TANK OR ENGINE SUMP CAPACITY (QT.) (TYPE) 7 7B._FUEL TANK CAPACITY (U.S. GAL.) (OCTANE RATING) 25 724 FRONT FORK OIL CAPACITY Tse 25,_TIRE SIZE (FRONT) (TYPE TREAD) 3.2519 WR (REAR) (TYPE TREAD) 400-18 APR 25._TIRE PRESSURE (LBS) (FRONT) it (REARY 7 27._DRIVE CHAIN TENSION (UP & DOWN FREEPLAY) ‘oan | 28. OIL PUMP STROKE ADJUSTMENT MIN. (100) 20-25 MAX. (MAM) 185-2,05mm 7. AUTOLUBE CABLE ADJUSTMENT (THROTTLE POSITION) ‘ACTleGENERAL - Specifications MODEL RT3 WODEL_— 16M 1.D. NUNBER NogeID[ RTS m8 STARTING ENGINE/FRAWE NUMBER E/F Nbr. | RTL TOT BASIC COLOR (FUEL TANK) Colar_| Bale Brown NET WEIGHT Weleht_| 252 bs. ENGINE (rvPe) (INDUCTION SySTEW) Engine | estone, pork sinlo/red valve BORE/STROKE/CYLINDERS/ DISPLACEMENT Displ, [ex e1 —_dslee 2.46, WORSEPOWER/TORQUE -FT. LB’. WP/Tore | 329 6000 20.7 @ 5800 COMPRESSION RATIO/NOMINAL PRESSURE Conpr. [61 ¢ PISTON SKIRT CLEARANCE (VOMINAL) (WAR. ALLOWABLE) | Skit Cl| 04S.0s0mm 02mm (00) RING END GAP (TOP) (2NO) (3RD) End Gop [3.5m (Al RING GROOVE CLEARANCE (TOP) (AND) (3RD) Groove [07mm (All) VALVE CLEARANCE (ENG. COLD) INTAKE/EXHAUST valves [6 CARBURETOR (MFR) (TYPE) (1.0. HUMBER) Carb. Mikoni _WNBISH OED WAN JET Wi | we NEEDLE JET NJ. [20 TET NEEDLE/CLIP POSITION TH | SONET ‘UT AWAY ca | 30 PLOTJET Psa AIRJET Ad Too STARTER JET sa. [neo AIRSOREW (TURNS OUT) aS [ ik FLOAT LEVEL. FL. | danm AIR FILTER (T¥PE) (QUANTITY) Filter_| Wet han ridber XT DRIVE - PRINARY (TYPE) (TEETH) (RATIO) Prinary_f Geer 7 T95 SECONDARY (TYPE) (TEETH) (RATIO) | oha ws 20 TRANSMISSION RATIOS IST (TEETH) (RATIO) (AD Ist Gear | ws 258 2.397 2D ma _[ ais 1788 1401 aR. va [7 Tae TAT TH | 2786 1.000 CMe ST ea | ase O65 E170 er sh oo | o CAPACITIES = TRANSHISSION (QUANTITY) (rYPa) Trans. | 1000: Soce SAE TOMO "GE" malo ol OTL TANK OR ENGINE SUNP (QUANTITY) CrYPEy FTak/Sumo | 15 as. Yamarube FUEL TANK (QUANTITY) [MINIMUM OCTANE) [Fun Tank 25 was FRONT FORKS (QUANTITY) (TYPE) Fos | ice SAE 1W30 01 Ses. Ope TIRES FRONT/REAR (SIZE) (NOMINAL PRESSURE) Tires | 30001 WPR/IGPST 400-18 APR/TIPS. ELECTRICAL - CHARGING SYSTEM (™FR) (TYPE) Gen, | Misubiaht —_Fipwheal Warnes NO LOAD VOLTAGE ADJUSTMENT Wate Aah | MAXIMUM OUTPUT™ Ouput |S FIELD COIL (end/or) CHARGING COIL RESISTANCE Fike | @ BATTERY (MFR) (MODEL) (RATING) Batey_[ CS ETAT HEADLIGHT/TAILLIGHT RATINGS, Lighis | SV35/35"__SV5a/17 IGNITION COIL SPARK GAP (WINI/PRI, RES/SEC. AES Sank | Tam a= CONDENSER CAPACITY Condens, [0 Buh POINT GAP (NOMINAL) SPARK PLUG(TYPE) (GAP) | Pail | 10% 0Gnn/NGK OSES. 5.ona7 00-0" THING Timing [23 Jann BTOC “ueGENERAL - Performance Curves 1-3, Performance Curves ‘repr. eanerenronunncg cunves zmagr- ovina penronwan CURVES saci: on 8 g _ Se “a i core | i 1 fo Leet cee 3 “sees Bane arerDInoe) agraaprs nang rengonwancs CURVES ge nan er eho a a 8 HoRserowen HP) Neseeea om = or ‘VEnNCLE SPEED imo) aint igo te vel? © =) & DRIVING FORGE OF REAR WHEEL th a8 LL ENGINE SPEEO leon) FUEL CONGUMIHON io:/BHP UR) TORQUE (uth ne cho taess vericus Seea ima eee e882 8 8GENERAL - Performance Curves GENERAL - Performance Curvas Performance Curves ower id 8 sr 0/8860 “Bm ov evo enronuancecunves ee eats Minin adibedoe lp ¥ bs @ Lao 5 9 5 : “I g 000, ed Pe }° ls a | 40072 ATO ENGINE PERFORMANCE CURVES TET ltsee em ‘0 872 wats DaIVING, erin Fone 92 8 EE i 3 engine Seed tooth enancr BEES. | hr og9 Lace + a a [ENGINE SPEED ram ‘Venite SPEED Imp) --GENERAL - Tools and Instruments 1-4 Tools and Instruments for Shop Service | The following tools and instruments are required to service the DT and RT Series. 1. Goneral Tools | 1 Pupwrerch 23x 20mm 7 Cirialas (TR typel——_13-Pilipshend serovar (Sh 2 A sat of wrenches: 8 Needle nose pil 14 Slot-head screwdriver (M) 3 Auet of socet wranchen 9 Plas 18 Slot head serevtrar (SI 4 Pie tip hommar 10 Priliponendrrmcrver 16 Tehanla socket wrench 5: Sta harman 11 Philipand screwdriver (L117 Trogue wrench 8 Cielo pi (ST type) 12 Pilipoad scrowcive IM) 4 2 Special Toole and Instruments 3 { } | IZ ox ole 1 Crmksate puller adaptor 6 Fhe! magento pull 2 Crankset suombling toot Fiyaneel magento Roding toot (or VFI and ¥G1) 7 Exhaust pipe wrench 29 Crankcate aiassembling tool 4 Cluteh holding tool In addition, ar electro-tester, a tachometer {engine r.p.m. meter), a hydrometer, atc, are needed, -4eGENERAL - Tools and Instruments 1 Yemahe Bond No. 4&5 5 ove 2 Autolubs oil 7 Oller 3 Grasse 8 ol lue 4 Wiping materish ‘The use of @ wooden box as shown in the above photo 6 will facilitate engine service and overhaul. Consumable parts (such as gaskets) and replacemont parts must also be on hand, <=YAMAHA AUTOLUBE - What is Yamohe Autolube? Features of Yamaha Autolube CHAPTER 2. YAMAHA AUTOLUBE (Automatic Separate Lubricating System) 21 What is YAMAHA Autolube? Conventional 2stroke engines are lubricated by oll premixed in gasoline, but YAMAHA'S Autolube furnishes an automatic, separate lubrication system. That is, the oil in a separate cll tank is automatically regulated by the oll pump and fed to the engina according to ‘ongine speed and load. 22. Features of YAMAHA Autolube The oil pump is driven by the engine through a reduction gear, and is connected to the carburetor throttle cable controlled by the accelerator grip Tre oll pump automatically regulates the volume of lubricating oll according to engine speed and throttle valve opening, thus pumping the optimum amount of oil for engine lubtiéation under any operating condition, This “automatic separate lubrication” does not meraly oliminate disacvantages in the conventional pre-mix system, but It further improves the performance and efficiency of 2-stroke designs by eliminating certain oilstarvation conditions which formerly existedYAMAHA AUTOLUBE - Handling the Oil Pump A) The Autolube feeds an optimum amount of lubricating oil to the engine under any ‘operating condition, thus featuering * Less oil consumption. * Lass carbon accumulation. * Less exhaust smoke, * Improved lubricating efficiency. 8). The Autolubo simplifies fuel supply, thus featuring: * Using straight gasoline directly in the gai tank. * Less fusl contamination. C]_The Autolube improves the reliability of lubrication, thus eliminating * Special care concerning oil/uel mixing ratio. 2:3 Handling the Oil Pump The oil pump is a precision-machine assembly. Make no attempt to disassemble it, When you remove the oil pump from the engine, protect it from dust, dirt, etc., and after reinstalling it, bleed and adjust the pump correétly. Proper handling will keep tho pump free from trouble, The oil pump is similar in both machanism and construction to other Autolube systems. The only differance is the employment of a 6.5% plunger because of the larger need for oil of 250 or 360 ce single cylinder engine 2:3-A Checking Minimum Pump Stroke 1) Checking a. Fully close the accelerator grip. 8. Turn the oll pump starter plate in ‘the direction of the arrow marked on the plats. Kegp the gap as wide as possible by observing it with the eye. Then measure the gap between adjusting pulley and the adjusting plateYAMAHA AUTOLUBE - Handling the Oil Pump ©. Insert @ faeler gauge (0.15 mm) into the gap. When the gap allows it to enter Stroke is correct When the g5p does not allow Stroke is insufficient. 2) Adjustmont 2. Remove the adjusting plate lock fut, and then jove the adjust ing plate b. Install 9 0.1 mm adjusting shim where the adjusting plate was, © Reinstall the adjusting plate lock nut, and measure minimum stroke When the gap allows @ 0.20 mm feeler gauge to enter but doss not allow a 0.25 ‘mm, the stroke is corractly adjusted Minimum stroke adjustmant limit. sense O15 MT Stroke adjustment tolerance 0.20 to 0.28 mmYAMAHA AUTOLUBE - Handling the Oth Pump 2-3-8 Carburetor and Autolube Cable Adjustments Perform the preceeding steps in Section 23-4 to check minimum stroke, and adjust the ‘Autolube and carburetor cables. 1 Throttle Cable Adjustment % To adjust the throttle cable free play with the engine at idle, begin by removing all slack from throttle cable B. Tryatte able 8 Adjusting bolt eck mat ‘Then remove all the free play from throttle cable A. Loosen or tighten the {ott cable adjusting screw until all slack has been taken up, Next, screw the cable adjustor in at the carburator until there is 1 mm fra play (1/32") in the cable at the top of the carburstor. b- The next adjustment is at the throttle grip. Loosen the lock nut and screw the ‘adjustor in or out, whichevar is necessary to got 0.5 the cable eng, 1.0 mm of free play at Trot cable (A) se ee Twist the throttle grip to chock the play of throttle cable A. If the play is ‘rcessiva or insufficient, adjust the free play with the adjusting screw. ~~YAMAHA AUTOLUBE - Handling the Oi! Pump 2) Autolube Cable Adjustment 8, Adjust the pump cable so that the marking farrow) on the Autolube pump \adjusting pully is aligned with the guide pin Begin by fully closing the accelerator grip, then slowly turning it back again so that the slack in the throttle cable is completely taken up. Next, adjust the ump cable so that the marking on the pump adjusting pulley will be aligned with the guide pin, as shown below. The point of adjustment is at the and of the cable just before it enters the case, Loosen the lock nut and screw the fadjustor in or out whichever direction is necessary to obtain the correct adjustment Coble adjusting nut Pump savie / Wr Look nut Bleodor bolt Starter pata ©), cide nin Ti Markiog 2 C Bleeding When the pump has been removed or the Autolube oll hes run out, air will enter the Pump. The air will cause an irregular flow of oil after the pump Is mounted again or the cll tank is refilled. In order to prevent such an irregular flow of oil, bleed the pump in the following manner. 1) Remove the bleeder bolt.YAMAHA AUTOLUBE - Handling the Oil Pump | 21x, rote the sara platen the dation ofthe row make onthe lt Coninu turing the pat unto a romans, nd gon the leer bok To | flit ths bdr, fly om the szestor gi and rote te Sartre ‘As the plunger stroke becornes greater, the air can be more quickly bled.ENGINE - Engine Removal CHAPTER 3 ENGINE The DT, RT Series engines have been designed with emphasis on both low speed tral-riding and high speed road riding The incorporation of the evenly spaced five-speed transmission and five or sovan-port induction system insures complate width handling in the roughest terrain ing versatility for the owner, The height, and weight of the engine has been kept at a bare minimum to insure ease of Disassembly and assembly of the engine and its components should be done in the following manner and order. This will Insure correct maintenance and service work for the owner and mechanic, All dirt, mud, dust, and foreign mtr should be thoroughly removed from the exterlor of the engine before removal and dissembiy. Ths will prevent any harmful foreign material from entering the interior of the engine axtebly | 2) Before engine removal and disassembly, be sure you have proper tools and cleaning | equipment so you can perform a clean and efficient Jo. \ 3 Dung csasembly of the angie, chan and place ll parts in trays and in order of | disassembly. This will eso and speed asembly time and insure coractreintallaton of | al engine pais 3-1 Engine Removal 1. Sure the engine and warm it up fora few minutes, then tun of the engin and dain the transmision ol Volume of oil: (1.0 gt) 1,000 c.c. {SAE 109/20 Motor Oil) TYPE "SE" -2-| ENGINE - Engine Removal | 2. Disconnect the decompression cele (960) and Avtolubs cable, 3. Remove the muffler 4, Remove the change pedal Remove the chain covar and. then disconnect the clutch cable,ENGINE - Eng! 6. Disconnect the master link and remove the chain \When replacing the chain, be sure that master link is facing in the correct direction. Driving direction ‘After replacing, adjust the chain free play to 25 mm. {1 in.) total at the center of the lower section with the rear wheel on the ground, with the rider in position 7. Remove the pump cover and pump cable 8, Remove the tachometer cable.ENGINE - Engine Removal 9 Remove the carburstor. 10, ‘Disconnect the ell line ot the bottom of the tank, Plug th nk fitting to pee vent oil drainage, Disconnect the fuel line and remove the fual tank. 12 Remove the four engine mounting bolts.ENGINE - Cylinder Head 13 Remove the engine from the frame. 3-2 Cylinder Head ‘The ovlinder head is bolted on the oylinder with special nuts, DIVE | 012,073 [ATI-8 [RT2, ATS cvinder nese volume icc.) 240 | 200 | 600 | 48.0 A. Removing 4 DT Series: Loosen all four cylinder head nuts evenly, «turn at a time, ond ine dross" pattern. This prevents head surface warpage. RT Series: First loosen oll four Sm nuts evenly, @' turn at a time, in @ “cross” Fettorns Then repost this procedure forthe TOmm huts B. Installing Replace the heud gasket If gouged, ripped, creased, or damaged such that it would not totaly sect, Next, install the head and tighten all four 10mm nuts ina "cross"” Pattern, in 3 progressively tighter torque ratings, until recommended torque specs are reached. NOTE: On the RT Series head nuts, tighten the 10mm nuts first, then tighten the 8mm nuts to specs. Follow the same progressive procedure on all 8mm nuts. Cylinder head tightening torque: 3.5~4.0 kgm (25~30 tts} for 10 mm bolts 20 kom — (15 fos) for 8 mm bolts (RT series) Renioving Carbon Deposits Carbon dovosits on the combustion chamber dome and piston crown will result in an increase in the compression ratio af well as preigaitian and engine overheating. Scrape the dome and piston crown lean. Do mot gouge the material, use a blunt scraper. mENGINE - Cylinder 33° Cylinder ‘A. Removing the Cylinder 1) Remove the oil delivery line banjo bolt from cylinder. 2) Remove the cylinder by striking it Tightly with @ plastic or rubber ham 3) Always replace the cylinder base gaskot when reassembling cylinder. BL Checking the Cylinder for Wear 1) Measura the amount of cylinder wall wear with a cylinder bore measuring micrometer or cylinder gouge. Measure it at four depths by positioning the Instrumant in line and than at right angles to the crankshaft.) If the difference between the maximum and minimum diameter exceeds 0.05 mm (0.0019"), rebore and hone the cylinder to the next aver size.ENGINE - Cylinder 0 if 2). The clearence betwoen the piston and the cylinder is 0,040~0.045 mm (0.0014~0.0018) ( DTI-€, DT2, OT3) 0.045~0.060 mm (0.0018~0.0020) (ATI-B, RT2, AT) ©. Gylinder Reconditioning 1). Pistons are available in 0.25 and 0.60 mm (0.010" and 0,020") oversizes 2) Cylinder should be rebored and honed to the diameter of the oversize piston plus the minimum allowable clesrance, 3) The error between the maximum and minimum cylinder diameters after boring and horing should be no mora than 0.02 mm (0,0008"). D, Removing Carbon Deposits Scrape off the carbon accumulation in the exhaust port of the cylinder with 2 hacksaw blade dulled at one end E, Installing the Cylinder Align the ring ends with the locating pins in each ring groove, ‘Thoroughly coat the rings, piston walls wrist pin and: bearing with oil Noxt, insert the piston into the cylinder. Tako care not to damage the rings| ENGINE - Cylinder r F. Decamoresion Deve (A718, RT RTS C Decomprenion valve closed -B-ENGINE - CylindsrENGINE - Cyl dor b. Operation y 2) 3) 4) In the compression stroke, the com- pression pressure passes to the exhaust (95 passage through the decompression valve until the piston closes the de ‘compression port in the cylinder. ‘As the piston rises further in the compression stroke and closes the de- compression port, the compression pressure continues to build up. In the. explosion and expansion strokes, the piston starts down, and Until it passes the decompression port, the explosion and expansion strokes ‘are in process as in the case of @ conventional two-stroke engine. ‘As the oxpansion stroke advances and the piston opens the decompras port, the explosion pressure passes to the exhaust gas pastage of the cylin- der CO — | \t \qJ “ne Cylinder Piston t Cylinder Piston t Piston 4 PistonENGINE - Cylinder Carbon removal Remove the decompression holder (screwed-in type), and remove the deposit fom the dteomranion tab, dcompreson ‘hole aed 2 g parots (elted 19 decomorer sion) in the cylinder. Note: It is always advisable, when the decompress device is reassembled, to replace the gasket and O-ring, When the valve face is found excessively worn or unevenly worn, —o08 | Caution After reassembling the decompression devics, be sure to check it for compression pressure leaks, -22-ENGINE - Reed Valve Construction and Handling 3-4 Reed Valve Construction and Handling Construction of the Roed Velve 3. Valve The valve is made of special flexible stalnles steel and designed to open and close the inlet port b. Case ‘The case is made of @ diecast aluminum alloy. ©. Gasket Mado of heatand oil-essting eubber, the gasket is “welded to the case by heat 4. Valve Stopper The valve stopper is made of highly-durable cold-rolled stainless stool plate, and controls the movernent of the valve > Vane >. cave © Gasket 4. Valve stoperENGINE - Reed Valve Construction and Handling Handling of the Reed Valve ‘As oxplained earliar, the read valve is operated by changes in the crankcase pressure and by the inertia offect of the fuel-air mixture stream. [tis @ high-precision work, and therefore, it must be handled with special care, a. Storage Tho reed valve must be stored a clean and dry plce and must not be exposed to the sun, Particularly, it must be kop tree from salt, Avld allowing your hand to touch the wave, Inspection (a) Valve Check tho valve for eracks and breskags tb) Vawve stopper ‘The valve stopper limits the movement of the read vale. The movement of the valve end measured from the gasket i controlled tos cata imi. Norrnat movement 072,078 9340.9 mm AT2, RT3_ 9.3 40.3 mm “If the valve stopper Is positioned more than the specitied distance from the gasket, it wt shortn the life of the valve and poor performance wil rs. (e} Set-screw ‘The valve and vale stopoer should be fastened with the sotseaw Tightening torque should be correct, otherwte, to vars vale stopper with pe deformed (a) Goskat ‘The gasket “wolded"to the case by fest, It should be checked for seperation from the case. If the gasket becomes loose, it may fail to achieve a good seal with the valve. fc. Valve Service The reed valve gaskat case and:set-screw ~ Is faulty. If so, It is advisable iovreplace the whole assembly, 9 not be perfect, if any of its components — valve, valve stopper, instead of replacing a faulty part.ENGINE - Piston Pin 3:5. Piston Pin A. Pulling out the Piston Pin Remove the clips at both ends of the piston pin with needle nose pliers, and press out the piston pin with a finger or a slot head screwdriver Note: Before removing the piston pin clips, ‘cover the crankcase with a clean ra you will not cidentally drop the clip, ‘or other foreign particles into the crank B. Piston-to-Piston Pin Fit The piston pin should fit snugly in its bore so that it drags a little you turn it. IF the pin is loose, replace the pin and/or the piston: If the pin has step-wear in its cent replace the needle bearing as well as the piston pin, Check the small end of the connecting rod for wi by inserting the pitton pin and bearing -35-ENGINE - Piston The L Type Keystone Ring is installed in the top ring groove. This type creases sealing efficiency due to direct combustion pressure that forces the out- er edge tightly against the cylinder sur- face, There is also less. es against the cyl- as the ring only pus sure above the indor whan there is pr ring. The ring Is "relaxed" the remain- der of the time has 7” taper. This iclent secling, plus The Jower ring ed alse permits more reduces ring sticking. the Piston. A. Removi Put your thums at each end of the piston ting and pull the piston ring ands apart. Remove the ring by moving the ring off the piston on the other side of thering ends B. Installing the Piston Ring First fit the No. 2 ring over the piston, and then the No. 1 ring, and align their lend gaps with the locating pin in each ring groove, ‘The printing on all rings must face up to p properly at the pin. position the: Fires Second Knock sin PS pon siaChecking the Piston Rings 1) Measuring piston ring wear Put the ring into the cylinder so that the ring is parallel to. the cylinder bottom edge, and then ‘measure the end gap with a feoler gauge. Piston ring end gap OTE fo.2-0.4mm O72, OTS, RT1-B, AT2, ATS |0.3-0.5mm 2) Removing carbon ENGINE - Piston Rings Carbon on the piston rings and in the ring grooves will make the rings stick in the Piston, thus causing gas blow-by. Remove’ the ringé from the piston, and clean the carbon fromm thé rings and rings grooves. —9-ENGINE - Piston 3-7 Piston ‘The piston is made of 2 highsilicon aluminum alloy. ‘A. Checking and Correcting the Piston to Cylinder Well Clearance 1) Measuring piston clearance Piston clearance is the difference between the minimum oylinder bore diameter and the maximum outside diamater of the piston. ‘As described in 53 Cylinder, pis ton clearance should be specitied below: 2,040~0.046mm | DTI-E, DT2, DTS 0045~0.05mm | ATI-B, RT2, ATS To determine the maximum piston diameter, measyre the piston with a micrometer at right angles to the skirt 10 mm (3/8 in} trom its bottom edge, 2) Checking and correcting scratches ‘on the piston A piston showing signs of seizure will result in noise snd. loss of engine power. it will also cause” damage to the cylinder wall If» piston that has soized is used again without correction, another seigure will develop at the same area. Lightly sand the seizure "nigh spot" on the ‘piston with #400 sandpaper until smooth. If the marks are deeper than 0.002" or are over a large surface, renlace the piston, 3) Removing carbon Remove carbon accumulations on the piston head with » screvedriver or a saveblade, Carbon and gum accumulations in the piston ring groove will result in piston ring seizure. Remove all carbam from the ring groove.| ENGINE - Flywheel Magneto B. Piston Installation Diraction | Install the piston with the arrow mark fon the head pointing forward (toward the exhaust port of the oyliner.) 3-8 Flywheel Magneto ‘A. Remove the dynamo cover, and then remove the gasket. Replace it If damage 8. Remove the nut using a flywheel mag- eto holding tool =ENGINE - Crankcase Cover C._Install tha flywheel magneto puller. (it has 3 left-hand thread.) ‘After the puller is secure, tighten the push screw and the flywheel will break loose, If necessary, tap the end of the 2 tems pe } tool smortly with a hammer to bresk sy 1 the magneto free D. Remove the three screws holding the flywheel magneto base to the crankcase and remove the flywhesl magneto base. E, Alamove the woodruff key. It is advisable to place the woodruff key on the flywheal magnets (using Its magnetic force) while the key Is removed for engine service in order to keep It from becoming lost. 3-9 Crankcase Cover (R.H.) A. Removal t 1) Remove the kick crank mou bolt and the crank. -40-8. 2) Remove the pan head screws hold: jing the crankcase cover, and then remove the case cover. (The cover can be femoved withou the oil pump.) 3) Rlemove the crankcase cover gas Replace it if damaged, Instal Soread YAMAHA Bond No, 5 over the mating surface of the right-hand crankcase. Place the crankcase cover gasket on the crankcase, apply Yamaha Bond No. 5 and install the Tight-hand crankcase cover, Be sure to apply YAMAHA Bond No. § to the mating surface, otherwise, the crankcase may leak Note: When installing the crankcase cover (R), make sure that the pump drive gear (made from synthetic resin) is correctly {engaged with the primary’ drive gearENGINE - Clutch | 3-10 Chitch ‘The clutch is a wet, multi-disc type, consisting ‘of six (seven on 360ce) molded cork friction: filutes and seven:clutch plates In the clutch housing which is mourited on the ‘Hatemissi¢n maj axle. |. The primary driven gear, “The primary drive gear has 21 tosth, and the primary driven-gear 65 teeth tray etre. 008 | 7) | Bae Primary rv gar St “| ~ te Friction lat (7 px) ive pe 7 pa 1.8 1 a ‘Spring holding scraw: | | ‘Adjusting serew lock nut 0 Push crown t tos ae | i oh — ” | MIF ser \ wile Thrist plateENGINE - Clutch cwrcH NOTES: . * #5 NOT USED ON 360¢c * #7 -- (7) USED ON 360ce ‘A. Removing the Pressure Plata Remove the six clutch spring holding screws, and take out the pressure plate end push crown, Removing the'Clutch Boss Install the cluteh holding taal an the clutch boss, Loosen the lock nut, and therr remova the clutch loss, 0. -ENGINE - Clutch . Chisckiag the Clutch Spring If the free length of the spring is 1 mm {0.04 in) or mora shortar than the standard free length, replace it wf ~ Fen length 6m (1.493 In D. Checking the Frigtion Plates Inspect the friction plates for waar. Replace them if they show 0.3 mm (0.012 In} or ‘more, uneven contact, ‘Standard tihness 3.0mm, (0.1183n) =ENGINE - Clurch $A ENGINE - Clutch Clutch Housing bly (integrated with the primary driven gear) ‘A rubber friction ring Is placed on the outside of the clutch between the priniary driven 922" and the clutch housing in order to reduce gear noisa at tow engine speeds, 1) Inspection Insert. the primary geer retaining collar (spacer) in the primary driv. en gear boss and check it for radial play. If any scratches are found, replace igo. it will not impair clutch aotion. I the play is excessive (allowable “clearance is betwoen 0.008°~ 0.048 mm, replace the g22r retaining collar bocause it will cause excessive noise, F. Checking the Primar Collar (Spacer) Place the primary gsar retaining collar Gear Retaining over the main axle and again check it for radial play, It play exists (allowable clearance is between 0.020~0.082 mm) replace the gear retaining collar Replace any collar with step-wear on its outer surface, G.Fitting Cushion Rings A cushion ring is Installed between each of the clutch boss and the frie tion plates to insure evan engagement and complete disengagement of the plates. When fitting cushion rings, be Sure they are flat and not twistedENGINE - Clutch Checking the Push Rod Remove the push rod and roll It over a surface plate, If the rod Is bent, straighten or replace it Caution on Re-assembling the Clutch On both ends of the primary gear spacer are thrust washers and thrust bearings. If these the clutch boss will rub washers and bearings are incorrectly installed, or omit against the primary driven gear, impairing clutch action, ‘The thrust bearing assembly fits on the primary retaining collar, but it may slip out of placa when installing clutch boss. ‘Therefore, apply grease to both surfaces of the bearing to make it stick to the gear retaining collar. corrsct Incorrect “Thrust plato 2 Kick pling [+] ‘Theust pte 1 Bearing aa \ENGINE - Primary Drive Gear the Clutch | = J Adjust 1) Adjusting the Push Screw Remove the clutch adjusting cover Rotate the push soraw in to a | ot lightly seated position, and back i off 1/4 turn to get the proper spacing. Then fully tighten the lock rut | 2) Adjusting the Clutch Cable Ten- The clutch cable adjustment | changes after boing used for @ long time. Occasionally the cable must be Roadjusted s0 that the play of the clutch handle is from 2 to 3 mm Somme, (1/96-1/8 in) at the pivot 3:11 Primary Drive Gear A. Removal Feed a rollad-up rag betwaan the tosth of the primsry drive gear and the primary driven ear to lock them, and loosen the primary drive gear lock nut. -a- .“EWGINE.- Kick Starter Mochanism 212, Kick Starter ‘Mechanism The kickstarter émploys the primary kick system, To start the engine, you just kick the starter with the, clutch’ disengaged or engaged. The ability to start the engine with the clutch disengaged can br @ great advantage when racing. When the’kick shaft rotates, the ratchet wheel is disengaged from the ratchat. wheel guide and meshes with the kick gear. The rotation of the kick gsar is transmitted through the idler goar to the kick pinion that is eng primary driven gbar. id with the Kick pinion gear Kick ilar goor Ratchot whoo! guide screw Ratchet whoa! guide achat whee! Kick goar Kick spring Soring guide L<& Kick axis Ly~ A. Removal 1) Remove the kick spring 2) Then romove the kick st sembly. Noto the location of any shims. -8- ENGINE - Kick Starter Mechanism SHIM (2) ciacuP COVER, spring GUIDE, spring AXLE, klok GEAR, kick WASHER cur WHEEL, ‘SPRING, atehat whoo! COVER, sorng circu sHiM (1) STOPPER (GUIDE, ratenat whoa WASHER, lock SCREW, ratchet whee! gui thetENGINE - Kick Starter Mechanism | Revs te Sequence fr Aeisttion | Noes on Asembing 1) Allg he marking onthe Kickster xl with that ofthe tcet whee i| 21 When ising he kick start oy In the nko, side th ratchet whe! po ove te ratchet wha uid toned the stoner atachd to the eae. Make sr that the pawl is in close contact with the stopper. Then pull the spring forward and hook it on the stopper | ck ala Ratchet whoo guise serow Lock washer fan: Ratchet whesi guide | ce rene J ‘Stopper | Crankeare (8.H.) Fatenat whoo! guide 6. Removing he Ki er Ger | nord D. Removing the Tachometer Drive Gear The tachometer drive gear is engaged withthe lok idler gear to convey the revolutions BRE minute ofthe crankshaf o the tchomater through th tachomatar cabin, ~~ |ENGINE - Shift Mechaitism 1. AXLE, drive go 2. Crip 3 Shim 3. Drive gear any 3-13 Shift Mechanism There ore two types of shift mechanisms used on the DT/RT Series machines: This. ‘early type used on the DTY-E & RT1-B hes one shift fork which is part of the Shift cam drum and two other shift forks which are installed on 2 guide bar parallel to the am eum ie The later type, used on DT2/3 & RT2/3 machines, hes three separate shift forks stolled on two guide bors These three shift forks slide back and forth in the slotted guides that are groovia ia the shift drum. A safety device has been provided to prevent the shifter from by-passiAg. the next gear when a quick or hard shift is made, This provides dependobility and as- surance for correct shifting for the desired goar oven under the roughest conditions such as competition racing. ‘A seeiiggnl. type shiftiag ‘arrangement is used that enables the rider to shift quickly and easily down for'the lower gears and up for the higher gears. Neutral position is located betwoon flistaid | dhfond gears SHIFTER (DTI/RT1 TYPE) ten as See?