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YH50 ' 99 5EU-AE2 SERVICE MANUAL
YH50 ' 99 5EU-AE2 SERVICE MANUAL
YH50 ' 99 5EU-AE2 SERVICE MANUAL
YH50 ' 99 5EU-AE2 SERVICE MANUAL
YH50 ' 99 5EU-AE2 SERVICE MANUAL
YH50 ' 99 5EU-AE2 SERVICE MANUAL

YH50

YH50 ' 99 5EU-AE2 SERVICE MANUAL
YH50 ' 99 5EU-AE2 SERVICE MANUAL

'99

5EU-AE2

SERVICE

MANUAL

EB000000

YH50

SERVICE MANUAL © 1999 MBK INDUSTRIE 2nd Edition, January 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited.

EB001000

NOTICE

This manual was written by the MBK INDUSTRIE primarily for use by Yamaha and MBK dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha and MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe.

MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha and MBK dealers and will, where applicable, appear in future editions of this manual.

NOTE:

Designs and specifications are subject to change without notice.

TECHNICAL DOCUMENTATION MBK INDUSTRIE

PARTICULARY IMPORTANT INFORMATION This material is distinguished by the following notation :

This material is distinguished by the following notation : WARNING CAUTION: NOTE: The safety Alert Symbol

WARNINGThis material is distinguished by the following notation : CAUTION: NOTE: The safety Alert Symbol means

CAUTION:

NOTE:

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander, or a person inspecting or repairing the scooter.

A CAUTION indicates special precautions that must be taken to avoid

damage to the scooter.

A NOTE provides key information to make procedures easier or clearer.

YP002000

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL This manual constits of chapters for the main catogories of subjects. (See "illustrated symbols")

1 st title :

2 nd title : This title indicates the section of the chapter and is only on the first page of each section It appears on the upper of each page on the left of the chapter symbol.

This is a chapter with its symbol on the upper right of each page.

3 rd title :

This title indicates a sub-section which is following by step-by-step procedures with corresponding illustrations.

EXPLODED DIAGRAM

To make the pieces identification easy and to make the procedures steps clear, exploded diagram are before each removal and disassembly section.

1. Exploded diagram easy to read is provided for removal and disassembly operations.

2. Numbered marks are indicated in the order of operations on the exploded diagram. A numeral corresponds to a disassembly step.

3. Note and indication of special operations are illustrated by symbols . The signification of this symbols is next page.

4. A work instrutions diagram goes with the exploded diagram, indicating the orders of the operations, the pieces name, notes concerning the work to do,etc.

5. For the operations which needs complementary informations, additionnal informations, step-by- step, are provided to complete the exploded diagram and the work instructions diagram.

ENG ENG CDI MAGNETO CDI MAGNETO CDI MAGNETO REMOVAL CDI MAGNETO, ROTOR, STATOR NOTE: It
ENG
ENG
CDI MAGNETO
CDI MAGNETO
CDI MAGNETO
REMOVAL
CDI MAGNETO, ROTOR, STATOR
NOTE:
It is not necessary to remove the engine for
removing the CDI magneto
1.Remove:
• Nut (rotor)
37 Nm (3.7 m.kg)
• Plate washer
T.R
NOTE:
Hold the rotor using flywheel holder to
loosen the nut
3
Flywheel holder:
4
90890-01235
T.R
5
T.R
6.5 Nm (0.65 m.kg)
2.Remove:
• Rotor
• Woodruff key
Use the flywheel puller.
9
7
Flywheel puller:
90890-01189
8
• Stator assembly
1
• Gasket
2
8.5 Nm (0.85 m.kg)
INSTALLATION
1.Install:
Order
Job name/Part name
Q'ty
Remarks
• Gasket
CDI magneto, Rotor, Startor removal
Seat cover
Side covers
Footrest board
Remove the parts in the order below
2.Apply
Refer to "COVERS" in Chapter 3.
• Lithium soap base grease
(to oil seal )
LS
1 Fan cover
1
2 Fan
1
3 Nut
1
4 Washer
1
3.Pass the CDI magneto lead through the
crankcase
5 Magneto rotor
1
Refer to "CDI MAGNETO REMOVAL"
6 Woodruff key
1
section.
7 Stator assembly
1
8 Gasket
1
9 Oil seal
1
For installation, reverse the removal procedure
4 - 27
4 - 28
LS
Q W GEN SPEC INFO E R INSP ENG REG T Y CARB CHAS U
Q
W
GEN
SPEC
INFO
E
R
INSP
ENG
REG
T
Y
CARB
CHAS
U
I
TRBL
ELEC
SHTG
O
P
{
}
q
w
T.R
e
r
t
y
u
i
o
p
B
LS
M
[
]

ILLUSTRATED SYMBOLS

(REFER TO THE ILLUSTRATION)

Illustrated symbols Q to I are designed as thumb tabs to indicate the chapter’s number and content.

Q

General information

W

Specifications

E

Periodic inspection and adjustment

R

Engine

T

Carburetion

Y

Chassis

U

Electrical

I

Troubleshooting

Illustrated symbols O to r are used to identify the specifications appearing in the text.

O

Repair without removal the engine

0

Filling fluid

{

Lubricant

}

Special tool

q

Tightening

w

Wear limit, clearance

e

Engine speed

r

, V, A

Illustrated symbols t to ] in the exploded diagram indicate grade of lubricant and location of lubrication point.

t

Apply engine oil

y

Apply gear oil

u

Apply molybdenum disulfide oil

i

Apply wheel bearing grease

o

Apply lightweight lithium-soap base grease

p

Apply molybdenum disulfide grease

[

Apply locking agent (THREADLOCK ®)

]

Use new one

INDEX

INDEX GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT SPEC 2 INSP REG

GENERAL INFORMATION

GEN

INFO

1

SPECIFICATIONS

SPECIFICATIONS

PERIODIC INSPECTION AND ADJUSTMENT

PERIODIC INSPECTION AND ADJUSTMENT
PERIODIC INSPECTION AND ADJUSTMENT
SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT SPEC 2 INSP REG 3
SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT SPEC 2 INSP REG 3

SPEC

2

SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT SPEC 2 INSP REG 3
SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT SPEC 2 INSP REG 3

INSP

REG

3

3

ENGINE OVERHAUL

ENGINE OVERHAUL

CARBURETION

CARBURETION
ENGINE OVERHAUL CARBURETION ENG 4 CARB 5
ENGINE OVERHAUL CARBURETION ENG 4 CARB 5

ENG

4

ENGINE OVERHAUL CARBURETION ENG 4 CARB 5
ENGINE OVERHAUL CARBURETION ENG 4 CARB 5

CARB

5

ENGINE OVERHAUL CARBURETION ENG 4 CARB 5 CHASSIS CHAS 6 ELECTRICAL ELEC 7 TROUBLESHOOTING TRBL SHTG

CHASSIS

CHAS

6

ENGINE OVERHAUL CARBURETION ENG 4 CARB 5 CHASSIS CHAS 6 ELECTRICAL ELEC 7 TROUBLESHOOTING TRBL SHTG

ELECTRICAL

ELEC

7

ENGINE OVERHAUL CARBURETION ENG 4 CARB 5 CHASSIS CHAS 6 ELECTRICAL ELEC 7 TROUBLESHOOTING TRBL SHTG

TROUBLESHOOTING

TRBL

SHTG

8

GEN INFO 1
GEN INFO 1

GEN

INFO

1

1

GEN

INFO

GEN INFO
GEN INFO

CHAPTER 1. GENERAL INFORMATION

SCOOTER IDENTIFICATION

1-1

VEHICULE IDENTIFICATION NUMBER

1-1

ENGINE SERIAL NUMBER

1-1

IMPORTANT INFORMATION

1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY

1-2

ALL REPLACEMENT PARTS

1-2

GASKETS, OIL SEALS, AND O-RINGS

1-2

LOCK WASHERS/PLATES AND COTTER PINS

1-3

BEARINGS AND OIL SEALS

1-3

CIRCLIPS

1-3

CHECKING OF CONNECTIONS

1-4

HOW TO USE THE CONVERSION TABLE

1-5

SPECIAL TOOLS

1-6

GENERAL INFORMATION

GEN

INFO

GENERAL INFORMATION GEN INFO 1-1 GENERAL INFORMATION SCOOTER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle
GENERAL INFORMATION GEN INFO 1-1 GENERAL INFORMATION SCOOTER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle
GENERAL INFORMATION GEN INFO 1-1 GENERAL INFORMATION SCOOTER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle

1-1

GENERAL INFORMATION

SCOOTER IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the frame.

NOTE:

The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your state.

ENGINE SERIAL NUMBER The engine serial number is stamped into the crankcase.

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

GEN

INFO

IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Removal all dirt, dust
IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Removal all dirt, dust
IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Removal all dirt, dust
IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Removal all dirt, dust
IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Removal all dirt, dust
IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Removal all dirt, dust

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Removal all dirt, dust and foreign material before

removal and disassembly.

2. Use proper tools and cleaning equipment.

3. Refer to the "SPECIAL TOOLS" section.

4. When disassembling the machine, always keep matedpartstogether.Thisincludegears,cylinders, pistons and other parts that have been "mated" through normal wear. Mated parts must always be reused or remplaced as an assembly.

5. During machine disassembly, clean all parts and place them in trays in order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

6. Keep all parts away from any source of fire.

EB101010

ALL REPLACEMENT PARTS

1. Use only genuine parts for all replacements. Use oil and /or grease recommended by MBK / Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality.

EB101020

GASKETS ,OIL SEALS, AND O-RINGS

1. All gaskets, seals and o-rings should be replaced when an engine is overhauled. All gaskets surfa-

ces, oil seal lips and o-rings must be cleaned.

2. Properly oil all mating parts and bearing during reassembly. Apply grease to the oil seal lips.

1-2

IMPORTANT INFORMATION

GEN

INFO

IMPORTANT INFORMATION GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.All lock washers/plates and cotter pins
IMPORTANT INFORMATION GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.All lock washers/plates and cotter pins
IMPORTANT INFORMATION GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.All lock washers/plates and cotter pins
IMPORTANT INFORMATION GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.All lock washers/plates and cotter pins
IMPORTANT INFORMATION GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.All lock washers/plates and cotter pins

EB101030

LOCK WASHERS/PLATES AND COTTER PINS 1.All lock washers/plates and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

EB101040

BEARING AND OIL SEALS 1.Install the bearing(s) and oil seal(s) with their manufacturer's marks or numbers facing outward. ( In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

CAUTION:

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

EB101050

CIRCLIPS 1.All circlips should be inspected carefully before reassembly. Always replace piston pin clips once they have been removed. Replace bent circlips. When installing a circlips make sure that sharp edge is positioned opposite to the thrust it receives. See the sectional view.

Shaft

1-3

CHECKING OF CONNECTIONS

GEN

INFO

CHECKING OF CONNECTIONS GEN INFO -+ -+ EB801000 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture,
CHECKING OF CONNECTIONS GEN INFO -+ -+ EB801000 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture,
CHECKING OF CONNECTIONS GEN INFO -+ -+ EB801000 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture,
CHECKING OF CONNECTIONS GEN INFO -+ -+ EB801000 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture,

CHECKING OF CONNECTIONS GEN INFO -+ -+ EB801000 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture,
-+
-+
-+
-+

EB801000

CHECKING OF CONNECTIONS

Dealing with stains, rust, moisture, etc. on the connector.

1.Disconnect:

• Connector

2.Dry each terminal with an air blower.

3.Connect and disconnect the connector two or three times.

4.Pull the lead to check that it will not come off.

5.If the terminal comes off, bend up the pin and reinsert the terminal into the connector.

6.Connect:

• Connector

NOTE:

The two connectors "click" together.

7.Check for continuity with a tester.

NOTE:

• If there is no continuity, clean the terminals.

• Be sure to perform the steps 1 to 7 listed above when checking the wireharness.

• For a field remedy, use a contact revitalizer available on the market.

• Use the tester on the connector as shown.

1-4

HOW TO USE THE CONVERSION TABLE

GEN

INFO

HOW TO USE THE CONVERSION TABLE GEN INFO HOW TO USE THE CONVERSION TABLE All specification

HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex:

METRIC

MULTIPLIER

IMPERERIAL

** mm

x

0.03937

=

**

in

2 mm

x

0.03937

=

0.08 in

CONVERSION TABLE

 

METRIC TO IMPERIAL

 

Metric unit

Multiplier

Imperial unit

Torque

 

m·kg

7.233

ft.lb

m·kg

86.794

in.lb

cm·kg

 

0.0723

ft.lb

cm·kg

0.8679

in.lb

Weight

 

kg

2.205

lb

g

0.03527

oz

Speed

 

km/h

0.6214

mph

Distance

 

km

0.6214

mi

m

3.281

ft

m

1.094

yd

cm

0.3937

in

mm

0.03937

in

Volume/

cc

(cm

3

)

0.03527

oz(IMP liq.)

Capacity

cc

(cm

3

)

0.061102

cu.in

lit (litre)

0.8799

qt(IMP liq.)

lit (litre)

0.2199

gal(IMP liq.)

Miscella-

kg/mm

 

55.997

lb/in psi(lb/in 2 ) Fahrenheit(° F)

neous

kg/cm 2

14.2234

Centrigrade

9/5( °C)+32

1-5

SPECIAL TOOLS

GEN

INFO

SPECIAL TOOLS GEN INFO EB102000 SPECIAL TOOLS The following special tools are necessary for complete and

EB102000

SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up an assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.

Tool N°

Tool name/usage

 

Illustration

90890-01135

Crankcase separating tool

90890-01135 Crankcase separating tool  
90890-01135 Crankcase separating tool  
 

This tool is used to separate the crank- case and remove the crankshaft.

This tool is used to separate the crank- case and remove the crankshaft.

90890-01189

Flywheel puller

90890-01189 Flywheel puller

This tool is used to remove the flywheel magneto.

90890-01235

Rotor holding tool

90890-01235 Rotor holding tool

This tool is used to remove the flywheel magneto.

90890-01274

Crankshaft installer set.

90890-01274 Crankshaft installer set.  
 

90890-01275

90890-01277

90890-01411

 
90890-01411  
90890-01411  

These tools are used to install the crank- shaft.

These tools are used to install the crank- shaft.

90890-11044

Locknut wrench

90890-11044 Locknut wrench

This tool is used when removing or installing the secondary sheave nut.

90890-01701

Sheave holder

 

This tool is used to hold the secondary sheave when removing or installing the nut.

This tool is used to hold the secondary sheave when removing or installing the nut.

90890-01337

Clutch spring holder.

 

This tool is used for compressing the spring of the secondary sheave when removing the nut.

This tool is used for compressing the spring of the secondary sheave when removing the nut.

1-6

SPECIAL TOOLS

GEN

INFO

SPECIAL TOOLS GEN INFO Tool N ° Tool name/usage Illustration 9079Q-02218 Ring nut wrench. This tool

Tool N°

Tool name/usage

Illustration

9079Q-02218

Ring nut wrench.

9079Q-02218 Ring nut wrench.

This tool is used to loosen and tighten the steering ring nut.

90890-01184

Fork seal driver weight. Fork seal driver attachment (ø28)

 

90890-01185

90890-01185  
 

These tools are used when installing the fork seals.

These tools are used when installing the fork seals.

90890-03112

Pocket Tester

90890-03112 Pocket Tester
90890-03112 Pocket Tester

This instrument is invaluable for checking the electrical system.

90890-03113

Engine tachometer.

90890-03113 Engine tachometer.

This tool is needed for detecting the engine rpm.

90890-06754

Ignition checker.

90890-06754 Ignition checker.  
 

This instrument is necessary for checking the ignition system components.

1-7

SPEC 2
SPEC 2

SPEC

2

SPEC

SPEC

CHAPTER 2. SPECIFICATIONS

GENERAL SPECIFICATIONS

2-1

MAINTENANCE SPECIFICATIONS

2-4

ENGINE

2-4

TIGHTENING TORQUES (ENGINE)

2-7

CHASSIS

2-8

TIGHTENING TORQUES (CHASSIS)

2-10

ELECTRICAL

2-11

GENERAL TORQUE SPECIFICATIONS

2-13

LUBRICATION POINT AND GRADE OF LUBRICANT

2-14

ENGINE

2-14

CHASSIS

2-15

CABLE ROUTING

2-16

GENERAL SPECIFICATIONS

SPEC

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model

 

YH50

Dimensions:

 

Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius

1,940 mm

685

mm

1,105 mm

765

mm

1,294 mm

125

mm

1,800 mm

Basic weight:

 

With oil and full fuel tank

78 kg

Engine:

 

Type Cylinder arrangement Displacement Bore x stroke Compression ratio

Air-cooled-2 stroke, gasoline torque induction. Single cylinder, horizontal

49.2

cm 3

40.0

x 39.2 mm

7.25

: 1 (B)(E)(F)(GB)(I)(P)

 

7.9

(D)

7.65

(NL)

Starting system

Electrical and Kick starter

Lubrication system:

Separate lubrification

Oil type or grade:

 

Engine oil:

SEMI-SYNTHETIC, in accordance with API TC TS C3 STANDARD. SAE 10W30 type SE motor oil

Transmission oil

Oil capacity:

 

Engine oil:

1.3

L

Transmission oil:

 

Periodic oil change Total amount

0.11

L

0.13

L

Air filter:

Wet type element

Fuel:

 

Type

Regular unleaded gasoline with a research octane number of 91 or higher.

Tank capacity:

7.2

L

Carburetor:

 

Type/quantity

PY 12 / 1 GURTNER

Manufacturer

2-1

GENERAL SPECIFICATIONS

SPEC

SPEC

Model

 

YH50

Spark plug:

 

Type

BR8HS

Manufacturer

NGK

Gap

0.5

~ 0.7 mm

Clutch type:

Dry, centrifugal automatic

Transmission:

 

Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission Operation

 

Helical gear

52

/ 13 (4.000)

Spur gear

45

/ 12 (3.750)

V-belt

Automatic

Chassis:

 

Frame type

Steel tube underbone °

27

Caster angle

Trail

90

mm

Tires:

 

Type

With tube

Size

Front

70

/ 90 -16 42M

Rear

80

/ 90 -16 46M

Manufacturer/Type Wear limit(Front/Rear)

MICHELIN/M 29 STT

0.8

mm

Tires pressure (Cold tire):

 

Front (single riding) Rear (single riding) Front (dual riding) Rear (dual riding)

 

180

kPa (1.80 Kg/cm 2 , 1.80 bar)

190

kPa (1.90 Kg/cm 2 , 1.90 bar)

200

kPa (2.00 Kg/cm 2 , 2.00 bar)

220

kPa (2.20 Kg/cm 2 , 2.20 bar)

Brakes:

 

Front brake type Operation Rear brake type Operation

Disk brake Right hand operation Drum brake Left hand operation

Suspension:

 

Front

Telescopic fork

Rear

Unit swing

Shock absorber:

 

Front

Coil spring/ Oil damper Coil spring/ Oil damper

Rear

2-2

GENERAL SPECIFICATIONS

SPEC

SPEC

Model

 

YH50

Wheel travel:

 

Front

71

mm

Rear

86

mm

Electrical:

 

Ignition system Charging system Battery type/model Battery capacity

 

CDI

Flywheel magneto GM4-3B, YB4L-B, FB4L-B 12V 4AH

Headlight type:

Bulb

Bulb wattage x quantity:

 

Headlight Taillight / brake light License light (Switzerland only) Flasher light

Front

12V 35W/35W x 1 12V 5W /21W x 1 12V 5Wx1 12V 10W x 2 12V 10W x 2 12V 1.2W x 2

Rear

Meter light Warning lights wattage/quantity:

"OIL"

12V 1.2W x 1 12V 1.2W x 1 12V 1.2W x 1

"TURN"

"HIGH BEAM"

2-3

MAINTENANCE SPECIFICATIONS

SPEC

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Model

 

Standard

Limit

Cylinder head:

   

Warp limit

Warp limit *** * Lines indicate straight edge measurements. 0.02 mm

*** * Lines indicate straight edge measurements.

0.02

mm

 
 

Cylinder:

   

Bore size

 

39.993

~ 40.012 mm *** ***

***

Taper

 

0.05

mm

Out-of-round

0.01

mm

Piston:

Piston:    
   

Piston size

 

39.952

~ 39.972 mm

***

Measuring point*

 

5 mm

***

Piston clearance Oversize:

   

0.034

~ 0.047 mm

0.1 mm

1

st

40.25

mm

***

 

2

nd

40.50

mm

***

Piston rings:

   

Sectional sketch (BxT)/Type:

 

Top ring

T
T

B

1.2

x 1.8 mm (B)(E)(F)(GB)(I)(P)

***

1.5

x 1.8 mm (D)(CH)(NL)

***

2nd ring

1.2

x 1.8 mm (B)(E)(F)(GB)(I)(P)

***

1.5

x 1.8 mm (D)(CH)(NL)

***

End gap (Installed):

 

Top ring 2nd ring Side clearance (Installed):

   

0.15

~ 0.35 mm

***

0.15

~ 0.35 mm

***

Top ring

0.03

~ 0.05 mm

***

2nd ring

0.03

~ 0.05 mm

***

Piston pin:

   

Outside diameter Piston pin to piston clearance

   

9.996 ~ 10.000 mm

***

 

0.004

~ 0.019 mm

***

2-4

MAINTENANCE SPECIFICATIONS

SPEC

SPEC

Model

 

Standard

Limit

Crankshaft:

Crankshaft:   ***
 

***

Crank width “A” Runout limit “C” Connecting rod big end side clearance “D” Connecting rod length

 

37.90 ~ 37.95 mm ***

0.03

mm

0.2 ~ 0.5mm

***

79.9

~80.1 mm

***

Automatic centrifugal clutch:

   

Clutch shoe thickness Clutch shoe spring free length Clutch housing inside diameter Clutch-in revolution Clutch-stall revolution

 

2 mm

1 mm

29.9

mm

***

105 mm

105.4

mm

3850

~ 4350 r/min

***

6100

~ 6900 r/min

***

V-belt:

   

Width

 

16.5

mm

14.85

mm

Transmission:

   

Main axle runout limit Drive axle runout limit

   

***

0.08

mm

***

0.08

mm

Kick starter:

   

Type Kick clip tension force

 

Ratchet type

***

0.15

~ 0.25 kg

***

Carburetor:

   

I.D. mark Main jet (M.J.)

 

***

Gurtner 402 # 74 (B)(E)(F)(GB)(I)(P) # 68 (D)(NL)

***

***

Main air jet (M.A.J.) Jet needle (J.N.)

 

2.0

***

B10A 2/3 (B)(E)(F)(GB)(I)(P)

***

 

B10A 1/3 (D)(NL) 2326 (B)(E)(F)(GB)(I)(P) 20608/8 (D)(NL)

***

Needle jet (N.J.)

***

***

Cutaway (C.A.) Pilot jet (P.J.) Bypass 1 (B.P.1) Air screw (A.S.)

   

3.0

***

#

38

***

***

***

 

***

1 - 1/8 (B)(E)(F)(GB)(I)(P) 1 - 1/2 (D) 1 - 3/4 (NL)

***

 

***

Valve seat size (V.S.) Starter jet (G.S.1) Engine idle speed

   

1.4

***

#

42

***

1800 ± 200 r/min (B)(E)(F)(GB)(I)(P)

***

 

2000 ± 200 r/min (D)(NL)

***

2-5

MAINTENANCE SPECIFICATIONS

SPEC

SPEC

Model

Standard

Limit

Reed valve:

   

Thickness Valve stopper height Valve bending limit

***

0.142 ~ 0.162 mm 6.0 ~ 6.4 mm

***

0.2

mm

***

Lubrication system:

Autolube pump

***

Stroke

0.5

mm

***

2-6

MAINTENANCE SPECIFICATIONS

SPEC

SPEC

TIGHTENING TORQUES

ENGINE

       

Tightening

 

Part to be tightened

Part

Thread

Q'ty

torque

Remarks

name

size

Nm

m.kg

Spark plug

-

M14

1

23

2.3

 

Head cylinder

Nut

M7

4

14

1.4

 

Cylinder stud bolt

bolt stud

M7

4

Fixed till end

 

Air shroud (fan cover)

Screw

M6

2

6.5

0.65

 

Fan

Screw

M6

3

6.5

0.65

 

Air shroud (cylinder cover)

Screw

5.5x40

1

1.5

0.15

 

Oil pump assembly

Screw

M5

2

4

0.4

 

Reed valve

Bolt

M6

4

11

1.1

 

Air filter

Screw

M6

2

8.5

0.85

 

Carburetor top

Bolt

M5

1

2.5

0.25

 

Exaust pipe/cylinder

Screw

M6

2

7.0

0.7

 

Muffler

Bolt

M8

2

29

2.9

 

Muffler protector

Screw

M6

2

18.5

1.85

 

Crankcase

Screw

M6

6

13

1.3

 

Holder

Bolt

M6

1

8

0.8

 

Crankcase cover (right cover)

Screw

M6

2

10

1.0

 
 

Bolt

M6

4

10

1.0

 

Crankcase cover (left cover)

Screw

M6

9

9

0.9

 
 

Bolt

M6

3

9

0.9

 

Drain bolt

Bolt

M8

1

17

1.7

 

Plug oil

Plug oil

M14

1

-

-

 

Plate idle gear

Bolt

M6

2

8

0.8

 

Self starting motor

Bolt

M6

2

8

0.8

 

Cluth housing

Nut

M10

2

40

4.0

 

Cluth one-way

Nut

M28

1

-

-

 

Pin pivot

Nut

M10

1

12

1.2

 

Base magneto

Screw

M6

2

8.5

0.85

 

C.D.I. rotor

Nut

M10

2

37

3.7

 

2-7

MAINTENANCE SPECIFICATIONS

SPEC

SPEC

CHASSIS

Model

Standard

Limit

Steering system:

   

Steering bearing type No/Size of steel balls:

Ball bearing

***

Upper

ø4.77 mm x 15 ø4.77 mm x 15

***

Lower

***

Front suspension:

   

Front fork travel Optional spring Oil quantity / tube Oil grade

 

80

mm

***

No 70 cc ISO 6743/4 LHV 46 or SAE 10

***

***

Rear suspension:

   

Shock absorber travel Spring free length Spring fitting length Srping rate Stroke Optional spring

 

70

mm

***

235

mm

***

208

mm

***

(K1)

23 N/mm 0 ~ 75 mm No

***

***

Wheels:

   

Front wheel type Rear wheel type Front wheel size/Material Rear wheel size/Material

Cast wheel Cast wheel MT 1.60 x16/Aluminium MT 1.85 x 16/Aluminium

Rim runout limit:

   

Front

Radial

 

***

1 mm

Lateral

***

1 mm

Rear

Radial

***

1 mm

Lateral

***

1 mm

2-8

MAINTENANCE SPECIFICATIONS

SPEC

SPEC

Model

 

Standard

Limit

Front disk brake:

   

Type Diameter and thickness Pad thickness Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type

***

Single disc 220 x 4 mm 4.5 mm

***

0.5 mm

 

11

mm

***

30

mm

***

DOT #3 or DOT#4

***

Rear drum brake:

   

Type Drum inside diameter Lining thickness Spring free length

Leading, trailing

***

 

110 mm

110.5 mm

4 mm

2 mm

50.5 mm

***

Brake lever freeplay:

   

Front brake lever free play Rear brake lever free play

10

~ 20 mm

***

10

~ 20 mm

***

2-9

MAINTENANCE SPECIFICATIONS

SPEC

SPEC

TIGHTENING TORQUES

CHASSIS

   

Tightening

 

Part to be tightened

Thread

torque

Remarks

size

Nm

m.kg

Frame with engine bracket

M10

42

4.2

 

Engine bracket with engine

M10

52

5.2

 

Rear schock absorber with frame (top)

M10

31.5

3.15

 

Rear schock absorber with engine (bottom)

M8

17.5

1.75

 

Handle with steering shaft

M10

60

6.0

 

Steering nut (securing nut)

M25

27.5

2.75

 

Front and rear flasher

M6

1.5

0.15

 

Cover handle under/handle

M8

4

0.4

 

Master cylinder/Handle

M6

8.5

0.85

 

Seat lock

M6

4

0.4

 

Box / Frame

M6

7

0.7

 

Fuel tank / Fuel cock

x

2.5

0.25

 

Carrier / Frame

M6

4

0.4

 

Fuel tank

M6

6.5

0.65

 

Front wheel axle

M12

45

4.5

 

Rear wheel axle

M14

103.5

10.35

 

Front disc brake

M10

23

2.3

 

Front caliper

M8

23

2.3

 

Rear brake camshaft lever

M6

9.75

0.98

 

Rear brake pin pivot

M10

12

1.2

Punch the nut.

Bolt union/Master cylinder

M10

23

2.3

 

Bolt union/Caliper

M10

23

2.3

 

Screws tapping in plastic

Ø5

3.25

0.33

 

Screws tapping in clip

Ø5

2.25

0.23

 

Board footrest / Frame

M6

4

0.4

 

Inner pannel / Frame

M6

4

0.4

 

Oil tank

M6

5

0.5

 

Guard flap / Frame

M6

7

0.7

 

Fender / Front fork

M6

4

0.4

 

Inner fender / Frame

M6

4

0.4

 

Bleed screw and caliper

***

6

0.6

 

2-10

MAINTENANCE SPECIFICATIONS

SPEC

SPEC

ELECTRICAL

Model

 

Standard

Limit

Voltage:

 

12 V

***

Ignition system:

   

Ignition timing(B.T.D.C.) Ignition timing type

 

14° at 5000 r/min Constant

***

***

CDI:

   

Model/Manufacturer Pickup coil resistance (color)

 

3KJ / MORYAMA

400

~ 600 at 20 ° C (68° F) (White/Red-Black)

Source coil resistance (color)

640

~ 960 at 20 ° C (68° F) (Black/Red-Black)

***

Ignition coil:

   

Model/Manufacturer Minimum spark length Primary coil resistance Secondary coil resistance

***

2JN / MORYAMA *** 0.32 ~ 0.48 at 20 ° C (68° F) 5.68 ~ 8.52 kat 20 ° C (68 ° F)

6 mm

***

***

Spark plug cap:

   

Type

 

Resin 5 kat 20° C (68 ° F)

Resistance

***

Charging system / Type

 

Flywheel magneto

 

CDI Magneto:

   

Model/Manufacturer Charging coil resistance (color)

***

F2JA / MORYAMA 0,48 ~ 0,72 at 20 ° C (68° F) (White-Black) 0,4 ~ 0,6 at 20° C (68° F) (Yellow/Red-Black)

***

Lighting coil resistance (color)

***

Voltage Regulator/Rectifier:

   

Type

 

Semi-conductor, Short-circuit type DUCATI 13 ~ 14 V

Model/Manufacturer No load regulated voltage Capacity

***

8A

***

2-11

MAINTENANCE SPECIFICATIONS

SPEC

SPEC

Model

 

Standard

Limit

Battery :

   

Specific gravity

 

1.280

***

Starter motor:

   

Model / Type Output Armature coil resistance Brush length Brush spring pressure Commutator diameter Mica undercut (depth)

 

3AA / YAMAHA

 

0.14

kW

***

0.06

~ 0.08 at 20 ° C (68° F) 3.9 mm 563 ~ 844 g

***

0.9 mm

***

 

15.8

mm

14.8 mm

1.15

mm

***

Starter relay:

   

Amperage rating Coil resistance

 

***

20 A 54 ~ 66 at 20 ° C (68° F)

***

Horn:

   

Type/Quantity Model/Manufacturer Maximum amperage

 

Plain type/1pc.

TR9/TRANSVAL

 

2.5 A

***

Flasher relay:

   

Type Self cancelling device Flasher frequency Wattage

 

Condenser type No 75 ~ 95 cycles/min 10W x 2 + 3W

***

***

Circuit breaker:

   

Type Amperage for individual circuit x Quantity

   

Fuse

7.5 A x 1

***

Fuel sender unit:

   

Resistance

(Full)

9.2 ~ 10.8 at 20 ° C (68 ° F)

***

(Empty)

89.2

~ 90.8 at 20 ° C (68° F)

***

2-12

GENERAL TORQUE SPECIFICATIONS

SPEC

SPEC

GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.

A B
A
B

A: Distance across flats. B: Outside thread diameter.

 

A

 

B

General torque

(Nut)

(Bolt)

specifications

Nm

m.kg

10

mm

6

mm

60

0.6

12

mm

8

mm

15

1.5

14

mm

10

mm

30

3.0

17

mm

12

mm

55

5.5

19

mm

14

mm

85

8.5

22

mm

16

mm

130

13.0

2-13

LUBRICATION POINTS AND GRADE OF LUBRICANT

SPEC

SPEC

LUBRICATION POINTS AND GRADE OF LUBRICANT

ENGINE

Lubrication points

Lubricant type

Oil seal lips

LS
LS

O-ring

LS
LS

Crankshaft bearings

Crankshaft bearings

Needle bearings (connecting rod)

Needle bearings (connecting rod)

Main axle bearings

Main axle bearings

Drive axle bearings

LS
LS

Secondary sheave axle bearing

Secondary sheave axle bearing

Piston rings, piston pin and piston

Piston rings, piston pin and piston

Kick pinion gear

LS
LS

Kick shaft

LS
LS

Starter idle gear

Starter idle gear

starter clutch pin

starter clutch pin

Oil pump driven gear and drive gear

LS
LS

Secondary sliding sheave cam groove

BEL-RAY ® assembly lube

Secondary fixed sheave inside diameter

BEL-RAY ® assembly lube

Crankcase surface

Yamaha N ° 1215

2-14

LUBRICATION POINTS AND GRADE OF LUBRICANT

SPEC

SPEC

CHASSIS

Lubrication points

Lubricant type

Front wheel oil seal (right/left)

LS
LS

Rear wheel oil seal

LS
LS

Steering bearing and bearing race (upper/lower)

LS
LS

Throttle grip inner surface

LS
LS

Lever pivots and cable end

LS
LS

Oil seal lips (front wheel)

LS
LS

Bearing (front wheel)

LS
LS

Speedometer gear

LS
LS

Center stand pivot

LS
LS

2-15

CABLE ROUTING

SPEC

SPEC

CABLE ROUTING

Fuel sender Fuel tank Oil tank Overflow pipes Box Fuel hose Sunction pipe Fuel cock

Place the fuel sender wire on the rear-right side of the vehicul.

Pipes must pass above the engine bracket axle.

Insert the fuel cock completly without turning and tighten the hose clamp assembly.

Place the fuel cock as specified.

A C B D 45 °
A
C
B
D
45 °

2-16

CABLE ROUTING

SPEC

SPEC

Wire throttle Rear brake cable Front brake hose Band switch Wire harness Speedometer cable Seat lock cable Right flasher connector Tail light connector Left flasher connector Oil gauge

Pass the speedometer cable through the fender guide.

Clamp the brake hose to the clip.

Clamp all the cables and wires to the frame with a plastic band. Place the plastic band on the seat lock cable mark.

Install the wire harness with the mudguard plastic band.

E Attach the rear brake cable, the seat lock cable and the wire harness all together on the frame.

the seat lock cable and the wire harness all together on the frame. 5~10 mm E
5~10 mm E 5~10 mm 5~10 mm B D A C 2-17
5~10 mm
E
5~10 mm
5~10 mm
B
D
A
C
2-17

CABLE ROUTING

SPEC

SPEC

Wire harness C.D.I. magneto wire Starter lead Autochoke lead Battery Plastic band Seat lock cable Rear brake cable Throttle cable Left flasher connector Tail light connector Right flasher connector Breather pipe Starter relay

Put the fuse in place.

Install the starter relay support into the box tongue.

Clamp the C.D.I. magneto wire,the starter lead and the autochoke lead all together.

Clamp all wires and cables to the frame on the right side only. Place the plastic band on the wire harness mark.

E Clamp the wire harness to the frame, on the right side only.

wire harness mark. E Clamp the wire harness to the frame, on the right side only.
B C A 5~7 mm E 5~10 mm D 2-18
B
C
A
5~7 mm
E
5~10 mm
D
2-18

CABLE ROUTING

SPEC

SPEC

Speedometer cable Seat lock cable Regulator/Rectifier Resistor Flasher relay Wire harness Rear brake cable Throttle cable Front brake hose Fuel meter Horn

A Pass the seat lock cable on the right side of the front trunk.

B Fix the starter ground wire with the CHC screw as shown.

A

A + 45¡ 0¡ 0 B
+ 45¡ 0¡ 0 B
+ 45¡
0
B

2-19

CABLE ROUTING

SPEC

SPEC

Spark plug lead Wire harness Oil gauge Ignition coil C.D.I. Unit Throttle cable

A B
A
B

Clamp all the wires and cables to the frame, only on the right side . Place the plastic band on the wire harness mark.

Do not clamp the spark plug lead to the frame.

C Pass the rear brake cable in the guide fixed to the centerstand.

D Clamp the wire harness to the frame, on the right side only.

guide fixed to the centerstand. D Clamp the wire harness to the frame, on the right
5~7 mm D B A C 2-20
5~7 mm
D
B
A
C
2-20

CABLE ROUTING

SPEC

SPEC

Stop switch Clamp Speedometer cable Wire harness Throttle cable Rear brake cable Brake hose Right handle switch Front master cylinder Left handle switch Grip

A B
A
B

Install the left screw first and the right after.

Do not install screw at the front of the handlebar.

Grip A B Install the left screw first and the right after. Do not install screw
A B 2-21
A
B
2-21

CABLE ROUTING

SPEC

SPEC

Handlebar switch Flasher Master cylinder Brake hose Speedometer assembly Speedometer cable Headlight assembly

Respect the position of the handlebar switch.

Respect the brake hose position.

Install the master cylinder close to the handlebar switch. Install the master cylinder bracket to be in accordance with the handlebar switch assembling line.

Install the handlebar as shown.

be in accordance with the handlebar switch assembling line. Install the handlebar as shown. 0–1 A
0–1 A C B 25¡ D 2-22
0–1
A
C
B
25¡
D
2-22
CHK ADJ 3

CHK

CHK ADJ 3

ADJ

3

CHK

CHK

ADJ

CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION

3-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

3-1

COVERS

3-3

SIDE COVERS (SINGLE RIDING)

3-3

SIDE COVERS (DUAL RIDING)

3-4

BOX AND FUEL TANK

3-5

HANDLEBAR COVERS

3-6

FENDERS AND FRONT PANEL

3-7

INNER PANEL AND BOARD FOOTREST

3-8

ENGINE

3-9

ENGINE IDLE SPEED ADJUSTMENT

3-9

THROTTLE CABLE FREE PLAY ADJUSTMENT

3-10

SPARK PLUG INSPECTION

3-11

AUTOLUBE PUMP AIR BLEEDING

3-12

ENGINE OIL LEVEL INSPECTION

3-13

TRANSMISSION OIL REPLACEMENT

3-14

AIR CLEANER ELEMENT CLEANING

3-15

EXHAUST SYSTEM INSPECTION

3-16

V-BELT INSPECTION

3-16

CHASSIS

3-17