2010

POWER PRODUCT

SERVICE MANUAL

Model : YS928J, YT1232ED, YT624E,

YT624EDJ

7RV28197E000 *7RV28197E000*
 FOREWORD HOW TO USE THIS MANUAL
This manual was written by the YAMAHA PARTICULARLY IMPORTANT
MOTOR POWERED PRODUCTS CO., LTD.
INFORMATION
primarily for use by Yamaha dealers and their
qualified mechanics. It is not possible to put
This material is distinguished by the following
an entire mechanics education into one man-
notation.
ual, so it is assumed that persons using this
book to perform maintenance and repairs on
Yamaha Snowblower have a basic under- This is the safety alert symbol. It is used to
standing of the mechanical precepts and pro- alert you to potential personal injury haz-
cedures inherent to Snowblower repair tech- ards. Obey all safety messages that follow
nology. Without such knowledge, attempted this symbol to avoid possible injury or
repairs or service to this model may render it death.
unfit for use and/or unsafe. WARNING
A WARNING indicates a hazardous situa-
YAMAHA MOTOR POWERED PRODUCTS
tion which, if not avoided, could result in
CO., LTD. is continually striving to further
death or serious injury.
improve all models manufactured by Yamaha.
Modifications and significant changes in spec- NOTICE
ifications or procedures will be forwarded to all A NOTICE indicates special precautions
Authorized Yamaha dealers and will, where that must be taken to avoid damage to the
applicable, appear in future editions of this machine or other property.
manual.
TIP
A TIP provides key information to make proce-
dures easier or clearer.

MANUAL FORMAT
The procedures in this manual are organized
in a sequential, step-by-step format. The infor-
mation has been compiled to provide the
mechanic with an easy to read, handy refer-
ence that contains comprehensive explana-
tions of all disassembly, repair, assembly, and
inspection operations.
In this revised format, the condition of a faulty
component will precede an arrow symbol and
YT624E/YT624EDJ/YS928J/YT1232ED the course of action required will follow the
SERVICE MANUAL symbol, e.g.,
©2010 by YAMAHA MOTOR POWERED 9 Bearings
PRODUCTS CO., LTD. Pitting/damage → Replace.
1st Edition, June 2010
All rights reserved. Any reprinting or EXPLODED DIAGRAM
unauthorized use without the written Each chapter provides exploded diagrams
permission of YAMAHA MOTOR before each disassembly section for ease in
POWERED PRODUCTS CO., LTD. identifying the correct disassembly and
is expressly prohibited. assembly procedures.
Printed in Canada.
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic.
Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check
procedures are laid out with the individual steps in sequential order.
9 The manual is divided into chapters and each chapter is divided into sections. The current sec-
tion title is shown at the top of each page 1.
9 Sub-section titles appear in smaller print than the section title 2.
9 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section 3.
9 Numbers are given in the order of the jobs in the exploded diagram. A number indicates a dis-
assembly step 4.
9 Symbols indicate parts to be lubricated or replaced 5.
Refer to “ILLUSTRATED SYMBOLS”.
9 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. 6.
9 Jobs requiring more information (such as special tools and technical data) are described
sequentially 7.

5 1

VALVE ENG VALVE ENG

REMOVING THE VALVE AND VALVE
5 1 SPRING
(YT1232ED)
2 1. Remove:
9 Valve cotter 1
3
9 Valve spring retainer 2
9 Valve spring 3
7 Nm (0.7 m · kgf, 5 ft · lbf) 2 4 9 Valve 4
Remove the parts using the valve
7
M

spring compressor 5.

3 4
TIP
Do not compress the spring more than neces-
3 sary.
5
4 9
10
7
6

Valve spring compressor:

7 Nm (0.7 m · kgf, 5 ft · lbf) 2 YM-04019, 90890-04019

8 5

6
3 CHECKING THE VALVE AND VALVE
SPRING
2
7 1. Measure:
9 Valve stem length a
9 Valve head diameter b

E 1
(YT624E/YT624EDJ)
Valve stem length:
E
SCF3180
Intake: 65.9 mm (2.59 in)
Exhaust: 66.2 mm (2.61 in)
Valve head diameter:
Intake: 24.0 mm (0.94 in)
6 Order Job/Parts to remove
Removing the rocker arm, valve
Q’ty Remarks
Remove the parts in the order listed.
Exhaust: 22.0 mm (0.87 in)
(YS928J)
and valve spring Valve stem length:
Cylinder head Refer to “CYLINDER HEAD”. Intake: 65.9 mm (2.59 in)
1 Rocker arm shaft 1 Exhaust: 66.2 mm (2.61 in)
2 Locknut 2 Valve head diameter:
3 Adjuster 2 Intake: 29.0 mm (1.14 in)
4 Rocker arm 2 Exhaust: 25.0 mm (0.98 in)
5 Valve cotter 2 (YT1232ED)
6 Valve spring retainer 2 Valve stem length:
7 Valve spring 2 Intake: 88.1 mm (3.46 in)
8 Exhaust valve 1 Exhaust: 87.9 mm (3.46 in)
9 Intake valve 1 Valve head diameter:
10 Valve stem seal 1 Intake: 32.0 mm (1.26 in)
For installation, reverse the removal pro- Exhaust: 27.0 mm (1.06 in)
cedure.
Out of specification → Replace.

3-16 3-17

chap03.indd 16 2010/05/28 11:26:34 chap03.indd 17 2010/05/28 11:26:34

ILLUSTRATED SYMBOLS
(Refer to the illustration)

SYMBOL DEFINITION SYMBOL DEFINITION

Periodic inspections and

General information
adjustments

Engine Carburetor

Transmission Chassis

Electrical system Specifications

Serviceable with engine mounted Gear oil

G

Filling fluid Molybdenum disulfide oil

M

Special tool Engine oil

E

Tightening torque B Wheel bearing grease

T.
R.

Wear limit, clearance C Low temperature grease

Engine speed M Molybdenum disulfide grease

Electrical data LS Lithium soap based grease

Replace the part with a new one. Apply locking agent (LOCTITE®).
LT
 INDEX
GENERAL INFORMATION GEN
INFO 1
PERIODIC INSPECTIONS
AND ADJUSTMENTS INSP
ADJ 2
ENGINE ENG 3
CARBURETOR CARB 4
TRANSMISSION TMI 5
CHASSIS CHAS 6
ELECTRICAL SYSTEM ELEC 7
SPECIFICATIONS SPEC 8
 CHAPTER 1. CHECKING THE AUGER CLUTCH....2-10
CHECKING THE SIDE CLUTCH
GENERAL INFORMATION
LEVER.................................................2-11
MACHINE IDENTIFICATION......................1-1 CHECKING THE AUGER CLUTCH
SERIAL NUMBER.................................1-1 AND DRIVE CLUTCH LEVERS..........2-12
CHECKING THE SHIFT LEVER.........2-12
IMPORTANT INFORMATION.....................1-2 ADJUSTING THE SHIFT LEVER “N”
PREPARATION FOR REMOVAL AND (NEUTRAL) POSITION ......................2-13
DISASSEMBLY......................................1-2 CHECKING THE SHIFT LEVER.........2-13
ALL REPLACEMENT PARTS................1-3 ADJUSTING THE SHIFT LEVER “N”
GASKETS, OIL SEALS AND (NEUTRAL) POSITION.......................2-14
O-RINGS................................................1-3
BEARINGS AND OIL SEALS................1-3 AUGER......................................................2-15
CHECKING THE CONNECTIONS........1-3 CHECKING THE SHEAR BOLT..........2-15
CHECKING THE SHEAR BOLT
SPECIAL TOOLS AND TESTERS..............1-5 GUARD MOUNTING BOLT.................2-15
CHECKING THE AUGER AND
CHAPTER 2. BLOWER ............................................2-15
CHECKING THE SCRAPER...............2-16
PERIODIC INSPECTIONS AND CHECKING THE CHUTE
ADJUSTMENTS DEFLECTOR CONTROL LEVER........2-16

INTRODUCTION.........................................2-1 V-BELT......................................................2-17
CHECKING THE AUGER V-BELT ......2-17
MAINTENANCE INTERVALS CHART.......2-1 CHECKING THE DRIVE V-BELT.........2-22
REPLACING THE AUGER/DRIVE
PERIODIC MAINTENANCE/ V-BELT.................................................2-25
LUBRICATION INTERVALS.......................2-1
TRANSMISSION.......................................2-29
FUEL TANK AND AIR FILTER CASE........2-3 CHECKING THE TRACK.....................2-29
(YT624E/YT624EDJ).............................2-3 WORM CASE OIL...............................2-30
(YT1232ED)...........................................2-4 CHANGING THE WORM CASE
OIL.......................................................2-30
COVERS AND FUEL TANK........................2-5
CHECKING THE HYDROSTATIC
(YS928J)................................................2-5
TRANSMISSION (H.S.T.) OIL
LEVEL..................................................2-30
MUFFLER...................................................2-6
TRANSMISSION OIL...........................2-31
(YT624E)................................................2-6
CHANGING THE TRANSMISSION
(YT624EDJ)...........................................2-7
OIL.......................................................2-31
(YT1232ED)...........................................2-8
ELECTRICAL............................................2-32
STEERING..................................................2-9
HANDLING THE BATTERY ................2-32
CHECKING THE HANDLEBAR.............2-9
CHECKING THE BATTERY FLUID
CHECKING THE AUGER HOUSING
LEVEL..................................................2-32
HEIGHT CONTROL...............................2-9
CHECKING THE BATTERY FLUID
CHECKING THE SKID........................2-10
SPECIFIC GRAVITY . .........................2-33
CONTROL.................................................2-10 CHARGING..........................................2-33
CHECKING THE THROTTLE/ CHECKING THE TERMINAL...............2-34
CHOKE LEVER...................................2-10 CHECKING THE SPARK PLUG..........2-34
ENGINE.....................................................2-35 REMOVING THE VALVE AND
ADJUSTING THE ENGINE IDLING VALVE SPRING...................................3-17
SPEED.................................................2-35 CHECKING THE VALVE AND
CHECKING THE RATED ENGINE VALVE SPRING...................................3-17
SPEED.................................................2-37 CHECKING THE ROCKER ARM........3-20
ADJUSTING THE GOVERNOR...........2-38 CHECKING THE VALVE SEAT............3-20
CHECKING THE COMPRESSION LAPPING THE VALVE.........................3-23
PRESSURE.........................................2-40 ASSEMBLING THE VALVE AND
CHECKING AND ADJUSTING THE VALVE SPRING...................................3-23
VALVE CLEARANCE . ........................2-41
CHECKING THE ENGINE OIL RECOIL STARTER AND TCI
LEVEL WARNING LIGHT....................2-43 MAGNETO................................................3-24
CHECKING THE ENGINE OIL............2-43 (YT624E/YT624EDJ)...........................3-24
CHANGING THE ENGINE OIL............2-44 RECOIL STARTER DISASSEMBLY
CHECKING THE FUEL LEAK.............2-45 (YT624E/YT624EDJ)...........................3-25
CHECKING THE FUEL COCK REMOVING THE ROTOR
STRAINER...........................................2-45 ASSEMBLY..........................................3-26
CHECKING AND CLEANING THE CHECKING THE RECOIL
MUFFLER SCREEN............................2-45 STARTER.............................................3-26
INSTALLING THE RECOIL
CHAPTER 3. STARTER.............................................3-26
ENGINE INSTALLING THE ROTOR
ASSEMBLY..........................................3-27
ENGINE.......................................................3-1 ASSEMBLING THE TCI UNIT.............3-28
COVERS AND CABLES
TCI MAGNETO..........................................3-29
(YT624E/YT624EDJ).............................3-1
(YS928J)..............................................3-29
BELT GUIDE, BELT AND ENGINE
(YT1232ED).........................................3-30
(YT624E/YT624EDJ).............................3-3
REMOVING THE ROTOR....................3-31
CABLES AND MUFFLER (YS928J)......3-4
ASSEMBLING THE TCI UNIT.............3-31
V-BELT AND ENGINE (YS928J)...........3-6
COVERS AND CABLES 1
CRANKCASE COVER AND
(YT1232ED)...........................................3-7
CAMSHAFT..............................................3-32
COVERS AND CABLES 2
(YT624E/YT624EDJ)...........................3-32
(YT1232ED)...........................................3-8
(YS928J)..............................................3-34
BELT GUIDE, BELT AND ENGINE
(YT1232ED).........................................3-35
(YT1232ED)...........................................3-9
CHECKING THE PULLEY...................3-36
CHECKING THE
CYLINDER HEAD . ..................................3-10
ELECTROMAGNETIC CLUTCH.........3-36
(YT624E/YT624EDJ)...........................3-10
CHECKING THE CAMSHAFT.............3-36
(YS928J)..............................................3-12
CHECKING THE VALVE LIFTER.........3-38
(YT1232ED).........................................3-13
INSTALLING THE BALANCER
CHECKING THE CYLINDER
SHAFT.................................................3-38
HEAD...................................................3-14
INSTALLING THE CAMSHAFT...........3-39
ASSEMBLING THE CYLINDER
INSTALLING THE CRANKCASE
HEAD...................................................3-14
COVER................................................3-39
VALVE.......................................................3-15
(YT624E/YT624EDJ/YS928J)..............3-15
(YT1232ED).........................................3-16
PISTON, CONNECTING ROD, HYDROSTATIC TRANSMISSION
CRANKSHAFT AND CRANKCASE.........3-40 (H.S.T.) (YT624E/YT624EDJ)................5-7
(YT624E/YT624EDJ)...........................3-40 (YS928J)................................................5-9
(YS928J)..............................................3-41 HYDROSTATIC TRANSMISSION
(YT1232ED).........................................3-42 (H.S.T.) AND TRANSMISSION
CHECKING THE CYLINDER...............3-43 (YT1232ED).........................................5-11
CHECKING THE PISTON AND SHIFTER AND CLUTCH
PISTON PIN.........................................3-44 (YT1232ED).........................................5-12
CHECKING THE PISTON RING.........3-47 TRANSMISSION AND CLUTCH
CHECKING THE CRANKSHAFT........3-48 GEAR (YT1232ED)..............................5-13
CHECKING THE CONNECTING CHECKING THE TRACKS..................5-15
ROD OIL CLEARANCE.......................3-49 CHECKING THE SHAFT, SLIDER
INSTALLING THE PISTON AND AND PIVOT ARM.................................5-15
PISTON RING......................................3-51 CHECKING THE H.S.T. ......................5-17
ASSEMBLING THE CRANKSHAFT....3-51 CHECKING THE SHIFTER AND
CLUTCH (YT1232ED).........................5-18
GOVERNOR..............................................3-53 CHECKING THE TRANSMISSION
(YT624E/YT624EDJ)...........................3-53 (YT1232ED).........................................5-19
(YS928J)..............................................3-55 ASSEMBLING THE CLUTCH,
(YT1232ED).........................................3-57 TRANSMISSION AND SHIFTER
CHECKING THE FLYWEIGHT (YT1232ED).........................................5-19
SHAFT GEAR . ...................................3-59 BLEEDING THE H.S.T.........................5-23
INSTALLING THE GEAR COVER
CHAPTER 4. AND H.S.T.
CARBURETOR (YT624E/YT624EDJ/YS928J)..............5-25
INSTALLING THE SPROCKET
CARBURETOR...........................................4-1 (YT624E/YT624EDJ/YS928J)..............5-27
(YT624E/YT624EDJ).............................4-1
(YS928J)................................................4-2 CHAPTER 6.
(YT1232ED)...........................................4-4 CHASSIS
DISASSEMBLING THE
CARBURETOR AUGER AND WORM CASE.......................6-1
(YT624E/YT624EDJ).............................4-6 (YT624E)................................................6-1
(YS928J)................................................4-7 (YT624EDJ)...........................................6-3
(YT1232ED)...........................................4-8 (YS928J)................................................6-5
ASSEMBLING THE (YT1232ED)...........................................6-7
CARBURETOR....................................4-10 REMOVING THE AUGER......................6-9
CHECKING THE AUTO CHOKE CHECKING THE AUGER AND
(YS928J)..............................................4-13 WORM CASE......................................6-10

CHAPTER 5. IMPELLER, SKID AND SCRAPER..........6-11

TRANSMISSION (YT624E/YT624EDJ)...........................6-11
(YS928J)..............................................6-12
TRANSMISSION.........................................5-1 (YT1232ED).........................................6-13
WHEEL AND TRACK CHECKING THE IMPELLER...............6-14
(YT624E/YT624EDJ).............................5-1 CHECKING THE SCRAPER AND
(YS928J)................................................5-3 SKID.....................................................6-14
(YT1232ED)...........................................5-5 INSTALLING THE SKID.......................6-15
CHUTE......................................................6-16 (YS928J)..............................................7-19
(YT624E/YT624EDJ)...........................6-16 (YT1232ED).........................................7-21
(YS928J)..............................................6-17 CHECKING THE STARTER
(YT1232ED).........................................6-19 MOTOR................................................7-23

STEERING................................................6-21 CHUTE CONTROL AND LIGHTING

(YT624E)..............................................6-21 SYSTEMS.................................................7-25
(YT624EDJ).........................................6-23 TROUBLESHOOTING.........................7-25
(YS928J)..............................................6-25
(YT1232ED).........................................6-26 SIGNAL SYSTEM.....................................7-29
TROUBLESHOOTING (YS928J).........7-29
AUGER HOUSING HEIGHT CONTROL
MECHANISM............................................6-28 CHAPTER 8.
(YT624EDJ).........................................6-28 SPECIFICATIONS
(YS928J)..............................................6-29
(YT1232ED).........................................6-30 GENERAL SPECIFICATIONS....................8-1
CHECKING THE TILT LOCK
CABLE.................................................6-31 ENGINE.......................................................8-4
CHECKING THE AUGER HOUSING
HEIGHT CONTROL MECHANISM......6-31 ELECTRICAL..............................................8-9
ASSEMBLING THE AUGER
HOUSING HEIGHT CONTROL TIGHTENING TORQUE
MECHANISM.......................................6-32 (YT624E/YT624EDJ).................................8-10
ENGINE...............................................8-10
CHAPTER 7. CHASSIS.............................................8-10
ELECTRICAL SYSTEM
TIGHTENING TORQUE (YS928J)............8-11
ELECTRICAL COMPONENTS ENGINE...............................................8-11
(YT624E/YT624EDJ)...................................7-1 CHASSIS.............................................8-12
CIRCUIT DIAGRAM
TIGHTENING TORQUE (YT1232ED).......8-13
(YT624E/YT624EDJ).............................7-2
ENGINE...............................................8-13
ELECTRICAL COMPONENTS CHASSIS.............................................8-14
(YS928J).....................................................7-3
GENERAL TORQUE
CIRCUIT DIAGRAM (YS928J)..............7-4
SPECIFICATIONS.....................................8-14
ELECTRICAL COMPONENTS
LUBRICATION POINTS AND
(YT1232ED).................................................7-5
LUBRICANT TYPES.................................8-15
CIRCUIT DIAGRAM (YT1232ED).........7-6
ENGINE...............................................8-15
IGNITION SYSTEM.....................................7-7 AUGER................................................8-15
TROUBLESHOOTING...........................7-7 CHASSIS.............................................8-15
DRIVE..................................................8-16
CHARGING SYSTEM...............................7-10 STEERING...........................................8-16
TROUBLESHOOTING.........................7-10
WIRE ROUTING DIAGRAM.....................8-17
ELECTRIC STARTING SYSTEM..............7-13 CHASSIS (YT624E/YT624EDJ)..........8-17
TROUBLESHOOTING.........................7-13 STEERING (YT624E)..........................8-18
STARTER MOTOR (YT624EDJ).........................................8-19
(YT624E/YT624EDJ)...........................7-17 ENGINE (YT624E/YT624EDJ)............8-20
CHASSIS (YS928J).............................8-22
STEERING (YS928J)..........................8-23
ENGINE (YS928J)...............................8-24
CHASSIS (YT1232ED)........................8-25
STEERING (YT1232ED).....................8-26
ENGINE (YT1232ED)..........................8-28
 CHAPTER 1.

GEN
MACHINE IDENTIFICATION
INFO
A GENERAL INFORMATION
MACHINE IDENTIFICATION
SERIAL NUMBER
The product serial number is affixed to the
position 1 of the Snowblower as shown in

1
the illustration.
The product name a and product serial 1
number b are printed on the label 2.

TIP
B
The first three digits identifies a model, and
the remaining digits indicates a production
number.

A YT624E/YT624EDJ
B YS928J
C YT1232ED
1
TIP
Designs and specifications are subject to
C change without notice.

1-1
 GEN
IMPORTANT INFORMATION
INFO
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
CAUTION ON SERVICE
1. Fire prevention
SVU1030
When servicing the engine, always keep the engine and
yourself away from fire.
NOTES ON SERVICE
1. Correct tools
Be sure to use the correct special tool for the job to guard
against damage.
SVU1040

2. Oil, grease and seals

Be sure to use genuine Yamaha oils, grease and sealers, or the
equivalents.

SVU1050

3. Expendable parts
Always replace the gaskets, O-rings, cotter pins and circlips
with new parts when servicing engine.

SVU1060

4. Tightening torque
Be sure to follow torque specifications. When tightening bolts,
nuts or screws, start with the largest-diameter fastener and
work from an inner position to an outer position in a crisscross
SVU1070
pattern.

5. Notes on disassembly and assembly

a. Par ts should be cleaned in solvent and blown dry with
compressed air after disassembly.

SVU1080

SVU1090

b. Contact surfaces of moving parts should be oiled when

reassembled.
c. Make sure that the parts move smoothly after each section of
the machine is assembled.
SVU1100

1-2
 GEN
IMPORTANT INFORMATION
INFO
ALL REPLACEMENT PARTS
We recommend the use of genuine Yamaha parts for all replace-
ments. Use oil and/or grease, recommended by Yamaha, for
assembly and adjustment.

GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, seals and O-ring should be replaced when an
engine is overhauled. All gaskets surfaces, oil seal lips and
O-rings must be cleaned.
2. Properly oil all mating parts and bearings during reassemble.
Apply grease to the oil seal lips.

BEARINGS AND OIL SEALS

Install the bearing(s) 1 and oil seal(s) 2 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 coating of lightweight lithium base grease to
SVU1110
the seal lip(s). Oil the bearings liberally when installing.

NOTICE
Do not use compressed air to spin the bearings dry. This
causes damage to the bearing surfaces.
SVU1120

CHECKING THE CONNECTIONS

Check the leads, couplers and connectors for stains, rust, mois-
ture, etc.
1. Disconnect:
9 Lead
9 Coupler
9 Connector
1 1 2. Check:
9 Lead
9 Coupler
9 Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
3. Check:
9 All connections
Loose connection → Connect properly.

TIP
If the pin 1 on the terminal is flattened, bend it up.
After disassembling and assembling the coupler, pull on the leads
to make sure that they are installed securely.

1-3
 GEN
IMPORTANT INFORMATION
INFO
4. Connect:
9 Lead
9 Coupler
9 Connector
5. Check:
9 Continuity
(with the pocket tester)

Pocket tester:
YU-03112-C, 90890-03112

TIP
9 If there is no continuity, clean the terminals.
9 When checking the wire harness, perform steps 1–5.
9 Make sure to check the connector and coupler of the TCI unit
when replacing the TCI unit.
9 Use the tester for checking the coupler as shown in the illustra-
tion.

NOTICE
For waterproof couplers, never insert the tester leads directly
into the coupler. When performing any checks using a water-
proof coupler, use the specified test harness or a suitable
commercially available test harness.

Checking the connections

Check the leads, couplers, and connectors for stains, rust, mois-
ture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
NOTICE
9 When disconnecting a coupler, release the coupler lock,
hold both sections of the coupler securely, and then dis-
connect the coupler.
9 There are many types of coupler locks;
therefore, be sure to check the type of coupler lock before
disconnecting the coupler.

1-4
 GEN
SPECIAL TOOLS AND TESTERS
INFO
SPECIAL TOOLS AND TESTERS
The proper special tools are necessary for complete and accurate
tune-up and assembly. Using the correct special tool will help pre-
vent damage caused by the use of improper tools or improvised
techniques.

1. Thickness gauge
P/N. YM-34483, 90890-03079
This gauge is used to adjust valve clearance, piston clearance
and piston ring end gap.
SVU1150

2. Cylinder gauge
Commercially obtainable
This instrument is used for checking cylinder bore size and
condition.
SVU1160

3. Digital tachometer
P/N. YU-39951-B, 90890-06760
This tool is needed for observing engine r/min.

4. Compression gauge
P/N. YU-33223, 90890-03081
This gauge is used for checking engine compression.

SVU1180

5. Dial gauge
P/N. YU-A8428, 90890-03097
This instrument is used for checking crankshaft side clearance.

SVU1190

6. Sheave holder
P/N. YS-01880-A, 90890-01701
This tool is necessary for holding the magneto rotor.

SVU1205

7. Tappet adjusting tool

P/N. YM-A5970, 90890-01311
This tool is used to adjust the valve clearance.

1-5
 GEN
SPECIAL TOOLS AND TESTERS
INFO
1 8. Flywheel puller
1 P/N. YU-33270
2 a P/N. 90890-01362
b P/N. 90890-01355 (M6)
This tool is necessary for removing the magneto rotor.
SVU1210

2
a

b
SVU1220

9. Pocket tester
P/N. YU-03112-C, 90890-03112
This instrument is necessary for checking the electrical system.

SVU1230

10. Ignition checker

P/N. YM-34487
This instrument is necessary for checking the ignition system
components.
SVU1240

11. Valve spring compressor

P/N. YM-04019, 90890-04019
This tool is used to remove the valve springs.

SVU1140

12. Piston ring compressor

P/N. YM-08037, 90890-05158
This tool is used to compress the piston rings when installing
the piston.
SVU1130

1-6
 INTRODUCTION/MAINTENANCE INTERVALS CHART/ INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
ADJ
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable machine
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to machines already in service as well as new machines that are being pre-
pared for sale. All service technicians should be familiar with this entire chapter.

MAINTENANCE INTERVALS CHART

Proper periodic maintenance is important. Especially important are the maintenance services
related to emissions control. These controls not only function to ensure air filter but are also vital
to proper engine operation and maximum performance.

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Pre- Initial Every
opera-
Item Routine 1 6 12 Remarks
tion
month months months
check
Handlebar • Looseness and play √ √ √ √
Skid • Mounting and parallel layout √ √ √
Auger height control • Working conditions √ √ √
• Working conditions √ √ √
Engine switch • Check for burnt-out bulb of oil
√ (*1)
level warning light
Auger clutch • Working conditions √ √ √
• Throttle/Choke lever opera-
√ √ √
tion
• Auger switch operation and
√ √ √ (*1)
working conditions
Controls
• Auger clutch operation √ √ √
• Shift lever operation √ √ √
• Shift lever adjustment status √ √ √
• Drive clutch operation √ √ √ √
Shear bolt guard • Looseness √ √ √
Auger and impeller • Mounting status and bending √ √ √
• Working conditions √ √ √
• Chute deflector/direction con-
√ √
trol lever operation
Chute
• Looseness and play √ √ √ √
• Wearing, cracks and breaking
√ √ √ √
of resin parts
V-belt • Wearing and damage √ √
Track • Tension √ √ √
Worm gear • Oil change √ √
• Oil level √
Transmission • Oil leakage √ √
• Oil change √ √
Ignition system • Checking the spark plug √ √ √

2-1
 INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
ADJ
Pre- Initial Every
opera-
Item Routine 1 6 12 Remarks
tion
month months months
check
Battery • Fluid level and specific gravity √ √
• Electric starter working condi-
√ √ √ √
tions
• Measurement of rated engine
√ √ √
Motor unit idle and operating speed
• Exhaust conditions √ √ √ √
• Compression pressure
• Valve clearance
√
√
2
• Oil leakage √
Lubricating system • Engine oil level √
• Engine oil change √ √
• Fuel leakage √ √
• Carburetor throttle valve and
√ √
choke valve conditions
• Carburetor adjustment condi-
Fuel system √ √
tions
• Fuel level √
Every 4
• Fuel hose replacement
years
• Check mounting for loose-
√ √
Muffler ness
• Muffler condition √
• Damage, including cracks,
Chassis and moving √
and loose parts
parts
• Lubricating each part √ √ √
Any troubles noticed when previously operating the
√
Snowblower.
(*1). .. YS928J only

2-2
 INSP
FUEL TANK AND AIR FILTER CASE
ADJ

FUEL TANK AND AIR FILTER CASE

(YT624E/YT624EDJ)

11 Nm (1.1 m · kgf, 7.9 ft · lbf)

9
8

3
5
2

6
7 Nm (0.7 m · kgf, 5 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the fuel tank and air fil- Remove the parts in the order listed.
ter case
1 Cover 1
2 Air filter case cap 1
3 Element fitting plate 1
4 Plate 1
5 Air filter case 1
6 Air duct 1
7 Gasket 1
8 Clip/Fuel hose 1/1 Turn the fuel cock lever to the “STOP”
position before removing.
9 Fuel tank assembly 1
For installation, reverse the removal pro-
cedure.

2-3
 INSP
FUEL TANK AND AIR FILTER CASE
ADJ

(YT1232ED)

7 Nm (0.7 m · kgf, 5 ft · lbf)

1
4

2 3

Order Job/Parts to remove Q’ty Remarks

Removing the fuel tank and air fil- Remove the parts in the order listed.
ter case
1 Link cover 1
2 Air duct 1
3 Air filter case cap 1
4 Fuel hose/Clip 1/1 Turn the fuel cock lever to the “STOP”
position before removing.
5 Fuel tank assembly 1
For installation, reverse the removal pro-
cedure.

2-4
 INSP
COVERS AND FUEL TANK
ADJ

COVERS AND FUEL TANK

(YS928J)
11 Nm (1.1 m · kgf, 7.9 ft · lbf) 11 Nm (1.1 m · kgf, 7.9 ft · lbf)

5 6 3

7
8
9

7 1

11 Nm (1.1 m · kgf, 7.9 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the side covers, upper Remove the parts in the order listed.
cover, front cover and fuel tank
1 Left side cover 1 1
2 Right side cover 2 1
3 Battery cover 1
4 Fuel hose/Clip 1/1 Turn the fuel cock lever to the “STOP”
position before removing.
5 Fuel tank assembly 1
6 Collar/Cover 4 4/1
7 Working light connector 2 Disconnect the connector.
8 Upper cover 1
9 Front cover 1
For installation, reverse the removal pro-
cedure.

2-5
 INSP
MUFFLER
ADJ

MUFFLER
(YT624E)

4
3

6
5

1
2
10 Nm (1.0 m · kgf, 7.2 ft · lbf)

7 Nm (0.7 m · kgf, 5 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the muffler Remove the parts in the order listed.
1 Muffler 1 1
2 Exhaust gasket 1
3 Band 1
4 Cap 1
5 Plate washer 1
6 Muffler screen 1
7 Protector assembly 1
For installation, reverse the removal pro-
cedure.

2-6
 INSP
MUFFLER
ADJ

(YT624EDJ)

9 4

1
6
5

8 7

2
3
10 Nm (1.0 m · kgf, 7.2 ft · lbf)

7 Nm (0.7 m · kgf, 5 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the muffler Remove the parts in the order listed.
1 Cover 1
2 Muffler assembly 1
3 Exhaust gasket 1
4 Protector 1
5 Band 1
6 Cap 1
7 Plate washer 1
8 Muffler screen 1
9 Protector assembly 1
For installation, reverse the removal pro-
cedure.

2-7
 INSP
MUFFLER
ADJ

(YT1232ED)

6
5
4
3

7 Nm (0.7 m · kgf, 5 ft · lbf)

7 Nm (0.7 m · kgf, 5 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the muffler Remove the parts in the order listed.
1 Muffler 1
2 Exhaust gasket 1
3 Silencer band 1
4 Cap 1
5 Muffler screen 1 1
6 Spark arrester 1
7 Protector assembly 1
For installation, reverse the removal pro-
cedure.

2-8
 INSP
STEERING
ADJ
STEERING
CHECKING THE HANDLEBAR
1. Check:
9 Handlebar for looseness or rattle
Looseness/rattle → Tighten.

CHECKING THE AUGER HOUSING HEIGHT

2 CONTROL
3 (YT624E)
1. Check:
9 Height control operation
When the height control pedal 1 is in
the free position 3, check that the
handlebar can be moved upward or
1
downward smoothly, and when the
height control pedal is in the lock posi-
tion 2, check that the handlebar is sta-
tionary.
Incorrect → Apply grease to contacting
parts.

(YT624EDJ/YS928J/YT1232ED)
1. Check:
9 Height control operation
When holding the height control lever
1, check that the handlebar can be
moved upward or downward smoothly,
and when not holding the height con-
trol lever, check that the handlebar is
1 stationary.
Incorrect → Check the height control
assembly.
Apply grease to the contacting parts →
Check the release and lock cables, and
lubricates leads, and check the cable
for tension.

2-9
 INSP
STEERING/CONTROL
ADJ
A CHECKING THE SKID
1. Check:
9 Clearance a between the road sur-
2
face and the auger end

1 Clearance a between the road

surface and the auger end
a
(Factory set):
5 mm (0.2 in)

According to the road surface condi-

B
tions, loosen the bolts 1 to adjust the
clearance so that the auger end and
skids 2 are parallel with the road sur-
face.
NOTICE
When the road surface is uneven while
clearing snow, increase the clearance.

A YT624E/YT624EDJ/YS928J
B YT1232ED

CONTROL
CHECKING THE THROTTLE/CHOKE LEVER
1 1. Check:
9 Throttle/Choke lever operation
When operating the throttle/choke lever
1, check that it operates smoothly.
Incorrect → Adjust the cable.

CHECKING THE AUGER CLUTCH

(YT624E/YT624EDJ/YT1232ED)
1. Check:
9 Auger clutch operation
Start the engine, and check that the
auger rotates when holding the auger
clutch lever 1 and that it stops rotating
within 3 seconds when releasing the
lever.
It does not stop within 3 seconds →
Adjust the cable.
2-10
 INSP
CONTROL
ADJ
(YS928J)
2 1 1. Check:
9 Auger clutch lever operation
Start the engine and hold the drive
clutch lever 1.
Check that the auger rotates with the
auger clutch lever 2 pulled and that it
stops rotating with the drive clutch lever
released.

It does not rotate when pulled → Adjust

or replace the auger switch 3, or
replace the electromagnetic clutch 4.
4 It does not stop rotating when released
3 → Adjust or replace the auger switch,
or replace the electromagnetic clutch.

CHECKING THE SIDE CLUTCH LEVER

(YT1232ED)
1. Check:
9 Side clutch lever play

Side clutch lever play:

1 mm (0.04 in)

Out of specification → Loosen the lock-

nuts 1 and adjust using the adjuster
2.
2. Check:
9 Side clutch levers 1 operation
Right lever → Right turn
Left lever → Left turn
Start the engine and move the left and
right side clutch levers alternately, and
check that the Snowblower turns in the
correct direction.

2-11
 INSP
CONTROL
ADJ
CHECKING THE AUGER CLUTCH AND
DRIVE CLUTCH LEVERS
(YT624E/YT624EDJ/YT1232ED)
1. Check:
9 Auger clutch and drive clutch levers
operation
Hold the drive clutch lever 1, and
when also holding the auger clutch
lever 2, check that the auger clutch
lever is locked by the ratchet 3, and
A B remains locked even when releasing
the auger clutch lever, and also check
that the auger clutch lever remains
locked even if there is vibration.
Incorrect → Replace the ratchet or
apply grease to the ratchet.

A Ratchet when locked

B Ratchet when released

A CHECKING THE SHIFT LEVER

(YT624E/YT624EDJ/YS928J)
1. Check:
9 Shift Lever 1
Check that the shift lever operates with
load of 3–5 kg on the end.
It operates other than specified →
Adjust.

A YT624E/YT624EDJ
B YS928J
B
1

2. Adjust:
9 While measuring using the spring
scale, adjust and tighten the locknuts
1.
20 Nm (2.0 m · kgf, 14 ft · lbf)

2-12
 INSP
CONTROL
ADJ
ADJUSTING THE SHIFT LEVER “N”
(NEUTRAL) POSITION
(YT624E/YT624EDJ/YS928J)
1. Install:
9 Shift cable 1
Temporarily install the shift cable 1 to
the H.S.T. (transmission) side.
2. Check:
9 Shift lever “N” (neutral) position
Check that the shift lever comes to the
center position when the shift lever is
moved from the “F” (Forward) or “R”
(Reverse) position to the “N” (Neutral)
position.
Misaligned from center → Adjust.
3. Adjust:
9 Adjustment nut
Adjust the adjustment nut 2 on the
H.S.T. (transmission) side and tighten
the locknut 3 so that the 1/2 (half)
point a in the “N” (Neutral) position is
aligned with the “N”.
20 Nm (2.0 m · kgf, 14 ft · lbf)

CHECKING THE SHIFT LEVER

a a
(YT1232ED)
1. Check:
9 Shift lever play a
Check that the shift lever play is the
same on both the left and right.
Uneveness → Adjust.
2. Remove:
9 Rear cover

2-13
 INSP
CONTROL
ADJ
3. Adjust:
9 Shift lever play
Loosen the locknut 1 and adjust using
the turn buckle 2.
9 Turn buckle
Clockwise → Shift lever moves to the
right.
Counterclockwise → Shift lever moves
to the left.
NOTICE
Check that the lengths of both ends of the
turn buckle are the same.

4. Securely tighten the locknut.

ADJUSTING THE SHIFT LEVER “N”

(NEUTRAL) POSITION
(YT1232ED)
1. Check:
9 Shift lever “N” (Neutral) position
Check that the shift lever comes to the
center position when the shift lever is
moved from the “F” (Forward) or “R”
(Reverse) position to the “N” (Neutral)
position.
Misaligned from center → Adjust.
2. Remove:
9 Rod cover
9 Ball link nut 1
3. Adjust:
9 Shift lever “N” (Neutral) position
Loosen the locknut 2 and adjust using
the shift rod 1 3.
9 Shift rod
Clockwise → Shift lever moves toward
the “R” (Reverse) position.
Counterclockwise → Shift lever moves
toward the “F” (Forward) position.

2-14
 INSP
AUGER
ADJ
AUGER
CHECKING THE SHEAR BOLT
(YT624E)
1. Check:
9 Shear bolt 1
Cracks/damage → Replace.
Looseness → Tighten.
6.5 Nm (0.65 m · kgf, 4.7 ft · lbf)

A CHECKING THE SHEAR BOLT GUARD

MOUNTING BOLT
(YT624EDJ/YS928J/YT1232ED)
1. Check:
9 Shear bolt guard mounting bolt 1
Cracks/damage → Replace.
Looseness → Tighten.
(YS928J)
1
19 Nm (1.9 m · kgf, 13 ft · lbf)

(YT624EDJ/YT1232ED)
B
23 Nm (2.3 m · kgf, 16 ft · lbf)

1
A YT624EDJ/YS928J
B YT1232ED

1 1

CHECKING THE AUGER AND BLOWER

WARNING
Make sure that the engine has stopped
1 before checking.

1. Check:
9 Blower 1
2
9 Auger 2
Incorrect installing → Repair.
Cracks/damage/bends → Replace.

2-15
 INSP
AUGER
ADJ
CHECKING THE SCRAPER
1 1. Check:
9 Scraper 1
Incorrect installing → Adjust.
Wear/damage → Replace.

2. Adjust:
9 Scraper 1
A Loosen the scraper mounting nuts a
a
and mounting bolts b (no bolts for
b A YT1232ED) and adjust the clearance
between the scraper and road surface
by moving the scraper.

B Clearance
1 Direction A Increase

Direction B Decrease
B
A YT624E/YT624EDJ/YS928J
a A B YT1232ED

TIP
The clearance between the scraper and road
B surface must be equal to or greater than the
clearance between the auger and road sur-
1 face.

A CHECKING THE CHUTE DEFLECTOR

CONTROL LEVER
1. Check:
9 Chute deflector control lever operation
Check that the chute deflector 1
moves upward or downward using the
chute deflector control lever.
It does not move upward or downward
→ Adjust the chute control cable.

A YT624E
B
B YT624EDJ/YS928J/YT1232ED
1

2-16
 INSP
AUGER/V-BELT
ADJ
A 2. Check:
9 Chute deflector operation
Move the chute deflector control lever
1 1 (YS928J/YT1232ED) or chute
deflector control switch 1 (YT624E/
YT624EDJ). Check that the chute turns
left and right smoothly.
Incorrect → Check the ring gear bush,
apply grease to the ring gear bush,
check the switch, chute motor and bat-
B tery.

A YS928J/YT1232ED
B YT624E/YT624EDJ
1

A V-BELT
CHECKING THE AUGER V-BELT
(YT624E/YT624EDJ/YT1232ED)
WARNING
Make sure to disconnect the battery leads
1 before checking.

1. Remove:
9 Belt guard (YT624E/YT624EDJ)
B 9 Belt guard 1, 2 (YT1232ED)
Refer to “ENGINE” in chapter 3.
2. Check:
9 Auger V-belt 1
Cracks/wear/damage → Replace.
1 A YT624E/YT624EDJ
B YT1232ED

3. Measure:
9 Auger clutch cable play a
a Place the auger clutch in the off posi-
1
1 tion and measure the play between the
2 auger clutch lever 1 and stopper plug
2.
Play a between the auger clutch
lever and stopper plug
0–1 mm (0–0.04 in)

Out of specification → Adjust.

2-17
 INSP
V-BELT
ADJ
A 4. Adjust:
9 Auger clutch cable play
Place the auger clutch in the off posi-
tion, loosen the locknut 1 on the auger
clutch cable, and then adjust using the
cable adjuster 2.

A YT624E/YT624EDJ
B YT1232ED

TIP
If the auger clutch cable play cannot be
adjusted by step 4, place the clutch in the off
position and adjust the clearance a between
the tension spring 1 and cable end to the
specified clearance using cable adjuster 2.

Clearance a between the cable

end and tension spring (clutch in
the off position):
1.0–1.5 mm (0.04–0.06 in)

2-18
 INSP
V-BELT
ADJ
5. Check:
9 Auger clutch tension spring set length
2 a
a
Place the auger clutch in the on posi-
tion and measure the tension spring 1
set length.
1
Auger clutch tension spring set
length a:
(YT624E/YT624EDJ)
47 mm (1.85 in)
(YT1232ED)
52 mm (2.05 in)

Out of specification → Loosen the lock-

nuts 2 and adjust using the clutch
cable.

A 6. Check:
9 Clearance a between the auger V-belt
and belt finger 1
Place the clutch in the on position and
measure the clearance between the
auger V-belt and belt finger 1.

Clearance a between the auger

V-belt and belt finger:
(YT624E/YT624EDJ)
1.0–2.0 mm (0.04–0.08 in)
B
(YT1232ED)
1.0–3.0 mm (0.04–0.12 in)

A YT624E/YT624EDJ
B YT1232ED

2-19
 INSP
V-BELT
ADJ
A 7. Check:
a
9 Clearance a between the auger V-belt
and guide plate 1 1
Clearance b between the auger V-belt
and guide plate 2 2
Place the clutch in the on position and
1 measure.

Clearance a between the auger

V-belt and guide plate 1:
(YT624E/YT624EDJ)
A
1.0–2.0 mm (0.04–0.08 in)
(YT1232ED)
2 2.0–3.0 mm (0.08–0.12 in)
Clearance b between the auger
b V-belt and guide plate 2
(YT624E/YT624EDJ/YT1232ED)
2.0–3.0 mm (0.08–0.12 in)

Out of specification → Adjust.

B
A YT624E/YT624EDJ
B YT1232ED

NOTICE
a 9 When the auger clutch lever is in the off
1
position, make sure that the clutch is
disengaged.
9 After placing the auger clutch lever in
the off position, make sure that the
auger completely stops rotating within 3
B seconds.

2-20
 INSP
V-BELT
ADJ
(YS928J)
WARNING
Make sure to disconnect the battery leads
before checking.

1. Remove:
9 Front cover

2. Check:
9 Auger V-belt 1
Cracks/wear/damage → Replace.

3. Measure:
1 9 Auger clutch tension spring 1 set
length a.

Auger clutch tension spring set

a length a:
52 mm (2.05 in)

Out of specification → Adjust.

4. Adjust:
9 Auger clutch tension spring set length
a.
Loosen the locknut 1 and adjust using
the adjusting bolt 2.
a 2
1

2-21
 INSP
V-BELT
ADJ
A CHECKING THE DRIVE V-BELT
WARNING
Make sure to disconnect the battery leads
before checking.

1 1. Remove:
9 Belt guard (YT624E/YT624EDJ)
9 Front cover (YS928J)
9 Rear cover (YT1232ED)
B 2. Check:
9 Drive V-belt 1
Cracks/wear/damage → Replace.

A YT624E/YT624EDJ
1 B YS928J
C YT1232ED

A 3. Measure:
9 Drive clutch tension spring set length
a
Place the clutch in the on position and
measure the tension spring 1 set
length a.

Drive clutch tension spring set

length a:
47 mm (1.85 in)
B
Out of specification → Adjust.
a
A YT624E/YT624EDJ
B YS928J
C YT1232ED
1

2-22
 INSP
V-BELT
ADJ
C

4. Adjust:
9 Drive clutch tension spring set length
2 a
a
Place the clutch in the on position and
loosen the locknuts 2.
1 Adjust the tension spring 1 set length
a using drive clutch cable.

A 5. Measure:
(Except YS928J)
9 Clearance a between the drive V-belt
and belt finger 1
Place the clutch in the on position and
measure.

Clearance a between the drive

V-belt and belt guide
(YT624E/YT624EDJ)
1.0–2.0 mm (0.04–0.08 in)
B
(YT1232ED)
1.0–3.0 mm (0.04–0.12 in)

Out of specification → Adjust.

A YT624E/YT624EDJ
B YT1232ED

2-23
 INSP
V-BELT
ADJ
A 6. Measure:
9 Clearance a between the drive V-belt
and guide plate 3 1
Place the clutch in the on position and
1
measure.
a
Clearance a between the drive
V-belt and guide plate 3:
(YT624E/YT624EDJ)
2.0–3.0 mm (0.08–0.12 in)
(YS928J)
B
1.0–2.0 mm (0.04–0.08 in)
(YT1232ED)
4.0–5.0 mm (0.16–0.20 in)

1 Out of specification → Adjust.

A YT624E/YT624EDJ
B YS928J
a
C YT1232ED

2-24
 INSP
V-BELT
ADJ
REPLACING THE AUGER/DRIVE V-BELT
(YT624E/YT624EDJ)
WARNING
Make sure to disconnect the battery leads
before checking.

1. Remove:
9 Battery
9 Belt guard
Refer to “ENGINE” in chapter 3.

2. Remove:
2 1
9 Auger clutch cable 1
9 Drive clutch cable 2
9 Bracket 1 3
3 TIP
Disconnect the tension spring from the cable
ends of the auger clutch cable 1 and drive
clutch cable 2.

1 3. Remove:
9 Guide plate 1 1
9 Auger V-belt finger
9 Drive clutch V-belt finger
Refer to “ENGINE” in chapter 3.

4. Remove:
9 Body lower plate 1

2-25
 INSP
V-BELT
ADJ
5. Remove:
9 Guide plate 2 1
9 Guide plate 3
Refer to “TRANSMISSION” in chapter 5.

6. Remove:
1
9 Auger V-belt 1
TIP
9 Remove the auger V-belt 1 by turning the
pulley 2.
3 9 Push the idler arm 3 toward the V-belt and
2 remove the auger V-belt 1 from the auger
pulley.

7. Remove:
1 9 Drive V-belt 1
TIP
Remove the drive V-belt 1 by turning the pul-
ley 2.

(YS928J)
WARNING
Make sure to disconnect the battery leads
before checking.

1. Remove:
9 Front cover
Refer to “COVERS AND FUEL TANK”.

2. Remove:
1 9 Auger V-belt 1
TIP
9 Remove the auger V-belt 1 by turning the
2 pulley 2.
9 Push the idler arm 3 toward the V-belt and
3 remove the auger V-belt 1 from the auger
pulley.

2-26
 INSP
V-BELT
ADJ
3. Remove:
1 9 Electromagnetic clutch 1
9 Guide plate 2
9 Tension spring
9 Spring sheet

4. Remove:
1 9 Guide plate 2
Refer to “TRANSMISSION” in chapter 5.
9 Drive V-belt 1

TIP
2 Remove the drive V-belt 1 by turning the pul-
ley 2.

(YT1232ED)
WARNING
Make sure to disconnect the battery leads
before checking.

1. Remove:
9 Belt guard
9 Belt guard 2
Refer to “ENGINE” in chapter 3.
2. Remove:
9 Guide plate 1 1
9 Guide plate 2

2-27
 INSP
V-BELT
ADJ
1 3. Remove:
9 Auger V-belt 1
TIP
9 Remove the auger V-belt 1 by turning the
pulley 2.
3 9 Push the idler arm 3 toward the V-belt and
2 remove the auger V-belt 1 from the auger
pulley.

4. Remove:
9 Top cover
2
9 Battery
Refer to “ENGINE” in chapter 3.
1 9 Battery tray 1
9 H.S.T. oil reservoir bracket 2

5. Remove:
1 9 Guide plate 3 1
9 Guide plate 4
Refer to “TRANSMISSION” in chapter 5.

6. Remove:
9 Drive V-belt 1
1
2 TIP
Remove the drive V-belt 1 by turning the pul-
ley 2.

2-28
 INSP
TRANSMISSION
ADJ
TRANSMISSION
a CHECKING THE TRACK
1. Check:
9 Track slack a
Place the Snowblower on a level sur-
face and check the slack when the
center of the track is pressed using the
specified force.

Track slack:
(YT624E/YT624EDJ/YS928J)
11–16 mm (0.43–0.63 in)/
5 kgf (11 lbf)
(YT1232ED)
20–30 mm (0.79–1.18 in)/
10 kgf (22 lbf)

Out of specification → Adjust.

2. Loosen:
9 Idler roller tightening nut 1

1
3 Adjust:
A 9 Track slack
2 Loosen the locknut 1 and adjust using
the adjuster 2.

Slack
A B Direction A Increase

Direction B Decrease
1
4. Tighten:
B 9 Idler roller tightening nut
1
(YT624E/YT624EDJ/YS928J)
54 Nm (5.4 m · kgf, 38 ft · lbf)
2
(YT1232ED)
24 Nm (2.4 m · kgf, 17 ft · lbf)
B

A A YT624E/YT624EDJ/YS928J
B YT1232ED

2-29
 INSP
TRANSMISSION
ADJ
WORM CASE OIL

Recommended worm case oil:

YAMALUBE
SAE 10W-40
Recommended worm case oil
grade:
API Service SE type or higher
Worm case oil quantity:
(YT624E/YT624EDJ/YS928J)
0.07 L
(0.073 US qt, 0.062 lmp qt)
(YT1232ED)
0.08 L (0.08 US qt, 0.07 imp qt)

A CHANGING THE WORM CASE OIL

WARNING
Disconnect the battery leads before chang-
ing.

2
1. Remove:
1 9 Drain bolt 1
9 Drain plug 2
2. Drain the worm case oil.
3. Install:
B 2
9 Drain bolt (Tighten up to the end sur-
face)
4. Fill with the specified amount of worm
case oil.
5. Install:
9 Drain plug (Tighten up to the end sur-
face)
1
A YT624E/YT624EDJ/YS928J
B YT1232ED

CHECKING THE HYDROSTATIC

TRANSMISSION (H.S.T.) OIL LEVEL
TIP
Check the oil level before starting the engine
and when the transmission (H.S.T.) oil is cool.

2-30
 INSP
TRANSMISSION
ADJ
1. Check:
9 Transmission (H.S.T.) oil level
Place the Snowblower on a level sur-
face and check that the transmission
(H.S.T.) oil is between the upper level
a mark a and lower level mark b.
b
At or below lower level mark → Add to
upper level mark.

Recommended H.S.T. oil:

Diesel engine oil
10W-30
Recommended H.S.T. oil grade:
CD or higher
H.S.T. oil quantity:
(YT624E/YT624EDJ/YS928J)
0.92 L (0.97 US qt, 0.80 lmp qt)
(YT1232ED)
0.5 L (0.53 US qt, 0.44 lmp qt)

TRANSMISSION OIL
(YT1232ED)

Recommended transmission oil:

YAMALUBE
SAE 10W-40
Recommended transmission oil
grade:
API Service SE type or higher
Transmission oil quantity:
2.0 L (2.11 US qt, 1.76 lmp qt)

CHANGING THE TRANSMISSION OIL

(YT1232ED)
WARNING
Disconnect the battery leads before
changing.

1. Remove:
9 Drain bolt 1
9 Drain plug 2
2. Drain the transmission oil.
3. Install:
9 Drain bolt
30 Nm (3.0 m · kgf, 21 ft · lbf)

4. Fill with the specified amount of transmis-

sion oil.
5. Install:
9 Drain plug
2-31
 INSP
ELECTRICAL
ADJ
ELECTRICAL
HANDLING THE BATTERY
WARNING
9 Electrolyte is poisonous and dangerous
since it contains sulfuric acid, which
causes severe burns. Avoid any contact
with skin, eyes or clothing and always
shield your eyes when working near bat-
teries. In case of contact, administer the
following FIRST AID.
9 EXTERNAL: Flush with plenty of water.
9 INTERNAL: Drink large quantities of
water or milk and immediately call a
physician.
9 EYES: Flush with water for 15 minutes
and seek prompt medical attention.
9 Batteries produce explosive hydrogen
gas. Therefore, keep sparks, flames, cig-
arettes, etc., away from the battery and
provide sufficient ventilation when
charging it in an enclosed space.
9 KEEP THIS AND ALL BATTERIES OUT
OF THE REACH OF CHILDREN.

CHECKING THE BATTERY FLUID LEVEL

1. Remove:
a 9 Battery cover
1 2. Check:
2 9 Battery fluid level
Check that the fluid level a falls
between the upper 1 and lower 2 lev-
els.
Below the specified level → Add dis-
tilled water up to the upper level.

2-32
 INSP
ELECTRICAL
ADJ
CHECKING THE BATTERY FLUID SPECIFIC
q w GRAVITY
1. Check:
9 Fluid specific gravity
Check the specific gravity of the cells.
Hydrometer 1
Line of sight when measuring 2

Battery fluid specific gravity:

1.280 at 20 °C (68 °F)

Out of specification → Recharge.

CHARGING
9 Battery charger 1
Charge using 10 Ah (i.e., 1/10th cur-
rent of the battery capacity) until the
specific gravity is within specification.

10 Ah current:
(YT624E/YT624EDJ)
q 1.4 A max.
(YS928J/YT1232ED)
2.7 A max.

WARNING
9 Batteries produce explosive hydrogen
gas. Therefore, keep sparks, flames, cig-
arettes, etc., away from the battery and
provide sufficient ventilation when
charging it in an enclosed space.
9 Remove the battery cap.
9 Do not quick charge a battery as it may
damage to the battery.
9 Make sure the battery fluid temperature
does not rise above 45 °C (113 °F).
9 After charging has been completed,
install the cap, wash with water, and
wipe down using the dry rags.

2-33
 INSP
ELECTRICAL
ADJ
CHECKING THE TERMINAL
1. Check:
9 Loose/corroded terminals
Looseness → Tighten.
Corrosion → Pour over warm water,
and clean using a soft wire brush.
NOTICE
After cleaning and tightening, apply a thin
coat of grease to the terminals.

CHECKING THE SPARK PLUG

WARNING
Inspect and adjust the areas around the
cylinder head after the engine has cooled
down completely.

NOTICE
Before removing the spark plug, use com-
pressed air to clean the cylinder head
cover to prevent dirt from falling into the
1
engine.
2
1. Remove:
9 Spark plug cap
9 Spark plug
2. Check:
9 Electrode 1
Wear/damage → Replace.
9 Insulator color 2
3. Measure:
9 Spark plug gap a
a Use a wire gauge or thickness gauge.
Out of specification → Re-gap.
If necessary, clean the spark plug with
a spark plug cleaner.

Spark plug gap:

0.7–0.8 mm (0.027–0.031 in)
Standard spark plug
(with resistor):
BPR4ES (NGK)

Before installing the spark plug, clean

the gasket surface and plug surface.

2-34
 INSP
ELECTRICAL/ENGINE
ADJ
4. Tighten:
9 Spark plug
TIP
To prevent threads from being damaged, tem-
porally tighten 1 the spark plug before tight-
ening it to the specified torque 2.

q
w Spark plug:
20 Nm (2.0 m · kgf, 14 ft · lbf)

ENGINE
ADJUSTING THE ENGINE IDLING SPEED
1. Remove:
(YS928J)
9 Left side cover
(Except YS928J)
9 Carburetor cover

2. Attach:
9 Digital tachometer
Attach the digital tachometer clip to the
high tension lead.

Digital tachometer:
YU-39951-B, 90890-06760

2-35
 INSP
ENGINE
ADJ
A 3. Tighten the pilot screw 1 all the way, and
turn it out the specified number of turns.

A YT624E/YT624EDJ/YT1232ED
B YS928J

Pilot screw specified number of

turns out:
(YT624E/YT624EDJ)
1-3/4
(YS928J)
B
1-7/8
(YT1232ED)
1-1/2

4. Start the engine and warm it up.

q

A 5. Adjust to the specified engine idling

speed using the throttle stop screw 1.

Engine idling speed:

2300 ± 100 r/min

A YT624E/YT624EDJ
B YS928J
C YT1232ED

B
q

2-36
 INSP
ENGINE
ADJ
CHECKING THE RATED ENGINE SPEED
1. Attach:
9 Digital tachometer
Attach the digital tachometer clip to the
high tension lead.

Digital tachometer:
YU-39951-B, 90890-06760

2. Start the engine and warm it up.

3. Move the throttle/choke lever 1 to the
A
“FAST” and check the rated engine
1 speed.

Rated engine speed:

3800 ± 50 r/min

Out of specification → Adjust.

A YT624E/YT624EDJ
B YT1232ED
B C YS928J
1

C
1

4. Adjust:
9 Rated engine speed
Loosen the locknut 1 on the throttle/
choke lever cable and adjust the
adjusting nut 2.
TIP
Move the throttle lever to the “SLOW” position,
and check that the engine speed slows down
to the idling speed.
2-37
 INSP
ENGINE
ADJ
A ADJUSTING THE GOVERNOR
1. Remove:
9 Fuel tank
2. Loosen:
9 Governor arm mounting bolt 1
Loosen the bolt, and turn the governor
arm clockwise until it stops. (Fully open
position)

A YT624E/YT624EDJ
B YS928J
B
q C YT1232ED

2-38
 INSP
ENGINE
ADJ
A 3. Holding the governor arm in the fully
open position, turn the governor fork 1
clockwise until it stops.

A YT624E/YT624EDJ
B YS928J
C YT1232ED

B
q

4. Tighten:
9 Governor arm mounting bolt
(YT624E/YT624EDJ/YS928J)
8 Nm (0.8 m · kgf, 5.8 ft · lbf)

(YT1232ED)
10 Nm (1.0 m · kgf, 7.2 ft · lbf)

Holding both the governor arm and

governor fork in the fully open position,
tighten the bolt.
TIP
Make sure that the governor arm and gover-
nor fork are not idling.

5. Check:
9 Rated engine speed

2-39
 INSP
ENGINE
ADJ
CHECKING THE COMPRESSION
PRESSURE
TIP
Measure the compression after checking and
adjusting the valve clearance.

1. Warm up the engine.

2. Remove:
9 Spark plug
3. Attach:
9 Compression gauge 1
q
Attach to the plug hole so that there is
no compression leak.

Compression gauge:
YU-33223, 90890-03081

4. Measure:
9 Compression pressure
Fully open the throttle lever, crank the
engine, and then read the maximum
value indicated on the compression
gauge.

Compression pressure:
(YT624E/YT624EDJ/YS928J)
400–600 kPa (4.0–6.0 kgf/cm2,
58–87 psi)
(YT1232ED)
450–550 kPa (4.5–5.5 kgf/cm2,
65.25–79.75 psi)

TIP
9 Make sure that the battery is fully charged
when measuring.
9 Make sure that there is no compression
leakage from the connecting section of the
gauge.
9 If the compression pressure is lower than
the specified compression pressure, fill with
4-stroke oil into the cylinder, and then
measure the compression pressure again.

2-40
 INSP
ENGINE
ADJ
WARNING
To prevent sparking when cranking the
engine, ground the high tension cord.

Testing steps (below minimum level):

9 Squirt a few drops of oil into the cylinder.
9 Measure the compression again.

Reading Diagnosis

If higher than 9 Worn cylinder, piston,

without oil and piston ring
9 Defective piston, ring(s),
valve(s), and cylinder
If the same
head gasket
as without oil
9 Improper valve timing
and valve clearance

Testing steps (above maximum level):

9 Check the cylinder head, valve surfaces,
and piston crown for carbon deposits.

CHECKING AND ADJUSTING THE VALVE

CLEARANCE
NOTICE
Valve clearance checking and adjustment
should be made on a cold engine.

1. Remove:
9 Left side cover (YS928J)
9 Front cover (YS928J)
9 Fuel tank
w 9 Muffler
e 9 Carburetor cover
9 Cylinder head cover 1
9 Cylinder head cover gasket
q 9 Spark plug cap 2
9 Spark plug 3
9 Cylinder air shroud

2-41
 INSP
ENGINE
ADJ
2. Set the piston at top dead center (TDC).
(When the screwdriver inserted into the
spark plug hole reaches the highest posi-
tion.)

A 3. Check:
9 Valve clearance

Intake and exhaust valve (cold):

0.08–0.12 mm
(0.0031–0.0047 in)

Out of specification → Adjust.

A YT624E/YT624EDJ/YS928J
B YT1232ED
B

A 4. Adjust:
2 9 Valve clearance
Loosen the locknut 1 and adjust using
the adjuster 2.

1 Adjuster Valve clearance

Turn clockwise Decrease

Turn
Increase
counterclockwise
B
A YT624E/YT624EDJ/YS928J
B YT1232ED

2-42
 INSP
ENGINE
ADJ
A 5. Tighten:
(YT624E/YT624EDJ/YS928J)
9 Locknut 1
10 Nm (1.0 m · kgf, 7.2 ft · lbf)

q Hold the adjuster using the spanner

and tighten the locknut.
(YT1232ED)
9 Locknut
7 Nm (0.7 m · kgf, 5 ft · lbf)

B Hold the adjuster using the valve

adjusting tool 1 and tighten the lock-
nut.

Tappet adjusting tool:

YM-A5970, 90890-01311

Check:
9 Valve clearance

A YT624E/YT624EDJ/YS928J
3 1 B YT1232ED
2

CHECKING THE ENGINE OIL LEVEL

WARNING LIGHT
(YS928J)
1. Check:
9 Engine oil level warning light 1
When the engine switch key is half-way
between “STOP” 2 and “ON” 3, check
A that the engine oil level warning light
comes on.
It does not come on → Bulb is burnt
out.
1
CHECKING THE ENGINE OIL
TIP
Make sure to check the engine oil level on a
level surface.
B
1. Remove:
1 9 Right side cover (YS928J)
9 Engine oil filler cap 1

A YT624E/YT624EDJ/YT1232ED
B YS928J

2-43
 INSP
ENGINE
ADJ
2. Check:
9 Engine oil level
After leaving the engine idling for 2–3
minutes, stop the engine, wait a further
a 2–3 minutes, and then check that the
oil level is between the upper level a
b and lower level b.
Below lower level → Add to upper level.

A CHANGING THE ENGINE OIL

1. Remove:
9 Drain bolt 1
9 Oil filler cap 2
Warm up the engine, and then drain
2 the engine oil.

A YT624E/YT624EDJ/YT1232ED
1 B YS928J

B 2. Install:
9 Gasket
9 Drain bolt
(YT624E/YT624EDJ)
w 17 Nm (1.7 m · kgf, 12 ft · lbf)

(YS928J)
30 Nm (3.0 m · kgf, 21 ft · lbf)

q (YT1232ED)
20 Nm (2.0 m · kgf, 14 ft · lbf)

3. Fill with the specified amount of engine

–30 –20 –10 0 10 20 30 40 °C
oil.

Recommended engine oil:

SAE 5W-30
YAMALUBE SAE 5W-30
Recommended engine oil grade:
–20 0 10 30 50 70 90 110 °F API Service SE type or higher
Engine oil quantity:
(YT624E/YT624EDJ)
0.6 L (0.63 US qt, 0.53 lmp qt)
(YS928J)
1.0 L (1.06 US qt, 0.88 lmp qt)
(YT1232ED)
1.1 L (1.16 US qt, 0.97 lmp qt)

4. Install:
9 Oil filler cap
5. Warm up the engine, and then check the
engine oil level.
2-44
 INSP
ENGINE
ADJ
CHECKING THE FUEL LEAK
1. Check:
9 Fuel leak
Check that there are no fuel leaks from
the fuel tank, fuel cock, fuel pipe, or
carburetor.

CHECKING THE FUEL COCK STRAINER

3
Turn off the fuel cock, and then remove the
2
fuel strainer cup and remove any foreign
materials from the inside.
1. Remove:
1 9 Fuel strainer cup 1
9 Filter 2
9 Gasket 3

A CHECKING AND CLEANING THE MUFFLER

SCREEN
1. Remove:
9 Band 1
9 Muffler screen assembly 2
9 Muffler assembly
NOTICE
Because the muffler is still very hot imme-
diately after the engine has stopped,
checking should be made after the engine
B
has completely cooled down.

A YT624E/YT624EDJ/YT1232ED
B YS928J

w
q

2-45
 INSP
ENGINE
ADJ
2. Check and clean:
9 Muffler screen and muffler
Remove any carbon and dirt, etc., from
inside the muffler screen using a wire
brush.
Lightly tap the muffler using a soft
hammer to remove the carbon.

A 3. Install:
9 Muffler assembly
9 Muffler screen assembly 1
9 Band 2

A YT624E/YT624EDJ/YT1232ED
B YS928J

2-46
 ENGINE ENG
ENGINE
ENGINE
COVERS AND CABLES (YT624E/YT624EDJ)

11 Nm (1.1 m · kgf, 7.9 ft · lbf)

28 Nm (2.8 m · kgf, 20 ft · lbf) 13
9
8
4
5

1 10
11
3 12
2

Order Job/Parts to remove Q’ty Remarks

Removing the covers and cables Remove the parts in the order listed.
Fuel tank Refer to “FUEL TANK AND AIR FILTER
CASE” in chapter 2.
1 Battery cover 1
2 Negative battery lead 1
3 Positive battery lead 1
4 Ground lead 2
5 Starter motor lead 1
6 TCI unit lead 1
7 Charging coil lead 2
8 Cover 1
9 Belt guard 1
10 Chute holder 1
11 Holder spring 1

3-1
 ENGINE ENG

11 Nm (1.1 m · kgf, 7.9 ft · lbf)

28 Nm (2.8 m · kgf, 20 ft · lbf) 13
9
8
4
5

3
7

1 10
11
3 12
2

Order Job/Parts to remove Q’ty Remarks

12 Holder bushing 1
13 Bracket assembly 1
For installation, reverse the removal pro-
cedure.

3-2
 ENGINE ENG

BELT GUIDE, BELT AND ENGINE (YT624E/YT624EDJ)

28 Nm (2.8 m · kgf, 20 ft · lbf)

11 Nm (1.1 m · kgf, 7.9 ft · lbf)

6
2

3 1

11 Nm (1.1 m · kgf, 7.9 ft · lbf)

5 4

Order Job/Parts to remove Q’ty Remarks

Removing the belt guide, belt and Remove the parts in the order listed.
engine
1 Guide plate 1 1
2 Auger V-belt finger 1
3 Drive V-belt finger 1
4 Auger V-belt 1 Refer to “REPLACING THE AUGER/
5 Drive V-belt 1 DRIVE V-BELT” in chapter 2.
6 Engine assembly 1
For installation, reverse the removal pro-
cedure.

3-3
 ENGINE ENG

CABLES AND MUFFLER (YS928J)

12 Nm (1.2 m · kgf, 8.6 ft · lbf)

5
20 Nm (2.0 m · kgf, 14 ft · lbf) 3
15
4

14
13
6

12 1 8
2 7

11

9 10

Order Job/Parts to remove Q’ty Remarks

Removing the cables and muffler Remove the parts in the order listed.
Left and right side covers, fuel tank Refer to “COVERS AND FUEL TANK” in
upper cover and front cover chapter 2.
1 Negative battery lead 1
2 Positive battery lead 1
3 Ground lead 1
4 Starter motor lead 1
5 TCI unit lead 1 Disconnect the connector.
6 Electromagnetic clutch lead 1 Disconnect the coupler.
7 Oil level switch lead 1 Disconnect the connector.
8 Auto choke lead 1 Disconnect the connector.
9 Battery 1
10 Frame carrier 1 1
11 Frame carrier 2 1

3-4
 ENGINE ENG

12 Nm (1.2 m · kgf, 8.6 ft · lbf)

5
20 Nm (2.0 m · kgf, 14 ft · lbf) 3
15
4

14
13
6

12 1 8
2 7

11

9 10

Order Job/Parts to remove Q’ty Remarks

12 Guide plate 1 1
13 Muffler protector 2 1 Loosen the engine mounting bolt, ele-
vate the engine, and then remove the
muffler protector 2 by removing the
engine mounting bolt.
14 Muffler/Gasket 1/1
15 Muffler protector 1 1
For installation, reverse the removal pro-
cedure.

3-5
 ENGINE ENG

V-BELT AND ENGINE (YS928J)

48 Nm (4.8 m · kgf, 34 ft · lbf)

1
2

Order Job/Parts to remove Q’ty Remarks

Removing the V-belt and engine Remove the parts in the order listed.
Carburetor Refer to “CARBURETOR” in chapter 4.
1 Drive V-belt 1 Refer to “REPLACING THE AUGER/
2 Auger V-belt 1 DRIVE V-BELT” in chapter 2.
3 Engine assembly 1
For installation, reverse the removal pro-
cedure.

3-6
 ENGINE ENG

COVERS AND CABLES 1 (YT1232ED)

7 1

3
6

8
9

Order Job/Parts to remove Q’ty Remarks

Removing the covers and cables 1 Remove the parts in the order listed.
Fuel tank Refer to “FUEL TANK AND AIR FILTER
CASE” in chapter 2.
Muffler Refer to “MUFFLER” in chapter 2.
1 Cover 1 Open.
2 Rear cover 1
3 Negative battery lead 1
4 Positive battery lead 1
5 Working light lead connector 2 Disconnect.
6 Throttle cable 1
7 Top cover 1
8 Belt retainer 2 1
9 Belt retainer 1
For installation, reverse the removal pro-
cedure.

3-7
 ENGINE ENG

COVERS AND CABLES 2 (YT1232ED)

Order Job/Parts to remove Q’ty Remarks

Removing the covers and cables 2 Remove the parts in the order listed.
1 Belt guard 1
2 Belt guard 2 1
3 Starter motor lead 1
4 TCI magneto lead 2
5 TCI unit lead 1
6 Ground lead 2
For installation, reverse the removal pro-
cedure.

3-8
 ENGINE ENG

BELT GUIDE, BELT AND ENGINE (YT1232ED)

54 Nm (5.4 m · kgf, 38 ft · lbf)

16 Nm (1.6 m · kgf, 11 ft · lbf)

5

2 1
4
3

Order Job/Parts to remove Q’ty Remarks

Removing the belt guide, belt and Remove the parts in the order listed.
engine
1 Auger V-belt finger 1
2 Drive V-belt finger 1
3 Auger V-belt 2 Refer to “REPLACING THE AUGER/
4 Drive V-belt 1 DRIVE V-BELT” in chapter 2.
5 Engine assembly 1
For installation, reverse the removal pro-
cedure.

3-9
 CYLINDER HEAD ENG

CYLINDER HEAD
(YT624E/YT624EDJ)

1 1st 12 Nm (1.2 m · kgf, 8.6 ft · lbf)

2nd 20 Nm (2.0 m · kgf, 14 ft · lbf)
4

7 6
4

8
1st 12 Nm (1.2 m · kgf, 8.6 ft · lbf)
2nd 20 Nm (2.0 m · kgf, 14 ft · lbf)

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

2
5

Order Job/Parts to remove Q’ty Remarks

Removing the cylinder head cover Remove the parts in the order listed.
and cylinder head
Fuel tank Refer to “FUEL TANK AND AIR FILTER
Air filter case CASE” in chapter 2.
Carburetor Refer to “CARBURETOR” in chapter 4.
Muffler Refer to “MUFFLER” in chapter 2.
1 Tank stay 1
2 Cylinder head cover 1
3 Cylinder head cover gasket 1
4 Spark plug cap/Spark plug 1/1
5 Cylinder air shroud 1
6 Cylinder head assembly 1
7 Cylinder head gasket 1
8 Dowel pin 2

3-10
 CYLINDER HEAD ENG

1 1st 12 Nm (1.2 m · kgf, 8.6 ft · lbf)

2nd 20 Nm (2.0 m · kgf, 14 ft · lbf)
4

7 6
4

8
1st 12 Nm (1.2 m · kgf, 8.6 ft · lbf)
2nd 20 Nm (2.0 m · kgf, 14 ft · lbf)

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

2
5

Order Job/Parts to remove Q’ty Remarks

9 Valve push rod 2
For installation, reverse the removal pro-
cedure.

3-11
 CYLINDER HEAD ENG

(YS928J)

1st 12 Nm (1.2 m · kgf, 8.6 ft · lbf)

2nd 44 Nm (4.4 m · kgf, 31 ft · lbf)

2
3
6

5
8
7
11 Nm (1.1 m · kgf, 7.9 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the cylinder head Remove the parts in the order listed.
Left and right side covers, fuel tank Refer to “COVERS AND FUEL TANK” in
upper cover and front cover chapter 2.
Muffler Refer to “ENGINE”.
Carburetor Refer to “CARBURETOR” in chapter 4.
1 Cylinder head cover 1
2 Cylinder head cover gasket 1
3 Spark plug 1
4 Cylinder air shroud 1
5 Cylinder head assembly 1
6 Cylinder head gasket 1
7 Dowel pin 2
8 Valve push rod 2
For installation, reverse the removal pro-
cedure.

3-12
 CYLINDER HEAD ENG

(YT1232ED)

1st 12 Nm (1.2 m · kgf, 8.6 ft · lbf) 1st 12 Nm (1.2 m · kgf, 8.6 ft · lbf)
2nd 50 Nm (5.0 m · kgf, 36 ft · lbf) 2nd 50 Nm (5.0 m · kgf, 36 ft · lbf)

4 6

2
5
8
7

11 Nm (1.1 m · kgf, 7.9 ft · lbf)

1
3

Order Job/Parts to remove Q’ty Remarks

Removing the cylinder head cover Remove the parts in the order listed.
and cylinder head
Fuel tank Refer to “FUEL TANK AND AIR FILTER
CASE” in chapter 2.
Muffler Refer to “MUFFLER” in chapter 2.
Carburetor Refer to “CARBURETOR” in chapter 4.
1 Cylinder head cover 1
2 Cylinder head cover gasket 1
3 Air shroud 1
4 Spark plug cap/Spark plug 1/1
5 Cylinder head assembly 1
6 Cylinder head gasket 1
7 Dowel pin 2
8 Push rod 2
For installation, reverse the removal pro-
cedure.

3-13
 CYLINDER HEAD ENG
CHECKING THE CYLINDER HEAD
1. Check:
9 Cylinder head combustion chamber
Check the combustion chamber for car-
bon deposits.
Any carbon deposits → Remove.
TIP
Be sure not to damage the contact surface of
the cylinder.

2. Check:
9 Cylinder head
Cracks/damage around the hole of
spark plug → Replace.
3. Measure:
9 Cylinder head warpage
Measure the warpage on the contact
surface of the cylinder head at six
points using the straight edge and
thickness gauge.

Warpage limit:
0.1 mm (0.004 in)

Out of specification → Resurface or

replace.

4
ASSEMBLING THE CYLINDER HEAD
2 1. Check:
9 Cylinder head bolts “1” to “4”.
(YT624E/YT624EDJ)
1st: 12 Nm (1.2 m · kgf, 8.6 ft · lbf)
2nd: 20 Nm (2.0 m · kgf, 14 ft · lbf)

(YS928J)
×
1 3 4 1st: 12 Nm (1.2 m · kgf, 8.6 ft · lbf)
2nd: 44 Nm (4.4 m · kgf, 31 ft · lbf)

(YT1232ED)
1st: 12 Nm (1.2 m · kgf, 8.6 ft · lbf)
2nd: 50 Nm (5.0 m · kgf, 36 ft · lbf)

TIP
Tighten the bolts to the specified torque in two
steps and in order from “1” to “4”.

3-14
 VALVE ENG

VALVE
(YT624E/YT624EDJ/YS928J)

10
E
5
M
7
6

M
M
2
4
3 1
2

10 Nm (1.0 m · kgf, 7.2 ft · lbf) 3

1

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the rocker arm, valve Remove the parts in the order listed.
and valve spring
Cylinder head Refer to “CYLINDER HEAD”.
1 Locknut/Adjuster 2/2
2 Rocker arm 2
3 Bolt 2
4 Push rod guide 1
5 Valve cotter 2
6 Valve spring retainer 2
7 Valve spring 2
8 Intake valve 1
9 Exhaust valve 1
10 Valve stem seal 1
For installation, reverse the removal pro-
cedure.

3-15
 VALVE ENG

(YT1232ED)

7 Nm (0.7 m · kgf, 5 ft · lbf) 2

M

3
6 5
9 7
10

7 Nm (0.7 m · kgf, 5 ft · lbf) 2

8 5

4
3
6
7

E 1

Order Job/Parts to remove Q’ty Remarks

Removing the rocker arm, valve Remove the parts in the order listed.
and valve spring
Cylinder head Refer to “CYLINDER HEAD”.
1 Rocker arm shaft 1
2 Locknut 2
3 Adjuster 2
4 Rocker arm 2
5 Valve cotter 2
6 Valve spring retainer 2
7 Valve spring 2
8 Exhaust valve 1
9 Intake valve 1
10 Valve stem seal 1
For installation, reverse the removal pro-
cedure.

3-16
 VALVE ENG
REMOVING THE VALVE AND VALVE
5 1 SPRING
2 1. Remove:
9 Valve cotter 1
3
9 Valve spring retainer 2
9 Valve spring 3
4 9 Valve 4
Remove the parts using the valve
spring compressor 5.
TIP
Do not compress the spring more than neces-
sary.

Valve spring compressor:

YM-04019, 90890-04019

CHECKING THE VALVE AND VALVE

SPRING
1. Measure:
9 Valve stem length a
9 Valve head diameter b

(YT624E/YT624EDJ)
Valve stem length:
SCF3180
Intake: 65.9 mm (2.59 in)
Exhaust: 66.2 mm (2.61 in)
Valve head diameter:
Intake: 24.0 mm (0.94 in)
Exhaust: 22.0 mm (0.87 in)
(YS928J)
Valve stem length:
Intake: 65.9 mm (2.59 in)
Exhaust: 66.2 mm (2.61 in)
Valve head diameter:
Intake: 29.0 mm (1.14 in)
Exhaust: 25.0 mm (0.98 in)
(YT1232ED)
Valve stem length:
Intake: 88.1 mm (3.46 in)
Exhaust: 87.9 mm (3.46 in)
Valve head diameter:
Intake: 32.0 mm (1.26 in)
Exhaust: 27.0 mm (1.06 in)

Out of specification → Replace.

3-17
 VALVE ENG
2. Measure:
9 Valve stem diameter a

a (YT624E/YT624EDJ)
Valve stem diameter:
Standard
Intake: 5.448–5.463 mm
(0.2144–0.2150 in)
Exhaust: 5.448–5.463 mm
(0.2144–0.2150 in)
Wear limit
Intake: 5.4 mm (0.21 in)
Exhaust: 5.4 mm (0.21 in)
(YS928J)
Valve stem diameter:
Standard
Intake: 5.984–5.963 mm
(0.2341–0.2347 in)
Exhaust: 5.940–5.955 mm
(0.2338–0.2344 in)
Wear limit
Intake: 5.9 mm (0.23 in)
Exhaust: 5.9 mm (0.23 in)
(YT1232ED)
Valve stem diameter:
Standard
Intake: 5.984–5.963 mm
(0.2341–0.2347 in)
Exhaust: 5.940–5.955 mm
(0.2338–0.2344 in)
Wear limit
Intake: 5.9 mm (0.23 in)
Exhaust: 5.9 mm (0.23 in)

Out of specification → Replace.

3-18
 VALVE ENG
3. Measure:
9 Valve stem runout

Runout limit:
0.01 mm (0.0004 in)

Out of specification → Replace.

TIP
The value is half of that indicated on the dial
gauge.

4. Measure:
9 Valve spring free length a

(YT624E/YT624EDJ/YS928J)
Valve spring free length:
26.5 mm (1.0433 in)
Limit: 25.0 mm (0.98 in)
(YT1232ED)
a Valve spring free length:
36.2 mm (1.4251 in)
Limit: 35.0 mm (1.38 in)

Out of specification → Replace.

5. Measure:
a 9 Valve spring tilt a

Tilt limit:
1.0 mm (0.03 in)

Out of specification → Replace.

3-19
 VALVE ENG
6. Check:
9 Valve spring contact surface a
a More than 2/3 of the contact surface
does not contact → Replace.

A B CHECKING THE ROCKER ARM

1. Check:
9 Rocker arm
Wear/damage/cracks → Replace.

A YT624E/YT624EDJ/YS928J
B YT1232ED

CHECKING THE VALVE SEAT

1. Remove carbon deposits from the valve
face and valve seat.
a 2. Apply a small amount of coarse mechan-
ic’s blueing dye (Dykem) to the valve face
a.
3. Insert the valve into the valve guide and
use a valve lapper to contact the valve
face with the valve seat.
TIP
Do not rotate the valve while the valve face is
contacting the valve seat.

3-20
 VALVE ENG
4. Measure:
9 Valve face contact width b
Make sure that the contact width along
the entire valve face is within specifica-
tions.

(YT624E/YT624EDJ/YS928J)
b
Valve face contact width (intake
and exhaust):
0.6–0.8 mm
(0.0236–0.0315 in)
Limit: 1.7 mm (0.07 in)
(YT1232ED)
Valve face contact width (intake
and exhaust):
0.7–0.9 mm
(0.0275–0.0354 in)
Limit: 1.4 mm (0.06 in)

Out of specification/rough/wear →
Replace.

3-21
 VALVE ENG
5. Measure:
a 9 Valve seat contact width a
Make sure that the contact width along
the entire valve seat is within specifica-
tions.

(YT624E/YT624EDJ/YS928J)
Valve seat contact width (intake
and exhaust):
0.6–0.8 mm
(0.0236–0.0315 in)
Limit: 1.7 mm (0.07 in)
(YT1232ED)
Valve seat contact width (intake
and exhaust):
0.7–0.9 mm
(0.0275–0.0354 in)
Limit: 1.4 mm (0.06 in)

Out of specification/rough/wear →
Replace.

6. Remove the carbon deposits on the valve

face a and valve seat.
9 Valve face contact seat width b
9 Valve margin thickness c
Apply a small amount of coarse
mechanic’s blueing dye (Dykem) to the
valve seat.
Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
9 Valve margin thickness
Out of specification → Replace.
9 Valve face contact width
Out of specification → Replace.

Valve margin thickness:

0.3 mm (0.012 in)

SCF3270

3-22
 VALVE ENG
LAPPING THE VALVE
1 1. Apply a coarse lapping compound evenly
on the valve face. Lap the valve by tap-
ping and rotating the valve lapper 1
clockwise and counterclockwise.
2. Clean off all of the lapping compound
from the valve face and valve seat. Apply
fine lapping compound on the valve face
and lap the valve as described in step 1.
3. Once the contacting surface of the valve
face is polished and becomes shinny,
apply mechanic’s blueing dye (Dykem) to
make sure that there are traces of even
contact in the center of the valve face.
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.

TIP
After every lapping procedure, clean off the
compound from the valve face and valve seat.

4 ASSEMBLING THE VALVE AND VALVE

5 SPRING
3
1. Install:
2 9 Valve 1
9 Valve spring 2
9 Valve spring retainer 3
1
9 Valve cotter 4
Apply a small amount of molybdenum
disulfide oil to the valve stem and use
the valve spring compressor 5 to
install the parts.

Valve spring compressor:

YM-04019, 90890-04019

NOTICE
Do not compress the valve spring more
than necessary.

3-23
 RECOIL STARTER AND TCI MAGNETO ENG

RECOIL STARTER AND TCI MAGNETO

(YT624E/YT624EDJ)

3 10 Nm (1.0 m · kgf, 7.2 ft · lbf)

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

65 Nm (6.5 m · kgf, 46 ft · lbf)

7
9
8

5
4

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

2
7 Nm (0.7 m · kgf, 5 ft · lbf) 1 7 Nm (0.7 m · kgf, 5 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the recoil starter and TCI Remove the parts in the order listed.
magneto
Fuel tank/Air filter case Refer to “FUEL TANK AND AIR FILTER
CASE” in chapter 2.
TCI unit/Charging coil lead Refer to “ENGINE”.
1 Recoil starter assembly 1
2 Fan case 1
3 Starter motor mounting bolt 2 Loosen.
4 Spark plug cap 1
5 TCI unit 1
6 Starter pulley 1
7 Rotor assembly 1
8 Charging coil 1
9 Woodruff key 1
For installation, reverse the removal pro-
cedure.

3-24
 RECOIL STARTER AND TCI MAGNETO ENG

RECOIL STARTER DISASSEMBLY (YT624E/YT624EDJ)

7 Nm (0.7 m · kgf, 5 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Disassembling the recoil starter Remove the parts in the order listed.
1 Recoil starter handle 1
2 Bolt 1
3 Drive plate 1
4 Drive pawl 2
5 Spring 2
6 Sheave drum 1
7 Starter spring 1
8 Starter case 1
9 Starter rope 1
For installation, reverse the removal pro-
cedure.

3-25
RECOIL STARTER AND TCI MAGNETO ENG
REMOVING THE ROTOR ASSEMBLY
1. Remove:
9 Rotor assembly 1
Remove using the bearing puller 2
(commercially available).

CHECKING THE RECOIL STARTER

1. Check:
9 Starter rope 1
Damage → Replace.
2. Check:
9 Starter spring 2
Damage/deformation → Replace.

3. Check:
9 Drive pawl 1
9 Drive plate 2
Wear/damage → Replace.

INSTALLING THE RECOIL STARTER

1. Install:
9 Starter spring 1
Install to the sheave drum 2.
TIP
Wind the starter spring counterclockwise into
the sheave drum.

2. Install:
9 Sheave drum 1
9 Starter rope 2

3-26
RECOIL STARTER AND TCI MAGNETO ENG
3. Install:
9 Drive pawl 1
9 Spring 2

4. Install:
9 Friction spring 1
9 Drive plate 2

5. Install:
9 Screw 1
Tighten the screw, fit the starter rope
2 into the notch a in the sheave
drum, and then wind four times coun-
terclockwise.

INSTALLING THE ROTOR ASSEMBLY

1. Install:
9 Charging coil 1
9 Woodruff key 2

2. Install:
9 Rotor 1
Align the notch in the rotor with the
woodruff key, and then install.

3-27
RECOIL STARTER AND TCI MAGNETO ENG
ASSEMBLING THE TCI UNIT
1. Install:
9 TCI unit 1
10 Nm (1.0 m · kgf, 7.2 ft · lbf)

2. Measure:
9 TCI unit air gap

Air gap:
0.4–0.6 mm (0.015–0.023 in)

Out of specification → Loosen the TCI

unit mounting bolts and adjust.

3-28
 TCI MAGNETO ENG

TCI MAGNETO
(YS928J)

7 Nm (0.7 m · kgf, 5 ft · lbf)

75 Nm (7.5 m · kgf, 54 ft · lbf)

2
6

4
10 Nm (1.0 m · kgf, 7.2 ft · lbf)
1

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the TCI magneto Remove the parts in the order listed.
Engine Refer to “ENGINE”.
1 Fan case 1
2 Spark plug cap 1
3 TCI unit 1
4 Rotor assembly 1
5 Clamp 1
6 Stator assembly 1
7 Woodruff key 1
For installation, reverse the removal pro-
cedure.

3-29
 TCI MAGNETO ENG

(YT1232ED)

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

3
4

120 Nm (12.0 m · kgf, 86 ft · lbf)

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

15 Nm (1.5 m · kgf, 10 ft · lbf)

1

Order Job/Parts to remove Q’ty Remarks

Removing the TCI magneto Remove the parts in the order listed.
Engine Refer to “ENGINE”.
1 Fan case 1
2 Engine pulley 1 1
3 Rotor assembly 1
4 TCI unit 1
5 Charging coil/Lighting coil 1/1
6 Woodruff key 1
For installation, reverse the removal pro-
cedure.

3-30
 TCI MAGNETO ENG
REMOVING THE ROTOR
1. Remove:
9 Nut 1
While holding the rotor with the sheave
holder 2, remove the nut.
1
Sheave holder:
YS-01880, 90890-01701
2

2. Remove:
9 Rotor 1
Remove using the flywheel puller 2.
2
Flywheel puller:
YU-33270, 90890-01362

TIP
1 Make sure the flywheel puller 2 is centered
over the rotor.

ASSEMBLING THE TCI UNIT

1. Install:
9 TCI unit
10 Nm (1.0 m · kgf, 7.2 ft · lbf)

2. Measure:
9 TCI unit air gap

Air gap:
0.4–0.6 mm (0.015–0.023 in)

Out of specification → Loosen the TCI

unit mounting bolts and adjust.

3-31
 CRANKCASE COVER AND CAMSHAFT ENG

CRANKCASE COVER AND CAMSHAFT

(YT624E/YT624EDJ)

8 E

23 Nm (2.3 m · kgf, 16 ft · lbf)

E
3 6
2 5
4

22 Nm (2.2 m · kgf, 15 ft · lbf)

1

Order Job/Parts to remove Q’ty Remarks

Removing the crankcase cover and Remove the parts in the order listed.
camshaft
Engine Refer to “ENGINE”.
Fuel tank Refer to “FUEL TANK AND AIR FILTER
CASE” in chapter 2.
Cylinder head Refer to “CYLINDER HEAD”.
1 Collar 1
2 Engine pulley (for auger) 1
3 Engine pulley (for drive) 1
4 Straight key 1
5 Crankcase cover 1
6 Crankcase cover gasket 1
7 Dowel pin 2
8 Camshaft 1

3-32
 CRANKCASE COVER AND CAMSHAFT ENG

8 E

23 Nm (2.3 m · kgf, 16 ft · lbf)

E
3 6
2 5
4

22 Nm (2.2 m · kgf, 15 ft · lbf)

1

Order Job/Parts to remove Q’ty Remarks

9 Valve lifter 2
For installation, reverse the removal pro-
cedure.

3-33
 CRANKCASE COVER AND CAMSHAFT ENG

(YS928J)

9 3

6
7

6
M

5
4
2 30 Nm (3.0 m · kgf, 21 ft · lbf)
1

24 Nm (2.4 m · kgf, 17 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the crankcase cover and Remove the parts in the order listed.
camshaft
Engine Refer to “ENGINE”.
Cylinder head Refer to “CYLINDER HEAD”.
1 Electromagnetic clutch assembly 1 Hold the rotor and remove the bolt.
2 Engine pulley (for drive) 1
3 Straight key 1
4 Crankcase cover 1
5 Crankcase cover gasket 1
6 Dowel pin 2
7 Camshaft 1
8 Valve lifter 2
9 Oil level switch 1
For installation, reverse the removal pro-
cedure.

3-34
 CRANKCASE COVER AND CAMSHAFT ENG

(YT1232ED)

8
4

5
6
7
3

1 5

2 4

19 Nm (1.9 m · kgf, 13 ft · lbf) 30 Nm (3.0 m · kgf, 21 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the crankcase cover, Remove the parts in the order listed.
camshaft and balancer shaft
Engine Refer to “ENGINE”.
Fuel tank Refer to “FUEL TANK AND AIR FILTER
CASE” in chapter 2.
Cylinder head Refer to “CYLINDER HEAD”.
1 Engine pulley 2 1
2 Straight key 1
3 Crankcase cover 1
4 Crankcase cover gasket 1
5 Dowel pin 2
6 Camshaft 1
7 Valve lifter 2
8 Balancer shaft 1
For installation, reverse the removal pro-
cedure.

3-35
 CRANKCASE COVER AND CAMSHAFT ENG
CHECKING THE PULLEY
(YS928J)
1. Check:
1 9 Engine pulley (for drive) 1
Cracks/damage/deformation →
Replace.
9 Electromagnetic clutch assembly 2
Check the electromagnetic clutch
2 assembly pulley.
Cracks/damage/deformation →
Replace.

CHECKING THE ELECTROMAGNETIC

CLUTCH
(YS928J)
1. Check:
a
9 Electromagnetic clutch air gap a

Electromagnetic clutch air gap:

0.3–0.9 mm (0.011–0.035 in)

Out of specification → Adjust.

CHECKING THE CAMSHAFT

1. Check:
9 Camshaft
Crack/damage/wear → Replace.

3-36
 CRANKCASE COVER AND CAMSHAFT ENG
a b 2. Check:
9 Cam lobes length a and b

(YT624E/YT624EDJ/YS928J)
Cam lobes length:
(Intake)
Dimension a: 26.85–26.95 mm
(1.057–1.061 in)
Limit: 26.65 mm (1.049 in)
(Exhaust)
Dimension a: 26.63–26.73 mm
(1.048–1.052 in)
Limit: 26.43 mm (1.032 in)
(Intake)
Dimension b: 21.95–22.05 mm
(0.864–0.868 in)
Limit: 21.75 mm (0.856 in)
(Exhaust)
Dimension b: 22.08–22.18 mm
(0.869–0.873 in)
Limit: 21.77 mm (0.857 in)
(YT1232ED)
Cam lobes length (intake and
exhaust):
Dimension a: 32.50–32.60 mm
(1.280–1.283 in)
Limit: 32.30 mm (1.272 in)
Dimension b: 26.03–26.13 mm
(1.024–1.028 in)
Limit: 25.83 mm (1.020 in)

Out of specification → Replace.

3. Check:
9 Surface of camshaft gear teeth
9 Decompressor
Crack/damage/wear → Replace.

3-37
CRANKCASE COVER AND CAMSHAFT ENG
4. Check:
a 9 Camshaft journal diameter a

Camshaft journal diameter:

(YT624E/YT624EDJ/YS928J)
14.965–14.990 mm
(0.5891–0.5901 in)
(YT1232ED)
15.965–15.990 mm
(0.6285–0.6295 in)

Out of specification → Replace.

CHECKING THE VALVE LIFTER

1. Check:
9 Valve lifter
Damage → Replace.

INSTALLING THE BALANCER SHAFT

(YT1232ED)
1. Install:
9 Balancer shaft 1
Align the punch mark a in the crank-
shaft with the punch mark b in the
balancer shaft, and then install.

3-38
 CRANKCASE COVER AND CAMSHAFT ENG
A INSTALLING THE CAMSHAFT
a 1. Install:
9 Camshaft 1
b
Align the crankshaft gear mark a with
the round hole b in the camshaft gear,
and then install.

1 A YT624E/YT624EDJ/YS928J
B YT1232ED

A INSTALLING THE CRANKCASE COVER

1. Install:
9 Dowel pin
9 Crankcase cover gasket
9 Crankcase cover
(YT624E/YT624EDJ)
1st: 12 Nm (1.2 m · kgf, 8.6 ft · lbf)
× 2nd: 22 Nm (2.2 m · kgf, 15 ft · lbf)
6
(YS928J/YT1232ED)
B 1st: 12 Nm (1.2 m · kgf, 8.6 ft · lbf)
1 2nd: 30 Nm (3.0 m · kgf, 21 ft · lbf)
5
Tighten in the proper tightening
8
sequence in 2–3 stages.
3
A YT624E/YT624EDJ
4
7 B YS928J/YT1232ED
6 2 ×
8

3-39
 PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG

PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE

(YT624E/YT624EDJ)

12 Nm (1.2 m · kgf, 8.6 ft · lbf) E

3
6 4

5 7

E 4

Order Job/Parts to remove Q’ty Remarks

Removing the piston, connecting Remove the parts in the order listed.
rod and crankshaft
Rotor Refer to “RECOIL STARTER AND TCI
MAGNETO”.
Camshaft Refer to “CRANKCASE COVER AND
CAMSHAFT”.
1 Connecting rod cap 1
2 Crankshaft assembly 1
3 Connecting rod 1
4 Piston pin circlip 2
5 Piston pin 1
6 Piston 1
7 Piston ring set 1
For installation, reverse the removal pro-
cedure.

3-40
 PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG

(YS928J)

12 Nm (1.2 m · kgf, 8.6 ft · lbf)

E
3
6 4
E

E
E
5
4
7

Order Job/Parts to remove Q’ty Remarks

Removing the piston, connecting Remove the parts in the order listed.
rod and crankshaft
Rotor Refer to “TCI MAGNETO”.
Camshaft Refer to “CRANKCASE COVER AND
CAMSHAFT”.
1 Connecting rod cap 1
2 Crankshaft assembly 1
3 Connecting rod 1
4 Piston pin circlip 2
5 Piston pin 1
6 Piston 1
7 Piston ring set 1
For installation, reverse the removal pro-
cedure.

3-41
 PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG

(YT1232ED)

20 Nm (2.0 m · kgf, 14 ft · lbf)

E
3
6 4
E

E
E
5
4
7

Order Job/Parts to remove Q’ty Remarks

Removing the piston, connecting Remove the parts in the order listed.
rod and crankshaft
Rotor Refer to “TCI MAGNETO”.
Camshaft Refer to “CRANKCASE COVER AND
CAMSHAFT”.
1 Connecting rod cap 1
2 Crankshaft assembly 1
3 Connecting rod 1
4 Piston pin circlip 2
5 Piston pin 1
6 Piston 1
7 Piston ring set 1
For installation, reverse the removal pro-
cedure.

3-42
PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG
CHECKING THE CYLINDER
1. Measure:
a 9 Cylinder inside diameter
TIP
b Take side to side a and front to back b
measurements at each of the three locations A,
B, C (total of six measurements), and then find
the average of the measurements.

Cylinder taper = Maximum A – Minimum C.

Out of specification → Replace the

crankcase.

(YT624E/YT624EDJ)
Cylinder inside diameter:
66.005–66.015 mm
(2.5986–2.5990 in)
Cylinder inside diameter wear
limit:
66.15 mm (2.6043 in)
(YS928J)
Cylinder inside diameter:
75.005–75.015 mm
(2.9529–2.9533 in)
Cylinder inside diameter wear
limit:
75.15 mm (2.9586 in)
(YT1232ED)
Cylinder inside diameter:
85.000–85.020 mm
(3.3464–3.3472 in)
Cylinder inside diameter wear
limit:
85.05 mm (3.3484 in)

3-43
 PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG
2. Measure:
9 Cylinder warpage
TIP
Measure the warpage on the contact surface
of the cylinder head at six points using a
straight edge and thickness gauge.

Warpage limit:
0.05 mm (0.002 in)

Out of specification → Replace.

CHECKING THE PISTON AND PISTON PIN

P 1. Measure:
a 9 Piston skirt diameter p
a = 10 mm (0.4 in) from the piston
bottom edge
Out of specification → Replace.

(YT624E/YT624EDJ)
Piston skirt diameter:
65.975–65990 mm
(2.5974–2.5980 in)
Wear limit:
65.9 mm (2.5944 in)
(YS928J)
Piston skirt diameter:
74.975–74.990 mm
(2.9517–2.9523 in)
Wear limit:
74.9 mm (2.9488 in)
(YT1232ED)
Piston skirt diameter:
84.977–84.998 mm
(3.3455–3.3463 in)
Wear limit:
84.9 mm (3.3425 in)

3-44
PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG
2. Measure:
9 Piston clearance
Out of specification → Rebore or
replace the cylinder, and then replace
the piston and piston rings.

Piston clearance =
Cylinder inside diameter –
Piston skirt diameter

(YT624E/YT624EDJ)
Piston clearance:
0.015–0.040 mm
(0.0005–0.0016 in)
Limit: 0.1 mm (0.004 in)
(YS928J)
Piston clearance:
0.024–0.038 mm
(0.0009–0.0014 in)
Limit: 0.1 mm (0.004 in)
(YT1232ED)
Piston clearance:
0.015–0.030 mm
(0.0005–0.0011 in)
Limit: 0.1 mm (0.004 in)

3-45
PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG
3. Measure:
9 Piston pin hole inside diameter a
Out of specification → Replace.
a
(YT624E/YT624EDJ)
Piston pin hole inside diameter:
16.002–16.013 mm
(0.6299–0.6304 in)
Wear limit:
16.05 mm (0.6318 in)
(YS928J)
Piston pin hole inside diameter:
18.004–18.015 mm
(0.7088–0.7092 in)
Wear limit:
18.05 mm (0.7106 in)
(YT1232ED)
Piston pin hole inside diameter:
20.000–20.015 mm
(0.7875–0.7879 in)
Wear limit:
20.05 mm (0.7893 in)

4. Measure:
9 Piston pin diameter a
Out of specification → Replace.

(YT624E/YT624EDJ)
Piston pin diameter:
15.995–16.000 mm
(0.6297–0.6299 in)
Wear limit:
15.95 mm (0.6279 in)
a (YS928J)
Piston pin diameter:
17.995–18.000 mm
(0.7084–0.7086 in)
Wear limit:
17.95 mm (0.7066 in)
(YT1232ED)
Piston pin diameter:
19.995–20.000 mm
(0.7872–0.7874 in)
Wear limit:
19.95 mm (0.7875 in)

3-46
PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG
5. Check:
9 Check the piston pin enters smoothly
into the piston pin hole.
If the piston pin fits too tightly into the
piston, check the piston pin hole. If
there is any protrusion, use a knife or
scraper to gently remove it so that pis-
ton pin can be pushed in smoothly with
your fingers.

CHECKING THE PISTON RING

1. Measure:
9 Piston ring end gap
a Out of specification → Replace.
TIP
Insert the piston ring 1 into the cylinder, and
push it approximately a 5 mm (0.2 in) into the
cylinder. Push the ring with the piston crown
so that the ring is at angles to the cylinder
bore.

(YT624E/YT624EDJ/YS928J)

Ring end gap Wear limit

0.20–0.40 mm 0.9 mm
Top ring
(0.008–0.016 in) (0.0354 in)
0.20–0.40 mm 0.9 mm
2nd ring
(0.008–0.016 in) (0.0354 in)
0.20–0.40 mm 0.9 mm
Oil ring
(0.008–0.016 in) (0.0354 in)

(YT1232ED)

Ring end gap Wear limit

0.20–0.35 mm 0.9 mm
Top ring
(0.008–0.013 in) (0.0354 in)
0.20–0.35 mm 0.9 mm
2nd ring
(0.008–0.013 in) (0.0354 in)
0.20–0.70 mm 1.2 mm
Oil ring
(0.008–0.027 in) (0.0472 in)

Out of specification → Replace the pis-

ton and piston ring as a set.

3-47
PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG
2. Measure:
9 Piston side clearance
Out of specification → Replace.
Use a thickness gauge 1.
TIP
9 Clean carbon deposits from the piston ring
1 grooves and rings before measuring the
side clearance.
9 Measure the side clearance at several por-
tions.

(YT624E/YT624EDJ/YS928J)

Piston ring side

Wear limit
clearance
0.04–0.08 mm 0.1 mm
Top ring
(0.0016–0.0031 in) (0.0039 in)
0.02–0.06 mm 0.1 mm
2nd ring
(0.0008–0.0023 in) (0.0039 in)

(YT1232ED)

Piston ring side

Wear limit
clearance
0.03–0.07 mm 0.1 mm
Top ring
(0.0011–0.0027 in) (0.0039 in)
0.03–0.07 mm 0.1 mm
2nd ring
(0.0011–0.0027 in) (0.0039 in)

CHECKING THE CRANKSHAFT

1. Check:
1 9 Crankshaft sprocket 1
Crack/damage/wear → Replace the
crankshaft.

3-48
PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG
2. Measure:
9 Crankshaft runout limit use a dial
gauge
Out of specification → Replace.

Runout limit:
0.04 mm (0.0016 in)

3. Measure:
9 Crank pin outside diameter a
Use a micrometer.
Out of specification → Replace.
a (YT624E/YT624EDJ)
Crank pin outside diameter:
27.969–27.984 mm
(1.1011–1.1017 in)
Wear limit:
27.9 mm (1.0984 in)
(YS928J)
Crank pin outside diameter:
31.969–31.984 mm
(1.2586–1.2592 in)
Wear limit:
31.9 mm (1.2559 in)
(YT1232ED)
Crank pin outside diameter:
35.969–35.984 mm
(1.4160–1.4166 in)
Wear limit:
35.9 mm (1.4133 in)

CHECKING THE CONNECTING ROD OIL

CLEARANCE
TIP
Measure the oil clearance if replacing the
crankshaft or connecting rod.

1. Place a piece of Plastigauge 1 on the

crank pin horizontally.
1
TIP
Wipe off oil from all parts thoroughly.

3-49
PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG
2. Install:
1 9 Connecting rod 1
9 Connecting rod cap 2
2 (YT624E/YT624EDJ/YS928J)
12 Nm (1.2 m · kgf, 8.6 ft · lbf)

(YT1232ED)
20 Nm (2.0 m · kgf, 14 ft · lbf)

TIP
Tighten the cap bolts so that the crankshaft
does not move while the oil clearance is being
measured.

3. Remove:
9 Connecting rod cap
9 Connecting rod
Crack/damage/wear → Replace the
crankshaft.
4. Measure:
9 Widest portion of the pressed
Plastigauge
Out of specification → Replace crank-
shaft or connecting rod, and then
measure the clearance again.

Connecting rod big end oil clear-

ance:
0.015–0.040 mm
(0.0006–0.0016 in)
Wear limit:
0.1 mm (0.004 in)

3-50
 PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG
INSTALLING THE PISTON AND PISTON
1
RING
2 a 1. Install:
9 Top ring 1
3 9 Second ring 2
9 Oil ring 3
TIP
9 Be sure to install the top ring and second
ring so that the “R” mark a faces toward
the piston head.
9 Make sure that the piston rings move
smoothly.

2. Apply 4-stroke engine oil to the inside of

the connecting rod small end.

3. Install:
1 9 Piston 1
3
9 Piston pin 2
a
9 Piston pin circlip 3
NOTICE
b
2 9 Make sure to install so that when the
“ ” mark a on the piston head is fac-
ing down, the “YAMAHA” mark b
becomes on the left with YT624E/
YT624EDJ, “7UH” mark b on the left
with YS928J, and “7CT” mark b on the
left with YT1232ED.
9 Make sure that the “ ” mark a on the
piston head faces toward the push rod.

ASSEMBLING THE CRANKSHAFT

90˚
a b 1. Make sure that the end gap of each pis-
ton ring is positioned correctly, as shown
45˚ in the illustration.
90˚
a Top ring
b Upper oil ring rail
c Second ring
d 90˚ c d Lower oil ring rail

3-51
 PISTON, CONNECTING ROD, CRANKSHAFT AND
CRANKCASE ENG
2. Install:
9 Piston ring compressor 1

Piston ring compressor:

YM-08037, 90890-05158

3. Install:
9 Piston already assembled to connect-
ing rod 1
NOTICE
9 Install so that the “ ” mark a on the
a piston head is facing down (valve push
b rod side).
1 9 Make sure that the “YAMAHA” mark b
on the connecting rod is visible from the
crankcase side with YT624E/YT624EDJ,
“7UH” mark b with YS928J, and “7CT”
mark b with YT1232ED.

4. Install:
9 Crankshaft 1
9 Connecting rod cap 2
1
(YT624E/YT624EDJ/YS928J)
2
a 12 Nm (1.2 m · kgf, 8.6 ft · lbf)

b (YT1232ED)
20 Nm (2.0 m · kgf, 14 ft · lbf)

NOTICE
Align the “ ” mark a on the connecting
rod and “ ” mark b on the connecting
rod cap, and then install.

3-52
 GOVERNOR ENG

GOVERNOR
(YT624E/YT624EDJ)

8 Nm (0.8 m · kgf, 5.8 ft · lbf)

7 8

9
10

8
11

Order Job/Parts to remove Q’ty Remarks

Removing the governor Remove the parts in the order listed.
Fuel tank
Crankcase cover Refer to “CRANKCASE COVER AND
CAMSHAFT”.
1 Tension spring 1
2 Link rod 1
3 Governor spring 1
4 Governor arm 1
5 Clip 1
6 Governor fork 1
7 Pin 2
8 Weight 2
9 Collar 1
10 Shaft 1

3-53
 GOVERNOR ENG

8 Nm (0.8 m · kgf, 5.8 ft · lbf)

7 8

9
10

8
11

Order Job/Parts to remove Q’ty Remarks

11 Weight gear 1
For installation, reverse the removal pro-
cedure.

3-54
 GOVERNOR ENG

(YS928J)

3 1

5 4 2

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

10 9

11

30 Nm (3.0 m · kgf, 21 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the governor Remove the parts in the order listed.
Engine Refer to “ENGINE”.
Crankcase cover Refer to “CRANKCASE COVER AND
CAMSHAFT”.
1 Tension spring 1
2 Link rod 1
3 Governor spring 1
4 Governor arm 1
5 Clip 1
6 Governor fork 1
7 Pin 3
8 Weight 3
9 Collar 1
10 Shaft 1

3-55
 GOVERNOR ENG

3 1

5 4 2

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

10 9

11

30 Nm (3.0 m · kgf, 21 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

11 Weight gear 1
For installation, reverse the removal pro-
cedure.

3-56
 GOVERNOR ENG

(YT1232ED)

12
1
3

2
4
5 10 Nm (1.0 m · kgf, 7.2 ft · lbf)

8
7 9

10

11

Order Job/Parts to remove Q’ty Remarks

Removing the governor Remove the parts in the order listed.
Fuel tank Refer to “FUEL TANK AND AIR FILTER
CASE” in chapter 2.
Crankcase cover Refer to “CRANKCASE COVER AND
CAMSHAFT”.
1 Tension spring 1
2 Link rod 1
3 Governor spring 1
4 Governor arm 1
5 Clip 1
6 Governor fork 1
7 Pin 3
8 Weight 3
9 Collar 1

3-57
 GOVERNOR ENG

12
1
3

2
4
5 10 Nm (1.0 m · kgf, 7.2 ft · lbf)

8
7 9

10

11

Order Job/Parts to remove Q’ty Remarks

10 Shaft 1
11 Weight gear 1
12 Throttle lever assembly 1
For installation, reverse the removal pro-
cedure.

3-58
 GOVERNOR ENG
CHECKING THE FLYWEIGHT SHAFT GEAR
1. Check:
9 Weight gear 1
Cracks/damage/wear → Replace.
9 Weight 2
Deformation/damage → Replace.

3-59
 CARBURETOR CARB
CARBURETOR
CARBURETOR
(YT624E/YT624EDJ)

4
5
2

4
1
8
7
6

3
1

Order Job/Parts to remove Q’ty Remarks

Removing the carburetor Remove the parts in the order listed.
Refer to “FUEL TANK AND AIR FILTER
CASE” in chapter 2.
1 Fuel hose 1 Turn the fuel cock lever to the “STOP”
position and disconnect the fuel hose at
the carburetor end.
2 Throttle cable 1
3 Carburetor assembly 1
4 Tension spring 1
5 Link rod 1
6 Gasket 1
7 Carburetor joint 1
8 Gasket 1
For installation, reverse the removal pro-
cedure.

4-1
 CARBURETOR CARB

(YS928J)

13 2
12 3
11 10 1
7
8

Order Job/Parts to remove Q’ty Remarks

Removing the carburetor Remove the parts in the order listed.
Left and right side covers, top cover Refer to “COVERS AND FUEL TANK” in
chapter 2.
Auto choke lead connector Refer to “ENGINE” in chapter 3.
1 Fuel hose 1 Turn the fuel cock lever to the “STOP”
position and disconnect the fuel hose at
the fuel cock end.
2 Vacuum hose 1
3 Air filter case cap 1
4 Damper 1
5 Element plate 1
6 Air filter case 1
7 Gasket/Carburetor joint 1/1
8 Carburetor assembly 1

4-2
 CARBURETOR CARB

13 2
12 3
11 10 1
7
8

Order Job/Parts to remove Q’ty Remarks

9 Tension spring/Link rod 1/1
10 Gasket/Plate 1/1
11 Gasket 1
12 Carburetor joint 1
13 Gasket 1
For installation, reverse the removal pro-
cedure.

4-3
 CARBURETOR CARB

(YT1232ED)

8
9

12
11 1

10
7
6
5
2
4
3

Order Job/Parts to remove Q’ty Remarks

Removing the carburetor Remove the parts in the order listed.
Air filter case Refer to “FUEL TANK AND AIR FILTER
CASE” in chapter 2.
1 Fuel hose 1 Turn the fuel cock lever to the “STOP”
position before removing.
2 Plate 1
3 Air filter case 1
4 Gasket 1
5 Carburetor cover 1
6 Gasket 1
7 Carburetor assembly 1
8 Tension spring 1
9 Link rod 1
10 Gasket 1

4-4
 CARBURETOR CARB

8
9

12
11 1

10
7
6
5
2
4
3

Order Job/Parts to remove Q’ty Remarks

11 Carburetor joint 1
12 Gasket 1
For installation, reverse the removal pro-
cedure.

4-5
 CARBURETOR CARB

DISASSEMBLING THE CARBURETOR (YT624E/YT624EDJ)

Order Job/Parts to remove Q’ty Remarks

Disassembling the carburetor Disassemble the parts in the order list-
ed.
1 Holding bolt 1
2 Gasket 1
3 Float chamber assembly 1
4 Float chamber gasket 1
5 Main jet 1
6 Float pin 1
7 Float 1
8 Needle assembly 1
9 Pilot screw 1
0 Pilot jet 1
q Main nozzle 1
For assembly, reverse the disassembly
procedure.

4-6
 CARBURETOR CARB

(YS928J)

6 7

8 9

3
2

Order Job/Parts to remove Q’ty Remarks

Disassembling the carburetor Disassemble the parts in the order list-
ed.
1 Holding bolt 1
2 Gasket 1
3 Float chamber assembly 1
4 Float chamber gasket 1
5 Ring 1
6 Main jet 1
7 Float pin 1
8 Float 1
9 Needle assembly 1
0 Pilot screw 1
q Pilot jet 1
w Main nozzle 1
For assembly, reverse the disassembly
procedure.

4-7
 CARBURETOR CARB

(YT1232ED)

5
0 8
9
7
6

2
1

Order Job/Parts to remove Q’ty Remarks

Disassembling the carburetor Disassemble the parts in the order list-
ed.
1 Holding bolt 1
2 Gasket 1
3 Float chamber assembly 1
4 Float chamber gasket 1
5 Main jet 1
6 Float pin 1
7 Float 1
8 Needle assembly 1
9 Main bleed pipe 1
0 Main nozzle 1
q Throttle stop screw 1
w Pilot screw 1

4-8
 CARBURETOR CARB

5
0 8
9
7
6

2
1

Order Job/Parts to remove Q’ty Remarks

e Pilot jet 1
For assembly, reverse the disassembly
procedure.

4-9
 CARBURETOR CARB
A ASSEMBLING THE CARBURETOR
1. Install:
9 Main nozzle 1

A YT624E/YT624EDJ/YT1232ED
B YS928J

A 2. Install:
9 Pilot jet 1
9 Pilot screw 2

A YT624E/YT624EDJ
B YS928J
C YT1232ED

4-10
 CARBURETOR CARB
A 3. Install:
9 Needle assembly 1
9 Float 2
9 Float pin 3

A YT624E/YT624EDJ
B YS928J/YT1232ED

A 4. Install:
9 Main jet 1
9 Ring 2 (YS928J)

A YT624E/YT624EDJ
B YS928J
C YT1232ED

1
2

4-11
 CARBURETOR CARB
5. Check:
9 Float height (H) a
Lift up the float so that the tip of the
needle valve lightly contacts the float
a
arm and measure the highest location
of the float.

Float height (H):

16.0 mm (0.63 in)

Out of specification → Replace the float and

measure.
TIP
The float height cannot be adjusted because
the float arm is fixed.

A 6. Install:
9 Float chamber gasket 1
9 Float chamber 2
9 Gasket 3
9 Holding bolt 4

A YT624E/YT624EDJ
B YS928J
C YT1232ED

B
1
2
3

4-12
 CARBURETOR CARB
CHECKING THE AUTO CHOKE
(YS928J)
1. Check:
9 Auto choke resistance

Auto choke resistance:

11.7–14.3 Ω at 23 ºC (73.4 ºF)

Out of specification → Replace.

TIP
Do not remove the auto choke from the carbu-
retor body.

2. Check:
9 Auto choke operation
Connect the 12 V battery to the auto
choke lead connector, and check that
12V the valve operates.

4-13
 TRANSMISSION TMI
TRANSMISSION
TRANSMISSION
WHEEL AND TRACK (YT624E/YT624EDJ)

54 Nm (5.4 m · kgf, 38 ft · lbf)

28 Nm (2.8 m · kgf, 20 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the wheel and track Remove the parts in the order listed.
Battery Refer to “ENGINE” in chapter 3.
Place the machine in the vertical posi-
tion.
1 Adjusting bolt 2
2 Slider 2
3 Spring 2
4 Track 2
5 Cotter pin 4
6 Pivot pin 2
7 Sprocket assembly 2
8 Axle spacer 2 2
9 Guide wheel 2
10 Idler roller collar 2

5-1
 TRANSMISSION TMI

54 Nm (5.4 m · kgf, 38 ft · lbf)

5
28 Nm (2.8 m · kgf, 20 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

11 Gusset 1
12 Pivot arm 1 1
13 Pivot arm 2 1
14 Axle shaft 1
15 Bearing housing 2
16 Cotter pin 1
17 Axle pin 1
18 Axle spacer 1 2
For installation, reverse the removal pro-
cedure.

5-2
 TRANSMISSION TMI

(YS928J)
35 Nm (3.5 m · kgf, 25 ft · lbf)
1
2
14

3
9

10

13
4
6
15
5
10 11
5 9
17
16 7
8
18
12 16 54 Nm (5.4 m · kgf, 38 ft · lbf)

8
28 Nm (2.8 m · kgf, 20 ft · lbf)
6
7

Order Job/Parts to remove Q’ty Remarks

Removing the wheel and track Remove the parts in the order listed.
Battery Refer to “ENGINE” in chapter 3.
Place the machine in the vertical posi-
tion.
1 Plate 1 1
2 Tilt lock assembly 1
3 Adjusting bolt 2
4 Slider 2
5 Track 2
6 Pivot pin 2
7 Sprocket assembly 2
8 Axle spacer 2 2
9 Guide wheel 2
10 Idler roller collar 2

5-3
 TRANSMISSION TMI

35 Nm (3.5 m · kgf, 25 ft · lbf)

1
2
14

3
9

10

13
4
6
15
5
10 11
5 9
17
16 7
8
18
12 16 54 Nm (5.4 m · kgf, 38 ft · lbf)

8
28 Nm (2.8 m · kgf, 20 ft · lbf)
6
7

Order Job/Parts to remove Q’ty Remarks

11 Gusset 1
12 Pivot arm 1 1
13 Axle shaft 1
14 Frame tension 1
15 Pivot arm 2 1
16 Bearing housing 2
17 Axle pin 1
18 Axle spacer 1 2
For installation, reverse the removal pro-
cedure.

5-4
 TRANSMISSION TMI

(YT1232ED)

24 Nm (2.4 m · kgf, 17 ft · lbf)

8
1

12 2
5
11
3 8 7 6
13 9

2 14
4
5 13
10
6 39 Nm (3.9 m · kgf, 28 ft · lbf)
7

Order Job/Parts to remove Q’ty Remarks

Removing the wheel and track Remove the parts in the order listed.
Battery Refer to “ENGINE” in chapter 3.
Place the machine in the vertical posi-
tion.
1 Nut 4
2 Slider 2
3 Track 2
4 Cotter pin 2
5 Pivot pin 2
6 Sprocket assembly 2
7 Axle spacer 2 2
8 Guide wheel 2
9 Pivot arm 1 1
10 Pivot arm 2 1

5-5
 TRANSMISSION TMI

24 Nm (2.4 m · kgf, 17 ft · lbf)

8
1

12 2
5
11
3 8 7 6
13 9

2 14
4
5 13
10
6 39 Nm (3.9 m · kgf, 28 ft · lbf)
7

Order Job/Parts to remove Q’ty Remarks

11 Gusset 1
12 Axle shaft 1
13 Bearing housing 2
14 Axle spacer 1 2
For installation, reverse the removal pro-
cedure.

5-6
 TRANSMISSION TMI

HYDROSTATIC TRANSMISSION (H.S.T.) (YT624E/YT624EDJ)

11 Nm (1.1 m · kgf, 7.9 ft · lbf)

23 Nm (2.3 m · kgf, 16 ft · lbf)

15 Nm (1.5 m · kgf, 10 ft · lbf) 12 Nm (1.2 m · kgf, 8.6 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the hydrostatic trans- Remove the parts in the order listed.
mission (H.S.T.)
1 Body lower plate 1
2 Cotter pin 1
3 Shift cable 1
4 Bearing housing 2
5 Cotter pin 1
6 Woodruff key 1
7 Axle shaft 1
8 Retaining ring (circlip) 1
9 Bearing housing 2
10 Return spring 2
11 H.S.T. spring 1
12 H.S.T. hose 1

5-7
 TRANSMISSION TMI

11 Nm (1.1 m · kgf, 7.9 ft · lbf)

23 Nm (2.3 m · kgf, 16 ft · lbf)

15 Nm (1.5 m · kgf, 10 ft · lbf) 12 Nm (1.2 m · kgf, 8.6 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

13 Flange nut 1
14 H.S.T. assembly 1
15 H.S.T. clutch rod 1
16 Input pulley 1
17 H.S.T. bracket 1
18 Gear cover 1
19 Washer 1
20 Idler gear 1
21 Idler collar 1
22 Final gear 1
23 Circlip 1
24 Primary gear 1
25 Nylon nut 1
For installation, reverse the removal pro-
cedure.

5-8
 TRANSMISSION TMI

(YS928J)
11 Nm (1.1 m · kgf, 7.9 ft · lbf) 7 23
8
22 20
23 Nm (2.3 m · kgf, 16 ft · lbf) 18

8 19

3 21
16 C
17
11
12 17
3 15 13

14 9

6
5

10

24 Nm (2.4 m · kgf, 17 ft · lbf) 12 Nm (1.2 m · kgf, 8.6 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the hydrostatic trans- Remove the parts in the order listed.
mission (H.S.T.)
Battery Refer to “ENGINE” in chapter 3.
Drain the transmission (H.S.T.) oil.
1 Cotter pin 1
2 Shift cable 1
3 Bearing housing 2
4 Set screw 1
5 Axle shaft 1
6 Woodruff key 1
7 Retaining ring (circlip) 1
8 Bearing housing 2
9 Return spring 2
10 Guide plate 1

5-9
 TRANSMISSION TMI

11 Nm (1.1 m · kgf, 7.9 ft · lbf) 7 23

8
22 20
23 Nm (2.3 m · kgf, 16 ft · lbf) 18

8 19

3 21
16 C
17
11
12 17
3 15 13

14 9

6
5

10

24 Nm (2.4 m · kgf, 17 ft · lbf) 12 Nm (1.2 m · kgf, 8.6 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

11 H.S.T. hose 1
12 Flange nut 1
13 H.S.T. assembly 1
14 Input pulley 1
15 H.S.T. bracket 1
16 Nylon nut 1
17 Gear cover 1
18 Washer 1
19 Idler gear 1
20 Idler collar 1
21 Final gear 1
22 Circlip 1
23 Primary gear 1
For installation, reverse the removal pro-
cedure.

5-10
 TRANSMISSION TMI

HYDROSTATIC TRANSMISSION (H.S.T.) AND TRANSMISSION (YT1232ED)

16 Nm (1.6 m · kgf, 11 ft · lbf)

16 Nm (1.6 m · kgf, 11 ft · lbf)

2
1
16 Nm (1.6 m · kgf, 11 ft · lbf)
3

3 5
7
8

1 6

Order Job/Parts to remove Q’ty Remarks

Removing the hydrostatic trans- Remove the parts in the order listed.
mission (H.S.T.) and transmission
1 Cotter pin/Shift rod 5 1/1
2 Cotter pin/Shift rod 4 1/1
3 Cotter pin/Side clutch pin 2/2
4 Guide plate 1
5 Clip/H.S.T. hose 1/1
6 Transmission assembly 1
7 Input pulley 1
8 Drive gear key 1
9 H.S.T. assembly 1
For installation, reverse the removal pro-
cedure.

5-11
 TRANSMISSION TMI

SHIFTER AND CLUTCH (YT1232ED)

9
3
8
11

8
16 Nm (1.6 m · kgf, 11 ft · lbf)

4
5 7

10

10

Order Job/Parts to remove Q’ty Remarks

Disassembling the shifter and Disassemble the parts in the order list-
clutch ed.
Drain the transmission oil.
1 Case cover 1
2 Shift fork bracket/Shift fork 1/1
3 Shift fork 1
4 Shifter spring 1
5 Shifter ball 1
6 Fork shaft 1
7 Bearing cover 2
8 Cotter pin 2
9 Pin 2
10 Clutch retainer 2
11 Clutch fork (left and right) 1 each
For assembly, reverse the disassembly
procedure.

5-12
 TRANSMISSION TMI

TRANSMISSION AND CLUTCH GEAR (YT1232ED)

16 Nm (1.6 m · kgf, 11 ft · lbf)

5
6

1
7 2

8 4
3
1

10 12

15
18 11
17
16
14
13
10
16 Nm (1.6 m · kgf, 11 ft · lbf) 19

Order Job/Parts to remove Q’ty Remarks

Disassembling the transmission Disassemble the parts in the order list-
and clutch gear ed.
1 Bearing 2
2 Driven gear 1 1
3 Slide gear 1
4 Drive shaft 1
5 Input retainer 1
6 Shim 4
7 Bevel gear 1 1
8 Bearing 2
9 Counter shaft assembly 1
10 Bearing 2
11 Clutch spring 1
12 Clutch gear 1

5-13
 TRANSMISSION TMI

16 Nm (1.6 m · kgf, 11 ft · lbf)

5
6

1
7 2

8 4
3
1

10 12

15
18 11
17
16
14
13
10
16 Nm (1.6 m · kgf, 11 ft · lbf) 19

Order Job/Parts to remove Q’ty Remarks

13 Clutch spring 1
14 Clutch gear 1
15 Clutch shaft 1
16 Gear 1
17 Final gear 2
18 Axle housing 2
19 Axle shaft 2
For assembly, reverse the disassembly
procedure.

5-14
 TRANSMISSION TMI
CHECKING THE TRACKS
1. Check:
9 Track
Cracks/fissures/missing cogs → Replace.

A 2. Check:
9 Guide wheel 1
1 2 9 Sprocket assembly 2
Deformation/damage → Replace.

A YT624E/YT624EDJ/YS928J
B YT1232ED

A CHECKING THE SHAFT, SLIDER AND

PIVOT ARM
1. Check:
9 Axle shaft
Bends → Replace.

A YT624E/YT624EDJ/YS928J
B YT1232ED

5-15
 TRANSMISSION TMI
A 2. Check:
9 Slider
Bends/cracks/deformation → Replace.

A YT624E/YT624EDJ/YS928J
B YT1232ED

A 3. Check:
9 Pivot arm
Bends/cracks/deformation → Replace.

A YT624E/YT624EDJ/YS928J
B YT1232ED

5-16
 TRANSMISSION TMI
A CHECKING THE H.S.T.
NOTICE
Do not disassemble the H.S.T. assembly.

1. Check:
9 H.S.T. assembly
Damage/oil leaks → Replace.

A YT624E/YT624EDJ/YS928J
B YT1232ED
B

A 2. Check:
9 H.S.T. pulley
Cracks/wear/damage → Replace.

A YT624E/YT624EDJ/YS928J
B YT1232ED

3. Check:
(Except YT1232ED)
1 2 3 9 Primary gear 1
9 Idler gear 2
9 Final gear 3
Wear/damage → Replace.

5-17
 TRANSMISSION TMI
CHECKING THE SHIFTER AND CLUTCH
(YT1232ED)
1. Check:
9 Set screw 1
Damage → Replace.
9 Shift fork 2
Burn/bends/wear → Replace.
9 Shifter spring 3
Wear/damage → Replace.
9 Shifter ball 4
Wear/damage → Replace.
9 Fork shaft 5
Bends/damage → Replace.

2. Check:
9 Clutch fork 1
Bends/wear → Replace.

3. Check:
9 Clutch spring free length a

Standard free length:

48 mm (1.89 in)
Limit
46 mm (1.81 in)

Out of specification → Replace.

4. Check:
9 Clutch shaft
Bends/damage → Replace.

5-18
 TRANSMISSION TMI
CHECKING THE TRANSMISSION
(YT1232ED)
1. Check:
9 Transmission gears
Wear/damage/pitting → Replace.

2. Check:
9 Drive shaft 1
9 Counter shaft 2
Bends/damage → Replace.

3. Check:
9 Check that the gears move and rotate
smoothly.
Unsmooth movement/wrong rotation →
Repair or replace.

4. Check:
9 Bevel gear assembly 1
Rattle/malfunction/noise → Replace.

ASSEMBLING THE CLUTCH,

TRANSMISSION AND SHIFTER
(YT1232ED)
1. Install:
9 Axle housings (left and right) 1
16 Nm (1.6 m · kgf, 11 ft · lbf)

9 Axle shafts (left and right) 2

5-19
 TRANSMISSION TMI
2. Install:
9 Final gears (left and right) 1
9 Circlips (left and right) 2

3. Install:
9 Clutch forks
NOTICE
Make sure to install the clutch forks in the
correct sides.

4. Install:
9 Counter shaft 1
9 Center gear 2
9 Circlips (left and right) 3

5. Install:
9 Clutch gears (left and right) 1
Slide the clutch forks in the direction of
the arrow, and install the clutch gears
to the counter shaft.
Move the counter shaft in the direction
of the arrow a and install the clutch
forks in the clutch gear groove.

6. Install:
9 Clutch springs (left and right) 1
9 Plain washers (left and right) 2
9 Bearings (left and right) 3
9 Clutch retainers (left and right) 4
16 Nm (1.6 m · kgf, 11 ft · lbf)

5-20
 TRANSMISSION TMI
7. Install:
9 Pins (left and right) 1
9 Cotter pins (left and right) 2

8. Install:
9 Drive gear 1
9 Bevel gear 2 2
9 Counter gear 3
9 Thrust washer 4
9 Counter shaft 5
9 Key 6

9. Install:
9 Counter gear assembly 1

10. Install:
9 Plain washers (left and right) 1
9 Bearings (left and right) 2

5-21
 TRANSMISSION TMI
11. Install:
9 Input retainer assembly 1
16 Nm (1.6 m · kgf, 11 ft · lbf)

12. Check:
9 Bevel gear backlash

Bevel gear backlash:

0.3–0.5 mm (0.01–0.02 in)

Out of specification → Adjust using

shim 2.

13. Install:
9 Driven gear 1
9 Slide gear 2
9 Drive shaft 3

14. Install:
9 Plain washers (left and right) 1
9 Bearings (left and right) 2
9 Bearing covers (left and right) 3
16 Nm (1.6 m · kgf, 11 ft · lbf)

5-22
 TRANSMISSION TMI
15. Install:
9 Fork shaft 1
9 Shifter ball 2
9 Shifter spring 3
9 Shift fork 4
9 Set screw 5

TIP
After tightening the set screw, stake it a with
a center punch to prevent it from loosening.

16. Install:
9 Transmission case cover 1
16 Nm (1.6 m · kgf, 11 ft · lbf)

9 Shift fork bracket 2

BLEEDING THE H.S.T.

1. Remove:
9 Drain bolt 1

NOTICE
Make sure that the drain bolt is facing up
as shown in the illustration.

5-23
 TRANSMISSION TMI
2. Slowly add oil into the reservoir 2.

Recommended H.S.T. oil:

Diesel engine oil
10W-30, Class CD or higher

3. Drain the transmission (H.S.T.) oil from

the drain bolt until all of the air bubbles
have disappeared.
4. Install:
9 Drain bolt
20 Nm (2.0 m · kgf, 14 ft · lbf)

TIP
Wipe clean any oil around the H.S.T.

5. Add the transmission (H.S.T.) oil to the

specified level of the oil reservoir.

6. Push in the neutral valve spool 2 using

the H.S.T. switch lever 1.

7. Install:
9 H.S.T. pulley 1
Install to the cross shaft 2, and turn
counterclockwise a approx. 10 times.

5-24
 TRANSMISSION TMI
8. Pull out the neutral valve spool.

9. Install:
9 H.S.T. pulley 1
Install to the pump shaft 2, and then
push the clutch arm 3 manually in
either direction until it stops.
Turn the H.S.T. pulley approx. 30 times
counterclockwise a as viewed from
the front. At this time, check that the
cross shaft 4 rotates.
NOTICE
Make sure to turn the pump shaft counter-
clockwise.

10. After mounting the H.S.T. to the chassis,

test drive for approx. 2–3 minutes on an
asphalt or concrete road surface.
NOTICE
9 If the bleeding in steps 7–9 is insuffi-
cient, a hydraulic noise may occur imme-
diately after driving.
In this case, test drive for approx. 5–6
minutes.
9 Add transmission (H.S.T.) oil if the oil is
insufficient.

INSTALLING THE GEAR COVER AND H.S.T.

C
2 (YT624E/YT624EDJ/YS928J)
1. Install:
9 Gear cover 1
1 9 Primary gear 2
9 Circlip 3
3

5-25
 TRANSMISSION TMI
2. Install:
9 Final gear 1
4 9 Idler collar 2
9 Idler gear 3
C 2 9 Primary gear 4
5
9 Washer 5
3 Apply the low temperature grease to
1 the gear teeth and idler collar, and then
temporarily install to the gear cover.
3. Install:
9 Gear cover assembly

NOTICE
9 Make sure to assemble so that the wash-
er does not fall off.
9 Make sure to tighten the gear cover tem-
porarily.

4. Install:
9 H.S.T. assembly 1
1
15 Nm (1.5 m · kgf, 10 ft · lbf)

5. Install:
9 Return spring 1

6. Install:
9 Axle shaft 1
1 3
9 Woodruff key 2
2 9 Set screw 3

5-26
 TRANSMISSION TMI
7. Install:
1
9 Bearing housing 1
11 Nm (1.1 m · kgf, 7.9 ft · lbf)

8. Tighten:
2
9 Gear cover assembly
12 Nm (1.2 m · kgf, 8.6 ft · lbf)

9 Nylon nut 2
24 Nm (2.4 m · kgf, 17 ft · lbf)

INSTALLING THE SPROCKET

(YT624E/YT624EDJ/YS928J)
3 1. Install:
2 9 Axle spacer 1
9 Axle pin 2
9 Bearing housing 3

2. Install:
2 9 Pivot arm 1 1
3 9 Axle shaft 2
9 Gusset 3
4 9 Pivot arm 2 4
1

3. Install:
9 Axle spacer 2 1
9 Washer 2
3
9 Idler roller collar 3

2
1

5-27
 TRANSMISSION TMI
4. Install:
9 Sprocket assembly 1
9 Guide wheel 2
2
5. Install:
1 9 Slider
28 Nm (2.8 m · kgf, 20 ft · lbf)

9 Track
After installation, adjust the track ten-
sion.
Refer to “CHECKING THE TRACK” in
chapter 2.

5-28
 AUGER AND WORM CASE CHAS
CHASSIS
AUGER AND WORM CASE
(YT624E)

12 Nm (1.2 m · kgf, 8.6 ft · lbf)

23 Nm (2.3 m · kgf, 16 ft · lbf)

10

1 11
13
14

12
8
9
7
6
3 5
4

6.5 Nm (0.65 m · kgf, 4.7 ft · lbf)

2
1

Order Job/Parts to remove Q’ty Remarks

Removing the auger and worm Remove the parts in the order listed.
case Place the auger housing on a suitable
stand so that it is approx. 10 cm (3.94
in) elevated.
Drain the oil from the worm case. Refer to “CHANGING THE WORM
CASE OIL” in chapter 2.
1 Bearing housing assembly 2
2 Auger 1 1
3 Auger 2 1
4 Shear bolt bracket 2
5 Circlip 1
6 Worm case cap 1
7 O-ring 1
8 Worm wheel 1

6-1
 AUGER AND WORM CASE CHAS

12 Nm (1.2 m · kgf, 8.6 ft · lbf)

23 Nm (2.3 m · kgf, 16 ft · lbf)

10

1 11
13
14

12
8
9
7
6
3 5
4

6.5 Nm (0.65 m · kgf, 4.7 ft · lbf)

2
1
6
Order Job/Parts to remove Q’ty Remarks
9 Straight key 1
10 Circlip 1
11 Worm case cover 1
12 O-ring 1
13 Worm gear 1
14 Worm case 1
For installation, reverse the removal pro-
cedure.

6-2
 AUGER AND WORM CASE CHAS

(YT624EDJ)

12 Nm (1.2 m · kgf, 8.6 ft · lbf)

23 Nm (2.3 m · kgf, 16 ft · lbf)

11

1 B 12
13
15

14
8
9
2
10
7
4 2 6

5 C

23 Nm (2.3 m · kgf, 16 ft · lbf)

5 B

3
1

Order Job/Parts to remove Q’ty Remarks

Removing the auger and worm Remove the parts in the order listed.
case Place the auger housing on a suitable
stand so that it is approx. 10 cm (3.94
in) elevated.
Drain the oil from the worm case. Refer to “CHANGING THE WORM
CASE OIL” in chapter 2.
1 Bearing housing assembly 2
2 Shear bolt guard mounting bolt 4
3 Auger 1 1
4 Auger 2 1
5 Shear bolt guard 2
6 Circlip 1
7 Worm case cap 1
8 Worm wheel 1

6-3
 AUGER AND WORM CASE CHAS

12 Nm (1.2 m · kgf, 8.6 ft · lbf)

23 Nm (2.3 m · kgf, 16 ft · lbf)

11

1 B 12
13
15

14
8
9
2
10
7
4 2 6

5 C

23 Nm (2.3 m · kgf, 16 ft · lbf)

5 B

3
1

Order Job/Parts to remove Q’ty Remarks

9 Straight key 1
10 O-ring 1
11 Circlip 1
12 Worm case cover 1
13 Worm gear 1
14 O-ring 1
15 Worm case 1
For installation, reverse the removal pro-
cedure.

6-4
 AUGER AND WORM CASE CHAS

(YS928J)

12 Nm (1.2 m · kgf, 8.6 ft · lbf)

23 Nm (2.3 m · kgf, 16 ft · lbf)

5
2
14
3 15

13
6
10 16
3 11 12
17
8
7

19 Nm (1.9 m · kgf, 13 ft · lbf)

1
4
9

Order Job/Parts to remove Q’ty Remarks

Removing the auger and worm Remove the parts in the order listed.
case Place the auger housing on a suitable
stand so that it is approx. 10 cm (3.94
in) elevated.
Drain the oil from the worm case. Refer to “CHANGING THE WORM
CASE OIL” in chapter 2.
1 Bearing housing assembly 2
2 Worm case stay 1
3 Shear bolt guard mounting bolt 4
4 Auger 1 1
5 Auger 2 1
6 Shear bolt guard 2
7 Circlip 1
8 Worm case cap 1

6-5
 AUGER AND WORM CASE CHAS

12 Nm (1.2 m · kgf, 8.6 ft · lbf)

23 Nm (2.3 m · kgf, 16 ft · lbf)

5
2
14
3 15

13
6
10 16
3 11 12
17
8
7

19 Nm (1.9 m · kgf, 13 ft · lbf)

1
4
9

Order Job/Parts to remove Q’ty Remarks

9 Auger shaft/Straight key 1/1
10 Worm wheel 1
11 Straight key 1
12 O-ring 1
13 Circlip 1
14 Worm case cover 1
15 Worm gear 1
16 O-ring 1
17 Worm case 1
For installation, reverse the removal pro-
cedure.

6-6
 AUGER AND WORM CASE CHAS

(YT1232ED)

19 Nm (1.9 m · kgf, 13 ft · lbf)

27 Nm (2.7 m · kgf, 19 ft · lbf)

2
5 1

9
10
11
8
6 19 Nm (1.9 m · kgf, 13 ft · lbf)

5
7
4

23 Nm (2.3 m · kgf, 16 ft · lbf) 3 C

Order Job/Parts to remove Q’ty Remarks

Removing the auger and worm Remove the parts in the order listed.
case Place the auger housing on a suitable
stand so that it is approx. 10 cm (3.94
in) elevated.
Drain the oil from the worm case Refer to “CHANGING THE WORM
CASE OIL” in chapter 2.
1 Worm case stay 1
2 Bearing housing 2
3 Auger 1 1
4 Auger 2 1
5 Shear bolt guard 2
6 Worm case cap 1
7 Auger shaft/Straight key 1/1
8 Worm wheel 1

6-7
 AUGER AND WORM CASE CHAS

19 Nm (1.9 m · kgf, 13 ft · lbf)

27 Nm (2.7 m · kgf, 19 ft · lbf)

2
5 1

9
10
11
8
6 19 Nm (1.9 m · kgf, 13 ft · lbf)

5
7
4

23 Nm (2.3 m · kgf, 16 ft · lbf) 3 C

Order Job/Parts to remove Q’ty Remarks

9 Worm case cover 1
10 Worm gear 1
11 Worm case 1
For installation, reverse the removal pro-
cedure.

6-8
 AUGER AND WORM CASE CHAS
A REMOVING THE AUGER
1. Place the suitable stand 1 under the
auger housing.
2
2. Remove:
9 Bearing housing 2

A YT624E/YT624EDJ/YS928J
B YT1232ED
1

A 3. Remove:
9 Auger assembly 1
9 Worm case assembly 2
Leaving the impeller shaft in place,
remove both the auger and worm case
assemblies.
9 Worm case stay (YS928J/YT1232ED)
1
2
1 A YT624E/YT624EDJ
B YS928J/YT1232ED

1
2
1

A 4. Leave the impeller shaft 1 and straight

key 2 on the blower side.

A YT624E/YT624EDJ
B YS928J/YT1232ED

6-9
 AUGER AND WORM CASE CHAS
B

2 1

A CHECKING THE AUGER AND WORM CASE

1. Check:
9 Auger
Deformation → Repair or replace.
Wear/damage → Replace.

A YT624E/YT624EDJ/YS928J
B YT1232ED

A 2. Check:
9 Auger shaft 1
2
Bends/damage → Replace.
1
3. Check:
9 Worm case 2
Cracks/damage → Replace.

A YT624E/YT624EDJ
B YS928J/YT1232ED

1
2

6-10
 IMPELLER, SKID AND SCRAPER CHAS

IMPELLER, SKID AND SCRAPER

(YT624E/YT624EDJ)

23 Nm (2.3 m · kgf, 16 ft · lbf)

16 Nm (1.6 m · kgf, 11 ft · lbf)

23 Nm (2.3 m · kgf, 16 ft · lbf)

1
25 Nm (2.5 m · kgf, 18 ft · lbf)

13 Nm (1.3 m · kgf, 9.4 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the impeller Remove the parts in the order listed.
Auger Refer to “AUGER AND WORM CASE”.
1 Auger pulley 1
2 Straight key 1
3 Shear bolt collar 1
4 Impeller shaft/Straight key 1/1
5 Impeller 1
6 Bearing housing 2 1
7 Skid 2
8 Scraper 1
For installation, reverse the removal pro-
cedure.

6-11
 IMPELLER, SKID AND SCRAPER CHAS

(YS928J)

11

10

6
2

8
3
7
9
4
16 Nm (1.6 m · kgf, 11 ft · lbf)
5 B
25 Nm (2.5 m · kgf, 18 ft · lbf)
25 Nm (2.5 m · kgf, 18 ft · lbf)
24 Nm (2.4 m · kgf, 17 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the impeller, skid and Remove the parts in the order listed.
scraper
Auger Refer to “AUGER AND WORM CASE”.
1 Cover 1 1
2 Auger pulley 1
3 Collar 1 1
4 Shear bolt collar 1
5 Impeller shaft/Straight key 1/1
6 Impeller 1
7 Bearing housing 2 1
8 Skid 2
9 Scraper 1
10 Auger V-belt 1
11 Drive V-belt 1
For installation, reverse the removal pro-
cedure.

6-12
 IMPELLER, SKID AND SCRAPER CHAS

(YT1232ED)

19 Nm (1.9 m · kgf, 13 ft · lbf)

23 Nm (2.3 m · kgf, 16 ft · lbf)

21 Nm (2.1 m · kgf, 15 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the impeller, skid and Remove the parts in the order listed.
scraper
Auger Refer to “AUGER AND WORM CASE”.
1 Belt guard 3 1
2 Auger V-belt 2
3 Auger pulley 1
4 Straight key 1
5 Impeller shaft/Straight key 1/1
6 Impeller/Straight key 1/1
7 Bearing housing 1
8 Skid 2
9 Scraper 1
For installation, reverse the removal pro-
cedure.

6-13
 IMPELLER, SKID AND SCRAPER CHAS
CHECKING THE IMPELLER
1. Check:
9 Impeller
Wear/damage/deformation → Replace.

2. Check:
9 Impeller shaft
Bends/damage → Replace.

A 3. Check:
9 Auger pulley
Wear/damage/deformation → Replace.

A YT624E/YT624EDJ/YS928J
B YT1232ED

A CHECKING THE SCRAPER AND SKID

2 1. Check:
9 Scraper 1
9 Skids 2
Deformation → Repair or replace.
Cracks/damage → Replace.
1
A YT624E/YT624EDJ/YS928J
B YT1232ED

6-14
 IMPELLER, SKID AND SCRAPER CHAS
B

A INSTALLING THE SKID

1. Install:
9 Skids 1
1
(YT624E/YT624EDJ/YS928J)
16 Nm (1.6 m · kgf, 11 ft · lbf)

(YT1232ED)
a
23 Nm (2.3 m · kgf, 16 ft · lbf)

2. Adjust:
9 Clearance a between the road surface
B and the auger end.
Refer to “CHECKING THE SKID” in
chapter 2.
1
A YT624E/YT624EDJ/YS928J
B YT1232ED

6-15
 CHUTE CHAS

CHUTE
(YT624E/YT624EDJ)
(YT624E) (YT624EDJ)
5

5
6

8 7

9
1
2
3
6.7 Nm (0.67 m · kgf, 4.8 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the chute Remove the parts in the order listed.
Negative battery lead
Refer to “ENGINE” in chapter 3.
Cover/Belt guard
1 Chute holder 4
2 Holder spring 4
3 Holder bush 4
4 Chute assembly 1
5 Deflector 1 1
6 Deflector 2 1
7 Ring gear bush 1
8 Chute holder (Resin parts) 2
9 Chute 1 (Resin parts) 1
For installation, reverse the removal pro-
cedure.

6-16
 CHUTE CHAS

(YS928J)

15

6
7
5

8
25 Nm (2.5 m · kgf, 18 ft · lbf)
23 Nm (2.3 m · kgf, 16 ft · lbf)
9 10
2
3
11
4

12

14

13
5.5 Nm (0.55 m · kgf, 4.0 ft · lbf)

5.5 Nm (0.55 m · kgf, 4.0 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the chute Remove the parts in the order listed.
Negative battery lead Refer to “ENGINE” in chapter 3.
Cover 3 Refer to “COVERS AND FUEL TANK” in
chapter 2.
1 Gear cover 1
2 Chute holder 4
3 Holder spring 4
4 Holder bush 4
5 Chute assembly 1
6 Deflector 1 1
7 Deflector 2 1
8 Ring gear bush 1
9 Chute holder (Resin parts) 2
10 Chute 1 (Resin parts) 1

6-17
 CHUTE CHAS

15

6
7
5

8
25 Nm (2.5 m · kgf, 18 ft · lbf)
23 Nm (2.3 m · kgf, 16 ft · lbf)
9 10
2
3
11
4

12

14

13
5.5 Nm (0.55 m · kgf, 4.0 ft · lbf)

5.5 Nm (0.55 m · kgf, 4.0 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

11 Impeller duct (Resin parts) 1
12 Plate 1 1
13 Bracket 2 2
14 Impeller housing (Resin parts) 1
15 Side marker 1
For installation, reverse the removal pro-
cedure.

6-18
 CHUTE CHAS

(YT1232ED)
3

8
7

2
4
12

6
9.8 Nm (0.98 m · kgf, 7.1 ft · lbf)

1 5
11 9

10

10

15 Nm (1.5 m · kgf, 10 ft · lbf)

6.7 Nm (0.67 m · kgf, 4.8 ft · lbf) 6.7 Nm (0.67 m · kgf, 4.8 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the chute Remove the parts in the order listed.
Negative battery lead Refer to “ENGINE” in chapter 3.
Belt guard
1 Retainer 3
2 Chute assembly 1
3 Deflector 1 1
4 Deflector 2 1
5 Ring gear bush 1
6 Cover 1 1
7 Chute holder (Resin parts) 2
8 Chute 1 (Resin parts) 1
9 Impeller duct (Resin parts) 1
10 Bracket 2
11 Impeller housing (Resin parts) 1

6-19
 CHUTE CHAS

8
7

2
4
12

6
9.8 Nm (0.98 m · kgf, 7.1 ft · lbf)

1 5
11 9

10

10

15 Nm (1.5 m · kgf, 10 ft · lbf)

6.7 Nm (0.67 m · kgf, 4.8 ft · lbf) 6.7 Nm (0.67 m · kgf, 4.8 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

12 Side marker 1
For installation, reverse the removal pro-
cedure.

6-20
 STEERING CHAS

STEERING
(YT624E)

17

16 Nm (1.6 m · kgf, 11 ft · lbf) 18

6.5 Nm (0.65 m · kgf, 4.7 ft · lbf)

16

15
16

15

Order Job/Parts to remove Q’ty Remarks

Removing the auger/drive clutch Remove the parts in the order listed.
levers
Negative battery lead Refer to “ENGINE” in chapter 3.
1 Right clutch lever 2 1
2 Plate washer 1
3 Collar 1
4 Collar 1
5 Ratchet spring 1
6 Ratchet cam 1
7 Ratchet cover 1
8 Auger clutch control cable 1
9 Drive clutch control cable 1
10 Spring pin 1
11 Left clutch lever 2 1

6-21
 STEERING CHAS

17

16 Nm (1.6 m · kgf, 11 ft · lbf) 18

6.5 Nm (0.65 m · kgf, 4.7 ft · lbf)

16

15
16

15

Order Job/Parts to remove Q’ty Remarks

12 Clutch lever shaft 1
13 Handle bolt 2
14 Instrument panel mounting nut 2
15 Instrument panel mounting bolt 2
16 Collar 2
17 Auger clutch lever 1
18 Drive clutch lever 1
For installation, reverse the removal pro-
cedure.

6-22
 STEERING CHAS

(YT624EDJ)
16 Nm (1.6 m · kgf, 11 ft · lbf)

6.5 Nm (0.65 m · kgf, 4.7 ft · lbf)

11
17
C 18
10

1 13

7
14

6
5
4 19
23 20 14

13
9 16

C
12 15
16

15

Order Job/Parts to remove Q’ty Remarks

Removing the auger/drive clutch Remove the parts in the order listed.
levers
Negative battery lead Refer to “ENGINE” in chapter 3.
1 Right clutch lever 2 1
2 Plate washer 1
3 Collar 1
4 Collar 1
5 Ratchet spring 1
6 Ratchet cam 1
7 Ratchet cover 1
8 Auger clutch control cable 1
9 Drive clutch control cable 1
10 Spring pin 1
11 Left clutch lever 2 1

6-23
 STEERING CHAS

16 Nm (1.6 m · kgf, 11 ft · lbf)

6.5 Nm (0.65 m · kgf, 4.7 ft · lbf)

11
17
C 18
10

1 13

7
14

6
5
4 19
23 20 14

13
9 16

C
12 15
16

15

Order Job/Parts to remove Q’ty Remarks

12 Clutch lever shaft 1
13 Handle bolt 2
14 Instrument panel mounting nut 2
15 Instrument panel mounting bolt 2
16 Collar 2
17 Auger clutch lever 1
18 Drive clutch lever 1
19 Tilt lock cable 1
20 Tilt lock lever 1
For installation, reverse the removal pro-
cedure.

6-24
 STEERING CHAS

(YS928J)
3

16 Nm (1.6 m · kgf, 11 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the drive clutch lever Remove the parts in the order listed.
Negative battery lead Refer to “ENGINE” in chapter 3.
1 Drive clutch lever 1
2 Right clutch lever 1
3 Arm 1 1
4 Drive clutch control cable 1
For installation, reverse the removal pro-
cedure.

6-25
 STEERING CHAS

(YT1232ED)

16 Nm (1.6 m · kgf, 11 ft · lbf)

7 Nm (0.7 m · kgf, 5 ft · lbf)

C

Order Job/Parts to remove Q’ty Remarks

Removing the auger/drive clutch Remove the parts in the order listed.
levers
Negative battery lead Refer to “ENGINE” in chapter 3.
1 Right clutch lever 2 1
2 Plate washer 1
3 Collar 1
4 Collar 1
5 Ratchet spring 1
6 Ratchet cam 1
7 Ratchet cover 1
8 Auger clutch control cable 1
9 Drive clutch control cable 1
10 Spring pin 1
11 Left clutch lever 2 1

6-26
 STEERING CHAS

16 Nm (1.6 m · kgf, 11 ft · lbf)

7 Nm (0.7 m · kgf, 5 ft · lbf)

C

Order Job/Parts to remove Q’ty Remarks

12 Clutch lever shaft 1
13 Handle bolt 2
14 Auger clutch lever 1
15 Drive clutch lever 1
16 Tilt lock lever 1
17 Tilt lock cable 1
For installation, reverse the removal pro-
cedure.

6-27
 AUGER HOUSING HEIGHT CONTROL MECHANISM CHAS

AUGER HOUSING HEIGHT CONTROL MECHANISM

(YT624EDJ)

35 Nm (3.5 m · kgf, 25 ft · lbf)

2 C

16 Nm (1.6 m · kgf, 11 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the auger housing Remove the parts in the order listed.
height control
Disconnect the tilt lock cable at the
height control lever side.
1 Nut/Plain washer 1/1
2 Bolt/Plain washer 1/1
3 Nut/Plain washer 1/1
4 Tilt lock assembly 1
5 Tilt lock cable 1
6 Boot 1
For installation, reverse the removal pro-
cedure.

6-28
 AUGER HOUSING HEIGHT CONTROL MECHANISM CHAS

(YS928J)

35 Nm (3.5 m · kgf, 25 ft · lbf) 1

5
4

8
9
6

10
35 Nm (3.5 m · kgf, 25 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the auger housing Remove the parts in the order listed.
height control
Disconnect the tilt lock cable at the
height control lever side.
1 Chute cable 1
2 Control cable 1
3 Duct 2 1
4 Nut/Plain washer 1/1
5 Bolt/Plain washer 1/1
6 Nut/Plain washer 1/1
7 Bolt/Plain washer 1/1
8 Tilt lock assembly 1
9 Tilt lock cable 1
10 Boot 1
For installation, reverse the removal pro-
cedure.

6-29
 AUGER HOUSING HEIGHT CONTROL MECHANISM CHAS

(YT1232ED)

2
2
1

3
4
3

7
5

Order Job/Parts to remove Q’ty Remarks

Removing the auger housing Remove the parts in the order listed.
height control
Rear cover
1 Tilt lock cable 1 Disconnect the tilt lock cable at the
height control lever side.
2 Cotter pin/Plain washer 2/2
3 Upper shaft/Plain washer 1/2
4 Cotter pin/Plain washer 2/2
5 Lower shaft 1
6 Tilt lock assembly 1
7 Boot 1
For installation, reverse the removal pro-
cedure.

6-30
 AUGER HOUSING HEIGHT CONTROL MECHANISM CHAS
CHECKING THE TILT LOCK CABLE
1. Check:
9 Lever pivot play a

Lever pivot play:

3–4 mm (0.12–0.16 in)

a Out of specification → Adjust.

A 2. Adjust:
9 Lever pivot play
Loosen the locknut 1 and adjust using
2 the adjuster 2.

A YT624EDJ/YT1232ED
1 B YS928J

1
2

A CHECKING THE AUGER HOUSING HEIGHT

CONTROL MECHANISM
1. Check:
9 Tilt rod 1
Bends/damage → Replace.
2
Rust → Clean using 400–600–grit
sandpaper.
9 Tilt lock assembly 2
1 Cracks/bends/damage → Replace.

A YT624EDJ/YS928J
B
B YT1232ED

6-31
 AUGER HOUSING HEIGHT CONTROL MECHANISM CHAS
A ASSEMBLING THE AUGER HOUSING
HEIGHT CONTROL MECHANISM
(YT624EDJ/YS928J)
1. Assemble:
9 Boot 1
4
9 Tilt lock cable 2
C
9 Tilt lock assembly 3
9 Bolt 4
35 Nm (3.5 m · kgf, 25 ft · lbf)
2
3 A YT624EDJ
C
B YS928J

6-32
AUGER HOUSING HEIGHT CONTROL MECHANISM CHAS
(YT1232ED)
1. Assemble:
9 Tilt lock assembly 1
9 Lower shaft 2
9 Plain washer
9 Cotter pin 3
9 Upper shaft 4
9 Plain washer
9 Cotter pin 5

6-33
 ELECTRICAL COMPONENTS ELEC
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS (YT624E/YT624EDJ)
1 Working light
2 Engine switch
3 Chute direction control switch
4 Wire harness
5 Spark plug cap
6 TCI unit
7 Chute motor
8 Battery
9 Starter relay
0 Rectifier/Regulator
q Fuse

7-1
 CIRCUIT DIAGRAM (YT624E/YT624EDJ)
B
5
B/W
STOP ON START
B/W
B R/W B/W B/W R/W
2 4 B/W Br R B B R R/Y
R R
W
Br
1 Y/R R R/W
R/Y

R/W
6

Y/R B
3

B
9 7

R LH STOP RH
B R/W W/G W/G R/Y R/B R/B R/Y W/G

7-2
R/Y R/B B W/G W/G B R/B
R/B
W/G
R/B
q B
B W/G
R/B

0
ELECTRICAL COMPONENTS

R/B
8
W/G

1 TCI unit 9 Starter relay Color code Y/R Yellow/Red

2 TCI magneto 0 Starter motor B Black W/G White/Green
3 Spark plug q Battery Br Brown
4 Rectifier/Regulator R Red
ELEC

5 Engine switch W White

6 Working light B/W Black/White
7 Chute direction control R/B Red/Black
switch R/W Red/White
8 Chute motor R/Y Red/Yellow
 ELECTRICAL COMPONENTS ELEC
ELECTRICAL COMPONENTS (YS928J)
1 Electromagnetic clutch switch t Battery
2 Chute direction control switch y Oil level warning light
3 TCI unit
4 Spark plug cap
5 Working light
6 Electromagnetic clutch
7 Chute motor
8 Oil switch
9 Starter motor
0 Voltage regulator
q Rectifier/Regulator
w Electromagnetic clutch relay
e Fuse
r Engine switch

1 6
2 5
y
3

e
0 9

w
q

7-3
 CIRCUIT DIAGRAM (YS928J)

2 3
7
4 5 6
Y G B G
B B B B B R
B R
1
W W B B B B B R
B R/Y

W W R B
L
8
G/R STOP ON STARTCHECK
B
B/W B/W B/W
R R
R
R/Y Br
W R/W
u B/R
B

B/R R/W B/W

y L
Br R B
G/R

B L R/Y R B
W B R/W B/W
R/Y
i B
R R R/Y R/W

7-4
9
B/R
R L LH STOP RH
R/B R/B
R/Y
W/G
R/B W/G
w q W/G W/G
t B
R/B
r 0 R/B

W/G
B/Y e R/B R/Y W/G

R W/G B R/B
R/Y
B R

W/G B R/B
R/B R/Y W/G
ELECTRICAL COMPONENTS

1 Rectifier/Regulator 9 Chute direction control y TCI magneto Color code B/W Black/White
2 Oil level warning light switch u TCI unit B Black B/Y Black/Yellow
3 Electromagnetic clutch 0 Chute motor i Spark plug Br Brown R/B Red/Black
switch q Oil level switch G Green R/W Red/White
ELEC

4 Electromagnetic clutch w Starter motor L Blue R/Y Red/Yellow

5 Voltage regulator e Electromagnetic clutch R Red W/G White/Green
6 Auto choke relay W White
7 Working light r Fuse Y Yellow
8 Engine switch t Battery B/R Black/Red
 ELECTRICAL COMPONENTS ELEC
ELECTRICAL COMPONENTS (YT1232ED)
1 Wire harness
2 Fuse
3 Engine switch
4 Chute direction control switch
5 Voltage regulator assembly
6 Rectifier/Regulator
7 Chute motor
8 Positive battery lead
9 Negative battery lead
0 Battery
q Working light

2
1

9
8
0
6

7-5
 CIRCUIT DIAGRAM (YT1232ED)
B/W
1 3
5
Y/R Y/R

B
4
L
2 B

6
STOP ON START
B
R B/W
R
Br R/W B/W
R/W R/W Br R B

R R/Y R B
B R/W B/W
R/Y

B W W R
8
7

7-6
LH STOPRH
R/B R/B
w R/Y
W/G W/G
W/G
B R R R R B B R/B R/Y W/G
W W W W R/B W/G B R/B

q
W/G B R/B
R/B R/Y W/G

M 0
R/B
ELECTRICAL COMPONENTS

9 W/G

1 TCI unit 9 Chute motor Color code R/Y Red/Yellow

2 Spark plug 0 Starter motor B Black W/G White/Green
3 TCI magneto q Battery Br Brown Y/R Yellow/Red
4 Voltage regulator w Rectifier/Regulator L Blue
ELEC

5 Working light R Red

6 Engine switch W White
7 Chute direction control B/W Black/White
switch R/B Red/Black
8 Fuse R/W Red/White
 IGNITION SYSTEM ELEC
IGNITION SYSTEM
TROUBLESHOOTING
THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK)

Checking procedures
1. Spark plug 5. Air gap
2. Checking sparks 6. Engine switch
3. Spark plug cap resistance 7. Wire harness (ignition system circuit)
4. TCI unit coil resistance

TIP
9 Remove the following part(s) before troubleshooting:
1) Battery cover (Except YS928J) 1) Left side cover (YS928J)
2) Fan case
9 Troubleshoot with the following special tool(s):
Pocket tester: Ignition checker:
YU-03112-C, 90890-03112 YM-34487

1. Spark plug
9 Check the spark plug condition.
Refer to “CHECKING THE SPARK PLUG”
in chapter 2.
OUT OF SPECIFICATION
OK OR DEFECTIVE
Re-gap or replace the spark plug.

2. Check sparks
9 Remove the spark plug cap 1.
3
9 Connect the ignition checker 2.

Spark plug cap 1 → Ignition checker 2

Ignition checker lead → Spark plug 3

9 Check whether the sparks a are at or

above specification when cranking the
engine.

Minimum spark gap:

6 mm (0.24 in)

MEETS
NO SPARKS SPECIFICATION
The ignition system is OK.

7-7
 IGNITION SYSTEM ELEC

3. Spark plug cap resistance TIP

9 Remove the spark plug cap. 9 Do not remove the spark plug cap by pull-
9 Connect the pocket tester (tester range “Ω ing it from the high tension lead.
× 1k”) to the spark plug cap. 9 To remove → Turn counterclockwise.
9 To install → Turn clockwise.
Tester positive lead → Spark plug side 9 When installing the spark plug cap, check
1 the high tension lead.
Tester negative lead → High tension lead 9 Cut the high tension lead approx. 5 mm
side 2 from the end, and then install.

Spark plug cap resistance:

3.7–6.3 kΩ at 20 ºC (68 ºF)

OUT OF
OK SPECIFICATION
Replace the spark plug cap.

4. TCI unit coil resistance

9 Remove the TCI unit.
9 Connect the pocket tester (tester range “Ω Ω×1K
× 1k”) to the TCI unit terminals.

Tester positive lead → Black/white termi- 1

nal 1
2
Tester negative lead → High tension lead
2

TCI unit coil resistance:

(YT624E/YT624EDJ)
6.5 kΩ ± 20 % at 20 ºC (68 ºF)
(YS928J/YT1232ED)
11.7 kΩ ± 10 % at 20 ºC (68 ºF)

OUT OF
OK SPECIFICATION
Replace the TCI unit.

7-8
 IGNITION SYSTEM ELEC

5. Air gap
9 Measure the air gap between the rotor
magneto and the TCI unit.

TCI air gap:

0.4–0.6 mm (0.015–0.023 in)

OUT OF
OK SPECIFICATION
Adjust the air gap.

6. Engine switch
9 Check the engine switch for conductance
between black/white and black.

NO CONDUCTANCE
CONDUCTANCE Replace the engine switch.

7. Wire harness
Refer to “CIRCUIT DIAGRAM”.
NO CONTINUITY
OK Correct or replace any faulty part.

Replace the TCI unit.

7-9
 CHARGING SYSTEM ELEC
CHARGING SYSTEM
TROUBLESHOOTING
THE BATTERY IS NOT BEING CHARGED

Checking procedures
1. Fuse 4. Charging coil resistance
2. Battery 5. Wire harness (charging system circuit)
3. Charging voltage

TIP
9 Remove the following part(s) before troubleshooting.
1) Battery cover (Except YS928J)
2) Left side cover (YS928J)
9 Troubleshoot with the following special tool(s).
Digital tachometer: Pocket tester:
YU-39951-B, 90890-06760 YU-03112-C, 90890-03112

1. Fuse
9 Check for continuity.

NO CONTINUITY
CONTINUITY Replace the fuse.

2. Battery
9 Check the battery.
Refer to “ELECTRICAL” in chapter 2.
OUT OF
OK SPECIFICATION
9 Clean the battery terminal.
9 Add distilled water.
9 Recharge or replace the battery.

7-10
 CHARGING SYSTEM ELEC

3. Charging voltage
9 Connect the engine tachometer to the high
tension lead.
9 Connect the pocket tester (tester range 20
V DC) to the battery.

Tester positive lead → Positive battery 2

terminal 1
Tester negative lead → Negative battery 1
terminal 2

9 Start the engine and measure the voltage

at the specified engine speed.

(YT624E/YT624EDJ)
2300 r/min
(YS928J)
3800 r/min
(YT1232ED)
3600 r/min

Charging voltage:
12–16 V

OUT OF SPECIFIED VOLTAGE

SPECIFICATION
Replace the battery.

7-11
 CHARGING SYSTEM ELEC

4. Charging coil resistance A

9 Disconnect the coil assembly coupler from
the wire harness.
9 Connect the pocket tester (tester range “Ω
× 1”) to the coil assembly lead terminal.

(Except YS928J)
Tester positive lead → White terminal 1
Tester negative lead → Body ground 2
(YS928J)
Tester positive lead → White terminal 1
Tester negative lead → White terminal 2

Charging coil resistance:

(YT624E/YT624EDJ)
0.5 Ω ± 20% at 20 ºC (68 ºF) 1
(YS928J)
0.26 Ω ± 20% at 20 ºC (68 ºF)
2
(YT1232ED)
B
1.2 Ω ± 20% at 20 ºC (68 ºF)

A YT624E/YT624EDJ
B YS928J
C YT1232ED
OUT OF
OK SPECIFICATION
Replace the stator coil.

5. Wire harness
Refer to the “CIRCUIT DIAGRAM”.

DEFECTIVE CONNECTION
OK OR BROKEN WIRING
Correct or replace any faulty part.

Replace the rectifier/regulator.

7-12
 ELECTRIC STARTING SYSTEM ELEC
ELECTRIC STARTING SYSTEM
TROUBLESHOOTING
THE STARTER MOTOR FAILS TO TURN

Checking procedures
1. Fuse 5. Engine switch
2. Battery 5. Electromagnetic clutch switch (YS928J)
3. Starter motor 6. Wire harness
4. Starter relay (Except YS928J)
4. Electromagnetic clutch relay (YS928J)

TIP
9 Remove the following part(s) before troubleshooting.
1) Control box (YT1232ED)
1) Fan case (Except YT1232ED)
9 Troubleshoot with the following special tool(s).
Pocket tester:
YU-03112-C, 90890-03112

1. Fuse
9 Check for continuity.

NO CONTINUITY
CONTINUITY Replace the fuse.

2. Battery
9 Check the battery.
Refer to “ELECTRICAL” in chapter 2.
OUT OF
OK SPECIFICATION
9 Clean the battery terminal.
9 Add distilled water.
9 Recharge or replace the battery.

7-13
 ELECTRIC STARTING SYSTEM ELEC

3. Starter motor
9 Remove the starter motor from the engine
and check it.

Positive battery terminal → Starter motor

terminal 1
Negative battery terminal → Starter
motor body 2

STARTER MOTOR
TURNS
WARNING
9 The check is likely to produce sparks,
* Except YS928J (Refer to therefore, make sure no flammable gas
P7-15 for YS928J) or fluid is in the vicinity.
9 If the starter motor turns, immediately
release the leads.
OK STARTER MOTOR
DOES NOT TURN Check the starter motor, and repair or
4. Starter relay replace.
9 Disconnect the coupler and terminals (× 2)
from the starter relay.
9 Connect the starter relay to the battery
using the jumper lead.

Positive battery terminal → Starter relay

green/yellow terminal 1
Negative battery terminal → Starter relay
blue/white terminal 2

9 Connect the pocket tester (tester range “Ω

× 1”) to the relay terminal, and check the
relay for continuity.

Tester positive lead → Terminal 3

Tester negative lead → Terminal 4

NO CONTINUITY
CONTINUITY Replace the defective starter relay.

7-14
 ELECTRIC STARTING SYSTEM ELEC

5. Engine switch
9 Check for conductance among brown, red/
white and red.

NO CONDUCTANCE
CONDUCTANCE Replace the engine switch.

6. Wire harness
Refer to “CIRCUIT DIAGRAM”.
DEFECTIVE CONNECTION
OR BROKEN WIRING
Correct or replace any faulty part.

(YS928J)
4. Electromagnetic clutch relay
9 Disconnect the coupler from the electro-
magnetic clutch relay. 3 1 2 1
9 Connect the electromagnetic clutch relay to
3 4
the battery using the jumper lead.
4 2
Positive battery terminal → Starter relay
red/yellow terminal 2 1
Negative battery terminal → Starter relay
black terminal 4 2

9 Connect the pocket tester (tester range “Ω

× 1”) to the relay terminal, and check the
relay for continuity.

Tester positive lead →Terminal 1 3

Tester negative lead → Terminal 3 4

NO CONTINUITY
CONTINUITY Replace the electromagnetic clutch relay.

7-15
 ELECTRIC STARTING SYSTEM ELEC

5. Electromagnetic clutch switch

9 Disconnect the coupler from the electro-
magnetic clutch switch lead.
9 Connect the pocket tester (tester range “Ω
× 1”) to the coupler terminal on the electro-
magnetic clutch switch lead.

Tester positive lead → Black terminal

Tester negative lead → Black terminal

9 Hold the drive clutch lever and check that

there is continuity when the auger clutch
lever is pulled, and check that there is no
continuity when the drive clutch lever is
released.

NO CONTINUITY
CONTINUITY Replace the electromagnetic clutch switch.

6. Engine switch
9 Check for conductance among brown, red/
white and red.
NO CONDUCTANCE
CONDUCTANCE Replace the engine switch.

7. Wire harness
Refer to “CIRCUIT DIAGRAM”.

DEFECTIVE CONNECTION
OR BROKEN WIRING
Correct or replace any faulty part.

7-16
 ELECTRIC STARTING SYSTEM ELEC

STARTER MOTOR (YT624E/YT624EDJ)

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the starter motor Remove the parts in the order listed.
Fan case
1 Starter motor lead 1
2 Starter motor 1
For installation, reverse the removal pro-
cedure.
Disassembling the starter motor Disassemble the parts in the order list-
ed.
1 Circlip 1
2 Pinion stopper/Return spring 1/1
3 Pinion assembly 1
4 Front bracket/Gasket 1/1
5 Washer 1
6 Rear bracket/Gasket 1/1

7-17
 ELECTRIC STARTING SYSTEM ELEC

10 Nm (1.0 m · kgf, 7.2 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

7 Brush/Brush spring 2/2
8 Armature assembly 1
9 Stator assembly 1
For assembly, reverse the disassembly
procedure.

7-18
 ELECTRIC STARTING SYSTEM ELEC

(YS928J)

7 2
1
1

6
3
2

Order Job/Parts to remove Q’ty Remarks

Removing the starter motor Remove the parts in the order listed.
Right side cover Refer to “COVERS AND FUEL TANK” in
chapter 2.
1 Starter motor lead 2
2 Starter motor 1
For installation, reverse the removal pro-
cedure.
Disassembling the starter motor Disassemble the parts in the order list-
ed.
1 Starter clutch 1
2 Rear bracket 1
3 Insulator 1
4 Stator assembly 1
5 Armature assembly 1

7-19
 ELECTRIC STARTING SYSTEM ELEC

7 2
1
1

6
3
2

Order Job/Parts to remove Q’ty Remarks

6 Brush spring 4
7 Housing assembly 1
8 Stator drive lever 1
For assembly, reverse the disassembly
procedure.

7-20
 ELECTRIC STARTING SYSTEM ELEC

(YT1232ED)
16 Nm (1.6 m · kgf, 11 ft · lbf)

2
8

3
2
1

5
6

Order Job/Parts to remove Q’ty Remarks

Removing the starter motor Remove the parts in the order listed.
Fan case
1 Starter motor lead 1
2 Starter motor 1
For installation, reverse the removal pro-
cedure.
Disassembling the starter motor Disassemble the parts in the order list-
ed.
1 Stop ring 1
2 Pinion stopper/Return spring 1/1
3 Pinion assembly 1
4 Front bracket/Gasket 1/1
5 Rear bracket/Gasket 1/1
6 Brush/Brush spring 2/2

7-21
 ELECTRIC STARTING SYSTEM ELEC

16 Nm (1.6 m · kgf, 11 ft · lbf)

2
8

3
2
1

5
6

Order Job/Parts to remove Q’ty Remarks

7 Armature assembly 1
8 Stator assembly 1
For assembly, reverse the disassembly
procedure.

7-22
 ELECTRIC STARTING SYSTEM ELEC
CHECKING THE STARTER MOTOR
1. Measure:
9 Carbon brush length a

Carbon brush length:

(YT624E/YT624EDJ)
10 mm (0.39 in)
a (YS928J)
10 mm (0.39 in)
(YT1232ED)
12.5 mm (0.49 in)
Limit:
(YT624E/YT624EDJ)
3.5 mm (0.14 in)
(YS928J)
6.0 mm (0.24 in)
(YT1232ED)
6.0 mm (0.24 in)

Out of specification → Replace.

2. Check:
9 Commutator
Damage/uneven wear/bur nout →
Replace or repair.

3. Check:
9 Armature coil (insulation/continuity)
Defects → Replace the starter motor.

1 Continuity check
2 Insulation check
3 Armature coil

7-23
ELECTRIC STARTING SYSTEM ELEC
4. Measure:
9 Commutator outside diameter a

Commutator outside diameter:

(YT624E/YT624EDJ)
22 mm (0.87 in)
(YS928J/YT1232ED)
28 mm (1.10 in)
Limit:
(YT624E/YT624EDJ)
21 mm (0.83 in)
(YS928J/YT1232ED)
27 mm (1.06 in)

Out of specification → Replace.

5. Measure:
9 Mica undercut (depth) a

a Mica undercut (depth):

(YT624E/YT624EDJ)
1.5 mm (0.06 in)
(YS928J)
0.6 mm (0.02 in)
(YT1232ED)
2.0 mm (0.08 in)

Out of specification → Repair.

TIP
9 Scrape the mica using a hacksaw blade.
9 The mica of the commutator must be under-
cut to ensure proper operation of the com-
mutator.

7-24
 CHUTE CONTROL AND LIGHTING SYSTEMS ELEC
CHUTE CONTROL AND LIGHTING SYSTEMS
TROUBLESHOOTING
THE CHUTE FAILS TO ROTATE

Checking procedures
1. Fuse 4. Chute direction control switch
2. Battery 5. Wire harness
3. Chute motor

TIP
9 Remove the following part(s) before troubleshooting.
1) Battery cover (Except YS928J) 2) Left side cover (YS928J)
2) Belt guard (Except YS928J)
9 Troubleshoot with the following special tool(s).
Pocket tester:
YU-03112-C, 90890-03112

1. Fuse
9 Check for continuity.

NO CONTINUITY
CONTINUITY Replace the fuses.

2. Battery
9 Check the battery.
Refer to “ELECTRICAL” in chapter 2.
OUT OF
OK SPECIFICATION
9 Clean the battery terminal.
9 Add distilled water.
9 Recharge or replace the battery.

7-25
 CHUTE CONTROL AND LIGHTING SYSTEMS ELEC

3. Chute motor TIP

9 Disconnect the chute motor coupler from A bimetal circuit breaker is built into the motor.
the wire harness. Restoration will take approx. 60 seconds once
9 Connect the pocket tester (tester range “Ω the motor is turned off.
× 1”) to the chute motor lead terminals.
A
Tester positive lead → Red/black termi-
nal 1
Tester negative lead → White/green ter-
minal 2

A YT624E/YT624EDJ
B YS928J/YT1232ED
NO CONTINUITY
CONTINUITY Replace the chute motor.

4. Chute direction control switch

NO CONTINUITY
CONTINUITY Replace the chute direction control switch.

5. Wire harness
Refer to “CIRCUIT DIAGRAM”.

7-26
 CHUTE CONTROL AND LIGHTING SYSTEMS ELEC

THE WORKING LIGHT FAILS TO COME ON

Checking procedures
1. Bulb and bulb socket 3. Wire harness
2. Lighting coil resistance 4. Voltage regulator

TIP
9 Remove the following part(s) before troubleshooting.
1) Right side cover (YS928J)
2) Working light unit
9 Troubleshoot with the following special tool(s).
Pocket tester:
YU-03112-C, 90890-03112

1. Bulb and bulb socket

9 Check the bulb and bulb socket for continui-
ty.

NO CONTINUITY
CONTINUITY Replace the bulb or bulb socket.

7-27
 CHUTE CONTROL AND LIGHTING SYSTEMS ELEC

2. Lighting coil resistance A

9 Disconnect the coil assembly coupler from
the wire harness.
9 Connect the pocket tester (tester range “Ω
× 1”) to the coil assembly lead terminal.

Tester positive lead → Yellow/red 1

Tester negative lead → Body ground 2

Lighting coil resistance:

(YT624E/YT624EDJ)
0.4 Ω ± 20 % at 20 ºC (68 ºF)
(YS928J)
0.61 Ω ± 20 % at 20 ºC (68 ºF)
(YT1232ED)
0.36 Ω ± 20 % at 20 ºC (68 ºF) 2

1
B

A YT624E/YT624EDJ
B YS928J
C YT1232ED
OUT OF
OK SPECIFICATION
Replace the stator coil.

3. Wire harness
Refer to “CIRCUIT DIAGRAM”.
DEFECTIVE CONNECTION
OR BROKEN WIRING
Correct or replace any faulty part.

7-28
 SIGNAL SYSTEM ELEC
SIGNAL SYSTEM
TROUBLESHOOTING (YS928J)
THE OIL LEVEL WARNING LIGHT DOES NOT COME ON

Checking procedures
1. Bulb and bulb socket 3. Oil level switch
2. Engine switch 4. Wire harness

TIP
9 Remove the following part(s) before troubleshooting.
1) Engine
2) Crankcase cover
9 Troubleshoot with the following special tool(s).
Pocket tester:
YU-03112-C, 90890-03112

1. Bulb and bulb socket

9 Check the bulb and bulb socket for continui-
ty.

NO CONTINUITY
CONTINUITY Replace the bulb or bulb socket.

2. Engine switch

NO CONTINUITY
CONTINUITY Replace the engine switch.

7-29
 SIGNAL SYSTEM ELEC

3. Oil level switch

9 Remove the oil level switch from the crank-
case.
9 Connect the pocket tester (tester range “Ω
× 1”) to the oil level switch lead coupler ter-
minal. 1 2
Tester positive lead → Blue terminal 1
Tester negative lead → Body ground 2

9 Check the oil level switch for continuity.

Continuity → OK
No continuity when reversed → OK

NO CONTINUITY
OK Replace the oil level switch.

4. Wire harness
Refer to “CIRCUIT DIAGRAM”.

7-30
 CHAPTER 8.

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model name YT624E YT624EDJ YS928J YT1232ED
Model code number 7RV1 7RV3 7VY1 7BE1
Dimensions:
Overall length mm (in) 1464 (57.63) 1558 (61.34) 1707 (67.20)
Overall width mm (in) 615 (24.21) 730 (28.74) 830 (32.68)
Overall height mm (in) 1095 (43.11) 1105 (43.50) 1360 (53.54)
Weight kg (lb) 102 (226) 118 (261) 169 (375) 246 (542)
Engine:
Engine name/ MZ175E/7CPS MZ250E/7VKS MZ360E/7CUT
code number
Engine type Air cooled 4-stroke gasoline OHV
Cylinder arrangement single-cylinder
Displacement L (cm3) 0.171 (171) 0.251 (251) 0.357 (357)
Bore × Stroke mm (in) 66.0 × 50.0 75.0 × 57.0 85.0 × 63.0
(2.59 × 1.97) (2.95 × 2.24) (3.35 × 2.48)
Compression ratio 8.5 : 1 8.2 : 1 8.1 : 1
Standard compression 400–600 450–550
pressure (4.0–6.0, 58–87) (4.5–5.5,
kPa (kgf/cm2, psi) 65.25–79.75)
Maximum torque 11 (1.1)/2500 17 (1.7)/2500 24.5 (2.5)/2500
Nm (m·kgf)/r/min
Starting method Electric starter and Recoil starter Electric starter
Ignition system TCI
Ignition timing 23°
Spark plug type NGK BPR4ES
Spark plug gap mm (in) 0.7–0.8 (0.027–0.031)
Air filter type Silencer
Lubrication system Wet sump

8-1
 GENERAL SPECIFICATIONS SPEC
Model name YT624E YT624EDJ YS928J YT1232ED
Model code number 7RV1 7RV3 7VY1 7BE1
Engine oil:
Engine oil quantity 0.6 1.0 1.1
L (US qt, lmp qt) (0.63, 0.53) (1.06, 0.88) (1,16, 0.97)
Recommended engine oil YAMALUBE SAE 5W-30,
type API Service SE type or higher
–30 –20 –10 0 10 20 30 40 °C

SAE 5W-30

–20 0 10 30 50 70 90 110 °F

Worm case oil:

Worm case oil 0.07 0.08
L (US qt, lmp qt) (0.073, 0.062) (0.08, 0.07)
Recommended worm case YAMALUBE
oil type SAE 10W-40 API Service SE type or higher
H.S.T. oil:
H.S.T. oil quantity 0.92 0.5
L (US qt, lmp qt) (0.97, 0.80) (0.53, 0.44)
Recommended H.S.T. oil Diesel engine oil 10W-30, Class CD or higher
type
Transmission oil:
Transmission oil quantity — 2.0
L (US qt, lmp qt) (2.11, 1.76)
Recommended transmis- — YAMALUBE
sion oil type SAE 10W-40
API Service SE
type or higher
Fuel tank:
Recommended fuel Unleaded regular gasoline
Fuel tank capacity 4.5 (1.19, 0.99) 6.7 (1.77, 1.47)
L (US gal, lmp gal)

8-2
 GENERAL SPECIFICATIONS SPEC
Model name YT624E YT624EDJ YS928J YT1232ED
Model code number 7RV1 7RV3 7VY1 7BE1
Snow blowing mechanism:
Snow blowing capacity 35 (77161) 50 (110231) 76 (167550)
t (lb)/h
Snow clearing width 615 (24.21) 715 (28.15) 815 (32.09)
mm (in)
Snow clearing height 440 (17.32) 510 (20.08) 570 (22.44)
mm (in)
Snow blowing distance 14 (551) 15 (590) 16 (629.92) 19 (748.03)
m (in)
Snow blowing system Dual-stage auger blower
Chute rotation angle 220° 220° 230°
Clearance between auger 5 (0.2)
end and road surface
mm (in)
Auger V-belt LB-36 × 1 Orange LB-42 × 1 LA-40 × 2
(Mitsuboshi Belting Co.) Super Gold Super Gold
1000 1000
(Mitsuboshi (Mitsuboshi
Belting Co.) Belting Co.)
Auger clutch tension spring 47 (1.85) 52 (2.05)
set length mm (in)
Drive:
Driving system Endless rubber crawler
Forward km/h 0–3.2 0–3.2 0–1.35 (Low)
(mi/h) (0–2.0) (0–2.0) (0–0.84)
0–3.49 (High)
(0–2.17)
Reverse km/h 0–2.45 0–2.4 0–0.75 (Low)
(mi/h) (0–1.52) (0–1.5) (0–0.47)
0–1.80 (High)
(0–1.12)
Track size (width × link 130 × 19 × 64 130 × 20 × 64 180 × 27 × 63.9
quantity × pitch) mm (in) (5.12 × 0.75 × 2.52) (5.12 × 0.79 × (7.09 × 1.06 ×
2.52) 2.52)
Track slack mm (in) 11–16 (0.43–0.63) 20–30 (0.79–
(when pressed by 5 kgf (11 lbf) force) 1.18) (when
pressed by
10 kgf (22 lbf)
force)
Drive V-belt LA-29 × 1 Orange LA-33 × 1 LA-32 × 1
(Mitsuboshi Belting Co.) Orange Orange
(Mitsuboshi (Mitsuboshi
Belting Co.) Belting Co.)
Drive clutch tension spring 47 (1.85)
set length mm (in)

8-3
 GENERAL SPECIFICATIONS SPEC
Model name YT624E YT624EDJ YS928J YT1232ED
Model code number 7RV1 7RV3 7VY1 7BE1
Battery:
Battery type GM14Z-3B 40B19R
Battery capacity 12 V, 14 Ah 12 V, 27 Ah
Electrolyte specific gravity 1.28
Working light:
Working light bulb 12 V, 23 W × 1

ENGINE
Model name YT624E YT624EDJ YS928J YT1232ED
Model code number 7RV1 7RV3 7VY1 7BE1
Piston: mm (in)
Piston clearance 0.015–0.040 0.024–0.038 0.015–0.030
(0.0005–0.0011) (0.0009– (0.0005–
0.0014) 0.0011)
<Limit> 0.1 (0.04)
Piston skirt “D” 65.975–65.990 74.975–74.990 84.977–84.998
(2.5974–2.5980) (2.9517– (3.3455–
2.9523) 3.3463)
<Limit> 65.9 (2.5944) 74.9 (2.9488) 84.9 (3.3425)
Measuring point “H” 10 (0.393) 10 (0.393) 5 (0.196)
Piston pin hole inside diam- 16.002–16.013 18.004–18.015 20.000–20.015
eter (0.6299–0.6304) (0.7088– (0.7875–
0.7092) 0.7879)
<Limit> 16.05 (0.6318) 18.05 (0.7106) 20.05 (0.7893)
Piston pin: mm (in)
Piston pin diameter 15.995–16.000 17.995–18.000 19.995–20.000
(0.6297–0.6299) (0.7084– (0.7872–
0.7086) 0.7874)
<Limit> 15.95 (0.6279) 17.95 (0.7066) 19.95 (0.7854)

8-4
 GENERAL SPECIFICATIONS SPEC
Model name YT624E YT624EDJ YS928J YT1232ED
Model code number 7RV1 7RV3 7VY1 7BE1
Piston ring: mm (in)
Top ring
Type Barrel face
Dimensions “B × T” 1.5 × 2.7 1.5 × 3.1 1.5 × 3.6
(0.059 × 0.106) (0.059 × 0.122) (0.059 × 0.141)
End gap 0.20–0.40 0.20–0.35
(0.008–0.016) (0.008–0.013)
<Limit> 0.9 (0.0354)
Side clearance 0.04–0.08 0.03–0.07
(0.0016–0.0031) (0.0011–
0.0027)
<Limit> 0.1 (0.0039)
2nd ring
Type Taper
Dimensions “B × T” 1.5 × 2.7 1.5 × 3.1 1.5 × 3.6
(0.059 × 0.106) (0.059 × 0.122) (0.059 × 0.141)
End gap 0.20–0.40 0.20–0.35
(0.008–0.016) (0.008–0.013)
<Limit> 0.9 (0.0354)
Side clearance 0.02–0.06 0.03–0.07
(0.0008–0.0023) (0.0011–
0.0027)
<Limit> 0.1 (0.0039)
Oil ring
B
Type 3-piece type
Dimensions T 2.5 × 2.8 2.5 × 2.5 3.0 × 3.0
“B × T” (0.098 × 0.110) (0.098 × 0.098) (0.118 × 0.118)
End gap 0.20–0.40 0.20–0.70
(0.008–0.016) (0.008–0.027)
<Limit> 0.9 (0.0354) 1.2 (0.0472)
Cylinder head: mm (in)
Warpage limit 0.1 (0.004)
Cylinder: mm (in)
Inside diameter “D” 66.005–66.015 75.005–75.015 85.000–85.020
(2.5986–2.5990) (2.9529– (3.3464–
2.9533) 3.3472)
<Limit> 66.15 (2.6043) 75.15 (2.9586) 85.05 (3.3484)
Warpage limit 0.05 (0.002)

8-5
 GENERAL SPECIFICATIONS SPEC
Model name YT624E YT624EDJ YS928J YT1232ED
Model code number 7RV1 7RV3 7VY1 7BE1
Crankshaft: mm (in)
Big end side clearance “A” 0.2–0.6 0.2–0.65
(0.007–0.025) (0.007–0.025)
<Limit> 0.8 (0.031)
Runout “B” 0.02 (0.0008)
<Limit> 0.04 (0.0016)
Crank pin outside diameter 27.969–27.984 31.969–31.984 35.969–35.984
“C” (1.1011–1.1017) (1.2586– (1.4160–
1.2592) 1.4166)
<Limit> 27.9 (1.0984) 31.9 (1.2559) 35.9 (1.4133)
Connecting rod:
Small end diameter “A” 16.006–16.020 18.006–18.020 20.006–20.020
(0.6301–0.6307) (0.7088– (0.7876–
0.7094) 0.7881)
Oil clearance 0.006–0.025 (0.0002–0.0009)
Big end diameter 28.000–28.015 32.000–32.015 36.000–36.015
“B” (1.1023–1.1029) (1.2598– (1.4173–
1.2604) 1.4179)
Oil clearance 0.015–0.040 (0.0006–0.0016)
<Limit> 0.1 (0.004)
Camshaft: mm (in)
Camshaft outside length
Cam dimension
“A” IN 26.85–26.95 32.50–32.60
(1.057–1.061) (1.280–1.283)
<Limit> 26.65 (1.049) 32.30 (1.272)
“A” EX 26.63–26.73 32.50–32.60
(1.048–1.052) (1.280–1.283)
<Limit> 26.43 (1.032) 32.30 (1.272)
“B” IN 21.95–22.05 26.03–26.13
(0.864–0.868) (1.024–1.028)
<Limit> 21.75 (0.856) 25.83 (1.020)
“B” EX 22.08–22.18 (0.869–0.873) 26.03–26.13
(1.024–1.028)
<Limit> 21.77 (0.857) 25.83 (1.020)
Camshaft journal diameter 14.965–14.990 (0.5891–0.5901) 15.965–15.990
(0.6285–
0.6295)

8-6
 GENERAL SPECIFICATIONS SPEC
Model name YT624E YT624EDJ YS928J YT1232ED
Model code number 7RV1 7RV3 7VY1 7BE1
Valve: mm (in)
Valve
Head diameter
“A” IN 24.0 (0.94) 29.0 (1.14) 32.0 (1.26)
EX 22.0 (0.87) 25.0 (0.98) 27.0 (1.06)
Stem diameter
“B” IN 5.448–5.463 (0.2144–0.2150) 5.984–5.963 (0.2341–0.2347)
EX 5.448–5.463 (0.2144–0.2150) 5.940–5.955 (0.2338–0.2344)
<Limit>
IN 5.4 (0.21) 5.9 (0.23)
EX 5.4 (0.21) 5.9 (0.23)
Stem length “C”
IN 65.9 (2.59) 88.1 (3.46)
EX 66.2 (2.61) 87.9 (3.46)
Valve face contact
width “D” 0.7–0.9
IN 0.6–0.8 (0.0275–
EX (0.0236–0.0315) 0.0354)
<Limit>
IN 1.7 (0.07) 1.4 (0.06)
EX 1.7 (0.07) 1.4 (0.06)
Valve seat contact width 0.7–0.9
IN 0.6–0.8 (0.0275–
EX (0.0236–0.0315) 0.0354)
<Limit>
IN 1.7 (0.07) 1.4 (0.06)
EX 1.7 (0.07) 1.4 (0.06)
Valve stem runout limit 0.01 (0.0004)
Valve guide
Guide inside diameter
IN 5.5–5.512 6.0–6.012
EX (0.2165–0.2170) (0.2362–0.2366)
Stem to guide clearance
IN 0.037–0.064 (0.0014–0.0025)
EX 0.037–0.064 (0.0014–0.0025) 0.045–0.072 (0.017–0.0028)
“ ”
θ 90°
Valve clearance (cold)
IN 0.08–0.12
EX (0.0031–0.0047)

8-7
 GENERAL SPECIFICATIONS SPEC
Model name YT624E YT624EDJ YS928J YT1232ED
Model code number 7RV1 7RV3 7VY1 7BE1
Push rod:
Runout limit mm (in) 0.5 (0.02)
Valve spring:
Free length mm (in)
IN 26.5 (1.0433) 36.2 (1.4251)
EX 26.5 (1.0433) 36.2 (1.4251)
<Limit> IN 25.0 (0.98) 35.0 (1.38)
EX 25.0 (0.98) 35.0 (1.38)
Set length mm (in)
IN 21.6 (0.8503) 30.8 (1.2125)
EX 18.9 (0.7440) 29.3 (1.1535)
Tilt limit mm (in) 1.0 (0.03)
Carburetor:
Bore size mm ø15 ø16 ø20
Main jet #101.3 #88.8 #111.3
Main air jet mm ø1.1 ø1.4 ø1.6
Pilot air jet mm ø1.1 ø1.0 ø0.9
Pilot outlet mm ø0.9 ø0.9 ø1.0
Valve seat size mm ø1.8 ø1.8 ø2.0
Main nozzle 31A 55P 106E
Pilot jet #42.5 #45 #57.5
Pilot screw 1-3/4 1-7/8 1-1/2
Throttle valve #150 #200 #120
Float height “H” mm (in) 16.0 (0.63)

Engine idle speed r/min 2300 ± 100

Rated engine speed r/min 3800 ± 50
Governor arm:
2
Tension spring hole
3
Auto choke:
Coil resistance — 11.7–14.3 Ω —

8-8
 GENERAL SPECIFICATIONS SPEC
ELECTRICAL
Model name YT624E YT624EDJ YS928J YT1232ED
Model code number 7RV1 7RV3 7VY1 7BE1
Ignition system:
Ignition timing 23°
Minimum spark gap 6 (0.24 in)
mm (in)
TCI:
Primary coil resistance 1.2 Ω ± 20 % 0.6 Ω ± 20 % 0.8 Ω ± 20 %
Secondary coil resistance 6.5 kΩ ± 20 % 11.7 kΩ ± 10 %
Air gap mm (in) 0.4–0.6 (0.015–0.023)
TCI magneto:
Charging coil resistance 0.5 Ω ± 20 % 0.26 Ω ± 20 % 0.13 Ω ± 20 %
(battery charging)/lead /white /white /white-white
color
Lighting coil resistance/lead 0.4 Ω ± 20 % 0.61 Ω ± 20 % 0.51 Ω ± 20 %
color /yellow/red /yellow/red /yellow/red-
black
Battery:
Model GM14Z-3B 40B19R
Voltage, capacity 12V, 14Ah 12V, 27Ah
Electrolyte specific gravity 1.28
Starter motor:
Power output 0.3 kW 0.6 kW
Armature coil resistance 0.035 Ω ± 10% /white 0.018 Ω ± 10%
Carbon brush length 10 (0.39) 12.5 (0.49)
mm (in)
<Limit> 3.5 (0.14) 6.0 (0.24)
Commutator outside 22 (0.87) 28 (1.10)
diameter mm (in)
<Limit> 21 (0.83) 27 (1.06)
Mica undercut (depth) 1.5 (0.06) 0.6 (0.02) 2.0 (0.08)
mm (in)
Starter relay:
Amperage A 4 — 20
Coil resistance 4.0 Ω ± 5% — 80 Ω ± 10%
Fuse:
Type Blade
Main 30 A × 1
Electromagnetic clutch:
Air gap mm (in) — 0.3–0.9 —
(0.011–0.035)
Electromagnetic clutch relay:
Amperage A — 20 —
Coil resistance — 100 Ω ± 10 % —

8-9
 TIGHTENING TORQUE SPEC
TIGHTENING TORQUE (YT624E/YT624EDJ)
ENGINE

Tightening torque
Item Thread size
Nm (m·kgf, ft·lbf)
Cylinder head stud bolt M6 × 1.0 4.5 (4.5, 3.2)
1st 12 (1.2, 8.6)
Cylinder head bolt M10 × 1.25
2nd 20 (2.0, 14)
Spark plug M14 × 1.25 18 (1.8, 12)
Cylinder head cover bolt M6 × 1.0 10 (1.0, 7.2)
Connecting rod cap bolt M8 × 1.25 12 (1.2, 8.6)
Governor arm and governor
M6 × 1.0 8 (0.8, 0.6)
fork bolt
Pivot arm nut M6 × 0.5 10 (1.0, 7.2)
Valve adjuster locknut M6 × 1.0 10 (1.0, 7.2)
Fan case cover bolt M6 × 1.0 7 (0.7, 5)
Air filter case cap M6 × 1.0 1.6 (0.16, 1.2)
Carburetor nut M6 × 1.0 10 (1.0, 7.2)
Muffler nut M6 × 1.0 7 (0.7, 5)
Muffler protector bolt M6 × 1.0 10 (1.0, 7.2)
Oil drain bolt M10 × 1.25 17 (1.7, 12)
1st 12 (1.2, 8.6)
Crankcase cover bolt M8 × 1.25
2nd 22 (2.2, 15)
Fuel tank bolt M6 × 1.0 11 (1.1, 7.9)
Starter motor bolt M8 × 1.25 10 (1.0, 7.2)
Rotor nut M18 × 1.5 65 (6.5, 46)
TCI unit bolt M6 × 1.0 10 (1.0, 7.2)
Stator assembly bolt M6 × 1.0 6.5 (0.65, 4.7)

CHASSIS

Tightening torque
Item Thread size
Nm (m·kgf, ft·lbf)
Auger pulley bolt M8 × 1.25 25 (2.5, 18)
Auger shaft bolt M8 × 1.25 23 (2.3, 16)
Auger shaft retainer
M6 × 1.0 12 (1.2, 8.6)
(bearing housing) bolt
Shear bolt (YT624E) M5 × 0.8 6.5 (0.65, 4.7)
Shear bolt guard mounting bolt M8 × 1.25 23 (2.3, 16)
Scraper nut M8 × 1.25 13 (1.3, 9.4)
Skid nut M8 × 1.25 16 (1.6, 11)
Gear cover bolt M6 × 1.0 12 (1.2, 8.6)
Engine mounting nut M8 × 1.25 28 (2.8, 20)

8-10
 TIGHTENING TORQUE SPEC
TIGHTENING TORQUE (YS928J)
ENGINE

Tightening torque
Item Thread size
Nm (m·kgf, ft·lbf)
Cylinder head stud bolt M8 × 1.25 18 (1.8, 12)
1st 12 (1.2, 8.6)
Cylinder head bolt M10 × 1.25
2nd 44 (4.4, 31)
Spark plug M14 × 1.25 20 (2.0, 14)
Cylinder head cover bolt M6 × 1.0 11 (1.1, 7.9)
Connecting rod cap bolt M7 × 1.0 12 (1.2, 8.6)
Crankshaft gear bolt M8 × 1.25 22 (2.2, 15)
Governor arm and governor
M6 × 1.0 8 (0.8, 0.6)
fork bolt
Pivot arm bolt M6 × 0.5 10 (1.0, 7.2)
Valve adjuster locknut M6 × 1.0 10 (1.0, 7.2)
Fan case cover bolt M6 × 1.0 10 (1.0, 7.2)
Air filter case cap M6 × 1.0 2 (0.2, 1.4)
Carburetor nut M6 × 1.0 20 (2.0, 14)
Muffler bolt M8 × 1.25 20 (2.0, 14)
Muffler protector bolt M6 × 1.0 12 (1.2, 8.6)
Oil drain bolt M12 × 1.5 30 (3.0, 21)
1st 12 (1.2, 8.6)
Crankcase cover bolt M8 × 1.25
2nd 30 (3.0, 15)
Fuel tank bolt M6 × 1.0 10 (1.0, 7.2)
Rotor nut M16 × 1.5 75 (7.5, 54)
TCI unit bolt M6 × 1.0 10 (1.0, 7.2)
Starter motor bolt M8 × 1.25 16 (1.6, 11)
Oil level switch unit bolt M6 2 (0.2, 1.4)
Oil level warning light M10 7 (0.7, 4.7)
Starter motor lead bolt M8 9 (0.9, 6.5)
Stator assembly bolt M6 × 1.0 7 (0.7, 4.7)

8-11
 TIGHTENING TORQUE SPEC
CHASSIS

Tightening torque
Item Thread size
Nm (m·kgf, ft·lbf)
Auger pulley bolt M8 × 1.25 25 (2.5, 18)
Auger shaft bolt M8 × 1.25 23 (2.3, 16)
Auger shaft retainer
M8 × 1.0 12 (1.2, 8.6)
(bearing housing) bolt
Shear bolt guard mounting
M6 × 1.0 19 (1.9, 13)
bolt
Scraper nut M6 × 1.0 8 (0.8, 5.8)
Skid nut M8 × 1.25 16 (1.6, 11)
Gear cover bolt M6 × 1.0 12 (1.2, 8.6)
Engine mounting nut M8 × 1.25 24 (2.4, 17)
Slider mounting bolt M8 × 1.25 28 (2.8, 20)
Shaft nut M14 × 1.5 92 (9.2, 66)
Rear axle nut M12 × 1.25 54 (5.4, 38)

8-12
 TIGHTENING TORQUE SPEC
TIGHTENING TORQUE (YT1232ED)
ENGINE

Tightening torque
Item Thread size
Nm (m·kgf, ft·lbf)
Cylinder head stud bolt M8 × 1.25 18 (1.8, 12)
1st 12 (1.2, 8.6)
Cylinder head bolt M10 × 1.25
2nd 44 (4.4, 31)
Spark plug M14 × 1.25 20 (2.0, 14)
Cylinder head cover bolt M6 × 1.0 11 (1.1, 7.9)
Connecting rod cap M8 × 1.0 20 (2.0, 14)
Governor arm and governor
M6 × 1.0 7 (0.5, 5)
fork bolt
Valve adjuster locknut M5 × 0.5 10 (1.0, 7.2)
Fan case cover bolt M6 × 1.0 10 (1.0, 7.2)
Air filter case cap M6 × 1.0 2 (0.2, 1.4)
Carburetor nut M6 × 1.0 11 (1.1, 7.9)
Muffler bolt M8 × 1.25 20 (2.0, 14)
Muffler protector bolt M6 × 1.0 10 (1.0, 7.2)
Oil drain bolt M12 × 1.5 30 (3.0, 21)
1st 12 (1.2, 8.6)
Crankcase cover bolt M8 × 1.25
2nd 30 (3.0, 15)
Fuel tank bolt M6 × 1.0 10 (1.0, 7.2)
Rotor nut M18 × 1.5 120 (12.0, 86)
TCI unit bolt M6 × 1.0 10 (1.0, 7.2)
Starter motor bolt M8 × 1.25 16 (1.6, 11)
Stator assembly M6 × 1.0 7 (0.7, 4.7)

8-13
 TIGHTENING TORQUE SPEC
CHASSIS

Tightening torque
Item Thread size
Nm (m·kgf, ft·lbf)
Auger shaft bolt M8 × 1.25 19 (1.9, 13)
Auger shaft retainer
M8 × 1.25 19 (1.9, 13)
(bearing housing) bolt
Shear bolt guard mounting bolt M8 × 1.25 19 (1.9, 13)
Scraper nut M8 × 1.25 21 (2.1, 15)
Front axle bolt M12 × 1.5 42 (4.2, 30)
Box stay mounting bolt (top) M8 × 1.25 19 (1.9, 13)
Box stay mounting bolt (bottom) M8 × 1.25 27 (2.7, 19)
Auger pulley nut M8 × 1.25 19 (1.9, 13)
Axle housing bolt M8 × 25 16 (1.6, 11)
Clutch retainer M8 × 25 16 (1.6, 11)

GENERAL TORQUE
Tightening torque
SPECIFICATIONS Thread size
This chart specifies torque for standard fasten- Nm m·kgf ft·lbf
ers with standard I.S.O. pitch threads. Torque M4 2 0.2 1.5
specifications for special components or M5 3 0.3 2.2
assemblies are included in the applicable sec- M6 7 0.7 5.2
tions of this book. To avoid warpage, tighten M7 10 1.0 7.4
multi fastener assemblies in a crisscross fash- M8 15 1.5 11.1
ion, in progressive stages, until full torque is M10 30 3.0 22.1
reached. Unless otherwise specifications call M12 60 6.0 44.3
for clean, dry threads. Components should be
at room temperature.

8-14
 LUBRICATION POINTS AND LUBRICANT TYPES SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Lubricant
All oil seal lips Lithium-soap-based grease
Connecting rod big end thrust surfaces YAMALUBE SAE 10W-40
Crank pin YAMALUBE SAE 10W-40
Crankshaft YAMALUBE SAE 10W-40
Connecting rod bolt threads YAMALUBE SAE 10W-40
Piston pin outer surface YAMALUBE SAE 10W-40
Piston outer surface YAMALUBE SAE 10W-40
Governor collar inner surface YAMALUBE SAE 10W-40
Governor fork contacting surface and moving
YAMALUBE SAE 10W-40
surface
Weight contacting surfaces YAMALUBE SAE 10W-40
Valve stem Molybdenum disulfide oil
Valve stem end Molybdenum disulfide oil
Rocker shaft Molybdenum disulfide oil
Push rod end YAMALUBE SAE 10W-40
Lifter stem outer surface YAMALUBE SAE 10W-40
Camshaft lobe YAMALUBE SAE 10W-40
Camshaft gear teeth YAMALUBE SAE 10W-40
Decompression pin YAMALUBE SAE 10W-40
Camshaft journal YAMALUBE SAE 10W-40
Crankcase ball bearing YAMALUBE SAE 10W-40
Crankcase cover ball bearing YAMALUBE SAE 10W-40
AUGER
Lubrication point Lubricant
Auger shafts (left and right) Low temperature grease
Bearing inner and outer surfaces Lithium-soap-based grease
Deflector spring hook Low temperature grease
Chute assembly contacting parts Low temperature grease
Impeller shaft bearing housing mating surfaces Lithium-soap-based grease
Auger pulley mounting bolt threads Three bond No.1324®
Chute motor gear and ring gear Low temperature grease
CHASSIS
Lubrication point Lubricant
H.S.T. switch lever spring pin Low temperature grease
H.S.T. arm shaft pin Low temperature grease
Clutch bracket bush Low temperature grease

8-15
 LUBRICATION POINTS AND LUBRICANT TYPES SPEC
DRIVE
Lubrication point Lubricant
Primary gear inner surface Low temperature grease
Axle outer surface Low temperature grease
Final gear parts (4 points) Low temperature grease
Rear pivot arm and pivot arm mating surfaces
Low temperature grease
(left and right)
Idle roller collar outer surface Low temperature grease
H.S.T. primary side left bearing outer race Low temperature grease
STEERING
Lubrication point Lubricant
Clutch shaft lever contacting parts Low temperature grease
Clutch shaft collar inner surface Low temperature grease
Handlebar grip inner surface Three bond No.575®
Cable inner ends Low temperature grease
Right clutch lever and clutch lever shaft contact-
Low temperature grease
ing parts
Clutch lever shaft mounting bolt threads Low temperature grease
Shift cable mounting parts Low temperature grease
Handlebar bolt threads Three bond No.1324®
Ratchet cam contacting parts Low temperature grease
Ratchet cam mounting collar inner and outer sur-
Low temperature grease
faces

8-16
 WIRE ROUTING DIAGRAM SPEC
WIRE ROUTING DIAGRAM
CHASSIS (YT624E/YT624EDJ)

1 Chute motor A Route over the starter motor D Fasten only leads using the
2 Motor drain hose and pull so that there is no plastic locking tie, and then cut
3 Black/white lead interference with the governor off the excess end of the plas-
4 White lead link, and fasten using the tic locking tie.
5 Yellow/red lead clamp. E Fasten the leads and cables
6 Negative battery lead (black) B After installing, cut off the using the plastic locking tie,
7 Positive battery lead (red) excess end of the plastic lock- and then cut off the excess
8 Starter motor ing tie. end of the plastic locking tie.
9 Auger and drive cables C Fasten using the clamp so F Fasten with the instrument
there is no interference with panel, and then cut off the
the rear arm pivot. excess end of the plastic lock-
ing tie.

8-17
 WIRE ROUTING DIAGRAM SPEC
STEERING (YT624E)
1 Chute deflector control lever A Fasten the chute cable using
2 Chute direction control switch the plastic locking tie so that it
3 Shift lever does not interfere with the rear
4 Throttle lever arm pivot, and then cut off the
5 Working light excess end of the plastic lock-
6 Engine switch ing tie.

8-18
 WIRE ROUTING DIAGRAM SPEC
(YT624EDJ)
1 Drive clutch lever A During seal assembly, be care-
2 Chute deflector control lever ful not to turn up or scratch the
3 Chute direction control switch lip.
4 Shift lever
5 Throttle lever
6 Working light
7 Auger clutch lever
8 Engine switch
9 Rectifier/Regulator
0 Tilt assembly
q Tilt lock cable

1 2 7
4 6

5
3

8-19
 WIRE ROUTING DIAGRAM SPEC
ENGINE (YT624E/YT624EDJ)
1 Carburetor cover assembly A Tighten together with the car-
2 High tension lead buretor
3 Spark plug cap B Route the TCI lead only from
the above the starter motor.
(The charging coil lead runs
under the starter motor.)

8-20
 WIRE ROUTING DIAGRAM SPEC
1 High tension lead A Route the charging coil lead
2 Breather hose under the starter motor.
3 Spark plug cap B Bend the clamp, and route the
4 Rotor assembly hose along the head cover.
5 TCI unit (Be careful not to compress
6 Carburetor assembly the hose end.)

8-21
 WIRE ROUTING DIAGRAM SPEC
CHASSIS (YS928J)
1 Oil level warning light t Fuse holder D Fasten together with the rub-
2 Electromagnetic clutch switch y Wire harness ber mount.
3 Battery E Also fasten together with the
4 Electromagnetic clutch ground lead.
5 Engine stop switch lead A Place the connectors for the F Fasten using a band so that it
6 Carburetor heater lead leads in the cover, and then does not contact the negative
7 Motor drain hose fasten using the plastic locking terminal.
8 Rectifier/Regulator tie. G From the positive battery.
9 Voltage regulator B After fastening, leave 10 mm H From the negative battery.
0 Negative battery lead and cut off the remaining. I Fasten with the remote control
q Positive battery lead C Fasten the coupler using the box.
w Oil level gauge lead clamp so that it does not pro-
e Working light lead trude from the cover.
r Starter relay

3
4

1
7
ç

ƒq 0 9 8 ´ ∂ å 6
5
∫
G B B
ˆ
˙
G/R B
B/W
©

e w

Y/R L

r
G/R B B
t Y/R
y

8-22
 WIRE ROUTING DIAGRAM SPEC
STEERING (YS928J)
1 Drive clutch lever t H.S.T. oil reservoir hose G Spring pin projects 2 mm (0.08
2 Auger clutch lever y Tilt assembly in) from the shaft.
3 Auger control switch
4 Shift lever
5 Chute direction control lever A Apply low temperature grease
6 Chute control switch to the inner end rotating parts.
7 Throttle lever B Apply low temperature grease.
8 Throttle control cable C When replacing the boot of the
9 Band chute control switch, cut off 15
0 Chute control cable mm of the end.
q Shift control cable D Route inside of the handlebar.
w Drive clutch control cable E Route above the H.S.T. control
e H.S.T. oil reservoir cable.
r Clip F Clamp to the duct.

2
15

8-23
 WIRE ROUTING DIAGRAM SPEC
ENGINE (YS928J)
1 Rated engine speed adjusting A Route through the clamp of
screw projection on the crankcase.
2 Governor spring B Clamp position
3 Starter motor C Route under the mounting
4 Fan case boss.
5 Spark plug cap
6 TCI unit
7 TCI magneto

G/R

Y/R

8-24
 WIRE ROUTING DIAGRAM SPEC
CHASSIS (YT1232ED)
1 Fuse (30 A) A Fasten together with the fuse F When raising or lowering the
2 Rectifier/Regulator using the plastic tie. After fas- chute deflector control lever,
3 Wire harness unit lead tening, cut off the excess end be careful not to over stretch
4 Wire harness assembly of the plastic locking tie. the wire harness.
5 Cable clamp B Pass through the back of the
6 Positive battery lead motor.
7 Negative battery lead C Place the connector inside the
8 Band cover, and clamp the outside
of the cover using a band.
D After fastening, cut off the
excess end of the plastic lock-
ing tie.
E Fasten using the clamp.

8
2 ∫ ç
R

R
B/W

W
1
Y/R

å ∂
R/W
B/W Y/R
W
B/R
3
B/Y

5 4 ∂
6 7

B/Y
B/R 8
R

´ ƒ

8-25
 WIRE ROUTING DIAGRAM SPEC
STEERING (YT1232ED)
1 Drive clutch lever A Apply low temperature grease. F Adjust the shift lever using the
2 Chute deflector control lever B Apply low temperature grease turn buckle so that the clear-
3 Rod to both sides inside the collar. ances to left and right are the
4 Chute direction control switch C Apply low temperature grease same, and tighten the nuts on
5 Shift lever to the inner end rotating parts. both sides.
6 Left side clutch lever D When the clutch is in the off G Adjust using the shift rod so
7 Right side clutch lever position, apply the brake and that the clearance from the for-
8 Engine switch adjust using the cable adjuster ward position to the neutral
9 Throttle lever so that the tension spring play position is equal to that from
0 Auger clutch lever is 1–1.5 mm. the reverse position to the neu-
q Tilt assembly E Apply low temperature grease tral position.
w Tilt lock cable to the pin. H During seal assembly, be care-
ful not to turn up or scratch the
lip.

8-26
 WIRE ROUTING DIAGRAM SPEC
I When the boot on the chute
direction control switch has
been replaced, cut off 15 mm
of the end.

8-27
 WIRE ROUTING DIAGRAM SPEC
ENGINE (YT1232ED)
1 TCI lead (black/white) A Tighten the black lead.
2 Oil level gauge lead B Securely fasten the black lead,
3 Clamp stop lead, and oil level gauge
4 Tube lead using the clamps.
5 High tension lead C Use the tube to cover the stop
6 Ignition coil lead and oil level gauge lead.
D Pass the ignition coil lead
through the hole in the crank-
case.
E When installing the fan case
scroll, be careful not to pinch
the high tension lead.
F Install the TCI magneto lead
so there is no slack or bite.

å
1 2

Y/R
L
R
Y/R

3 ∫

Y/R
B

ç
B
4
R

´
∂

8-28
CIRCUIT DIAGRAM 2010
(YT624E/YT624EDJ)
B
5
B/W
STOP ON START
B/W

2 4
R
W

1 Y/R R
R/Y

R/W
6

Y/R B
3

B
9 7

LH STOP RH

W/G
q
B
R/B

0
B W R
Br B/W R/B
R/W R/Y Y/R
R/B W/G
8
1 TCI unit 7 Chute direction control W/G
2 TCI magneto switch
3 Spark plug 8 Chute motor
4 Rectifier/Regulator 9 Starter relay
5 Engine switch 0 Starter motor
6 Working light q Battery
(YS928J)
2 3
7
4 5 6
B G
1

W W R B
L
8
G/R STOP ON START CHECK

B/W B/W
R
R
R/Y

u W
B

y L
G/R

B L
W
R/Y
i B
R R R/Y R/W
9
B/R
R L LH STOP RH
R/B

R/B W/G
w q W/G
t
r 0 R/B

W/G
B/Y e

B W R
L G Y
Br B/W B/R
B/Y R/B R/W

1 Rectifier/Regulator 7 Working light e Electromagnetic clutch R/Y W/G G/R

2 Oil level warning light 8 Engine switch relay

3 Electromagnetic clutch 9 Chute direction control r Fuse
switch switch t Battery
4 Electromagnetic clutch 0 Chute motor y TCI magneto
5 Voltage regulator q Oil level switch u TCI unit
6 Auto choke w Starter motor i Spark plug
cover.indd
3
(YT1232ED)

B/W
1 3
5
Y/R Y/R

B
4
L
2 B

6
STOP ON START

R/W

R
B
R/Y

B W W R
8
7
LH STOP RH
R/B
w
W/G

B W R
M0
1 TCI unit 8 Fuse L Br B/W
R/B
2 Spark plug 9 Chute motor 9 W/G
R/B R/W R/Y
3 TCI magneto 0 Starter motor Y/R W/G
4 Voltage regulator q Battery
5 Working light w Rectifier/Regulator
6 Engine switch
7 Chute direction control
switch

2010/06/08
14:55:52
Yamaha Motor Canada Ltd.
480 Gordon Baker Road
Toronto, ON M2H 3B4