Documente Academic
Documente Profesional
Documente Cultură
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MOTORCYCLE
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SERVICE MANUAL
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2YT281972000 *2YT281972000*
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CE50T
SERVICE MANUAL
1986 by Yamaha Motor Co., Ltd.
1st Edition, November 1986
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
3
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NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha 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 scooter
have a basic understanding of the mechanical concepts and procedures inherent in scooter repair tech-
nology. Without: such knowledge, attempted repairs or service to this model may render it unfit to
use and/or unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all Autho-
rized Yamaha dealers and will, where applicable, appear in future editions of this manual.
TECHNICAL PUBLICATIONS
SERVICE DIVISION
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MOTORCYCLES OPERATIONS
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YAMAHA MOTOR CO., LTD.
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HOW TO USE THiS MANUAL
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PARTICULARLY iMPORTANT iNFORMATiON
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This material is distinguished by the following notation.
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NOTE: A NOTE provides key information to make procedures easier or clearer.
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MANUAL FORMAT
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All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
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tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
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In this revised format, the condition of a faulty component will precede an arrow symbol and the course
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ENG %_JDI IC
OOL _i Periodic inspection and adjustment
General information
_ Cooling
Engine system
(_ (_) _ Carburetion
@ Chassis
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Illustrated symbols (_ to (_) are used to identify
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(_) Filling fluid
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6_ _ the Lubricant
(_ specifications appearing in the text.
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(_) Tightening
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@ @
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@ (_ (_ @(_Apply wheel
molybdenum
bearing disulfide
grease oil
_ _ _ _L_.._ _(_))Apply
Apply molybdenum disulfide grease
lightweight lithium-soap base grease
Apply locking agent (LOCTITE )
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INDEX
GENERAL
,NFORMAT,
ON
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ENGINE OVERHAUL '_'%_
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CARBURETION
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CARB_,
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CHASSIS CHAS_
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L..,-.-----J
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ELECTRICAL ELEC_
APPENDICES APPX_
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GEN
CHAPTER 1
GENERAL INFORMATNON
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SPECIAL TOOLS .................................................. B-4
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FOR TUNE-UP .................................................. B-4
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FOR ENGINE SERVICE .......................................... B-4
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FOR CHASSIS SERVICE ......................................... B-5
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FOR ELECTRICAL COMPONENTS ................................ B-5
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INFO SCOOTER IDENTIFICATION
GENERAL
INFORMATION
SCOOTER IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number ( ~ is stamped
into the frame.
NOTE:
The vehicle identification number is used to iden-
tify your scooter and may be used to register your
scooter with the licensing outhority in your state.
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Starting Serial Number:
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JYA2U G00-~ H A720101
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ENGINE SERIAL N U M B E R
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The engine serial number ( ~ is stamped into the
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crankcase.
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NOTE:
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14T-720101
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NOTE:
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without notice.
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1-1
IMPORTANT INFORMATION
IMPORTANT
IE"
INFO
INFORMATION
ALL REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and/or grease recom-
mended by Yamaha for assembly and adjust-
ment. Other brands may be similar in func-
tion and appearance, but inferior in quality.
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be cleaned.
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2. Properly oil all mating parts and bearings dur-
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ing reassembly. Apply grease to the oil seal
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lips.
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LOCK WASHERS/PLATES AND COTTER
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PINS
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perly tightened.
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1-2
INFO iMPORTANT iNFORMATiON
BEARINGS AND OIL SEALS
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surfaces.
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(_ Bearing
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CIRCLIPSot
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1. All circlips should be inspected carefully
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ereas
ore reeo
ace
O ton
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_/._/7_/_////_ When
posite installing a cirelip
to the thrust (_) it(_,receives.
make sure
Seeththe
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/J sectional view.
(_) (_) Shaft
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1-3
I GEN
3 SPECIAL TOOLS I
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or improvis-
ed techniques.
FOR TUNE-UP
1. Inductive Tachometer
P/N. YU-08036
This tool is needed for detecting engine rpm.
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2. Compression Gauge
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P/N. YU-33223
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ession.
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P/N. YU-01235
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1-4
I GEN SPECIAL TOOLS
i . . . . . . . . . . . . . ir
P
3. Primary Sheave Holder
P/N. YS-01880
This tool is used when holding the clutch hub.
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5. Thickness Gauge
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P/N. YU-03001
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P/N. YU-33270
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the crankcase.
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1-5
I GEN
SPECIAL TOOLS I
8. Crankshaft Installation Set
,.Fol l
P/N. YU-90050 . . . . . . . . . . . . . . . . . . . . . . (~)
Adapter (M10)
P/N. YM-90062 . . . . . . . . . . . . . . . . . . . . . (~
Adapter (M12)
P/N. YM-90063 . . . . . . . . . . . . . . . . . . . . . ~)
These tools are used to install the crankshaft.
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FOR C H A S S I S SERVICE
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1. Ring Nut Wrench
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@ P/N. YU-01268 (~
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P/N. YU-33975 . . . . . . . . . . . . . . . . . . . . . (~
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FOR ELECTRICAL C O M P O N E N T S
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1. Pocket Tester
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P/N. YU-03112
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2. Electro Tester
P/N. YU-33260
This instrument is necessary for ignition system
!J inspection.
1-6
INSP
CHAPTER 2
PERiODiC iNSPECTiONS AND ADJUSTMENTS
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INSTALLATION ................................................ C5
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HANDLEBAR COVERS ........................................... C-5
REMOVAL ..................................................... C-5
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INSTALLATION ................................................ C-5
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ENGINE .......................................................... C-5
ENGINE IDLE SPEED ADJUSTMENT ............................. C-5
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INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventiw, maintenance procedures, if followed, will ensure more reliable vehicle operation and
a longer service life. The need for costly overhaul work will be greatly reduced. This information ap-
plies to vehicles already in service as well as new vehicles that are being prepared for sale. All service
technicians should be familiar with this entire chapter.
EVERY
BREAK-IN
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ITEM REMARKS 500 3,000 6,000
(300) (2,000) or (4,000) or
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6 months 12 months
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Spark plug Check/Clean or replace. O O
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Air filter Clean. Replace if necessary. O
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Carburetor Check/Adjust/idle speed, starter operation.
Fuel line ot
Check fuel hose for cracks or damage. O O
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Transmission oil Replace (Warm engine before draining). Replace Check Check
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Steering bearing Moderately repack every 12,000 (8,000) Check Check Check
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or 24 months.**
Rear shock absorber Check operation. O O
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2-1
TAIL COVER ADJ
TAIL COVER
REMOVAL
2. Remove:
=Seat
3. Remove:
-Cover (_
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4. Remove:
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,Grab bar
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_ , Rear carrier
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5. Disconnect:
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Taillight leads
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6. Remove:
Side covers (Right and left)
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NOTE:
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7. Remove:
=Tail cover
: !!
2-2
INSP
ADJ _1 TA'LCOVER E
INSTALLATION
When installing the tail cover, reverse the
"REMOVAL" procedure.
Note the following points.
1. Install:
Side covers
NOTE:
After installing the side covers, make sure that
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all hooks are securely fitted.
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2. Connect:
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eRear flasher light leads
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NOTE:
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31 install:
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4. Install:
eSeat
m,kg,
!_ 7 Nm (0.7 5.1 ft,lb)
2-3
- I FRONT AND
FENDER, FRONT BOARD
FOOTREST PANEL
FRONT FENDER, FRONT PANEL
iINSP
ADJ
2. Remove:
Front fender
_, NOTE:
Before removing the fender, make sure that all
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!_-::
@ i:Q::!i hooks are free.
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_N % - -_ - ot
3. Remove:
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_iiiii:iiii_
__" ,Main switch cap
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i:iiii!
i!ili ii_i Turn the cap counterclockwise.
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4. Remove:
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Front panel
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5. Remove:
, Footrest board
2-4
I INSP FRONT FENDER, FRONT PANEL
A N D FOOTREST B O A R D / H A N D L E B A R COVERS E
I NSTALLATION
Reverse the " R E M O V A L " procedure.
Note the following points,
1. Install:
Front fender
NOTE:
After installing the front fender, make sure that
all hooks are securely fitted.
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HANDLEBAR COVERS
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REMOVAL
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1. Remove:
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2. Disconnect:
oa
3. Remove:
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4. Disconnect:
Leads
-Speedometer cable ( ~
5. Remove:
Handlebar cover (Rear) ( ~
2-5
ENGINE iDLE SPEED A D J U S T M E N T I ADJ I
INSTALLATION
1. Install:
oHandlebar cover (Rear) (~)
2. Connect:
Leads
oSpeedometer cable (~)
NOTE:
Position the cables as shown.
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3. Connect:
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eHeadlight lead and flasher ]~ght leads
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4. Install:
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ENGINE
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1. Remove:
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Tail cover,.
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NOTE:
A warm engine is defined as one which had been
operated for about 3 minutes at 3,000 r/min with
no load.
2-6
I INSP ENGINE IDLE SPEED A D J U S T M E N T /
THROTTLE CABLE FREE PLAY A D J U S T M E N T E
3. Attach:
Inductive Tachometer (YU-08036)
4. Check:
eEngine idle speed
Out of specification-*Adjust.
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increase engine speed and counterclockwise
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to decrease engine speed.
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5. Install:
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eTail cover
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ADJUSTMENT
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1. Check:
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2-7
AUTOLUBE PUMP CABLE ADJUSTMENT ADJ
=Loosen the Iocknut (_.
oTurn the adjuster (_ in or out until the cor-
!_:__...... rect free play is obtained.
=Tighten the Iocknut.
NOTE:
Beforeadjustingthe pump cable, adjustthe throt-
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tle cable free play.
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1. Remove:
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=Tail cover
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* Front fender
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=Front panel
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eFootrest board
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2. Check:
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Out of specification_Adjust.
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2-8
4. Close the throttle grip completely.
5. Check:
Autolube pump pulley position (_
Out of position-*Adjust.
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:
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0.0-1.0 mm (0.0-0.04 in)
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_ Autolube Pump Pulley Position
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Autolube pump pulley position adjustment
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steps:
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6. Install:
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oFootrest board
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Front panel
Front fender
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eTail cover
Refer to "FRONT FENDER, FRONT PANEL
AND FOOTREST BOARD" and "TAIL
COVER" section.
2-9
__ AUTOLUBE PUMP AIR BLEEDING
1. Remove:
I,.sPl l
ADJ
=Tail cover
Front fender
-Front panel
Footrest board
Refer to "TAIL COVER" and "FRONT
FENDER, FRONT PANEL AND FOOTREST
BOARD" section.
2. Remove:
Autolube pump cover
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3. Remove:
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Bleed screw @
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NOTE:
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5. Air bleed:
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disappear.
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NOTE:
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Pull the pump cable all the way out to set the
pump stroke to a maximum.
6. Inspect:
Bleed screw gasket
Damage_Replace.
7. Install:
,Bleed screw gasket
Bleed screw
2-10
t ADJ
INSP AiR CLEANER
AUTOLUBE ELEMENT
PUMP CLEANING
AiR BLEEDING/
8. Keep the engine runningat about 2,000 r/min
for two minutes or so, and both distributor
and delivery pipe can be completely bled.
NOTE:
It is difficult to bleed the distributor completely
with the pump stroke at a minimum, and therefore
the pump stroke should be set to a maximum.
9. Install:
eAutolube pump cover
Footrest board
Front panel
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Front fender
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oTail cover
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Refer to "FRONT PANEL, FRONT FENDER
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ANT FOOTREST BOARD" and "TAIL
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COVER" section.
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AIR CLEANER ELEMENT CLEANING
1. Remove:
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;_ NOTE:
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2. Remove:
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2-11
;'='8 I AiR CLEANER FUEL
ELEMENT
COCK CLEANHNG/
CLEANING INSP
ADJ
3. Clean:
oAir cleaner element
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Do not twist the element when squeezing
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the element.
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4. Inspect:
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oElement
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Damage-_ Replace.
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5. Apply:
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motor oil
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NOTE:
The element should be wet but not dripping.
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7. Install:
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2-12
I,NsP
ADJ FUEL COCK CLEANHNG
2. Drain:
E
=Fuel
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3. Remove:
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(_ *Cap (_
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_*_'!_ii!
_iiii_ _:::_ 4. Clean:
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Filter
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oCap
Wash the filter and cap gently using solvent.
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5. Inspect:
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Filter
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oO-ring
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Damage--* Replace.
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6. Install:
O-ring
Filter
oCap
oTail cover
Refer to "TAIL COVER" section.
2-13
COMPRESSION PRESSURE MEASUREMENT INSP
ADJ
;!i...... COMPRESSION PRESSURE
1. Remove:
Cover (_
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4. Connect:
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Compression Gauge (YU-33223) (_
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_ _..._:_::,.
"" ::::
::::
........ 5. Measure:
Co mpression
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NOTE:
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Start the starter motor and throttle valve wide-
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open until the pressure indicated on gauge can
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rise no further. Compression should be within the
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specified levels.
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114 psi)
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Reading Diagnosis
Worn cylinder,
Higher than
without oil piston and piston
rings
Defective piston,
Same
withoutas oil ring(s), valve(s) and
cylinder head gasket
Compression test steps (above standard
levels):
eCheck cylinder head or piston crown for car-
bon deposits.
2-14
IiNSP
ADJ J_l ENGINE OIL LEVEL INSPECTION
ENGINE OiL LEVEL INSPECTION
1. Place the scooter on the level place.
NOTE:
Be sure the scooter is positioned stratight up and
":":%_{iii_ 2. Inspect:
...... ":<_ o Engine oil level
__:_-_ .... "............
- 0il level low-,Add sufficient oil by the
" _ following inspection steps.
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(_) "OIL" indicator light
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_3N _0-_ _$E ONLY
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Engine oil level visual inspection steps:
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position.
I Turn main switch to "_" I
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"ON" position.
I urn main switch to
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I
does not come on. ?1 iomeson i
e,ec-
1en0ine
I trical circuit,o"'eve'"
e'ec-
I Sueat'he
0'"'l
trical circuit are OK.
2-15
TRANSMISSION
ENGINE OiL LEVEL
OiL REPLACEMENT
iNSPECTiON/ ADJ
l lNSPI_I_ I
_ Yamalube 2 orOil:
Recommended Air Cooled 2
Stroke Engine Oil
Oil Capacity:
Total:
0.8 L (0.7 Imp qt, 0.84 US qt)
NOTE:
Install the oil tank filler cap (_ and push it fully
into the filler.
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Always use the same type of engine oil; mix-
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ing oils may result in a h_rmful chemical
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reaction and lead to poor performance.
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it.
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3. Remove:
oDrain bolt (_
Drain the transmission oil.
oOil filler plug
2-16
ADJ
t INSPt_ FUEL LiNE iNSPECTiON
I TRANSMISSION OIL REPLACEMENT/
4. Inspect:
Gasket (Drain bolt)
O-ring (Oil filler plug)
Damage_ Replace.
5. Install:
Gasket
Drain bolt
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18 Nm (1.8 m.kg, 13 ft.lb)
I_ Drain Bolt:
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6. Fill:
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Transmission case
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SE Motor Oil
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Capacity:
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NOTE:
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wheel.
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7. Install:
Oil filler plug
2-17
F.ONT
B LEVE.
F.EE
P.A
C.ECK/
I,.SP[ I
REAR BRAKE LEVER FREE PLAY CHECK ADJ
_ o Fuel pipe (_
2. Inspect:
Cracks/Damage -_ Replace.
3. Install:
oTail cover
Refer to "TAIL COVER" section.
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CHASSIS
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Out of specification-_Adjust.
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Front brake lever free p|a adjustment
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steps:
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1. Check:
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2-18
ADJ I (i_
I INSP TIRE
FRONTAND WHEEL
AND REAR iNSPECTION
BRAKE LNNING INSPECTION/ l
[] _. FRONT AND REAR BRAKE LINING
) 1. Activate the brake lever.
2. Inspect:
-_; Wear indicator (_
Indicator at wear limit line (_Replace
brake shoes.
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TiRE AND WHEEL INSPECTION
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1. Measure:
.S
Air pressure
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Out of specification-_Adjust.
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2-19
" STEERING ADJUSTMENT ADJ
2. Inspect:
'_._=q _ oTire surface
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(]_) 3. Measure:
Tire tread depth
.S
Out of specification_Replace.
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Wear indicator
Side wall
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STEERING ADJUSTMENT
1. Place the scooter on its centerstand, then
elevate the front wheel.
2-20
INSP
STEERING A D J U S T M E N T / B A T T E R Y
2. Check:
=Steering assembly bearings
Grasp the bottom of the forks and gently
rock the rock assembly back and forth.
Looseness-*Adjust.
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30 Nm (3.0 m okg, 22 ftolb)
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NOTE:
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Set the torque wrench to the ring nut wrench
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so that they form right angle.
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*Move the handlebar up and down, and/or
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back and forth. If handlebar free play is ex-
cess, tighten the bolt ( ~ to specification.
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Bolt (~:
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ELECTRICAL
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BATTERY
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1. Check:
ow
= Fluid level
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Incorrect-* Refill.
Fluid level should be between upper and
lower level marks.
(~ Upper level
(~) Lower level
iiii!!iiiiiiiiiii!iii!!i
Refill with distilled water only; tap water
contains minerals harmful to a battery.
2-21
BATTER*
2. inspect:
L'NSP1
Breather hose
Obstruction_ Remove.
Damage-* Replace.
3. Inspect:
Battery
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cumulation of material exists in the bottom
e.
of the cell.
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Specific gravity readings after a long, slow
charge indicate one cell to be lower than the
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rest.
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Warpage or buckling of plates or insulators
is evident.
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Specific gravity:
nl
Charging Current:
_ 4. Measure:
0.4 amps/10 hrs
Specific Gravity:
1.280 at 20C (68F)
2-22
I INSP
ADJ l( l BATTERY/FUSE INSPECTION
injury.
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=Wear protective eye gear when handling or
working near batteries.
e.
Antidote (EXTERNAL):
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_\_J--_ 9/ -SKIN-- Flush with water.
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____= '_ "_ EYES--Flush
can cause servere
with water
burns for
or permanent
15 minutes and
eye
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get immediate medical attention.
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Antidote (INTERNAL):
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eDrink large quantities of water or milk
.S
attention.
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ing batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
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OF REACH OF CHILDREN.
FUSE INSPECTION
1. Open the seat lock.
2-23
FUSE iNSPECTION/SPARK PLUG iNSPECTiON ADJ
2. Inspect:
e Fuse C)
Defective--* Replace.
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Do not use fuses of higher amperage rating
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than recommended. Extensive electrical
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system damage and fire could result from
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substitution of a fuse of impcoper amperage:
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Description Amperage Quantity
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Main 7A 1
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1. Remove:
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i =Cover @
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" --?: i
2. Inspect:
=Electrode _)
Wear/Damage--, Replace.
=Insulator (_
Abnormal Color_ Replace.
@
" @ Standard Spark Plug:
BPR6HS (N.G.K.)
2-24
I INSP SPARK PLUG INSPECTION/
HEADLIGHT BEAM ADJUSTMENT/IGNITION TIMING
3. Measure:
ePlug gap (~
Out of specification--* Regap.
Use a Wire Gauge or Feeler Gauge.
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and plug surfaces.
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NOTE:
e.
Finger,tighten the spark plug before torquing to
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specification.
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Spark Plug:
.S
1. Adjust:
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Headlight (Vertically)
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Vertical adjustment
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Horizontal adjustment
Loosen the adjuster (~) or tighten
Right the adjuster (~)
Left Loosen the adjuster (~) or tighten
the adjuster (~)
IGNITION T I M I N G
Adjustment free.
2-25
D
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I ENG ri
CHAPTER 3
ENGINE OVERHAUL
ENGINE REMOVAL . ............................................. D-3
P R E P A R A T I O N FOR R E M O V A L ................................. D-3
T A I L COVER .................................................. D-3
FRONT FENDER, F R O N T P A N E L A N D FOOTREST BOARD ........ D-3
CARBURETOR ................................................. D-3
C A B L E S , L E A D S A N D PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
ENGINE REMOVAL ............................................. D-4
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CYLINDER .................................................... D-6
P I S T O N PIN A N D P I S T O N D-6
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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STARTER SYSTEM ............................................ D-7
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C.D.I. M A G N E T O .............................................. D-8
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AUTOLUBE PUMP ............................................. D-8
TRANSMISSION ............................................... ot D-8
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CRANKCASE AND CRANKSHAFT ............................... D-9
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ENGINE OVERHAUL
ENGINE R E M O V A L
NOTE:
It is necessary to remove the engine in order to
remove the following components.
oCylinder head
Cylinder
Piston
CDI magneto
Starter motor
Primary and secondary sheave
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PREPARATION FOR R E M O V A L
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1. Remove all dirt, mud, dust and foreign
.S
NOTE:
D
3-1
ENGINE REMOVAL I E.o I, .l
. During engine disassembly, clean all parts and
place them in trays in the order of
disassembly. This will speed up assembly time
and help assure that all parts are correctly
reinstalled in the engine.
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TAIL COVER
co
1. Remove:
.S
.Seat
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Tail cover
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Rear carrier
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section.
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FOOTREST BOARD
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1. Remove:
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Front fender
Front panel
D
= Footrest board
Refer to "CHAPTER 2.--FRONT FENDER,
FRONT PANEL AND FOOTREST BOARD"
section.
CARBURETOR
1. Remove:
- A i r cleaner case
3-2
[ENO EOO,NE.EMOVA, 2. Remove:
Fi
oFuel pipe (_
oOil delivery pipe (_)
Vacuum pipe (_)
Auto choke unit lead
3. Remove:
_, Carburetor top cover
oCarburetor
NOTE:
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Cover the carburetor with a clean rag to prevent
e.
dirt or foreign matter into the carburetor.
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i _i 1. Remove:
CABLES, LEADS AND PIPES
.S
2. Remove:
oa
NOTE:
D
Plug the oil pipe so the oil will not run out of the
oil tank.
3. Remove:
Battery negative lead (_
3-3
4 ENGINE REMOVAL
4. Remove:
ENG %_ ]
Spark plug cap
5. Remove:
.Earth lead (_
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6. Remove:
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Rear brake cable (_
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7. Disconnect:
oa
+,
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ENGINE REMOVAL
1. Remove:
Air shroud (_
3-4
[ENG ENGINEREMOVAL/DISASSEMBLY
2. Remove:
oEngine mounting bolts
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3. Remove:
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Engine
.S
DISASSEMBLY
MUFFLER
1. Remove:
oExhaust pipe
3-5
O'SASSEMB'
IEN
2. Remove:
`"Muffler
CYLINDER HEAD
1. Remove:
`"Fan cover
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2. Remove:
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" _::_:_ Air shroud
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3. Remove:
........
::: : _ ,,Cylinder head (_
(_,
Cylinder head gasket
NOTE:
`"Before loosening the cylinder head, loosen the
spark plug _).
The cylinder head holding nuts should be loosen-
ed 1/2 turn each time, and remove.
3-6
O,SASSEMBL* CYLINDER
E
1. Remove:
Cylinder (_
i_ Cylinder gasket
2. Remove:
Carburetor joint (_
oReed valve assembly
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PISTON PIN AND PISTON
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1. Remove:
.S
NOTE:
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2. Remove:
oa
oPiston pin (_
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Piston (_)
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3-7
PRIMARY AND SECONDARY SHEAVE
1. Remove:
*Crankcase cover (Left)
* Dowel pins
2. Remove:
*Fan (_
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;i4 _! '- __ 3. Remove:
*Nut @ (Primary sheave)
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NOTE:
oa
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_ (YU-01235).
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4. Remove:
- *Conical spring washer (_
*One-way clutch (_
_ ._,. *Primary fixed sheave _)
"_'_, ,,V-Belt
3-8
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2. Remove:
-Plate (_ (Idle gear)
3-9
q O,SASSEMB.! I' .1
3. Remove:
j ii eStarter wheel gear (~)
Bearing (~
.Z ; !;;~!! Washers (~
oldie gear (~)
4. Remove:
Stay (~
oCollar (~)
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5. Remove:
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oStarter motor (~
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6. Remove:
oa
Kick crank (~
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7. Remove:
oKick torsion spring (~
3-10
9. Remove:
oCirclip (_
o Plain washer (_
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C.D.I. MAGNETO
oa
1. Remove:
nl
._ ii;_ 2. Remove:
_- __..9 C. D.I. magneto
Use Flywheel Magneto Puller (YM-01189)
oWoodruff key
3-11
O'SASSEMB'
IE"O
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_ 3. Remove:
eStator assembly (_
4. Remove:
Gasket @
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AUTOLUBE PUMP
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1. Remove:
.S
*Autolube pump @
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2. Remove:
oa
Circlip (_
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*Shim (_)
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_0\ 0 "Pin @
TRANSMISSION
1. Remove:
Rear wheel
oBrake shoe plate
3-12
ENGr DISASSEMBLY I-q
2. Unhook:
= Spring (Centerstand)
3, Remove:
Clip ( ~
Centerstand
4. Remove:
Transmission case cover ( ~
Gasket (~)
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5. Remove:
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=Main axle ( ~
.S
Drive axle ( ~
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6. Remove:
oa
Oil seal
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oCirclip ( ~
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7. Remove:
Secondary sheave axle ( ~
3-13
O,SASSEMOL
[ENOL
_zi;ili_:_
_- CRANKCASE AND CRANKSHAFT
1. Remove:
"'_ 2. Remove:
oScrews (Crankcase)
NOTE:
Loosen each screw 1/4 turn, and remove them
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after all are loosened.
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_, 3. Attach:
oa
_ Fully
NOTE: tighten the-tool holding bolts, but make sure
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_ _i__:i: _:.....
_:?. _
4. Remove:
eCrankcase (Left)
As pressure is applied, alternately tap on the
engine mounting bosses.
5. Remove:
= Crankshaft
Use Universal Puller Set (YU-33270) (~.
NOTE:
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Use the following bolts available on the market.
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Lenght: 160 mm (6.3 in)
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Thread: 6 mm (0.24 in)
Pitch: 1.25 mm
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INSPECTION A N D REPAIR
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CYLINDER HEAD
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1. Remove:
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=Carbon deposits
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NOTE:
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2. Inspect:
=Cylinder head warpage
Out of specification ~ Re-su rface.
W a r p a g e m e a s u r e m e n t and re-surface-
m e n t steps:
=Attach a straight edge and a thickness gauge
on the cylinder head.
=Measure the warpage limit.
3-15
oq .osONANO.EPA.
IE"O
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0.02 mm (0.0008 in)
_ Warpage Limit:
olf the warpage is out of specification, reface
the cylinder head.
oPlace a 400-600 grit wet sandpaper on the
surface plate, and re-surface the head using
a figure-eight sanding pattern.
NOTE:
Rotate the head several times to avoid remov-
ing too much material from one side.
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CYLINDER AND PISTON
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/ 1. Eliminate:
.S
-_ _ ( /
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-- _ NOTE:
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3. Inspect: +'
D
Piston wall
sively.Wear/Scratches/Damage_ Replace.
4. Eliminate:
Carbon deposits
Use a rounded scraper (_.
i+:_ ,!+++,
3-16
5. Inspect:
oCylinder wall
Wear/Scratches -_Rebore or replace.
6. Measure:
i_ Piston-to-cylinder clearance
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steps:
First step:
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:_ D_ Bore Gauge.
Measure the cylinder bore "'C" with a Cylinder
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NOTE:
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/
.-,_
_-,._
_ ...... r__ Measure the cylinder bore "C" in parallel to and
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0.05 mm
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C= Maximum D
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T=(Maximum Dz or D2) -
(Maximum Ds or D6)
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__ 2nd step:
307,000
3-17
INSPECTION AND REPAIR ENG]
Piston-to-cylinder Clearance =
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Cylinder bore "C"-
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Piston skirt diameter "P"
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olf out of specification, rebore or replace
cylinder, and replace piston and piston rings
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as a set.
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_ Piston-to-cylinder
0.034-0.047 mm Clearance:
.S
oEnd gap
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3-18
,SPEOT,ONANO.EPA 8. Oversize piston ring size:
Ring size is stamped on top of the ring.
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2. Install:
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oPiston pin
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Piston pin bearing
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Into the small end of the connecting rod.
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3. Check:
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rod as required.
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4. Install:
oa
pin
oPiston
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5. Check:
oFree play (when the piston pin is in place in
D
the piston)
There should be no noticeable for the play.
Free play exists--* Replace piston pin and/or
(___j_ Into the piston pin hole.
piston.
6. Inspect:
oPiston pin and bearing
Signs of heat discoloration-_Replace.
3-19
'OSPEOT'ON
AOO"EPA'"
IENo AUTOLUBE PUMP
Wear or an internal malfunction may cause pump
output to vary from the factory setting. This situa-
tion is, however, extremely rare. If improper out-
put is suspected, inspect the following:
1. Inspect:
Delivery line
Obstructions_ Blow out.
cO-ring
Wear/Damage _ Replace.
2. Inspect:
.._
_ I_ Autolube pump driven
oAutolube drive gear
gearteeth
teeth (_(_
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_i_?!i:!_!i
!_ Pitting/Wear/Damage--* Replace.
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F CRANKSHAFT
-= =- 1. Measure:
.S
Out of Specification_Replace.
_Connecting rod big end side clearance "D"
m
gauge.
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0.03 mm
Runout (0.0012
Limit "'C": in)
oa
Clearance "D":
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2. Inspect:
oBearings (Crankshaft)
Spin the bearing inner race.
Excessive play/Roughness_ Replace.
Pitting / Damage_ Replace.
3-20
m
[ENG ,NSPEOT,
OO
AND.EPA,.
TRANSMISSION
1. Inspect:
_,_,:;_ .Primary drive gear teeth (_
_,_ 4_ ,_i_,,/ . Primary driven gear teeth (_)
,_;_;
_!_#_, _,_,/'_ *Secondary drive gear teeth
/ / ......... _i .Secondary driven gear teeth _)
@/ / Burrs/Chips/Roughness/Wear_ Replace.
2. Inspect:
Drive gear bearing (_
Main axle bearing (_)
QSecondary sheave axle bearing (_)
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_i!!i_i Spin the bearing inner race.
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Excessive play/Roughness-* Replace.
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(_) Pitting/Damage--* Replace.
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1. Inspect: SHEAVE
PRIMARY
.S
Collar (_)
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Wear/Cracks/Scratch/Damage--* Replace.
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2. Check:
oa
Free movement
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or collar.
__:_;__<;_.-.
...... S ECO NDA RY SH EAVE
_:_;;_.... Disassembly
1. Attach:
_--_ _ ,Primary Sheave Holder (YS-01880) (_)
Socket Wrench (41 mm) (_
:, _., _
,oose :
_Clutch securing nut
_i_i_:.:. :.
Do not remove the clutch securing nut yet.
3-21
3q ,osPEoT,oN
AOO.EPA,.
lENO
I' .i 3. Attach:
oClutch Spring Holder (YS-28891) (_
NOTE:
Use the following bolt (_ available on the
market.
Thread: 10 mm (0.39 in)
Pitch: 1.25 mm
4. Remove:
Clutch securing nut (_
5. Remove:
Clutch spring (_
...._-_[_,, Spring seat (_
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(_ . __ Clutch assembly @
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6. Remove:
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,Guide pins @
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7. Remove:
oa
.-::5*"
Inspection
(_ 1. Inspect:
3-22
2. Inspect:
oTorque cam groove (~)
oGuide pin (~
Wear/Damage-*Replace as a set.
Oil seals (~
F ~ oO-rings (~)
Damage-* Replace.
y
3. Measure:
Clutch spring free length (~
Out of specification-* Replace.
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Clutch Spring Free Length:
,' If l! !f
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109.6 m m (4.31 in)
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< Limit > :
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94.0 m m (3.70 in)
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4. Inspect:
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Clutch housing inner surface
Oil/Scratches-* Remove.
.S
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Oil
thinner or solvent.
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5. Measure:
oClutch housing inside diameter (~)
oa
Ouf of specification-*Replace.
nl
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r
Clutch Housing Inside D i a m e t e r :
D
6. Inspect:
oClutch shoes
Glazed parts-* Sand with coarse sandpaper.
NOTE:
After using the sand paper, clean of the polished
particles with cloth.
3-23
INSPECTION AND REPAIR I ENG
7. Measure:
oClutch shoe thickness ( ~
Out of specification-* Replace.
Assembly
When assemblying the secondary sheave, reverse
the disassembly procedure. Note the following
points.
t
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1. Apply:
e.
+BEL-RAY Assembly Lube
(to the inside of the sliding sheave)
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2. Install:
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Sliding sheave
NOTE:
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,!:,.~.... ~+~ii,si~.
= .......
Be careful so that the oil seal lips are not turned
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~; ++.
+.;+!:i:~!
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3. Apply:
eBEL-RAY Assembly Lube
oa
4. Check:
Sliding sheave
Unsmooth operation-* Repair.
3-24
5. Install:
Clutch securing nut
Use Clutch Spring Holder (_) (YS-28891).
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e.
[_ 50 Nm (5.0 m,kg, 36 ftlb)
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V-BELT ot
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1. Inspect:
.S
oV-belt
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Crack/Wear-_ Replace.
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NOTE:
m
grease.
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2. Measure:
oa
oV-belt width (_
nl
Out of specification_Replace.
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/ _ 15.0 Width:
V-Belt mm 10.59 in)
a
I <Wear Limit>:
3-25
,osooAoo.EPA,.
!ENO
I I
2. Inspect:
oStarter wheel gear teeth (_
oldie gear teeth (_)
Burrs/Chips/Roughness/Wear-* Replace.
3. Inspect:
Pitting/Damage--* Replace.
_Z(_ oBearing (_) (Starter wheel gear)
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4. Inspect:
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_ Kick gear teeth (_
.S
(_ Burrs/Chips/Roughness/Wear-* Replace.
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/
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; /
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5. Inspect:
oa
clutch)
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6. Measure:
eClip tension (Kick pinion gear)
Out of spedification-*Replace.
Standard Tension:
250- 300 g (8.83- 10.6 oz)
3-26
ENGINE A S S E M B L Y A N D A D J U S T M E N T
ENGINE A S S E M B L Y A N D
ADJUSTMENT
CRANKSHAFT AND CRANKCASE
1. Attach:
t
oCrankshaft Installing Tool
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(YU-90050 (~, YM-90062 (~)
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2. Install:
rT
Crankshaft
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To left crankcase.
ot
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NOTE:
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3. Apply:
oa
(ACC-11001-30-00)
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5. Install:
Right crankcase
Use crankshaft Installing Tool (YU-90050
(~, YM-90063 (~)).
3-27
NOTE:
Tighten the crankcase holding screws in stage,
using a crisscross pattern.
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7. Check:
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oCrankshaft operation
.S
8. Install:
oa
Circlip (_)
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3-28
m
E.oIIEOO,NE
ASSEMB,
CRANKSHAFT
ANO
AOJOSTME A: 37.90-37.95 mm
0 Oil seal F (1.492-1.494 in)
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3-29
q Eoo.NE
AssEMB,Y
Aoo
AOJOSTMEO
IENO
I'.. TRANSMISSION
J, 1. Apply:
o10W30 Type SE Motor oil
(to transmission case cover bearing)
2. Install:
Secondary sheave axle (_
(to transmission case cover)
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3. Install: ot
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Circlip @
.S
Oil seal
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NOTE:
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i_i_i Apply lithium soap base grease onto the oil seal
m
_,_i .% lips.
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4. Apply:
oa
_ '_{_
...... 5. Install:
D
Drive axle (_
Main axle (_)
,Washer (_) (Main axle)
(_) ,Washer @ (Drive axle)
3-30
ENG _ ENGINEASSEMBLYAND ADJUSTMENT
7. Install:
8. Install:
i:._i_ ' * Centerstand
9. Install:
*Brake shoe plate @
-t Soe
P'ate':
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18 Nm (1.8 mkg, 13 ft,lb)
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10. Install:
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*Plain washer (_
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(_ *Plain
Nut @ washer _)
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3-31
TRANSMISSION
EOO,NE
ASSEMBL
ANO
AOJUSTM
"OJ OT
Bearing
Oil seal
Drive axle
(_ Bearing
q_) Main axle
(_) Plain washer
_ Bearing
econdary sheave axle
(_ Circlip
(_ Oil seal
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3-32
3-33
D
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o AUTOLUBE PUMP
oo,oE Aoo
AOJOSTMEN
IE"OI I
(_ Autolube pump
(_ Pin
(_ Circlip
@ Shim
(_) Wave washer
(_) Pump drive gear
(_ Circlip
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3-34
[ ENG '__D] ENGINE ASSEMBLY AND ADJUSTMENT h
C.D.I. MAGNETO
1. Install:
eGasket (_
,.,_*'_
, .:.:z,.:.,
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'"_ 3. Install:
eStator assembly (_)
.S
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_ !_ 8 Nm(Statr
Screw (0.8 m,kg, 5.8 ftolb)
Assemb'y): I
w
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_.......... _ 4. Woodruff
Install: key
_, *C.D.I. magneto
d
Plain washer
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,_Spring washer
oa
_Nut
nl
NOTE:
ow
[8 Nm(08___.kg,
5.8ft._b)}
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I
oa
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3-36
ENG _ ENGINEASSEMBLYAND ADJUSTMENT [
STARTER SYSTEM
1. Install:
oCollar (_
Kick shaft (_)
t
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.S
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4. Install:
oa
NOTE:
D
3-37
_=_ ENGINE ASSEMBLY AND ADJUSTMENT ENG
_. 6. Install:
oStarter motor (_
NOTE:
Apply lithium soap base grease to the O-ring of
(_ the starter motor.
7. Install"
Stay (_
:' .............
"............. oCollar (_)
t
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8 Nm 10.8 m okg, 5.8 ftolb)
e.
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, :_._:_..,.'_.,
_: _'_ "-:;:'._'_t ............
_,:;'&:-"_, _':: ,::!:i::':_!:!
"_ i_i:::_:_
ot
8. Install:
co
" _:: ,-_i:_,, :i_.... * Plain washers (_
.S
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ii:i 9.Plate
, sta,"
oa
8 Nm ('die
(0.8 mGear
okg, Plate):
5.8 ft-lb)
I_ Screw
D
10. Install:
eStarter clutch assembly (_
3-38
ENG ENGINE ASSEMBLY AND ADJUSTMENT
STARTER SYSTEM
(~) Kick shaft (~) Bearing
(~) Kick torsion spring Starter wheelgear
(~) Kick crank (~) Starterclutch assembly
@ Idle gear (~ Kick piniongear
~ ollar
Stay
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/ ~ J
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/
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/ ~ ~
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"~v / ~ /
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3-39
Eoo,oE
ASSEMBL
ANO
AOUSTMEOT
E"O
I'. I PRIMARY AND SECONDARY SHEAVE
1. Install"
-Secondary sheave assembly
=Clutch housing (_
i
2. Tighten:
Nut (Secondary sheave)
Use Sheave Holder (_ (YS-01880).
t
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[_40 Nm (4.0 m,kg, 29 ftolb) ]
e.
im
3. Install:
cO-ring
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I 4. Apply: ot
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Lithium soap base grease
.S
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L>
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......
:_;- ..,_::-_,,_,:-:,:_
:_-:_
.......,, .,,_::; 5. Install:
oa
_i::
!!ii_iiiii_iiii i_i -Collar (_
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_;;!_:!:_!_:ililili_i!_iii_i_i _ - Shim (_ .,
D
6. Install:
_V-belt
Place the V-belt around the secondary
sheave, and compress the secondary sheave
spring hard so that the V-belt moves toward
the clutch hub.
NOTE:
The V-belt must be installed with the arrow
': frontward.
3-40
I ENG ENGINE ASSENIBLY AND ADJUSTMENT E
7. Install:
ePrimary fixed sheave (_
One-way clutch (_)
Conical spring washer @
oNut
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NOTE:ot
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When tightening the nut (primary sheave), hold
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(YU-01235).
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9. install:
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oFan (_
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ii_ [_ Screw
8 Nm(Fan):
(0.8 m-kg, 5.8 ft-lb) ]
10. Install:
Dowel pins
oCrankcase cover (Left)
8 Nm(Crankcase
Screw (0.8 m,kg, Cover):
5.8 ft,lb) ]
3-41
q PRIMARY AND
Eoo
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AssEMB.,
Aoo
AOJOSTMEO
SECONDARY
[ENOl
SHEAVE
Secondary fixed sheave (_) Clutch assembly
(_ Oil seal (_ Clutch housing
(_ Secondary sliding sheave (_ O-ring
(_ O-ring O Primary sheave assembly
(_) Oil seal (_ V-belt
(_) Spring seat (_ Primary fixed sheave
(_ Clutch spring (_) One-way clutch
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CLUTCH SHOE WEAR LIMIT: /_" _ ,
C 2.5mm (0.10 in) _ / 150 Nm (5.0 m kg, 36ft.lb) I
e.
VBELT_,L,_,T /_% /
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O 135
mm(0.53
_nl __ / /_
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_r///%: _ / /
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3-42
I ENG ENGINE ASSEMBLY AND ADJUSTMENT
PISTON PIN AND PISTON
1. Apply:
oYamalube 2 cycle oil
To the piston pin, bearing, piston ring
grooves and piston skirt areas.
2. Install:
Small end bearing
Piston
Piston pin
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Piston pin clip
e.
NOTE:
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=The arrow (_ on the piston must point to the
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front of the engine.
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-Before installing the piston pin clip, cover the
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crankcase with a clean towel or rag so you will
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not accidentally drop the pin clip and material
.S
3-43
ENGINE ASSEMBLY AND ADJUSTMENT ENG
PISTON PIN AND PISTON
(_ Piston ring (1st, 2nd)
(_) Piston
(_ Piston pin clip
@ Piston pin
_ Small
Piston end
pin bearing
clip
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B 0.015-0.03 mm (0.006- 0.012 in)
<LIMIT>: 0.7 mm (0.028 in)
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3-44
_i CYLINDER AND CYLINDER HEAD
_; 1. Install:
Cylinder gasket (New gasket)
2. Offset the piston ring end gaps as shown.
(_ 1st ring
_) 2nd ring
NOTE:
oBe sure to check the manufacturer's marks or
numbers stamped on the rings are on the top
side of the rings.
oBefore installing the cylinder, apply a liberal
coating of 2-stroke to the pisotn rings.
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3. Install:
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Reed valve
.S
oCarburetor joint (_
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;_i_;_
J 4. Install:
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Cylinder (_
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;_ NOTE:
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3-45
ENGINE ASSEMB'YA.OIA.OSTMETIENO
eCylinder head gasket (New gasket)
7. Install:
oCylinder head (~
oSpark plug (~
NOTE:
Tighten the cylinder head holding nuts in stage,
using a crisscross pattern.
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20 Nm (2.0 mkg, 14 ftolb)
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8. Install:
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eAir shroud
.S
Q
~, 4 : . ,~, ~:.
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9. Install:
Fan cover
l~
Screw (Fan cover):
8 Nm (0.8 m.kg, 5.8 ft.lb)
3-46
[ ENGI &~] ENGINEASSEMBLYAND ADJUSTMENT
CYLINDER AND CYLINDER HEAD
(~) Spark plug
(~) Cylinderhead
Gasket
@ Cylinder
Gasket
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SPARK PLUG:
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C BPR6HS (N.G.K,)
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GAP: 0.9-1.0 mm (0.035-0.039 in)
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3-47
ENGINE ASSEMBLY A N D A D J U S T M E N T I ENG
MUFFLER
1. Install:
Muffler
Bolt (Muffler):
27 Nm (2.7 m . k g , 19 ft.lb)
Bolt (Exhaust pipe):
8 Nrn (0.8 m.kg, 5.8 ftolb)
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i~!?i~:i!i:~i;:~i)!::
!iiiiiiiiiiii~i
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R E M O U N T I N G ENGINE
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When remounting the engine, reverse the removal
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procedure.
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1. Install:
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2. Tighten:
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Bolt ~--]:
42 Nm (4.2 rn.kg, 30 ft.lb)
nl
Bolt r-~:
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3. Install:
Carburetor
Carburetor top together with throttle valve
NOTE:
When installing the throttle valve into the car-
buretor, align the groove (~ of the throttle valve
with the projection (~) of the carburetor.
3-48
ENG ENGINE ASSEMBLY AND ADJUSTMENT
4. Air bleeding:
Autolube pump
Refer to "CHAPTER 2--AUTOLUBE PUMP
AIR BLEEDING" section.
5. Apply:
Transmission oil
Refer to "CHAPTER 2--TRANSMISSION
OIL REPLACEMENT" section.
6. Adjust:
,Brake lever free play
Refer to "CHAPTER 2--BRAKE LEVER
FREE PLAY ADJUSTMENT" section.
Autolube pump cable
Refer to "CHAPTER 2--AUTOLUBE PUMP
t
CABLE ADJUSTMENT" section.
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Throttle cable free play
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Refer to "THROTTLE CABLE FREE PLAY
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ADJUSTMENT" section.
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3-49
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CHAPTER 4
CARBURETION
AUTO CHOKE SYSTEM .......................................... F-3
CONSTITUENTS ................................................ F-3
WIRING SCHEMATIC .......................................... F-3
OPERATION ................................................... F-3
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INSTALLATION ................................................ F-7
AUTO CHOKE UNIT CHECK .................................... F-8
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REED VALVE ........................... . ........................ F-8
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REMOVAL .................................................... F-8
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INSPECTION .................................................. F-8
INSTALLATION ................................................ ot F-9
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A U T O CHOKE S Y S T E M r-i
CARBURETION
A U T O CHOKE S Y S T E M
CONSTITUENTS
The electric auto-choke consists of the Positive
Temperature Coefficient (P.T.C.) thermistor, wax
element and starter plunger.
~ P.T.C.thermistor
Wax element
O-ring
(~) Starter plunger
I P.T.C. thermistor I
When electric current flows in this thermistor, it
t
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begins to be heated up to a specified temperature.
This specified temperature is then reained.
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I Wax element I
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The wax element changes its volume according
e
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to a varying temperature of the thermistor,
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thereby causing the starter plunger to operate.
.S
I Starter plunger I
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WIRING SCHEMATIC
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lighting coil.
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(~) Rectifier/Regulator
(~ Auto choke unit
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4-1
AOTO
C.OKE
S,STEM
[OA"
OPERATION
j Cold engine J
On the cold engine the wax element changes
(reduces) its volume according to the ambient
temperature.
In this state the starter plunger is at the top,
thereby opening the starter plunger.
: Air
_==J= Fuel
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J Running engine J
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passage.
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idling.
The wax element expands during the ride as well
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: Air
_" Fuel
4-2
JCARB[ AUTO CHOKE SYSTEM E
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4-3
CARBURETOR
.....CA.BO.ETO
[CA"B
4]
_ Spring seat (_)
(_ Needle
Float valve
(_ Jet needle (_ Gasket
_) Throttle valve _) Float chamber
(_) Throttle stop screw (_ Drain screw
(_ Pilot air jet @ Auto choke unit
(_) Pilot jet 1_ O-ring
Main jet
nozzle @ Starter jet
plunger
needle
j_ME/_
SPECIFICATIONS
IN JET #82
NEEDLE 3S30-4/5
IN AIR JET _2.0
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(_ PILOT JET #42
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_""=) _) _ e FLOAT HEIGHT 15.0-17.0 mm
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ENGINE IDLE SPEED 1,500~2,100 r/rain
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_, (0.59-0.67 in)
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4-4
IOARB[
4] CARBORETOR D
SECTION VIEW
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4-5
cA.Bo.ETo.
REMOVAL
[CA"BI
4]
1. Remove:
Tail cover
Refer to "CHAPTER 2-TAIL COVER"
section.
oAir cleaner case
_:: 2. Disconnect:
:.'.'_ oFuel pipe (_)
Vacuum pipe (_)
oOil delivery pipe (_.
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3. Remove:
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Carburetor top (_
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4. Remove:
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Carburetor assembly
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5. Disconnect:
oa
DISASSEMBLY
;_,,, 1. Remove:
_-.. _!_;i Float chamber (_
:.
4-6
CA"B]CA.B0.ETO. 2. Remove.
i:
...... oFIoat pin stop screw (_)
Float pin
oFloat
oNeedle valve
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:_:::::;:::
..... ot
4. Remove:
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Throttle stop screw (_
.S
" 6. Remove:
Auto choke unit (_
O-ring (_)
4-7
CA.BO.ETO
CA""]
4l
INSPECTION
1. Inspect:
_,_, Carburetor body
Contamination--* Clean.
NOTE:
2. Inspect:
"_ * Float (_
(_ Damage-* Replace.
Gasket (_
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Damage-* Replace.
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3. Inspect:
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oNeedle valve (_
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Wear/Contamination-* Replace.
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4. Inspect:
oa
Throttle valve (_
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Wear/Damage-* Replace.
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D
5. Check:
Free movement
Stick-* Replace.
Insert the throttle valve into the carburetor
body, and check for free movement.
4-8
cA.. l CA"BO"ETO" 6. Inspect:
*Jet needle (_
_X _ Contamination-*
*Pilot jet @ Replace.
/
7. Inspect:
eThrottle stop screw (_
Wear/Damage--* Replace.
O
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% "_._
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8. Inspect:
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*Starter plunger (_
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9. Measure:
oa
Float height @
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4-9
CA.BO.
CA"B
TO.
4]
Measure the distance between the mating sur-
face of the float chamber (gasket removed)
and top of the float using a gauge.
NOTE:
_ The float arm should be resting on the needle
.......
"J valve, but not compressing the needle valve.
.:::ii__..........
i!_ _: e inspect
If the float
the height
needleis not within
valve, specification,
float and ralve seat.
i;_;:;, _i;::_::!_::;:_i::.i -If it is worn, replace it.
NOTE:
The float height is properly adjusted at the
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Yamaha factory. Never attempt to adjust it.
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ASSEMBLYot
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To assemble the carburetor, reverse the dis-
.S
gasoline.
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1. Install:
oa
NOTE:
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I NSTA LLATI O N
1. Install:
Carburetor assembly
Reserve the removal procedure.
4-10
leA"B[
]CA.BU.ETO. AUTO CHOKE UNIT CHECK
E
_"_*_ 1. Remove:
Auto choke unit
2. Measure:
!_i Starter plunger height (_)
Plunger height will not change with the
temperature change-_ Replace.
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about 30 minutes, again measure plunger
height at room temperature.
e.
*If both measurements are the same, auto
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choke unit is defective. Replace it. For
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reference, below is a table of plunger heights
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at respective temperature.
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Temperature Plunger height
.S
NOTE:
In the above table, auto choke was first freez-
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4-11
_
"EEO
VA'VE
REED VALVE
IOA"B
1
REMOVAL
1. Remove:
Tail cover
Refer to "CHAPTER 2-TAIL COVER"
section.
Air cleaner case (_
2. Remove:
QCarburetor
Refer to "CARBURETOR-REMOVAL"
section.
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3. Remove:
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oCarburetor joint (_)
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INSPECTION
oa
1. Inspect:
nl
Carburetor joint
ow
Damage/Cracks_ Replace.
eReed valve
D
Fatigue/Cracks-* Replace.
Inspection steps:
eVisually inspect the reed valve.
NOTE:
Correct reed valve should fit flush or nearly
flush against valve seat.
4-12
[cA. 41 .EEOVALVE
2. Measure:
Valve stopper height (~:
Out of specification-,Adjust stopper/
Replace valve stopper.
J ]
r
! ~ Valve Stopper Height (~: ]
3.0-3.4 mm (0.12-0.13 in)
NOTE:
If it is 0.4 mm (0.016 in) more or less than
specified, replace the valve stopper.
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3. Measure:
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Reed valve clearance (~)
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~
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iNSTALLATION
oa
1. Install:
oGasket (New)
D
2. Tighten:
Reed valve securing bolts
NOTE:
Tighten each bolt gradually to avoid warping.
4-13
91
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[CHAS _!
CHAPTER 5
CHASSIS
FRONT WHEEL ................................................. G-3
REMOVAL ................................................... G-3
INSPECTION ................................................. G-3
ASSEMBLY (BRAKE SHOE PLATE) ............................ G-4
INSTALLATION ............................................... G-5
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FRONT FORK AND STEERING ................................... G-8
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REMOVAL .................................................... G-9
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DISASSEMBLY ................................................ G-10
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INSPECTION .................................................. G-10
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ASSEMBLY AND INSTALLATION ............................... G-10
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REAR SHOCK ABSORBER ....................................... G-12
.S
_ Spacer
Bearing (Flange) _ Brakeseal
Dust camshaft _ Stop
O-ringring
(_) Spacer @ Camshaft seal (_ Plain washer
(_ Bearing (_ Brake shoe plate _) Speedometer driven gear
(_ Speedometer drive gear (_ Wear indicator
TIRE SIZE:
A
2.75-10-4PR
RIM RUNOUT LIMIT:
t
.,_ B RADIAL: 2.0 mm (0.08 in)
ne
e.
C BRAKE DRUM WEAR LIMIT:
80.5 mm (3.17 in)
im
--__ LATERAL: 2.0 mm (0.08 in)
D BRAKE SHOE WEAR LIMIT:
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2.0 mm (0.08 in)
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WHEEL AXLE RUNOUT LIMIT:
ot 0.25 mm (0.01 in)
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_
D
5-1
FRONT WHEEL CHAS l_
REMOVAL
1. Place the scooter on its centerstand.
2. Remove:
oBrake cable
oSpeedometer cable
3. Remove:
eFront wheel
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1. Measure:
.S
INSPECTION
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2. Measure:
oa
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wnout
ee
Out of specification -+Replace.
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D
3. Inspect:
oWheel
Cracks/Bends/Warpage-_ Replace.
5-2
c.AsI .oo+
w.EE.
Wheel bearings
Bearings allow play in the wheel hub or
4. Inspect:
wheel turns roughly-* Replace.
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Do not strike the inner race of balls of the
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bearing. Contact should be made only
with the outer race.
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-Brake shoes
nl
NOTE:
6. Measure:
" ,Brake shoe thickness (_
Out of specification-* Replace.
_ S.T.D,:
Brake Shoe3.5Thickness:
mm (0.14 in)
Limit: 2.0 mm (0.08 in)
5-3
m
.4
_ F.oT
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IC.AS!
7. Inspect:
oBrake drum inner surface
Oil/Scratches-* Remove.
8. Measure:
Brake drum inside diameter (_)
Out of specification-* Replace.
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e.
80.5 mm (3.17 in)
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[_ Brake Drum Wear Limit: ]
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ASSEMBLYot (BRAKE SHOE PLATE)
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When assembling the brake shoe plate, reverse
.S
_i_i
_,?_ _ Note the following points.
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/ 1. Apply:
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m
_-.......
, oLithium-soap
(to speedometer
base
driven
grease
gear)
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2. Apply:
oa
3. Install:
Dust seal (New)
NOTE:
Install the dust seal with their manufacturer's
marks or numbers facing outward.
5-4
[c,As 1F,o,T
W.EE, ....
-_.:;,._t#_.,:_,:-,_::--.
_ 4. Apply:
-G
" ,:._% ,:_,:-_-_._ oLithium-soap base grease
,:_-:_i " .... (to the brake camshaft)
5. Install:
Brake camshaft
(_ Camshaft lever
NOTE:
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e.
(_) as shown.
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Align the camshaft mark (_) with the lever mark
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INSTALLATION
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When installing the front wheel, reverse the
.S
removal procedure.
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W 1. Install:
oa
..... Make sure the projections inside the gear unit are
meshed with the flats in the wheel hub.
D
iT
_ _i!i!!_
:
2. Install:
Front wheel
NOTE:
Be sure the boss on the front fork correctly
engages with the locating slot on the brake shoe
plate assembly.
5-5
FROOT
WNEEL
iOHAS
I
3. Tighten:
oAxle nut
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5-6
Ic,AsIi,EA,
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REAR WHEEL
B
(_ Wheel ring
(_) Plain washer
(_) Spring
(_ Brake shoes
(_ Brake camshaft
(_) Brake shoe plate
(_ Camshaft seal
Camshaft
Wear lever
indicator
TIRE SIZE:
A
2.75-10-4PR
rn.kg, 67 ft.lb)
I B 95,5 mm (3.76 in)
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BRAKE SHOE WEAR LIMIT:
2.0 mm (0.08 in)
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WHEEL RUNOUT LIMIT:
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RADIAL: 2.0 mm (0.08 in)
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_ LATERAL:
BRAKE 2.0 WEAR
DRUM mm (0.08 in)
LIMIT:
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5-7
REMOVAL
1. Remove:
oTail cover
Refer to "CHAPTER 2--TAIL COVER"
section.
2. Remove:
-Fan cover (_
3. Remove:
Exhaust pipe
Muffler
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4. Remove:
oa
NOTE:
!
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5. Remove:
eRear wheel
6. Remove:
oAdjuster
Rear brake cable
_ oBrake shoe plate
5-8
Ic.AsI .EA.
w.EEL INSPECTION
Le
1. Inspect:
=Wheel
Cracks/Bends/Warpage-_ Replace.
2. Measure:
=Wheel runout
Out of specification_Replace.
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...... Radial 2.0 mm 10.08 in)
e.
Lateral 2.0 mm (0.08 in)
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_ Runout Limit:
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3. Inspect:
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r/ = Brake shoes
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NOTE:
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4. Measure:
oa
5. Inspect:
=Brake drum inner surface
Oil/Scratches_ Remove.
5-9
,q .......
.EA.W.EE.
6. Measure:
Brake drum inside diameter (_
Out of specification _ Replace.
95.5 Drum
mm (3.76
[_ Brake Wearin) Limit: ]
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:;;_ii:
4_;' 1. Apply: ot
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oLithium_soap base grease
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_;:_!i_ 2. Install:
Brake camshaft
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Camshaft lever
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_ NOTE:
D
INSTALLATION
When installing the rear wheel, reverse the
removal procedure.
Note the following points.
1. Install:
Brake shoe plate
5-10
[CHAS
_] REAR
WHEEL 2. Install:
Le
oRear wheel
3. Install:
Muffler
oExhaust pipe
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18 Nm (1.8 m,kg, 13 ft,lb)
Muffler:
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Exhaust pipe:
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8 Nm (0.8 m,kg, 5.8 ft,lb)
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5-11
FRONT FORK AND STEERING [-C-_ (_ 1
FRONT FORK AND STEERING
(_ Handlebar (_ Lower bearing race (Top)
(_ Flange bolt (_ Lower bearing race (Bottom)
(_ Frange nut (_ Steering column
@ Ring nut (_) Front fork spring
(_) Washer (_ Rubber (Left side only)
(_ Upper bearing race (Top) (_) Spring seat
(_ Bearings (_ Inner tube (Right and left)
(_) Upper bearing race (Bottom)
BEARING SIZE:
A
5/32 in
FORK
LENGTH:SPRING FREE ,__
>
' ,
STANDARD: L..... "
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B 92 mm (3.62 in)
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LIMIT:
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87 mm (3.42 in) -_k_
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Ic us,.,_o._i- o,_._wo.
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15/32inx26j_'=.--_
_'_'_-k _"_'_ _
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5-12
FRONT FORK A N D STEERING
REMOVAL
1. Place the scooter on the centerstand,
S e c u r e l y s u p p o r t t h e s c o o t e r so t h e r e is no
danger of it falling over.
2. Remove:
Front wheel
Refer to "FRONT W H E E L - - R E M O V A L "
section.
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3. Remove:
Front fender
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Front panel
im
Refer to "CHAPTER 2 -- FRONT FENDER,
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FRONT PANEL AND FOOTREST BOARD"
e
section.
4. Remove:ot
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Handlebar cover
.S
COVER" section.
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5. Remove:
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6. Remove:
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-Bracket ~ )
Throttle cable (~)
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Throttle grip
5-13
FRONT FORK AND STEERING ICHASI(_ 1
7. Remove:
-Rear brake lever assembly (_
8. Remove:
Bolt (_
"Nut (_)
Handlebar (_)
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9. Remove:
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*Inner fender with cable guide t_)
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10. Remove:
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NOTE:
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_! i .Washer (_
: -Upper bearing race (Top) (_)
Turn it counterclockwise.
Steering column
Bearings
NOTE:
Take care not to lose the bearings. (Upper: 26
pieces, Lower: 26 pieces)
5-14
[CHAS _I FBONT FOBK AND STEE.ING
DISASSEMBLY
1. Remove:
, ,_.:ii_,_,:+_:_:.,_:ii
.................... =Dust seal (_
=Circlip (_)
2. Remove:
Inner tube (Left and right) (_)
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Front fork
(__,,_ =Spring seatspring
(_) @
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INSPECTION
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2. Inspect:
ow
Bearing races
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..... NOTE:
Always replace the bearing and race as a set.
Bearing Size:
Upper: 5/32 in
Lower: 5/32 in
Bearing Quantity:
Upper: 25 pcs.
Lower: 26 pcs.
5-15
F.oNT.o.K
Aoo
STEE.,OO
"AS1
Bearing race replacement steps:
o Remove the bearing race by hitting it on
several points.
oSet the bearing race.
oDrive in the bearing race evenly by hitting it
on several points.
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3. Inspect:
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._-_, Steering column
.S
_:;:_:_
.... Bends/Damage--* Replace.
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.....
:_ Do not attempt to straighten a bent fork
tube.
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4. Measure:
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5-16
oMolybdenum disulfide grease
To inner tube (_ and rubber (_.
2. Install:
I (___'_ 1. Apply:
,/ _'--_ Front fork spring (_)
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3. Check:
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Front fork operation
.S
4. APply:
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5. install:
Steering column
i:i::
::i: Upper bearing race (Top) @
Turn it clockwise completely.
Washer (_
Ring nut
5-17
FRONT FORK AND STEERING [CHASI ]
6. Tighten:
Ring nut (_
Using the Ring Nut Wrench _ (YU-33975).
[_ 30 Nm
Ring Nut (3.0
@: m,kg, 22 ft.ib) 1
NOTE:
Set the torque wrench to the Ring Nut Wrench
so that they form a right angle (_.
7. Check:
oSteering column for smooth action
!i_i!_i_:_i_:. Slack_Tighten the ring nut.
t
_:i.:_-_,:\_,_: Sticky--* Loosen the ring nut.
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8. Install:ot
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oHandlebar (_
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oBolt (_ (New)
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Nut (_ (New)
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NOTE:
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5-18
CHAS 1 FRONT FORK AND STEERING
10. Install:
=Rear brake lever assembly (:_
11. Apply:
oLithium_soap base grease
To throttle cable end and handlebar right
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_-_,/-_ i 12. Install:
=Throttle grip (_)
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Bracket _)
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=Front brake lever assembly (_)
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_L__.. _( =Handlebar switch
(2_)(Right) (_
___ _
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=Throttle cable
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_, 13. =Front
Install: brake cable (_)
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NOTE:
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14. Install:
=Handlebar covers (Front and rear)
Speedometer cable
,,Front panel
Front fender
Refer to "CHAPTER 2 -- FRONT FENDER,
FRONT PANEL AND FOOTREST BOARD"
and "HANDLEBAR COVERS" section.
15. Adjust:
Front and rear brake lever free play
-,Throttle cable free play
Refer to "CHAPTER 2" section.
5-19
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5-20
m
Ic.AslI.EA.
o s.ocK
ABSO.BE. REMOVAL
1. Place the scooter on its centerstand.
2. Remove:
oTail cover
Refer to "CHAPTER 2--TAIL COVER"
section.
3. Remove:
*Air cleaner case
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4. Remove:
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Rear shock absorber
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INSPECTION
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1. Inspect:
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INSTALLATION
When installing the rear shock absorber, reverse
the removal procedure. Note the following points.
1. Instal[:
eRear shock absorber
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CIRCUIT DIAGRAM ............................................ H-11
TROUBLESHOOTING CHART ................................... H-12
e.
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CHARGING SYSTEM ............................................. H-15
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CIRCUIT DIAGRAM ............................................ H-15
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TROUBLESHOOTING CHART ................................... H-16
ot
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LIGHTING SYSTEM .............................................. I-2
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=__L-=_ Y'=
z'_
=.- _ _ T
L + "],I
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LO 001 = (_
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E..oo_.,,,,v -=J
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_[-,,--i_o
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Hi C_ __@
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= __--Y _ ==, =/.
_E-= o, ot
=_l,l,k_..__
: +
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LOCK
L LI --Br ..L_ -x-. C
= ON CO -0
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Gy Br
.zB _'R_
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Gy I B/W_
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@-
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= oo ,-----_,- B,W
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=r I W/R 2-
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=,/w I
B
Oh Br/W Dg ==L=,
R (3-0 ---
N 0
-L-B_ L 0-0 @
.2-=----e
T
6-I
CE50T CIRCUIT D I A G R A M ELECI
(~ C.D.I. magneto (~ "TURN" switch
(Lighting coil, charging coil) (~ Left flasher light (Front and rear)
(~) Rectifier/Regulator ~ ight flasher light (Front and rear)
(~) Starter motor "TURN" indicator light
~ tarter relay (~) Horn
"START" switch (~ Horn ( ~ ) switch
(~ Main switch (~ Oil level gauge
(~ Fuse (~ "OIL" indicator light
(~) Battery Front brake switch
(~)
(~
"ENGINE STOP" switch
C.D.I. magneto
~ Tail/Brake
Rear brake switch
light
(Source coil, pick-up coil) ~) "LIGHTS" switch (Dimmer)
(~) C.D.I. unit ~) Headlight
(~) Ignition coil ~) "HIGH BEAM" indicator light
(~) Spark plug ~) Meter light
(~ Flasher light relay ~) Auto choke unit
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COLOR CODE
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R Red P Pink
B Black L Blue
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6-2
IELECI I_a ] ELECTRICAL COMPONENTS E
ELECTRICAL COMPONENTS
(_ Fuse BATTERY
(_) Oil level gauge A TYPE: GM4-3B
(_ Ignition coil SPECIFIC GRAVITY: 1.280
_ C.D.I.
Battery unit IGNITION COIL RE1TANCE
(_) Starter relay B PRIMARY: 0.21 -0.25[} at 20C (68F)
SECONDARY: 4.5-6.7kft at 20C (68F)
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//
//
6-3
ELECT.,OA"
COMPOOEN
[E'ECl
]
Main switch
_ Horn
lasher light relay
@ Rectifier/Regulator
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6-4
ELECTRICAL STARTING SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows starter circuit.
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.ELECTRICALSTARTING SYSTElVl ELECI_ 1
(_) Starter motor
(_) Starter relay
(_) "START" switch
(_) Main switch
(_ Fuse
(_ Battery
(_ Front brake switch
(_) Rear brake switch
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6-6
[E.EC E.EOT.,OA.
STA.T,.O
S STEM
TROUBLESHOOTING CHART
Continuity
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Continuity
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!
Incorrect I ,Refill battery fluid.
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harmful to a battery.
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6-7
ELECTRICAL STARTING SYSTEM ELEC _ 1
! i
1. Remove caps.
2. Inspect specific gravity of all celt using Bat- Low specific Charging Current:
tery Hydrometer. jgravity (voltage)J 0.4 amps/10 hrs
NOTE:
Battery electrolyte is poisonous and Replace the battery if:
dangerous, causing severe burns, etc. it Batery voltage will not rise to a
contains sulfuric acid. Avoid contact with specific value or bubbles fail to
skin, eyes or clothing. Antidote: rise even after many hours of
EXTERNAL-Flush with water. INTERNAL- charging.
Drink large quantities of water or milk. Sulfation of one or more cells oc-
Follow with milk of magnesia, beaten egg, curs, as indicated by the plates
or vegetable oil. Call a physician turning white, or an accumula-
t
ne
immediately, tion of materiad exists in the bot-
e.
Eyes: Flush with water for 15 minutes and tom of the cell.
im
get prompt medical attention. Batteries Specific gravity readings after a
produce explosive gases. Keep sparks, long, slow charge indicate on cell
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flame, cigarettes etc., away. Ventilate to be lower than the rest.
e
when charging or using in an enclosed
ot Warpageor buckling of plates or
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space. Always shield your eyes when insulators is evident.
working near batteries.
.S
Specific Gravity:
m
1. Remove battery.
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12 V or more.
_1 Battery Voltage:
6-8
ELEC ELECTRICAL STARTING SYSTEM
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Continuity
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[ ,
Continuity
6-9
ELECTRICALSTARTING SYSTEM IELEC ]
Front and rear brake switches
conduct check: No
1. Disconnect brake switch leads. Continuity _ I Replace front and/or rear brake
2. Set pocket Tester'(YU-03112) selector to
"_ x 1" position.
3. Connect teser leads to brake switch leads
I
switch.
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.....
......
.-1
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Continuity
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2. ter-minals
Connectas12V
shows.
battery to starter relay _! Replace starter relay" l
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NOTE:
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minals as shows.
_ Continuity
6-10
ELEC I ELECTRICAL START, NG SYSTEM [_
_U7 Poor
_U7OK Poor
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6-11
ELECTRICALSTARTiNG SYSTEM [ELEC
STARTER MOTOR NOTE:
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(_ 14.5 mm (0.57 in) [14.8 mm (0.58 in)]
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C 2.5 mm (0.10 in) [0.9 rnm (0.04 in)]
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__)_ BRUSH WEAR LIMIT:
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6-12
[ELEC\ ELECTRICAL STARTING SYSTEM _'_
STARTER MOTOR CHECK
Removal
1. Remove:
Starter motor
Refer to "CHAPTER 3 -- ENGINE DISAS-
SEMBLY" section.
2. Remove:
Yoke assembly
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3. Remove:
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Armature
.S
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1. Measure:
nl
_ Minimum
2.5 mm (0,10
Brushin)Length:
[0.9 mm (0.04 in)]
2. Inspect:
eBrush spring
Wear/Damage--* Replace the starter motor
_._ assembly.
6-13
ELECTRICAL S T A R T I N G S Y S T E M I ELECl
3. Inspect:
Commutator (Outer surface)
Grooved wear/Burning/scratches~
Smooth out using a sandpaper ( # 5 0 0 -
6O0).
NOTE:
Sand the commutator outer surface lightly and
evenly.
4. Measure.
Commutator diameter
Out of specification--* Replace the starter
motor assembly.
t
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e.
Outside Diameter Limit:
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14.5 mm (0.57 in)
[14.8 turn (0.58 in)]
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5. Measure:
co
oMica undercut
.S
~
Out of specification-~Scrape mica using a
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hacksaw blade.
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..
[1.15 mm (0.045 in)]
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NOTE:
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commutator.
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D
6. Measure:
oArmature coil resistance
Out of specification~Replace the starter
motor assembly.
: iii!~!iii!iiiiiiiiiii!iii!i!iil
jiil
;i;ili!iiiiiii!:i;;:; i~ ~'
6-14
[ELEC I ELECTRICAL S T A R T I N G S Y S T E M
7. Check:
oArmature coil insulation
Set the pocket tester selector to " 9 1K"
position.
Continuity--* Replace the starter motor as-
sembly.
Assembly
Reverse the removal procedure.
Note the following points.
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1. Install:
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~Brush
.S
Brush spring
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2. Install:
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3. Install:
=O-ring (New)
6-15
EL,EOT"'OALSTA"T'O SYSTEM I ELEC I I
4. Install:
e Starter motor cover
NOTE:
Align the projection on the cover with the groove
.... on the housing.
5. Install:
Bolts ( ~
eO-rings (New) (~)
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6. Install:
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O-ring (New) ( ~
.S
NOTE:
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Installation
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1. Install:
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Starter motor
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D
6-16
ELEC J IGNITIONSYSTEM
IGNITION SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows ignition circuit.
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6-17
IGNITION SYSTEM I ELEC
Main switch
(~) "ENGINE STOP" switch
(~ C.D.I. magneto
(Source coil, pick-up coil)
(~) C.D.I. unit
~ gnitioncoil
Spark plug
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l 6-18
LECI ] IGNITION SYSTEM
TROUBLESHOOTING CHART
t
Electrode
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v
Insulator
e.
oPlug gap
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Refer to "CHAPTER 2 -- SPARK PLUG
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INSPECTION" section.
e
Plug Gap:
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0.9-1.0 mm (0:035-0.039 in)
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Spark
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6-19
iGNITION SYSTEM IE'EC[' I
~~No spark
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1. Disconnect main switch leads.
2. Set Pocket Tester (YU-03112) selector to
e.
"'9 x 1" position.
im
3. Connect tester leads to main switch leads
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(Black/White, Black/Red).
e
No continuity ,
Tester ( + ) lead-*Black/Red lead
~ 1 ot Replace main switch.
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Tester ( - ) lead-~Black/White lead
.S
J v~Continuity
6-20
l ,EcI ] OOTOOSSTEM
~T NO continuity
t
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2. Measure:
e.
=Primary coil resistance [ ]
im
(Orange lead -- Ignition coil base)
Set Pocket Tester (YU-03112) selector to
rT
"'~ x 1" position.
e
oSecondary coil resistance r-~
(Orange lead -- Spark plug lead)
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Set Pocket Tester selector to " 9 x 1K"
.S
position.
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Out of
Primary Coil Resistance:
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~JL OK
6-21
'ON'T'ONSYSTEM I E'EC I I
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216-264~3 at 20C (68F)
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~v~OK
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6-22
[ELEC _ ] ,GNmON SYSTEM
__LOK Poor
t
Check
Refer to
entire
"WIRING
ignition DIAGRAM".
system for connections, _lconnection Correct. 1
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I CD' unit is faulty' replace it I
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6-23
-
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iGNITION
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SYSTEM
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ELEC
]
6-24
_L___1CHARO,NO
SYSTEM i_'
CHARGING SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows charging circuit.
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6-25
CHARGING SYSTEM ELEC E_
(_ C.D.I. magneto
(Lighting coil, charging coil)
(_ Rectifier/Regulator
(_) Fuse
(_) Battery
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6-26
[ELEC CHARGING SYSTEM
TROUBLESHOOTING CHART
Fuse inspection:
1. Remove fuse.
2. Inspect fuse using Pocket Tester (YU-
03112).
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No
e.
i.,e0.ace,use
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Continuity
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harmful to a battery.
D
6-27
c ,oosYSTEM
ELSe]
I
Battery fluid specific gravity inspection: oRecharge battery
1. Remove caps.
2. Inspectspecificgravity of allcell using Bat- Charging Current:
tery Hydrometer. Low specific 0.4 amps/lO hrs
gravity (voltage)
_ NOTE:
Battery electrolyte is poisonous and v Replace the battery if:
dangerous, causing severe burns, etc. It Battery voltage will not rise to a
contains sulfuric acid. Avoid contact with specific value or bubbles fail to
skin, eyes or clothing, rise even after many hours of
Antidote: EXTERNAL-Flush with water, charging.
INTERNAL-Drink large quantities of water oSulfation of one or more cells oc-
or milk. Follow with milk of magnesia, curs, as indicated by the plates
beaten egg, or vegetable oil. Call a physi- turning white, or an accumula-
t
ne
clan immediately, tion of material exists in the bot-
Eyes: Flush with water for 15 minutes and tom of the cell.
e.
get prompt medical attention. Batteries oSpecific gravity readings after a
im
produce explosive gases. Keep sparks, long, slow charge indicate on cell
rT
flame, cigarettes etc., away. Ventilate to be lower than the rest.
e
when charging or using in an enclosed Warpage or buckling of plates or
space. Always shield your eyes when ot insulators is evident.
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working near batteries.
.S
Specific Gravity:
1.2804-0.01 at 20C (68F)
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1. Remove battery.
2. Set the Tester selector to "DC2OV"
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position.
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12V orVoltage:
more
_ Battery
J_L!7
K
6-28
IELECI CHARGING SYSTEM E
Charging voltage test:
1. Connect InductiveTachometer (YU-08036)
to ignition lead.
2. Set Pocket Tester (YU-03112) selector to
"DC20V" position.
3. Connect tester leads to battery terminals.
t
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r/min
e.
12.5-17.5V at 4,000
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Out of specification
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6-29
___ CHARGING SYSTEM [ ELEC ___
4. Measure:
Charging coil resistance
Out of
I_ I 0.63_-0.77_ at 20C (68F)
specification |
Replace charging coil,
I
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Poor
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OK
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Check entire chargingDiAGRAM,,.system
for connections. _ I Correct. I
e
Refer to "WIRING _1
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I Replace rectifier/regulator.
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6-30
ELEC I~ ] LIGHTINGSYSTEM r-
LiGHTiNG SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows lighting circuit.
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6-31
LIGHTING SYSTEM
(~ C.D.I. magneto
(Lighting coil, charging coil)
Rectifier/Regulator
~) "LIGHTS" switch (Dimmer)
~) Headlight
(~ "HIGH BEAM" indicator light
(~) Meter light
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6-32
ELECI LIGHTING S Y S T E M P
TROUBLESHOOTING CHART
H e a d l i g h t condition c h e c k :
1. Remove headlight lens unit.
2. Set Pocket Tester (YU-03112) selector to Continuity does
"~ x 1" position. not exist on
3. Connect tester leads to headlight terminals
and check it for continuity. ~ j Replace headlight lens unit.
t
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Tester ( + ) lead-~Terminal 1
Tester (-) lead-*Terminal 3
e.
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T e s t e r ( + ) lead-~Terminal 2
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Tester ( + ) lead--Terminal 3
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Lighting v o l t a g e test:
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6-33
LIGHTING SYSTEM [ ,EoI
4. Connect Inductive Tachometer (YU-08036)
to ignition lead.
5. Start engine and accelerate to about 4,000
r/min.
6. Measure: OK
Lighting voltage
~>1 Lighting system is good.
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" L I G H T S " switch c o n d u c t check:
.S
Tester ( - ) l e a d - * Y e l l o w lead
~ Continuity exists
o n b o t h circuits.
6-34
I E'ECI I LIGHTINGSYSTEM 13
Lighting coil resistance test:
1. Disconnect C.D.I. magneto leads.
2. Set Pocket Tester (YU-03112) selector to
"~ 1" position.
3. Connect tester leads to lighting coil leads.
t
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e.
~1 0.27-0.33G at 20C (68F)
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Poor
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connection
Check entire lighting system for connections.
Correct.
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/L OK
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I Replace rectifier/regulator.
6-35
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LiGHTiNG SYSTEM
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ELEC
6-36
E,EcE
1s,ooAL
SIGNAL
S STEM
SYSTEM
I'
CIRCUIT DIAGRAM
Below circuit diagram shows signal circuit.
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6-37
q (_) Main switch @ Horn
s,ooA,
s sTEM
I,E' cli
(_ Fuse _) "HORN" switch
(_ Battery @ Oil level gauge
(_) Flasher light relay @ "OIL" indicator light
(_ "TURN" switch (_ Front brake switch
(_ Left flasher light (Front and rear) (_ Rear brake switch
(_) Right flasher light (Front and rear) _) Tail/Brake light
@ "TURN" indicator light
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6-38
E.EoI_
!s,ooAL
S,STEM
TROUBLESHOOTING CHART
D
SIGNAL SYSTEM SHOULD BECOME
INOPERATIVE.
Fuse inspection:
1. Remove fuse.
2. Inspect fuse using Pocket Tester 1YU-
03112).
No
continuity
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___ _1 "_e0'acef_se.
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Continuity
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Correct
Dirty or poor
6-39
SIGNAL
SYSTEM
Battery fluid specific gravity inspection: oRecharge battery.
1. Remove caps.
2. Inspectspecific gravity of allcell using Bat- Low specific Charging Current:
tery Hydrometer. Iravity (voltage) 0.4 amps/10 hrs
_ NOTE:
Battery electrolyte is poisonous and Replace the battery if:
dangerous, causing severe burns, etc. It oBattery voltage will not rise to a
contains sulfuric acid. Avoid contact with specific value or bubbles fail to
skin, eyes or clothing, rise even after many hours of
Antidote: EXTERNAL-Flush with water, charging.
INTERNAL-Drink large quantities of water Sulfation of one or more cells oc-
or milk. Follow with milk of magnesia, curs, as indicated by the plates
beaten egg, or vegetable oil. Call a physi- turning white, or an accumula-
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clan immediately, tion of material exists in the bot-
e.
Eyes: Flush with water for 15 minutes and tom of the cell.
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get prompt medical attention. Batteries oSpecific gravity readings after a
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produce explosive gases. Keep sparks, long, slow charge indicate on cell
flame, cigarettes etc., away. Ventilate to be lower than the rest.
e
when charging or using in an enclosed
ot Warpage or buckling of plates or
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space. Always shield your eyes when insulators is evident.
working near batteries.
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Specific Gravity:
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1. Remove battery.
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position.
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12V orVoltage:
more
--_ Battery
'_,/lzOK
6-40
[ELECS,OAL
S STEM E
Main switch conduct check: I No
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Poor
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condition
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Poor
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Check entire
(Refer to signal DIAGRAM"
"WIRING system for connections
section.) Ii connection _l
IF Correct, I
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Jv LK
Poor
Check condition of each circuit for signal ____,.l,__ |
6-41
SIGNAL SYSTEM ELEC ]
SIGNAL SYSTEM TEST AND CHECKS
NOTE:
The battery provides power for operation of the
horn, flasher lights, indicator light and brake light.
If none of the above operates, always check the
battery voltage before proceeding further. Low
battery voltage indicates either a faulty battery,
low battery electrolyte, or a defective charging
system. See "CHARGING SYSTEM" for checks
of the battery and charging system. Also, check
the fuse condition. Replace the fuse if necessary.
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1. Brake light does not work
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brakeeheck
frntswitch
fr vltage
connector.
(12V) n "Br" lead at frnt I_1
-- Wiring
repair.brake
switch
circuit connector
frm fuse istfaulty,
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Check for voltage 112V) on "Br" lead at rear v brake switch connector is faulty,
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Checkfor voltage (12V) on'G/Y" lead at front I No voltage _ I Front brake switch is faulty,
D
6-42
E,EC S,ONAL
S STEM
2. Flasher lights (left and/or right) do not
Fi
work
_o_
Check
_or
vo,taoe,l_V,
oo"_r_",ead
at1_v'ta_e
:1
flasher relay terminal.
J
Flasher relay is faulty, replace.
1
'Jx_ OK
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Check for voltage (12V) on "Br/W" lead at '1 No voltage _, Wiring circuit from flasher relay to
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"TURN" switch connector. _ r "TURN" switch is faulty, repair.
e.
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Check for voltage (12V) on "'Ch" and/or "Dg" I No voltage _ "TURN" switch is faulty replace.
lead at "TURN" switch connector. ot
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Check for voltage (12V) on "Br" lead at horn No voltage _ I Wiring circuit from fuse to horn
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_o_
No voltage I. i
Check for voltage (12V) on "P" lead at
"HORN" switch connector. _ 1 Horn is faulty, replace. l
_o_
Check for continuity of "HORN" switch, while I No continuity .I "HORN" switch is faulty, replace. I
pushing it. !! v I I
_ Continuity
6-43
sq 4. "'OIL" indicator light does not work
s,ooAL
S,STEM
I 1
No
Checkfor voltage (12V) on "Br" lead at oil level voltage I Wiring circuitfrom fuse to oil level
'_ No |
Check fOrconnector.VOltage
gauge (12V) on "Gy" lead at oil level ____1, Check for condition of oil level
I condition, replace it.
-- i gauge. If oil level gauge is poor
_,_OK No
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indicator light connector, ty, replace it.
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Check for voltage (12V)on "B" lead at "OIL" I vItage_ __i IndicatOr light bulb socket is faul-
e.
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[Oil level gauge check]
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1. Disconnect:
.S
2. Remove:
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3. Connect:
Pocket Tester (YU-03112)
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/_ ....i_;;, 4. Check:
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Check for voltage (12V) on "Br" lead at taillight No voltage _ I Wiring circuit from fuse to taillight
connector, r _ connector is faulty, repair.
L
6-44
[ELEC _I AUTO CHOKE SYSTEM F =_
AUTO CHOKE SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows auto choke circuit,
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6-45
AUTO CHOKE SYSTEM [ELECI_ ]
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6-46
IELEC _] AUTOCHOKESYSTEM D
TROUBLESHOOTING CHART
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Tester (-) lead--Black lead Replace lighting coil.
Tester (+)lead-_Yellow/Red lead specificatin _ I I
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4. Measure:
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oLighting coil resistance
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_ 0.27-0.33_ at 20C (68F)
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F-,
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OK
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] Poor
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6-47
AoTo
C.OKE
S,STEM
ELEOI
AUTO CHOKE UNiT TEST
1. Remove:
oTail cover
Refer to "CHAPTER 2 -- TAIL COVER"
section.
2. Remove:
eAir cleaner case
3. Disconnect:
oAuto choke unit leads
4. Connect:
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oPocket tester (YU-03112)
Set the tester selector to "_ x 1" position.
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5. Measure:
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oAuto choke unit resistance
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Out of specification_Replace.
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6-48
CHAPTER 7
APPENDICES
SPECIFICATIONS ................................................ J-3
GENERAL SPECIFICATIONS ..................................... J-3
MAINTENANCE SPECIFICATIONS ................................ J-4
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APPENDICES
SPECIFiCATiONS
GENERAL SPECIFICATIONS
Model CE50T
Model Code Number 2UG
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Overall Height 972 mm (38.3 in)
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Seat Height 690 mm (27.1 in)
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Wheelbase 1,085 mm (42.7 in)
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Minimum Ground Clearance 100 mm (3.9 in)
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Basic Weight:
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With Oil and Full Fuel Tank 58.5 kg (129 Ib)
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Minimum Turning Radius 1600 mm (63 in)
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Engine:
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Displacement 49 cm 3
m
oil
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7-1
m
Model CE50T
i
Carburetor:
Type/Manufacturer Y12P/TEIKEI KIKAKI
Spark Plug:
Type/Manufacturer BPR6HS/NGK
Gap 0.9-1.0 mm (0.036-0.039 in)
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Transmission Type V-belt
Operation Auto matic
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Chassis:
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Frame Type Steel Tube Underbone
Caster Angle 25
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Trail
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62 mm (2.44 in)
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Tire:
.S
Brake:
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Suspension: .
Front Suspension Telescopic Fork
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7-2
{APPX[_ SPECiFiCATION [
Model CE50T
Electrical:
Ignition System CDI
Generator System Flywheel magneto
Battery Type or Model GM4-3B
Battery Capacity 12V 4AH
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Meter light 12V 3.4Wx 1
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Indicator Light Wattage x Quantity:
"TURN" 12V 1.7Wx 1
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"HIGH BEAM" 12V 1.7Wxl
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"OIL" 12V 3.4Wx 1
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MAINTENANCE SPECIFICATIONS
SPEO,F,OAT,ON
APPXJ '
Engine
Model CE50T
Cylinder Head: *
Warp Limit _"
___, /_ - 0.02 mm (0.0008 in)
,#
Cylinder:
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Bore Size 40.0 mm (1.575 in)
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< Limit> 40.1 mm (1.579 in)
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Taper Limit 0.05 mm (0.002 in)
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Out of Round Limit 0.01 mm (0.0004 in)
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Piston:
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Piston Size _ 40.0 mm (1.575 in)
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Piston Ring:
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Crankshaft: F
7-4
[APPx sPEo.F.oAT.o. [
Model CE50T
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Transmission:
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Main Axle Runout Limit 0.08 mm (0.003 in)
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Drive Axle Runout Limit 0.08 mm (0.003 in)
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Kick Starter:
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Type Ratchet Type
Kick Clip Tension ot
250-300 g (8.83-10.6 oz)
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Carburetor:
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Reed Valve:
D
7-5
Tightening Torque
Tightening torque
Part to be tightened Thread size Q'ty Remarks
Nm mokg ftolb
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Reed valve (carburetor joint) M 8 x 1.0 4 8 0.8 5.8
Air cleaner Case M 6 x 1.0 2 8 0.8 5.8
e.
Exhaust pipe M 6 x 1.0 2 8 0.8 5.8
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Muffler M 8x 1.25 2 27 2.7 19
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Muffler protector M 6xl.0 2 8 0.8 5.8
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Crankcase M 6 x 1.0 6 8 0.8 5.8
Transmission case cover M 6 x 1.0 ot 5 8 0.8 5.8
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Crankcase cover M 6x 1.0 10 8 0.8 5.{]
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7-6
I
APPX
I
Chassis
r
Model CE50T
Steering System:
Steering Bearing Type Ball bearing
No./Size of Steel Balls
Upper 5/32 in/26 pcs
Lower 5/32 in/26 pcs
Front Suspension:
Front Fork Travel 48.6 mm (1.91 in)
Fork spring Free Length 92 mm (3.62 in)
<Limit> <87 mm (3.42 in)>
Spring Rate (K1) 9.55 N/mm (0.974 kg/mm, 53.6 lb/in)
Stroke 0.0-48.6 mm (0.0-1.91 in)
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Optional Spring No.
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Rear Suspension:
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Shock absorber Travel 45 mm (1.77 in)
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Spring Free Length 187.5 mm (7.38 in)
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Spring Fitting Length 182.5 (7.18 in)
Spring Rate (K1) ot
37.2 N/mm (3.8 kg/mm, 209.3 Ib/in)
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(K2) 48.1 N/mm (4.9 kg/mm 269.9 Ib/in)
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Wheel:
Front Wheel Type Disc wheel
d
7-7
kSPEC,F,OAT
[APPXI
Tightening Torque
Tightening torque
Part to be tightened Thread size Q'ty Remarks
Nm mkg ftlb
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Rear brake cam lever M 5 x 0.8 1 6 0.6 4.3
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Rear wheel axle M14x 1.5 1 93 9.3 67
e.
Rear brake shoe plate M 8x 1,25 3 18 1.8 13
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Rear stay M 6x1.0 4 10 1.0 7.2
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Seat bracket and seat M 6x 1.0 2 7 0.7 5.1
Rear Carrier M 6x1.0 4 7 0.7 5.1
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7-8
Electrical
Model CE50T
Voltage: 12V
Ignition System:
Ignition Timing (B.T.D.C.) 18/5,000 r/min
Advancer "Fype Electrical
25
L3
c_ 20
_ 15
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N 10
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*- 5
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0 1 2 3 4 5
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6 7 8 9
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Enginespeed (x 103r/min)
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C.D.I.:
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Ignition Coil:
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Model/Manufacturer 2EX/YAMAHA
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C.D.I. Magneto:
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Model/Manufacturer F 1HH/YAMAHA
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7-9
m
Model CE50T
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Voltage Regulator:
Type Semi conductor short circuit type
Model/Ma nufactu rer EHU-01TR05/MATS US HITA
No Load Regulated Voltage 13.5-14.5V
Rectifier:
Model/M anufactu rer EHU-01TR15/MATS US HITA
Capacity 4A
Withstand Voltage 240V
Battery:
Capacity 12V, 4AH
Specific Gravity 1.280
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Starter Motor:
Model DA5AG 2EX-81800-M0
e.
Manufacturer NIPPON DENSO YAMAHA
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Out Put 0.15 kW 0.14 kW
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Armature Coil Resistance 0.08 - 0.109 0.08 - 0.10n
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Brush Length 5.5 mm (0.22 in) 3.9 mm (0.15 in)
<Wear Limit> ot
<2.5 mm 0.10 in)> <0.9 mm (0.03 in)>
co
Commutator Diameter 15.5 mm (0.61 in) 15.8 mm (0.62 in)
.S
Starter Relay:
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Model/Manufacturer 27V/TATEISHI
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Horn:
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Flasher Relay:
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7-10
IAPPX
GENERAL TORQUE
DEFINITION OF UNITS
General torque
A B specifications
SPECIFICATIONS (Nut) (Bolt)
Nm mokg ftolb
This chart specifies torque for standard fasteners
10 mm 6 mm 6 0.6 4.3
with standard I.S.O. pitch threads. Torque
12 mm 8 mm 15 1.5 11
specifications for special c o m p o n e n t s or
assemblies are included in the applicable sections 14 mm 10 mm 30 3.0 22
of this book. To avoid warpage, tighten multi- 17 mm 12 mm 55 5.5 40
fastener assemblies in a crisscross fashion, in pro- 19 mm 14 mm 85 8.5 61
gressive stages, until full torque is reached. Unless 22 mm 16 mm 130 13.0 94
otherwise specified, torque specifications call for
clean, dry threads. Components should be at
room temperature.
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DEFINITION OF UNITS
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7-11
CABLE ROUTING
CABLEROTN
IAPPXI
!
(_ Main switch [] Route along left side of leg shield bracket and
(_) Leg shield bracket frame,
Rear brake cable [] Route wire harness along left side of leg shield
_) Throttle cable bracket and then, along left side of frame
(_) Carrier stay 2 down-tube.
Horn [] Wire harness should be on the left side.
(_ Rectifier/Regulator
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[]
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[]
7-12
(_ Throttle cable [] It should be firmly installed on the engine pro-
Rear brake cable rector.
(_) Wire cylinder ass'y [] Route wire harness between rear stay and fuel
(_ Oil level gauge tank.
(_ Breather hose [] Insert fuse case (wire harness assembly) into
(_ Band holder {integrated with battery casel.
[] Route wire harness over frame.
[] Route breather hose along engine protector
slit.
[] Route wire harness under back stay.
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[]
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7-13
m
(_ Inner fender [] Pass meter cable and brake cable through the
(_) C.D.I. unit window in inner fender.
_) Ignition coil [] Meter cable and front brake cable should be
(_ Fuel pipe (tank to cock) free of twists.
(_ Clamp [] Clamp rear brake cable.
(_) Band [] Be sure the casing cap of brake cable is com-
(_ Auto choke unit lead pletely in crankcase.
[] Clamp wire harness only.
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7-14
CABLE ROUTING
(~ Main switch [ ] Push the projecting portion of clamp into the
~ Oil pipe
Fuel tank
mounting hole on the stay side.
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1
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7-15
(_) High tension cord
CABLE.OOT,
[]
OOClamp firmly.
(_ Auto choke unit lead [] Route battery breather hose inside the back
(_) Band stay and hold with clamp.
@ Boot When installing cover, use care so that pipe is
(_) C.D.I. magneto lead not pinched.
(_) Oil pump cover [] Pass flasher lead through holes in flasher stay
(_ Exhaust pipe and carrier 2.
(_) Clamp [] As shown, after connecting the taillight and
(_ Starter motor lead flasher leads, push the connections completely
(_ Carrier 2 into the tail cover.
(_) Taillight assembly No coupler and connector are allowed to be
@ Tail cover assembly outside the case.
@ License bracket
(_) Flasher stay
(_ Cap
(_ Flasher light assembly
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7-16
CE50T WIRING DIAGRAM
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light (Right)'k jU B_ --L=_-B uw s
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"TURN" _T=_Dg--:'!
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indicator lightk_U -c"-] _ r,_._,.y--Gv--I
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" " I
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Meter light 0 B. _ . .
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Headlight _[ P
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relay [ J B'L2L-I----8'
___G L Y_ B
OFFB P
LO-O
N G/Y Br
"LIGHTS" Horn R 0-0'
(Dimmer) switch "TURN" Rear brake Horn
switch switch switch
gauge
r _ Oil level
switch -..L_._
Gy Br
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_ Rear Iflasher
light Rightl
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Tail/brake light
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ic.C3<:1
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Rear flasher
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light (keftl
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Fuse
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W/R B/R
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R B .......... Black
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l COLOR CODE
8/R S L .......... Blue
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O .......... Orange
R P ......... . Pink
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Y .......... Yellow
R .......... Red
G .......... Green
Br .......... Brown
O _ Gy ......... Gray'
Ch ......... Chocolate
--= Dg ......... Dark green
:o choke CDI magneto CDI unit Battery Starter. Starter W .......... White
t relay motor B/R ........ Black/Red
L/W ....... Blue/White
Y/R ........ Yellow/Red
G/Y ........ Green/Yellow
Br/W ....... Brown/White
W/R ....... White/Red
B/W ....... Black/White
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YAM/liiA
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2YT-AE1
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UPPLEMENTARY
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RViCE MANUAL
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FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and new data for
the CG50U. For complete information on service procedures, it is necessary to use this Supplemen-
tary Service Manual together with following manual:
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE GROUP
Y A M A H A MOTOR CO., LTD.
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CG50U
SU PPLEM ENTARY
SERVICE MANUAL
1987 by Yamaha Motor Co., Ltd.
1st Edition, November 1987
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
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NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha 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 scooters
have a basic understanding of the mechanical concepts and procedures inherent in scooter repair tech-
nology. Without such knowledge, attempted repairs or service to this model may render it unfit to
use and/or unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all Authorized
Yamaha dealers and will, where applicable, appear in future editions of this manual.
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H O W TO USE T H i S M A N U A L ot
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to the scooter.
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M A N U A L FORMAT .
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All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course
of action required will follow the symbol, e.g.,
Bearings
Pitting/Damage~ Replace.
EXPLODED D I A G R A M
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
0
ILLUSTRATED SYMBOLS
I,GEN I INSP (Refer to the illustration)
NFO Illustrated symbols (~ to (~ are designed as
thumb tabs to indicate the chapter's number and
content.
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IELEC[ IAPP l
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@ Illustrated symbols (~) to (~) are used to identify
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the specifications appearing in the text.
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(~ Filling fluid
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(~ Lubricant
(~ Tightening
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@ @ Engine speed
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(~ 0, V, A
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@ @
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m m
of lubrication point.
E~ E~ Apply engine oil
(~) Apply gear oil
@ @ (~ Apply molybdenum disulfide oil
(~) Apply wheel bearing grease
(~ Apply lightweight lithium-soap base grease
~) Apply molybdenum disulfide grease
(~) Apply locking agent (LOCTITE)
@
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CONTENTS
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HANDLEBAR COVERS ...................................... L-8
e.
ENGINE. ..................................................... L-8
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ENGINE OIL LEVEL INSPECTION .............................. L-8
AUTOLUBE PUMP AIR BLEEDING ............................. L-9
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ELECTRICAL ................................................. L-10
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CGEOU CIRCUIT DIAGRAM .................................. L-10
ELECTRICAL COMPONENTS ................................. L-11
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ENGINE SERIAL N U M B E R
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The engine serial number (~) is stamped into the
.S
crankcase.
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NOTE:
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NOTE:
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without notice.
--1--
INTRODUCTION/PERIODIC MAINTENANCE/ I INSP
LUBRICATION INTERVALS . =
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and
a longer service life. The need for costly overhaul work will be greatly reduced. This information ap-
plies to vehicles already in service as well as new vehicles that are being prepared for sale. All service
technicians should be familiar with this entire chapter.
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ITEM REMARKS
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5OO (300) (2,000) or (4,000) or
6 months 12 months
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Check condition.
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Spark plug
Clean or replace if necessary.
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Air filter* Clean. Replace if necessary.
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Correct if necessary.
Steering bearing*
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--2--
T A I L COVERS A N D MOLES
I INSP
COVERS
TAIL COVERS AND MOLES
Removal
1. Open the seat lock.
2. Remove:
Seat (~
Helmet holder (~
3. Remove:
Moles ~ (Left and right)
NOTE:
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Unhook the pawl (~ out of groove (~ of the
e.
footrest board.
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oSlide the mole backward and unhook the pawl
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(~ out of groove (~) of the tail cover.
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4. Disconnect:
oTaillight leads
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5. Remove:
D
Carrier assembly (~
6. Remove:
Cover ~)
--3--
TAIL COVERS A N D MOLES
7. Remove:
Cover @
8. Remove:
Tail cover (~)
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Installation
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1. Install:
.S
-Tail cover (~
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2. Install:
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-Cover (~
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NOTE:
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3. Install:
-Carrier assembly (~
Nut (Carrier):
7 Nm (0.7 m , k g , 5.1 ft,lb)
Bolt (Carrier):
7 Nm (0.7 m , k g , 5.1 ft,lb)
4. Connect:
Taillight leads
Rear flasher light leads
-4-
INSP
FRONT PANEL, LEG SHIELD A N D FOOTREST BOARD
5. Install:
=Mole (Left and right) ~)
NOTE:
=Hook the pawl (~) onto the opening (~, and
slide the mole forward.
Hook the pawl ~) onto the opening (~).
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6. Install:
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Seat (~
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Helmet holder (~
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~ Nut(Seat):
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FOOTREST BOARD
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Removal
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1. Remove:
=Covers (~ (Left and right)
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NOTE:
Unhook the projection by pulling up the cover.
2. Remove:
Front panel (~
NOTE:
Unhook the projection by pulling up the front
panel.
--5--
'3 FRONT PANEL, LEG SHIELD A N D FOOTREST BOARD
I INSP
3. Remove:
Leg shield (~)
4. Remove:
Tail cover
Refer to "TAIL COVERS AND MOLES"
section.
5. Remove:
Footrest board
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installation
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1. Install:
.S
2. Install:
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Tail cover
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section.
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3. Install:
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Leg shield ( ~
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4. Install:
Front panel (~)
NOTE:
Install the projection into the slot.
--6--
HANDLEBAR COVERS I INSP
ADJ 1 D
5. Install:
=Covers ( ~ (Left and right)
NOTE:
Install the projection into the slot.
HANDLEBAR COVERS
Removal
1. Remove:
=Screws (Handlebar cover -- Front)
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2. Disconnect:
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=Headlight lead and flasher light leads
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3. Remove:
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4. Disconnect:
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Leads
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5. Remove:
Rear view mirror (~)
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Installation
1. Install:
-Handlebar cover (~) (Rear)
Rear view mirror ( ~
2. Connect:
= Leads
Speedometer cable
WARNING:
ENGINE
ENGINE OIL LEVEL INSPECTION
1. Place the scooter on the level place.
NOTE:
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Be sure the scooter is positioned straight up and
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on both wheels when inspecting the oil level.
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2. Check:
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oOil level
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Oil level low--Add sufficient oil.
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Recommended Oil:
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Refer to ELECTRICAL I
"SIGNAL SYSTEM" I
I Engline oil level and electrical I
circuit are OK
1_ t Supply engine oil I
--8--
ENGINE OIL LEVEL INSPECTION ADJ
_
NOTE:
If the main switch is turned off after the "OIL"
light goes off and then immediately again the main
switch is turned on, the "OIL" light may not come
on. This is not because of failure.
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AUTOLUBE PUMP AIR BLEEDING
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The oil pump and delivery line must be bled
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on the f o l l o w i n g occasions:
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connected.
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e During predelivery.
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1. Remove:
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oTail cover
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section.
ePump cover ( ~
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2. Fill:
Oil tank
Recommended Oil:
Yamalube " 2 " or Air-cooled 2
Stroke Engine Oil
--9--
AUTOLUBE PUMP AIR BLEEDING IIINSPL tl
6. Keep the oil running out until air bubbles dis-
appear from the oil hose and bleed hole.
7. Install:
Gasket (Bleed screw)
Bleed screw
8. Disconnect:
oOil delivery hose (~)
From the carburetor (~.
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9. Feed the engine oil into the oil delivery hose
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using a oil can from complete air bleeding.
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buretor.
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NOTE:
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1'0. Install:
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oTail cover
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section.
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--10--
CG50U CIRCUIT D I A G R A M I ELECI E,
ELECTRICAL
CG50U CIRCUIT D I A G R A M
B/Wi B RIBr
LOCK o-
B/R B
OFF
ON
-'="W/R @ "~-
B/R---- 1 B/R _ B/W
=J._
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Y/R Y/R (~
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B
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( ~ =J.-
~S .J-=
-~
S (~) ~ g , -=-
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"=- B T
_J._ G/Y B
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F -~ L/W 2
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N, IotO
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B B B B
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~~'--~,-T--:, ~' ~ I J, !
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Gy
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B
-__- .J-- -J-- ...L __L 2 2_
N
11
o3 CG50U CIRCUIT D I A G R A M [ELECI
I Spark plug (~ Tail/Brake light
Ignition coil
CDI magneto
~ Fuelmeter
Fuel sender
CDI unit ~ Flasherrelay
Rectifier/Regulator "TURN" switch
Auto choke unit ~ "TURN"indicatorlight
~ ENGINESTOP"switch Left flasher light (Front)
Main switch Left flasher light (Rear)
~~ Starterrelay
Fuse
Battery
"START" switch
Right flasher light (Front)
Right flasher light (Rear)
~ Horn
"HORN" switch
Starter motor (~ Front brake switch
"LIGHTS" (Dimmer) switch ~) Rear brake switch
Headlight ~ OIL"indicatorlight
~) "HIGH BEAM" indicator light Oil level gauge
(~ Meter light
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COLOR CODE
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R Red P Pink
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B Black L Blue
W White Y/R ot
Yellow/Red
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Y Yellow L/W Blue/White
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Br/W Brown/White
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Dg Dark green
G Green
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--12--
ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS IE'EC[ I
~ ireharness BAI-rERY
Fuel sender A TYPE: YB4L-B
~ Ignitioncoil SPECIFIC GRAVITY: 1.280
Battery
~ tarterrelay IGNITION COIL RESISTANCE
PRIMARY: 0.56-0.84~3 at 20C (68F)
Oil level gauge B
(~ CDI unit SECONDARY: 5.68-8.52k~ at
20oc (68OF)
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6
--13--
ELECTRICAL COMPONENTS I ELECI
Horn
Main switch
~ Rectifier/Regulator
Flasher .relay
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tj S
--14--
SIGNAL SYSTEM ELEC
SIGNAL SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows signal system.
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--15--
SIGNAL SYSTEM [ ELEC .
NOTE:
For color codes, see page 12.
o Unlike the previous CE5OT, this model has a fuel
meter and fuel sender added and the oil level
gauge changed. This signal system explains the
checking of only such addition and change.
~ Main switch
Fuse
(~ Battery
~ Fuel meter
Fuel sender @
~ "OIL" indicator light
Oil level gauge
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--16--
SIGNAL SYSTEM ELECI
TROUBLESHOOTING
NOTE:
The battery provides power for operation of the
fuel meter and "OIL" indicator light. If none of
the above operates, always check the battery vol-
tage before proceeding further. Low battery vol-
tage indicates either a faulty battery, low battery
electrolyte, or defective charging system. Also,
check the fuse condition.
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Check for voltage (12V) on "Br" lead at fuel Wiring circuit from fuse to fuel meter
meter connector. connector is faulty, repair.
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J v L OK
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NO
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VOLTAGE
Check for voltage (12V) on " G " lead at fuel
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Check for condition of fuel meter. If
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meter connector. Y fuel meter is poor condition, replace it.
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J~ OK
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NO
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VOLTAGE
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Check for voltage (6-12V) on "G" lead at fuel Wiring circuit from fuel meter to fuel
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J~ OK
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--17--
SIGNAL SYSTEM ELEC
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2. Connect:
Pocket Tester (YU-03112)
Set the tester selector to " ~ x 10" position.
3. Check:
Fuel sender conduct
Refer to following table.
Not per result~Replace.
NOTE:
Check from top to bottom.
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Fuel M e t e r C h e c k
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1. Connect:
.S
3. Check:
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Fuel meter
Refer to following table.
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Up (~) "F"
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NOTE:
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--18--
2. "OIL" indicator light does not work
SONA.
S STEM
[ELEC
]
NO
VOLTAGE
Check for voltage (12V) on "Br" lead at "OIL" _ Wiring circuit from fuse to "OIL" indi-
indicator light connector. _ cator light connector is faulty, repair.
JvL OK NO
Check for voltage (12V) on "Gy" lead at "OIL .... OIk" indicator light socket is faulty,
indicator light connector. _ replace it.
-J_,LOK NO
VOLTAGE
Check for voltage (12V) on "Gy" lead at oil ___ Wiring circuit from "OIL" indicator
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level gauge connector. ----------F light to oil level gauge is faulty, repair.
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Check for condition of oil level gauge. Refer
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to "OIL LEVEL GAUGE CHECK".
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1. Remove:
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NOTE:
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3. Check
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--19--
E
APPENDICES
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model CG50U
Model Code Number 2YT
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Overall Height 985 mm (38.8 in)
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Seat Height 700 mm (27.5 in)
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Wheelbase 1,115 mm (43.9 in)
im
Minimum Ground Clearance 95 mm (3.7 in)
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Basic Weight:
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With Oil and Full Fuel Tank 58 kg (128 Ib)
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Minimum Turning Radius 1,600 mm (63 in)
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Engine:
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Displacement 49 cm3
m
Oil Capacity:
Oil Tank (Engine Oil) 0.8 L (0.7 Imp qt, 0.84 US qt)
Transmission Oil:
Periodic Oil Change 0.10 L (0.09 Imp qt, 0.11 US qt)
Total Amount 0.11 L (0.10 Imp qt, 0.12 US qt)
-20-
SPEO,F,OAT,
OOS
APPXj ,
Model CG50U
Carburetor:
Type/Manufacturer Y12P/TEIKEI KIKAKI
Spark Plug:
Type/Manufacturer BPR7HS/NGK, W22FPR-U/N.D
Gap 0.6- 0.7 mm (0.024- 0.028 in)
t
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Transmission Type V-belt
Operation Automatic
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Chassis:
Frame Type Steel tube underbone
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Caster Angle 26.5
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Trail 72 mm (2.83 in)
ot
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Tire:
.S
Brake:
d
Suspension:
Front Suspension Telescopic fork
D
-21 -
Model
SPEO,F,CAT,
ONS
APPI
i CG50U
Electrical:
Ignition System CDI
Generator System Flywheel magneto
Battery Type or Model YB4L-B
Battery Capacity 12V 4AH
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Indicator Light Wattage x Quantity:
"TURN" 12V 1.7Wx 1
e.
"HIGH BEAM" 12V 1.7W1
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"OIL" 12V 3.4W 1
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-22-
MAINTENANCE SPECIFICATIONS
SPEC,
OOS
APPxt
,CAT,
1
Engine
Model CG50U
Cylinder Head: *
Warp Limit _ /_ 0.03 mm (0.0012 in)
Cylinder:
Bore Size 39.993-40.012 mm (1.575 in)
t
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<Limit> 40.1 mm (1.579 in)
Taper Limit 0.05 mm (0.002 in)
e.
Out of Round Limit 0.01 mm (0.0004 in)
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Piston:
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Piston Size _ 39.952-39.972 mm (1.573-1.574 in)
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Measuring Point* ___ 5 mm (0.2 in)
.S
Piston Ring:
m
2nd Gap
End Ring(Installed): _-4 1.5 x 1.8 mm (0.059 0.071 in)/Keystone
de
Crankshaft: F
-23-
Model
SPEO,F,OAT
APP'I CG50U
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Transmission:
e.
Main Axle Runout Limit 0.08 mm (0.003 in)
im
Drive Axle Runout Limit 0.08 mm (0.003 in)
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Kick Starter:
e
Type Ratchet type
Kick Clip Tension ot
150-250 g (5.3-8.8 oz)
co
Carburetor:
.S
Lubrication System:
Autolube Pump Stroke 0.34-0.55 mm (0.013-0.022 in)
-24--
b
Tightening Torque:
Tightening torque
Part to be tightened Thread size Q'ty Remarks
Nm mkg ftlb
Spark plug M14x 1.4 1 20 2.0 14
Cylinder head M 6x 1.0 4 10 1.0 7.2
Stud bolt M 6 x 1.0 4 9 0.9 6.5
Stator assembly M 6 x 1.0 2 9 0.9 6.5
C.D.I. magneto M10x 1.25 1 38 3.8 27
Air shroud M 6x 1.0 2 9 0.9 6.5
Fan cover M 6 x 1.0 2 9 0.9 6.5
Fan M 6x 1.0 3 7 0.7 5.1
Autolube pump M 5 x 0.8 2 4 0.4 2.9
Reed valve (carburetor joint) M 6 1.0 4 9 0.9 6.5
t
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Air cleaner Case M 6 x 1.0 2 9 0.9 6.5
e.
Exhaust pipe M 6 1.0 2 9 0.9 6.5
im
Muffler M 8 1.25 2 33 3.3 24
Muffler protector M 6 x 1.0 2 9 0.9 6.5
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Crankcase M 6 x 1.0 6 9 0.9 6.5
e
Transmission case cover M 6 x 1.0
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5 8 0.8 5.8
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Crankcase cover M 6xl.0 10 9 0.9 6.5
Transmission oil drain bolt M 8x 1.25 1 18 1.8 13
.S
-25-
Chassis
sPEo,F,
cAT,
os
IAPPxI
Model CG50U
Steering System:
Steering Bearing Type Ball bearing
No./Size of Steel Balls
Upper 5/32 in 26 pcs.
Lower 5/32 in 26 pcs.
Front Suspension:
Front Fork Travel 48.6 mm (1.91 in)
Fork spring Free Length 91.5 mm (3.60 in)
<Limit> <87 mm (3.42 in)>
Spring Rate 11.28 N/mm (1.128 kg/mm, 62.1 Ib/in)
Stroke Zero-48.6 mm (Zero- 1.91 in)
t
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Optional Spring No.
e.
Rear Suspension:
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Shock absorber Travel 45 mm (1.77 in)
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Spring Free Length 191.5 mm (7.54 in)
e
Spring Fitting Length 181.5 mm (7.15 in)
Spring Rate: (K1) ot
38.0 N/mm (3.8 kg/mm, 209.3 Ib/in)
co
(K2) 49.0 N/mm (4.9 kg/mm, 269.9 Ib/in)
.S
Wheel:
Front Wheel Type Panel wheel
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-26-
SPEC,F,OAT,ONS
APPX
Tightening torque:
Tightening torque
Part to be tightened Thread size Q'ty Remarks
Nm mokg ft.lb
Frame and engine bracket MlOx 1.25 2 42 4.2 30
Engine bracket and engine MlOx 1.25 1 42 4.2 30
Rear shock absorber (Upper) MIOx 1.25 1 32 3.2 23
(Lower) M 8x 1.25 1 18 1.8 13
Handlebar and steering column MIO 1.25 1 60 6.0 43
Ring nut (Steering column) M25 1 30 3.0 22
Front wheel axle MIOx 1.25 1 35 3.5 25
Front brake cam lever M 5x 0.8 1 4 0.4 2.9
Rear brake cable holder M 6 1.0 1 9 0.9 6.5
t
Rear brake cam lever M 5x 0.8 1 4 0.4 2.9
ne
Rear wheel axle M14x 1.5 1 95 9.5 68
e.
Rear brake shoe plate M 8 1.25 3 18 1.8 13
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Rear stay M 6 1.0 4 10 1.0 7.2
Seat bracket and seat M 61.0 2 7 0.7 5.1
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Rear carrier M 6 1.0 4 7 0.7 5.1
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-27-
Electrical
Model CG50U
Voltage:
Ignition System:
Ignition Timing (B.T.D.C.) 14 at 5,000 r/min
Advancer Type Electrical
25
t,.) 20
r~
F~
~; 1 5
f
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E 10
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F=
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33
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0 1 2 3 4 5 6 7 8 9
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Engine speed ( x 103 r/min)
.S
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C.D.I.:
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Ignition Coil:
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Model/Manufacturer 2JA/YAMAHA
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C.D.I. Magneto:
Model/Manufacturer F2JA/YAMAHA
Charging Coil Resistance (Color) 0.48-0.72fl at 20C (68F) (White--Black)
Charging Current
Full Charged Battery (1.280) 0.5A or less at 3,000 r/min
Half Charged Battery (1.180) 1.0A or more at 3,000 r/min
Charging Voltage 13-14V at 4,000 r/min
Lighting Coil Resistance (Color) 0 . 4 - 0 . 6 9 at 20C (68F) (Yellow/Red--Black)
Lighting Voltage 11.5- 13.5V at 4,000 r/min
Voltage Regulator:
Type Semi conductor short circuit type
Model/Manufacturer EHU-01TR05 or SU232Y/MATSUSHITA or
STANLEY
No Load Regulated Voltage 13.5- 14.5V
--28--
SPEC,F,CAT,
OOS
APPXt
Model CG50U
Rectifier:
Model/Manufacturer EHU-01TR21/MATSUSHITA or SH592-12/
SHINDENGEN
Capacity 5A
Withstand Voltage 240V
Battery:
Capacity 12V, 4AH
Specific Gravity 1.280
Starter Motor:
t
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Out Put 0.15 kW 0.14 kW
Armature Coil Resistance 0.08- 0.10_ 0.07 - 0.09_t
e.
at 20C (68F) at 20C (68F)
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Brush Length 5.5 mm (0,22 in) 3.9 mm (0.15 in)
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<Wear Limit> <2.5 mm (0.10 in)> <0.9 mm (0.035 in)>
e
Brush Spring Pressure 250-450 g (8.8- 15.9 oz) 560-840 g (19.8-29.7 oz)
Commutator Diameter ot
15.5 mm (0.61 in) 15.8 mm (0.62 in)
co
<Wear Limit> <14.5 mm (0.57 in)> <14,8 mm (0.58 in)>
.S
(0.035-0.047 in)
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Starter Relay:
Model/Manufacturer 27V/OMRON 27V/MATSUSHITA
m
Horn:
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Model/Manufacturer GF-12/NIKKO
nl
Flasher Relay:
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-29-
DEFiNITiON OF UNITS
GENERAL TORQUE SPECiFiCATiON/
GENERAL TORQUE General torque
A B specifications
SPECiFiCATiONS (Nut) (Bolt)
Nm m-kg ft.lb
This chart specifies torque for standard fasteners
10 mm 6 mm 6 0.6 4.3
with standard I.S.O. pitch threads. Torque
12 mm 8 mm 15 1.5 11
specifications for special components or
assemblies are included in the applicable sections 14 mm 10 mm 30 3.0 22
of this book. To avoid warpage, tighten multi- 17 mm 12 mm 55 5.5 40
fastener assemblies in a crisscross fashion, in pro- 19 mm 14 mm 85 8.5 61
gressive stages, until full torque is reached. Unless 22 mm 16 mm 130 13.0 94
otherwise specified, torque specifications call for
clean, dry threads. Components should be at
room temperature.
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DEFINITION OF UNITS
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--30--
CABLE ROUTING
[...x
(_ Front brake cable
(_) Flasher relay
(_) Rear brake cable
@ Speedometer cable
(_) Throttle cable
(_ Band
Horn
Main switch
(_) Rectifier/Regulator
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--31 --
(_ Rear brake cable
CABLE.OT,
NOAPPX[
1
Band
Wireharness
Starter relay
CDI unit
Oil level gauge
Battery positive lead
Fuse
i Throttle cable
(_ Fuel sender
(_) Clamp
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000 000
-32-
m
_ Rectifier/Regulator
peedometer cable
(_) Throttle cable
(_) Fuel hose
(_) Vacuum hose
(_) Ignition coil
(_) Rear brake cable
(_)Band
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--33--
(_ Battery breather pipe
CABLE.OOT
0[APP
(_) CDI unit
(_ Oil level gauge
(_) Fuse
(_) Auto choke unit
_ Starter
hrottle motor
cable lead
(_) CDI magneto lead
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--34--
t"
Y=
r
y v v v ,.--
",-' _ _.r= _ _ _
-" "- --ICI
,_ = _8=
.-
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