Professional Documents
Culture Documents
MOTORCYCLE
SERVICE MANUAL
2YT281972000 *2YT281972000*
CE50T SERVICE MANUAL 1986 by Yamaha Motor Co., Ltd. 1st Edition, November 1986 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
D
NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha scooter have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology. Without: such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLES OPERATIONS YAMAHA MOTOR CO., LTD.
ili
MANUAL
FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., Bearings Pitting/Damage_ Replace.
EXPLODED
DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.
(9
iLLUSTRATED
SYMBOLS
IGENINFO
(_ (_)
ENG
(_
%_JDI
IC (_)
OOL _i
_ _
Periodic inspection and adjustment General information Cooling system Engine Carburetion Chassis
ICARB[
]_
_"AS1_I
Illustrated
symbols
6_
appearing
in the text.
(_)
(_)
--
.,1 -
_ _ _
@
j = _
Illustrated
symbols
(_
to (_
in the
exploded
diagram indicate grade of lubricant of lubrication point. Apply engine o,1 Apply gear oil @(_ Apply wheel bearing disulfide oil molybdenum grease
and location
@ _ _
(_ _
(_ _L_.._
Apply lightweight disulfide _(_)) pply molybdenum lithium-soapgrease grease A base Apply locking agent (LOCTITE )
INDEX
GENERAL ON ,NFORMAT,
ENGINE OVERHAUL
'_'%_
ENG _
CARBURETION
CARB_,
CHASSIS
CHAS_
L..,-.-----J
ELECTRICAL
ELEC_
APPENDICES
APPX_
i
!
i i
1
p,
GEN
CHAPTER 1 GENERAL INFORMATNON
SCOOTER IDENTIFICATION ....................................... VEHICLE IDENTIFICATION NUMBER .............................. ENGINE SERIAL NUMBER ....................................... IMPORTANT INFORMATION ...................................... ALl. REPLACEMENT PARTS ..................................... GASKETS, OIL SEALS, AND O-RINGS ............................ LOCK WASHER/PLATES AND COTTER PINS ..................... BEARINGS AND OIL SEALS ..................................... CIRCLIPS ...................................................... SPECIAL TOOLS .................................................. FOR TUNE-UP .................................................. FOR ENGINE SERVICE .......................................... FOR CHASSIS SERVICE ......................................... FOR ELECTRICAL COMPONENTS ................................ B-3 B-3 B-3 B-3 B-3 B-3 B-3 B-4 B-4 B-4 B-4 B-4 B-5 B-5
INFO
The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing outhority in your state.
Starting Serial Number: JYA2U G00-~ H A720101 ENGINE SERIAL N U M B E R The engine serial number ( ~ is stamped into the crankcase. NOTE:
The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.
1-1
IMPORTANT
INFORMATION IMPORTANT
ALL REPLACEMENT
IE"
INFO
PARTS
INFORMATION
1. Use only genuine Yamaha parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality.
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 during reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES PINS AND COTTER
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. 1. All lock washers/Plates (_ and cotter pins
1-2
INFO
iMPORTANT
iNFORMATiON
BEARINGS AND OIL SEALS manufacturer's marks or numbers facing outward. (In other words, the stamped letters
__)
installing oil seal(s), apply a to view.) light coating of i. must be on the side exposedseal(s) withWhen Install the bearing(s) and oil their lip(s). Oil the bearings liberally when installing. light-weight lithium base grease to the seal (_ Oil seal
(_
Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.
(_ Bearing CIRCLIPS 1. All circlips should be inspected carefully clips after one use. Replace distorted circlips.
_/._/7_/_////_ /J (_)
the sharp edged corner (_ is positioned opWhen installing a cirelip it receives. sure th at posite to the thrust (_) (_, make See the sectional view. (_) Shaft
1-3
I GEN
I
The proper special tools are necessary for complete 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 Tachometer P/N. YU-08036 This tool is needed for detecting engine rpm.
2. Compression Gauge P/N. YU-33223 This gauge is used to measure engine compression.
FOR ENGINE SERVICE 1. Flywheel Holding Tool P/N. YU-01235 This tool is used to the hold the flywheel magneto and clutch assembly when removing or installing the securing nut.
2. Flywheel Magneto Puller P/N. YM-01189 This tool is used to remove the flywheel.
1-4
I GEN
SPECIAL TOOLS
i . . . . . . . . . . . . . ir
P
3. Primary Sheave Holder P/N. YS-01880 This tool is used when holding the clutch hub.
4. Clutch Spring Holder P/N. YS-28891 This tool is used to disassembly and assembly the secondary sheave.
6. Universal Puller Set P/N. YU-33270 This tool is used to remove the crankshaft from the crankcase.
7. Crankcase Separating Tool P/N. YU-01135 This tool is used to remove the crankshaft or separate the crankcase.
1-5
SPECIAL TOOLS I
I GEN
,.Fol l
8. Crankshaft Installation Set P/N. YU-90050 . . . . . . . . . . . . . . . . . . . . . . (~) Adapter (M10) P/N. YM-90062 . . . . . . . . . . . . . . . . . . . . . (~ Adapter (M12) P/N. YM-90063 . . . . . . . . . . . . . . . . . . . . . ~) These tools are used to install the crankshaft.
9. Sealant (Quick Gasket~) P/N. ACC-11001-05-01 This sealant (bond) is used for crankcase mating surfaces.
(~ (~
This tool is used to loosen and tighten the steering ring nut.
FOR ELECTRICAL C O M P O N E N T S 1. Pocket Tester P/N. YU-03112 This instrument is invaluable for electrical system inspection and djustment.
!J
2. Electro Tester P/N. YU-33260 This instrument is necessary for ignition system inspection.
1-6
PERIODIC MAINTENANCE/LUBRICATION
TAIL COVER ..................................................... REMOVAL .................................................... INSTALLATION ................................................ FRONT FENDER, FRONT PANEL AND FOOTREST BOARD ......... REMOVAL .................................................... INSTALLATION ................................................ HANDLEBAR COVERS ........................................... REMOVAL ..................................................... INSTALLATION ................................................ ENGINE .......................................................... ENGINE IDLE SPEED ADJUSTMENT ............................. THROTTLE CABLE FREE PLAY ADJUSTMENT ................... AUTOLUBE PUMP CABLE ADJUSTMENT ........................ AUTOLUBE PUMP AIR BLEEDING ............................... AIR CLEANER ELEMENT CLEANING ............................. FUEL COCK CLEANING ........................................ COMPRESSION PRESSURE MEASUREMENT ..................... ENGINE OIL LEVEL INSPECTION ................................ TRANSMISSION OIL REPLACEMENT .... ........................ FUEL LINE INSPECTION ........................................ CHASSIS ........................................................ FRONT BRAKE LEVER FREE PLAY CHECK ....................... REAR BRAKE LEVER FREE PLAY CHECK ....................... FRONT AND REAR BRAKE LINING INSPECTION ................ TIRE AND WHEEL INSPECTION ................................. STEERING ADJUSTMENT ...................................... ELECTRICAL ..................................................... BATTERY ..................................................... FUSE INSPECTION ............................................. SPARK PLUG INSPECTION ..................................... HEADLIGHT BEAM ADJUSTMENT .............................. IGNITION TIMING .........................................
.....
ADJ I INSPli
PERIODIC INTRODUCTION
MAINTENANCE/ ADJUSTMENTS
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventiw, maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies 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
MAINTENANCE/LUBRICATION
INTERVALS
Unit: km (mi) EVERY BREAK-IN 500 3,000 6,000 (300) (2,000) or (4,000) or 6 months 12 months O O Replace O O O O Check O O O Check O O O O
ITEM
REMARKS
Spark plug Air filter Carburetor Fuel line Transmission oil Autolube pump Brake Wheels* Wheel bearings Steering bearing Rear shock absorber Fittings/Fasteners Battery V-belt **:
Check/Clean or replace. Clean. Replace if necessary. Check/Adjust/idle speed, starter operation. Check fuel hose for cracks or damage. Replace (Warm engine before draining). Every 12,000 (8,000) or 24 months. Check/Adjust/Air bleeding. Check operation. Adjust if necessary. Check balance/damage/runout. Check bearings assembly for looseness/ damage. Replace if damaged. Check bearings assembly for looseness. Moderately repack every 12,000 (8,000) or 24 months.** Check operation. Check all chassis fittings and fasteners. Check specific gravity. Check breather pipe for proper operation. Check damage and wear. Replace if necessary.
Check
Check O
Check O O O O
O O
2-1
ADJ
3. Remove: -Cover (_
4. Remove: ,Grab bar , Rear carrier (With rear flasher lights and taillight) 5. Disconnect: ,Rear flasher light leads Taillight leads
6. Remove: Side covers (Right and left) NOTE: When removing the side cover, unhook it at the front and slide it forward.
2-2
INSP _1 ADJ
TA'LCOVER
INSTALLATION When installing the tail cover, reverse the "REMOVAL" procedure. Note the following points.
1. Install: Side covers NOTE: After installing the side covers, make sure that all hooks are securely fitted.
2. Connect: eRear flasher light leads NOTE: The leads of identical colors should be connected.
31 install: i_J_. i__i Rear carrier 7Nm (0.7 m,kg, 5.1 ft-lb)
4. Install: eSeat
2-3
INSP ADJ
_, @ i:Q::!i
!_-::
2. Remove: Front fender NOTE: Before removing the fender, make sure that all hooks are free.
-_
2-4
I INSP
HANDLEBAR COVERS
REMOVAL 1. Remove: =Screws (Handlebar cover -- Front) =Rear view mirror(s)
2. Disconnect: -Headlight lead and flasher light leads 3. Remove: -Handlebar cover (Front) ( ~
2-5
I ADJ
INSTALLATION 1. Install: oHandlebar cover (Rear) (~) 2. Connect: Leads oSpeedometer cable (~) NOTE: Position the cables as shown.
Front brake cable (~) Throttle cable (~) Rear brake cable
3. Connect: eHeadlight lead and flasher ]~ght leads 4. Install: Handlebar cover (Front) Rear view mirror(s)
ENGINE
ENGINE iDLE SPEED A D J U S T M E N T 1. Remove: Tail cover,. Refer to " T A I L COVER" section.
2. Start the engine and warm it up before checking the idle speed. NOTE: A warm engine is defined as one which had been operated for about 3 minutes at 3,000 r/min with no load.
2-6
I INSP
Engine idle speed adjustment steps; Start the engine at idle speed. eTurn the throttle stop screw (~ clockwise to increase engine speed and counterclockwise to decrease engine speed.
ADJUSTMENT
1. Check: *Throttle cable free play (~ Out of specification-*Adjust.
[~
NOTE:
Before adjusting the throttle cable free play, the engine idle speed should be adjusted.
2-7
ADJ
!_:__ ......
=Loosen the Iocknut (_. oTurn the adjuster (_ in or out until the correct free play is obtained. =Tighten the Iocknut.
AUTOLUBE NOTE:
1. Remove: =Tail cover Refer to "TAIL COVER" section. * Front fender =Front panel eFootrest board Refer to "FRONT FENDER, FRONT PANEL AND FOOTREST BOARD" section.
2. Check: *Throttle cable free play (_ (at carburetor side) Out of specification_Adjust.
.....
J_
Throttle cable free play adjustment steps; =Loosen the Iocknut (_. =Turn the adjuster _ in or out until the correct free play is obtained. =Tighten the Iocknut.
2-8
4. Close the throttle grip completely. 5. Check: Autolube pump pulley position (_ Out of position-*Adjust.
:
0.0-1.0 _ Autolube mm (0.0-0.04 in) Pump Pulley Position
Autolube pump pulley position adjustment steps: oLoosen the Iocknut _. Turnthe adjuster (_ in or out until the pump plunger pin (_ is aligned with the mark _) on the pump pully. eTighten the Iocknut.
6. Install: oAutolube pump cover oFootrest board Front panel Front fender eTail cover Refer to "FRONT FENDER, FRONT PANEL AND FOOTREST BOARD" and "TAIL COVER" section. AUTOLUBE PUMP AIR BLEEDING The Autolube pump and delivery lines must be bled on the following occasions: ,Whenever the Autolube tank has run dry. oWhenever any portion of the Autolube system is disconnected. oIf the scooter lies on its side after falling over.
2-9
__
AUTOLUBE
I,.sPl l
ADJ
-Front panel Footrest board Refer to "TAIL COVER" and "FRONT FENDER, FRONT PANEL AND FOOTREST BOARD" section.
3. Remove: Bleed screw @ NOTE: Place a rag under the Autolube pump.
5. Air bleed: Keep the oil running out until air bubbles disappear. NOTE: Pull the pump cable all the way out to set the pump stroke to a maximum.
6. Inspect: Bleed screw gasket Damage_Replace. 7. Install: ,Bleed screw gasket Bleed screw
2-10
t ADJ INSP
9. Install: eAutolube pump cover Footrest board Front panel Front fender oTail cover Refer to "FRONT PANEL, FRONT FENDER ANT FOOTREST BOARD" and "TAIL COVER" section.
;_
AIR Remove: 1. CLEANER ELEMENT CLEANING Side cover (Left) NOTE: When removing the side cover, unhook it at the front and slide it forward.
Never operate the engine with the air cleaner element removed. This will allow unfiltered air to enter, causing rapid wear and possible engine damage. Additionally, operation without the cleaner element will affect carburetor jetting with subsequent poor performance and possible engine overheating. Be careful not to have rags or the like blocking the intake area of the air cleaner.
2-11
;'='8
INSP ADJ
Air cleaner element cleaning steps: oWash the element gently, but thoroughly in solvent.
Never use low flash point solvents such as gasoline to clean the element. Such solvent may lead to a fire or explosion. oSqueeze the excess solvent out of the element and let dry.
:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
4. Inspect: oElement Damage-_ Replace. 5. Apply: oFoam-air-filter oil or SAE 10W30 type SE motor oil Onto the element. 6. Squeeze out the excess oil. NOTE: The element should be wet but not dripping. 7. Install: oAir cleaner element Air cleaner case cover Side coyer (Left)
FUEL COCK CLEANING 1. Remove: -Tail cover Refer to "TAIL COVER" section.
2-12
I,NsP
ADJ
__ ' =_ { _k,_ ==_
FUEL COCK
CLEANHNG
2. Drain: =Fuel
E
or in the
FUEL IS HIGHLY FLAMMABLE: =Take care not to spill any fuel on the engine Always turn off the engine when draining. or exhaust pipe/muffler when draining. " oNever drain fuel while smoking
vicinity
of an open flame.
_* '!_ii! _ _iiii_
_:::_
4. Clean: Filter oCap Wash the filter and cap gently using solvent. 5. Inspect: Filter oO-ring Damage--* Replace. 6. Install: O-ring Filter oCap oTail cover Refer to "TAIL COVER" section.
2-13
COMPRESSION
PRESSURE MEASUREMENT
;!i ...... COMPRESSION
INSP ADJ
PRESSURE
__4
Insufficient compression pressure will result in performance loss and may indicate worn or damaged piston rings. 1. Remove: Cover (_
........ _ I
2. Warm up engine for serveral minutes, then stop the engine. 3. Remove: eSpark plugs 4. Connect: Compression Gauge (YU-33223) (_
5. Measure: Co mpression NOTE: Start the starter motor and throttle valve wideopen until the pressure indicated on gauge can rise no further. Compression should be within the specified levels. Compression Pressure (at sea level): Standard ....... 800 kPa (8.0 kg/cm 2, 114 psi) Minimum ...... 640 kPa (6.4 kg/cm 2, 91 psi)
When cranking engine, ground spark plug wires to prevent sparking. Compression test steps (below minimum levels): oSquirt a few drops of oil into cylinder. eMeasure compression again. Reading Higher oil without than Same as oil without Diagnosis Worn cylinder, piston and piston rings Defective piston, ring(s), valve(s) and cylinder head gasket
Compression test steps (above standard levels): eCheck cylinder head or piston crown for carbon deposits. 2-14
2. Inspect: o Engine oil level 0il level low-,Add sufficient following inspection steps.
oil by the
+
I
i"OIL"
indicator light
I trical circuit,
?1
iomeson
2-15
l lNSPI_I_ ADJ
Yamalube Recommended 2 or Air Cooled 2 Oil: Stroke Engine Oil Oil Capacity: Total: 0.8 L (0.7 Imp qt, 0.84 US qt)
NOTE: Install the oil tank filler cap (_ and push it fully into the filler.
Always use the same type of engine oil; mixing oils may result in a h_rmful chemical reaction and lead to poor performance.
TRANSMISSION OIL REPLACEMENT 1. Warm up the engine at idle speed, then stop it. 2. Place the oil pan under the drain hole.
3. Remove: oDrain bolt (_ Drain the transmission oil. oOil filler plug
2-16
ADJ t INSPt_
I_
13 ft.lb)
___
Yamalube or Transmission 4 Oil: SAE 10W30 Type SE Motor Oil Capacity: 0.1 L (0.09 Imp qt, 0.11 US qt)
NOTE: Wipe off any oil split on the crankcase, tire or wheel.
FUEL LINE INSPECTION 1. Remove: eTail cover Refer to "TAIL COVER" section.
2-17
ADJ
o Fuel pipe (_ 2. Inspect: Cracks/Damage -_ Replace. 3. Install: oTail cover Refer to "TAIL COVER" section.
,0- 0
Front brake lever free p|a adjustment steps: oTurn the adjuster (_ in or out until the correct free play is obtained.
REAR BRAKE LEVER FREE PLAY CHECK 1. Check: Rear brake lever free play (_ Out of sP, cification_ Adjust. e '_ 10-20 mm (0.4-0.8 in)
Rear brake lever free play adjustment steps; Turn the adjuster (_ in or out until the correct free play is obtained.
2-18
TIRE AND WHEEL iNSPECTION FRONT AND REAR BRAKE LNNING INSPECTION/
FRONT ) AND REAR BRAKE LINING 1. Activate 2. Inspect: -_; Wear indicator (_ limit line (_Replace Indicator at wear brake shoes. the brake lever.
1. Measure: Air pressure Out of specification-_Adjust. Cold tire pressure Front Rear 125 kPa (1.25 kg/crn 2, 18 psi) 225 kPa (2.25 kg/crn 2, 32 psi)
Proper loading
of your scooter
is important
for the handling, braking, and other performance and safety characteristics of your scooter. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the scooter, and destribute the weight evenly side. And check the condition from side to and pressure
of your tires. NEVER OVERLOAD YOUR SCOOTER. Make sure the total weight to the cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model) does not exceed the maximum load of the scooter. Operation scooter could cause tire dent, or even injury. of an overloaded damage, an acci-
2-19
"
'_._=q __, _ _:._\1 "-"
STEERING ADJUSTMENT
2. Inspect: oTire surface
ADJ
Wear/Damage/Cracks/Road
hazards--*
__._
ii.
+Aluminum wheels Damage/Bends--* Replace. Never attempt even small repairs to the wheel. Replace.
Ride conservatively after installing a tire to allow it to seat itself properly on the rim.
(]_)
3. Measure: Tire tread depth Out of specification_Replace. _ Minimum Tire Tread Depth: (front and rear) 0.8 mm (0.03 in)
(_
STEERING ADJUSTMENT 1. Place the scooter on its centerstand, then elevate the front wheel.
2-20
INSP
STEERING A D J U S T M E N T / B A T T E R Y
2. Check: =Steering assembly bearings Grasp the bottom of the forks and gently rock the rock assembly back and forth. Looseness-*Adjust. Steering head adjustment steps: =Remove the front fender and front panel. Refer to "FRONT FENDER, FRONT PANEL AND FOOTREST BOARD" section. =Tighten the ring nut ~ to specification using the Ring Nut Wrench (YU-33975).
Bolt (~:
60 Nm (6.0 m-kg, 43 ft-lb) =Install the front fender and front panel.
ELECTRICAL
BATTERY 1. Check: = Fluid level Incorrect-* Refill. Fluid level should be between upper and lower level marks. (~ Upper level (~) Lower level
iiii!!iiiiiiiiiii!iii!!i
Refill with distilled water only; tap water contains minerals harmful to a battery.
2-21
BATTER* L'NSP1
2. inspect: Breather hose Obstruction_ Remove. Damage-* Replace. 3. Inspect: 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 indicated by the plates turning white, or an accumulation 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.
Specific gravity: Less than 1.280-*Recharge battery. Charging Current: 4. Measure: 0.4 amps/10 hrs Specific Gravity: 1.280 at 20C (68F)
2-22
I INSP l( l ADJ
BATTERY/FUSE
INSPECTION
Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. __,=== oAvoid bodily contact with electrolyte as it Always follow these preventive measures: injury. =Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): _\_J--_ ____= '_ "_ 9/ -SKIN-- Flush with water. EYES--Flush with water for permanent and can cause servere burns or 15 minutes eye get immediate medical attention. Antidote (INTERNAL): eDrink large quantities of water or milk follow with milk of magnesia) beaten egg, or vegetable oil. Get immediate medical attention. Batteries also generate explosive hydrogen gas, therefore you should always follow these preventive measures: eCharge batteries in a well-ventilated area. Keep batteries away from fire, sparks, or open flames (e.g., welding equipment, lighted cigarettes, etc.) =DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.
2-23
FUSE iNSPECTION/SPARK
PLUG iNSPECTiON
2. Inspect: e Fuse C) Defective--* Replace.
ADJ
Blown fuse procedure steps: =Turn off ignition and the circuit. =Install a new fuse of proper amperage. =Turn on switches to verify operation of electrical device. If fuse blows immediately again, check circuit in question.
Do not use fuses of higher amperage rating than recommended. Extensive electrical system damage and fire could result from substitution of a fuse of impcoper amperage: Description Main Amperage 7A Quantity 1
"
--?: i
H_
"
2-24
I INSP
4. Clean the plug with a spark plug cleaner if necessary. 5. Tighten: Before installing a spark plug, clean the gasket and plug surfaces.
NOTE:
1. Adjust: Headlight (Vertically) Vertical adjustment Loosen the adjusters (~) Tighten the adjusters (~)
Higher Lower
Headlight (Horizontal) Horizontal adjustment Loosen the adjuster (~) or tighten the adjuster (~) Loosen the adjuster (~) or tighten the adjuster (~)
Right Left
IGNITION T I M I N G
Adjustment free.
2-25
ri
P R E P A R A T I O N FOR R E M O V A L T A I L COVER
..................................................
FRONT FENDER, F R O N T P A N E L A N D
DISASSEMBLY
..................................................
PUMP .............................................
INSPECTION
AND
REPAIR
.......................................
D-10
D-10 D-10 D-12 D-12 D-12 D-13 D-13 D-13 D-15 D-15 D-16 D-16 E-1 E-3 E-4 E-5 E-6 E-8 E-9 E-10 E-10
CYLINDER HEAD .............................................. CYLINDER AND AUTOLUBE PISTON ....................................... ........................ P I S T O N PIN A N D P I S T O N PIN B E A R I N G
SECONDARY SHEAVE ......................................... V-BELT ....................................................... STARTER CLUTCH AND GEARS ................................
ENGINE
ASSEMBLY
AND
ADJUSTMENT
.........................
PUMP .............................................
C.D.I. M A G N E T O
STARTER SYSTEM
PRIMARY AND SECONDARY SHEAVE ........................... P I S T O N PIN A N D P I S T O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER AND CYLINDER HEAD ............................... MUFFLER ..................................................... R E M O U N T I N G ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENG %-j]
ENGINE R E M O V A L
ENGINE OVERHAUL
ENGINE R E M O V A L
NOTE: It is necessary to remove the engine in order to remove the following components. oCylinder head Cylinder Piston CDI magneto Starter motor Primary and secondary sheave
PREPARATION FOR R E M O V A L 1. Remove all dirt, mud, dust and foreign material before removal and disassembly.
2. Use proper tools and cleaning equipment. Refer to "CHAPTER 1. GENERAL INFORMATION-SPECIAL TOOLS" section. NOTE: When disassembling the engine, keep mated parts together. This includes gears, cylinder, piston and other parts that have been mated" through normal wear. Mated parts must be reused as an assembly or replaced.
"
3-1
ENGINE REMOVAL
I E.o I, .l
. During engine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled in the engine. . Drain the transmission oil completely. Refer to "CHAPTER 2 . - - T R A N S M I S S I O N OIL REPLACEMENT" section.
TAIL COVER 1. Remove: .Seat Tail cover Rear carrier Refer to "CHAPTER 2 . - - T A I L COVER" section.
FRONT FENDER, FRONT PANEL A N D FOOTREST BOARD 1. Remove: Front fender Front panel = Footrest board Refer to "CHAPTER 2.--FRONT FENDER, FRONT PANEL AND FOOTREST BOARD" section. CARBURETOR 1. Remove: - A i r cleaner case
3-2
[ENO EOO,NE.EMOVA,
2. Remove: oFuel pipe (_ oOil delivery pipe (_) Vacuum pipe (_) Auto choke unit lead
3. Remove: _, Carburetor top cover oCarburetor NOTE: Cover the carburetor with a clean rag to prevent dirt or foreign matter into the carburetor.
i
i
_i
2. Remove: oOil pump cable (_ oOil pipe (_) NOTE: Plug the oil pipe so the oil will not run out of the oil tank.
3-3
ENGINE REMOVAL
4. Remove: Spark plug cap
ENG %_
3-4
[ENG
ENGINEREMOVAL/DISASSEMBLY
2. Remove:
DISASSEMBLY
MUFFLER
1. Remove: oExhaust pipe
3-5
2. Remove: `"Muffler
O'SASSEMB' IEN
" _::_:_
3. Remove: (_, ........ : _ ::: ,,Cylinder head (_ Cylinder head gasket NOTE: `"Before loosening the cylinder head, loosen the spark plug _). The cylinder head holding nuts should be loosened 1/2 turn each time, and remove.
3-6
O,SASSEMBL*
CYLINDER 1. Remove: i_ Cylinder (_ Cylinder gasket
PISTON PIN AND PISTON 1. Remove: Piston pin clip (_ NOTE: Before removing the piston pin clip, cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase.
2. Remove: oPiston pin (_ Piston (_) Piston pin bearing NOTE: Before removing the piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and piston pin is still difficult to remove, use Piston Pin Puller (YU-01304).
3-7
SHEAVE
2. Remove: *Fan (_
;i4 _!
'-
__
NOTE: --...... _ When loosening the nut (primary sheave), hold the C.D.I. magneto using Flywheel Holding Tool (YU-01235).
4. Remove: _ ._,. "_'_, *Conical spring washer (_ *One-way clutch (_ *Primary fixed sheave _) ,,V-Belt
3-8
_ /
3-9
q
j ii
O,SASSEMB.!
.Z ; !;;~!!
3. Remove: eStarter wheel gear (~) Bearing (~ Washers (~ oldie gear (~)
I' .1
3-10
C.D.I. .... _
._
ii;_ _- __..9
2. Remove: C. D.I. magneto Use Flywheel oWoodruff key Magneto Puller (YM-01189)
3-11
O'SASSEMB IE"O t
_ 3. Remove: eStator assembly (_
4. Remove: Gasket @
2. Remove: Circlip (_ *Shim (_) -,Wave washer. (_) \. Pump drive gear @
_0\
3-12
ENGr
DISASSEMBLY
2. Unhook: = Spring (Centerstand) 3, Remove: Clip ( ~ Centerstand
I-q
5. Remove: =Main axle ( ~ Drive axle ( ~ -Washer ( ~ (Main axle) Washer ( ~ (Drive axle)
~ii!ii~:~
!ii~i~i~~ii~ O i~
3-13
O,SASSEMOL [ENOL
_zi;ili_:_ _: : CRANKCASE 1. Remove: AND CRANKSHAFT eOil seal stopper (_) Circlip (_)
"'_
2. Remove: oScrews (Crankcase) NOTE: Loosen each screw 1/4 turn, and remove them after all are loosened.
_,
may be backed
_i __:i:
_:.... .
_
4. Remove: eCrankcase (Left) As pressure is applied, alternately tap on the engine mounting bosses.
"::"- i ": !: i. :: "" "
hammer
to tap
half.
Tap
on reinforced on gasket
portions surface.
Do not slowly
mating
and carefully. Make sure the case halves separate evenly. If one end "hangs up", take 3-14
[ENoI
D I S A S S E M B L Y / I N S P E C T I O N A N D REPAIR
pressure off t h e push s c r e w , realign, and start over. If t h e cases do n o t separate, check f o r a r e m a i n i n g case s c r e w or f i t t i n g . Do n o t force.
5. Remove: = Crankshaft Use Universal Puller Set (YU-33270) (~. NOTE: Use the following bolts available on the market. Lenght: 160 mm (6.3 in) Thread: 6 mm (0.24 in) Pitch: 1.25 mm
INSPECTION A N D REPAIR
CYLINDER HEAD 1. Remove: =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. Inspect: =Cylinder head warpage Out of specification ~ Re-su rface. W a r p a g e m e a s u r e m e n t and re-surfacem e n t steps: =Attach a straight edge and a thickness gauge on the cylinder head. =Measure the warpage limit. 3-15
oq
.osONANO.EPA. IE"O I .l
0.02 mm (0.0008 in) _ Warpage Limit: olf the warpage is out of specification, reface the cylinder head. oPlace a 400-600 grit wet sandpaper on the surface plate, and re-surface the head using a figure-eight sanding pattern. NOTE: Rotate the head several times to avoid removing too much material from one side.
/
-_ _ ( /
CYLINDER AND PISTON 1. Eliminate: From the piston crown and ring grooves.
< \
._ . .,.
_/_ -
1 -_
_ _ _
2. Eliminate: Score marks and lacquer deposits From the sides of piston. Use a 600-800 grit wet sandpaper. -Carbon deposits NOTE: Sand in a crisscross pattern. Do not sand exces-
Replace.
i+:_ ,!+++,
3-16
6. Measure: i_ ::_ ......... _ (_ Piston-to-cylinder Piston-to-cylinder steps: First step: clearance clearance measurement
:_
D_
Bore Gauge. Measure the cylinder bore "'C" with a Cylinder NOTE: Measure the cylinder bore "C" in parallel to and _ --=_" at right angles to the crankshaft. average of the measurements. Then, find the
r__
_ Standard Cylinder bore 40.00-40.02 mm "C" (1.575-1.583 in) Taper "'T" Out of round "'R" C= Maximum T=(Maximum (Maximum R=(Maximum (Minimum D Dz or D2) Ds or D6) D1, D3 or Ds) D2, D4 or D6) rebore
Wear Limit 40.50 mm (1.594 in) 0.05 mm (0.0019 in) 0.01 turn (0.0004 in)
or replace
_/
"P"
with
__
2nd step:
307,000
3-17
ENG]
Piston Size P 40.05- 40,07 mm (1.577 - 1.578 in)
clearance with
Piston-to-cylinder
Clearance "P"
rebore or replace
....
i;:i
7. Measure: oEnd gap Out of specification--* Replace rings as a set. Use a Feeler Gauge (_.
_:i
3-18
,SPEOT,ONANO.EPA
8. Oversize piston ring size: Ring size is stamped on top of the ring. Oversize piston ring Oversize 1 25 Oversize 2 50
PISTON PIN AND PISTON PIN BEARING 1. Apply: e2 cycle oil To the piston pin and bearing. 2. Install: oPiston pin Piston pin bearing Into the small end of the connecting rod.
3. Check: / __. _]]_ There should be no noticeable for the play. Free play .Free play exists_ Inspect the connecting rod rod as required. _._/ for wear/Replace the pin and/or connecting
4. Install: oPiston 5. Check: oFree play (when the piston pin is in place in the piston) There should be no noticeable for the play. Free play exists--* Replace piston pin and/or Into the piston pin hole. piston. 6. Inspect: oPiston pin and bearing Signs of heat discoloration-_Replace. pin
(___j_
3-19
.._ _ _i_?!i:!_!i !_
I_
oAutolube Autolube pump drive gear teeth (_ driven gear teeth (_ Pitting/Wear/Damage--* Replace.
-=
=-
CRANKSHAFT 1. Measure: eRunout limit "C" oSmall end free play limit "'F" Out of Specification_Replace. _Connecting rod big end side clearance "D" Use V-Blocks, Dial Gauge and thickness gauge.
0.03 Limit "'C": Runout mm (0.0012 in) Connecting Rod Big End Side Clearance "D": 0.2-0,5 mm (0.008-0.02 in) Small End Free Play: 0.4-0.8 mm (0.015-0.031 in)
2. Inspect: oBearings (Crankshaft) Spin the bearing inner race. Excessive play/Roughness_ Replace. Pitting / Damage_ Replace.
3-20
_i!!i_i (_)
2. Inspect: Drive gear bearing (_ Main axle bearing (_) QSecondary sheave axle bearing (_) Spin the bearing inner race. Excessive play/Roughness-* Pitting/Damage--* Replace. Replace.
....
1. Inspect: PRIMARY SHEAVE Primary sliding sheave (_ Primary fixed sheave (_ Collar (_) Wear/Cracks/Scratch/Damage--*
Replace.
2. Check: Free movement Insert the collar into the primary sliding sheave, and check for free movement. Stick or excessive play-* Replace the sheave or collar.
.....
S ECO NDA RY SH EAVE Disassembly 1. Attach: ,Primary Sheave Holder (YS-01880) (_)
:,
_.,
,oose :
Do not remove
_i_i_:.:. :.
the clutch
securing
nut yet.
3-21
3q
.... _-_[_,, (_ .
.-::5*"
Inspection (_ ............... 1. Inspect: _Secondary fixed sheave (_(_) oSecondary sliding sheave
i_
Scratch/Crack/Damage--*
Replace as a set.
3-22
F ~
y
,' If l! !f
2. Inspect: oTorque cam groove (~) oGuide pin (~ Wear/Damage-*Replace as a set. Oil seals (~ oO-rings (~) Damage-* Replace.
r
NOTE:
6. Inspect: oClutch shoes Glazed parts-* Sand with coarse sandpaper. After using the sand paper, clean of the polished particles with cloth.
3-23
I ENG
Assembly When assemblying the secondary sheave, reverse the disassembly procedure. Note the following
points. 1. Apply: +BEL-RAY Assembly Lube (to the inside of the sliding sheave)
2. Install: Sliding sheave NOTE: Be careful so that the oil seal lips are not turned over when installing the sheave.
~; +.;+!:i:~!
++.
3. Apply: eBEL-RAY Assembly Lube (to the torque cam grooves and O-rings)
3-24
5. Install: Clutch securing nut Use Clutch Spring Holder (_) (YS-28891).
_z,_,_._ .........
6. Tighten: securing nut oCtutch Use Sheave Holder (_ Wrench (41 mm).
(YS-01880) and
[_
50 Nm (5.0 m,kg,
36 ftlb)
V-BELT 1. Inspect: oV-belt Crack/Wear-_ Replace. NOTE: Replace the V-belt smeared with a lot of oil or grease.
15.0 mm 10.59 in) V-Belt Width: <Wear Limit>: 13.5 mm (0.53 in)
STARTER CLUTCH AND GEARS 1. Inspect: -Starter clutch Push the dowel pin to arrow direction. Unsmooth operation-_Replacce starter clutch assembly.
3-25
,osooAoo.EPA,. !ENO I I
2. Inspect: oStarter wheel gear teeth (_ oldie gear teeth (_) Burrs/Chips/Roughness/Wear-* Replace.
_Z(_
_ (_
Burrs/Chips/Roughness/Wear-*
Replace.
5. Inspect: oMating dogs (Kick pinion gear and one-way clutch) Rounded edges/Damage_ Replace.
6. Measure: eClip tension (Kick pinion gear) Out of spedification-*Replace. f,]_ _ :_ Use a spring balance. Standard Tension:
3-26
or to f a c i l i t a t e the o p e ra tio n of the installation. Apply the grease to the oil seal lips, and apply the engine oil to each bearing.
1. Attach: oCrankshaft Installing Tool (YU-90050 (~, YM-90062 (~) 2. Install: Crankshaft To left crankcase.
NOTE:
Hold the connecting rod at top dead center with one hand while turning the nut of the Installing Tool with the other. Operate the Installing Tool until the crankshaft bottoms against the bearing.
3. Apply: Sealant (Quick Gasket ) (ACC-11001-30-00) To the mating surfaces of both case halves. 4. Install: Dowel pins (~) oSpacer (~)
5. Install: Right crankcase Use crankshaft Installing Tool (YU-90050 (~, YM-90063 (~)).
3-27
NOTE: Tighten the crankcase holding screws in stage, using a crisscross pattern.
8. Install: Oil seal stopper plate (_ Circlip (_) Screw (Oil Seal Stopper Plate): 13 Nm (1.3 m=kg, 9.4 ft.lb)
3-28
3-29
q
J,
3. Install: Circlip @ Oil seal NOTE: i_i_i _,_i .% Apply lithium soap base grease onto the oil seal lips.
4. Apply: 10W30 type SE Motor oil (to main axle bearing and drive axle bearing) _ '_{_ ...... 5. Install: Drive axle (_ Main axle (_) ,Washer (_) (Main axle) ,Washer @ (Drive axle)
(_)
3-30
ENG _
_..... :_:'_::_!..... _iii:_;_;_ ii;_ili! !
ENGINEASSEMBLYAND ADJUSTMENT
7. Install: i_ii_ii: !ilili;_ _ 'i (_ _ _ *Transmission case cover (_ Screw (Case cover): 8 Nm (0.8 m,kg, 8. Install: * Centerstand 9. Install: *Brake shoe plate @ 5.8 ft,lb)
i:._i_
'
-t Soe P'ate':
18 Nm (1.8 mkg, 13 ft,lb) 10. Install: *Plain washer (_ Rear wheel (_) (_ *Plain @ Nut washer _)
I_LI
3-31
3-32
3-33
PUMP
Autolube pump Pin Circlip Shim Wave washer Pump drive gear Circlip
3-34
[ ENG
AND ADJUSTMENT
C.D.I. MAGNETO 1. Install: eGasket (_
,.,_*'_ , .:.:z,.:.,
'"_
!_
_.......... _,
4. Woodruff key Install: *C.D.I. magneto Plain washer ,_Spring washer _Nut NOTE: When installing the C.D.I. magneto, make sure the woodruff key is properly seated in the key way of the crankshaft. Apply a light coating of lithium soap base grease to the tapered portion of the crankshaft end.
_" ,i:_
_:_._,
5. Tighten: Nut (C.D.I. magneto) Use Flywheel Holding Tool (YU-01235) (_.
......
3-35
141
C.D.I. MAGNETO
(_ Fan Stator assembly Gasket Woodruff key
(_ C.D.I. magneto
(_
>%'--.
3-36
ENG _
4. Install: Kick torsion spring (_ NOTE: Set the kick torsion spring to the spring hook.
3-37
_=_
ENGINE ASSEMBLY
AND ADJUSTMENT
_. 6. Install: oStarter motor (_
ENG
8 Nm 10.8 m,kg, 5.8 ft-lb) NOTE: Apply lithium soap base grease to the O-ring of (_ the starter motor. 7. Install" :' ............. " ............. Stay (_ oCollar (_)
:_._:_..,.'_.,
_: _'_ ,::!:i::':_!:! "-:;:'._'_t i_i:::_:_ ............ _,:;'&:-"_, _':: "_ _:: ,-_i:_,, :i_ ....
"
"Starter wheel gear (_ -Apply Yamalube 2 cycle oil to the idle gear (_. -Apply lithium soap base grease to the bearing
@_:!_i_:
.:..:.:,._
ii:i
3-38
ENG
STARTER SYSTEM (~) Kick shaft (~) Kick torsion spring (~) Kick crank @ Idle gear ~ ollar Stay
(~
/ /
~ J
"~v / ~ /
3-39
29 ftolb)
...... :_;-
.,,_::;
6. Install: _V-belt Place the V-belt around the secondary sheave, and compress the secondary sheave spring hard so that the V-belt moves toward the clutch hub. NOTE:
The V-belt must be installed with the arrow
':
frontward. 3-40
I ENG
_ ::_
--
_;_
NOTE: When tightening the nut (primary sheave), hold the C.D.I. magneto using Flywheel Holding Tool (YU-01235).
9. install: oFan (_
ii_
[_
3-41
AND
Secondary fixed sheave Oil seal Secondary sliding sheave O-ring Oil seal Spring seat Clutch spring
A B
CLUTCH SPRING FREE LENGTH LIMIT: 94.0 rnrn (3.70 in) CLUTCH HOUSING WEAR LIMIT: 105,4 mrn (4.15 in) CLUTCH SHOE WEAR LIMIT: 2.5mm (0.10 in) _ / /_" _ 150 Nm (5.0 m kg, 36ft.lb) , I
_r///%:
/_% / __ /
_ /
/_
3-42
I ENG
ENGINE
ASSEMBLY
AND
ADJUSTMENT
PISTON PIN AND PISTON 1. Apply: oYamalube 2 cycle oil To the piston pin, bearing, piston ring grooves and piston skirt areas.
2. Install: Small end bearing Piston Piston pin Piston pin clip NOTE: =The arrow (_ on the piston must point to the front of the engine. -Before installing the piston pin clip, cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and material into the crankcase. Always use a new piston pin clip.
3-43
ENGINE ASSEMBLY
PISTON (_ (_) (_ @ _ PIN AND PISTON Piston ring (1st, 2nd) Piston Piston pin clip Piston pin Small end bearing Piston pin clip
AND ADJUSTMENT
ENG
PISTON RING SIDE CLEARANCE: 0.03-0.05 mm (0.0012-0.0020 in) < LIMIT>: 0.10 mm (0.004 in) 0.015-0.03 <LIMIT>: mm (0.006- 0.012 in) 0.7 mm (0.028 in)
3-44
_i _;
CYLINDER 1. Install:
AND
CYLINDER
HEAD
Cylinder gasket (New gasket) 2. Offset the piston ring end gaps as shown. (_ 1st ring _) 2nd ring NOTE: oBe sure to check the manufacturer's numbers stamped side of the rings. oBefore coating installing of 2-stroke marks or
;_i_;_ J
4. Install: Cylinder ;_ NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. (_
3-45
ENGINE
ASSEMB'YA.OIA.OSTMET IENO
eCylinder head gasket (New gasket) 7. Install: oCylinder head (~ oSpark plug (~ NOTE: Tighten the cylinder head holding nuts in stage, using a crisscross pattern.
Cylinder Head Holding Nuts: 10 Nm (1.0 m.kg, 7.2 ftolb) Spark Plug: 20 Nm (2.0 mkg, 14 ftolb)
l~
l~
3-46
A PISTON TO CYLINDER CLEARANCE: 0.034-0.047 mm (0.0013-0.0018 in) CYLINDER HEAD WARPAGE LIMIT: 0.02 mm (0.0008in) SPARK PLUG: BPR6HS (N.G.K,) C GAP: 0.9-1.0 mm (0.035-0.039 in)
3-47
ENGINE ASSEMBLY A N D A D J U S T M E N T
MUFFLER 1. Install: Muffler
I ENG
Bolt (Muffler): 27 Nm (2.7 m . k g , 19 ft.lb) Bolt (Exhaust pipe): 8 Nrn (0.8 m.kg, 5.8 ftolb)
i~!?i~:i!i:~i;:~i)!::
!iiiiiiiiiiii~i
R E M O U N T I N G ENGINE When remounting the engine, reverse the removal procedure. 1. Install: Engine mounting bolts These bolts should be temporarily secured. 2. Tighten: oEngine mounting bolts
Bolt ~--]: 42 Nm (4.2 rn.kg, 30 ft.lb) Bolt r-~: 17 Nm (1:7 mkg, 12 ft-lb)
3. Install: Carburetor Carburetor top together with throttle valve NOTE: When installing the throttle valve into the carburetor, align the groove (~ of the throttle valve with the projection (~) of the carburetor.
3-48
ENG
ENGINE ASSEMBLY
AND ADJUSTMENT
4. Air bleeding: Autolube pump Refer to "CHAPTER 2--AUTOLUBE PUMP AIR BLEEDING" section. 5. Apply: Transmission oil Refer to "CHAPTER 2--TRANSMISSION OIL REPLACEMENT" section. 6. Adjust: ,Brake lever free play Refer to "CHAPTER 2--BRAKE LEVER FREE PLAY ADJUSTMENT" section. Autolube pump cable Refer to "CHAPTER 2--AUTOLUBE PUMP CABLE ADJUSTMENT" section. Throttle cable free play Refer to "THROTTLE CABLE FREE PLAY ADJUSTMENT" section.
3-49
CHAPTER 4 CARBURETION
AUTO CHOKE SYSTEM .......................................... CONSTITUENTS ................................................ WIRING SCHEMATIC .......................................... OPERATION ................................................... CARBURETOR ................................................... SECTION VIEW ................................................ REMOVAL .................................................... DISASSEMBLY ................................................ INSPECTION .................................................. ASSEMBLY ................................................... INSTALLATION ................................................ AUTO CHOKE UNIT CHECK .................................... REED VALVE ........................... . ........................ REMOVAL .................................................... INSPECTION .................................................. INSTALLATION ................................................ F-3 F-3 F-3 F-3 F-4 F-5 F-5 F-5 F-6 F-7 F-7 F-8 F-8 F-8 F-8 F-9
A U T O CHOKE S Y S T E M
r-i
CARBURETION
A U T O CHOKE S Y S T E M
CONSTITUENTS The electric auto-choke consists of the Positive Temperature Coefficient (P.T.C.) thermistor, wax element and starter plunger.
~ P.T.C.thermistor
I P.T.C. thermistor I
When electric current flows in this thermistor, it begins to be heated up to a specified temperature. This specified temperature is then reained.
I Wax
element I
The wax element changes its volume according to a varying temperature of the thermistor, thereby causing the starter plunger to operate.
I Starter
plunger I
The starter plunger opens or closes the starter passage according to changes in the volume of the wax element,
WIRING SCHEMATIC
Power source is provided by the C.D.I. magneto lighting coil. (~) C.D.I. magneto (~) Rectifier/Regulator (~ Auto choke unit
4-1
J Running engine J When the engine is started, the heated P.T.C. thermistor expands the wax element, gradually pushing the starter plunger and controlling the opening of the starter passage. The further heated thermistor expands the wax element to a complete extent, thereby fully closing the starter passage. This in turn causes the engine r.p.m, to change (be reduced) with time, finally coming to specified idling. The wax element expands during the ride as well by means of the P.T.C. thermistor, thereby keeping the starter passage fully closed. : Air Fuel
_"
4-2
J CARB[
AUTO
CHOKE
SYSTEM
j Restarting after engine warm-up J 1. Restarting right after ride: The wax element is fully expanded, so the starter passage is fully closed by the starter plunger. 2. Restartingafter leavingenginefor a particular time: The wax element beginsto reduce its volume according to the ambient temperature, permitting the starter plunger to open the passage to meet the engine requirement.
4-3
CARBURETOR
_ (_ _) (_) (_ (_) Spring seat Jet needle Throttle valve Throttle stop screw Pilot air jet Pilot jet Main jet nozzle (_) (_ (_ _) (_ @ 1_
.....CA.BO.ETO [CA"B 4]
Needle valve Float Gasket Float chamber Drain screw Auto choke unit O-ring @ Starter jet needle plunger
(_
_""=)
_) _
15.0-17.0
mm r/rain in)
1,500~2,100 (0.59-0.67
_,
4-4
IOARB[ 4] CARBORETOR D
SECTION (_) (_ _) _) (_ (_ VIEW Jet needle Throttle valve Main nozzle Main jet Pilot air jet Pilot jet Auto choke unit (_) _ (_ (_) (_ (_ Starter Starter Starter Starter Needle Float plunger jet needle needle jet jet valve [] [] [] [] [] [] [] Main metering system Slow metering system Starter metering system Fuel metering system Air Mixture Fuel
[]
[]
4-5
REMOVAL 1. Remove: Tail cover Refer to "CHAPTER section. oAir cleaner case
cA.Bo.ETo. [CA"BI 4]
2-TAIL COVER"
_:: :.'.'_
2. Disconnect: oFuel pipe (_) Vacuum pipe (_) oOil delivery pipe (_.
!!iii_.._
,_
_
:.
Gasket (_)
4-6
CA"B ]CA.B0.ETO.
2. Remove. ...... oFIoat pin stop screw (_) Float pin oFloat oNeedle valve
i:
:_:::::;::: .....
"
4-7
INSPECTION _,_,
CA.BO.ETO CA""] 4l
Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air.
Replace.
5. Check: Free movement Stick-* Replace. Insert the throttle valve into the carburetor body, and check for free movement.
4-8
cA.. l CA"BO"ETO"
6. Inspect: *Jet needle (_ "_'z//@"_b,_ '"_'_'d/'@ _ _X _ / ,Main Replace.jet Bends/Wear-_ (_) *Main nozzle (_) Contamination-* Replace. *Pilot jet @
%
"_._ 8. Inspect: *Starter plunger (_ // Wea r/Damage-_ Replace.
\
9. Measure: Float height @ Out of specification--* Inspect needle valve, float and valve seat.
15.0-17.0
mm 10.59-0.67
in)
Float height measurement steps: *Install the needle valve, float and float pin to the carburetor body. *Hold the carburetor in an upside down position.
4-9
_: _i;::_::!_::;:_i::.i
e inspect the height is not within and ralve seat. If the float needle valve, float specification, -If it is worn, replace it.
NOTE: The float height is properly adjusted at the Yamaha factory. Never attempt to adjust it.
ASSEMBLY To assemble the carburetor, reverse the disassembly procedures. Note the following points.
Before reassembling, wash all parts in clean gasoline. =Always use a new gasket.
1. Install: Throttle valve (_) NOTE: Align the groove (_) of the throttle valve with the projection (_ of the carburetor body.
4-10
leA"B[ ]CA.BU.ETO.
_"_*_ AUTO CHOKE UNIT CHECK 1. Remove: Auto choke unit 2. Measure: !_i Starter plunger height (_) Plunger height will not change with the temperature change-_ Replace. Plunger height measurement steps: oFreeze auto choke unit to -5C (23.5F) in freezer. oMeasure plunger height at -5C (23.5F). _Take auto choke unit out of freezer and after about 30 minutes, again measure plunger height at room temperature. *If both measurements are the same, auto choke unit is defective. Replace it. For reference, below is a table of plunger heights at respective temperature. Temperature -5C (23.5F) 10C (50.5F) 20C (68.5F) 30C (86.5F) 40C (104.5F) NOTE: In the above table, auto choke was first freezed to -5C (23.5F) and then the measurements were made at while the temperature was raised gradualy. Plunger height 16.1+0.3 mm (0.63+0.01 17.80.3 mm (0.70+0.01 18.8+0.3 mm (0.740.01 19.7+0.3 mm (0.780,01 20.10.3 mm (0.790.01
4-11
REED VALVE
REMOVAL 1. Remove: Tail cover Refer to "CHAPTER section. Air cleaner case (_
:_
!:
INSPECTION 1. Inspect: Carburetor joint Damage/Cracks_ Replace. eReed valve Fatigue/Cracks-* Replace. Inspection steps: eVisually inspect the reed valve. NOTE: Correct reed valve should fit flush or nearly flush against valve seat. elf in doubt as to sealing ability, apply suction to carburetor side of assembly. eLeakage should be slight to moderate.
4-12
[cA. 41 .EEOVALVE
2. Measure: Valve stopper height (~: Out of specification-,Adjust stopper/ Replace valve stopper.
J ]
r
! ~
NOTE: If it is 0.4 mm (0.016 in) more or less than specified, replace the valve stopper.
3. Measure: Reed valve clearance (~) Out of specification-* Replace reed valve.
iNSTALLATION When installing the reed valve assembly, reverse the removal procedure. Note the following points. 1. Install: oGasket (New)
91
[CHAS
FRONT WHEEL
_) Collar (_ Oil seal _ (_) (_ (_
F_
CHASSIS
(_ Brake shoe (_) Return spring _ @ (_ (_ Brake camshaft Dust seal Camshaft seal Brake shoe plate Wear indicator _) Camshaft lever (_ Stop ring _ Stop ring O-ring (_ Plain washer _) Speedometer driven gear
.,_
B C --__ D
RADIAL:
BRAKE DRUM WEAR LIMIT: 80.5 mm (3.17 in) LATERAL: 2.0 mm (0.08 in) BRAKE SHOE WEAR LIMIT: 2.0 mm (0.08 in) WHEEL AXLE RUNOUT LIMIT: 0.25 mm (0.01 in)
35 Nm 13.5 m,kg,
25 ft,lb) I
5-1
FRONT WHEEL
CHAS l_
REMOVAL 1. Place the scooter on its centerstand. 2. Remove: oBrake cable oSpeedometer cable
1. Measure: Wheel axle runout Out of specification-* Replace. L_ILI_ $_ _ INSPECTION 0.25 mm (0.01 in) I_--h_ Wheel Axle Runut Limit: Do not attempt to straighten a bent axle. 2. Measure: I
w ee nout
Out of specification -+Replace. f _ _ Lateral 2.0 mm (0,08 in) Runout Limit: Radial 2.0mmlO.O8in) 3. Inspect: oWheel Cracks/Bends/Warpage-_ Replace. 5-2
_//_/
Do not strike the inner race of balls of the bearing. Contact should with the outer race. be made only
_j
-Brake shoes Glazed parts-* Sand with coarse sandpaper+ 5. Inspect: After using the sand paper, clean of the polished particles with cloth.
NOTE:
"
S.T.D,: 3.5 mm (0.14 Brake Shoe Thickness: in) Limit: 2.0 mm (0.08 in)
5-3
.4 _
F.oTIC.AS w.EE. !
7. Inspect: oBrake drum inner surface Oil/Scratches-* Remove. Oil Scratches Use a rag soaked in lacquer thinner or solvent. Use an emery cloth (lightly and evenly polishing).
80.5 mm (3.17 in) [_ Brake Drum Wear Limit: (BRAKE SHOE PLATE) ]
When assembling the brake shoe plate, reverse the disassembly procedure. Note the following points. 1. Apply: oLithium-soap base grease (to speedometer driven gear)
3. Install: Dust seal (New) NOTE: Install the dust seal with their manufacturer's marks or numbers facing outward.
5-4
-G
Align the camshaft mark (_) with the lever mark INSTALLATION When installing the front wheel, removal procedure. Note the following points. reverse the
1. Install: o Brake shoe plate NOTE: Make sure the projections inside the gear unit are meshed with the flats in the wheel hub.
iT
_ _i!i!!_ : 2. Install: Front wheel NOTE: Be sure the boss on the front fork correctly engages with the locating slot on the brake shoe plate assembly.
5-5
5-6
Ic,AsI,EA, i w.EE,
REAR WHEEL
Wheel ring Plain washer Spring Brake shoes Brake camshaft Brake shoe plate Camshaft seal Camshaft lever Wear indicator (_ (_) (_) (_ (_ (_) (_
A rn.kg, 67 ft.lb) I B
TIRE SIZE: 2.75-10-4PR 95,5 mm (3.76 in) BRAKE SHOE WEAR 2.0 mm (0.08 in) LIMIT:
WHEEL RUNOUT LIMIT: RADIAL: 2.0 mm (0.08 in) LATERAL: 2.0 mm (0.08 in) BRAKE DRUM WEAR LIMIT:
I 18 Nm 11.8 m.kg,
13 ftolb)
I _'-
6 Nm (0.6
n3okg,
4.3 ftlb)
5-7
REMOVAL 1. Remove: oTail cover Refer to "CHAPTER section. 2. Remove: -Fan cover (_
2--TAIL
COVER"
4. Remove: Rear axle nut NOTE: _ When loosening axle nut, apply the rear brake.
5-8
Le
...... _
Radial 2.0 mm 10.08 in) Lateral 2.0 mm (0.08 in) Runout Limit:
r/
3. Inspect: = Brake shoes Glazed parts_Sand with coarse sandpaper. NOTE: After using the sand paper, clean of the polished
particles with cloth. 4. Measure: =Brake shoe thickness (_ Out of specification-* Replace.
Brake Shoe Thickness: S.T.D.: 3.0 mm (0.12 in) Limit: 2.0 mm (0.08 in)
5. Inspect: =Brake drum inner surface Oil/Scratches_ Remove. Oil Scratches Use a rag soaked in lacquer thinner or solvent. Use an emery cloth (lightly and evenly polishing).
5-9
,q
.......W.EE. .EA.
6. Measure: Brake drum inside diameter (_ Out of specification _ Replace. [_ 95.5 mm Brake Drum (3.76 in) Limit: Wear ]
ASSEMBLY
(BRAKE
SHOE PLATE)
When assemblying the brake shoe plate, reverse the disassembly procedure. Note the following points.
_;:_!i_
2. Install: Brake camshaft Camshaft lever NOTE: Align the camshaft mark (_) with the lever mark
@.
INSTALLATION When installing the rear wheel, removal procedure. Note the following points. 1. Install: Brake shoe plate
reverse the
5-10
[CHASREAR _] WHEEL
2. Install: oRear wheel I_ 93 Nm (9"3 m'kg' NOTE: 67 ft'lb) i
Le
Make sure the splines on the wheel hub fit the rear drive axle. 3. Install: Muffler oExhaust pipe
18 Nm (1.8 m,kg, 13 ft,lb) Muffler: Exhaust pipe: 8 Nm (0.8 m,kg, 5.8 ft,lb)
5-11
[-C-_
(_
Lower bearing race (Top) Lower bearing race (Bottom) Steering column Front fork spring Rubber (Left side only) Spring seat Inner tube (Right and left)
FORK SPRING FREE LENGTH: STANDARD: B 92 mm (3.62 in) LIMIT: 87 mm (3.42 in)
-_k_
Ic us,,_o._ . i-
/
/
o,_ ._wo.
I 30 Nm 13.0 m,kg, 22 ft.lb)
5-12
2. Remove: Front wheel Refer to "FRONT W H E E L - - R E M O V A L " section. 3. Remove: Front fender Front panel Refer to "CHAPTER 2 -- FRONT FENDER, FRONT PANEL AND FOOTREST BOARD" section. 4. Remove: Handlebar cover Refer to "CHAPTER 2 -- HANDLEBAR COVER" section. 5. Remove: oFront brake cable ( ~ Rear brake cable ( ~
6. Remove: Handlebar switch (Right) ( ~ Front brake lever assembly ( ~ -Bracket ~ ) Throttle cable (~) Throttle grip
5-13
FRONT
FORK
AND
STEERING
ICHASI(_
10. Remove: .Ring nut (_) Using the Ring Nut Wrench (_ (YU-01268). NOTE: Support the steering column so that it may not fall down.
_! i :
',
11. Remove: .Washer (_ -Upper bearing race (Top) (_) Turn it counterclockwise. Steering column Bearings NOTE: Take care not to lose the bearings. (Upper: 26 pieces, Lower: 26 pieces) 5-14
[CHAS _I
2. Remove: Inner tube (Left and right) (_) Rubber (_ (Left side only) Front seat (_) =Spring fork spring @
(__,,_
INSPECTION 1. Wash the bearings in solvent. 2. Inspect: Bearing races _ill ...... Pitting/Damage--* Replace. oBearings Pitting/Damage--* Replace. NOTE: Always replace the bearing and race as a set.
.....
Bearing Size: Upper: 5/32 in Lower: 5/32 in Bearing Quantity: Upper: 25 pcs. Lower: 26 pcs.
5-15
..... :_
to straighten
a bent fork
Fork Spring
Standard: 92 mm (3.62 in) ASSEMBLY AND INSTALLATION Reverse the disassembly and removal steps. Note the following points.
5-16
oMolybdenum disulfide grease To inner tube (_ and rubber (_. 2. Install: 1. Apply: Front fork spring (_) -Spring seat _) Inner tube @ Rubber (_ (Left side only) oCirclip (_ oOil seal (_)
(__"
/"_
/ ,_
;;:;:_
5. install: i:i:: ::: i Steering column Upper bearing race (Top) @ Turn it clockwise completely. Washer (_ Ring nut
[CHASI
(YU-33975).
[_ NOTE:
22 ft.ib)
Set the torque wrench to the Ring Nut Wrench so that they form a right angle (_. 7. Check: oSteering column for smooth action !i_i!_i_:_i_:. _:i.:_-_,:\_,_: Slack_Tighten the ring nut. Sticky--* Loosen the ring nut.
8. Install: oHandlebar (_ oBolt (_ (New) Nut (_ (New) NOTE: Fit the handlebar bridge @ into the steering column notcher (_.
! .......... .....
,Before installing the handlebar, wipe the oil off the insertion portion (_) using thinner,
etc.
olnstall the bolt (_ from the right as shown. Make sure that the slit (_ has enough clearance after tightening the nut _).
*/_
L
FWD
60 Nm (6.0 m,kg, 43 ft.lb) I_ BltlHandlebar) @: 9. Install: ,,Inner fender with cable guide
5-18
CHAS
11. Apply: oLithium_soap base grease To throttle cable end and handlebar _-_,/-_ i 12. Install: =Throttle grip (_) Bracket _) =Front brake lever assembly (_) . _L__. _( ___ _ =Handlebar switch (Right) (_ =Throttle cable (2_)
right
_, ,
13. =Front brake cable (_) Install: =Rear brake cable (_ NOTE:
_s___/
Apply lithium-soap base grease onto the cable end pivot. 14. Install: =Handlebar covers (Front and rear) Speedometer cable ,,Front panel Front fender Refer to "CHAPTER 2 -- FRONT FENDER, FRONT PANEL AND FOOTREST BOARD" and "HANDLEBAR COVERS" section. 15. Adjust: Front and rear brake lever free play -,Throttle cable free play Refer to "CHAPTER 2" section.
5-19
_"
,-
)_/
5-20
COVER"
INSTALLATION When installing the rear shock absorber, reverse the removal procedure. Note the following points. 1. Instal[: eRear shock absorber
p 5-21
23 ft-lb) 13 ftib)
[E'EO ]D
CHAPTER 6 ELECTRICAL
CE50T CIRCUIT DIAGRAM ....................................... ..................................... H-3 H-4 H-5 H-5 H-6 H-8 H-9 H-11 H-11 H-12 H-15 H-15 H-16 I-2 I-2 I-3 I-5 I-5 I-6 I-7 I-9 I-9 1-10 1-10 ELECTRICAL COMPONENTS ELECTRICAL STARTING SYSTEM ................................ CIRCUIT DIAGRAM ............................................ TROUBLESHOOTING CHART ................................... STARTER MOTOR ............................................ STARTER MOTOR CHECK ..................................... IGNITION SYSTEM .............................................. CIRCUIT DIAGRAM ............................................ TROUBLESHOOTING CHART ................................... CHARGING SYSTEM ............................................. CIRCUIT DIAGRAM ............................................ TROUBLESHOOTING CHART ................................... LIGHTING SYSTEM .............................................. CIRCUIT DIAGRAM ............................................ TROUBLESHOOTING CHART ................................... SIGNAL SYSTEM ............................................... CIRCUIT DIAGRAM ............................................ TROUBLESHOOTING CHART ................................... SIGNAL SYSTEM TEST AND CHECKS ......................... AUTO CHOKE SYSTEM .......................................... CIRCUIT DIAGRAM ............................................ TROUBLESHOOTING CHART ................................... AUTO CHOKE UNIT TEST .....................................
ELECI _
=__L-=_ Y'=
z'_
=.-
T
L LO 001 =
Hi C_
+
__@
"],I
(_
_[-,,--i_o
= __--Y _E-=
L
E..oo_.,,,,v -=J
o,
LI Gy d2:[:
=_l,l,k_..___
..L_
--Br
+
LOCK -x-. C Br OFF Gy_ B/W_ B/R'_"
==,
=/.
-0
ON CO
.zB "="
__Gy_
_'R_
Gy
zB-"---_I
GY
r--
oo
,-----_,=r
R
N
B,W
I
B
@W/R
it
-O
&
2-
=,/w
Oh Br/W Dg
(3-0
==L=,
---
-L-B _
L 0-0
.2-=----e T
6-I
CE50T CIRCUIT D I A G R A M
(~ C.D.I. magneto (Lighting coil, charging coil) (~) Rectifier/Regulator (~) Starter motor
ELEC I
~
(~ (~ (~) (~) (~ (~) (~) (~) (~
tarter relay
"START" switch Main switch Fuse Battery "ENGINE STOP" switch C.D.I. magneto (Source coil, pick-up coil) C.D.I. unit Ignition coil Spark plug Flasher light relay
(~ "TURN" switch (~ Left flasher light (Front and rear) ~ ight flasher light (Front and rear) "TURN" indicator light (~) Horn (~ Horn ( ~ ) switch (~ Oil level gauge (~ "OIL" indicator light Front brake switch
~) ~) ~) ~) ~)
"LIGHTS" switch (Dimmer) Headlight "HIGH BEAM" indicator light Meter light Auto choke unit
COLOR CODE
R B Red Black White Yellow Brown Gray Orange Chocolate Dark green P L Y/R L/W G/Y B/W B/R W/R Br/W Pink Blue Yellow/Red Blue/White Green/Yellow Black/White Black/Red White/Red Brown/White
W Y
Br
Gy O Ch
Dg
6-2
//
6-3
//
6-4
.ELECTRICALSTARTING SYSTElVl
(_) (_) (_) (_) (_ (_ (_ (_) Starter motor Starter relay "START" switch Main switch Fuse Battery Front brake switch Rear brake switch
ELECI_
6-6
i
No Continuity
Fuse inspection: 1. Remove fuse. 2. Inspect fuse using Pocket Tester (YU-03112).
_xl
vi
"Replace fuse"
Continuity Battery fluid level inspection: Fluid level should be between upper (_ and lower (_) level mark. ! I ,Refill battery fluid.
Incorrect
Refill with distilled water only; tap water contains minerals harmful to a battery.
Dirty or poor connection r _Cleanbrush. battery terminals using wire NOTE: After cleaning terminals, apply grease lightly to both terminals. oConnect battery leads correctly.
OK
6-7
STARTING I
SYSTEM
ELEC
2. Inspect specific gravity of all celt using Bat- Low specific tery Hydrometer. jgravity (voltage)J
! Recharge battery
NOTE: Battery electrolyte is poisonous and dangerous, causing severe burns, etc. it contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL-Flush with water. INTERNALDrink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call a physician immediately, Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes etc., away. Ventilate when charging or using in an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. Replace the battery if: Batery 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 indicated by the plates turning white, or an accumulation of materiad exists in the bottom of the cell. Specific gravity readings after a long, slow charge indicate on cell to be lower than the rest. Warpageor buckling of plates or insulators is evident.
Specific Gravity: 1.2800.01 at 20C (68F) If there is not Battery Hydrometer, check battery voltage using Pocket Tester (YU-03112). 1. Remove battery. 2. Set the Tester selector to "DC20V" position. 3. Connect tester leads to battery terminals. Tester (+) Tester (-) lead-*(+) terminal iead_ (-) terminal
_1
6-8
ELEC
ELECTRICAL
STARTING
SYSTEM
Main switch conduct check: 1. Disconnect main switch leads. 2. Set Pocket Tester (YU-03112) selector to "t x 1" position. 3. Connect tester leads to main switch leads (Red lead, Brown lead). Tester (+)lead --*Red lead Tester (-) lead-,Brown lead 4. Turn main switch to "ON" position.
No
Continuity =, I
_" I Replace main switch.
Continuity "START" switch conduct check: 1. Disconnect handlebarswitch (Right) leads. "_ 1" position. 3. Connect tester leads to "START" switch 2. Set Pocket Tester (YU-03112) selector to leads (Black lead, Blue/White lead).
Continuity
_"1|
switch
[
Continuity 6-9
ELECTRICALSTARTING
Front and rear brake switches conduct check: 1. Disconnect brake switch leads. 2. Set pocket Tester'(YU-03112) selector to "_ x 1" position. 3. Connect teser leads to brake switch leads (Brown lead, Green/Yellow lead). Tester (+) lead -*Brown lead Tester (-) lead-*Green/Yellow 4. Apply front or rear brake. No Continuity
SYSTEM IELEC
lead
TI ,
..... .-1 I ...... J
Continuity Starter relay conduct check: 1. Remove starter relay. 2. Connect 12V battery to starter relay ter-minals shows. as NOTE: Use full charge battery. 3. Set Pocket Tester (YU-03112) selector to "_ 1" position. 4. Connect tester leads to starter relay terminals as shows. No Continuity _! Replace starter relay" l
Continuity
6-10
ELEC I
ELECTRICAL
START, NG SYSTEM
[_
Poor
_.1
Correct.
_U7OK Check starter motor condition. Refer to "STARTER MOTOR CHECK" section
_[
6-11
COMMUTATOR UNDER CUT: 1.0 mm (0.039 in) [1.15 rnm (0.045 in)] COMMUTATOR LIMIT: DIAMETER WEAR
B (_ C
14.5 mm (0.57 in) [14.8 mm (0.58 in)] 2.5 mm (0.10 in) [0.9 rnm (0.04 in)]
__)_
6-12
[ELEC\
ELECTRICAL STARTING
SYSTEM
_'_
STARTER MOTOR CHECK Removal 1. Remove: Starter motor Refer to "CHAPTER 3 -- ENGINE DISASSEMBLY" section.
3. Remove: Armature
Inspection and Repair 1. Measure: Brush length (Each) Out of specification-* Replace the starter motor assembly.
2. Inspect: eBrush spring Wear/Damage--* Replace the starter motor _._ assembly.
6-13
ELECTRICAL S T A R T I N G S Y S T E M
I ELECl
3. Inspect: Commutator (Outer surface) Grooved wear/Burning/scratches~ Smooth out using a sandpaper ( # 5 0 0 -
6O0).
NOTE:
Sand the commutator outer surface lightly and evenly. 4. Measure. Commutator diameter Out of specification--* Replace the starter motor assembly.
~1
Mica Undercut (~): 1.0 rnm (0.039 in) [1.15 mm (0.045 in)]
..
NOTE:
The mica insulation of the commutator must' be undercut to ensure proper operation of the commutator.
6. Measure: oArmature coil resistance Out of specification~Replace the starter motor assembly.
!i!i!:; ;;iii:i: ,
I ~
: iii!~!iii!iiiiiiiiiii!iii!i!iiljiil
;i;ili!iiiiiii!:i;;:; i~
~'
6-14
[ELEC I
ELECTRICAL S T A R T I N G S Y S T E M
7. Check: oArmature coil insulation Set the pocket tester selector to " 9 1K" position. Continuity--* Replace the starter motor assembly.
Assembly
Reverse the removal procedure. Note the following points.
6-15
I~
6-16
ELEC
J IGNITIONSYSTEM
IGNITION SYSTEM
CIRCUIT DIAGRAM Below circuit diagram shows ignition circuit.
6-17
~ gnitioncoil
Spark plug
6-18
LECI ]
IGNITION
SYSTEM
TROUBLESHOOTING CHART
IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE (NO SPARK OR INTERMITTENT SPARK).
Spark plug inspection: 1. Remove spark plug. 2. Clean spark plug with spark plug cleaner if necessary. 3. Inspect: Electrode Insulator oPlug gap Refer to "CHAPTER 2 -- SPARK PLUG INSPECTION" section. Plug Gap: 0.9-1.0 mm (0:035-0.039 in)
No good ~" j
v
Ignition spark test: 1. Install spark plug to plug cap. 2. Ground spark plug to air shroud. 3. Start starter motor.
Spark ~>1 Ignition circuit is good. I
Ignition spark gap test: 1. Remove spark plug and plug cap. 2. Hold spark plug lead 5 mm (0.20 in) from air shroud. 3. Start starter motor.
S.ark
6-19
iGNITION SYSTEM
IE'EC[' I
~~No spark Main switch conduct check: 1. Disconnect main switch leads. 2. Set Pocket Tester (YU-03112) selector to "'9 x 1" position. 3. Connect tester leads to main switch leads (Black/White, Black/Red).
Tester ( + ) lead-*Black/Red lead Tester ( - ) lead-~Black/White lead
J v~Continuity "ENGINE STOP" switch conduct check: 1. Disconnect handlebar switch (Right)leads. 2. Set Pocket Tester (YU-03112) selector to "9 x 1" position. Continuity 3. Connect tester leads to "ENGINE STOP" switch leads. ~ 1 Tester (+)lead-*Black/Red lead Tester ( - ) lead-~Black lead 4. Turn "ENGINE STOP" switch to "RUN" position.
6-20
l ,EcI
] OOTOOSSTEM
~T
NO continuity
1. Disconnect ignition coil lead (orange lead). 2. Measure: =Primary coil resistance [ ] (Orange lead -- Ignition coil base) Set Pocket Tester (YU-03112) selector to "'~ x 1" position. oSecondary coil resistance r-~ (Orange lead -- Spark plug lead) Set Pocket Tester selector to " 9 x 1K" position.
Primary Coil Resistance: 0.21-0.25~ at 20C (68F) Secondary Coil Resistance: 4.5-6.7k~t at 20C (68F)
~JL OK
6-21
'ON'T'ONSYSTEM I E'EC I
Source coil resistance test: 1. Disconnect C.D.I. magneto leads. 2. Set Pocket Tester (YU-03112) selector to "~3 100" position. 3. Connect tester leads to source coil leads.
~v~OK Pick-up coil resistance test: 1. Set Pocket Tester (YU-03112) selector to "G 10" position. 2. Connect tester leads to pick-up coil leads. Tester (+) lead--White/Red lead Tester (-)lead-~Black lead 3. Measure: Pick-up coil resistance Out of specification ~ 1
- ~
6-22
[ELEC
] ,GNmON SYSTEM
__LOK
Poor
_lconnection
Correct.
I CD'
6-23
iGNITION
SYSTEM
ELEC
6-24
_L___1CHARO,NO SYSTEM
CHARGING
CIRCUIT
i_
SYSTEM
DIAGRAM
6-25
CHARGING SYSTEM
(_ C.D.I. magneto (Lighting coil, charging coil) (_ Rectifier/Regulator (_) Fuse (_) Battery
ELEC
E_
6-26
[ELEC
TROUBLESHOOTING
CHARGING
CHART
SYSTEM
Fuse inspection: 1. Remove fuse. 2. Inspect fuse using Pocket Tester (YU03112).
No
i.,e0.ace,use
Continuity Battery fluid level inspection: Fluid level should be between upper (_ and lower (_ level mark. oRefill battery fluid.
Incorrect
Refill with distilled water only; tap water contains minerals harmful to a battery.
Dirty or poor . .nnnp.c.tinn _ I v oCleanbrush. wire battery terminals using NOTE: After cleaning terminals, apply
OK
i I t
6-27
c ,oosYSTEM ELSe] I
Battery fluid specific gravity inspection: 1. Remove caps. 2. Inspectspecificgravity of allcell using Battery Hydrometer. Low specific gravity (voltage) _ v oRecharge battery Charging Current: 0.4 amps/lO hrs Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing, Antidote: EXTERNAL-Flush with water, INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call a physiclan immediately, Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes etc., away. Ventilate when charging or using in an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. NOTE: Replace the battery if: Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging. oSulfation of one or more cells occurs, as indicated by the plates turning white, or an accumulation of material exists in the bottom of the cell. oSpecific gravity readings after a long, slow charge indicate on cell to be lower than the rest. Warpage or buckling of plates or insulators is evident.
Specific Gravity: 1.2804-0.01 at 20C (68F) If there is not Battery Hydrometer, check battery voltage using Pocket Tester (YU-03112). 1. Remove battery. 2. Set the Tester selector to "DC2OV" position. 3. Connect tester leads to battery terminals. Tester ( + ) lead--,( + ) terminal Tester (-) lead-*(- ) terminal
J_L!7 K 6-28
IELECI
CHARGING SYSTEM
Charging voltage test: 1. Connect InductiveTachometer (YU-08036) to ignition lead. 2. Set Pocket Tester (YU-03112) selector to "DC20V" position. 3. Connect tester leads to battery terminals. Tester ( + ) lead-*( + ) terminal Tester (-) lead-_() terminal OK _.! _1/_1 eplace battery. R
4. Start engine and accelerate to about 4,000 r/rain. 5. Measure: Charging voltage r/min 12.5-17.5V at 4,000
Out of specification Charging coil resistance test: 1. Disconnect C.D.I. magneto leads. 2. Set Pocket Tester (YU-03112) selector to "_ 1" position. 3. Connect tester leads to charging coil leads. Tester (+) lead-+White Tester (-) lead-*Black lead lead
6-29
___
4. Measure: Charging coil resistance
I_
Out
of
OK
Poor
I Correct.
I Replace rectifier/regulator.
6-30
ELEC I~ ] LIGHTINGSYSTEM
LiGHTiNG SYSTEM
CIRCUIT DIAGRAM Below circuit diagram shows lighting circuit.
r-
6-31
LIGHTING SYSTEM
(~ C.D.I. magneto (Lighting coil, charging coil) Rectifier/Regulator ~) "LIGHTS" switch (Dimmer) ~) Headlight (~ "HIGH BEAM" indicator light (~) Meter light
6-32
ELEC I
LIGHTING S Y S T E M
H e a d l i g h t condition c h e c k :
1. Remove headlight lens unit. 2. Set Pocket Tester (YU-03112) selector to Continuity does "~ x 1" position. not exist on 3. Connect tester leads to headlight terminals and check it for continuity. ~ j Replace headlight lens unit. Tester ( + ) lead-~Terminal 1
Tester (-) lead-*Terminal 3
T e s t e r ( + ) lead-~Terminal 2
Tester ( + ) lead--Terminal 3
<ists uit.
Lighting v o l t a g e test:
1. Set Pocket Tester (YU-03112) Selector to "AC20V" position. 2. Turn "LIGHTS" switch to "HI" position, 3. Connect tester leads to headlight leads. Tester ( + ) lead-*Yellow lead T e s t e r ( - ) lead-~Black lead
6-33
LIGHTING SYSTEM
4. Connect Inductive Tachometer (YU-08036) to ignition lead. 5. Start engine and accelerate to about 4,000 r/min. 6. Measure: Lighting voltage
[ ,EoI
1. Remove front fender and disconnect left handlebar switch lead. 2. Set Pocket Tester (YU-03112) selector to "'~ x 1" position. 3. Connect tester leads to "LIGHTS" switch leads. If switch is turned to "LO'" position.
Tester ( + ) l e a d - * B l u e lead Tester ( - ) lead-~Green lead
Continuity does not exist on one circuit. ~'1 Replace left handlebar switch.
6-34
I E'ECI
I LIGHTINGSYSTEM
13
Lighting coil resistance test: 1. Disconnect C.D.I. magneto leads. 2. Set Pocket Tester (YU-03112) selector to "~ 1" position. 3. Connect tester leads to lighting coil leads. Tester ( + ) lead-*Yellow/Red lead Tester ( - ) lead--Black lead
4. Measure: Lighting coil resistance
Out of specification
~1
Check entire lighting system for connections. Refer to "WIRING DIAGRAM". /L OK I Replace rectifier/regulator.
6-35
LiGHTiNG SYSTEM
ELEC
6-36
SIGNAL
CIRCUIT
I'
6-37
Main switch Fuse Battery Flasher light relay "TURN" switch Left flasher light (Front and rear) Right flasher light (Front and rear) "TURN" indicator light
@ _) @ @ (_ (_ _)
Horn "HORN" switch Oil level gauge "OIL" indicator light Front brake switch Rear brake switch Tail/Brake light
s,ooA,I,E' cl s sTEM i
6-38
TROUBLESHOOTING
___
_1
"_e0'acef_se. N
Continuity Battery fluid level inspection: Fluid level should be between upper (_ and lower _ level mark. Incorrect oRefill battery fluid.
Refill with
distilled
water
on-
minerals
Correct Dirty or poor Check battery terminals. _ I connection oClean battery terminals using wire brush. NOTE: After cleaning terminals, apply grease lightly to both terminals. Connect battery leads correctly.
7
L -
OK
6-39
SIGNAL SYSTEM
Battery fluid specific gravity inspection: 1. Remove caps. 2. Inspectspecific gravity of allcell using Bat- Low specific tery Hydrometer. Iravity (voltage) _ Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing, Antidote: EXTERNAL-Flush with water, INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call a physiclan immediately, Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes etc., away. Ventilate when charging or using in an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. oRecharge battery. Charging Current: 0.4 amps/10 hrs NOTE: Replace the battery if: oBattery 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 indicated by the plates turning white, or an accumulation of material exists in the bottom of the cell. oSpecific gravity readings after a long, slow charge indicate on cell to be lower than the rest. Warpage or buckling of plates or insulators is evident.
Specific Gravity: 1.2804-0.01 at 20C (68F) If there is not Battery Hydrometer, check battery voltage using Pocket Tester (YU-03112). 1. Remove battery. 2. Set the tester selector to "DC20V" position. 3. Connect tester leads to battery terminals. Tester ( + ) lead-_( + ) terminal Tester (-) lead--*(- ) terminal
--_
'_,/lz OK 6-40
[ELECS,OAL S STEM
Main switch conduct check: 2. Set Pocket Tester (YU-03112) selector to 1. Disconnect main switch leads. "9 x 1" position. ! continuity 3. Connect tester leads to main switch leads (Red lead, Brown lead). Tester (+) lead-,Red lead Tester ( - ) lead-,Brown lead 4. Turn main switch to "ON" position. I No _ I _ I Replace main switch.
Poor condition Check bulb conditions of flasher lights, in- _1 dicator lights and tail/brake light.
Replace bulb(s)
Poor
Check to "WIRING DIAGRAM" connections I connection (Refer entire signal system for section.) i
_l IF
Correct,
Jv LK Check condition of each circuit for signal _ _i Poor ____,.l,__ | component(s). Replace poor condition electrical
SYSTEM TEST
6-41
SIGNAL
SIGNAL NOTE:
SYSTEM
ELEC
CHECKS
The battery provides power for operation of the horn, flasher lights, indicator light and brake light. If none of the above operates, always check the battery voltage before proceeding further. Low battery voltage indicates either a faulty battery, low battery electrolyte, or a defective charging system. See "CHARGING SYSTEM" for checks of the battery and charging system. Also, check the fuse condition. Replace the fuse if necessary.
I_1 -i No voltage
Check for voltage 112V) on "Br" lead at rear brake switch connector,
|
_ I Wiring circuit from fuse to rear v brake switch connector is faulty, i repair.
_ I Front I replace.
brake
switch
is faulty,
while applying
!
_
Check for voltage (12V) on "G/Y" lead at rear brake switch connector while applying rear brake.
No voltage
_ v
! I
6-42
_o_
'Jx_ OK Check for voltage (12V) on "Br/W" "TURN" switch connector. lead at '1 No voltage _, Wiring circuit from flasher relay to _ J r "TURN" switch is faulty, repair.
_o_
Check for voltage (12V) on "'Ch" and/or "Dg" lead at "TURN" switch connector. I No voltage _ "TURN" switch is faulty replace.
J_o_
I Flasher light bulb socket is faulty, replace it.
_o_
Check for voltage "HORN" (12V) on "P" lead at _ No voltage . I 1 Horn is faulty, replace. i switch connector.
l
I
_o_
Check for continuity of "HORN" switch, while I No continuity .I "HORN" switch is faulty, replace. I pushing it. ! v I ! _ Continuity
sq
4. "'OIL" indicator light does not work Checkfor voltage (12V) on "Br" lead at oil level gauge connector. '_
s,ooAL 1 S,STEM I
No voltage __1 No
|
Check fOrconnector.VOltage (12V) on "Gy" lead at oil level ____1, gauge I -_,_OK No
Check for condition of oil level condition, replace it. i gauge. If oil level gauge is poor
indicator light connector, Check for voltage (12V)on "B" lead at "OIL" I vItage_
[Oil level gauge check] 1. Disconnect: eOil level gauge leads 2. Remove: Oil level gauge 3. Connect: Pocket Tester (YU-03112) Set the tester selector to "9 x 1" position. /_ ....i_;;, 4. Check: Oil level gauge conduct Refer to following table Not per result--* Replace.
5. Taillight
does not work No voltage _ I Wiring circuit from fuse to taillight r _ connector is faulty, repair. L
1 6-44
[ELEC _I
AUTO
CIRCUIT
F =_
CHOKE
DIAGRAM
6-45
AUTO (_) C.D.I. magneto (Charging coil, lighting coil) (_ Auto choke unit
CHOKE
SYSTEM
[ELECI_
6-46
IELEC
_]
AUTOCHOKESYSTEM CHART
TROUBLESHOOTING
Lighting coil resistance test: 1. Disconnect C.D.I. magneto leads. 2. Set Pocket Tester (YU-03112) selector to "_ 1" position. 3. Connect tester leads to lighting coil leads. Out of
Tester (-) lead--Black lead Tester (+)lead-_Yellow/Red 4. Measure: oLighting coil resistance
lead
specificatin _ I
0.27-0.33_
at 20C (68F)
F-,
OK ] Poor Check entire auto Choke system for connec- I connection I Refer to "WIRING DIAGRAM". tions. !
b,
/ Correct.
v l
Check auto choke condition. Refer to "AUTO CHOKE UNIT TEST" section.
6-47
3. Disconnect: oAuto choke unit leads 4. Connect: oPocket tester (YU-03112) Set the tester selector to "_ x 1" position.
I!
0oc,.o,I
6-48
CHAPTER
7
J-3 J-3 J-4 J-8 J-8 J-8
APPENDICES
SPECIFICATIONS ................................................ GENERAL SPECIFICATIONS ..................................... MAINTENANCE SPECIFICATIONS ................................ GENERAL DEFINITION CABLE TORQUE SPECIFICATIONS ............................
ROUTING
CES0S WIRING
DIAGRAM
APPENDICES SPECIFiCATiONS
GENERAL SPECIFICATIONS Model Model Code Number Vehicle Identification Number Engine Starting Number Dimensions: Overall Length Overall Width Overall Height Seat Height Wheelbase Minimum Ground Clearance Basic Weight: With Oil and Full Fuel Tank Minimum Turning Radius Engine: Engine Type Cylinder Arrangement Displacement Bore x Stroke Compression Ratio Starting System Lubrication System Oil Type or Grade: Engine Oil Transmission Oil Oil Capacity: Oil Tank (Engine Oil) Transmission Oil Periodic Oil Change Total Amount Air Filter Fuel: Type Tank Capacity Regular gasoline 2.9 L (0.64 Imp gal, 0.77 US gal) 2UG JYA2UG00-X-HA720101 14T-720101 1,560 620 972 690 1,085 100 mm mm mm mm mm mm (61.4 in) (24.4 in) (38.3 in) (27.1 in) (42.7 in) (3.9 in) CE50T
58.5 kg (129 Ib) 1600 mm (63 in) Air cooled 2-stroke, gasoline torque induction Single cylinder, Forward inclined 49 cm 3 40.0 x 39.2 mm (1.57 x 1.54 in) 7.2:1 Electric and Kick Starter Separate lubrication (Yamaha Autolube) Yamalube 2-cycle oil or Air cooled 2-stroke engine oil Yamalube 4-cycle oil or SAE 10W30 type SE motor oil or GL gear oil 0.8 L (0.70 Imp qt, 0.84 US qt) 0.10 L (0.09 Imp qt, 0.11 US qt) 0.11 L (0.10 Imp qt, 0.12 US qt) Wet type element
7-1
i
Model Carburetor: Type/Manufacturer Spark Plug: Type/Manufacturer Gap Clutch Type Transmission: Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type Operation Chassis: Frame Type Caster Angle Trail Tire: Size (F) Size (R) Tire Pressure (Cold tire): Front Rear Brake: Front Brake Type Operation Rear Brake Type Operation Suspension: Front Suspension Rear Suspension Shock Absorber: Rear Shock Absorber Wheel Travel: Front Wheel Travel Rear Wheel Travel Coil Spring/Oil Damper Drum brake Right hand operation Drum brake Left hand operation . Telescopic Fork Unit Swing CE50T Y12P/TEIKEI KIKAKI BPR6HS/NGK 0.9-1.0 mm (0.036-0.039 Dry, Centrifugal Automatic Spur gear 52/14 (3.714) Spur gear 36/12 (3.000) V-belt Auto matic Steel Tube Underbone 25 62 mm (2.44 in) in)
2.75-10-4PR 2.75-10-4PR
125 kPa (1.25 kg/cm 2, 18 psi) 225 kPa (2.25 kg/cm 2, 32 psi)
7-2
{APPX[_
SPECiFiCATION
Model CE50T
Electrical: Ignition System CDI Flywheel magneto GM4-3B 12V 4AH Shealed Beam
Generator System Battery Type or Model Battery Headlight Capacity Type: x Quantity:
Bulb Wattege Headlight Tail/Brake Licence Meter Flasher light Light light
12V 25W/25W light 12V 5W/21Wx 12V 10Wx4 12V 5Wx 12V 3.4Wx x Quantity: 12V 1.7Wx 1 1 12V 1.7Wxl 12V 3.4Wx 1 1
x 1 1
_ ,#
Cylinder: Bore Size < Limit> Taper Limit Out of Round Limit Piston: Piston Size _
mm mm mm mm
Measuring Point* Piston Clearance Oversize 1st 2nd Piston Ring: Sectional Sketch (BxT)
----L__*
5 mm (0.2 in) 0.034-0.047 mm (0.0013-0.0018 40.25 mm (1.585 in) 40.50 mm (1.594 in) in)
Top Ring 2nd Ring End Gap (Installed) Top Ring 2nd Ring Side Clearance (Installed) Top Ring 2nd Ring Crankshaft:
t/"_-i[B L_____JJ__ __
1.2x 1.6 mm (0.047x0.063 in) 1.2 x 1.6 mm (0.047 x 0.063 in) 0.15-0.30 0.15-0.30 0.03-0.05 0.03-0.05 mm (0.006-0.012 in) mm (0.006-0.012 in) ,. mm (0.0012-0.0020 in) mm (0.0012-0.0020 in)
Crank Width "A" Run Out Limit "C" Connecting Rod Big End Side Clearance "D" Small End Free Play "F"
37.90-37.95 mm (1.492-1.494 0.03 mm (0.0012 in) 0.2-0.5 0.4-0.8 mm (0.008-0.020 mm (0.015-0.031 in) in)
in)
7-4
[APPx sPEo.F.oAT.o.
Model Automatic Centrifugal Clutch: Shoe Thickness <Wear Limit> Clutch Spring Free Length <Limit> Clutch Housing Inside Diameter <Wear Limit> Clutch-In Revolution Clutch-Stall Revolution V-Belt: Width <Wear Limit> Transmission: Main Axle Runout Limit Drive Axle Runout Limit Kick Starter: Type Kick Clip Tension Carburetor: I.D. Mark Main jet Jet Needle-clip Position Main Air Jet Cutaway Pilot Jet Pilot Ait Jet Valve Seat Size Starter Jet Float Height Engine Idling speed Reed Valve: Thickness Valve Stopper Height Reed Valve Clearance Lubrication System: Minimum Stroke Maximum Stroke Pulley Adjusting Mark Autolube Pump 0.10-0.15 mm (0.004-0.006 0.55-0.65 mm (0.022-0.026 At idle (_: 0.0-1.0 mm (0.0-0.039 in) in) in)/at idle 0.15 mm (0.006 in) 3.0-3.4 mm (0.12-0.13 in) Less than 0.2 mm (0.008 in) (M.J.) (J.N.) (M.A.J.) (C.A.) (P.J.) (P.A.J.) (V.S.) (G. S. ) 1UV00 #82 3S30-4/5 2.0 3.0 #42 _1.04 1.5 # 46 15.0-17.0 mm (0.59-0.67 1,500-2,100 r/min Ratchet Type 250-300 g (8.83-10.6 oz) 0.08 mm (0.003 in) 0.08 mm (0.003 in) 15 mm (0.59 in) < 13.5 mm (0.53 in)> 4.0 mm (0.16 in) <2.5 mm (0.10 in)> 109.6 mm (4.31 in) <94.0 mm (3.70 in)> 105.0 mm (4.13 in) <105.4 mm (4.15 in)> 2,300-2,700 r/min 3,700- 4,300 r/min CE50T
in)
7-5
Tightening Torque Tightening torque Part to be tightened Spark plug Cylinder head Stud bolt Startor assembly C.D.I. magneto Air shroud Fan cover Fan Autolube pump Reed valve (carburetor joint) Air cleaner Case Exhaust pipe Muffler Muffler protector Crankcase Transmission case cover Crankcase cover Transmission oil drain bolt Autolube pump cover Stay (starter clutch) Kick crank Clutch Clutch housing Primary sheave Idle gear plate Oil seal stopper plate Thread size M14x 1.25 M 6x 1.0 M 6xl.0 M 6 x 1.0 M12x 1.25 M 6x 1.0 M 6 x 1.0 M 6x 1.0 M 5x0.8 M 8 x 1.0 M 6 x 1.0 M M M M M M M 6 x 1.0 8x 1.25 6xl.0 6 x 1.0 6 x 1.0 6x 1.0 8x 1.25 1.0 1.0 1.0 1.0 Q'ty 1 4 4 2 1 3 2 2 2 4 2 2 2 2 6 5 10 1 2 3 1 1 1 1 2 1 Nm 20 10 10 8 43 8 8 8 4 8 8 8 27 8 8 8 8 18 8 8 10 50 40 30 8 13 mokg 2.0 1.0 1.0 0.8 4.3 0.8 0.8 0.8 0.4 0.8 0.8 0.8 2.7 0.8 0.8 0.8 0.8 1.8 0.8 0.8 1.0 5.0 4.0 3.0 0.8 1.3 ftolb 14 7.2 7.2 5.8 31 5.8 5.8 5.8 2.9 5.8 5.8 5.8 19 5.8 5.8 5.8 5.{] 13 5.8 5.8 7.2 36 29 22 5.8 9.4 Remarks
M 6x M 6x M 6x M28 x
7-6
I PPX A I
Chassis Model Steering System: Steering Bearing Type No./Size of Steel Balls Upper Lower Front Suspension: Front Fork Travel Fork spring Free Length <Limit> Spring Rate (K1) Stroke Optional Spring Rear Suspension: Shock absorber Travel Spring Free Length Spring Fitting Length Spring Rate (K1) (K2) (K3) Stroke (K1) (K2) (K3) Optional Spring Wheel: Front Wheel Type Rear Wheel Type Front Rim Size/Material Rear Rim Size/Material Rim Runout Limit Vertical Lateral Front Drum Brake: Type Drum Inside Diameter <Wear Limit> Lining Thickness <Wear Limit> Rear Drum Brake: Type Drum Inside Diameter <Wear Limit> Lining Thickness <Wear Limit> Leading, Trailing 95.0 mm (3.74 in) <95.5 mm (3.76 in)> 3.0 mm (0.12 in) <2.0 mm (0.08 in)> Leading, Trailing 80.0 mm (3.15 in) <80.5 mm (3.17 in)> 3.5 mm (0.14 in) <2.0 mm (0.08 in)> Disc wheel Disc wheel 1.50x 10 DC/Steel 1.50 10 DC/Steel 2.0 mm (0.08 in) 2.0 mm (0.08 in) CE50T Ball bearing 5/32 in/26 pcs 5/32 in/26 pcs 48.6 mm (1.91 in) 92 mm (3.62 in) <87 mm (3.42 in)> 9.55 N/mm (0.974 kg/mm, 53.6 lb/in) 0.0-48.6 mm (0.0-1.91 in) No. 45 mm (1.77 in) 187.5 mm (7.38 in) 182.5 (7.18 in) 37.2 N/mm (3.8 kg/mm, 209.3 Ib/in) 48.1 N/mm (4.9 kg/mm 269.9 Ib/in) 72.6 N/mm (7.4 kg/mm 407.6 Ib/in) 0.0-25 mm (0.0-0.98 in) 25-40 mm (0.98-1.57 in) 40-45 mm (1.57-1.77 in) No.
7-7
kSPEC,F,OAT [APPXI
Tightening Torque Tightening torque Part to be tightened Frame and Engine bracket Engine bracket and Engine Rear Suspension (Upper) (Lower) Handlebar and Steering column Ring nut (Steering column) Front wheel axle Front brake cam lever Rear brake cable holder Rear brake cam lever Rear wheel axle Rear brake shoe plate Rear stay Seat bracket and seat Rear Carrier Thread size MlOx 1.25 MIOx 1.25 MlOx 1.25 M 8x 1.25 M 8 x 1.25 M25 MIO 1.25 M 5 x 0.8 M 6x 1.0 M 5 x 0.8 M14x 1.5 M 8x 1,25 M 6x1.0 M 6x 1.0 M 6x1.0 Q'ty 2 1 1 1 1 1 1 1 1 1 1 3 4 2 4 Nm 42 42 32 17 29 30 35 4 7 6 93 18 10 7 7 mkg 4.2 4.2 3.2 1.7 2.9 3.0 3.5 0.4 0.7 0.6 9.3 1.8 1.0 0.7 0.7 ftlb 30 30 23 12 21 22 25 2.9 5.1 4.3 67 13 7.2 5.1 5.1 Remarks
7-8
Electrical Model Voltage: Ignition System: Ignition Timing (B.T.D.C.) Advancer "Fype 25
L3
c_ 20
_
e--
15
10 5
E N
tO o_
*-
J
0 1 2 3 4 5 6 7 8 9 Enginespeed (x 103r/min)
C.D.I.: C.D.I. Unit-Model/Manufacturer Ignition Coil: Model/Manufacturer Primary Winding Resistance Secondary Winding Resistance Charging System/Type: C.D.I. Magneto: Model/Manufacturer Pickup Coil Resistance (Color) Charging Voltage Lighting Voltage Source Coil Resistance (Color) Charging Coil Resistance (Color) Lighting Coil Resistance (Color)
24L--MO/YAMAHA 2EX/YAMAHA 0.21 -0.25ft at 20C (68F) 4.5-6.7kft at 20C (68F) Flywheel Magneto F 1HH/YAMAHA 27-33_ at 20C (68F) (White/Red--Black) 13.0-17.5V at 4,000 r/min 11.5-13.5V at 4,000 r/min 216-264_ at 20C (68F) (Black/Red--Black) 0.63-0.77_ at 20C (68F) (White--Black) 0.27-0.33[_ at 20C (68F) (Yellow/Red-- Black)
7-9
i
Model Voltage Regulator: Type Model/Ma nufactu rer No Load Regulated Voltage Rectifier: Model/M anufactu rer Capacity Withstand Voltage Battery: Capacity Specific Gravity Starter Motor: Model Manufacturer Out Put Armature Coil Resistance Brush Length <Wear Limit> Commutator Diameter <Wear Limit> Mica Undercut Starter Relay: Model/Manufacturer Amperage Rating Coil Resistance Horn: Type/Quantity Model/M anufactu rer Maximum Amperage Flasher Relay: Type Model/Manufacturer Self Cancelling Device Flasher Frequency Wattage Circuit Breaker: Type Fuse Amperage for Individual Circuit Quantity Main 7A x 1 Plain type GF-12/NIKKO 1.5A Semi conductor short circuit type EHU-01TR05/MATS US HITA 13.5-14.5V EHU-01TR15/MATS US HITA 4A 240V 12V, 4AH 1.280 DA5AG NIPPON DENSO 0.15 kW 0.08 - 0.109 5.5 mm (0.22 in) <2.5 mm 0.10 in)> 15.5 mm (0.61 in) <14.5 mm (0.57 in)> 1.0 mm (0.039 in) 27V/TATEISHI 20A 54- 66_ 2EX-81800-M0 YAMAHA 0.14 kW 0.08 - 0.10n 3.9 mm (0.15 in) <0.9 mm (0.03 in)> 15.8 mm (0.62 in) <14.8 mm (0.58 in)> 1.15 mm (0.045 in) CE50T
DENSO
7-10
APPX
DEFINITION OF UNITS
A (Nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm
B (Bolt)
6 mm 8 mm 10 mm 12 mm 14 mm 16 mm
General torque Nm
6 15
30 55 85 130
assemblies are included in the applicable sections of this book. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.
DEFINITION OF UNITS
Unit mm cm kg N Nm m-kg Pa N/mm L cm 3 r/rain Read millimeter centimeter kilogram Newton Newton meter Meter kilogram Pascal Newton per millimeter Liter Cubic centimeter Rotation per minute Definition 10- 3meter 10 - 2meter 103gram 1 kg x m / s e c 2 Nx m m x kg N/ m2 N/ram --Measure Length Length Weight Force Torque Torque Pressure Spring rate Volume or Capacity Engine Speed
7-11
CABLE ROUTING
(_ Main switch (_) Leg shield bracket Rear brake cable _) Throttle cable (_) Carrier stay 2 Horn (_ Rectifier/Regulator
CABLEROTN IAPPXI !
[] [] Route along left side of leg shield bracket and frame, Route wire harness along left side of leg shield bracket and then, along left side of frame down-tube. Wire harness should be on the left side. []
[]
[]
7-12
(_ Throttle cable Rear brake cable (_) Wire cylinder ass'y (_ Oil level gauge (_ Breather hose (_ Band
[]
It should be firmly installed on the engine prorector. [] Route wire harness between rear stay and fuel tank. [] Insert fuse case (wire harness assembly) into holder {integrated with battery casel. [] Route wire harness over frame. [] Route breather hose along engine protector slit. [] Route wire harness under back stay.
[]
7-13
(_ (_) _) (_ (_ (_) (_
Inner fender C.D.I. unit Ignition coil Fuel pipe (tank to cock) Clamp Band Auto choke unit lead
[] [] [] [] []
Pass meter cable and brake cable through the window in inner fender. Meter cable and front brake cable should be free of twists. Clamp rear brake cable. Be sure the casing cap of brake cable is completely in crankcase. Clamp wire harness only.
7-14
CABLE ROUTING
(~ Main switch
Oil pipe
[ ] Push the projecting portion of clamp into the mounting hole on the stay side.
Fuel tank Fuel cock Oil tank Starter relay Clamp Band
7-15
(_) (_ (_) @ (_) (_) (_ (_) (_ (_ (_) @ @ (_) (_ (_ High tension cord Auto choke unit lead Band Boot C.D.I. magneto lead Oil pump cover Exhaust pipe Clamp Starter motor lead Carrier 2 Taillight assembly Tail cover assembly License bracket Flasher stay Cap Flasher light assembly
CABLE.OOT, OO
[] [] [] [] Clamp firmly. Route battery breather hose inside the back stay and hold with clamp. When installing cover, use care so that pipe is not pinched. Pass flasher lead through holes in flasher stay and carrier 2. As shown, after connecting the taillight and flasher leads, push the connections completely into the tail cover. No coupler and connector are allowed to be outside the case.
7-16
CE50T WIRING
DIAGRAM
Front brake
IV
switch
switch
switch
G/Y Br
light (Right)'k jU
B_
--L=_-B
uw
!
"TURN" _T=_Dg--:'! indicator lightk_U -c"-]
"
r,_._,.y--Gv--I
" I
indicator ligh.t_,J.JGv Meter light 0 "HIGH BEAM" f_'T=].y " indicatr light _'L}'B Headlight
1 B. _
[_4L_L%U . C:=_Z]-Y-_ /
_=._1_._ B .
_[
light (Left)
8_
s=L2.j_ B _
relay [
B'L2L-I---8'
___G
Y_ B
OFF B
Horn switch
LO-O
N
G/Y
Br
Horn
switch
-..L_._
Gy Br
OBg _
ic.C3<:1
Fuse
W/R B/R
R l 8/R S R
B .......... Black COLOR CODE L .......... Blue O .......... Orange P ......... . Pink Y .......... Yellow R .......... Red G .......... Green Br .......... Brown Gy ......... Ch ......... Gray' Chocolate Dark green White Black/Red Blue/White Yellow/Red Green/Yellow Brown/White White/Red Black/White
:o choke t
CDI magneto
CDI unit
Battery
Starter. relay
Dg ......... W .......... B/R ........ L/W ....... Y/R ........ G/Y ........ Br/W ....... W/R ....... B/W .......
YAM/liiA
2YT-AE1
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and new data for the CG50U. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with following manual: I CE50T Service Manual: 2UG-IVIE1 I
CG50U SU PPLEM ENTARY SERVICE MANUAL 1987 by Yamaha Motor Co., Ltd. 1st Edition, November 1987 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha scooters have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
0
I,GEN
NFO
IINSP
cool
IoA.B 4
(~ (~ (~ (~
ngine
IELEC[
@
IAPP l
@
Illustrated symbols (~) to (~) are used to identify the specifications appearing in the text. (~ Filling fluid (~ Lubricant (~ Tightening
@
m
i
@ @
i E~
m
i E~
Illustrated symbels (~ to (~ in the exploded diagram indicate grade of lubricant and location of lubrication point. Apply engine oil (~) Apply gear oil (~ Apply molybdenum disulfide oil (~) Apply wheel bearing grease (~ Apply lightweight lithium-soap base grease ~) Apply molybdenum disulfide grease (~) Apply locking agent (LOCTITE)
@
l
D
CONTENTS
GENERAL INFORMATION ................................. L-5
L-5 L-5 L-5 SCOOTER IDENTIFICATION .................................. VEHICLE IDENTIFICATION NUMBER ........................... ENGINE SERIAL NUMBER ....................................
.........
L-5
L-5 L-5 L-6 L-6 L-7 L-8 L-8 L-8 L-9
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ....... COVERS ..................................................... TAIL COVERS AND MOLES ................................... FRONT PANEL, LEG SHIELD AND FOOTREST BOARD .......... HANDLEBAR COVERS ...................................... ENGINE. ..................................................... ENGINE OIL LEVEL INSPECTION .............................. AUTOLUBE PUMP AIR BLEEDING .............................
ELECTRICAL .................................................
CGEOU CIRCUIT DIAGRAM .................................. ELECTRICAL COMPONENTS ................................. SIGNAL SYSTEM ............................................ CIRCUIT DIAGRAM ......................................... TROUBLESHOOTING ........................................
L-10
L-10 L-11 L-12 L-12 L-13
APPENDICES
...............................................
L-14
L-14 L-14 L-16 M-3 M-3 M-4
SPECIFICATIONS ............................................ GENERAL SPECIFICATIONS ................................. MAINTENANCE SPECIFICATIONS .... ........................ GENERAL TORQUE SPECiFiCATIONS ........................ DEFINITION OF UNITS ....................................... CABLE ROUTING ............................................
SCOOTER IDENTIFICATION
I GEN
GENERAL INFORMATION
SCOOTER IDENTIFICATION
VEHICLE iDENTIFICATION N U M B E R The vehicle identification number ( ~ is stamped into the frame. NOTE: The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your state.
ENGINE SERIAL N U M B E R The engine serial number (~) is stamped into the crankcase. NOTE: The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.
Starting Serial Number: 2YT-000101 NOTE: Designs and specifications are subject to change without notice.
--1--
I INSP
REMARKS
Check condition. Clean or replace if necessary. Clean. Replace if necessary.
I
Check idle speed/starter operation. Adjust if necessary. Check fuel hose for cracks or damage. Replace if necessary. Check oil leakage. Correct if necessary. Replace every 12,000 (8,000) or 24 months. (Warm engine before draining.) Check operation. Correct if necessary. Air bleeding. Check operation. Adjust if necessary. Check/damage/runout. Repair if necessary. Check bearings assembly for looseness/ damage. Replace if damaged. Check bearings assembly for looseness. Correct if necessary. Moderately repack every 12,000 (8,000) or 24 months.** Check operation/oil leakage. Repair if necessary. Check all chassis fittings and fasterners. Correct if necessary. Check operation. Repair if necessary. Check specific gravity. Check breather pipe for proper operation. Correct if necessary. Check damage and wear. Replace if necessary.
REPLACE
I
Autolube pump* Brake Wheels* Wheel bearings* Steering bearing* Rear shock absorber*
Fittings/Fasteners*
Centerstand* Battery* V-belt
*" It is recommended that these items be serviced by a Yamaha dealer. **: Medium weight wheel bearing grease.
--2--
I INSP
TAIL COVERS AND MOLES Removal 1. Open the seat lock. 2. Remove: Seat (~ Helmet holder (~
3. Remove:
Moles ~ (Left and right) NOTE: Unhook the pawl (~ out of groove (~ of the footrest board. oSlide the mole backward and unhook the pawl (~ out of groove (~) of the tail cover.
4. Disconnect: oTaillight leads oRear flasher light leads 5. Remove: Carrier assembly (~
6. Remove:
Cover ~)
--3--
Cover @
(~)
Installation
2. Install: -Cover (~
NOTE:
3. Install: -Carrier assembly (~ Nut (Carrier): 7 Nm (0.7 m , k g , 5.1 ft,lb) Bolt (Carrier): 7 Nm (0.7 m , k g , 5.1 ft,lb) 4. Connect: Taillight leads Rear flasher light leads
-4-
INSP
=Hook the pawl (~) onto the opening (~, and slide the mole forward. Hook the pawl ~) onto the opening (~).
Nut(Seat):
7 Nm (0.7 m-kg, 5.1 ft,lb)
--5--
'3
I INSP
(~)
installation 1. Install: Footrest board (~) 2. Install: Tail cover Refer to "TAIL COVER AND MOLES" section.
4. Install: Front panel (~) NOTE: Install the projection into the slot.
--6--
HANDLEBAR COVERS
I INSP ADJ
5. Install: =Covers ( ~ (Left and right) NOTE: Install the projection into the slot.
2. Disconnect: =Headlight lead and flasher light leads 3. Remove: =Handlebar cover ( ~ (Front)
4. Disconnect: Leads ,Speedometer cable (~) 5. Remove: Rear view mirror (~) = Handlebar cover (~) (Rear)
Installation 1. Install: -Handlebar cover (~) (Rear) Rear view mirror ( ~ 2. Connect: = Leads Speedometer cable WARNING: Proper cable and lead routing is essential to insure safe scooter operation. Refer to "'CABLE R O U T I N G " section. -7
I INSP
3. Connect: oHeadlight lead Flasher light leads 4. Install: oHandlebar cover (Front)
ENGINE
ENGINE OIL LEVEL INSPECTION 1. Place the scooter on the level place. NOTE: Be sure the scooter is positioned straight up and on both wheels when inspecting the oil level. 2. Check: oOil level Oil level low--Add sufficient oil. Recommended Oil: Yamalube 2 or Air Cooled 2 Stroke Engine Oil Oil Tank Capacity: 0.8 L (0.70 Imp qt, 0.84 US qt)
OIL LEVEL AND " O I L " INDICATOR LIGHT CHECKING METHOD I Turn main switch to "ON" I
I "'OIL"indicator light
1_
stays on
--8--
ADJ
_
If the main switch is turned off after the "OIL" light goes off and then immediately again the main switch is turned on, the "OIL" light may not come on. This is not because of failure.
Always use the same type of engine oil; mixing oils may result in a harmful chemical reaction and lead to poor performance.
The oil pump and delivery line must be bled on the f o l l o w i n g occasions: =Any portion of the oil system has been disconnected. =The scooter has been turned on its side. =Whenever the oil tank has been run empty. e During predelivery.
1. Remove: oTail cover Refer to "TAIL COVERS AND MOLES" section. ePump cover ( ~ 2. Fill: Oil tank Recommended Oil: Yamalube " 2 " or Air-cooled 2 Stroke Engine Oil 3. Place a rag or oil pan under the oil pump to catch oil. 4. Remove: o Bleed screw ( ~ 5. Inspect: Gasket (Bleed screw) Damage-* Replace.
--9--
IIINSPL tl
6. Keep the oil running out until air bubbles disappear from the oil hose and bleed hole.
9. Feed the engine oil into the oil delivery hose using a oil can from complete air bleeding. Then, connect the oil delivery hose to the carburetor. NOTE: Thoroughly clean the engine exterior of oil.
1'0. Install: oTail cover Refer to "TAIL COVERS AND MOLES" section.
--10--
CG50U CIRCUIT D I A G R A M
I ELEC I
E,
ELECTRICAL
CG50U CIRCUIT D I A G R A M
B/R
-'="W/R @ B/R----1
=J._
"~B/R _ B/W
LOCK OFF ON
B/Wi B RIBr
o-
B ..L
(~
-=-
m
G/Y L/W
N,
F -~ IotO
L
B B
~L-~G/Y
~B
_L.
_L.
B Sr
~~'--~,-T--:,
~'
I J, !
Gy
'1
b
-__-
.J-- -J--
...L __L 2
2_
N
11
o3
I
CG50U CIRCUIT D I A G R A M
Spark plug Ignition coil CDI magneto CDI unit Rectifier/Regulator Auto choke unit (~ Tail/Brake light
[ELEC I
~ Starterrelay ~
COLOR CODE
R B Red Black
~ Horn
Left flasher light (Front) Left flasher light (Rear) Right flasher light (Front) Right flasher light (Rear)
Starter motor "LIGHTS" (Dimmer) switch Headlight ~) "HIGH BEAM" indicator light (~ Meter light
"HORN" switch (~ Front brake switch ~) Rear brake switch Oil level gauge
~ OIL"indicatorlight
W Y Br Gy O Ch
Dg G
White Yellow
Brown
Green
--12--
IE'EC[ I
BAI-rERY TYPE: YB4L-B SPECIFIC GRAVITY: 1.280 IGNITION COIL RESISTANCE PRIMARY: 0.56-0.84~3 at 20C (68F) SECONDARY: 5.68-8.52k~ at 20oc (68OF)
6
--13--
ELECTRICAL COMPONENTS
Main switch Horn
I ELECI
~ Rectifier/Regulator
Flasher .relay
tj
--14--
ELEC
--15--
SIGNAL SYSTEM
NOTE: For color codes, see page 12. o Unlike the previous CE5OT, this model has a fuel meter and fuel sender added and the oil level gauge changed. This signal system explains the checking of only such addition and change.
[ ELEC
~ ~ Fuel meter
--16--
SIGNAL SYSTEM
TROUBLESHOOTING NOTE:
ELECI
The battery provides power for operation of the fuel meter and "OIL" indicator light. If none of the above operates, always check the battery voltage before proceeding further. Low battery voltage indicates either a faulty battery, low battery electrolyte, or defective charging system. Also, check the fuse condition.
NO VOLTAGE Check for voltage (12V) on "Br" lead at fuel meter connector. J v L OK Check for voltage (12V) on " G " lead at fuel meter connector.
NO VOLTAGE Y
Check for condition of fuel meter. If fuel meter is poor condition, replace it.
J~
OK
NO VOLTAGE
J~
OK
Check for condition of fuel sender and fuel meter. Refer to "FUEL SENDER CHECK" and "FUEL METER CHECK".
--17--
SIGNAL SYSTEM
ELEC
2. Connect: Pocket Tester (YU-03112) Set the tester selector to " ~ x 10" position. 3. Check: Fuel sender conduct Refer to following table. Not per result~Replace. Float position Up (~ Down (~ NOTE: Check from top to bottom. Fuel sender resistance 4-10~ 90 - 100~
Fuel M e t e r C h e c k 1. Connect: Fuel sender lead 2. Turn the main switch to "ON". 3. Check: Fuel meter Refer to following table. Not per result~Replace. Float position Up (~) Down (~) Fuel meter position "F" "E"
NOTE: Before reading the meter, stay put the float for more than three minutes respectively at ( ~ and
--18--
Wiring circuit from "OIL" indicator light to oil level gauge is faulty, repair.
Check for condition of oil level gauge. to "OIL LEVEL GAUGE CHECK".
Refer
Oil Level Gauge Check 1. Remove: oOil level gauge (_) NOTE: Do not disconnect the oil level gauge lead.
2. Turn the main switch to "ON". 3. Check oOil level gauge Refer to follOwing table. Not per result-* Replace. Oil level gauge position Upright position "OIL" indicator light Light comes on eWait a few second Light goes out oLight comes on eWait a few second Light stays on
--19--
APPENDICES SPECIFICATIONS
GENERAL SPECIFICATIONS Model Model Code Number Vehicle Identification Number Engine Starting Number Dimensions: Overall Length Overall Width Overall Height Seat Height Wheelbase Minimum Ground Clearance Basic Weight: With Oil and Full Fuel Tank Minimum Turning Radius Engine: Engine Type Cylinder Arrangement Displacement Borex Stroke Compression Ratio Starting System Lubrication System Oil Type or Grade: Engine Oil Transmission Oil Oil Capacity: Oil Tank (Engine Oil) Transmission Oil: Periodic Oil Change Total Amount Air Filter Fuel: Type Tank Capacity Regular gasoline 3.5 L (0.77 Imp gal, 0.92 US gal) Yamalube 2 or Air cooled 2-stroke engine oil Yamalube 4 or SAE 10W30 type SE motor oil 1,610 625 985 700 1,115 95 mm mm mm mm mm mm (63.4 in) (24.6 in) (38.8 in) (27.5 in) (43.9 in) (3.7 in) 2YT 2YTN0-X'JA000101 2YT-000101 CG50U
Air cooled 2-stroke, gasoline torque induction Single cylinder, Forward inclined 49 cm3 40.0 x 39.2 mm (1.575x 1.543 in) 6.7 : 1 Electric and kick starter Separate lubrication (Yamaha Autolube)
0.8 L (0.7 Imp qt, 0.84 US qt) 0.10 L (0.09 Imp qt, 0.11 US qt) 0.11 L (0.10 Imp qt, 0.12 US qt) Wet type element
-20-
-21 -
-22-
MAINTENANCE Engine
SPECIFICATIONS
Cylinder: Bore Size <Limit> Taper Limit Out of Round Limit Piston: Piston Size _
39.993-40.012 mm (1.575 in) 40.1 mm (1.579 in) 0.05 mm (0.002 in) 0.01 mm (0.0004 in)
39.952-39.972
mm (1.573-1.574
in)
___
Piston Ring: Sectional Sketch (B x T)/Type Top Ring 2nd Ring End Gap (Installed): Top Ring 2nd Ring Side Clearance (Installed)" Top Ring 2nd Ring Crankshaft: _"_--_B _-4 1.5x1.8 mm (0.0590.071 in)/Keystone
1.5 x 1.8 mm (0.059 0.071 in)/Keystone 0.15-0.35 mm (0.006-0.014 in) 0.15-0.35 mm (0.006-0.014 in) 0.03-0.05 0.03-0.05 mm (0.0012-0.0020 mm (0.0012-0.0020 in) in)
Crank Width "A" Run Out Limit "C" Connecting Rod Big End Side Clearance "D" Small End Free Play "F"
37.90-37.95 mm I1.492- 1.494 in) 0.03 mm (0.0012 in) 0.2- 0.5 mm (0.008- 0.020 in) 0.4-0.8 mm (0.015-0.031 in)
-23-
SPEO,F,OAT APP'I
Model Automatic Centrifugal Clutch: Shoe Thickness <Wear Limit> Clutch Spring Free Length < Limit> Clutch Housing Inside Diameter <Wear Limit> Clutch-In Revolution Clutch-Stall Revolution V-Belt: Width <Wear Limit> Transmission: Main Axle Runout Limit Drive Axle Runout Limit Kick Starter: Type Kick Clip Tension Carburetor: I.D. Mark Main jet Jet Needle-clip Position Main Air Jet Cutaway Pilot Jet Pilot Air Screw Valve Seat Size Starter Jet Float Height Engine Idling speed Reed Valve: Valve Stopper Height Reed Valve Clearance Lubrication System: Autolube Pump Stroke Ratchet type 150-250 g (5.3-8.8 2YR00 #90 3P01-4/5 _2.0 2.5 #42 1 and 3/4 turns out _1.8 # 48 15,0-17.0 mm (0.59-0.67 1,800 r/min "" 4.0-4.4 mm (0.013-0.022 in) Less than 0.2 mm (0.008 in) 0.34-0.55 mm (0.013-0.022 in) in) oz) 0.08 mm (0.003 in) 0.08 mm (0.003 in) 15 mm (0.59 in) <13.5 mm (0.53 in)> CG50U 4.0 mm (0.16 in) <2.5 mm (0.10 in)> 109.6 mm (4.31 in) <94.0 mm (3.70 in)> 105.0 mm (4.13 in) <105.4 mm (4.15 in)> 3,150-3,650 r/rain 4,650- 5,350 r/rain
-24--
Tightening Torque: Part to be tightened Spark plug Cylinder head Stud bolt Stator assembly C.D.I. magneto Air shroud Fan cover Fan Autolube pump Reed valve (carburetor joint) Air cleaner Case Exhaust pipe Muffler Muffler protector Crankcase Transmission case cover Crankcase cover Transmission oil drain bolt Autolube pump cover Starter motor Kick crank Clutch Clutch housing Primary sheave Idle gear plate Oil seal stopper plate Thread size M14x 1.4 M 6x 1.0 M 6 x 1.0 M 6 x 1.0 M10x 1.25 M 6x 1.0 M 6 x 1.0 M 6x 1.0 M 5 x 0.8 M 6 1.0 M 6 x 1.0 M 6 1.0 M 8 1.25 M 6 x 1.0 M 6 x 1.0 M 6 x 1.0 M 6xl.0 M 8x 1.25 M 6 1.0 M 6x 1.0 M 6x 1.0 M28 x 1.0 MIOx 1.0 MIO x 1.25 M 6 x 1.0 M 6x 1.0 Q'ty 1 4 4 2 1 2 2 3 2 4 2 2 2 2 6 5 10 1 2 2 1 1 1 1 2 1 Tightening torque Nm 20 10 9 9 38 9 9 7 4 9 9 9 33 9 9 8 9 18 9 13 10 50 40 33 9 9 mkg 2.0 1.0 0.9 0.9 3.8 0.9 0.9 0.7 0.4 0.9 0.9 0.9 3.3 0.9 0.9 0.8 0.9 1.8 0.9 1.3 1.0 5.0 4.0 3.3 0.9 0.9 ftlb 14 7.2 6.5 6.5 27 6.5 6.5 5.1 2.9 6.5 6.5 6.5 24 6.5 6.5 5.8 6.5 13 6.5 9.4 7.2 36 29 24 6.5 6.5 Remarks
-25-
Chassis Model Steering System: Steering Bearing Type No./Size of Steel Balls Upper Lower Front Suspension: Front Fork Travel Fork spring Free Length <Limit> Spring Rate Stroke Optional Spring Rear Suspension: Shock absorber Travel Spring Free Length Spring Fitting Length Spring Rate: (K1) (K2) (K3) Stroke: (K1) (K2) (K3) Optional Spring Wheel: Front Wheel Type Rear Wheel Type Front Rim Size/Material Rear Rim Size/Material Rim Runout Limit: Vertical Lateral Front Drum Brake: Type Drum Inside Diameter <Wear Limit> Lining Thickness <Wear Limit> !Rear Drum Brake: Type Drum Inside Diameter <Wear Limit> Lining Thickness <Wear Limit>
Leading, Trailing 80.0 mm (3.15 in) <80.5 mm (3.17 in)> 3.5 mm (0.14 in) <2.0 mm (0.08 in)>
Leading, Trailing 95.0 mm (3.74 in) <95.5 mm (3.76 in)> 3.0 mm (0,12 in) <2.0 mm (0.08 in)>
-26-
SPEC,F,OAT,ONS APPX
Tightening torque: Tightening torque Part to be tightened Frame and engine bracket Engine bracket and engine Rear shock absorber (Upper) (Lower) Handlebar and steering column Ring nut (Steering column) Front wheel axle Front brake cam lever Rear brake cable holder Rear brake cam lever Rear wheel axle Rear Rear Seat Rear brake shoe plate stay bracket and seat carrier Thread size MlOx MlOx MIOx M 8x MIO M25 MIOx M 5x M 6 M 5x M14x M M M M 1.25 1.25 1.25 1.25 1.25 1.25 0.8 1.0 0.8 1.5 Q'ty Nm 2 1 1 1 1 1 1 1 1 1 1 3 4 2 4 42 42 32 18 60 30 35 4 9 4 95 18 10 7 7 mokg 4.2 4.2 3.2 1.8 6.0 3.0 3.5 0.4 0.9 0.4 9.5 1.8 1.0 0.7 0.7 ft.lb 30 30 23 13 43 22 25 2.9 6.5 2.9 68 13 7.2 5.1 5.1 Remarks
-27-
Electrical
Model Voltage: Ignition System: Ignition Timing (B.T.D.C.) Advancer Type 25 t,.) 20 r~ F~ ~; 1 5 ._ E 10
F= to t33
CG50U
C.D.I.: Magneto Model/Manufacturer Pickup Coil Resistance (Color) Source Coil Resistance (Color) C.D.I. Unit-Model/Manufacturer Ignition Coil: Model/Manufacturer Primary Coil Resistance Secondary Coil Resistance Charging System/Type: C.D.I. Magneto: Model/Manufacturer Charging Coil Resistance (Color) Charging Current Full Charged Battery (1.280) Half Charged Battery (1.180) Charging Voltage Lighting Coil Resistance (Color) Lighting Voltage Voltage Regulator: Type Model/Manufacturer No Load Regulated Voltage
2JA/YAMAHA 400-600~ at 20C (68F) (White/Red--Black) 640-960~ at 20C (68F) (Black/Red--Black) 2JA/YAMAHA 2JA/YAMAHA 0.56-0.84~ at 20C (68F) 5.68-8.52k~ at 20C (68F) Flywheel magneto '~
F2JA/YAMAHA 0.48-0.72fl at 20C (68F) (White--Black) 0.5A or less at 3,000 r/min 1.0A or more at 3,000 r/min 13-14V at 4,000 r/min 0 . 4 - 0 . 6 9 at 20C (68F) (Yellow/Red--Black) 11.5- 13.5V at 4,000 r/min Semi conductor short circuit type EHU-01TR05 or SU232Y/MATSUSHITA or STANLEY 13.5- 14.5V --28--
Starter Relay: Model/Manufacturer Amperage Rating Coil Resistance Horn: Type/Quantity Model/Manufacturer Maximum Amperage Flasher Relay: Type Model/Manufacturer Self Cancelling Device Flasher Frequency Wattage Oil Level Gauge: Model/Manufacturer Circuit Breaker: Type Amperage for Individual Circuit x Quantity: Main
DENSO
-29-
specifications Nm 6 15 30 55 85 130 m-kg 0.6 1.5 3.0 5.5 8.5 13.0 ft.lb 4.3 11 22 40 61 94
assemblies are included in the applicable sections of this book. To avoid warpage, fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise clean, specified, torque specifications Components should call for be at dry threads.
room temperature.
DEFINITION OF UNITS
U nit mm cm kg N Nm m-kg Pa N/ram L cm 3 r/rain Read millimeter centimeter kilogram Newton Newton meter Meter kilogram Pascal Newton per millimeter Liter Cubic centimeter Rotation per minute Definition 10 - 3meter 10 - 2meter 103gram 1 kg m/sec 2 Nm m x kg N/m 2 N/ram --Measure Length Length Weight Force Torque Torque Pressure Spring rate Volume or Capacity Engine Speed ._
--30--
[...x
CABLE ROUTING
(_ (_) (_) @ (_) (_ Front brake cable Flasher relay Rear brake cable Speedometer cable Throttle cable Band Horn Main switch (_) Rectifier/Regulator
--31 --
CABLE.OT, NO 1 APPX[
(_ Rear brake cable Band Wireharness Starter relay CDI unit Oil level gauge Battery positive lead Fuse i Throttle cable (_ Fuel sender (_) Clamp
000
000
-32-
(_) Front brake cable _ Rectifier/Regulator peedometer cable (_) Throttle cable (_) Fuel hose (_) Vacuum hose (_) Ignition coil (_) Rear brake cable (_)Band
--33--
CABLE.OOT 0[APP
(_ (_) (_ (_) (_) Battery breather pipe CDI unit Oil level gauge Fuse Auto choke unit _ Starter motor lead hrottle cable (_) CDI magneto lead
--34--
t" r
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Yamaha Motor Canada Ltd. 480 Gordon Baker Road Toronto, ON M2H 3B4