Yamaha JT2 (1972), JT2M (1972), JT2-L (1972) Assembly Manual

JT1-JT2

SERIES

ASSEMBLY

MANUAL

LIT

11662-88-72

Introduction

The

individu I who

pr

p r s Y m h

motorcycl

for d liv ry ha

th

responsibility

of

b irn . n

import

nt

link b tw,

,n

th

factory

nd

th

custom

r.

Th

tI f

t1on

that

th

cu tornr:ir

will

r c

iv

from

hi

Yamaha. both

1n1ti

II

nd ov r

th

l1f

of

th"

rn

chin

, is v ry

much

dep

nd

nt

on

th

c r

with

which

th

s t-up

proc

~ctur

i p rforrn d.

As

the

on

doing

the

work

. you hould b

owur

of

this r

sponsibility

.

Th

degr

of

car

that

you

t,1k

in

doing

th \ job

will

rcfl

ct

on you .

the

deal

r.

and

th

factory

A properly s t up

Yamaha

will

give

many

miles

of

satisfaction

to

th

owner

and

1s

important

to

future

sales and

service

business On the

other

hand. a

poorly

prepared

machine

is sure

to

result

in

a dissat1sf1ed

customer

and possibly extra

work

due

to

the

need

for

subsequent

re

doing

of

portions

of

the

Job

Follow

the

procedures

in

this

manual

rn

the

order

in

which

they

are

presented

Don

't

skip around and

perform

them

out

of

sequence, and

don't

omit

any

of

them

. They are all essential

to a well

done

Job

Remember, this

initial

set

up

Is

the

most

important

servicing

the

motorcycle

will

ever

receive .

Service Department Yamaha International Corporation

Buena

Park,

California 90620

JT

1/ JT2

SERI

ES

ASSEMBLY

MANUAL

1st

Printing

July,

1972

Copyright

©

1972

Yamaha

International

Corp.

All

Rights

Reserved

Yam oho

Int'

I.

Corp.,

Buena

Pork,

Calif.

JTt/JT2

SRS

ASSY

MNL

P N

LIT

11662-88-72

Table

of

Contents

Section

I -

Unpacking

The

Motorcycle

Page

A.

Opening

the

Carton

................................

.

B.

Checking

for

Damage

and

Shortages

.................

.

Section

II -

Assembling

The

Motorcycle

1 2

A.

Installing

the

Handlebars

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

B.

Installing

the

Front

Fender . . . . . . . . . . . . . . . . . . . . . . . . . . 4

C.

Installing

the

Front

Wheel

. . . . . . . . . . . . . . . . . . . . . . . . . . . 5

D.

Installing

the

Footrests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

E.

Installing

the

Transmission

Change Pedal . . . . . . . . . . . . . . 7

F.

Attaching

the

Brake Cable

to

the

Front Brake . . . . . . . . . . 8

G.

Securing

Clutch

and

Brake

Cables

to

the

Levers . . . . . . . . 8

H.

Installing

the

Rear Brake Rod . . . . . . . . . . . . . . . . . . . . . . . . . 9

I.

Installing

the

Tail

Light

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

J .

Connecting

Wiring

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

K.

Connecting

the

Throttle

Control

. . . . . . . . . . . . . . . . . . . . . . .

12

Section

111 -Adjusting

Components

A.

Adjusting

the

Front Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

B.

Adjusting

the

Clutch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

C.

Adjusting

the

Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

D.

Adjusting

the

Rear Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

E.

Bleeding

the

Autolube

Pump

......

...

....

.........

....

16

F.

Checking

Autolube

Pump

Minimum

Stroke . . . . . . . . . . . . . .

18

G.

Adjusting

the

Carburetor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

H.

Checking

Ignition

Timing

......

..........

............

.

19

Section

IV -Making

Preliminary

Checks

A. Filling Fuel

Tank

............

......................

22

B.

Checking

Transmission

Oil Level

....

.......

....

.. ..

23

C.

Checking

for

Loose

Nuts

and

Bolts .............

.

.......

23

D.

Checking

Tire

Pressure

...

. .

...

....

.........

. .

...

• .

24

Section

V -

Making

Running Checks

A.

Starting

the

Engine

.. ..

....

• • • • • • • • · · · · · · · · · · · · · · · · · ·

25

B.

Checking

the

Transmission

Oil . . . . . . . . . . . . . . . . . . . . . . . .

25

c.

Adjusting

Carburetor

and

Autolube

Cable

....

......

....

26

D.

Checking

Lights

.......

......

· . · · · · · · · · · · · · · · · · · · · · · ·

27

E. Road

Testing

.............

. . • • • • • • • • • • • • • • • • • · • • • · • · ·

28

Section

VI

-

JT2

Supplement

A.

Miscellaneous

Section

VII

- Service Data

Page

. . . . .

31

A.

Torque Specif i co ti ons . . . . . . . . . . . . . . . . . . . . . . . . .

36

Section I - Unpacking

the

Motorcycle

A. Opening

the

Carton

1. Using scissors

or

a pen-

knife .

cut

the

tape

from

around

the

carton.

Caution

Don't

cut

too

deeply

when

removing

the

masking

tape. You

might

damage

components

directly

be-

neath

the

tape

.

COMPONENT

TRAY

MASKING

TAPE

FIBER

TAPE

2. Open

the

flaps

of

the

car-

ton

and I

ift

out

the

tray

of

components. Set

the

tray

·

aside.

Caution

Don't

try

to

lift

the

tray

by

the

wooden

frame

around

it. Lift

the

tray

itself.

1

3.

Lift

the

sides

of

the

carton

straight up.

exposing

the

motorcycles

B.

Checking

for

Damage

and

Shortages

1.

If

shipping

damage

has

occurred

, record

the

num-

bers

of

the

engine. frame

,

crate

, and

damaged

part

.

2.

Shipping

damage

should

be

corrected

by

the

dealer

. Replace

parts

that

are

missing

or

dam-

aged

in

shipment

from

your

parts

stock,

or

order

them

from

the

Yahama

Parts

Department. Sub-

mit a Standard

Warranty

Claim

Form

and

the

ship-

per

's

damage

inspection

report

to

the

Warranty

Department

of

Yahama

International

Corporation

for

credit

. Mark

the

form

"DAMAGED

IN

SHIP-

MENT"

.

2

Section

11

- Assembling

the

Motorcycle

Note

The

following

proce-

dures

apply

to

either

of

the

two

motorcycles

in

the

carton

.

A.

Installing

the

Handlebars

1. L

ift

the

front

wheel

out

of

the

carton

and

set

it

aside.

2. Using a

10

mm

wrench

.

remove

the

four

bolts

that

secure the

two

handlebar

retaining

clamps

. Re-

move the

clamps

.

3.

Remove

the

handlebars

from the

tray

and

ins

ta II them on the handle crown. Secure the

retaining

clamps

(handle holders)

with

the

bolts

(4)

and

lock

washers

(4)

provided.

Tighten

grad-

ually

and

in

pattern, ,

until

secure.

RETAINING

CLAMP

3

8 .

Installing

the

Front

Fender

4

Untie the rope

that se-

cures the front fender

to the rear wheel. Remove the fender and unwrap the paper

that

covers it.

FRO

NT FENDER

2. Remove

the

two

nails

holding the plastic

block

that

secures

the

front

of

the

motorcycle

to

the

wooden

frame

.

3. Lift

the

motorcycle from

the

wooden

frame

. This

is a

job

for

two

men.

Place a

support

under

the

engine

to

hold

the

motorcycle

upright

.

4. Using a

10

mm

wrench

.

remove

the

three

front

fender

mounting

bolts

and washers

from

the

frame..

5. Position

the

front

fender

on

the

yoke. Secure

it

with

the

three

mounting

bolts and washers.

BUSHING

~ LOCK

AXLE

C. Installing

the

Front

Wheel

1. Using a

17

mm

wrench

.

remove

the

axle

from

the

front

fork

assembly. Dis-

card

the

plastic

block. Re

-

move

the

bushing

from

the

axle.

6

2. Remove

the

brake

assem-

'

bly

from

the

component

tray. Slide

it

into

the

front

wheel

hub

from

the

right

side

.

3.

Slide

the

bushing

in

the

left

side

of

the

wheel

hub

.

RIGHT

TUBE

6

BUSHING

LEFT

SIDE

4. Position

the

front

wheel

between

the

fork

tubes

.

Fit

the

locating

lug

on

the

right

tube

into

the

slot

in

the

hub.

5. Put a

light

coat

of

oil

or

light

grease

on

the

axle.

This

will

help

to

prevent

it

from

rusting.

6. Slide

the

axle in

from

the

left

side

through

the

left

tube. bushing,

wheel

, and

right

tube. Using

the

17

mm

wrench,

install

and

tighten

the

axle

nut

.

Proper

tightening

torque

is

: 25-30ft/ lbs.

D.

Installing

the

Footrests

1. Remove

the

footrest. pin

and

cotter

from

the

plastic

bag

in

the

compo

-

nent

tray

.

Note

The

following

steps

apply

to

either

footrest

.

2. Slide

the

footrest

into

the

frame

bracket

. Hold

the

footrest

vertical.

with

the

cover

tread

forward

.

3. Slide

the

(head

for

-

ward)

into

the

bracket and

footrest

. Slide

the

cotter

into

the

hole

and

bend

up

the

ends.

CHANGE

PEDAL

E.

Installing

the Transmission Change

Pedal

1.

Remove

the

change

pedal

from

the

component

tray

.

2.

Using

a

10

mm

wrench

.

remove

the

bolt

from

the

pedal

and

set

it aside.

3. Push

the

pedal

on

the

splined

stud

with

the

arm

facing

forward

.

Note

You

might

have

to

pry

the

pedal

jaws

apart

slightly

with a screwdriver

to

al-

low

it

to

slip

all

the

way

on

the

stud

.

4.

Install

and

tighten

the

bolt

.

7

Yamaha JT2 (1972), JT2M (1972), JT2-L (1972) Assembly Manual

Specifications and Main Features

Frequently Asked Questions

User Manual