YAMAHA [ez] ar YP 20TA-3OTA -40TAFOREWORD This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, 0 it is assumed that persons using this book to perform maintenance and repairs on Yamaha water pump have a basic understanding of the mechanical precepts and procedures inherent to water pump repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit for use and/or unsafe. Yamaha Motor Company Ltd. is continually striving to further improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. OVERSEAS SERVICE DEPT SALES & MARKETING DIV LEISURE VEHICLES & POWER PRODUCTS OPERATIONS YAMAHA MOTOR CO., LTD HOW TO USE THIS MANUAL Particularly important information is distinguished ir this manual by the following notations: NOTE: A note provides key information to make procedures easier or clearer. CAUTION: 4 caution indicates special precautions that must be taken to avoid damage to the machine erent ‘A warning indicates special procedures that must be followed to avoid INJURY to 2 machine operator, bystander, or person inspecting or repairing the machine.GEN INFO @ PUMP) ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols (7) to @) are designed as, thumb tabs to indicate the chapter's number and content, Q General information @ Periodic inspection and adjustment & Pump & Engine Cerburation @ Electical D Appendices Illustrated symbols @) to (2 are used to identify the specifications appearing. ® Filling fluid @ Tightening Wear limit, clearance Engine speed Da,V,AINDEX GENERAL INFORMATION os INFO PERIODIC INSPECTIONS AND ADJUSTMENTS nee e PUMP ; pow | ENGINE = CARBURETION consol ELECTRICAL L = i cLec | as APPENDICES noiCHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION ...... 5 tel IMPORTANT INFORMATION ...... oo 14 SPECIAL TOOLS AND TESTERS 12MACHINE IDENTIFICATION’ [ GEN |/aa IMPORTANT INFORMATION | INFO 1 GENERAL INFORMATION MACHINE IDENTIFICATION ENGINE SERIAL NUMBER The engine serial number (7) is stamped into the right side of the engine. NOTE: The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. Starting Serial Number: YP20GA... +207 U-000101 ~ 30GA....... 74 V -000101 ~ 20TA....... 7.3W.-000101 ~ BOTA... 73 X -000101~ 40TA : 74 Y -000101 ~ NOTE: Designs and specifications are subject to change without notice. IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1, We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assenmbly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all matng parts and bearings dur- ing reassembly. Apply grease to the cil seal lips. BEARINGS AND OIL SEALS 1. Install the bearing(s) @) and oil sealls) @) with their manufacture's marks or numbers, facing outward, (In other words, the stamped letters must be on the side exposed to view.) ‘When installing oil seal(s), apply a light coat ing of light-weight lithium base grease to the seal lip(s}. Oil the bearings liberally when in- stalling. CAUTION: Do not use compressed air to spin the bear- ings dry. This causes damage to the bearing surfaces.Re ea SPECIAL TOOLS AND TESTERS | INFO 12 SPECIAL TOOLS AND TESTERS The proper special tools are necessary for com- plete and accurate tune-up and assembly. Using the correct special too! will help prevent damage caused by the use of improper tools or improvised techniques. 1. Body, magneto puller P/N. YU-90105 (90890-01351) This tool is used to remove the flywheel. 2, Piston ring compressor P/N. YU-33294 (90890-05158) This tool is used to compress the piston rings when installing the piston. 3, Pocket tester P/N. YS-03112 (90890-03112) This instrument is necessary for troubleshooting the electrical system. 4, Service gauge (Thickness gauge) P/N. YU-26900-9 (90880-03079) This gauge is used to adjust valve clearance, piston clearance and piston ring end gap.SPECIAL TOOLS AND TESTERS GEN INFO 13 (es P/N. ACC-11001-05-01 (90890-05143) This sealer is used during reassembly of engine. 6. Cylinder gauge P/N. YU-03017 (90890-03017) This instrument is used for checking cylinder bore size and condition 7. Tachometer P/N. YU-08036 (90890-03082) ‘This instrument is used for reading engine r.p.m. 8. Compression gauge P/N. YU-33223 (90890-03081) Used for checking engine compression 9. Dial gauge P/N. YU-03097 (90890-03097) This instrument is used for checking crankshaft side clearance.INSP ADJ CHAPTER 2 PERIODIC INSPECTIONS AND ADJUSTMENTS. INTRODUCTION ..............065 24 PERIODIC MAINTENANCE/LUBRICATION INTERVALS. . pee ENGINE cee ” 22 ENGINE OIL on 5 22 FUEL COCK 5 23 AIR FILTER... : 23 MUFFLER .... : 24 SPARK PLUG . eee a COMBUSTION CHAMBER DECARBONIZATION .............20000.625 COMPRESSION PRESSURE MEASUREMENT ... 26 VALVE CLEARANCE ADJUSTMENT teeter eee DT GOVERNOR ADJUSTMENT 28 ENGINE SPEED ADJUSTMENT. 28 CRANKSHAFT SIDE CLEARANCE ADJUSTMENT ee 29 T.C.1. AIR GAP : 210 PUMP .. 210 IMPELLER: GAP. ADJUSTMENT . 211INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION aa) This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and @ longer service life. The need for costly overhaul work will be greatly reduced This information applies to machine already in service as well as new machine that are being prepared for sale. All serv- ice techni ians should be familiar with this entire chapter. PERIODIC MAINTENANCE/LUBRICATION INTERVALS No. Item Remarks. Pre-Operation check (daily) Initial Every 1 month oF 20 Hr | ‘3 months or 50 Hr (6 months jor 100 Hr [12 months| or 300 Hr 1. | Spark Plug ‘Cheok condition adjust gap and clean. Replace if necessary. 2. | Engine Oi 3. | Air Filter Check oil level [ Replace Clean! Replace if necessary i 4. | Fuel Filter lean fuel cock and | fuel tank filter Replace if necessary. | 5.*| Valve Clearance Fuel Line | Check and adjust when engine is | cold. | Check fuel hose for ‘crack or damage. Replace if necessary. Exhaust System (Check for leakage. Retighten or replace gasket if necessary, 8 | Carburetor Check choke (Control lever! operation. 9. | Starting System Check recoil starter. Operation. 10.*| Decarbonization More frequently if necessary. 11, | Water Pump Check for leakage. Retighten or replace O-ring and/or gasket. 12.*| Fittings/ Fasteners ‘Cheok all fitings and fasteners. Correct if necessary *: Itis recommended that these items be serviced by a Yamaha dealer or other qualified mechanic. 2415°C ENGINE OIL [ASF QI ENGINE ENGINE OIL Np Recommended Engine Oil: 4-stroke engine oil API Service Classification SE or SF, if not available, SD NOTE: Do not use with API CD rating. YPAOTA Oil Level Measurement 1. Check: Oil level Oil level measurement steps: ‘Place the engine on level ground. ‘*Warm up the engine for a few minutes. ‘Stop the engine. ‘Make sure the engine oil is between upper and lower levels. Add oil as necessary. Q Upper tevel ® Lower level oil Replacement 1. Warm up engine for several minutes. 2. Place a receptacle under the engine. 3. Remove: *0il filler cap 4, Remove: *Drain plug Drain the engine oil 5. Tighten: *Drain plug D Oil Drain Plug: 48 Nm (4.8 mskg, 34.7 ftelb) 6. Fill *Crankcase NI Recommended Engine Oil: YP20GA: 0.5 L (0.44 Imp at, 0.53 US qt) YP30GA/20TA: 0.68 L (0.60 Imp at, 0.72 US at) YP3OTA: 0.96 L. (0.84 Imp qt, 1.00 US at) YPaOTA: 1.10 L (0.97 Imp at, 1.16 US at 22FUEL COCK/AIR FILTER INSP Q| ADJ CAUTION: Do not allow foreign material to enter the crankcase. Q 23 FUEL COCK Removal and Inspection 1. Inspect: Fuel cock operation Leakage/ Contamination Disassemble 2. Remove: *Fuel cock (7) 3. Inspect: Fitter D Contamination-+ Replace fuel cock. O-ring @ Damage Replace. *Fitter cup @ Contamination-»Clean. 4. Assemble: Fuel cock 5. Install: ‘Fuel cock (on to fuel tank) AIR FILTER, 1, Remove: ‘air filter cover Air filter element 2)INSP MUFFLER | ADJ ey 2. Inspect: Element, Clogging-+Wesh the element in solvent and avy. Oil the element and squeeze out excess cil Damage—-Replace. Recommended oil: Foam-air-filter oil or SAE #20 motor oil 3, Install Air filter element Air filter cover NOT Do not wring out the elament. This could it to tear. CAUTION: The engine should never run without the el ment; excessive piston and/or cylinder wear may result. MUFFLER 1, Remove: *Muffler D *Protecter muffler @ ‘Muffler gasket @) 2. Inspect: Muffler gasket Damage~ Replace. 3. Decarboniz “Muffler ‘Tap on the muffler in the area shown in the illustration to loosen carbon buildup then shake out of end of muffler. CAUTION: Don't use a wire to clean or the noise damp- ing material may come out, reducing the damping effect. 24SPARK PLUG/COMBUSTION CHAMBER DECARBONIZATION 25 INSP ADJ SPARK PLUG 1. Remove: Spark plug Inspect: *Electrode @) Wear/Damage~Replace ‘Insulator color (2) Measure: *Plug gap @ Out of specification Regap Use a Wire Gauge of Feeler Gauge. 2. Spark Plug Gap 0.6~0.7 mm (0.024 ~ 0.028 in) Clean the plug with a spark plug cleaner if necessary. Standard Spark Plug: BPR6HS (NGK) Before installing a spark plug, clean the gasket surface and plug surface. 4. Tighten: Spark plug(s) ‘Spark Plug: 20 Nm (2.0 mekg, 14.5 ft-lb) NOTE: Finger-tighten @ the spark plug{s) before torqu- ing @ to specification. COMBUSTION CHAMBER DECARBONIZATION 1. Decarbonize: *Cylinder head Piston “ValveINSP COMPRESSION PRESSURE MEASUREMENT NSrQ | 26 COMPRESSION PRESSURE MEASUREMENT Insufficient compression pressure will result in performance loss and may indicate leaking valves ‘or worn or damaged piston rings. 1, Measure: *Valve clearance 2. Warm up engine for several minutes, then stop the engine. Remove: *Spark plugs 4, Connect: *Compression Gauge YU-33223 (90890- 03081) @) 5. Measure: *Compression Compression pressure (at sea level) == MIN. | MAX, 262 kPa_| 668 kPa YP20GA/30GA/20TA) (4 ka/em?, |(6 ka/em?, Sr psi) | 80 si 343 kPa | 699 kPa YP30TA (3.5 kg/cm’ {5.5 kg/cm? |" ‘Spall | 78 490 kPe, | 686 KPa year | Skg/em, |(7 kglem. Preps | 100 WARNIN When cranking engine, ground spark plug wires to prevent sparkingINSP VALVE CLEARANCE ADJUSTMENT | ADJ Compression test steps (below minimum. levels): ‘*Squirt a few drops of oil into cylinder. ‘Measure compression again. Reading Higher than without oil Diagnosis ‘*Worn cylinder, piston and piston rings fective piston, ring(s), valve(s) and cylinder head gasket improper valve ‘Same as without oil ‘Compression test steps (above maximum levels): Check cylinder head, valve surfaces, or piston crown for carbon deposits. VALVE CLEARANCE ADJUSTMENT 1. Remove: Air filter ‘Carburetor Muffler ‘Breather cover (D) 2. Measure: Valve clearance @ Above maximum— Replace valve (3). Below minimum Grind the valve stem end squarely. NOTE: ‘*Be sure piston is at Top Dead Center (TDC) on ‘compression stroke when measuting clearance. Valve clearance must be measured when the en- gine is cool to the touch. Use the Thickness Gauge @) YU-26900-9 (90890-03079) 27GOVERNOR ADJUSTMENT/ENGINE SPEED [INSP ADJUSTMENT | ADJ Intake valve | Exhaust valve told ‘eaten YOGA | 505-018 mm| BOA | tite2“o008 011-03 mm ‘YROOTA (0.004 — 0.012 in) = 02-03 mm eee (0.008 ~ 0.012 ind GOVERNOR ADJUSTMENT 1. Adjust *Governor Governor adjustment steps: 1. Loosen the locknut ( 2. Turn the governor arm (2) counterclock- wise until it stops, 3. Turn the governor shaft @) counterclock- wise until it stops. 4, Tighten the locknut. ENGINE SPEED ADJUSTMENT 1. Adjust: ‘*Engine speed (with no load) Engine speed adjustment steps: 1. Install the Tachometer (YU-08036, 90890- 03082). 2. Start the engine and warm up for a few minutes. 3, Turn the throttle lever (to the “HIGH” @® position. 4. Adjust the engine speed by turning the throttle stop screw @) in or out. {(2°}| Engine Speed (With No Load) ‘YP20GA/30GA ‘YP20TA/30TA oaaeee YPAOTA 3,750 —3,850 rpm 28INSP CRANKSHAFT SIDE CLEARANCE ADJUSTMENT | ADJ [Ql CRANKSHAFT SIDE CLEARANCE ADJUSTMENT 1. Remove: ‘*Pump assembly 2. Measpre: *Crankshaft side clearance Use Dial Gauge ) (YU-03079, 90890- 03079), Incorrect Adjust. Crankshaft side clearance adjustment steps: 1. Remove crankcase cover (2). 2. Add or subtract the shim @). ‘YP20GA/30GA Model | ere orn YP4OTA (0.1. mm (0.0039 in) [0.2 mm (0.0079 i ‘Shim 0.2 mm (0.0079 in)|0.3 mm (0.0118 in) size |0.3 mm (0.0118 in) |0.4 mm (0.016 in) 3. Install crankcase cover. Crankcase Cover Bolts: YP20GA/30GA/20TA. 14. Nm (1.4 mekg, 10.1 ft-lb) YP30TA/40TA, 22 Nm (2.2 mekg, 15.9 ft-lb) ‘4, Measure the crankshaft side clearance by lightly pushing in or out A Standard Crankshaft Side Clearance: 0~0.2 mm (0~0.0079 in) '5. Repeat the step 1 104 until the proper clea rance is obtained. 29INSP T.C.l, AIR GAP/IMPELLER GAP ADJUSTMENT | ADJ T.C.l. AIR GAP 1. Remove: Fuel tank ‘Fan case 2. Measure: *T.C.. air gap Use Thickness Gauge (1) (YU-26900-9, 90890-03079). Incorrect» Adjust. T.C.I. air gap adjustment steps: 1. Loosen the bolts @). 2. Adjust the T.C.I. air gap between T.C.1. pulser and flywheel by moving the T.C.I. unit up or down. @ T.C.1. Air Gap: 0.4~0.6 mm (0.016 ~0.024 in} PUMP IMPELLER GAP ADJUSTMENT 1. Remove: *Pump case 2. Measure: ‘impeller gap Use Thickness Gauge (@) (YU-26900-9 90890-03079). Incorrect» Adjust gap. Impeller gap adjustment steps: 1. Remove volute casing (2) and impeller @) 2. Add or subtract the adjusting washer @. 3. Install the impeller and volute casing, NOTE: Be sure the impeller is tightened securely. 4, Measure the impeller gap 6) ZB | Standard Impeller Gap: YP20GA/30GA, eecuaen YP20TA/30TA/40TA, '5. Repeat the step 1 to 4 until the proper gap is obtained. 210INSP IMPELLER GAP ADJUSTMENT | ADJ Adjusting washer ‘Model P/No. Thickness YP20GA 7JU-51136-00] 0.3 mm (0.012 in} YP30GA /JV-51136-00| 0.3 mm (0.012 in) . YP20TA/30TA| 7JW-51136-00 0.3 mm (0.072 inl] YPAOTA __| 7JY-51135-00| 0.3 mm (0.012 ini] 2CHAPTER 3 PUMP PUMP DISASSEMBLY “G” TYPE SUCTION COVER AND PUMP CASE IMPELLER....... MECHANICAL SEAL PUMP DISASSEMBLY “T” TYPE SUCTION COVER AND PUMP CASE IMPELLER = MECHANICAL SEALPUMP DISASSEMBLY “G” TYPE PUMP PUMP. PUMP DISASSEMBLY “G” TYPE Suction cover @® Adjusting washer Check valve Mechanical soa! set Pump case 1 O-ring @ seta Pump case 2 Dalvery bend Spring Oxina Rotating seal lute case ied seal Voki Fixed seal set YP20GA: 7 Nm (0.7 m: [YP30GA: 10 Nm (7 mekg, ¢ ib) Q (30. Nm (3 mekg, 21.7 ft-lb) ow. NN . oy [YPS0GA: 20 Nm (2 m-kg, 145 ft-lb) 34PUMP DISASSEMBLY “G” TYPE Pump i REMOVAL “G" TYPE SUCTION COVER AND PUMP CASE 1. Remove: *Suction cover D) *Check valve 2. Remove: ‘Pump case 1 @) *Valute case Q) IMPELLER 1. Remove: simpler @) Adjusting washer NoTE: ‘Turn the impeller counterclockwise by tapping the mpeller outer edge with a plastic hammer. MECHANICAL SEAL 1, Remove ‘Spring Pump case 2 2) 2. Remove: *Rotating seal D 32PUMP DISASSEMBLY “G” TYPE [PUMP| & 3. Remove: Fixed seal set NOTE: Use the driver. 4, Remove: ‘*Damper rubber (2) *Seal @ *0-+ing @ Inspection 1. Inspect: Mechanical seal set (2) simpeer Cracks/Wear/ Damage Replace. Inner circumference of rubber lip Friction surface @ Outer circumference of buffer rubber Assembly Reverse the removal procedure. 1. Install sVolute case 7 NOTE: ——_______ Mesh the pump case projection (2) with the vo- lute case slot.PUMP DISASSEMBLY “T” TYPE Pum PUMP DISASSEMBLY “T” TYPE @ Front cover Spring 2) O-ring Rotating seal Volute case Fixed seal sot @ O-ring Pump case 2 Pump case 1 ® O-ring © Impeller Delivery bend @ Adjusting washer Packing Mechanical seal set ‘Suction cover 2 Oring ® Check valve [EXIT | CONCRETE ‘YP20TA/30TA: 10 Nm (1 mek: YP20TA/30TA: 10 Nm (1 mekg, 7.2 ftelb) YPAOTA: 15 Nm (1.5 mekg, 10.8 ft-lb)PUMP DISASSE! 35 MBLY “'T” TYPE PUMP & REMOVAL “T” TYPE SUCTION COVER AND PUMP CASE 1, Remove: Suction cover @) Check valve @) 2. Remove: ‘*Front cover *Volute ca: 3. Remove: *O-rng IMPELLER 1. Remove: impeller *Adjusting washer Nore: — Turn the impeller counterclockwise by tapping the impeller outer edge with a plastic hammer. MECHANICAL SEAL 1, Remove: *Sloeve ® “Spring ¢ ‘*Roxating sealPUMP DISASSEMBLY “'T” TYPE ume & 36 2. Remove: *Lower mounting bolt 3. Remove: ‘*Side mounting bolts (1) *Pump case 1) 4, Remove: *Pump case 2 @) 5. Remove: Fixed seal @) *O-ring @ NOTE: Place a suitable socket (on the fixed seal (2) then press @) out the fixed sealPUMP DISASSEMBLY “T” TYPE pume| & Inspection 1. Inspect: ‘Mechanical seal set (7) *Sleeve Q) O-ring @) Spring @ Cracks/Wear/ Demage--Replace. 8 Inner and outer surfaces and sides of O-ring ©) Inner circumference of rubber lip @ Friction surface Outer circumference of butfer rubber Assembly Reverse the removal procedure. 37ENG CHAPTER 4 ENGINE OVERHAUL ENGINE REMOVAL NOTES ON SERVICE FRAME FUEL TANK AIR FILTER CARBURETOR AND MUFFLER GOVERNOR ARM . RECOIL STARTER FAN CASE . FLYWHEEL MAGNETO T.C., UNIT. ENGINE DISASSEMBLY CYLINDER HEAD VALVE . CAMSHAFT CRANKSHAFT, CONNECTING ROD AND PISTON INSPECTION AND REPAIR CYLINDER . PISTON, PISTON RING, AND PISTON PIN . CRANKSHAFT CAMSHAFT . VALVE AND VALVE SPRING ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT PISTON CONNECTING ROD VALVE AND VALVE LIFTER CAMSHAFT GOVERNOR CRANKCASE COVER CYLINDER HEAD. TCL. UNIT FLYWHEEL MAGNETO FAN CASE RECOIL STARTER BREATHER COVER... CARBURETOR ASS'Y AND GOVERNOR ARM MUFFLER ASS'Y AND AIR FILTERENGINE REMOVAL ENG | gy ENGINE OVERHAUL ENGINE REMOVAL NOTES ON SERVICE 1. Fire prevention ‘When servicing the engine, always keep away from fire. 2. Right tools Be sure to use the right special tool for the job to guard against damage 3. Oil, grease and sealers Be sure to use genuine Yamaha oil, grease and sealers. 4. Expendable parts Always replace gaskets, O-rings, cotter pins, and circlips with new parts when servicing engine.ENGINE REMOVAL ENG Solvent 42 5. Tightening torque Be sure to follow torque specifications. When tightening bolts, nuts or screws, start with a largest diameter one and work from an inner Position to an outer position in a crisscross pattern. 6. Notes on disassembly and assembly a, Parts should be cleaned in solvent and blown off with compressed air after disassembly. b. Contact surfaces of moving parts should be oiled when reassembled c. Make sure that parts move smoothly after each section of the machine is assembled. d. Self-tapping screws, Self-tapping screws (which cut their own threads when used) are used in some areas of this engine. Take care so that their threads are not damaged. For holes which are already tapped, standard type screws are used,ENGINE REMovAL | ENG FRAME 1, Remove: *Pump assembly *Frame @) Engine mounting nuts FUEL TANK 1, Remove: Fuel tank @ 2. Remove: Fuel tank stay D AIR FILTER 1. Remove: ‘Air filter cover @) *Element Air filter case 2) CARBURETOR AND MUFFLER 1. Remove: *Caburetor @ Mutter 2) 43ENGINE REMovAL | ENG 44 GOVERNOR ARM 1. Remove: *Governor arm Rod link @) *Spring tension @ RECOIL STARTER AND FAN CASE 1. Remove: ‘Recoil starter Fan case 2) ‘Breather cover @) 2, Disconnect: “Engine stop switch leads (1) warning light leads (2) 3. Remove: Air shround @ 4, Remove *Starter handle @ NOTE: Before untying knot @), make knot @) on the rope s0 that the rope is not pulled into the case. 5. Remove: nut © "Washer (2) *Friction plate @) *Spring @ENGINE REMOVAL ENG = _ CAUTION: Release the spring pre-road before removing the sheave drum nut. Hook the rope into the sheave drum slot () and trun the sheave drum assembly clockwise. 6. Remove: *Sheave drum assembly (1) *Sterter spring @) Rerrove: Drive pawl @) *Pawl spring @) *Rove 3) *Sheave drum @ FLYWHEEL MAGNETO Remove: Flywheel nut Washer *Starter pulley DENGINE REMOVAL | ENG 2. Remove: ‘Flywheel magneto @) Key NOTE: Use body, magneto puller (2) (P/N. YU-90105, 90890-01351). T.C.1. UNIT 1, Remove: STC. unit D ENGINE DISASSEMBLY CYLINDER HEAD 1. Remove: *Cylinder head @) *Cylinder head gasket @ VALVE 1. Remove: “valve @) Valve spring @ *Valve spring seat @) *Valve spring retainer (4) (tL | eee se eee nee ee SES ee SSS ESSE eE SES EEEEEE=e Using two slotted-head screwdrivers, Ift up the valve spring seat and remove the retainer. Now the valve can be disassembled. CAUTION: 9 @ Pa: a é When lifting up the valve spring seat with screwdrivers, be careful not to scratch the valve stem with the valve spring seat. 46ENGINE DISASSEMBLY | ENG CAMSHAFT 1, Remove: *Crank case cover () *Crank case cover gasket Q) 2. Remove: “Governor fork @ *Collar 2) 3. Remove: *Camshatt NOTE: Except for YP40TA: ‘Remove the camshaft facing the camshaft gear mark @) to the crankshaft gear mark @). For YP4OTA: *Disengage the camshaft gear from the crank- shaft gear facing gear marks @) each other. ‘Turn the camshaft to align the gear mark @) with the crankcase hole ©). ‘*Remove the camshaft. 47ENGINE DisassemBLy | ENG 4, Remove: Valve lifter @ CAUTION: Mark the valve lifters so that the exhaust and intake valve sides are not confused. CRANKSHAFT, CONNECTING ROD AND PISTON 1, Remove: Oil splasher @) ‘*Connecting rod cap @) ‘*Connecting rod and piston assembly (3) *Crankshaft @) 4849 INSPECTION AND REPAIR INSPECTION AND REPAIR CYLINDER 1. Decarbonize: Cylinder exhaust port NOTE: When decarbonizing, take care not to scratch the inner wall of the exhaust port 2. Inspect: Cylinder walls Vertical sctatchesRebore or Replace cylinder. 3, Measure: *Cylinder inside diameter NOTE: Obtain measurements at three depths by placing ‘measuring instrument parallel to and at right an- gles to crankshaft. Out of specification-»Rebore cylinder, and replace piston and piston rings. A Model sTD Limit 62.0 mm | 62.15 mm | L YP20GA | (2.441 in) | (2.447 in) YP30GA | 65.0 mm | 65.15 mm Cylinder |_YP20TA_| (2.559 in) | (2.565 in) 2c bor 73.0 mm | 73.15 mm pee | (2.874 in) | (2.880 in) 186.0 mm | 86.15 mm YPAOTA | (3.386 in) | (3.392 in) Cylinder 0.05 mm taper: T _ (0.002 in) Maximum © Maximum Dj, D2-Minimum Ds, DsINSPECTION AND REPAIR | ENG | geg PISTON, PISTON RING, AND PISTON PIN Piston 1. Measure: Piston skirt diameter “P”" (2) NOTE: Measure the piston skirt diameter where the dis- tance 10 mm (0.4 in) @ from the piston bottom edge. t vangarg| 82.0 rm [81.3 mm [Standard gat nl |c.437 I 62.25 mm62.16 mn "YP20GA Oversize 1 (2.461 in} |(2.447 in} 62.50 mm62.40 vn M461 tn c2487 in) 66.0 mm|64.8 mm [Standard 9 |c2655 In vesoca 6.25 mr6.15 ran Pypaara Oversize V2 360 nt |c2.568 In 5.50 mr5.40 ran (2m nl (2576 in) 73.0 mm|72.9 mm aren |(2870 in Jove Standard S, oversize 2 Standard 173.25 mm73.15 mm| (2.884 in) | (2.880 in) | 01) YP3OTA Over | Standard 186.50 mm'86.40 mm| vorsize 2 Sei ae 2. Measure: Piston clearance Piston Clearane= Cylinder inside diameter “C” — Piston skirt diameter ” 410INSPECTION AND REPAIR [ena | i | Out of specification» Rebore cylinder, and replace piston and piston rings. — \. N ‘Thickness gauge Piston Clearance: YP20GA/30TA/40TA: 0.065 ~0.075 mm (0.00256 ~ 0.00295 in) YP30GA/20TA: 0.080 ~ 0.090 mm (0.00316 ~ 0.00354 in) Piston Ring 1. Measure: *Ring side clearance Uso a feoler gauge. Out of specification Replace piston. Nore: — Clean carbon from piston ring grooves and rings before measuring side clearance. sTD 0.04~0.08 ma TeP | (0.0016 ~ 0.0031 in) | fing anal. 0.02~0.08 aide nd | (0.0008 ~ 0.002 in) clearance] 5] 0.02~0.06 | (0.0008 ~ 0.002 in) 2. Position: Piston ring (in cylinder) NOTE: Insert a ring into cylinder, and push it approxi- ‘mately 20 mm (0.8 in) into cylinder. Push ring with piston crown so that ring will be at a right angle to cylinder bore.INSPECTION AND REPaIR | ENG | gem 3. Measure: ‘*Ring end gap Out of specification Replace. NOTE: ‘You cannot measure end gap on expander spacer of oil control ring. If oil zontrol ring rails show ex- cessive gap, replace all three rings. ZX ston ingen gn tata Mode! STD Limit YP20GA |Top 306A [oe)02-0.4mm | 1.0 mm 20TA (0.0079~0.016 in) {0.0393 In) aorta [03 Trop), @1-02mm | 05 mm P | {0.0039 ~ 0.0079 in) _|10.0197 in) cee [2nd 0.1-0.25 mm 0.5mm [oi | (0.0039 ~0.0098 in)_|(0.0197 im) Piston Pin 1. Measure: *Piston pin diameter @) Use a micrometer. Out of specification Replace. Ay iston pin diameter soca estin | tote ara | Baim | laren worn | Biarim | loses 42INSPECTION AND REPAIR | ENG CRANKSHAFT 1. Measure: *Crank pin outside diameter (7) Use a micrometer Out of specification Replace. Crank pin outside diameter ‘STD Limit 25.0 mm 24.9 mm. (0.984 in) (0.980 in) 23.0 mm 28.9 mm (1.142 in) (1.138 in} 37.0 mm 36.9 mm (1.457 in) (1.453 in} 2. Measure: *Oil clearance Use a plastigage @. Out of specification-Replace connecting rod. 4 il clearance — sto | timit 0.016-0.034 mm | 0.18 mm (0.0006 ~0.0013 im) (0,006 im} Oil clearance measuring steps: 1. Clean all parts thoroughly, 2. Attach Plastigage® onto crankpin, 3, Install the connecting rod and cap onto crankshaft 4, Torque both cap bolts evenly. Z 4 Connecting rod cap bolt: YP20GA | 10 Nm (1.0 mekg, 7.2 fteIb) YP30GA/20TA [12 Nm (1.2 mekg, 8.7 ft-lb) | yp30TA | 16 Nm (1.6 11.6 fe-ib) [_YP40TA | 20 Nm (20 m-kg, 145 ft-lb] 5. Remove the connecting rod cap and meas: ure the Plastigage width. 413INSPECTION AND REPAIR | ENG | aH, CAMSHAFT 1. Measure: *Camshaft cam lobe length @) *Camshaft outside diameter Q) Use a micrometer. Out of specification— Replace. ZX camsnat cam oe nat “Model__| STD “Limi W208 755mm | 2730 mm goa | Ties | Tann Emm | Simm eens (1.319 in) (1-309 in) 380 min] 3778 mim = e (1.496 in) (1.486 in) Wedel [S16 [ti YOGA 60mm | 1495 mmm ace bat | Teas ‘comm | ES | Mis (0.630 in) (0.628 in) 23 mm ~ z (0. d] VALVE AND VALVE SPRING 1. Measure: *Valve stem diameter (i) Use 2 micrometer. Out of specification Replace. Valve stem diameter STD Limit in 7.0 mm 6.75 mm (0.276 in) (0.266 in) 7.0 mm 6.80 mm gE (0.276 in) | (0.268 in)INSPECTION AND REPAIR | ENG | gm Valve Seat 1. Inspect: *Valve seat Poor seating and sealing->Lapping. Out of specification—-Replace. Valve contact width 30GA 0.8 mm 1.6 mm 20TA (0.0316 in) (0.0630 in) 30TA, YpaoT 0.7-0.9 mm 2.0 mm (0.028 0.036 in) | (0.079 in) 415 Valve/Valve Seat Assembly Lapping 1. Apply: *Coarse lapping compound (Small amount) (to valve face) 2. Position: Valve (in cylinder head) 3. Rotate: Valve Turn until valve and valve seat are evenly polished, then clean off compound. 4. Repeat above steps with fine compound and continue lapping until valve face shows @ completely smooth surface uniformly. 5. Eliminate: *Compound (from valve face} 6. Apply: ‘*Mechanic's bluing dye (Dykem) (7) (to valve face and seat)INSPECTION AND REPAIR | ENG 7. Rotate: Valve Valve must make full seat contact indicat- ed by grey surface all around valve face where bluing was removed, 8. Apply: *Solvent {into each intake and exhaust port) Leakage past valve seat—Replace valve until seal is complete. Note; — Pour solvent into intake and exhaust ports only after completion of all valve work and assembly of head parts. 9. Check: Install the valve and pour gasoline into the port, then check if gasoline leaks pass the valve. A small amount of seapage is al- lowable. Wns Inflammables. Valve Spring 1, Measure: *Valve spring free length () ut of specification—-Replace. ( b inet ese = YP20GA_ pte won| Eg | YraoTA rari) {1.260 yeaora flowin) | (assim) 416ENGINE ASSEMBLY AND ADJUSTMENT | ENG | ggg 2. Measure: Valve spring tilt D Using a Square. Out of specification» Replace. “4 Vaive Spring Tilt: Within 2 mm (0.08 in} ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT 1. Install: “Crankshaft (into the crankcase) NOTE: Be sure the taper end of crankshaft is inserted into crankcase hole. PISTON YP2IGA/S0TA] Piston eeaee a /2are) 40TA head 1. Install: Piston rings Top| WD | —¥D { NoTE: | The piston ring set consists of the top, 2nd and ma; wa | ye v il rings, and they differ in shape as shown. Piston OW Ee Ee ‘skirt NOTE: Be sure to install rings so that Manufacture’s marks or numbers are located on the top side of the rings. Oil the pisten and rings liberally. Nore: — The piston ring should be installed so that the end gaps @) do not line up with the piston boss and are 120° off each other. The sequence of instal- lation is the oil ring, 2nd ring and top ring. 4aa7ENGINE ASSEMBLY AND ADJUSTMENT | ENG | ggg 2. Install: Piston pin Piston Piston pin circlip (New) NOTE: Be sure the arrow mark (1) on the piston face to valve hole (2) and the YAMAHA mark @) on the connecting rod face to crankcase cover @) side NOTE: Use Piston Ring Compressor @ (YU-33294, 90890-05158). CONNECTING ROD 1. Install ‘Connecting rod Connecting rod cap *Splasher (1) NOTE: Be sure the connecting rod marks (2) is aligned with the cap marks @). CAUTION: Be sure the splasher bending side (@) face to. crankcase side (2) except for YPAOTA.ENGINE ASSEMBLY AND ADJUSTMENT ENG Connecting Rod Bolt: YP20GA: 10 Nm (1.0 mekg, 7.2 ft-lb) YP30GA/20TA: 12 Nm (1.2 mekg, 8.7 ft-lb) YP30TA: 16 Nm (1,6 mekg, 11.6 ftelb) YP40TA: 20 Nm (2.0 m-kg, 14.5 ft-lb) VALVE AND VALVE LIFTER 1. Install Valve springs Valve seats intake valve Exhaust valve *Valve spring retainers NOTE: Install the retainer by lifting up the valve seat us: ing screw driver with pushing down the valve. 2. Install: Valve lifters @) NOTE: Place the crankcase up side down to install the valve lifter and camshaft. CAMSHAFT 1. Install: *Camshaft CAUTION: Be sure the camshaft gear mark (1) is aligned with the crankshaft gear mark (2). 419ENGINE ASSEMBLY AND ADJUSTMENT ENG YPaOTA | GOVERNOR = 1. Install: ‘*Governor weight (D) (Except for YP40T) ‘*Governor holder @) (Except for YP40T) *Governor collar @) Nore; — Install the governor weights (@ in the each straight portions (2) of the holder, then insert the holder edge @) into the camshaft gear slot @). (Except for YP40TA) 2. Install Governor fork @) [Oxy JAE ® Algal © Vi Ea AAs 7 Us Sr St W CRANKCASE COVER 1. Install: *Crankease cover Crankcase Cover Bolt: YP20GA/30GA/20TA: 14 Nm (1.4 mekg, 10.1 ftelb) YP30TA: 22. Nm (2.2 m+kg, 15.9 ft-lb) YP4OTA: 22 Nm (2.2 mekg, 15.9 ft-lb) NOTE: For YP40TA Place the piston at top dead center and align the holes in the balancer gear () and the crankcase cover using a rod or screwdriver (2), then install the crankcase cover on the crankcase. 4.20ENGINE ASSEMBLY AND ADJUSTMENT | ENG | CYLINDER HEAD 1. Install: Cylinder head gasket ‘Cylinder head @) Note: — When reassembling the cylinder head, be sure to use a new head gasket. Be sure that the gasket is positioned correctly. Cylinder Head Nuts: YP20GA/30GA/20TA/30TA: 20 Nm (2.0 m-kg, 14.5 ft-lb) YP40TA: 45 Nm (4.5 m-kg, 32.6 ft-lb) 2. Adjust: *Valve clearance Refer to page 2-7. @ Valve Lifter 3) Clearance ® Cam T.C.L. UNIT 1. Install: *T.C.l. unit Refer to page 2:9. 2. Adjust: sT.C.l. air gap Refer to page 2-9. 424ENGINE ASSEMBLY AND ADJusTMENT | ENG FLYWHEEL MAGNETO 1. Install: ‘*Flywheel magneto Refer to page 4-5. Flywheel Nut: YP20GA/30GA/20TA: 55 Nm (5.5 m-kg, 39.8 ft-lb) YP3OTA: 75 Nm (7.5 mekg, 54.2 ftelb) YPAOTA: 120 Nm (12.0 m-kg, 86.8 ft-lb) FAN CASE 1. Install: Fan case Refer to page 4-4. Q) Fan Case Nut: 10 Nm (1.0 mekg, 7.2 ft-lb) YP20GA7S0GA RECOIL STARTER | (207A 1. Install: *Starter spring D *Sheave drum assembly @ NOTE: ‘*Mesh the spring hook @) with the case or drum. slit, then wind the spring clockwise into the case or drum from larger to smaller diameter. ‘Mesh the sheave drum or case hook @) with the spring hook 6). 'YPSOTA TATA NOTE: “Wind the rope 2-1/2 turns counterclockwise around the sheave drum. Then insert the rope into the drum slit @. 422ENGINE ASSEMBLY AND ADJUsTmENT | ENG | ggg YEDUGATSOGA, YESOTA | [207A YPaOTA, 2. Install: Return spring Drive plate NOTE: Make sure the drive paw! faces in the correct direction and it is positioned on the inner side of the return spring. 3. Turn the sheave drum (7) turns counterclock- wise to give preload to the spring. 4. Install *Starter handle (7) Nore: — Pass the rope through the case hole and make knot @ on the rope so that the rope is not pulled into the case. Untying knot @ after making knot @). 423ENGINE ASSEMBLY AND ADJusTmENT | ENG BREATHER COVER 1. Install: Refer to page 4.4. YI Breather Cover Bol 7Nm (0.7 51 CARBURETOR ASS'Y AND GOVERNOR ARM 1. Install: Refer to page 4-3, 44. 2. Adjust: Refer to page 7-3. MUFFLER ASS'Y AND AIR FILTER 1. Install: Refer to page 2:3, 2-4. 4.24ENG 425[ears 5d CHAPTER 5 CARBURETION CARBURETOR . INSPECTION ....0..0000000ccccceeeeveceeseeeeeeeeeeetsaeseseeeee BDCARBURETOR CARB) 4 CARBURETOR CARBURETION ‘SPECIFICATIONS ® Pilot screw 7 @ Pitt jet ye2oGa YE2GA/) vegora | yPaOTA @ Needle valve ~ if | @ Float Main jet #775 | #825 | #88 | #1125 ) Main jet pate es © Choke lever Pilot jet [Seb | Sense Se aOSe @ Main nozzle Pilot screw : an ® Main bieed pipe (ivan ute | eee | eee | eter | ane [Float height | 18.5 [185 711.0 | 7341.0 YP20GA] 'YPS0GATZOTA | SO Qe a YPSOTACARBURETOR [care 7 Grooved wear Z INSPECTION 1. Inspect’ *Carburetor body Fuel passage Contamination—-Clean as indicated, Carburetor cleaning steps: ‘*Wash carburetor in petroleum based solvent. (Do not use any caustic carburetor cleaning solution). “Blow out all passages and jets with com- pressed air. Float Height 1. Measure: Float height Damage~ Replace. NOTE: Place the carburetor in an inverted po measurement. Lift up the float so that the tip of the float valve lightly contacts the float arm, and measure the float height. (This measurement should be made with the gasket removed.) ion for YP20GA/30GA/20TA [18.5 mm (0.728 in) YP3OTA 11.0 mm (0.433 in) 13.021 mm (0.5112 + 0.039 in) YP4OTA Valve Seat Assembly 1. Check: Valve seat Damage~Replace. Contamination-*Clean. 52cars| +CHAPTER 6 ELECTRICAL CIRCUIT DIAGRAM. ELECTRICAL COMPONENTS IGNITION SYSTEM soos TROUBLESHOOTING CHART . ENTIRE IGNITION SYSTEM CHECK IGNITION COIL SPARK GAP SIGNAL SYSTEM TROUBLESHOOTING CHART OIL LEVEL SWITCH SWITCH (eel 61 62 63 64 66 67 68 69 69circuit DIAGRAM | ELEC ELECTRICAL CIRCUIT DIAGRAM @® Oil warning light COLOR CODE Engine stop switch R: Red CDI unit Br Brown @) TCI unit Y: Yellow Spark plug B: Black © Ignition coil Or: Orange 7 Oil level switch Lk: Blue @ Flywheel magneto B/W: Black/White @) Oil warning unit WIR: White/Red 9 Pulser coil 'YP20GA/30GA/20TA/30TA ® B YPAOTA B/W: Bw ‘or— |-er. W/R) z ®ELECTRICAL COMPONENT | ELEC ELECTRICAL COMPONENT @D Oil warning unit @ Stop switch 3) Oil warning light Ass'y @) Oil level switch @ CDI Unit @ Ignition coi ‘Stop switch @ Oil warning light Ass'y ® T.C.1. Unit ® Charge coil ® Pulser coil @® Oil level switch 'YP20GA/30GA/20TA SOTA [ YPaoTA 62Icnition system | ELEC | B= IGNITION SYSTEM COLOR CODE RK: Red Br: Brown Y: Yellow B: Black Or: Orange Lk: Blue B/W: Black/White WIR: White/Red ‘ ® lw Lea @ | 63TROUBLESHOOTING CHART NO SPARK OR WEAK SPARK ] u A 1. Remove: Spark plugs 2. Check: ‘*Spark plug type ‘Standard Spark Plug: BPR6HS (NGK) 3. Measure: Electrode gap Out of specification Spark Plug Electrode Gap @): 0.6~0.7 mm Clear off carbon/Regap/Replace spark plug. [ =~ +0 | Bice st @ Flywheel magneto 3. Measure: Pulser coil resistance *Source coil resistance fal Pulsor Coil Resistance: 19701 + 10% at 20°C (68°F) (w/R—B) Source Coil Resistance: 3150+ 10% at 20°C (68°F) (Br—B) J Out of specification Replace faulty parts. 65inition system | ELEC| ES 66 ENTIRE IGNITION SYSTEM CHECK The entire ignition system can be checked for mis- fire and weak spark by using the Electro Tester. 1. Warm up the engine so that all of the electri- cal components are at operating temperature. 2. Connect: ‘Electro Tester @) YU-33260 (90890-03021) 3. Start the engine, and increase the spark gap until misfire occurs. (Test at vairous r/min be- ‘tween idle and red line.) Spark plug wire & Spark plug CAUTION: Do not run the engine in neutral above 4,000 r/min for more than 1 or 2 seconds. Minimum Spark Gap: 6 mm (0.24 in) Faulty ignition system operation (at the minimum spark gap or smaller)—-Follow the troubleshoot- ing chart until the source of the problem is located. IGNITION COIL SPARK GAP 1. Disconnect: ignition coil @ lead connecters (For YP40TA) *TCI unit @) lead connector (Except for YPAOTA) 2. Connect: *Electro Tester @ YU-33260 (90890-03021) NOTE: Be sure to use a fully charged battery. 3. Tur the spark plug gap adjuster and increase the gap to the maximum limit unless misfire occurs first, Minimum Spark Gap: 6 mm (0.24 in) ® Battory (12V)sinat system | ELEC) e D Oil Warning light coLOR CODE SIGNAL SYSTEM Engine stop switch Red DI unit Be Browa Yellow B: Black Or Orange Ble BIW Block/Woite W/R White/Red ® Pulser coil [YPROGRISOGATROTATSOTA | YPAOTA | -Or- 67TROUBLESHOOTING CHART SIGNAL system | ELEC) Ej THE OIL WARNING LIGHT DOES NOT COME ON. u Oil level switch lead 2. Connect: “Oil level switch lead (Wire harness side) | Faulty 1. Remove: *0il warning bulb 2. Check: Bulbs Replace bulb. a” Do not light B 1. Disconnect: ¢] 1. Disconnect: *CDI unit lead (B/W) (For YP4OTA) *TCI unit lead (R) (Except for YP4OTA) 2. Connect: ‘Pocket Tester Gil level switch 3) Yellow (For YPAOTA) @ Blue (Except for YPAOTA) 3. Check: Oil warning light condition ‘Pull the recoil starter and check if the oil warning light come on. ® {to unit side connector) L a ® ® \o = @ Jumper lead ® CDI unit check @® TCI unit check 4. Measure: *Unit output voltage (on the "B/W" and “'R” lead) Start the engine and accelerate to belows CAUTION: Be sure the engine oil is between upper and lower levels. Add oil as necessary. Engine Speed (with no load) _ Except for YPAOTA | 3,650~3,950 rom YPaOTA | 8.780-3,880 rpm 68SIGNAL SYSTEM e a Over 2V Replace oil level switch Replace CDI unit or TCI unit Correct connections and/or replace oil warning unit. OIL LEVEL SWITCH 1. Remove: *0il level switch 2. Measure: Oil level switch resistance Out of specification—-Replace. - i Float is down (+02 Float is up Qo 3. Install *0il level switch SWITCH Switch may be checked for continuity with the Pocket Tester on the “ohm x 1" position. position FREE PUSH 69APPX CHAPTER 7 APPENDICES SPECIFICATIONS GENERAL SPECIFICATIONS: MAINTENANCE SPECIFICATIONS PERFORMANCE CURVE TIGHTENING TORQUE . GENERAL TORQUE SPECIFICATIONS ......... DEFINITION OF UNITS WIRING DIAGRAM TROUBLESHOOTING mW 72 76 77 “77 78 79appenpices |APPX/AC% SPECIFICATIONS GENERAL SPECIFICATIONS Nae MOOT vroca «| veooca | vr2ota | vraora | vPaoTA Mode! Code Number 7U 7IV Jw | 7x WY mmm tind | 88) ae | cy | gaa | do ower wae | Be 8 we ‘eo oo Mim ty} ah ao | &e | ao | do bry Weigt “woth | a 3 oe e or me | aise | 39 | soe ane ad : = ~ | o- = |e ie = x aa Bos Soke ave eaves : 2 | eda ‘eitpm tin sac BS in| aeet70 | (0.98%.06) 102 cram ebony! | OSS Ses : ee 110 BIE | oak ba | 1o0h2m ost ton | ost 126 orc 15°C SAE #10 an 32°F 59°F ‘Sperk Plug Type | = NGK (BP6HS) = = (o2e 0.085 9APPENDICES [apex MAINTENANCE SPECIFICATION Engine ‘Model YP2OGA, 'YP30GA/20TA, ‘YPSOTA YPAOTA ~ stD | Limit | std | Umi | STD | Limt | STD em PISTON mm (inh = (2.441) | 2.437) | (2.559) | (2.986) | (2.874) | (2.870) | (3.386) | (3.382) Over Size 62.25 | 6215 | 65.25 | 65.15 | 73.25 | 73.15 | 86.25 | 86.15 (2.451) | (2.447) | (2.569) | (2.565) | (2.884) | (2.880) | (3.396) | (3.392) 62.50 | 62.40 | 65.50 (2.461) | (2.457) | (2.579) 65.40 | 73.50 | 73.40 | 86.50 | 86.40 | Piston Size eo | 619 | 65.0 | 649 | 730 | 729 | 830 (2.875) | (2.894) | (2.890) | (3.406) | (3.402) Piston Clearance | 0.065~ 0.080 ~ 0.065 ~ 0.085 ~ ors | O15 | Ooe9 | O15 015 | Opes | 0.18 (0.026~ 0.0032 ~ (0.0326 ~ fiogoy | 10.008 |G OO | (0.006) 050), | (0-006) PISTON PIN / mm (in) Piston Pin Dia ao | 1395 | 140 | 1395 | 180 | 17.95 | 2.0 | 19.95 __| 10.551 | (0.549 | 10.709) | (0.707) | (0.787) | 10.785) | 10.787 | (0.785) PISTON RING Top | 2nd [ Oi | Top | 2nd [ Oi | Top oil_| Top | 2nd [OW mm (in) Ring Design |e | ee | yz |r Tia) Ring End Gap [0.2 Ot [01 os) fe fe fefefefe |] - [02 [o2) - jo.0079-| (0.003 }0.0039~ 0.016) 0.007) | c.0098) RingEndGaptimi] 10 | — | 2 | 2} of of 2] ef}. fos) |e 0.0383) | 0.017 Ring Groove Side |0.04~ |0.02~ (0.04 ~ |0.02~ l0.04~ |0.02~ (0.04~ |o.02~ Clearance 0.08} 0.06] _ |o08!o06| _ | 0.08 | 0.06] , | 008 | 0.06 | , 0.0016 -}0.0008-| 0018 fo.008 0.0016 }o.008 | 0.00% ~f.c008~| 0.031) | 0.002 0.003 | 0.00 3.01 | 0.002) .0at | 0.0024 Ring Groove sido 0.15| |. |. |) | ele] ee Pep ep ee} Clearance Limit (0.006) CYLINDERmm (in) Bore Dia 20 | 62.15 | 650 | 6515 | 730 | 73.15 | 950 | 96.15 (2.441) | (2.447) | (2.559) | (2.565) | (2.874) | (2.880) | (3.386) | 13.302) CRANKSHAFT ‘mm (ind AcCrank Pin Dia | 25.0 | 249 | 250 | 249 | 290 | 289 | 37.0 | 369 (0.984) | 0.980) | (0.984) | (0.980) | (7.142) | (1.138) | (1.487) | (7.453) B-Clearance 0.2~08} 1.0 |02~08| 10 |02~06! 10 |02~08| 10 {0.0079 ~ | (0.0039) | (0.0079~ | (0.0039) | (0.0079 ~ | (0.0039) | (0.0079~ | (0.0039) 0.031) 0.031) 0.024) 0.0318) il Clearance 0.016 ~ 0.016~ 0.016 ~ o.c16~ Joe | O15 | Sass | 9:15 | ase | 0.18 | tae | 05 (0.0006~ | 0.006) | (0.0006~ | (0.008) |(0.0006~ | (0.006) | (0.0006~ | (0.006) 0.0013) 0.0013) 0.0013) 0.0013) C-Run Cut 0.03 03 0.03 0.03 (0.0012) (0.0012) (0.0012) (0.0012) 72appenpices |APPX An cies YRROGATBOTA YeRTA [va Item _— | stp Limit STD Limit STO Limit CONNECTING ROD mm tin) Big End Dia. 250 | 2505 | 250 | 2505 | 290 | 2005 | 370 | 37.05 (0.980) | (o9a6 | (0.900 | (0.986 | tira) | citer | (457) | (1.459) Small End Dia 140 | 1408 | 140 | 1405 | 160 | 1605 | 300° | 20.05 cossn | 0.55 | oss | oss | (0.630) | (0.632) | (0.787 | 10.789) COVER CRANK CASE | mm Journal 150 | 1605 | 150 | 1505 | 160 | 1605 | 25.0 | 24.90 ——— cosa | 10.59% | c0.591 | (0.599) | (0.690) | 10.632) | (0.984) | 10.980) CAMSHAFT mm {in} Cam Height 25 | 273 va | ms | x25 | 20 | 9775 (1.088) | 11.075) «i.076) | ciate) | (309) | (496) | (1.486 Journal 150 | 14.95 1495 | 160 | 1695 | 25.0 | 24.90 __ | esa | (0.580) | (o.ze) | 10.984) | (0.960) VALVE min ~~ f Valve Clearance (Cold) IN| 0.05~ 0.05~ ine ine 01-03 01-02 10.002~ | (0.002 — ~ {0.0039 ~ ~ (0.0039 ~ 7 0.006) 0.006) 000118) 00079) ex) 0015~ | o.1s~ | | ons | 0.15 o1~03| | 02-03 10.0006 ~ (0.0006 ~ (0.0039 ~ (0.0079 0.006) 6.006) 0.0118) 0.0118) ValveSeatwieth | 08 | 16 | 08 | 16 | 08 | 16 |07~09| 20 0315) | 08) | roosts | 10.0631 | cst | @.06x | 228- | ror Valve Stem Dia, | iv) 70 | 68 | 70 | 68 | 70 | 68 | 70 | 68 | (0.276) | (0.266 | 10.276) | 0.268) | 10.276) | (0.268) | (0.276) | 10.260) ex) 70 | 675 | 70 | 675 | 70 | 675 | 70 | 675 (0.276) | (0.266 | (0.276) | (0.266) | (0.276) | (0.266) | (0.276) | 10.266) VawveSpringFree | 335 | 26 | 335 | 25 | 370 | 320 | 10 | 290 Length ci3ig) | aaza | asia, | 12 | aaen | 4.260) | (614) | (7.535) Valve Spring Tilt 2.0 20 | 2.0 2.0 (0.079 (0.079) coor) |__| 07 CARBURETOR | Type | MikuMrevie | wikunt evie | MIKUNI Bv24 | MIKUNI 8V2621 Bore Size sn fin 8 18 24 26 Setting | | ‘Main Jot (M.J.1 ems #925 #88 125 Pilot Jet (Pd. #45 vo | a #65 Pilot Screw es.) 1 (tur out! wa | tae 1a Valve Seat Size ‘mm (in) 20 20 Float Height | mm (in) 185. 110 13210 73APPX' is] 74 APPENDICES Model ‘YP20GA YP30GA/207A ‘YP3OTA YPAOTA ~~ _|FsTo [time [sto [ume [sto [Limit [sto [Limit ELECTRICAL Ignition System Tc. . C.D. Primary Coll = - 0.760 10% Resistance Secondary Coil 10K9+ 10% + 10K + 20% Resistance Pulser Coil = = 1970+ 10% Resistance Charge Coil | - 316 + 10% ResistanceAPPENDICES [appx TIGHTENING TORQUE Model | YP20GA YPROGAT20TA YPaOTA YPAOTA — Tore Torque Toraue | Torae S| rand | TRS" | siraat | "Nim" | iroas | "in | ticad | “i Seo" |mtg)) "See |rmetay| “See” Joma) “Se ne | weas)| °° | (Rae) (fa) Te) Cinder Heed 2 2 20 6 maxtzs| 20 \mexta5, 20. Maxtas| 20. |atoxtas| 43 _ is is ia a Connecting Rod D 2 16 2 moxto| 1D lw 7x10) 12 maxras, 16 |maxizs} 20 _ _ 72 |. a7_| n6 145 Spork Plug 7% 3] 8 78 voract.25) 18 femaxtzs] 18 |amextas) 18 frat] 18 13.0 13.0 | 13.0 13.0 Crakcaso Cover rn “ i 2 mexto| 1% |wexto| te |waxizs| 22 hnaxias| 22 11 ctor MO) ee ie par agree 8 3 7 i29 wraxts | 85 unaxts| £8 femoris | 78 |maxre| ‘a Se 3a dia we Breather Cove 7 7 7 7 IM 6x 1.0 07 |M6x1.0 0.7 [M6x1.0 07 [M6x1.0| 07 Secs BH Br at Fan Case 0 70 70 [10 mexto| 10 |wexto) 10 | exo) 10 mexto| 10 72 72_| | | 72 | 72 0 10 10 | 10 mexio] 19 lwexro) 10 |mexto, 10 |wexto) 10 sar Swe 2 oh ao [Metet ao Mextel oe 5 5 75 5 tw axi.25] 13 |waxizs| 1 |Mexis 15 |wioxt25) 43 wa [YO a | 33 Adjust Pate 0 0 70 0 moxio] 10 |wexro| 10 jmexto| 10 mexio| 10 2 1 n % Muffler 1 18 18 18 18 vw 9125) 18 |waxizs 18 |waxis) 18 |maxias| 1 ho MO eo MO a MOS | Fol Cok 7 7 7 7 moxi0| 07 |wexro| o7 |mexro| o7 mexio| o7 at Ler | 3 B1 = vraoca | vesoca | veaora | vesora | vewora ————— 0 “eo | 6 | | 10 Caliber mm (n) Q@ | @_ 2 @ | af “iim in gal tn 560 0 soo 00 1700 imp gal/min, vias tg) | ene: 260) | 132"t60) | ext S00. | sr 80 ilies 2 7 7 % 7 ToulHed mini] 26 z, z z, a Priming Heat mtn | aly = - = =PERFORMANCE CURVE |APPX PERFORMANCE CURVE Ci) tin L araee t09) YP30GA, 2 aot 2 g 3 & 60 = 60} : : 5 40 2 ao} 2 a af e T50(US gal/min) © 100 200 300 (US gal/min) caeacrty CAPACITY (int (in) vyP20TA TA. 109 vyP30 a a0 g 8 = gol = 60o- Zz z = z 2 aoh- 2 oy 20} 20h ° TEOTUS gal/min) 0 100200300108 gal/min) caraciny CAPACITY Ci 100 yeaoTA, sof 2 a 3 oh z 5 oh 20 capacity 16 5OOTUS gal/min}TIGHTENING TORQUE/GENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNIT |APPX TIGHTENING TORQUE Model Ye20GA_[___YPa0GA__—| __YPa = Torque Torque = Thread Thwead | Nm. | Thread Thread | | Nm \ | ‘see ie | (meta) | ste sie” | (meta) [item (Re) (rag) | | | (eas) w 20 0 Pump Case 2 /MBx1.25| 3 [MBx1.25| 3 |waxi.25] 3. (Mex125| 3 (eee ise [thos eeeered [etiize 27 | 2i7_| 6 2 | 30 30 Pump Case1 — (MBx1.25| 15 WMioxt29 2 Maxi} 3 MI2x1.25 3 108 145 27 27 7 10 10 15 Suction Cover MBx1.25| 0.7 MI0x1.29 1 AMOxt.25) 1 MIDI. 1.5 | ° Ee 72 72 108 = 7 10 10 15 Delivery Bend —|MBx1.25| 07 fMtoxt.24 1 Mtoxt.28 t M2x1.25 18 51 72 12 10.8 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners = with standard |.8.0. pitch threads. Torque specifi- Thread size | —__"shtening torque _ cations for special components or assemblies are. Nm__| em-kg included in the applicable sections of this book. ears 2 a To avoid warpage, tighten multifastener assem- mare 3 30 blies in a crisscross fashion, in progressive stages, mare = 70 until full torque is reached. Unless otherwise M7 0 100 specified, torque specifications call for clean, dry Ms | 1 750 threads. Components should be at room tem- [M0 30 300 perature. M12 oo | 600 DEFINITION OF UNITS Unit Definition Measure mm 10-) meter om ____|10-? meter == = [ke Kilogram Werahe N Newton SS eee Nm Newton meter Torque | mek __| Meter kilogram Torque Pa Paskal Pressure Nimm Newton per millimeter Spring rate t Li = _| Bebe eantimacer = Volume or Capacity | r/min Rotation per minute 7 Engine spe 7wirine piacram | ELEC | ES WIRING DIAGRAM D Oil warning light COLOR CODE Engine stop switch Ro Red CDI unit Br Brown @) TCI unit Y Yellow Spark plug B Black © Ignition coil Or Orange Oil evel switch L Blue Flywheel magneto B/W Black/White @ Oil warning unit WIR White/Red YP20GA/30GA/20TA/30TAAPPX TROUBLESHOOTING TROUBLESHOOTING Engine Does not start + Gasoline level x >| Add gasoline. o [rasa saring -—-— Spark plug «+f clean or replace. i | Lack of power }+—| Carburetor o Valve clearance x | i Compression pressure | x ——e o Governor x 79 Check T.C.l. unit or replace. Clean and adjust. Adjust. Overhaul engine and check. Adjust or replace,LIT- 19616-00-. 17 vu YAMAHA MOTOR CO.,LTD.