1987 YAMAHA YSR 50T Service Manual

@YAM AHA
YS R5OT
SERVICE MANUAL
01987 by Yamaha Motor Corporation, U.S.A.
1st Edition, March 1987
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
PINO. LIT-Il616-O6-05
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 motor-
cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle
repair technology. Without such knowledge, attempted repairs or service to this model may render
it unfit to use andlor 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.
TECHNICAL PU BLlCATlONS
SERVICE DIVISION
MOTORCYCLE OPERATIONS
YAMAHA MOTOR CO., LTD.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.
NOTE: A NOTE provides key information to make procedures easier or clearer.
A CAUTION indicates special procedures that must be followed to avoid damage

to the motorcycle.
A WARNING indicates special procedures that must be followed to avoid injury to

a motorcycle operator or person inspecting or repairing the motorcycle.
MANUAL FORMAT
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
Pitting1Damage-, Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols @ t o @ are designed as

thumb tabs to indicate the chapter's number and
I ENG 1 content.
a General information
@ Specifications
@ Periodic inspection and adjustment
@ Engine
@ Cooling system
@ Carburetion
a Chassis
@ Electrical
@ Troubleshooting
Illustrated symbols @ to @ are used to identify

the specifications appearing in the text.
@ Filling fluid
Lubricant
@ Special tool
@ Tightening
@ Wear limit, clearance
@ Engine speed
@ 9,v, A
Illustrated symbols 0to @ in the exploded dia-

gram indicate grade of lubricant and location of
lubrication point.
0 Apply engine oil
@ Apply gear oil
8 Apply molybdenum disulfide oil
@ Apply wheel bearing grease
Apply lightweight lithium-soap base grease
@ Apply molybdenum disulfide grease
@ Apply locking agent (LOCTITE@)
INDEX
GENERAL INFORMATION
m
GEN
INFO
SPECIFICATIONS
Pf
PERIODIC INSPECTION em
AND ADJUSTMENT INSP
ADJ
@
+o,
ENGINE OVERHAUL
&O
CHASSIS
El
ELECTRICAL
ELEC
0
TROUBLESHOOTING
CONTENTS
CHAPTER 1 .
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.
.1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 .

PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . . . . . 1.2
ALL REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
GASKETS, OIL SEALS. AND O.RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 1..3
LOCK WASHERSIPLATE AND COTTER PINS . . . . . . . . . . . . . . . . . . . .1.3
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1..3
ClRCLlPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
.
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4.

FOR TUNE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
.
FOR ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 .
FOR CHASSIS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1..6
FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7
CHAPTER 2 .
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1

.
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2..4

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
..
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
.
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11.
GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

.
DEFINITION OF UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

.
t N t i I N t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
.
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 .
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

.
CHAPTER 3.
-- -
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE/LUBRlCATlON INTERVALS . . . . . . . . . . . . 3.1
COWLINGS REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 3.3

COWLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 INFO
SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
THROTTLE CABLE FREE PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 3.5
AUTOLUBE PUMP CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 3.5
AUTOLUBE PUMP STROKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 3.6
AUTOLUBE PUMP AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
TRANSMISSION OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .3.11
TRANSMISSION OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
CARBURETOR JOINT INSPECTOIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Y.E.I.S. HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
BRAKE SHOE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
BRAKE LIGHT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
BRAKE HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
DRIVE CHAIN SLACK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
DRIVE CHAIN LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
STEERING HEAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CABLE INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 3.24
LEVER AND PEDAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
SIDESTAND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26 .
FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28 .
HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29 .
HEADLIGHT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
CHAPTER 4 .
ENGINE OVERHAUL
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 .

TRANSMISSION OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 .
COWLING AND SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 .
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ..
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 .
AUTOLUBE PUMP CABLE AND HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 .
LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
..
CLUTCH CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 .
DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ..
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 .
ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4..5

CYLINDER HEAD. CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . .4.5
CLUTCH AND PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6
KICK AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
.
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 .
CDI MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 .
TRANSMISSION. SHIFTER AND CRANKSHAFT . . . . . . . . . . . . . . . . . .4.11
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13 .

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 .
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
.
PISTON PIN AND BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16 .
rl I I T ~ U 4-17
... .
w. w . . ....
L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .".
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
.
TRANSMISSION AND SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
.
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
..
AUTOLUBE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 .
ENGINE ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 4.24 .

CRANKSHAFT. SHIFTER AND TRANSMISSION . . . . . . . . . . . . . . . . . 4.24 .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
.
CDI MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
.
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
.
KICK AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
.
CLUTCH AND PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . .4.34
CYLINDER HEAD. CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . .4.37
REMOUNTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
CHAPTER 5.
CARBURETION
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-5-1 .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6 .
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

.
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
.
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
CHAPTER 6.
CHASSIS
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 .

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10

BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11 .
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 .
MASTER CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21 .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
STEERING HEAD AND HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
lNSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.30
REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . .6.33

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
.
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-6-36
DRIVE CHAIN AND SPROCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.38

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38
.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39 .
CHAPTER 7.
ELECTRICAL
YSR50T CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

COLOR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
.
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3
IGNITION AND STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

IGNITION CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . .7.6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7..7
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16

.
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
.
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22

.
TROUBLESHOOTING (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.24
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30

.
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
DISPLAY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.42

DISPLAY SYSTEM TEST AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . .7.50
CHAPTER 8.
TROUBLESHOOTING
STARTING FAILUREIHARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8..1
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8..2
COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ..3
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3
POOR M E D I U M AND HIGH SPEED PERFORMANCE . . . . . . . . . . . . . .8.4

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..4
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8..6

.
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

.
pqm
INFO
CHANGE PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 .
JUMP-OUT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6 .
CLUTCH SLIPPINGIDRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. .7
CLUTCH SLIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..7
CLUTCH DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 .
IMPROPER KICKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 .

SLIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
.
HARD KICKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 .
KICK CRANK NOT RETURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 .
FAULTY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9

.
POOR BRAKING EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.9 .
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION . . . .8.9

OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
.
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9..
INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10

.
INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10.
FAULTY SIGNAL AND LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8.11 .

HEADLIGHT DARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
.
BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11
.
FLASHER DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11 .
FLASHER KEEPS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11
FLASHER WINKS SLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12
FLASHER WINKS QUICKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12 .
HORN IS INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12 .
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
.
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
.
YSR5OT WIRING DIAGRAM

your state.
IAL N
The engine serial num
left side sf the en
. : : -
cThe first three di ts sf these numbers are for
model identificat ns; %heremainin
duction number.
specifications are su
without notice.
IMPORTANT INFORMATION I 1-
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removing and disassembling.
2. Use proper tools and cleaning equipment.

Refer to "SPECIAL TOOL."
3. When disassembling the motorcycle, keep

mated parts together. This includes gears,
cylinders, pistons, and other mated parts that
have been "mated" through normal wear.
Mated parts must be reused as an assembly
or replaced.
4. During the motorcycle 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 rein-
stalled.
5. Keep away from fire.

IMPORTANT INFORMATION PI
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine parts
for all replacements. Use oil and/or grease
recommended by Yamaha for assembly and
adjustment.
GASKETS, OIL SEALS, AND O-RINGS

1. All gaskets, seals and O-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips and O-rings must
be cleaned.
2. Properly oil all mating parts and bearings dur-

ing reassembly. Apply grease to the oil seal
lips.
LOCK WASHERSIPLATES AND COlTER

PINS
1. All lock washers1Plates @ and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
BEARINGS AND OIL SEALS

1. Install the bearing(s1and oil seal(s) with their
manufacturer's marks or numbers facing out-
ward. (In other words, the stamped letters
must be on the side exposed to view. When
installing oil seal(s), apply a light coating of
light-weight lithium base grease to the seal
lip(s). Oil the bearings liberally when installing.
@ Oil seal
Do not use compressed air to spin the bear-

ings dry. This causes damage to the bearing
surfaces.
@ Bearing
SPEClAL TOOLS
ClRCLlPS
1-
1. All circlips should be inspected carefully be-
fore reassembly. Always replace piston pin
clips after one use. Replace distorted circlips.
When installing a circlip @, make sure that
the sharp edged corner @ is positioned op-
posite to the thrust @ it receives. See the
sectional view.
@ I
Shaft
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 improvised
techniques.
FOR TUNE UP
1. Inductive Timing Light
PIN. YM-33277
This tool is necessary for adjusting ignition timing.
2. Fuel Level Gauge

P I N . YM-01312
This gauge is used to measure the fuel level in

the float chamber.
1-4
3. Inductive Tachometer
PIN. YU-08036
This tool is needed for detecting engine rpm.
FOR ENGINE SERVICE

1. Universal Clutch Holder
PIN. YM-91042
This tool is used to hold the clutch when loosen-

ing or tightening the clutch boss locknut.
2. Universal Rotor Holder

PIN. YU-01235
This tool is used when loosening or tightening the

flywheel magneto securing bolt.
3. Flywheel Puller
PIN. YM-01189
This tool is used for removing the flywheel.
4. Piston Pin Puller

PIN. YU-01304
This tool is used to remove the piston pin.

SPECIAL TOOLS
5. Crankcase Separating Tool
PIN. YU-01135
wl
This tool is used to split the crankcases as well
as remove the crankshaft from either case.
6. Crankshaft Installing Tool . . . . . . . . . . . . . 0

PIN. YU-90050
0
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIN. YM-90063
These tools are used to install the crankshaft.
FOR CHASSIS SERVICE

1. Front Fork Seal Driver (Weight) . . . . .
PIN. YM-33963
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . .
PIN. YM-33281
This tool is used when installing the fork seal.
2. Ring Nut Wrench

PIN. YU-33975
This tool is used to loosen and tighten the steer-

ing ring nut.
1-6
SPECIAL TOOLS
FOR ELECTRICAL COMPONENTS
wlGEN
1. Coil Tester
PIN. YU-33261
This tester is necessary for checking the ignition

system components.
2. Pocket Tester
PIN. YU-03112
This tester is invaluable for checking the electri-

cal system.
GENERAL SPECIFICATIONS I / pf I
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Model Code Number:
Vehicle Identification Number:
Engine Starting Number
Dimensions:
Overall Length 1,630 mm (64.2 in)
Overall Width 635 mm (25.0 in)
Overall Height 930 mm (36.6 in)
Seat Height 660 mm (26.0 in)
Wheelbase 1,055 mm (41.5 in)
Minimum Ground Clearance 120 mm (4.7 in)
Basic Weight:
With Oil and Full Fuel Tank
Minimum Turning Radius: 2,400 mm (94.5 in)
Engine:
Engine Type Air cooled 2-stroke
Induction System Reed valve
Cylinder Arrangement Forward inclined single cylinder
Displacement 49.3 cm3
Bore x Stroke 40.0 x 39.2 mm (1.57 x 1.54 in)
Compression Ratio 7.4 : 1
Starting System Kick starter
Lubrication System:
TYpe Separate lubrication (Yamaha Autolube)
Engine Oil Type Yamalube " 2 or air cooled 2 stroke engine oil with
"BIA certified for service TC-W"
Transmission Oil Type Yamalube " 4 , SAE 10W30 type SE motor oil or
"GL" gear oil
Oil Capacity:
Engine Oil (Oil Tank) 0.73 L (0.64 Imp qt, 0.77 US qt)
Transmission Oil:
Periodic Oil Change 0.60 L (0.53 Imp qt, 0.63 US qt)
Total Amount 0.65 L (0.57 Imp qt, 0.69 US qt)
Air Filter
Type Wet type element
GENERAL SPECIFICATIONS I SPEC / pf I
Model
Fuel:
TYpe Regular gasoline
Fuel Tank Capacit I
Full Amount 8.0 L (1.76 Imp gal, 2.1 1 US gal)
Reserve Amount 1.5 L (0.33 Imp gal, 0.39 US gal)
Carburetor:
Type/ Quantity VM16SH/1 pc.
Manufacturer MIKUNI
Spark Plug:
TypeIQuantity B7HS or B8HS
Manufacturer NGK
Plug Gap - -
0.5 0.6 mm (0.020 0.024 in)
Clutch:
Type Wet, multiple disc
Transmission:
TYpe Constant mesh 5-speed
Primary Reduction System Helical gear
Primary Reduction Ratio 68/19 (3.579)
Secondary Reduction System Chain drive
Secondary Reduction Ratio 44/12 (3.667)
Operation Left foot operation
Gear Ratio
1st
2nd
3rd
4th
5th
Chassis:
Frame Type Double cradle
Caster Angle 25.3'
Trail 64 mm (2.52 in)
Tire:
TYpe Tubeless
Size
Front 3.50-12 2PR
Rear 4.00-12 2PR
Tire Pressure (Cold Tire):
Basic Weight:
With Oil and Full Fuel Tank
Maximum Load*
Cold Tire Pressure: FRONT
Zero - Maximum Load*
* Load is total weight of cargo, rider, and accessories.
2-2
GENERAL SPECIFICATIONS 1-
Model
Brake:
Front Brake Type Single disc brake
Front Brake Operation Right hand operation
Rear Brake Type Drum brake
Rear Brake Operation Right foot operation
Suspension:
Front Suspension Type Telescopic fork
Rear Suspension Type Swingarm (Monocross suspension)
Shock Absorber:
Front Shock Absorber Coil springloil damper
Rear Shock Absorber Coil springloil damper
Wheel Travel:
Front Wheel Travel 90 mm (3.5 in)
Rear Wheel Travel 75 mm (3.0 in)
Electrical:
Ignition System CDI Magneto
Generator System Flywheel magneto
Battery:
Type
Capacity
Headlight:
TYpe Sealed beem
Bulb Wattage (Quantity):
Headlight
TailIBrake Light
Flasher Light
Licence Light
Meter Light
"NEUTRAL" lndicator Light
"HIGH BEAM" lndicator Light
"TURN" lndicator Light
"OIL" Warning lndicator Light
(Light Emitting Diode)
MAINTENANCE SPECIFICATIONS I SPEC 1 p9 I
MAINTENANCE SPECIFICATIONS
ENGINE
Model
Cylinder Head: *
Warpage Limit 0.02 mm (0.001 in)
"Lines indicate straightedge measurement.
Cylinder:
Bore Size 40.00-40.02 mm (1.575- 1.576 in)
Taper Limit 0.05 mm (0.002 in)
Out of Round Limit 0.01 mm (0.0004 in)
Piston:
Piston Size "D" 39.96-39.98 mm (1.573- 1.574 in)
Measuring Point "a" 5 mm (0.20 in)
Piston Off-Set 0.2 mm (0.008 in)

Piston-to-Cylinder Clearance - -
0.030 0.035 mm (0.0012 0.0014 in)
< Limit > < 0.1 mm (0.004 in) >
Oversize 1st 40.25 mm (1.58 in)
Oversize 2nd 40.50 mm (1.59 in)
Piston Ring:
Sectional Sketch Top Ring Keystone type
B = 1.2 mm (0.047 in)
T = 1.6 mm (0.063 in)
End Gap (Installed)

OTg
L T ~
Top Ring
Plain type
B = 1.2 mm (0.047 in)
T = 1.6 mm (0.063 in)
-
0.15 0.35 mm -
(0.006 0.014 in)
2nd Ring 0.15-0.35 mm (0.006-0.014 in)
Side Clearance Top Ring 0.03-0.05 mm (0.001 -0.002 in)
2nd Ring 0.03-0.05 mm (0.001 -0.002 in)
MAINTENANCE SPECIFICATIONS I SPEC 1 pp I
Model
Crankshaft:
Crank Width "A" 37.90-37.95 mm (1.492- 1.494 in)
Runout Limit "B" 0.03 mm (0.0012 in)
Big End Side Clearance "C" -
0.2- 0.7 mm (0.008 0.028 in)
< Limit > < 1.0 mm (0.04 in) >
Small End Free Play "D" 0.8- 1.0 mm (0.032-0.039 in)
< Limit >
- D
< 1.5 mm (0.06 in) >
Clutch:
Friction Plate:
Thickness 3.5 mm (0.138 in)
Quantity 2 pcs.
Wear Limit 2.7 mm (0.106 in)
Clutch Plate:
Thickness 2.0 mm (0.079 in)
Quantity 1 PC.
Warpage Limit 0.05 mm (0.002 in)
Clutch Spring:
Free Length 28.2 mm (1.11 in)
Quantity 4 pcs.
Minimum Free Length 26.2 mm (1.03 in)
Clutch Release Method Inner push, cam push
< Push Rod Bending Limit > 2 (0.008 in) >
~ 0 . mm
Transmission:
Main Axle Runout Limit 0.08 mm (0.003 in)
Drive Axle Runout Limit 0.08 mm (0.003 in)
-
Shifter:
TYpe Cam drum and guide bar
Guide Bar Bending Limit 0.025 mm (0.001 in)
Kick Starter:
TYpe Kick and Mesh type
MAINTENANCE SPECIFICATIONS 1-
Model
Air Filter:
Oil Grade Foam-Air-Filter oil or Yamalube "2"
Carburetor:
I.D. Mark 2AL 01
Main Jet # 120
Air Jet 42.5
Jet Needle-Position 3621-4
Needle Jet E-0
Cutaway 2.0
Pilot Outlet 40.9
Pilot Jet # 17.5
Air Screw 1-118
Valve Seat Size 41.5
Starter Jet # 20
Fuel Level 0 - 1 mm (0- 0.04 in)
Float Height -
21 -23 mm (0.83 0.91 in)
Idling Speed -
1,300 1,400 rlmin
Reed Valve:
Valve Thickness 0.15 mm (0.006 in)
Valve Stopper Height 6.7-7.3 mm (0.26- 0.29 in)
Valve Bending Limit 0.3 mm (0.012 in)
Lubrication System:
Autolube Pump
Color Code Green
Minimum Stroke - -
0.20 0.25 mm (0.008 0.010 in)
Maximum Stroke 1.85-2.05 mm (0.073-0.081 in)
Minimum Output 0.50-0.63 cm3 per 200 strokes
Maximum Output -
4.64 5.15 cm3 per 200 strokes
Pulley Adjusting Mark A t idle
MAINTENANCE SPECIFICATIONS I / p9 I
SPEC
TIGHTENING TORQUE
BoltINut Tightening torque

Part to be tightened
size
Spark plug
Cylinder head
Autolube pump
Intake manifold
Muffler (Front)
Muffler (Rear)
Crankcase
Crankcase cover
Transmission oil drain bolt
Autolube pump cover
Kick crank assembly
Primary drive gear
Clutch boss
Pressure plate
Stopper plate (Bearing)
Stopper plate (Shift cam)
Shift lever adjuster nut
Change pedal
Stator
CDI magneto
Neutral switch
MAINTENANCE SPECIFICATIONS pi+q
CHASSIS
Model
Steering System:
Bearing Type Ball Bearing
Bearing Size (Quantity)
Upper
Lower
Front Suspension:
Front Fork Travel 90 mm (3.54 in)
Fork Spring Free Length (Left side only) 374.2 mm (14.7 in)
< Limit > <367 mm (14.4 in) >
Spring Rate (K1) 8.2 N l m m (0.83 kglmm, 46.6 Iblin)
Stroke (KI) 0.0-90.0 mm (0.0 -3.5 in)
Optional Spring No.
LEFT RIGHT
Oil Capacity 126 cm3 (4.44 Imp oz, 164 cm3 (5.77 Imp oz,
4.26 US oz) 5.54 US oz)
Oil Level 146 mm (5.74 in) 51 mm (2.01 in)
From top of inner tube From top of inner tub(
fully compressed without compressed without
spring. spring.
Oil Grade Yamaha fork oil 10WT or t
equivalent
3ear Suspension:
Shock Absorber Travel 18.0 mm (0.71 in)
Spring Free Length 86 mm (3.4 in)
Fitting Length 82 mm (3.2 in)
Spring Rate (K1) 353 Nlmm (36 kglmm, 2,020 Iblin)
Stroke (K1) 0.0- 18 mm (0.0-0.71 in)
Optional Spring No.
Swingarm:
Free Play Limit (Swingarm end) 1.0 mm (0.039 in)
Move swingarm end side to side
Front Wheel:
TYpe Panel wheel
Rim Size MT2.50 x 12
Rim Material Steel
Rim Runout Limit
Vertical 2.0 mm (0.08 in)
Lateral 2.0 mm (0.08 in)
MAINTENANCE SPECIFICATIONS pqi$q
I Model
Rear Wheel:
Type Panel wheel
Rim Size MT2.50 x 12
Rim Material Steel
Rim Runout Limit
Vertical 2.0 mm (0.08 in)
Lateral 2.0 mm (0.08 in)
Drive Chain:
Type! Manufacturer 420M/ DAIDO
Number of Links 99 Links +joint
Chain Free Play 25-30 mm (1.0- 1.2 in)
Front Disc Brake:
TYpe Single
Disc Outside Diameter 203 mm (8.00 in)
Disc Thickness 4.0 mm (0.16 in)
Pad Thickness 6.0 mm (0.24 in)
<Wear Limit > < 0.5 mm (0.02 in) >
Master Cylinder lnside Diameter 11.O mm (0.433 in)
Caliper Cylinder lnside Diameter 34.9 mm (1.37 in)
Brake Fluid Type DOT No. 3
Rear Drum Brake:
TYpe Leading, Trailing
Brake Drum lnside Diameter 110 mm (4.33 in)
< Limit > < 111 mm (4.37 in) >
Shoe Spring Free Length 50.5 mm (1.99 in)
Lining Thickness 4 mm (0.16 in)
< Limit > <2 mm (0.08 in)>
Brake Lever and Brake Pedal:
Brake Lever Free Play 2-5 mm (0.08-0.20 in)
Brake Pedal Free Play 20-30 mm (0.8-1.2 in)
Below top of footrest
Clutch Lever Free Play 2-3 mm (0.08-0.12 in)

Throttle Cable Free Play 3-7 mm (0.12-0.28 in)
At grip flange
MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUE
Tightening torque
Part to be tightened BoltlNut size
ft-lb
Chassis:
Engine mounting;
Engine stay
Frame and engine
Pivot shaft and nut
Rear shock absorber and frame
Front fork cap bolt (Handlebar)
Under bracket and inner tube
Steering ring nut
Refer to NOTE
Steering stem bolt
Wheel hub and wheel rim
Front brake disc and wheel hub
Brake caliper and outer tube
Front wheel axle and nut
Brake cam lever and camshaft
Rear wheel sprocket and wheel hub
Tension bar and platelframe
Rear wheel axle and nut
Rear view mirror and stay
Brake hose union bolt
Footrest and frame
Cowling stay and frame
Windscreen and cowling
CDI unit and frame
Rectifier1Regulator
Down tube and frame
Engine bracket (Front) and frame
Engine bracket (Rear) and frame
NOTE:
1. First, tighten the ring nut approximately 30 Nm (3.0 m-kg, 22 ft-lb) by using the torque wrench,
then loosen the ring nut one turn.
2. Retighten the ring nut to specification.
ELECTRICAL
Model
- - - -
Voltage:
Ignition System:
Ignition Timing (B.T. D.C.) 22O at 5,000 r l m i n
Advancer Type Electrical type
0 1 2 3 4
Engine
C.D.I.:
Magneto ModelIManufacturer 2RRlYAMAHA
C. D.I. Unit Model/ Manufacturer 2GXlYAMAHA
Pickup Coil Resistance (Color) 16-240 at 20°C (68OF)
(WhiteIRed- Black)
Source Coil Resistance (Color) 264- 396fl at 20°C (68OF)
(Black/ Red - Black)
Ignition Coil:
ModelIManufacturer 2JNlYAMAHA
Minimum Spark Gap 6 mm (0.24 in)
Primary Coil Resistance 0.7- 1.1Q at 20°C (68OF)
Secondary Coil Resistance 5.7-8.5kQ at 20°C (68OF)
Spark Plug Cap:
TYpe Resin Type
Plug Cap Resistance 4-6kQ at 20°C (68OF)
Model Y S R50T
-
Charging System: I Flywheel Magneto

C.D.I. Magneto:
ModelIManufacturer 2RRlYAMAHA
Charging Coil Resistance (Color) 0.24-0.36Q at 20°C (68OF) (White- Black)
Standard Output 7.4-8.2V at 5,000 rlmin
Engine Speed ( x 1,000 rlmin)
Lighting Coil Resistance (Color) 0.16-0.24Q at 20°C (68OF) (YellowIRed- Black)

Standard Output 6.2-7.2V at 3,000 rlmin or more
I Voltage Regulator:
ModelIManufacturer
Rectifier:
ModelIManufacturer
Capacity
Withstand Voltage
Battery:
Specific Gravity
Horn:
TYpe Plane Type
Quantity 1 PC.
Model1Manufacturer GF-12lNIKKO
Maximum Amperage 1.5A
MAINTENANCE SPECIFICATIONS I SPEC I p? I
Model
Flasher Relay:
Type Condenser Type
ModelIManufacturer FZ636SDlNIPPON DENS0
Self Cancelling Device No
Flasher Frequency -
75 95 cycles1min
Wattage +
17W x 2 3W (6V)
Oil Level Switch:
ModelIManufacturer
Curcuit Breaker:
Type Fuse
Curcuit (Fuse):
"MAIN"
GENERAL TORQUE SPECIFICATIONS1
DEFINITION OF UNITS
GENERAL TORQUE
SPECIFICATIONS
This chart specifies torque for standard fasteners General torque
with standard I.S.O. pitch threads. Torque specifi- A B specifications
cations for special components or assemblies are
included in the applicable sections of this book.
(Nut) (Bolt)
Nm 1 m-kg / ft-lb ,
To avoid warpage, tighten multi-fastener assem-
blies in a crisscross fashion, in progressive stages,
until full torque is reached. Unless otherwise
specified, torque specifications call for clean, dry
threads. Components should be at room tem-
perature.
I
A: Distance across flats
B: Outside thread diameter
DEFINITION OF UNITS
Unit Read Definition Measure

mm millimeter meter Length
cm centimeter meter Length
kg kilogram lo3 gram Weight
N Newton 1 kg x m /sec2 Force
Nm Newton meter Nxm Torque
m-kg Meter kilogram m x kg Torque
Pa Pascal ~ / m ~ Pressure
N/mm Newton per millimeter N/mm Spring rate
L Liter -
cm3 Cubic centimeter Volume or capacity
rlmin Rotation per minute - Engine speed
LUBRlCATlON POINTS AND LUBRICANT TYPE I SPEC 1 p f I
LUBRICATION POINTS AND LUBRICANT TYPE
ENGINE
I Lubrication Points (Part name) Lubricant Type

I Oil seal lip I --.~SI
O-ring -=a&
I Small end1Big end bearing
Bearing -IQ
Piston ring -IQ
I Piston
Cylinder inner surface
Piston pin
I Kick axle
Primary drivenldrive gear -+a
I
Push rod
Push lever
A=
PinionIWheel gears -4
Collar (Drive axle) -la
I Guide bar (Shift fork)
Shift shaft -la
Shift cam -a
CHASSIS
Lubrication Points (Part name) 1 Lubricant Type I

Steering UpperlLower balls 1 A = I
FrontIRear wheel oil seal lip - 5
Brake cam shaft - =
Speedometer gear unitloil seal -?as4
Brake pedal pivot 1 -+a I
Rear shock absorber collar -a
Handlebar (Right) end - =
Sidestand pivot -la
Footrest pivot -IQ

Clutch lever pivotlcable end -IQ
Brake lever pivot -4

Pin (Rear shock absorber) - =
Pivot shaft --=&
2-15
CABLE ROUTING I SPEC / p9 I
CABLE ROUTING
a Handlebar switch (Right) lead
@ Main switch lead
@ Clutch cable
@ Handlebar switch (Left) lead
@ Clamp
@ Throttle cable
a Front brake hose
CABLE ROUTING I SPEC I p9 I
CABLE ROUTING
@ Headlight lead Pass the speedometer cable through the cable
@ Spark plug lead holder.
@ Clutch cable
@ Horn lead
@ Sidestand switch lead
@ Band
a Cable holder
@ Speedometer cable
@ Meter light lead
CABLE ROUTING I SPEC 1 pp 1
CABLE ROUTING
Front brake hose @ Carburetor breather hose Clamp the brake hose.
Clamp @ Carburetor air vent hose 1Si] Pass thebattery breather hose through the
Cable guide 0 CDl magneto lead hole o n the rear fender.
Oil hose @ Battery breather hose
@ Oil pump cable @ Rear brake switch lead
@ Oil delivery hose @ Band
@ Fuel tank breather hose @ Taillbrake light lead
@ Wireharness
CABLE ROUTING 1-
CABLE ROUTING
a Clamp @ Wireharness Pass the oil tank breather hose through the
a Band
@ Throttle cable
@ Clutch cable
0 Sidestand switch lead
hole o n the frame.
IB] Pass the main switch and brake switch lead in-
@ Front brake hose @ Handlebar switch (Left) lead side of the oil tank cap
@ Brake switch lead @ Spark plug lead Pass the sidestand lead above the Y.E.I.S.
@ RectifierIRegulator @ Ignition coil hose.
a Main switch lead @ Oil tank breather hose
@ Oil level switch
CABLE ROUTING 1-
CABLE ROUTING
@ Band Pass the wireharness, flasher light lead and
@ Cable guide battery breather hose through the guide.
@ Rear flasher light (Right) lead CB] Pass the flasher light lead through the guide.
@ Taillight lead
@ Rear flasher light (Left) lead
@ Battery negative ( - ) lead
a Battery positive
@ Battery
( +) lead
@ Flasher relay
@ CDI unit
lNTRODUCTlONlPERlODlC MAINTENANCE1
LUBRICATION INTERVALS 1 lNSP
I
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary t o 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.
PERIODIC MAINTENANCEILUBRICATION INTERVALS Unit: km (mi)
I ITEM
1
REMARKS
BREAK-IN
1,000 (600)
7 EVERY
(2,000) or
6,000
(4,000) or
1 6 months 1 12 months
I Spark plug(s)
Check condition. Clean or replace if
necessarv.
I Air filter" Clean. Replace if necessary.
Check idle speedlstarter operation.
Carburetor*
Adjust if necessary.
Check fuel hose for cracks or damage.
Fuel line*
Replace if necessary.
Check oil levelloil leakage.
Correct if necessary.
Replace every 12,000 (8,000) or 24 months
REPLACE 0 0
(Warm engine before draining.
Check operation. Correct if necessary.
Air bleeding.
Check operation/fluid IeakageISee NOTE.
Brake* Correct if necessary (front).
Check operation. Adjust if necessary (rear).
Check operation. Adiust if necessarv.
Check balanceldamagelrunout.
Wheels*
Repair if necessary.
I Wheel bearings*
Check bearings assembly for looseness/
damage. Replace if damaged.
Check bearings assembly for looseness.
Steering bearing*
Moderately repack every 24,000 (16,000)
or 24 months.**
Check operationloil leakage.
Front forks*
Repair if necessary.
Check operationloil leakage.
absorber* Repair if necessary.
Check chain slacklalignment.
Drive chain EVERY 500 (300)
Adjust if necessary. Clean and lube.
Check all chassis fittings and fasteners.
Fittings1Fasteners*
Check operation. Repair if necessary.
I Sidestand switch*
Check operation.
Clean or replace if necessary.
Check specific gravity.
Battery* Check breather pipe for proper operation.
*: It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
**: Medium weight wheel bearing grease. (bearing type) 3-1
INTRODUCTION/PERIODIC MAINTENANCE1
LUBRICATION INTERVALS
NOTE:
Brake system:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add the fluid as required.
2. W e recommend that, on the inner parts of the master cylinder and caliper cylinder, replace the
oil seals every t w o years.
3. W e recommend that, replace the brake hoses every four years, or if cracked or damaged.
"Front seat @
@Sidecover @
everse removal ste
a and warm it up.
@Engineidle speed
ut of specification* Adjust.
@Engineidle speed
p screw in or out un-

. Install:
efore adjusting throttle ca le free play, engine

idle speed should be adjusted.
1. Check:
@Throttlecable free play @
2. Adjust:
@Turnthe adjuster or out until the cor-
tle cable free pl
1. Remove:
Lower cowling
e pump cover a
Check:
~Aiignmenimark
r out until the ali
9Tighten the locknut.

P pP , .. -
5. Install:
autol lube pum
@Lowercowling
tart the engine and warm it up.
the engine at idle

g plate carefully.
gine the moment that the adjus
moves out to its limit.
5. Measure:
ut of speci3icatioi~-~Adjus-t~
Measure ?he gap with the Thickness gauge
between the raised boss @ on the pump
-
adjusting pulley an the adjusting plate a.
@Autolubepump minimum stroke
stroke is increase
@Installthe adjustin
locknut.
7. Install:
. Air bleed:
appear.
@ W h e nair bubbles are expelled completely,
tighten the bleed screw.
damaged, replace w i t h a n e w one.

4. Air bleed:
ump distributor andlor delivery hose
: - -- 4
It is difficult to bleed the distri

urnp stroke a t a rn
maximum.
5. Install:
Q Lower cowlin
PA
'1. Remove:
4. Inspect:
@Electrode
@Insulator a
Abnormal coIor-9
orrnal color is a medium-$0-light tan color.
5. Clean the spark
er or wire brus
. Measure:
auge or Feeler Gau

u t sf specification-. Wegap.
7. Tighten:
efore installing a s ark plug, clean the

gasket and plug surfaces.
OTE: -...- ,-- -

-.-
- - --
Finger-tighten the spark d u g ( ~befcwe
) rorquing
t o specifics cisn.
N TBMINNG CHECK
Adjustment free.
E Olk LEVEL CHECK

1. Check:
@Oillevel
31 level low-+Add sufficient oil.
il Tank Capacity:
"OIL" warning indicator light
A
1. Place the motorcycle on a level surface and
warm up the engine for several minutes.
2. Stop the engine and remove the oil filler cap.
false readings.
4. Inspect:
il level should b
A
he engine for several minutes an
stop the engine.
2. Place an oil pan under the engine.
rain the engine oil.

. Install:
. Fill:
7. Install:
@ Loosen the locknuts @.

adjusters @ in or out until the
free play is obtained.
5- 14
ten the locknuts.
~Clutcchpush lever free play
tighten the locknut while hoiding the ad-

juster.
5. Install:
@Flywheelmagneto cover
"Lower cowling
6. Adjust:
@Clutchcable free play
efer to "Free play adjustment" section.
@ Front seat
2. Turn the fuel cock to "
"Fenel tank @
4. Remove:
ir filter cover @
ever operate t h e en ine with the air filter

element removed. This will a l i s w unfiltered
air t o enter, causin id wear and possi-
withaut the filter will affect cavbu-

uewt poor perfor-
ne overheating.
Clean:
@Airfilter element
nt gently, but thoroughly in

solvent.
@Squeezethe excess solvent out of the element
and let dry.
r-filter oil or Vamalu

to the element.
out the excess oil.
; ;
The element should be wet ut not dripping.
@Airfilter case cover
4 '1. Install:
@Fueltank
Front seat
cSide cover
2. Inspect:
@Carburetorjoint @
"Lower cowl
"Lower cowl
@bowercowling
. Install:
@ l o w e rcowling
1. Check:
rake lever free play @
ut of specification+lnspect the brake
section.
REA ENT
1 . Check:
edal free play @
Out of specification-AcdjuS
Adjustment st8 I
@Turnthe adjuste in or out until the spsci-
fied free play is obtained.
i
BRAKE FLUID !
1. Make sure the r top is horimontaal
by turning the handlebars.
2. 1nspecr:
oBrake fluid level
Fluid lwei is under "L WER" level line
a+~eplenisk.
Recornmewdad Brake FBui I
rake fluid may erode painted surfaces or

pRasPie parts. AGway
- - - -
INSPECTIOPJ
1. Activate the brake lever,
2. Inspect:
r @ almost contacts brake
2. Inspect:
ar indicator @
cator at wear limit line
brake shoes.
AICE LIGHT SbVITCH ADJUSTMENT

TE: - -- -
The brake light switch is operated by movemenu
of the brake pe
Proper adjustment is achieved when the bralee
light comes on just before the brake begins to take
effect.
e switch body a with your &an

that it does not rotate and turn the adjusting
nut Q.
1. Inspect:
rack/ Damage/ Fluid lea

andlor adjust the chain slack with the rear wheel
in this "tightest"
I . Check:
rive chain slack @
ut of specification-tAdjcest.
slack is obtained
alignment.)
eTighten the nut ( ear wheel axle)
@Inserta new cotter pin.
center rollers.
2. To clean the chain, remove 'he
machine, dip it in solvent, an
9. Remove:
bower cowling
2. Elevate the front wheel by placing a suitable

under the engine.
3-21
3. Check:
Grasp t h e bottom o$ the forks and gently

rock the fork assembly back and forth.
seness-Adjust steerin
oRstighten "re ring nut using the Ring Nclr
r Avoid over-tightening.
--
- - - - , -- , , .,
5. Install:
Lower cowling
TlRE INSPECTION ml INSP I
TlRE INSPECTION
Do not attempt t o use tubeless tires on a

wheel designed for tube type tires only. Tire
failure and personal injury may result from
sudden deflation.
I wheel I Tire I
I Tube type 1 Tube type only I
I Tubeless ( Tube type or tubeless I
Be sure t o install the correct tube when us-
ing tube type tires.
1. Measure:
*Tire pressure
Out of specification-+Adjust.
Tire inflation pressure should be checked and

adjusted when the temperature of the tire
equals the ambient air temperature. Tire in-
flation pressure must be adjusted according
t o total weight of cargo, rider, passenger,
and accessories (fairing, saddlebags, etc. if
approved for this model), and vehicle speed.
Basic weight:
With oil and full
fuel tank
I Maximum load* / 68 k g (150 Ib) I
I Cold tire Dressure I Front / Rear I
Zero - Maximum
load*
1 130 kPa 150 kPa
(1.3 kg/cm2, (1.5 kg/cm2,
18 psi1 21 psi)
*Load is the total w e i g h t o f cargo, rider, and
I
accessories.
2. Inspect:
*Tire surfaces
Wear/ Damage-+Replace.
Minimum Tire Tread Depth:

(Front and Rear)
@ Tread depth
a Side wall
@ Wear indicator
WHEEL INSPECTIONICABLE INSPECTION AND lNSP
LUBRICATION
ADJ
WHEEL INSPECTION
1. Inspect:
Wheels
Damage/ Bends* Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
Never attempt even small repairs t o the

wheel.
2. Tighten:
*Valve stem locknut
Ride conservatively after installing a tire t o

allow it t o seat itself properly on the rim.
CABLE INSPECTION AND LUBRICATION
Damaged cable sheath may cause corrosion

and interfere w i t h the cable movement. A n
unsafe condition may result so replace such
cable as soon as possible.
1. Inspect:
*Cable sheath
Damaged Replace.
CABLE INSPECTION AND LUBRICATIONILEVER AND
PEDAL LUBRICATIONISIDESTAND LUBRICATION
2. Check:
@Cableoperation
Unsmooth operation* Lubricate.
Recommended Lubricant:
Yamaha Chain and Cable Lube
or SAE 10W30 Motor Oil
NOTE:
Hold cable end high and apply several drops of
lubricant to cable.
LEVER AND PEDAL LUBRICATION

Lubricate pivoting parts of each lever and pedal.
SIDESTAND LUBRICATION
Lubricate the sidestand at pivot points.
1. Remove:
@Frontseat
@Sidecover
Refer t o "'SIDE COVER" section
2. Inspect:
Fluid level should be between upper aand
lower @ level marks.
Incorrect-. Refill.
3. Inspect:
@Batteryterminal
Dirty terminal-Clean with wire brush,
Poor connection+Correct.
--:
After cleaning the terminals, apply grease lightly
t o the terminals.
--------
4. Connect:
@Breatherhose
Be sure the hose is properly attached and
routed.
@ Pass the breather hose into the clamp.
5. Inspect:
@Breatherhose
Obstruction-+ Remove.
Damage-+Replace.
6. Check:
@Specificgravity
Less than 11.280-.Recharge battery.
Replace the battery if:
Battery voltage will not rise to a specific value
or bubbles fail to rise even after many hours
of charging.
*Sulfation of one or more cells occurs, as in-
dicated by the plates turning white, or an ac-
cumulation of material exists in the bottom
of the cell.
*Specific gravity readings after a long, slow
charge indicate one cell to be lower than the
rest.
*Warpage or buckling of plates or insulators
is evident.
Always charge a new battery before using

it t o ensure maximum performance.
Battery electrolyte is dangerous; it contains

sulfuric acid and therefore is poisonous and
highly caustic.
Always follow these preventive measures:
*Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
*Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):
*SKIN- Flush w i t h water.
*EYES-Flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):
*Drink large quantities of water of milk. Fol-
low with milk of magnesia, beaten egg, or
vegetable oil. Get immediate medical at-
tention.
Batteries also generate explosive hydrogen
gas, therefore you should always follow
these preventive measures:
*Charge batteries in a well-ventilated area.
*Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
inspection steps:
@Connectthe Pocket Tester to the fuse and
check it for continuity.
-
Set the tester selector to "Q x 1" position.
elf the tester is indicated at a.The fuse is

blown, replace it.
4. Replace:
@Blownfuse
@Turnoff ignition and the circuit.

elnstall a new fuse of proper amperage.
@Iffuse blows immediately again, check circuit
3-28
'I. Adjust:
@Headlightbeam (Vertical)
2. Adjust
@Headlightbeam (Horizontal)
@Lowercowling
*Flasher lights (Left and right)
sflasher light stay
Refer t o "COWLINGS" section.
2. Remove:
@Headlight@
3
Install:
@Headlight(New)
Install:
@Flasherlight stay
@Flasherlights (Left and right)
@Lowercowling
Adjust:
@Headlightbeam
Refer to "HEADLIGHT BEAM ADJUST-
MENT" section.
@Autolubepump
@Transmissionoil
section.
@Frontseat
section.
'1. Turn the fuel cock to " FF" position and dis-
connect the fuel hose @.
2. Remove:
@Fueltank
VAL
@Autolubepump cover @
@Autolubepump cable
@Oilhose a
Plug the oil hose end with a suitable screw.
eNecatral switch leads
crankcase cover (Left) a

oGasket (Crankcase cover - Left)
RBVE cwim
Loosen:
adjuster @
2. Push forward t e rear wheel to loosen the
drive chain.
. Place a suitable stand under the engine.
QLower cowlin
0Muffler
2. Remove:
~ G a s k e ?(Cylinder head) @
cylinder @ J
gasket (Cylinder)
~ I n t a k ernanifoid @
--
pin circlip, cover crank-
ing into crankcase cavity.

out.
CLUTCH AND P R I M A R Y
TE: - --
Bower cowl
2 , IYsi-xve:
-
8 Boles (Pressure plate) .
:,
^Springs (Pressure plats)
4. Remove:
Use the Universal Clutch Holder

the clutch boss.
imary drive gear) @
lace a folded rag a between the teeth of the

primary drive gear and driven gear.
m
mounted, the kick axle and kick

maintained by removing the fol-
[owing parts.
cable and hoses
1. Unhook the sprin
@Kickaxle assembly a
NOTE: -..-- - -.
With the engine mounted, the CDB ma
be mainlained by removing the fcallo
Lower covviiiyj
- ---
1. Remove:
Rotor Holder a t o hold

Use the Flywheel Puller a to remove the
rotor.
hift cam stopper)
ttern, loosen all screws

them after all are
loosened.
NOTE: -- - P
hten the tool holdin bolts, but make

sure the fool body is parallel with the ease, Ef
one screw may be backed out slightly
"14s pressure is a plied, alternately tap on the

front engine mounting boss, transmission shafts,
and shift cam.
Use soft hammer to t a p on the case half. Tap

only on asinforced ortiona of case. Do not
t a p sn gasket m a t i g surface. Wdwk s!owOy
a;qd carsffuiiy. M a k e sure the ease h a h e s
separate evenly. If one wad "'hangs up," take
pressure of8 t h e p u s h screw, realign, a n d
start over. BB t h e eases do n o t separate,
check For a remaisping case screw ~ t fitting.
.
Do not force.
- -- -
= - ---
TRANSMQSSBObJ,SHiFTER AND
Remove the transmission assern

INSPECTION AND REPAIR I ENG /~o)(
INSPECTION AND REPAIR
CYLINDER HEAD
1. Eliminate:
.Carbon deposits
Use a rounded scraper.
NOTE:
Take care to avoid damaging the spark plug
threads. Do not use a sharp instrument. Avoid
scratching the aluminum.
- -- - - - -
2. Measure:
.Cylinder tiead warpage
Out of specification-+Resurface.
Warpage Limit:
0.02 m m (0.001 in)
Warpage measurement and resurface-

ment steps:
.Attach a straight edge @ and a thickness
gauge @ on the cylinder head.
.Measure the warpage.
.If the warpage is out of specification, resur-
face the cylinder head.
-
P l a c e a 400 600 grit wet sandpaper on the
surface plate, and resurface the head using
a figure-eight sanding pattern.
NOTE:
Rotate the head several times to avoid remov-
ing too much material from one side.
CYLINDER A N D PISTON
1. Eliminate:
.Carbon deposits
From the piston crown and ring grooves.
2. Eliminate:
.Score marks and lacquer deposits
From the sides of piston.
Use a 600-800 grit wet sandpaper.
NOTE:
Sand in a crisscross pattern. Do not sand exces-
sively.
3. Inspect:
.Piston wall
4. Remove:
1-
.Carbon deposits
Use a rounded scraper.
5. Measure:
*Piston-to-cylinder clearance
Piston-to-cylinder clearance measurement

steps:
First Step:
Measure the cylinder bore "C" with a Cylinder
Bore Gauge.
NOTE:
Measure the cylinder bore "C" in parallel to and
a t right angles to the crankshaft. Then, find the
average of the measurements.
Standard Wear Limit
"C"
TaperJ1T" 1 - / 0.05 mm
10.0019 in)
)ut of Round
"R" 1 - 1 0.01 mm
10.0004 in1
C = Maximum D
T = (Maximum Dl, or D2)-
(Maximum Ds or D6)
R = (Maximum Dl, D3 or D5)-
(Minimum Dz D4 or D6)
.If out of specification, rebore or replace

cylinder, and replace piston and piston rings
as a set.
Second Step:
@Measurethe piston skirt diameter "P" with
a micrometer.
a 5 mm (0.20 in) from the piston bottom
edge.
INSPECTION AND REPAIR I ENG I \ j (
fz "
Standard
Piston size P
39.96-39.98 mm
-
(1.573 1.574 in)
Oversize 1 40.25 mm (1.58 in)
Oversize 2 40.50 mm (1.59 in)
*If out of specification, replace piston and
piston rings as a set.
Third Step:
*Calculate the piston-to-cylinder clearance with
following formula:
- - -
Piston-to-cylinder Clearance =
Cylinder Bore "C" -
Piston Skirt Diameter "P"
*If out of specification, rebore or replace

cylinder, and replace piston and piston rings
as a set.
Piston-to-cylinder Clearance:
-
(0.0012 0.0014 in)
Limit: 0.1 m m (0.004 in)
PISTON RINGS
1. Measure:
*Side clearance
Out of specification+Replace piston and/or
rings.
Use a Feeler Gauge @.
0.03-0.05 mm
Clearance 0.03-0.05 mm
-
(0.001 0.002 in)
INSPECTION AND REPAIR I ENG 1 a-1
2. Install:
*Piston ring
lnto the cylinder.
Push the ring with the piston crown.
3. Measure:
*End gap
Out of specification-+Replace rings as a set.
1 :l 1 I
Use a Feeler Gauge.
1
4 End Gap
0.15-0.35 mm
(0.006-0.014 in1
0.15-0.35 mrn
(0.006-0.014 in)
Oversize Piston Ring

Oversize 1
Oversize 2
PISTON PIN A N D BEARING

1. Lubricate:
*Piston pin (Lightly)
2. Install:
.Small end bearing
*Piston pin
lnto the small end of connecting rod.
3. Check:
*Free play
There should be no noticeable free play.
Free play exists+lnspect the connecting rod
for wear1Replace the pin and/or connect-
ing rod as required.
4. Install:
@Pistonpin
lnto the piston pin hole.
INSPECTION AND REPAIR ( ENG 1 \ j l
5. Check:
.Free play (when the piston pin is in place in
the piston)
There should be no noticeable free play.
Free play exists-+ Replace piston pin and/or
piston.
6. Inspect:
.Piston pin and bearing
Signs of heat discoloration-+Replace.
CLUTCH
1. Inspect:
.Friction plate
Damage/Wear-+Replace friction plate as a
set.
2. Measure:
.Friction plate thickness
Out of specification-+Replace friction plate
as a set.
Measure at all four points.
'C( Wear Limit: 2.7 mm (0.106 in)
3. Inspect:
.Clutch plate
Damage+Replace clutch plate as a set.
4. Measure:
.Clutch plate warpage
Out of specification+Replace clutch plate
as a set.
Use a surface plate and Feeler Gauge a.
Warp Limit: 0.05 mm (0.002 in)
5. Inspect:
.Clutch damper
Wear/ Damage-+Replace.
INSPECTION AND REPAIR [ ENG 1
6. Measure:
*Clutch spring free length @
Out of specification+Replace spring as a
set.
Clutch Spring Minimum Length:

26.2 m m (1.03 in)
7. Inspect:
*Dogs on the clutch housing
Cracks/Wear/Damage+Deburr or replace.
*Clutch housing bearing
ScoringlWear/Damage+Replace clutch
housing.
NOTE:
Scoring on the clutch housing dogs will cause
erratic operation.
8. Inspect:
*Clutch boss splines
Scoring1Wear/ Damage+Replace clutch
boss.
NOTE:
Scoring on the clutch boss splines will cause er-
ratic operation.
9. Check:
*Circumferential play
Free play exists+Replace.
10. Measure:
@Pushrod runout
Ou i: of specification+ Replace.
primary drive gear teeth
~ P r i r n s r ydriven gear teeth
KICK STARTER
1. Inspect:
Measure:
ick clip Pension
u l of specification+
Use a spring balance a.
Do n o t try ts bend the dip.

- - -
SHBFT SHAFT
4 . Inspect:
rk cam foliower
2. Inspect:
fork movement
Unsrnooth speratiois+Repface shiftfork
andlor guide bar.
uide bar on a flat surface.
Do not attempt t o strai Rten a bent gui

bas.
. Measure:
se centering device
UT of specification-+
6. Inspect:
1-
.Gear teeth
Blue discoloration/ Pitting/ Wear+ Replace.
.Mated dogs
Rounded edges/Cracks/Missing portions-+
Replace.
7. Check:
.Proper gear engagement (Each gear)
( t o its counterpart)
Incorrect+ Reassemble.
.Gear movement
Roughness+ Replace.
8. Inspect:
.Circlips
Damage/ Looseness/ Bends+Replace.
CRANKSHAFT
1. Measure:
.Runout
Use a centering device and Dial Gauge.
Out o f specification-+ Replace or repair.
Runout Limit:
0.03 mm (0.0012 in)
2. Measure:
.Small end free play a
Use a Dial Gauge.
Out of specification-+Replace the defective
parts.
1
Small End Free Play:
0.8- 1.0 mm (0.032-0.039 in)
I1
<Limit > :
< 1.5 mm (0.060 in) >
3. Measure:
.Big end side clearance @
Use a Feeler Gauge.
Out of specification-+ Replace the defective
parts.
I
- -
-End Side Clearance:

0.2-0.7 mm (0.008-0.028 in) I
< Limit >
~ 1 . mm
0 (0.04 in)>
4. Inspect:
1-
-Crankshaft bearing
Pitting/ Damage-+ Replace.
NOTE:
Lubricate the bearings immediately after examin-
ing them to prevent rust.
5. Inspect:
-Oil seals
Wear/ Damage* Replace.
CRANKCASE
1. Thoroughly wash the case halves in mild
solvent.
2. Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly.
3. Inspect:
-Crankcase
Cracks/Damage+Replace.
-Oil delivery passages
Clog+Blow out with compressed air.
AUTOLUBE PUMP
Wear or an internal malfunction may cause pump
output to vary from the factory setting. This sit-
uation is, however, extremely rare. If improper
output is suspected, inspect the following:
1. Inspect:
-Delivery line
Obstructions+Blow out.
-Pump body seallcrankcase cover seal
Wear/ Damage+Replace.
-Check ball/Spring
Miss/ lmproper+Repair.
2. Inspect:
-Allowing air
Air exists+Air bleed.
edt of specification -,A
4. Inspect:
rankshaft Installing Tool @
@Adapter a
Installing Tool:
2 Install:
other, Operate the
3. Install:
heck:
@ $ l i f t e r operation
@Transmissionoperation
eration- Repair.
90 the mating surfaces of both crank-
~i.ase
halves.
nto l h e crankcase (Ls\rver)
ht crankcase onto the left case. Tap

iightly on the case with a soft hammer.
Before instaliin t h e crankease

ewm, be sure t o check whether
ission is ff uwctioning properly by
manually rotating the shift cam either way.
-
4. Tighten:
NOTE: . - . ,
hreu the crankcase tightenin

stages, using a crisscross pattern.
- -- . --
Forced out on-the cylinder
hole.
7 . Check:
. Install:
@ Bearing
@ Connecting rod 0 Piston pin clip

@ Big end bearing @ Small end bearing
@ Crank pin @ Woodruff key
a Bearing @ Collai.
@ Main axle
@ 4th pinion gear @ 4th wheel gear
@ Circlip 3rd wheel gear
@ 3rd pinion gear @ 2nd wheel gear
@ 2nd pinion gear @ 5th wheel gear
@ Oil seal
0 Drive sprocket
@ Circlip
Guide bar (Shift fork) 8 Shift cam assembly
@ Shift fork # 2 @ Shift cam plate
@ Shift fork # 3 @ Shift cam stopper
@ Pin Q Spring
@ Circlip 5011
@ Shift fork # 1 @ Circlip
a Cotter pin @ Segment
1. Install:
@Neutralswitch lead
2. Install:
When installing the rotor, make sure the woodruff

key is properly seated in the keyway of the
crankshaft.
Clean the tapered ortion of the cranks
with a cloth.
3. Tighten:
o"Er Holder a to hold

the rotor.
a Rotor
@ Stator assembly
@ Charge coil
@ Lighting coil
@ Pickup coil
1. Install:
@Shiftshaft
e sure the shift lever correctly en
KlCK AXLE
I . Install:
@Kickaxle assembly
: 1
eMake sure that the kick stopper is sto

n epf the crankcase.
at the kick clip is engaged with the
crankcase hole.
2. Hook the kick spring @).
3, Install:
@Kickidle gear a
@Washers@
@ Circlip @ Kick crank
@ Shift lever @ Return spring
@ Rotor 0 Collar
@ Return spring @ Kick axle
@ Pin Kick idle gear
0 Oil seal
IMAWY DRIVE GEAR
I . Install:
primary drive gear @

oThrust washer @
~Gonicalspring washer
NOTE: ------- - - ,
e sure to install the conical spring was

as shown.
oApply the transmission oil onto the collars.
2. Tighten:
o N u k (Primary drive gear)
NOTE: - -
etween the teeth of the
3. Install:
@Thrustwasher a
@Clutchboss Q
e sure to install the conical spring washer 13

as shown.
4. Tighten:
nut (Clutch boss) a
niversal Clutch older @ to hold
clutch boss.
5. Install:
lutch damper Q
and f r i c t i ~ nplate alter-
friction plate and second clutch damper.
. Install:
NOTE: --...-- - -.-

Tighten the bolts in stages, using a crisscross
pattern.
@Gasket(Crankcase cover-New) @
Tighten the screws in stages, using a crisscross

A
@ Straight key @ Clutch boss
@ Primary drive gear 0 Clutch damper
@ Conical spring washer @ Friction plate
@ Push rod # 2 @ Clutch plate
@ Ball @ Cushion spring
@ Thrust washer @ Conical spring washer
a Collar
@ O-ring
@
0
Push rod # 1
Pressure plate
@ Clutch housing
To the small end bearin
bearing.
the crankcase.
Asways use a new piston pin d i p .

-
-
4. Install:
askets (Cylinder-
5. Install:
Install the cylinder with one ha d while compress-

ing the piston rings wit the other hand.
Tighten the nuts in stages, using a crisscross
7. Install:
Vkl A
a Cylinder head
@ Gasket (Cylinder head)
@ Spark plug
@ Cylinder
@ Gasket (Cylinder)
Note the following points.
1. Install:
Q Engine assembly
efore installing t e drive sprocket, loosen the

rear wheel axle and push forward the rear wheel.
Tighten the screws in stages, using a crisscross
pattern.
- . , -p - P
rive chain slack @
ENT" section.
9. Adjust:
@Throttlecable free play @
Spring (Throttle valve)
Jet needle assembly @ Main jet
Throttle valve @ Valve seat assembly
@ Throttle stop screw 0 Float
@ Pilot screw @ Pin (Float)
@ Starter plunger @ Float chamber
a Pilot jet @ Drain screw
Float height
REb?QOAk
MOTE : - -- , .
The fallov2;ir-g parts can be cleaned and inspect-

ed without carburetor disassern
"Pilot screw
0 Lower cowling
Refer so "'CHA
sectioja.
2 , Turn the fuel cock to "OFF" piaskion and dis-
connect the fuel hose a.
3, Loosen:
Screws (Carburetor joint)
4" Eernove:
srburetor assembly a
DiSASSEMBL?!
4 . Remove:
~ T h r o t t i evalve assembly
oSpring (Throttle valve) @
2. Remove:
tarter plunger g]
throttle stop screw @
pilot screw
I . Inspect:
@Carburetorbody
@Fuelpassage
Contamination-~Cleanas indicated.
based solvent.
(Do not use any caustic carburetor cleaning
solution).
low out all passages and jets with com-
pressed air.
P -.
2. Inspect
@Float
amage+ Replace.
Inspect:
o Needle va!ve
@Valveseat @
@Gasket@
amage/Wear/Contamination+ Replace.
-: -
Always replace the needle valve and valve seat
as a set.
- -
4. Inspect:
@Throttlevalve
5. Check:
Free movement
Insert the throttle valve into the carburetor

body, and check for free movement.
Inspect:
@Clipposition
7 . Inspect:
@Starterplunger @
@Throttlestop screw @
everse the disassemby procedure.

Note the following points.
1. Measure:
ut of specification+Adjust.
5-5
__-p_-____n_l__- -
Float height measurement an
the carburetor in an up
sition.
measure the distance between the w
valve, but not cormpressing the needle valve.
olf h e float height is nor within specification,

insped the valve seat and needle valve.
@Ifeither is worn,
@Ifboth are fine,
Recheck the float height.

Q
-__-_ -
---_Y__YV___L_ _ -&-- ---iT_ --
BfqSTALLATIOM
Reverse the removal procedures.
ole the foilowin
1. ins tali^
~ThrottEevalve assern
MOTE: - - - .-
i4iigi-e the groove @ of the thvoirle valve with the

projection @ of the carburexor body.
- --- - --- . -
2. Adjust:
oldie speed
-
BMENT" section.
ADJUSTLdEMT
Fuel Levee A d j u s t m e n t
OTE: -- ->- " - - - - - - -
efore adjusting the fuel level, the float height

should be adjusted.
lace the motorcvcle on a leve! place.

se a garage jack under the engine l o ensure
that the carbuoeior is positioned veskecaliy.
3. Attach the Fuel Level Gauge @ to h e iioet
4, Loosen the drain screw a,

and warm up the
engine for sevehai minuies.
5. Pdeasure:
oFdel level @
ut of specification-Adjust.
I elow the Carburetor
Adjust:
a Fuel level
Adjustment steps:
e m w e the carbbirelor.
@Inspectthe valve seat and needle vaive.
0 1 % either is worn, i. place them both.
@Ifboth are fine, a jusd the float height by
ending the float tang a
on the float.
echeck the fuel level.
I . Measure:
@Valvestopper hei
u t o f specification-~Replace.
2. Measure:
eed valve bending @
@Installthe reed valves (New)

REED VALVE
I
INSTALLATION
Reverse the removal procedure.
Note following points.
1. Tighten:
Carburetor joint
Bolt (Carburetor Joint):

b? 8 Nrn (0.8 rn-kg, 5.8 ft-lbl
@ Cotter pin
*Load is the total weight of cargo, rider, and

accessories.
ova
efer t o "CHA
@ N u t(Front wheel axle) @

Elevate the front el by placing a suitable
"Collar
ofront wheel axle
n y corrosion f r o m parts
2. Inspect:
@Frontaxle
oll the axle o n a flat surface.
ten a bent axle.
. Inspect:
4. Measure:
@Wheelrunout
heck the wheel and
earings allow play in t

wheel turns roughly-aReplace.
lean the out side o

ernove the bearing
puller
se a socket @ that matche

ameter of the race of the bearing.
Do not strike t e inner race of

houid be made only
w i t h the outer race.
-
e esnservatiwely
tor injury.
@Aftera tire repair or re
hten the valve stem locknut @
t o specification.
val procedure. Roae the follow-
2. Install:
Make sure the projections insi

the flats in the
- -- - , - --
Install:
sys use a new cotter

--
end the end sf cotter pin,

@ Brake shoes
@ Bearing
Collar
@ Bearing
@ Joint
Brake cam shaft @ Rear wheel axle
lacing a suitable
nd remove "ce drive

chain
a Wear wheel
I Ti 8
1 . Inspect:
@Wearwheel axle
EEL-INSPECTI
section.
2. Inspect:
-6
section.
-_Je"
a
I
11
3. Measure:
section.
section.
Use a coarse sand paper.
articles with cloth.
7. Measure:
__=----
brake lining Ihiclcness

A
-----
9u-h. of specification-. Replace.

Measuring points
Brake Lining Th1cknsss:

4 mim (0.16in)
Wear L i r ~ i t :
2 rmtm !0.Q8% I
-----
can of the polished
Inspect:
rum inner surface
9. Measure:
Brake drum inside diameter
ut of specification-Replacs
BNSTALLATUO
everse the removal procedure. Note the follow-
ing points.
-
--.
-
~ A p p l ythe Bi"ri7ium soap base grease onto the

brake cam shaft.
align the slot @ on the b a k e cam shaft with
the projection @ on the wear indicator.
2. Install:
rake cam lever @
- , -
Install the brake cam lever as s

-.- - .
. Apply:
ium soap base
nto the brake cam lever aand pivot shaft
0.
ipe off the s x c s
e n installing t h e spying and brake shoe,
take care rest to damage t h e spring and not
to apply grease to the brake sb:oes.
-----_ -__ rr_Z___----------- _--_Xg____
5.Apply:
Lithiurn b a s e grease
rease to uhe oil seal lips.
. Adjust:
rive chain slack
Refer to "CHAPTER 3--DRIVE CHAIN A
JUST:\hRfi T'" section.
. Install:
@Colterpin
Always u s e a new cotter pin.
evd the e n d s of cotter pins.
I@. Adjust:
rear brake pedal pree piay
--REAR BRAKE A
TM ENT" section.
@ Brake hose
@ Union bolt
0 Copper washer
@ Brake pads aster cylinder kit
@ Bust seal
@ Piston seal
@ Brake disc
1 is not necessa to disassemble the brake caliper
8
and brake hose t o replace the brake pads.
. -----
w o r n t o the wear limit.
a suitable hose
eed screw. Then,
this hose into an open container.
4. Loosen the cali
istons into the calipe
NOTE: -
- -
7, Install:
@Calipercoves
a "LOWER" level line
lever operation
A softy or spongy fillin
-- P
sassembig/ing the brake caliper, drain the

rake system of the brake fluid.
section.
emre disassemblying the front master cylinders,
drain the brake syste of the brake flui
-
@Mastercylinder boot @
eCirclip
@Mastercylinder kit @
P
2. Measure:
rake pad thickness
u t of specification
et if either is found t o be
---
4. Inspect:
@Mastercylinder body @
@Mastercylinder kit
eat of specification-+
0All internal parts should be cleaned in new

brake fluid only.
be lubricated with
the piston seals whenever a caliper

~Replaee
is disassembled.
NOTE: ----- . -- -
ly the lithium soap
piston seal, caliper
3. Install:
@Padsprings @
E
section.
4. Install:
5. Install:
bracket with the "
mark facing upward.

8. Install:
Air
From brake system.
" section
'8%. Install:
Q Master cylinder cap

Bleed the brake system if:
oThe system has beem disassembled.
hose has beem lossen
eBhe brake fluid is very Osw.

@%hebrake operation is fauity.
erous loss of braking performance
ay occur if the
bled.
- . , . -
-. -
fluid t o the reservoir.
fluid or allow the
r plastic tube (4.5 mm

htly t o the caliper
d. Place the other end of the tube into a con-

tainer.
e . Slowly apply the rake lever several times.
f . Pull the lever in. old the lever in position.
g . Loosen the bleed screw an
to travel towards its limit.
hten the bleed screw when the lever
limit has been reached; then release the
lever.
at steps (el t o (h) until
les have been remove
system.
u
Cap bolt lain washer
il seal
lick metal
@ Inner tube
@ Fork spring Outer tube
@ Circlip
VAL
. Remove:
ofron-l: fender
4- Loosen:
inch bolt (bower) a
@Frontfork @
seat a (Left si
ring @ (Left si
1. Inspect:
@Innerfork rube a
- - -=- - - - -=
~s- - - - - -?
m
pT- -=
Do i20t a.ta8~ip.t $tr'aigB7y$ef-i9 b~~i3.2

inpier
2. Inspect:
oDusl seal
Reverse t h e disassern
Note the following poin'.s.
NOTE: --..-..-----. - . - - - 7 . A - - -.2-n
i-:
e sure all components are clean before as-

sembly.
_ - -
, -
.
-
--
-
b -
-
a _yl
i
-
1. Install:
@Clip@
To inner tube.
. Install:
~ l n n e tube
r @
To outer tube.
apply the lithium soap base grease onto the oil

seal lip before installing the oil seal.
e sure oil seal numbered side face upward.
4 Press the oil seal into the inner tube with Fork
5. Install:
oPlain washer
a6irclip a
. Fill:
Front fork
126 em3 (4A4 Imp qt,
Rig ha:
164 cm3 E5.77 lamp qt,
5.54US st)
Grade:
Yamaha Fork OBI "MWT oa
the front ffok with Cork oil, slowly

pump the front Car u p and down to distri
7 . Measure:
ert of specification->Add or reduce oil,
Left: 146 mm (5-74

in)
Right: 51 mm %2.Qli ? a j
From the top of the inner fork 1
rubs f d l y compressed w i t h o u t i
Place the front fork on u p r i g h ~ o s i t i o n .

- - -- -- . -. & -
spring a (Left side only)

g seat @ (Left side only)
Install the fork spring so that tapere

upward.
- - P
1. Install:
Q front fork
2. Install:
0TE: . , , -
Apply the lithium soap base rease onto the
-ring.
-- - -
A
a Bearing race (Lower- Bottom)
all (114 i n 4 9 pcs.)
@
@
Handle crown
Steering stembolt
earing race (Lower-Bop)
earing race (Upper- @ Handlebar (Left)
all (3116 in-22 pcs.) Q Cap
earing race (Upper-Top) @ Throttle housing
earing race cover @ Throttle grip
ing nut
otorcyele ss there is
"Lower cowling
QUpper cowling
ofront wheel
section.
@Frontforks
section.
'j F'emove:
~ S l e e r i ~stern
g bolt
washer 2
handle crown
. .-
all bearings and bearing races with
a solvent.
Inspect:
~Dnstallthe new dust seal and races.

G HEAD A A
ote the follow-
bower balls @
To bearing race (bower-Bottom).
rrange the bearings around race, and ap-
3. Install:
H-ilold t h e under bracket until 68 is secured.

- -.-
ring nut using the

- .
et the torque wrench to the ring nut wrench
- - ----- ~---
~Loosenthe rin
Avoid over-tightening.
handle crown
NOTE: , -- a
porary tighten the steering fitting bolt

- & ,
a.
6. Install:
front forks
section.
7. Tighten:
. Install:
. Install:
@Frontbrake master cylin
-:
~ I n s t a lthe
l master cylinder bracket w i t h the '"
ht coat of lithium soap base grease onto
11. Install:
section.
ear shock absorber
@ Cotter pin
@ Swingarm
@ Push
@ Spacer
Chain support
Chain cover
SecuueEy support the motorcycle so there is
sr of it falling over.
, , , , &
Wear Shock Absorber

4 . Remove:
0 Lower cowling
section.
2 . Place a jack under % e engine and elevate the

motorcycle.
3. Remove:
* ~@
Q C O ~pin
oPBain washer
QPin (Rear shock absorber- Lower) a
SscureBy support the mstorcycBs so there is

no danger of it fallin
section.
Remove:
DISASSEMBLY
oChain guide
tension bar
1. W a s h the bushes and swingarm pivot in a

solvent.
5. Inspect:
A
1. Install:
Apply the lithium soap base grease onto the pivot
2. Install:
ear shock absorber- Lower)
@Cotterpin
3. Install:
section.
1. Install:
ear shock absorber
Apply the lithium soap base grease onto t

bolt and oil seal lip.
2. Clean:
lace it in solvent, and brush off as much

ble. Then remove the chain from
the solvent and
lean and oil the chain an

trated.
lace drive chain.
114 tooth
Q Correct
@ Roller
@ Slip off
~BnstalI a new driven sprocket and Is&
Always use new lock was I
end the lock washer tabs alsn

I
INSTALLATION
everse the removal steps.
ate the following points.
1. Install:
rear wheel
Refer t o "'CHAPTE
2. Install
3. install:
join^ (Drive chain)
NOTE: .- -- ., --
During reassern ly, the master link clip must be
installed with the rounded en facing the direc-
tion sf travel.
-
a Turning direction
4. Lubricate:
o5rive chain
Chain Lube:
Yemaha Chain Lube or
NOTE: - . - ... ---

Align the punch mark @ with slit @.
YSRSOT CIRCUIT DIAGRAM I ELEC I I
ELECTRICAL
YSR50T CIRCUIT DIAGRAM
la-=
-
YSRSOT CIRCUIT DIAGRAM
@ Spark plug @ Flasher relay
a Ignition coil
@) CDI magneto
0 "TURN"
@
switch
"TURN" indicator light
@ CDI unit @ Flasher light (Left)
@ RectifierIRegulator @ Flasher light (Right)
@ "ENGINE STOP" switch @ Horn
a Main switch
@ Fuse
@
@
"HORN" switch
"OIL" warning indicator light
@ Battery @ Oil level switch
@! "LIGHTS" (Dimmer) switch @ "NEUTRAL" indicator light
@ "HIGH BEAM" indicator light @ Neutral switch
@ Headlight a Front brake switch
@ Rear brake switch
@ Meter light
@ Sidestand switch @ TailIBrake light
@ lgnition control unit
COLOR CODE
B Black P Pink
R Red Sb Sky blue
Br Brown BIR Black1Red
0 Orange BIW BlackIWhite
W White WIR WhiteIRed
L Blue BrIW BrownIWhite
G Green GIY GreenIYellow
Y Yellow YIR YellowIRed
D!3 Dark green
- LIY BlueIYellow
Ch Chocolate -
ELECTRICAL COMPONENTS I ELEC 1 El 1
ELECTRICAL COMPONENTS BATTERY:
@ Wireharness @ Sidestand switch I CAPACITY 6V 4AH
@ Main switch @ Neutral switch
@ Ignition control unit @ lgnition coil
1 SPECIFIC GRAVITY 1.280
@ Oil level switch @ CDl unit I IGNITION COIL:
@ Rectifier/Regulator @ Flasher relay PRIMARY COlL
@ Horn @ Battery 0.7- 1.1Q at 20°C (68OF)
@ Rear brake switch @ Fuse
SECONDARY COlL
IGNITION AND STARTING SYSTEM I ELEC 1 IS I
For the color codes, see page 7-2.
Spark plug
Ignition coil
CDI magneto
CDI unit
"ENGINE STOP" switch
Main switch
Sidestand switch
Ignition control unit
Neutral switch
IGNITION AND STARTING SYSTEM
-
I ELEC 1 'B1
IGNITION CONTROL CIRCUIT OPERATION
The ignition control circuit on this model consists
of the ignition control unit, neutral switch, neu-
I I Transmission I Sidestand Isparkt
(Neutral switch) (Sidestand switch) plug
tral indicator light, and the sidestand switch. If
Neutral
the engine stop switch and the main switch are (close)
both on, the ignition spark can produce only if:
Neutral Down
1. The transmission is in neutral (the neutral
(open)
switch is on).
I N gear
2. The sidestand is up (the sidestand switch is (close) Spark
on).
I N gear
(open) (open) spark
Bypass current flows into the thyristor which is I T' ' Y

2- thus turned on, thereby grounding the current of
the source coil. In this way, no sparks will be
produced.
--,
1
@ lgnition control unit @ CDI unit

a Sidestand switch
@ Neutral switch
@
a Ignition coil
Spark plug
Bypass current
Current of source coil
@ CDI magneto @ Thyristor
7-6
IGNITION AND STARTING SYSTEM I ELEC 1 El I
I I I
TROUBLESHOOTING
IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE (NO SPARK OR INTERMllTENT

SPARK).
Procedure (1)
Check;
1. Spark plug Ignition coil resistance
2. lgnition spark gap Pick-up coil resistance
3. Ignition circuit Source coil resistance
4. Main switch Wiring connection
5. Spark plug cap resistance (Entire ignition system)
6. "ENGINE STOP" switch
NOTE:
*Remove the following parts before troubleshooting.
1) Lower cowling
2) Upper cowling
3) Seat
4) Side cover
5) Fuel tank
*Use the following special tool(s) in this troubleshooting.
Pocket Tester:
Y U-03112
1. Spark plug
*Check the spark plug condition.
*Check the spark plug type.
*Check the spark plug gap.
Refer to the "SPARK PLUG INSPECTION"
section in the CHAPTER 3.
Standard Spark Plug:

1 INCORRECT
B7HS (N.G.K.), B8HS (N.G.K.)
Spark Plug Gap:

0.5-0.6 mm (0.20-0.24 in) Repair or replace spark plug.
U CORRECT
IGNITION AND STARTING SYSTEM I ELEC 1 a
V
2. lgnition spark gap

*Connect the Coil Tester a as shown.
a Spark plug cap
@ Spark plug
MEETS SPECIFICATION
Ignition system is good.
*Start the engine, and increase the spark gap

until misfire occurs.
Minimum Spark Gap:

6 mm (0.24 in)
OUT OF SPECIFICATION
OR NO SPARK
I
3. Ignition circuit I
*Disconnect the ignition control unit lead
(Brown).
*Start the engine.
ENGINE STARTS (SPARK)
- P
Starting circuit is faulty, go to "Procedure (2)".
NOT START
IGNITION AND STARTING SYSTEM I ELEC I I
4. Main switch
*Disconnect the main switch coupler (Red,
Brown and Black) and lead (BlackIWhite)
from the wireharness.
Connect the Pocket Tester (flx 1) to the main
switch.
+
Tester ( 1 Lead-+Black/White @ Lead
Tester ( - 1 Lead-+Black @ Lead.
BAD CONDITION
*Turn the main switch to "ON" and "OFF".
*Check the main switch for continuity.
-
Switch
position
OFF
1 condition
Oood
0
1 x
Bad condition
x 0
Main switch is faulty, replace it.
ON x 0 x 0
0:Continuity x: Nocontinuity
- --
1I
5. Spark plug cap resistance
GOOD CONDITION
*Remove the spark plug cap.

*Connect the pocket Tester (fl x 1k) to the
spark plug cap.
IGNITION AND STARTING SYSTEM I ELEC 1 m 1
*Check the spark plug cap for specificated OUT OF SPECIFICATION
resistance.
Spark Plug Cap Resistance: Spark plug cap is faulty, replace it.
4-6kQ at 20°C 168OF)
1 1
MEETS
SPECIFICATION
6. "ENGINE STOP" switch

Disconnect the "ENGINE STOP" switch leads
(BlackIWhite and Black) from the wire-
harness.
*Connect the Pocket Tester (!2 x 1) to the "EN-
GINE STOP" switch.
+
Tester ( 1 Lead+Black/Whie @ Lead
Tester ( - 1 Lead+Black @) Lead
*Turn the "ENGINE STOP" switch to"0FF"

and "RUN".
*Check the "ENGINE STOP" switch for con-
tinuity.
BAD CONDITION
Bad condition
condition
"ENGINE STOP" switch is faulty, replace it.

I 0: Continuity x : Nocontinuity
7. Ignition coil resistance

.Disconnect the ignition coil lead (Orange)
*Connect the Pocket Tester (Qx 1) to the ig-
nition coil.
IGNITION AND STARTING SYSTEM I ELEC 1 s 1
Tester ( + Lead-+Orange @) Lead
Tester ( - Lead-Ignition Coil Base
.Check the primary coil for specificated

resistance.
1 Primary Coil Resistance:

(Orange-Coil Base)
*Connect the Pocket Tester (Q x 1k) the igni-

tion coil.
Tester ( + ) Lead-tSpark Plug Lead @)

Tester ( - ) Lead+lgnition Coil Base
J
.Check the secondary coil for specificated
resistance.
1 Secondary Coil Resistance: Ignition coil is faulty, replace it.

(Spark Plug Lead-Coil Base)
.
1I BOTH MEET
SPECIFICATIONS
8. Pickup coil resistance

.Disconnect the CDI magneto lead (White1
Red) and coupler (Sky blue, White, Black and
YellowIRed) from the wireharness.
.Connect the Pocket Tester (Q x 10) to the
pickup coil leads.
7-1 1
IGNITION AND STARTING SYSTEM I ELEC 1 IS 1
Tester ( + Lead+White/Red @ Lead
Tester ( - ) Lead+Black @ Lead
*Check the pickup coil for specificated OUT OF SPECIFICATION

resistance.
1 Pickup Coil Resistance:

Pickup coil is faulty, replace it.
(WhitelRed- Black)
I1 MEETS SPECIFICATION
9. Source coil resistance

*Disconnect the CDI magneto lead (Black/
Red) and coupler (Sky blue, White, Black and
YellowIRed) from the wireharness.
*Connect the Pocket Tester ( Q x100) to the
source coil leads.
Tester ( + Lead+Black/Red @ Lead

*Check the source coil for specificated
resistance.
1 Source Coil Resistance:

-
264 396Q at 20°C (68OF)
Source coil is faulty, replace it.
(BlackIRed- Black)
it MEETS SPECIFICATION
.3c 7-12
IGNITION AND STARTING SYSTEM I ELEC 1 I9 I
10. Wiring connection
- POOR CONNECTION
Check the entire ignition system for connec-
tions. Refer to the "WIRING DIAGRAM" b I
section.
I Correct.
CORRECT
I CDI unit is faulty, replace it. I
Procedure (2)
Check;
1. Sidestand switch
2. Neutral switch
(Entire starting system)
I 1. Sidestand switch
*Disconnect the sidestand switch coupler
(Blue/Yellow and Black) from the wire-
harness.
*Connect the Pocket Tester ( Q x 1) to the side-
stand switch.
Tester ( + ~Lead-tBlue/Yellow@ Lead

Tester ( - ) Lead+ Black @ Lead
IGNITION AND STARTING SYSTEM I E L K 1 Eli 1
I .Move the sidestand to up position and down (
I position. I
( .Check the sidestand switch for continuity. I
BAD CONDITION
Sidestand Good
Bad condition
position condition
.
UP 0 X X 0
Down x 0 x 0 Sidestand switch is faulty, replace it.
0:Continuity x : Nocontinuity
II GOOD CONDITION
2. Neutral switch
.Disconnect the CDI magneto coupler (Sky
blue, White, Black and Yellow/Red) from the
wireharness.
Connect the Pocket Tester (52 x 1) to the neu-
tral switch leads.
Tester ( + 1 Lead'Sky blue Lead a

Tester ( - 1 Lead'Black @ Lead.
.Shift the transmission in neutral and gear

.Check the neutral switch for continuity.
BAD CONDITION
'ransmission Good
Bad condition
position condition
Neutral I 0 I x 1 x I 0
I Neutral switch is faulty, replace it.
I
U GOOD CONDITION
IGNITION AND STARTING SYSTEM
-x
POOR CONNECTION
Check the entire starting system for connec-
tions. Refer to the "WIRING DIAGRAM"
section. Correct.
II
U CORRECT
- -- ---
Ignition control unit is faulty, replace it.

--
T
elow circuit diagram shows chargin
CHARGING SYSTEM I ELEC I I
NOTE:
@ CDl magneto
@ RectifierIRegulator
@ Fuse
@ Battery
CHARGING SYSTEM I ELEC I I
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED.
Procedure
Check;
1. Fuse 4. Charging coil resistance
2. Battery 5. Wiring connection
3. Charging voltage (Charging system)
NOTE:
Remove the following parts before troubleshooting.
1) Side cover
.Use the following special tool(s) in this troubleshooting.
1. Fuse NOCONTINUITY
.Connect the Pocket Tester ("M x 1") to the

fuse.
.Check the fuse for continuity. Replace fuse.
CONTINUTY
INCORRECT
2. Battery
-
.Check the battery condition. Refer to "CHAP-
TER 3. BATTERY INSPECTION".
Specific Gravity: .Clean battery terminals.

1.280 at 20°C (68OF)
CORRECT
3. Charging voltage
@Connectthe Engine Tachometer to the s
plug lead.
battery.
attery ( + ) Ter
attery B - 1 Ter
charging coil leads.
-.
@Check the charging coil for speci%icated
resistance.
CDI magneto
tifierl Regulator
n switch
Fuse
Headlight
TailIBrake light
ove the following arrs before trou
ecial tool(s1 in this "roubleshootin
@Checkthe headlight for continuity.

LIGHTING SYSTEM I ELEC I
V
2. "LIGHTS" (Dimmer) switch

.Disconnect the handlebar switch couplers
[(Chocolate, Green, Dark green and Yellow)
(Black, Pink, YellowIRed and Brown1White)l
*Connect the Pocket Tester (flx 1) to the
"LIGHTS" (Dimmer) switch leads.
When turning "LIGHTS" (Dimmer) switch

to "HI".
Tester ( + ) Lead+Yellow/Red @ Lead
Tester ( - Lead-+Yellow @ Lead

to "LO".
Tester ( + Lead+Yellow/Red @ Lead
Tester ( - Lead-+Green @ Lead
*Turn the "LIGHTS" (Dimmer) switch to the

"HI" and "LO".
.Check the "LIGHTS" (Dimmer) switch for
continuity.
Switch
position
HI
I condition
Oood
0
I x
Bad condition
0 x "LIGHTS" (Dimmer) switch is faulty, replace

LO 0 0 X X handlebar switch.
GOOD CONDITION
3. Lighting circuit output

.Turn the "LIGHTS" (Dimmer) switch to
"LO".
*Connect the Pocket Tester (AC V-20) to the
headlight leads.
- -
Tester ( + ) Lead+Green @ Lead

7-25
LIGHTING SYSTEM 1ELK/ m1
.Connect the Inductive Tachometer to the

spark plug lead.
.Start the engine and check the output
voltage.
MEETS SPECIFICATION
Do not run the engine in neutral above d
6,000 rlmin for more than 1 or 2 seconds.
a Standard Output:
62-7.2" at 3,000 rlmin or more
OUT OF
Lighting system is good.
SPECIFICATION
4. Lighting coil resistance

blue, White, Black and YellowIRed) from the
wireharness.
.Connect the Pocket Tester (f2x 1) to the light-
ing coil leads.
Tester ( + Lead+Yellow/Red @ Lead

Tester ( - ) Lead-Black @ Lead
.Check the lighting coil for specificated

resistance.
LIGHTING SYSTEM I ELEC 1 %I 1
Lighting Coil Resistance: OUT OF SPECIFICATION
0.16 -0.2411 a t 20°C (68OF1
(YellowIRed- Black)
MEETS SPECIFICATION
Lighting coil is faulty, replace it. I
Check the entire lighting system for connec- POOR CONNECTION
section.
( I CORRECT I Correct. I
I Rectifier/Regulator is faulty, replace it.
TROUBLESHOOTING (2)
TAILLIGHT DOES NOT COME ON.
Procedure
1. Fuse
2. Battery
3. TailJBrake light bulb
4. Main switch
NOTE:
1) Seat
2) Side cover
1. Fuse
NOCONTINUITY
, *Remove the fuse.
Connect the Pocket Tester (Q x 1) to the fuse.
*Check the fuse for continuity.
Fuse if faulty, replace it.
CONTINUITY
LIGHTING SYSTEM I ELEC 1 IS 1
2. Battery
*Check the battery condition. Refer to the INCORRECT
"BATTERY INSPECTION" section in the
CHAPTER 3.
Specific Gravity:
*Refill battery fluid.
1.280 a t 20°C W 0 F )
*Clean battery terminals.
*Recharge or replace battery.
U
3. TailIBrake light bulb
CORRECT
*Remove the taillbrake light bulb.

*Connect the Pocket Tester (Ox l k ) to the
taillbrake light bulb.
Tester ( + Lead-Terminal @
Tester ( - ) Lead-Terminal @
Tester ( + 1 ~ e a d - ~ e r m i n a@
l
Tester ( - ) Lead-Terminal @
CONTINUITY DOES NOT

EXIST ON ONE CIRCUIT.
I
-
C h e c k the taillbrake light bulb for continuity.
TailIBrake light bulb is faulty, replace it.
I I
CONTINUITY EXISTS
ON BOTH CIRCUITS.
4. Main switch
*Disconnect the main switch coupler (Red,
Brown and Black) from the wireharness.
*Connect the Pocket Tester (fl x 1) to the main
switch leads.
LIGHTING SYSTEM I ELEC 1 I
Tester ( + ) Lead-Red @ Lead
Tester ( - Lead+Brown @ Lead
.Turn the main switch t o "ON" and "OFF".

BAD CONDITION
position
Switch I condition
=Ood I Bad condition
OFF x 101 x 10 Main switch is faulty, replace it.


GOOD CONDITION
I
Check the entire lighting system for connec-
INCORRECT
section.
I I CORRECT I
Correct.
TailIBrake light bulb socket is faulty, replace

taillbrake light assembly.
slow circuit diagram shows si
NOTE:
For the color code, see page 7-2.
a Main switch
@ Fuse
@ Flasher light (Right)
@C Horn
@ Battery @ "HORN" switch
@ Flasher relay Front brake switch
0 "TURN" switch @ Rear brake switch
@ Flasher light (Left) @ TailIBrake light
SIGNAL SYSTEM 1-
TROUBLESHOOTING
FLASHER LIGHT, BRAKE LIGHT AND/OR HORN DO NOT OPERATE.
Procedure
Check;
1) Fuse
2) Battery
3) Main switch
4) Wiring connection
NOTE:
1) Seat
2) Side cover
Pocket Tester:
Y U-03112
1. Fuse I
*Remove the fuse. NOCONTINUITY
*Connect the Pocket Tester (Q x 1) to the fuse.
*Check the fuse for continuity.
CONTINUITY Fuse is faulty, replace it.
2. Battery
*Check the battery condition. Refer to the
"BATTERY INSPECTION" section in the
CHAPTER 3. INCORRECT
--
Specific Gravity:
1.280 a t 20°C (68OF)
*Refill battery fluid.
*Clean battery terminals.
CORRECT Recharge or replace battery
-
3. Main switch
.Disconnect the main switch coupler (Red,
Brown and Black) from the wireharness. I
Connect the Pocket Tester (Q x 1) to the main
switch leads.
SIGNAL SYSTEM ( ELEC 1
Tester ( + 1 L e a d j R e d @ Lead
Tester ( - ) Lead+ Brown @ Lead
*Turn the main switch to "ON" and "OFF".

BAD CONDITION
position
Switch I condition
Good I Bad condition
OFF 1 x I O x I O I Main switch is faulty, replace it. I

GOOD CONDITION
INCORRECT
4. Wiring connection I
Check the entire signal system for connections.
Refer to the "WIRING DIAGRAM" section.
I I
Correct.
CORRECT
Go t o the "SIGNAL SYSTEM TEST AND

CHECK" section.
SIGNAL SYSTEM I ELK 1 a 1
SIGNAL SYSTEM TEST AND CHECK
1. Horn does not sound, when pushing "HORN" switch.
1. "HORN" switch check

*Disconnect the handlebar switch couplers
[(BrownIWhite, YellowIRed, Black and Pink)
(Yellow, Green, Dark green and Chocolate)l
.Connect the Pocket Tester (Qx I)to the
"HORN" switch.
+
Tester ( 1 Lead+Pink @ Lead
Tester ( - ) Lead* Black @ Lead
- -
*Check the "HORN" switch for continity.

BAD CONDITION
Switch Good
Bad condition
position condition
"HORN" switch
is pushed.
"HORN" switch
is not pushed
0:Continuity x
q$
-
: Nocontinuity
"HORN" switch is faulty, replace handlebar
switch.
I( GOOD
CONDITION
2. Voltage check
.Connect the Pocket Tester (DC20V) to the
1 horn at the brown terminal.
I
r Tester ( + 1 Lead+Brown @ Lead
Tester ( - ) Lead* Frame Ground
SIGNAL SYSTEM I ELEC 1 s 1
-
3(Dz -@
* OUT OF SPECIFICATION
.Check for voltage (6V) on the "Brown" lead

at the horn terminal. I I Wiring circuit from main switch to horn termi-
I nal is faulty, repair.
II MEETS
3. Horn check
disconnect the "Pink" lead at the horn
terminal.
connect a jumper lead @ to the horn termi-
nal and ground the jumper lead.
HORN IS SOUNDED
V Horn is good.
HORN IS NOT
SOUNDED
4. Voltage check

horn at the Pink terminal.
+
Tester ( ) Lead+Pink @ Lead
Tester ( - 1 Lead+Frame Ground
SIGNAL SYSTEM I ELEC 1 I
.Check for voltage (6V) on the "Pink" lead at OUT OF SPECIFICATION
the horn terminal.
MEETS SPECIFICATION
(6V)
Horn is faulty, replace it.
Adjust or replace horn.
2. Brake light does not come on when applying rear or front brake.
*Connect the Pocket Tester (Qx 1k) to the

bulb.
Tester ( + ) Lead-tTerminal @
Tester ( - ) Lead-tTerminal @
+
Tester ( ) LeadjTerminal @
Tester ( - LeadjTerminal @
CONTINUITY DOES NOT

EXIST ON ONE CIRCUIT
TailIBrake light bulb is faulty, replace it.

I .Check the bulb for continuity.
CONTINUITY EXISTS
BOTH CIRCUITS
2. Front brake switch check

.Disconnect the front brake switch coupler
(Brown and GreenIYellow) from the wire-
harness.
.Connect the Pocket Tester (Qx 1) to the brake
switch leads.
Tester ( + ) Lead-t Brown @ Lead

Tester ( - ) Lead+Green/Yellow @
Lead
SIGNAL SYSTEM I ELEC 1 E3 1
@Checkthe brake switch for continuity.

BAD CONDITION
Switch
position
/ c o ~ I ~Bad~condition
~ n
Front brake
is applied.
Front brake
is not applied 1 Front brake switch is faulty, replace it.
0: Continuity x : Nocontinuity
GOOD
CONDITION
3. Voltage check
@Connectthe Pocket Tester (DC20V) to the
front brake switch.
- - - -
Tester ( + ) Lead-Brown @ Lead

Tester ( - ) Lead+Frame Ground
.Check for voltage (6V) on the "Brown" lead

at the brake switch coupler.
I Wiring circuit from main switch to brake switch
connector is faulty, repair. I
MEETS
SPECIFICATION (6V)
3C
SIGNAL SYSTEM I ELEC 1 Is 1
4. Rear brake switch check
*Disconnect the rear brake switch leads

(Brown and Yellow) from the wireharness.
*Connect the Pocket Tester ( Q x 1) to the brake
switch lead.
*Check the brake switch for continuity.
Switch
position
1 c ~ ~ I ~Bad~condition
o n
BAD CONDITION
Rear brake
is applied.
Rear brake
X O X 0 Rear brake switch is faulty, replace it.
is not applied
5. Voltage check
*Connect the Pocket Tester (DC2OV) to the
rear brake switch.
+
Tester ( ) Lead-Brown @ Lead
Tester ( - ) Lead+ Frame Ground
SIGNAL SYSTEM I ELK 1 a 1
*Check for voltage (6V) on the "Brown" lead OUT OF SPECIFICATION
at the brake switch connecter.
MEETS
Wiring circuit from main switch to brake switch
SPECIFICATION (6V)
connector is faulty, repair.
TailIBrake light bulb socket is faulty, replace

taillbrake light assembly.
3. Flasher lights do not blink.
1. Bulb check
*Remove the flasher light bulb.

*Connect the Pocket Tester ( Q x 1k) to the
bulb.
+
Tester ( ) LeadjTerminal @
Tester ( - ) Lead-+Terminal @
*Check the bulb for continuity. I Bulb is faulty, replace it. I

CONTINUITY
2. Bulb socket check
*Install the bulb t o the socket.

*Disconnect the flasher light leads [(Chocolate
and Black) or (Dark green and Black)]
*Connect the Pocket Tester ( Q x 1k) to the
flasher light leads.
When checking right flasher light:

+
Tester ( ) Lead-+DarkGreen @) Lead
Tester ( - 1 Lead-Black @ Lead
When checking left flasher light:

+
Tester ( ) Lead-+Chocolate @ Lead
Tester ( - ) LeadjBlack @) Lead
n
7-39
SIGNAL SYSTEM I ELEC I I
NOCONTINUITY
Bulb socket is faulty, replace flasher light as-

*Check the bulb socket for continuity. sembly.
4 ICONTINUITY
I I
3. "TURN" switch check

[(Chocolate, Dark green, Yellow and Green)
*Connect the Pocket Tester (Qx I ) to the
"TURN" switch leads.
When turning "TURN" switch to "R":

+
Tester ( ) Lead-BrownIWhite @
Lead
Tester ( - 1 Lead-Dark green @ Lead
When turning "TURN" switch to "L":

+
Tester ( ) Lead-BrownIWhite @
Lead
Tester ( - ) Lead-Chocolate @ Lead
.Turn the "TURN" switch to the "R" and "L".

*Check the "TURN" switch for continuity.
BAD CONDITION
position
Switch I condition
Oood I Bad condition
0: Continuity
-- - -
x: Nocontinuity
U GOOD
I "TURN" switch is faulty, replace handlebar
switch.
* CONDITION
SIGNAL SYSTEM I ELEC 1 1
4. Voltage check
*Connect the Pocket Tester (DC20V) t o the

flasher relay.
Tester ( + 1 Lead-tBrown @ Lead

Tester ( - 1 Lead* Frame Ground
0
f /DCZOV(
u -
-
*Check for voltage (6V) on the "Brown" lead

at the flasher relay terminal.
II
Wiring circuit from main switch t o flasher re-
lay connector is faulty, repair.
I
SPECIFICATION (6V)
Flasher relay is faulty, replace it.

DISPLAY SYSTEM I ELEC 1 1
NOTE:
@ CDl magneto @ Ignition control unit

@ RectifierIRegulator @ Flasher relay
a Main switch
@ Fuse
0 "TURN" switch
@ "TURN" indicator light
@ Battery @"OIL"
I warning indicator light
@ "LIGHTS" (Dimmer) switch @ Oil level switch
0 "HIGH BEAM" indicator light @ "NEUTRAL" indicator light
@ Meter light @ Neutral switch
DISPLAY SYSTEM I 1 ELEC I
TROUBLESHOOTING (1)
METER LIGHT AND/OR "HIGH BEAM" INDICATOR LIGHT DO NOT COME ON.
Procedure
Check;
1) Meter light and "HIGH BEAM" indicator light
2) "LIGHTS" (Dimmer) switch
3) Lighting circuit output
4) Lighting coil resistance
5)Wiring connection
NOTE:
.Remove the following parts before troubleshooting.
1) Seat
2) Side cover
Pocket Tester: Inductive Tachometer:

YU-03112 Y U-08036
1. Meter light and "HIGH BEAM" indicator

light
*Remove the bulb (Meter light or "HIGH

BEAM" indicator light).
*Connect the Pocket Tester (Ox 1k) to the
bulb.
+
Tester ( ) Lead-tTerminal @
Tester ( - 1 Lead-tTerminal @
I Bulb is faulty. replace it.

.Check the bulb for continuity.
CONTINUITY
*
DISPLAY SYSTEM I ELEC 1
2. "LIGHTS" (Dimmer) switch
lDisconnect the handlebar switch couplers

[(Chocolate, Green, Dark green and Yellow)
.Connect the Pocket Tester ( a x 1) to the
"LIGHTS" (Dimmer) switch leads.

to "HI":
Tester ( + 1 Lead-tYellowIRed @ Lead
Tester ( - ) Lead-tYellow @ Lead

to "LO":
Tester ( + ) Lead-tYellowIRed @ Lead
Tester ( - ) Lead-t Green @) Lead
*Turn the "LIGHTS" (Dimmer) switch to the

"HI" and "LO".
*Check the "LIGHTS"' (Dimmer) switch for
continuity. BAD CONDITION
Switch
~osition
I condition
I Bad condition
I 1 I I
"LIGHTS" (Dimmer) switch is faulty, replace
0:Continuity x : Nocontinuity handlebar switch.
GOOD CONDITION
3. Lighting circuit output

*Turn the "LIGHTS" (Dimmer) switch to
"LO".
*Connect the Pocket Tester (AC V-20) to the
headlight leads.
Tester ( + 1 Lead-Green @ Lead

7-45
Tester ( - 1 Lead-tBlack @ Lead
DISPLAY SYSTEM I ELEC 1 1
.Connect the Inductive Tachometer to the

spark plug lead.
.Start the engine and check the output
voltage.
MEETS SPECIFICATION
Do not run the engine in neutral above
6,000 rlmin for more than 1 or 2 seconds.
0 Bulb socket is faulty, replace it.
4. Lighting coil resistance

wireharness.
K o n n e c t the Pocket Tester (Qx 1) to the light-
ing coil leads.
Tester ( + ) Lead+Yellow/Red @ Lead

Tester ( - ) Lead-tBlack @ Lead
.Check the lighting coil for specificated

resistance.
DISPLAY SYSTEM I ELEC ( I
I
n
a Lighting Coil Resistance:
0.16-0.24, at 20°C (68OF)
(YellowIRed- Black)
I
I
Lighting coil is faulty, replace it.
MEETS
SPECIFICATION
1 5. Wiring connection
Check the entire display system for connec-

section.
I i
I I
Correct.
CORRECT
I RectifierIRegulator is faulty, replace it.

I
DISPLAY SYSTEM IELK1 m I
TROUBLESHOOTING (21
"TURN", "NEUTRAL" INDICATOR LIGHT AND/OR "OIL" WARNING INDICATOR LIGHT

DO NOT COME ON.
Procedure
Check;
1) Fuse
2) Battery
3) Main switch
4) Wiring connection
NOTE:
.Remove the following parts before troubleshooting.
1) Seat
2) Side cover
I 1. Fuse I NOCONTINUITY
.Remove the fuse.

Connect the Pocket Tester (Q x 1) to the fuse. i
.Check the fuse for continuity. Fuse is faulty, replace it.
CONTINUITY
1 2. Battery I
.Check the battery condition.
Refer to the "BATTERY INSPECTION" sec- INCORRECT
tion in the CHAPTER 3.
- -- -
Specific Gravity:
1.280 at 20°C (68OF) .Refill battery fluid.
.Clean battery terminals.
I CORRECT .Recharge or replace battery.
1 3. Main switch
.Disconnect the main switch coupler (Red,

Brown and Black) from the wireharness.,
Connect the Pocket Tester (Qx 1) to the main
switch leads.
DISPLAY SYSTEM 1 ELK 1 a 1
Tester ( + 1 Lead+Red @ Lead
Tester ( - 1 Lead* Brown @ Lead
.Turn the main switch to "ON" and "OFF".

.Check the main switch for continuity.
BAD CONDITION
Switch
position
ON
I condition
Oood
0
I x
Bad condition
x 0
OFF x 0 x 0 F s s w i t c h i s a u ~
replace
t y , it.
(I GOOD CONDITION
INCORRECT
Check the entire display system for connec-
section.
I Correct.
I
CORRECT
Go to the "DISPLAY SYSTEM TEST AND

CHECK" section.
DISPLAY SYSTEM
DISPLAY SYSTEM TEST AND CHECK
1. "NEUTRAL" indicator light does not come on.
1. Bulb check
*Remove the bulb.

*Connect the Pocket Tester ( Q x l k ) to the
bulb.
+
Tester ( ) Lead-+Terminal @
Tester ( - 1 Lead-+Terminal @
*Check the bulb for continuity 1 Bulb is faulty, replace it.

I
2. Neutral switch check

#Disconnect the CDI magneto coupler (Sky
wireharness.
.Connect the Pocket Tester ( Q x 1) to the neu-
tral switch leads.
Tester ( + ) Lead+Sky blue @ Lead

DISPLAY SYSTEM I ELEC I El (
.Shift the transmission in neutral and gear.
.Check the neutral switch for continuity.
1
Trans- BAD CONDITION

Good
mission Bad condition
condition
position
Neutral I
0 I
xx / 0
Gear x 101 x 0 Neutral switch is faulty, replace it.
I
GOOD CONDITION
3. Voltage check
-
"NEUTRAL" indicator light lead.
-
Tester ( + 1 LeadhBrown @ Lead
Tester ( - ) Lead-+Frame Ground
-
Q 1 EVT2 S b Y
D Ch
B
L
B Y Sb
L Ch Dg
I
-
3 Wireharness
.Check for voltage (6V) on the "Brown" lead Wiring circuit from main switch to "NEUTRAL"
at the connector. indicator light connector is faulty, repair.
-
MEETS
II SPECIFICATION (6V)
Ignition control unit is faulty, replace it.

DISPLAY SYSTEM I ELEC 1 Is 1
2. "OIL" warning indicator light does not come on.
1. "OIL" warning indicator light (L.E. D.

check
*Disconnect the meter coupler (BlackIRed,

Brown, Sky blue, Yellow, Black, Dark green,
Chocolate and Blue) from the wireharness.
.Connect a full charged battery (6V) to the
meter coupler.
Battery ( + Lead+Brown @) Lead

Battery ( - 1 Lead-+Black/Red @ Lead
INDICATOR LIGHT DOES

NOT COME ON.
"OIL" warning indicator light (L.E.D.) is faulty,

replace it.
I1
II
INDICATOR LIGHT
COMES ON.
2. Oil level switch check ( 1 )
*Remove the oil level switch from the oil tank. (

.Connect the Pocket Tester (M x 1) to the oil (
level switch lead.
Tester ( + 1 Lead+Black/Red @) Lead

Tester ( - 1 Lead-+Sky blue @ Lead
Oil level switch is faulty, replace it.

.Check the oil level switch for continuity.
CONTINUITY
3C
DISPLAY SYSTEM 1 ELEC
fiV
3. Oil level switch check (2)
.Connect the Pocket Tester ( Q x 1) t o the oil

level switch.
Tester ( + ) Lead-+Black/Red @ Lead

Tester ( - 1 Lead-tBlack @ Lead
.Check the oil level switch for continuity.

Switch
position
Good
condition
1 Bad condition
BAD CONDITION
Upright
position
Up-side down
position
Oil level switch is faulty, replace it.
I
II
4 V
!
GOOD
CONDITION
4. Voltage check
- -
.Connect the Pocket Tester (DC2OV) t o the

"OIL" warning indicator light.
+
Tester ( ) L e a d 4 Brown @ Lead
@@y,RLE&Tl
Tester ( - 1 Lead+Frame Ground
S b Y B B Y Sb
D Ch L L Ch Dg
@ Wireharness
DISPLAY SYSTEM I ELEC 1 a 1
I *Check for voltage (6V) on the "Brownr' lead I OUT OF SPECIFICATION
at connector.
MEETS i
@PECIFICATION (6V) Wiring circuit from main switch to "OIL" warn-
ing indicator light connecter is faulty, repair.
Wiring connection is faulty, correct.
3. "TURN" indicator light does not come on.
1. Bulb Check
*Remove the bulb.
*Connect the Pocket Tester (Q x 1k) to the
bulb.
Tester ( + 1 Lead-Terminal @
Tester ( - 1 Lead-tTerminal @
*Check the bulb for continuity. I Bulb is faulty, replace it.

I
II
I 2. "TURN" switch check

[(Chocolate, Dark green, Yellow and Green)
*Connect the Pocket Tester (Q x 1) to the
"TURN" switch leads.
- --
turning "TURN" switch to "R":

Tester ( + 1 Lead+Brown/White @
Tester ( - 1 Lead-+Dark green @ Lead
Tester ( + 1 Lead+ BrownIWhite @

*Turn the "TURN" switch to the "R" and "L".
.Check the "TURN" switch for continuity.
BAD CONDITION
Switch
position
1 c ~ ~ 1 ~Bad~condition
o n
L 0 l o l x j x "TURN" switch is faulty, replace handlebar

switch.
II GOOD
db CONDITION
3. Voltage check

flasher relay.
+
Tester ( ) Lead+Brown @ Lead
Tester ( - ) Lead-Frame Ground
u -
.Check for voltage (6V) on the "Brown" lead Wiring circuit from main switch to flasher re-
at the flasher relay terminal. lay connector is faulty, repair.
MEET
SPECIFICATION (6V)
Flasher relay is faulty, replace it.

I
STARTING FAILUREIHARD STARTING
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide t o troubleshooting. Refer to the relative procedure in this manual for inspection,
adjustment and replacement of parts.
STARTING FAILUREIHARD STARTING
rt
FUEL S'rE T E M PROBABLE CAUSE
Empty
.Clogged fuel filter
Clogged air passage (Fuel tank cap)
.Deteriorated fuel or fuel containing water or
foreign material
lanky
Fuel cock .Clogged fuel hose
- Carburetor - .Deteriorated fuel, fuel containing water or

foreign material
*Clogged pilot jet
.Clogged pilot air passage
.Sucked-in air
Deformed float
*Groove-worn needle valve
Improperly sealed valve seat
Improperly adjusted fuel level
.Improperly set pilot jet
*Clogged starter jet
.Starter plunger malfunction
L
- *Improperly adjusted starter cable
- Air cleaner *Clogged air filter

STARTING FAlLURE/HARD STARTING lSHTG 1 3. I
TRBL
:AL SYSTEM PROBABLE CAUSE

- Spark plug *Improper plug gap
.Worn electrodes
*Wire between terminals broken
*Improper heat range
*Faulty spark plug cap
Ignition coil *Broken or shorted primarylsecondary

*Faulty spark plug lead
*Broken body
C.D.I. unit system *Faulty C.D.I. unit
-7 *Faulty source coil

*Faulty pick-up coil
*Broken woodruff key
L Switches and wiring *Faulty main switch
7 *Faulty engine stop switch

*Broken or shorted wiring
*Faulty neutral switch
*Faulty sidestand switch
*Faulty Ignition control unit
STARTING FAILUREIHARD STARTINGIPOOR
COMPRESSION SYSTEM
IDLE SPEED PERFORMANCE
PROBABLE CAUSE
rTRBL 3
l
Cylinder and cylinder head .Loose spark plug
.Loose cylinder head or cylinder
.Broken cylinder head gasket
*Broken cylinder gasket
.Worn, damaged or seized cylinder
Piston and piston rings .Improperly installed piston ring

.Worn, fatigued or broken piston ring
.Seized piston ring
.Seized or damaged piston
t Crankcase and crankshaft
Reed valve
.Improperly seated crankcase
.Improperly sealed crankcase (Damaged oil seal)
.Seized crankshaft
Deformed reed valve stopper

.Improperly seated read valve
Loose intake manifold
.Broken gasket
.Broken reed valve
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE PROBABLE CAUSE
Carburetor .Improperly returned starter plunger
.Clogged or loose pilot jet
.Clogged pilot air jet
*Improperly adjusted idle speed
(Throttle stop screw)
.Improper throttle cable play
- *Flooded carburetor
POOR MEDIUM AND HlGH SPEED PERFORMANCE 1- SHTG
POOR MEDIUM AND HlGH SPEED PERFORMANCE
FUEL SYSTEM PROBABLE CAUSE
I"'t
.Clogged fuel filter
Deteriorated fuel or fuel containing water
or foreign material
Clogged air passage (Fuel tank cap)
' kna t
Fuel cock .Clogged fuel hose
- Carburetor - .Deteriorated fuel, fuel containing water or

foreign material
.Sucked-in air
.Deformed float
.Groove-worn needle valve
.Improperly sealed valve seat
.Improperly set clip position of jet needle
.Improperly adjusted fuel level
.Clogged or loose main jet
-
- .Clogged or loose main nozzle
I- Air cleaner .Clogged air filter
ELECTRICAL SYSTEM PROBABLE CAUSE

Spark plug .Improper plug gap
.Worn electrodes
*Wire between terminals broken
.Improper heat range
.Faulty spark plug cap
L- C.D.I. unit system .Faulty C.D.I. unit

*Faulty source coil
.Faulty pick-up coil
POOR MEDIUM AND HIGH SPEED PERFORMANCE 1 3. 1
FGTRBL
COMPRESSION SYSTEM PROBABLE CAUSE

Cylinder and cylinder head *Loose spark plug
Broken cylinder head gasket
*Broken cylinder gasket
*Loose cylinder head or cylinder
*Worn, damaged or seized cylinder
Piston and piston ring Improperly installed piston ring

*Worn, fatigued or broken piston ring
.Seized piston ring
.Seized or damaged piston
Crankcase and crankshaft *Improperly seated crankcase

Improperly sealed crankcase
(Damaged oil seal)
*Seized crankshaft
Reed valve *Deformed reed valve stopper

*Improperly adjusted reed valve stopper height
elmproperly seated reed valve
*Loose intake manifold
*Broken gasket
*Broken reed valve
FAULTY GEAR SHIFTING
FAULTY GEAR SHIFTING

HARD SHIFTING PROBABLE CAUSE
- Clutch .Improperly adjusted clutch cable
*Improperly adjusted push lever position
*Improper engagement of push lever and push
rod
*Seized bush at primary driven gear
*Warped clutch plate
*Swollen friction plate
-*Broken clutch plate
Transmission oil *High oil level

*Improper quality (High viscosity)
*Deterioration
CHANGE PEDAL DOES NOT MOVE PROBABLE CAUSE
t Shift shaft *Improperly adjusted shift rod

.Bent shift shaft
t Shift cam and shift fork
Transmission
.Groove jammed with impurities
.Seized shift fork
.Bent shift fork guide bar
.Seized transmission gear

*Jammed impurities
*Incorrectly assembled transmission
JUMP-OUT GEAR PROBABLE CAUSE
t Shift shaft *Improperly adjusted shift lever position

*Improperly returned stopper lever
t Shift fork *Worn shift fork
t Shift cam
Transmission
L
*Improper thrust play
*Worn shift cam groove
*Worn gear dog

CLUTCH SLIPPINGIDRAGGING lSHTG 1 3. I
TRBL
CLUTCH SLIPPINGIDRAGGING
CLUTCH SLIPPING PROBABLE CAUSE
.Improperly adjusted clutch cable
Noose clutch spring
Watigued clutch spring
.Worn friction plate
.Worn clutch plate
L Transmission oil .Low oil level

-Improper quality (Low viscosity)
-Deterioration
CLUTCH DRAGGING PROBABLE CAUSE

I
- Clutch - .Improperly adjusted clutch cable
.Improperly adjusted pull lever position
elmproper engagement of pull lever and pull rod
.Seized bush at primary driven gear
.Warped clutch plate
.Swollen friction plate
- .Broken clutch boss
L Transmission oil -High oil level
elmproper quality (High viscosity)
-Deterioration
IMPROPER KICKING
SLIPPING PROBABLE CAUSE
Kick axle assembly .Low tension of kick clip
.Worn kick axle
.Worn or damaged kick idle gear
.Worn or damaged kick gear
.Damaged kick clip
@Kickclip coming off
.Damaged kick clip stopper
L Transmission oil -Improper quality (Low viscosity)

.Deterioration
HARD KICKING PROBABLE CAUSE
t
Kick axle assembly .High tension of kick clip
*Seized kick gear
.Seized kick idle gear
t Transmission oil
Cylinder, piston and piston ring

.Improper quality (High viscosity)
.Deterioration
.Damaged or seized cylinder
T
.Damaged or seized piston
.Damaged or seized piston ring
Crankcase and crankshaft -Improperly seated crankcase
7 @Improperlyseated crankshaft
.Damaged or seized crankshaft
.Damaged or seized crankshaft bearing
KICK CRANK NOT RETURNING PROBABLE CAUSE

L Kick axle assembly -Damaged kick return spring
.Kick return spring coming off
@Kickclip coming off
* Damaged kick return spring stopper
FAULTY BRAKEIFRONT FORK OIL LEAKAGE
A N D FRONT FORK MALFUNCTION
FAULTY BRAKE
POOR BRAKING EFFECT PROBABLE CAUSE
.Worn brake pad
.Worn brake disc
.Air in brake fluid
.Leaking brake fluid
.Faulty cylinder kit cup
*Faulty caliper kit seal
.Loosen union bolt
.Broken brake hose
*Oily or greasy brake disc
.Oily or greasy brake pad
.Improper brake fluid level
L ~ r u mbrake .Worn brake shoe
I .Worn or rusty brake drum

.Improperly adjusted brake cablelpedal free play
.Improper brake cam lever position
.Improper brake shoe position
.Fatigued orldamaged return spring
.Oily or greasy brake shoe
*Rusty, oily or greasy brake drum
.Broken brake cable
FRONT FORK OIL LEAKAGE A N D FRONT FORK MALFUNCTION

OIL LEAKAGE PROBABLE CAUSE
.Bent, damaged or rusty inner tube
.Damaged or cracked outer tube
.Damaged oil seal lip
.Improperly installed oil seal
.Improper oil level (too much)
Loose damper rod holding bolt
.Broken cap bolt O-ring
*Loose drain bolt
L Damaged drain bolt gasket
MALFUNCTION PROBABLE CAUSE

- .Bent, deformed or damaged inner tube
.Bent or deformed outer tube
.Damaged fork spring
.Worn or damaged slide metal
.Bent or damaged damper rod
Improper oil viscosity
- .Improper oil level
INSTABLE HANDLING
1
INSTABLE HANDLING
Handlebars
PROBABLE CAUSE
4mproperly installed or bent
Steering .Improperly installed handle crown

.Bent under-bracket
.Improperly installed steering shaft
(Improperly tightened ringnut)
.Damaged ball bearing or bearing race
Irt
Front forks .Uneven oil levels on both sides
.Uneven spring tension
(Uneven damping adjuster position)
.Broken spring
.Twisted front forks
Tires .Uneven tire pressures on both sides

.Incorrect tire pressure
.Unevenly worn tires
Wheels rlncorrect wheel balance
T .Deformed cast wheel

.Loose bearing
.Bent or loose wheel axle
excessive wheel run-out
.Twisted
.Damaged head pipe
.Improperly installed bearing race
Swingarm .Worn bearing or bush

cent or damaged
tt Rear shock absorber
Drive chain
-Fatigued spring
-Improperly adjusted spring preload
.Oil leakage
.Improperly adjusted chain slack
mDamaged or broken
.Incorrectly installed
FAULTY SIGNAL A N D LIGHTING SYSTEM 1- SHTG
FAULTY SIGNAL AND LIGHTING SYSTEM
HEADLIGHT DARK PROBABLE CAUSE
*Improper bulb
*Too many electric accessories
*Hard charging (Broken charging coil and/or
faulty rectifierlregulator)
.Incorrect connection
*Improperly grounded
- *Poor contacts (main or light switch)

*Bulb life expired
BULB BURNT OUT PROBABLE CAUSE

*Improper bulb
*Faulty battery
*Faulty rectifierlregulator
*Faulty main and/or light switch
- *Bulb life expired
FLASHER DOES NOT LIGHT PROBABLE CAUSE

*Discharged battery
.Faulty flasher switch
@Faultyflasher relay
*Broken wireharness
*Loosely connected coupler
- *Bulb burnt out
FLASHER KEEPS ON PROBABLE CAUSE

*Faulty flasher relay
*Insufficient battery capacity
(nearly discharged)
*Bulb burnt out
FAULTY SIGNAL AND LIGHTING SYSTEM pTTJ
SHTG
FLASHER WINKS SLOWER PROBABLE CAUSE
Faulty flasher relay
.Insufficient battery capacity
(nearly discharged)
.Improper bulb
.Faulty main and/or flasher switch
,
FLASHER WINKS QUICKER PROBABLE CAUSE
.Improper bulb
.Faulty flasher relay
HORN IS INOPERATIVE PROBABLE CAUSE
7 Faulty battery
.Faulty main and/or horn switch
.Improperly adjusted horn
.Faulty horn
.Broken wireharnes
3
OVERHEATING
TRBL
IsmGI I
OVERHEATING
OVERHEATING PROBABLE CAUSE
t
Ignition system
Fuel system
.Improper spdrk plug gap
.Improper spark plug heat range
.Faulty C.D.I. unit
.Improper carburetor main jet

(Improper setting)
.Improperly adjusted fuel height
.Clogged air cleaner element
.Lean mixture (Faulty autolube pump settings)
t Compression system Heavy carbon build-up
t
t
Transmission oil
Brake
.Incorrect oil level
Improper oil viscosity
.Inferior oil quality
Dragging brake
.Worn friction plate

Clutch C *Worn clutch plate

1987 YAMAHA YSR 50T Service Manual

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1987 YAMAHA YSR 50T Service Manual

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@YAM AHA

HOW TO USE THIS MANUAL

PARTICULARLY IMPORTANT INFORMATION

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

A CAUTION indicates special procedures that must be followed to avoid damage

A WARNING indicates special procedures that must be followed to avoid injury to

Illustrated symbols @ t o @ are designed as

Illustrated symbols @ to @ are used to identify

Illustrated symbols 0to @ in the exploded dia-

MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 .

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4.

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1

MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2..4

GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

DEFINITION OF UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

PERIODIC INSPECTION AND ADJUSTMENT

PERIODIC MAINTENANCE/LUBRlCATlON INTERVALS . . . . . . . . . . . . 3.1

COWLINGS REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 3.3

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 .

ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4..5

INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13 .

ENGINE ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 4.24 .

REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 .

REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10

FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20

REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . .6.33

DRIVE CHAIN AND SPROCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.38

YSR50T CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3

IGNITION AND STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16

LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22

SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30

DISPLAY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.42

STARTING FAILUREIHARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1

POOR M E D I U M AND HIGH SPEED PERFORMANCE . . . . . . . . . . . . . .8.4

FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8..6

HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

IMPROPER KICKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 .

FAULTY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION . . . .8.9

INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10

FAULTY SIGNAL AND LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8.11 .

YSR5OT WIRING DIAGRAM

PREPARATION FOR REMOVAL AND

2. Use proper tools and cleaning equipment.

3. When disassembling the motorcycle, keep

4. During the motorcycle disassembly, clean all

5. Keep away from fire.

GASKETS, OIL SEALS, AND O-RINGS

2. Properly oil all mating parts and bearings dur-

LOCK WASHERSIPLATES AND COlTER

BEARINGS AND OIL SEALS

Do not use compressed air to spin the bear-

This tool is necessary for adjusting ignition timing.

2. Fuel Level Gauge

This gauge is used to measure the fuel level in

This tool is needed for detecting engine rpm.

FOR ENGINE SERVICE

This tool is used to hold the clutch when loosen-