Yamaha CS3-E Manuals

Manuals and User Guides for Yamaha CS3-E. We have 1 Yamaha CS3-E manual available for free PDF download: Service Manual

Yamaha CS3-E Service Manual (79 pages)

Brand: Yamaha | Category: Motorcycle | Size: 36.25 MB

Contents
5
General
7
Features
7
Specifications & Performance
8
Performance Curves
10
Engine Performance Curves
10
Running Performance Curves
10
Service Tools
11
Standard Tools
11
Special Tools
11
Other Miscellaneous Tools
12
Yamaha Autolube
13
What Is Yamaha Autolube?
13
Handling the Oil Pump
13
Bleeding
13
Setting the Carburetor and Pump
14
Checking Minimum Pump Stroke
14
5-Port Cylinders
15
Description of 5-Port Cylinder
15
Construction and Features
15
5-Port Cylinder Exploded View
15
Engine
16
Removing the Engine
16
Cylinder Heads
19
Removing Carbon
19
Cylinders
19
Checking the Cylinder for Wear
20
Cylinder Reconditioning
20
Carbon Removal
20
Piston Pins
21
Pulling out the Piston Pin
21
Miscellaneous
21
Piston-To-Piston Pin Fit
22
Piston Rings
22
Keystone Type Piston and Keystone Ring
22
Technical Notes on Keystone Rings
23
Removing the Rings
23
Fitting the Rings
24
Checking the Piston Ring
24
Piston
24
Checking and Reconditioning the Piston
24
Piston Clearance Measurement
25
Checking and Reconditioning Pistons
25
Crankcase Cover
26
Piston Installation Direction
26
Tachometer Drive Gear Assembly
27
Tachometer Drive Gear Assembly Components
27
Clutch
27
Clutch Exploded View
28
Removing the Pressure Plate
29
Checking the Friction Plate
29
Checking the Clutch Spring
29
Fitting the Cushion Rings
29
Removing the Clutch Boss
30
Checking the Spacer
30
Checking the Primary Driven Gear Ass'y
30
Checking the Push Rod
30
Primary Drive Gear
31
Clutch Adjustment
31
Adjusting the Clutch Cable
31
Distance Collar
32
Kick Starter
32
Exploded View of the Kickstarter
33
Removing the Kick Idler Gear
34
Checking the Drive Sprocket
34
Drive Sprocket
34
Shifting Mechanism
36
Removing the Gear Shift Shaft Ass'y
36
Checking Gear Shift Parts
37
Reconditioning
37
Gear Shift Arm
37
Splitting
37
Transmission
39
Layout of Transmission Gears
39
Exploded View of Transmission
39
Crankshaft
40
Caution on Reinstallation
40
Crankshaft Ass'y Component Parts
41
Assembled Crnakshaft Dimensions
41
Removing the Crankshaft Ass'y
42
Disassembling the Crankshaft Ass'y
42
Reassembling the Crankshaft Ass'y
43
Aligning Cranksahft Ass'y
45
Accuracy of the Cranksahft Ass'y
45
Bearings and Oil Seals
46
Reinstalling the Crankshaft Ass'y
46
Carburetors
47
Carburetor Components
47
Checking the Carburetor
48
Adjusting the Fuel
48
Float
48
Overflowing
48
Air Cleaners
49
Synchronizing Carburetors
49
Carburetor Setting
49
Adjusting the Idle Speed
49
Cleaning
50
Chassis
51
Front Wheel
51
Spokes
53
Brake Shoe
53
Brake Drum
53
Repairing the Brake Shoe
54
Replacing the Wheel Bearing
54
Replacing the Clutch Hub Bearing
54
Rear Wheel Components
55
Replacing Tires
57
Rear Sprocket Wheel
57
Runout of the Rim
57
Rear Arm
58
Fuel Tank
58
Replacing Rear Swing Arm Bushings
58
Front Fork
59
Inner Tube
59
Disassembling the Outer and Inner Tubes
59
Rear Cushion
60
Checking Method of Oil Leakages
60
Electrical
61
Electrical Equipment
61
Main Components
61
Charging and Starting Systems
61
Connection Diagram
62
Electrical Parts List
62
Starter Dynamo
63
Checking the Dynamo
63
Charging System
63
Starting System
63
Conductivity Test of Field Coil
64
Checking the Brushes
64
Checking the Armature Ass'y
64
Checking the Commutator Mica Under-Cut
64
Checking the Condenser
65
Capacity Tests
65
Contact Breaker
66
Adjusting Ignition Timing
66
Dynamo Adjustment Standards
68
Regulator
69
Voltage Regulator
69
Cut-In Voltage of the Cut-Out Relay
69
Regulator Maintenance Standards
70
Ignition Coil
71
Spark Plugs
71
How to Judge Plug Condition
72
Periodic Inspection and Supplementary Charging
72
Battery
72
Before the First Ride
72
Millimeters to Inches
73
Inches to Millimeters
73
Conversion Table
74
Lengths
74
Weights
74
Volumes
74
Circuit Diagram
75

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