1990 Yamaha Ovation LE (Elec. Start) Service & Repair Manual

CD ® GEN I~ INSP ~ INFO ADJ ® ® ENG '" •• ICOOll)C I (j) ® ICHASI..:! II --- El-EC~I .---'-1 ® @ i tTl ® ~ ® 1 IT) @~ i a ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content. CD General information ® Periodic inspection and adjustment ® Engine ® Cooling system ® Carburetion ® Power train (j) Chassis ® Electrical ® Appendices Illustrated symbols @ to @ are used to iden tify the specifications appearing. @ Filling fluid QD Lubricant @Special tool @Tightening @ Wear limit, clearance @ Engine speed @Q,V,A Illustrated symbols @ to ® in the exploded diagram indicate grade of lubricant and location of lubrication point. @ Apply engine oil @ Apply gear oil @ Apply molybdenum disulfide oil ® Apply wheel bearing grease @ Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease ® Apply locking agent (LOCTITE®)

INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL CARBURETION POWER TRAIN ENG • 1----

CHAPTER 1. GENERAL INFORMATION GEN INFO MACHINE IDENTIFiCATION .................................... 1-1 FRAME SERIAL NUMBER .................................... 1-1 ENGINE SERIAL NUMBER ................................... 1-1 STORAGE .................................................... 1-2 PRE-SEASON PREPARATION .................................... 1-2 IMPORTANT INFORMATION .................................... 1-3 PREPARATION FOR REMOVAL AND DISASSEMBLY ............. 1-3 ALL REPLACEMENT PARTS .................................. 1-4 GASKETS, 01 L SEALS, AND O-RINGS .......................... 1-4 LOCK WASHERS/PLATES AND COTTER PiNS ................... 1-4 BEARINGS AND OIL SEALS .................................. 1-4 CI RCLIPS ......................................... ; ........ 1-5 SPECIAL TOOLS ............................................... 1-5 FORTUNE UP ............................................. 1-5 FOR ENGINE SERViCE ...................................... 1-6 FOR POWER TRAIN SERVICE ................................ 1-6 FOR ELECTRICAL SERVICE ................................. 1-7

GEN MACHINE IDENTIFICATION INFO- ,-, GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number CD is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number CD is located on the right-hand side of the crankcase. NOTE: ______________________ __ The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. Starting Serial Number: For U.S.A. and CANADA: CS340N ..... 85L-000101 CS340EN ... 85N-000101 For EUROPE: CS340 ...... 85M-000101 NOTE: ________________________ _ Designs and specifications are subject to change without notice.

GEN STORAGE/PRE-SEASON PREPARATION IN FO .......,;;...,;;,..;....~L--__ ...1 1-2 STORAGE If a snowmobile will not be used for several months, it should be stored in a proper place so that both the engine and the track are not damaged . • Completely drain the fuel tank, and disconnect the fuel line from the carburetor . • With the engine running at idle, squirt oil into the carburetor until the engine dies. This will distribute oil evenly throughout the engine, and protect it against rust. • Disassemble the suspension, clean and grease all parts, and reassemble the suspension. • Lightly coat all shafts and axles with grease. • Oil all fittings and cable controls with a lightly oiled cloth. • Loosen the track. • Block the chassis so that the track is off the floor . • Protect the snowmobile with a covering. PRE-SEASON PREPARATION Perform the predelivery service as described in the predelivery check list before operating any snowmobile that has been stored for several months. (Refer to CHAPTER 2. "PERIODIC MAINTENANCE TAB LE" section.)

GEN IMPORTANT INFORMATION INFO 1-3 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DIS- ASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. While cleaning, take care to protect the electrical parts, such as relays, switches, motor, resistors, controllers, etc., from high pressure water splashes. 2. Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS". 3. When disassembling the machine, keep mated parts together. This includes gears, cylinders, pistons, and other mated parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced. 4. During the machines disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire. 6. Be sure to keep to tightening torque specifications. When tightening bolts, nuts, and screws, start with a larger-diameter one and from an inner-positioned one to an outer- positioned one in a criss-cross pattern.

IMPORTANT INFORMATION 300-000 300-002 300-003 1-4 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and a-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and a-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates CD and cotter pins must be replaced when they are removed. Lo~k tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. BEARINGS AND OIL SEALS 1. Install the bearing(s) CD and oil seal(s) ® with their manufacturer'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 coating of light-weight lithium base grease to the seal lip(s). Oil the bearings libe- rally when installing. Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

300-001 1-5 GEN SPECIAL TOOLS INFO ..... _---...... __ .... CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD , make sure that the sharp edged corner ® is positioned opposite to the thrust @ it receives. See the sectional view. @Shaft SPECIAL TOOLS The proper special tools are necessary for com- plete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or impro- vised techniques. FOR TUNE UP 1. Sheave Gauge PIN YS-91047 This gauge is used for sheave distance and offset adjustment. 2. Inductive Tachometer PIN YU-08036, 90890-03113 This tool is used for ignition timing checking. 3. Timing Light PIN YU-08037, 90890-03109 This tool is used for ignition timing checking.

1-6 GEN SPECIAL TOOLS INFO L..";,,;;"';;;";;""";;;;;...,,A.. __ _ FOR ENGINE SERVICE 1. Piston Pin Puller PIN YU-01304, 90890-01304 This tool is used to remove piston pin. 2. Universal Clutch Holder PIN YM-91042, 90890-04086 This tool is used to hold starter pulley. 3. Rotor Puller PIN YU-33270, 90890-01362 This tool is used to remove COl magneto. 4. Dial Gauge PIN YU-03097, 90890-03097 This gauge is used for crankshaft runout measure- ment. FOR POWER TRAIN SERVICE 1. Primary Sheave Holder PIN YS-01880, 90890-01701 This tool is used to hold primary sheave.

1-7 GEN SPECIAL TOOLS INFO 2. Primary Sheave Puller PIN YS-01882-A, 90890-01898 This tool is used for removing primary sheave. 3. Sheave Compressor PIN YS-28891, 90890-01712 This tool is used for disassembling and assembling sheave. 4. Clutch Spider Separator PIN YS-28890-A,90890-01711 These tools are used for disassembling and assembling primary sheave. 5. Clutch Separator Adapter PIN YS-34480 This tool is used for disassembling arid assembling primary sheave. FOR ELECTRICAL SERVICE 1. Pocket Tester PIN YU-03112, 90890-03112 This instrument is necessary for checking the electrical components.

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1990 Yamaha Ovation LE (Elec. Start) Service & Repair Manual

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