Yamaha 1968 YR2 Manuals

Manuals and User Guides for Yamaha 1968 YR2. We have 1 Yamaha 1968 YR2 manual available for free PDF download: Service Manual

Yamaha 1968 YR2 Service Manual (189 pages)

Brand: Yamaha | Category: Motorcycle | Size: 46.19 MB

Contents
5
General Information
9
Model Description
9
Service Hints
10
Tools
11
Safety Hints
11
Theory, Troubleshooting and Tuning
12
Two-Stroke Engine Principles
12
Engine Lubrication
13
Engine Troubleshooting
14
Fuel System Troubleshooting
14
Carburetor
14
Carburetor Disassembly and Inspection
14
Typical Carburetor
15
Idle Mixture/Idle Speed Adjustment
17
Float Level Adjustment
17
Throttle Cable Free-Play
18
Carburetor Synchronization
18
Throttle Cable Replacement
19
Carburetor Disassembly and Assembly Notes
20
Mixture Control Components
20
Reed Valves
21
Starter Jet System
21
Removing the Reed Valve
21
Main Jet Sizes
21
Petcock Filter
22
Air Filter
22
Reed Valve Maintenance
22
Carburetor Mounting Flanges
23
Ignition System
23
Miscellaneous Carburetor Problems
23
Functionsl Operation
23
Spark Plug
24
Ignition System Malfunctions
24
Ignition Point Maintenance
25
Point Gap Adjustment
25
Spark Plugs and Gaps
25
Ignition Points Replacement
26
Ignition Standards
26
Ignition Timing
27
Ignition Coil
28
Charging System
29
Condenser
29
Hitachi 108-08 Alternator
29
Mitsubishi AZ2010N Alternator
31
Output Current
31
DC Generators
34
Troubleshooting
34
Yoke Inspection and Testing
35
Brush Inspection
35
Typical Generator
36
Armature Inspection and Testing
36
Voltage Regulator Inspection
37
Voltage Regulator Adjustment
37
Starter/Generator
38
Generatot Testing
39
Starter Relay
39
Typical Starter/Generator
39
Battery
40
Starter Troubleshooting
40
Resistance
40
Battery Service Standards
40
Fuse
41
Autolube System
42
Service Procedures
42
Minimum Pump Stroke Adjustment
42
Typical Autolube Pump
43
Pump Cable Adjustment
44
Bleeding the Autolube Pump
45
Engine, Transmission and Clutch
46
Preparation for Engine Disassembly
46
Engine Removal
46
Engine Installation
48
Cylinder Head
48
Removal and Installation
48
Cylinder Head Torques
48
Carbon Removal
49
Cylinder Removal
49
Cylinder Inspection
49
Cylinder Reconditioning
49
Piston Rings
50
Cylinder Installation
50
Piston Pin Removal
50
Piston Pin Fit
50
Piston Ring Replacement
51
Piston Clearance
52
Piston-To-Cylinder Clearance
52
Piston Ring Gap
52
Piston Installation
53
Clutch
54
Clutch Removal/Installation
54
Removal
54
Disassembly
54
DS3 and YM1 Clutch
55
Installation
56
Removal and Disassembly
56
YDS5, YM2, R1, R2, R3 and DS6 Series Clutch
57
Clutch Assembly
59
Clutch Inspection and Adjustment
61
Friction Plates
61
Metal Plates
61
Clutch Springs
61
Primary Driven Gear
62
Spacer
62
Clutch Adjustment
62
Clutch Cable Adjustment
62
Primary Drive Gear
63
Drive Sprocket and Chain
63
Kickstarter
63
Kickstarter Types
64
Type 1 Kickstarter
65
Type 2 Kickstarter
66
Type 3 Kickstarter
67
Type 4 Kickstarter
68
Type 5 Kickstarter
69
Gearshift Mechanism
70
Gearshift Types
70
Type 1 Shifter
71
Type 1 Gearshift Mechanism
71
Type 2 Shifter
73
Type 2 Gearnift Mechanism
73
Type 3 Shifter
76
Type 3 Gearshift Mechanism
77
Type 4 Shifter
79
Type 4 Gearshift Mechanism
81
Type 5 Shifter
83
Crankcase
84
Left and Right Split Type
84
Type 5 Gearshift Mechanism
85
Crankshaft
87
Upper and Lower Split Type
87
Bolt Torques
87
Older Type Crankshaft
88
Newer Type Crankshaft
88
Crankshaft Inspection
89
Crankshaft Disassembly
89
Crankshaft Reassembly
90
Crankshaft Alignment
91
Crankshaft Standards
92
Crankshaft Installation, Horizontally Split Crankcase
93
Crankshaft Installation, Vertically Split Crankcase
93
Transmission
94
Type 1 Transmission
94
Transmissions Types
94
Type 2 Transmission
95
Type 3 Transmission
97
Type 4 Transmission
98
Type 5 Transmission
99
Bearings and Oil Seals
102
Type 6 Transmission
102
Chassis, Suspension and Steering
105
Front Wheel
105
Front Wheel Removal
105
Front Tire Sizes
105
Front Wheel with Drum Brake
106
Front Wheel with Disc Brake
107
Front Wheel Inspection
108
Front Wheel Bearing Replacement
108
Brake Shoe Diameter
108
Hydraulic Brake System
109
Brake Disc Inspection
109
Caliper Disassembly and Reassembly
109
Brake Disc and Caliper
110
Master Cylinder
111
Master Cylinder Disassembly and Assembly
112
Rear Wheel
113
Brake System Bleeding
113
Rear Wheel Removal
113
Rear Tyre Sizes
113
Spokes
115
Rear Sprocket
115
Rear Wheel Inspection
115
Brake Shoe Wear Limits
115
Tires and Tubes
116
Front Fork
116
Clutch Hub
116
Tire Pressure
116
Disassembly, Except R5 Series
117
Typical Front Fork
117
R5, RD250 Series and RD350 Series Front Fork
117
Rear Suspension
118
Fork Inspection
118
Disassembly, R5, RD250 and RD350 Series
118
Fork Tube Reassembly
118
Steering Head
119
Shock Absorber Inspection
119
Trailing Arms
119
Steering Head Bearing and Race Replacement
119
Typical Steering Head
120
Periodic Service and Maintenance
121
Maintenance Intervals
122
Specifications
123
Models HS1 and HS1-B
124
Model LS-2
126
Models YL1 and YL1-E
128
Model AS2C
130
Model YAS1
132
Model YAS1-C
134
YCS-1 and YCS1-C
136
Model CS3-B and CS3-C
138
Cs5
140
DS6 and DS6-B
142
Ds6-C
144
Ds7
146
Models RD250 and RD250A
148
YDS3, YDS3-C and YM1
150
Yds5
152
Ym2
154
Ym2-C
156
R3
158
R3-C
160
R5
162
R5-B
164
R5-C
166
Models RD350 and RD350A
168
YR1, YR2 and YR2-C
170
Useful Formulas and Tables
172
Conversions
173
Piston Displacement
174
Bolt Torque
174
Examples of Conversions
174
Bolt Tightening Torques
175
Index
177

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Yamaha 1968 YR2 Service Manual (189 pages)

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