Table Of Contents - Yamaha 1970 HS1 Service Manual

Table of Contents

Contents5
General Information9
Model Description9
Service Hints10
Tools11
Safety Hints11
Theory, Troubleshooting And Tuning12
Two-Stroke Engine Principles12
Engine Lubrication13
Engine Troubleshooting14
Fuel System Troubleshooting14
Carburetor14
Carburetor Disassembly And Inspection14
Typical Carburetor15
Idle Mixture/Idle Speed Adjustment17
Float Level Adjustment17
Throttle Cable Free-Play18
Carburetor Synchronization18
Throttle Cable Replacement19
Carburetor Disassembly And Assembly Notes20
Mixture Control Components20
Reed Valves21
Starter Jet System21
Removing The Reed Valve21
Main Jet Sizes21
Petcock Filter22
Air Filter22
Reed Valve Maintenance22
Carburetor Mounting Flanges23
Ignition System23
Miscellaneous Carburetor Problems23
Functionsl Operation23
Spark Plug24
Ignition System Malfunctions24
Ignition Point Maintenance25
Point Gap Adjustment25
Spark Plugs And Gaps25
Ignition Points Replacement26
Ignition Standards26
Ignition Timing27
Ignition Coil28
Charging System29
Condenser29
Hitachi 108-08 Alternator29
Mitsubishi Az2010N Alternator31
Output Current31
Dc Generators34
Troubleshooting34
Yoke Inspection And Testing35
Brush Inspection35
Typical Generator36
Armature Inspection And Testing36
Voltage Regulator Inspection37
Voltage Regulator Adjustment37
Starter/Generator38
Generatot Testing39
Starter Relay39
Typical Starter/Generator39
Battery40
Starter Troubleshooting40
Resistance40
Battery Service Standards40
Fuse41
Autolube System42
Service Procedures42
Minimum Pump Stroke Adjustment42
Typical Autolube Pump43
Pump Cable Adjustment44
Bleeding The Autolube Pump45
Engine, Transmission And Clutch46
Preparation For Engine Disassembly46
Engine Removal46
Engine Installation48
Cylinder Head48
Removal And Installation48
Cylinder Head Torques48
Carbon Removal49
Cylinder Removal49
Cylinder Inspection49
Cylinder Reconditioning49
Piston Rings50
Cylinder Installation50
Piston Pin Removal50
Piston Pin Fit50
Piston Ring Replacement51
Piston Clearance52
Piston-To-Cylinder Clearance52
Piston Ring Gap52
Piston Installation53
Clutch54
Clutch Removal/Installation54
Removal54
Disassembly54
Ds3 And Ym1 Clutch55
Installation56
Removal And Disassembly56
Yds5, Ym2, R1, R2, R3 And Ds6 Series Clutch57
Clutch Assembly59
Clutch Inspection And Adjustment61
Friction Plates61
Metal Plates61
Clutch Springs61
Primary Driven Gear62
Spacer62
Clutch Adjustment62
Clutch Cable Adjustment62
Primary Drive Gear63
Drive Sprocket And Chain63
Kickstarter63
Kickstarter Types64
Type 1 Kickstarter65
Type 2 Kickstarter66
Type 3 Kickstarter67
Type 4 Kickstarter68
Type 5 Kickstarter69
Gearshift Mechanism70
Gearshift Types70
Type 1 Shifter71
Type 1 Gearshift Mechanism71
Type 2 Shifter73
Type 2 Gearnift Mechanism73
Type 3 Shifter76
Type 3 Gearshift Mechanism77
Type 4 Shifter79
Type 4 Gearshift Mechanism81
Type 5 Shifter83
Crankcase84
Left And Right Split Type84
Type 5 Gearshift Mechanism85
Crankshaft87
Upper And Lower Split Type87
Bolt Torques87
Older Type Crankshaft88
Newer Type Crankshaft88
Crankshaft Inspection89
Crankshaft Disassembly89
Crankshaft Reassembly90
Crankshaft Alignment91
Crankshaft Standards92
Crankshaft Installation, Horizontally Split Crankcase93
Crankshaft Installation, Vertically Split Crankcase93
Transmission94
Type 1 Transmission94
Transmissions Types94
Type 2 Transmission95
Type 3 Transmission97
Type 4 Transmission98
Type 5 Transmission99
Bearings And Oil Seals102
Type 6 Transmission102
Chassis, Suspension And Steering105
Front Wheel105
Front Wheel Removal105
Front Tire Sizes105
Front Wheel With Drum Brake106
Front Wheel With Disc Brake107
Front Wheel Inspection108
Front Wheel Bearing Replacement108
Brake Shoe Diameter108
Hydraulic Brake System109
Brake Disc Inspection109
Caliper Disassembly And Reassembly109
Brake Disc And Caliper110
Master Cylinder111
Master Cylinder Disassembly And Assembly112
Rear Wheel113
Brake System Bleeding113
Rear Wheel Removal113
Rear Tyre Sizes113
Spokes115
Rear Sprocket115
Rear Wheel Inspection115
Brake Shoe Wear Limits115
Tires And Tubes116
Front Fork116
Clutch Hub116
Tire Pressure116
Disassembly, Except R5 Series117
Typical Front Fork117
R5, Rd250 Series And Rd350 Series Front Fork117
Rear Suspension118
Fork Inspection118
Disassembly, R5, Rd250 And Rd350 Series118
Fork Tube Reassembly118
Steering Head119
Shock Absorber Inspection119
Trailing Arms119
Steering Head Bearing And Race Replacement119
Typical Steering Head120
Periodic Service And Maintenance121
Maintenance Intervals122
Specifications123
Models Hs1 And Hs1-B124
Model Ls-2126
Models Yl1 And Yl1-E128
Model As2C130
Model Yas1132
Model Yas1-C134
Ycs-1 And Ycs1-C136
Model Cs3-B And Cs3-C138
Cs5140
Ds6 And Ds6-B142
Ds6-C144
Ds7146
Models Rd250 And Rd250A148
Yds3, Yds3-C And Ym1150
Yds5152
Ym2154
Ym2-C156
R3158
R3-C160
R5162
R5-B164
R5-C166
Models Rd350 And Rd350A168
Yr1, Yr2 And Yr2-C170
Useful Formulas And Tables172
Conversions173
Piston Displacement174
Bolt Torque174
Examples Of Conversions174
Bolt Tightening Torques175
Index177