999 - 2002 MOTORCYCLE SERVICE MANUAL Model : CW50L, CW50M, CW50N, CW50P 4RW281972K00 *4RW281972K00*
IA-21 NOTICE This manual was written by the MBK INDUSTRIE 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.
IA-31 HOW TO USE THIS MANUAL ® ® ILLUSTRATEDSYMBOLS (_ L_ Illustrated symbols _ to _ are designed as thumb tabs to indicate the chapter's number and CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See <
A-4 I INDEX SPECIFICATIONS PERIODIC INSPECTION I _ AND ADJUSTMENT I '"sP ENGINEOVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING I
I I1 II! [! 1
I GEN CHAPTER 1. GENERAL INFORMATION SCOOTER IDENTIFICATION ....................................................................... A-8 VEHICLE IDENTIFICATION NUMBER ................................................... A-8 ENGINE SERIAL NUMBER .................................................................... A-8 IMPORTANT INFORMATION ...................................................................... ALL REPLACEMENT PARTS ................................................................
SCOOTER IDENTIFICATION IGE" I INFO A- 8 1 IMPORTANT INFORMATION INFORMATION SCOOTER _ IDENTIFICATION The vehicle identification numbere is stamped NOTE: into the frame, The vehicle identification number is used to _ _'-.._ _ _._ __ _O YAMAHAforassemblyandadjustment.Other _ brands may be similar in function and appearance, but inferior in quality.
IMPORTANT INFORMATION/SPECIAL I°E" _ I INFO TOOLS A" 9 J SPECIAL CIRCLIPS c_) [_ TOOLS IGE"I INFO Flywheel magneto puller care,u,, 08 e- 0- clips once they have been removed. Replace fore reassembly. Always replace piston pin bent circlips. When installing a circlip _) make sure that the sharp edge _ is positioned opposite to the thrust L_ it receives. See the sectional view.
SPECIAL GEN I 'NFO TOOLS I _1_1 Ring nut wrench 90890-01268 _ 90890-01403 _) ,_ FOR CHASSIS SERVICE Damper rod holder 90890o01294 T-Handle 90890-01326 Oil seal guide 90890-01184 Oil seal guide adapter 90890-01186 Pocket Tester FOR COMPONENT ELECTRICAL 90890-03112 1-5 _ _ IA- _ol II.
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IsPEc _'1tA-131 IsPEc _1 CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS .................................................................... A-14 MAINTENANCE SPECIFICATIONS ........................................................... A-15 ENGINE ................................................................................................ A-15 CHASSIS .............................................................................................. A-16 ELECTRICAL ...........................................
GENERAL SPECIFICATIONS I SPEc /'(_'1 IA-41 GENERAL SPECIFICATIONS SPECIFICATIONS Model GENERAL SPECIFICATIONS CW50 Clutch type: Transmission: Model Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance CW50 1,740 mm (68.5 in) 665 mm (26.2 in) 1,050 mm (41.3 in) 745 mm (29.3 in) 1,170 mm (46.0 in) 125 mm (4.9 in) Basic weight: With oil and full fuel tank 78 kg (172 Ib) Minimum turningradius: 1,800mm(70.
I P'=c Model CW50 Electrical: MAINTENANCE SPECIFICATIONS I SPEc /'_'1 MAINTENANCESPECIFICATIONS ENGINE Ignition system Charging system Battery type/model Battery capacity CDI Flywheel magneto GM4-3B/YB4L-B/FB4L-B 12V 4AH Headlight type: Bulb wattage / quantity: Taillight/brake light Flasher light IA-lSI Model Cylinder head: Warp limit Bulb 12V 5W/21 W x 1 12V 10W x 2 Front Rear 12V 10W x 2 12V 3W x 1 Meter light Warning lights wattage / quantity: "OIL" "TURN" 12V 3W x 1 12V 3W x 1 "HIGH BE
MAINTENANCE SPECIFICATIONS Model IsPECIA-161 CW50 MAINTENANCE SPECIFICATIONS CHASSIS Crankshaft: Model EB__:J Crank width "A" 37.90 - 37.95 mm (1.492 - 1.494 in) Runout limit "C" Connecting rod big end side clearance "D" i Automatic centrifugal clutch: Shoe thickness Clutch shoe spring free length Clutch-in revolution 0.03 mm (0.0012 in) 0.2 - 0.5 mm (0.008 - 0.020 in) 4.0 mm (0.16 in) <2.5 mm (0.10 in)> 26.2 mm (1.03 in) 3.200 ~ 3.600 r.p.m.
M.,.TE.A.OE.PEC,..C..,O.S Is Ec B-1I M.,.TE...CES.EC,F,C ISPEC ELECTRICAL Model Model CW50 Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) CDI: Pickup coil resistance (color) Source coil resistance (color) Ignition coil: Minimum spark length Primary coil resistance Secondary coil resistance 14° at 5.000 r/rain 400 ~ 600 Q at 20°C (68°F) (White/Red-Black) 640 ~ 960 Q at 20°C (68°F) (Black/Red-Black) 6 mm (0.23 in) 0.56 ~ 0.84 Q at 20°C (68°F) 5.68 - 8.
CA..E.OUT,.O IS" clPI IB'2 _3) Rim _) Tire ® Brake disc Brake caliper _) Brake hose guide (Lower) ® Brake hose guide (Upper) Throttle cable ® Wire harness Speedometer cable Brake hose _) Choke cable [] [] [] [] [] Do not cover the frame number. Attach the brake hose, starter switch cable and the brake cable together behind the horn bracket. The throttle cable must have sufficient free play. Clamp the brake hose into the upper holder.
OASLERO°T, NO ISPECl;] IB'3 (_) (_) ® (_ Choke cable Throttle cable Rear brake cable Speedometer cable ® (_ (_) ® ® Front brake hose Main switch Wire harness Horn Steedng tube Lower cover [] [] [] [] [] [] [] [] [] [] [] [] Tie the choke cable,throttle cable, rear brake cable, and speedometer cable to the left side of the handlebar. Pass the wire harness along the right side of the handlebar. Clamp the front brake hose to the lower cover.
I INSP BEI - I I CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION ........................................................................................... B-7 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................... B-7 COVERS ....................................................................................................... REMOVAL ............................................................................................... INSTALLATION ...............................
LUBRICATION INTERVALS INTRODUCTIONIPERIOOIC MAINTENANCEI PERIODIC INSPECTION I ADJ INSP IF_ I I B- 7 COVERS AND ADJUSTMENT _ I __ i_ d 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. ,/___I_ ITEM PERIODIC BREAK-IN 1,000(600) ROUTINE Check condition. O Replace if necessary. Check idle speed/choke operation. Adjust if necessary. Clean.Clean if necessary.
COVERS , :__ _ B-8 I COVERS I INSP_ _1 • Footrest board (D • Bottom cover (_) . t_ I INSP _ _ffr_ I • Front panel (D • Main switch cover (_) _ _ _ NOTE: Insert the main switch cover and turn it clockwise. 8. Remove: • Screws (Handlebar cover) (D eove Insert the projections of the front panel into the 4. Install: slot of the footrest board. NOTE: ___ : ::_' ; • Headlight leads Conn • Speedometer cable (_) • Couplers 6. Install: • Front fender 0 11.
ENGINE ij IDLE SPEED j __ I'"sP II ADJUSTMENT _ _ B - 9 THROTTLE CABLE FREE PLAY I'"sP I ADJUSTMENT _ 1. Tighten: • Pilot air screw O Turn the pilot air screw in until lightly seated. 1. Check: -Throttle cable free play @ Out of specification ---*Adjust. 2. Loosen: o Pilot air screw ENGINE IDLE SPEED ADJUSTMENT Back out from the lightly seated position. MENT .-.:=::::::==::::=_xx=_==:_x-,=:=:=__ ~ 3.0@: mm (0.06 ~ 0.12 in) --_Free 1.
I SPARK PLUG INSPECTION INSP IB-101 I I SPARK PLUG INSPECTION /_ • Spark plug 2. Check: • Spark plug type Incorrect _ Replace ;_ ,i,/_ _,_'_-_H_'/I_ ' 1. Remove: _ i I BR8HS (NGK) .4 AUTOLUBE PUMP AIR BLEEDING " Fan cover (_ _ _, 1, Remove: '_ .... 2. Bleed: Wear/Damage _ Replace. @ *...................................................... •. Insulator Electrode(_) O Abnormal color _ Replace. ___ -_ //_-_(,_.=_E_i Normal color is a medium-to-light tan color, __/_i_ '_ 3.
ENGINE OIL LEVEL INSPECTION B - 11 I TRANSMISSION OIL REPLACEMENT ENGINE OIL LEVEL INSPECTION _ II II 30 20_'?_- t __"_" _ • Oil level Oillevellow --Add oiltoproperlevelas _ 8o ,= ,_-_l _-- _ _'_'°°El_-_ _e_ _'_'_h,40 50 60 70 .(_ ,, II __!_//: O "OIL" indicator light I to. Drain the transmission oil. •"Oil Gasket filler (drain plug_ plug) 2. Check: • O-ring (oil filler plug) Damaged _ Replace. / _ _, T 3. Install: ,_,_ -Gas ket(_ Drain plug: •Drain plug (_) 17.5 Nm (1.75 m.
FRONT BRAKE LEVER FREE PLAYADJUSTMENT/ AIR FILTER ELEMENT CLEANING -J-_ z I _ _ IIB - 12 I BRAKE PAD INSPECTION AIR FILTER ELEMENT CLEANING _ _ 1. Remove: : CAU_i0N_:: • Air cleaner case cover (_) element removed. Unfiltered air will cause Never operate the engine with the air cleaner rapid wear of engine parts and possible engine damage. / / ._ J _ 1. Check: • Front brake lever free play @ Out of specification _ Adjust. JUSTMENT 10 play: ~ 20 mm (0.4 ~ 0.
"E'"S"OE''"SPEC"O"'I'"SP IIB = 13 I BRAKE FLUID // J LEVEL INSPECTION -A_ R_ AIR BLEEDING (HYDRAULIC BRAKE 1. pp,y therear bra e,ever. Air bleeding steps: a. Add proper brake fluid into the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect a clear plastic tube O tightly to the .RAKE S.OE,NSPECT.ON A,R=EEO..O BRAKE FLUID LEVEL INSPECTION NOTE: / /// / _ _I\ ' //_ , , caliper bleed screw. d.
I'"sP I 1. Check: • Steering assembly bearings Grasp the bottom of the forks and gently rock the fork assembly back and forth, Looseness _ Adjust steering head. 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.
CABLE INSPECTION AND LUBRICATION TIRE INSPECTION/WHEEL INSPECTION/ I:_ I _ INSP _ I I B - 15 REAR SHOCK ABSORBER CABLE INSPECTION AND LUBRICATION/ I • Tire tread depth Out of specification ._ Replace. ivuco Recommended (front and Minimum tire rear): tread depth 0.8 mm (0.03 in) I_ I lubricant: Engine oil SAE 10W30 CENTERSTAND LUBRICATION 1. Lubricate rotating parts (D Tread depth (_) Wear Side wall ® indicator I_=_ Rec°mmended lubricant: Engine oil SAE 10W30 WHEEL INSPECTION 1.
BATTERY I_ I t _ _'_ /_) INSPECTION UPPER -__ ADJ _ - 1 6 FUSE INSPECTION _ BATTERYINSPECTIONI IINSP ELECTRICAL BATI'ERY INSPECTION LOWER -- IINSPIIB I I :CAgTiONi • Battery fluidlevel it to ensuremaximum performance. Fluid level low --_Add to proper level. Fluid level should be between upper and lower level marks. 1. Inspect: _) Upper level _IW:I--I_JI_[_ Battery electrolyte is dangerous.
HEADLIGHT OS'"SPEOT'O"'I'"SP I BEAM ADJUSTMENT _ _ C - 1 I'"sp I I *************************************************** Fuse replacement steps: Turn off the ignition, • install a new fuse of the right amperage. • Turn on the switches to verify the operation of the electric circuit. if the fuse immediately blows again, check the electric circuit. Never use a fuse with a rating higher than specified. An improper fuse may cause damage to the electrical circuit, and possibly cause a fire.
I lc-l CHAPTER 4. I ENGINE OVERHAUL ENGINE REMOVAL ...................................................................................... COVER REMOVAL ................................................................................. CARBURETOR ....................................................................................... CABLES, LEADS AND HOSES .............................................................. ENGINE REMOVAL .........................................................................
E.O,.E.EMOV.L IE"O ''1 IC'I E.O,.E.EMOV.L ENGINE REMOVAL 1. Remove: • Oil hose (_ on oil pump side COVER REMOVAL 1. Remove: • Covers Refer to "COVERS" in CHAPTER 3. NOTE: Plug the hose to prevent oil spillage. ENGINE OVERHAUL CABLES, LEADS ANDHOSES 1. Remove: • Air cleaner case assembly (_) CA RBUR ETOR • Earth (ground lead) • Spark plug cap 0 • Starter motor lead (_) • CDI magneto lead (_) ______,__ • Carburetor cover _ • Hoses __ 2. Disconnect: - _._ \ • Rear brake cable (_ % 3.
_rJ. 1. Place a suitable stand under the frame. REAR WHEEL _-_ 2, Remove: 1, Remove: • Left pillion footrest • Rear shock absorber bolt (lower) (D . Engine mounting bolt _) _ .f_(_ _ -_._ • Rear wheel nut • Rear wheel washer • Rear wheel • Brake shoes (_) • Plate washer (_) 34S001 3. Remove: j_ _ CENTERSTAND • Spring (_) • Clip 0 • Rubber washer (_) ° Axle (_) • Clamp (_) • Center stand (_) 1. Remove: NOTE: Lift up the frame and remove the engine. 4. Place the frame on a suitable stand.
E.O,NEO,..SSE.SLY IE"O _'1IC'_] E.O,NEO,SASS IE"O ''1 2. Remove: • Piston (_) • Piston pin bearing (_) PRIMARY SHEAVE • Fan 2. Remove: • Nut C) (primary sheave) :j: NOTE: __)(__) 3070O2 Do not use a hammer to drive out the piston pin. •Piston pin(_ __ 319035 KIGKSTARTER _--------_ _V _---J'-"==__(_).._F_ o o- To loosen the primary sheave nut hold the CDI magneto with a flywheel holder (_). 1. Remove: I_ Flywhee190890.
l..olo,..l 2. Remove: • Crankcase cover gasket \ _._" /_ _/ _ • Dowel pins 3. Attach: • Sheave holder (_) 2" Remove: • Nut wrench (41 mm) • Secondary sheave (_) _/_ •o,utc, housing ® 90890-01701 sheave h°lder: l_ • Starter motor ° Bearing _ _ _______ __ t _--'--_ ___'_L • Clutch securing nut - Washer ® (_ •Spacer • Transmission case O TRANSMISSION 1. Remove: o._ ___II tc_ _, • Dowel pins Loosen the nut but do not remove it yet, _o3 4.
I..o"-.I c-91 ?_ L/ • Rotor (_ • Woodruff key level the tool body. Use the flywheel puller (_) 3. Remove: ° Crankcase I 90890-01189 _ 32'005 I _ 314001 ] 1 I'"° "1 As pressure is applied, keepbosses. tapping carefully on the engine mounting Stator assembly 2. ••Remove: Gasket :sary, CAUTION: loosen :one screw as much as required to Use a soft hammer to tap on the case. Tap • Autolube oil pump (D 1. Remove: slowly and carefully. Make sure the cases tap separate on the evenly.
I..o Ic-01 I..o°.-I 1. Eliminate: Wear/Scratches/Damage --*Replace. • Carbon deposits Use a rounded scraper (_) NOTE: Take care toHEAD avoid damaging CYLINDER __ 3o,ool J • Piston wall _ .J 3o7oo, J 2. Inspect: • Cylinder head warpage Out of specification --* Resurface, •****************************************************** • Piston to cylinder clearance .....................................................
If out of specification, replace piston and piston rings as a set. (_,X'%I 3rd step: Calculate the piston-to-cylinder clearance with following formula: B I Cylinder Bore "C" Piston Skirt Diameter "P" Piston-to cylinder clearance= I If out of specification, replace cylinder, piston and piston rings as a set. Piston=to-cylinder i Wear limit : 0.1 mm (0.004 in) 0.034 ~ ~ (0.0013 0.047 0.0018 mmin) clearance: Top ring 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.70 mm (0.028 in) 2nd 0.15 ~ 0.30 mm 0.
,.SPECT,O...O.EP... IC'121 ,.SPECT,O...O.EP IE"O KICK STARTER AUTOLUBE PUMP • Kick gear teeth (_) • Kick pinion gear teeth (_) Burrs/Chips/Roughness/Wear _ Replace. (_ pump output to vary from the factory setting. This situation is, however, extremely rare. If improper output is suspected, inspect the follow- 1. Inspect: Wear or an internal malfunction may cause the 1. Inspect: ing: • Delivery line Obstructions .-.*Blow out. 31_5 2.
• Free movement Insert the collar (_) into the primary sliding sheave 0, and check for free movement. Stickorexcessive play_ Replace the sheave and/or collar, oClutch housing inner surface Oil/Scratches _ Remove. Oil Use a rag soaked in lacquer thinner or solvent. Use an emery cloth (lightly Scratchesand evenly polishing). 319OO7 319O30 3. Measure: L,., ,_ 5. Measure: Out of specification -.-*Replace. I_1 I _ 319008 Out of specification --* Replace, Outsidelimit>: diameter (weight):
,.s..c.,o...o....,. I..o"-.IIc- 41 -- (_---_ 3120o_ ..o,.. ..o.o,us....T °"1 • V-belt width @ CRANKCASE AND CRANKSHAFT Out of specification --* Replace. (_ Oil seal Oil seal holder ® Crankshaft pin _ Connecting rod Dowel _ Crankshaft (right) @Crankcase(right) _ Bearingpin ENGINE ASSEMBLY _ Bearing Bearing @ (left) _ Crankcase @ Crankshaft Engine mount (left) shaft AND ADJUSTMENT _ Oil seal 15.0 width: (0.59 in) 13.5 mm (0.53 i_ Measure: j2.
• Crankshaft To protect the crankshaft against scratches and to facilitate the engine assembly and installation, apply grease to oil seal lips, and engine oil to bearings.
..O,...SS...'_'"O'O'OS'M'"' I'"" °,-IIc-_6l _Fan (_ Plain washer @ Rotor assembly (_ Lighting coil _)Charge coil ® Pick Upcoil Stator assembly (_ Oil seal @Gasket _Oil hose @ Oil delivery hose @Clip _Autolube pump _ O-ring _ Circlip _) Oil pump drive gear ..o....ss...._..o.o,os..... I,.o"-I /_ 1. Install: • Circlip @ • Pin (_) o Pump drive gear@ • Circlip (_ :. 3,,oo4 2. Apply: 3. Install: _-_ _\ '_ [4 Nm(0.4 m.kg. 2.9 ft.
E"O'"EASSE"B'Y'"O'O'°ST"E"T IE"o O11 E.O,.E.SS. LY..OAOJ 5. Install: TRANSMISSION • Magneto rotor (_) • Plain washer (_) • Nut (_) _)(_ _1_ NOTE: • Woodruff When installingkey the(_magneto rotor, 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.
_.O..E,SSE.LYA.O,O, OST.E.T _ 0-21 TRANSMISSION 1. Apply: • 10W30 Type SE Motor oil (to transmission case cover bearing) 2. Install: • Bearing C) • Secondary sheave axle (_) ,' _ _C_, _l E"O'"EASS_--_'"O,O,0 IE"O _I STARTER SYSTEM (_ Collar (_ Washer _ Bearing _) Starter wheel gear _ Collar _ Starterclutch _ Plate _ Shaft _ Plain washer _ Idle gear @ O-ring @ Startermotor _- NOTE:. 3. Install: Apply lithium soap base grease onto the oil seal lips.
E"O"E'SSE"BLY'"O'O'0STME"T I 1I0 3 E.O.E,,,EMLY,.O,O, USTM IE"O .TI ,_ , STARTER SYSTEM - __(_ 317010 PRIMARY AND SECONDARY SHEAVE . Collar (D • Washer (_) • Bearing (_) • Starter wheel gear (_) 1. •Install: Starter clutch O _Clutch _Clutch _Clutch _Spring _Clutch ®Gasket NOTE: • Apply lithium soap base grease to the bearing ®Secondary sliding sheave @Oil seal @V-belt _Primary sliding _Spacer sheave @Guide pin _Clutch weights ' 17O11 1 __3 "_ • Apply clutch).
E"O'"E'SSE"O_'"O'O'UST"E"T I--__-] O''J E"O'"E'SSE''YA"O'O'O IE"°_1 KICK STARTER ® Return spring (_Collar (_ Plain washer Circlip ® Gasket SECONDARY SHEAVE ® Transmission case (_Kick crank verse the disassembly procedure. Note the following points. 1. Apply: • BEL-RAY Assembly Lube ® (tothesliding parts ofthesheave) csa oowein ena--e 319018 2. Install: rA ! KICK CLIP FRICTION FO_R_RCE : 0,15 ~ 0,25 kg(5.3 ~ 8.
E.O..E.SSE.B..O.O, OST"E"T IE"OI'IO'SI I XJ _ • Gasket ° Secondary sheave assembly(_) • Clutch housing (D _0o2_ I UST"E"T I "O1 '1 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 arrow on the V-belt must point to the front. • Make sure the V-belt is not stained with oil or 5. Install: • V-belt grease. 8. •Instalh Dowel pin 9. Tighten: Use sheave holder _ c c c • Shim (_) Sheave holder: PIN.
• Fan O _ 9. Install: 6.5 Nm (0.65 m.kg, 4.7 ff.lb) Screw (fan): _ Carburetor joint Reed valve I _!__ CYLINDER AND CYLINDER _PISTON, Cylinder (_ Piston pinHEAD _ Gasket head @Piston (_ Cylinder (_ Bearing CST •c,rc,, o i • Return spring (_) • Kick shaft (_) • Collar (_) • Washer (_ • Return spring • Kick pinion gear (D -'- _ - _ _o,_ 3. (to the kick gear and boSS)lnstall: Install the spring as shown. 4.
E.O,.E.'SE.BLY'"O'O'UST D' I E"T E"O'"E'SSEMBLYA"O IE"o _ • Engine oil O 1. Apply: (to crankshaft bearing, connecting rod big end bearing, small end bearing, piston pin, , _ I __ - J// C) NOTE: • CylinderO Install the cylinder with one hand, while corn- piston ring grooves and piston skirt.) 3¢aoo4 pressing the piston rings with the other hand. PISTON PIN AND PISTON • • • • :" 3. Install: Small end bearing Piston O Piston pin (_) Piston pin clip (_) • Cylinder head gasket (new gasket) 5.
E"O'"E'SSE"B,.O,O, OSTME.T IE"O 10"8 E"O'"E'SSE OSTME.T B ,.O,O, 8. Install: =j _, 5. Tighten: • Oil hose • Oil delivery hose NOTE:. When tightening the rear wheel axle nut, apply the rear brake. NOTE: Pass the oil delivery hose and oil hose asshown. • Air shroud 9. Air bleeding: Refer to "AUTOLUBE PUMP AIR BLEEDING" in CHAPTER • Autolube 3. pump Rear 103.5wheelNm axle(10.35nUt:m.kg, 74.8 ft.lb) I • Rear wheel axle nut (T) _ ___._ (_)__ 6. Install: • Muffler assembly 0 •• Air shroud (_).
tU ply
I c OI R" L_.B_ I Io-_l CHAPTER 5. CARBURETION CARBURETOR ........................................................................................... REMOVAL ............................................................................................. DISASSEMBLY ..................................................................................... INSPECTION ........................................................................................ ASSEMBLY ...................................................
CARBURETOR (_ Carburetor REMOVAL top _ Pilot jet 1. Remove: Gasket Throttlevalvespring Needle set ® Throttle valve _ _ _ _ • Covers and footrest board Referto" COVERS" in CHAPTER 3. ° Air filter case assembly ® Starter plunger Starter plunger Air screw _ Float _ Float chamber gasket @ Float chamber spring Throttle stop screw % Needle jet Needlevalve Main jet Float pin _ Drain screw 0ElL LO_O ___ %_ (___ (_) -_._ I.D. mark Main jet (M.J.) PHBN12HS # 93 Jet needle (J.N.
• • • • __ Throttle stop screw C) Spring (throttle stop screw) Air screw (_) Spring (air screw) 4. Remove: • Throttle valve 0 Wear/Damage --* Replace. _j,j,j 4. Check: 322028 322014 5. Remove ( _/_\\ • Needle clip (_) 5. Check: \\ oThrottle valve free movement • Throttle valve _) 2_ Insert the throttle valve C) into the carburetor body (_) and check for smooth movement. • Jet needle (_) 322029 Unsmooth/stickiness --, Replace. 322015 1. Check: • Carburetor body (D Dirt --, Clean. .
C,.BO.ETO. IC'"B 0 IID'I'I C,.BO.ETO. IOA"B 01 NOTE: _ • Carburetor The float arm should be resting on the needle valve. It should not compress the needle valve. NOTE: Align projection (D with projection (_). If the float height is not within specification, inspect the needle valve, float and valve seat. If one of these parts is worn, replace the 3. Install: If both parts are in good condition, replace the float. (T_ To installthe carburetorreversethe"REMOVAL" procedures.
REED FUELCOCK/ VALVEI CARB [ D-15 REED VALVECARB FUELCOCK/ iNSPECTiON ] FUEL COCK I 1. Check: INSPECTION 1. Stop the engine, • Carburetor joint Damage/Cracks _ Replace. • Reed valve Wear/Cracks/Damage-._ Replace. 2. Remove: Refer to "COVERS" in CHAPTER 3. Reed valve inspection steps: Visually inspect the reed valve. NOTE: • Fuel cock pletely or at least nearly flush with the valve seat. Fuel cock inspection steps: • Disconnect the fuel hose (_. Place a receptacle under the fuel hose end.
_v,,wIC'R_ 0 I ID'_sl I_'_ 01 INSTALLATION TOinstall the reed valve reverse the "REMOVAL" procedure. Note the following points. 1. Install: • Gasket (new) 2, Tighten: • Reed valve assembly bolts 8.5 Nm (0.85 m.kg, 6.15 fLIb) NOTE: Tighten the screws crosswise inseveral steps to preventwarpage of the read valve assembly and the carburetor joint.
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CHAPTER 6. CHASSIS FRONT WHEEL ............................................................................................ REMOVAL ............................................................................................... INSPECTION .......................................................................................... INSTALLATION ...................................................................................... E-4 E-4 E-4 E-5 FRONT BRAKE ....................................................
.O.TW.EEL IC"'SI E-'] CHASSIS F.O.T..EEL IO"'S ,_ REMOVAL FRONT WHEEL _) Axle _ Oil seal Speedometer gear Bearing (_ Flange (_ Collar (_ (_ _ _ 1. Remove: D Front caliper fixing /!_ Collar Axle nut Front wheel Tire (3.)_i v _ _,_/_ o o /_ Valve TIRESIZE: 120/90- 10 B RIMRUNOUTLIMIT: _3 V LATERAL:2.0 mm(0.08in) 0.25mm(0.01in) ® NOTE: • Front caliper Never depress the brake lever when the wheel is Offthe scooter. Otherwise the brake pads will be forced shut. JL _ RADIAL:2.0 mm(0.
F--.EEL IC"'SI E-SI ..O.,,.,.E IC"'S INSTALLATION FRONTBRAKE Reverse the =Removal" procedure. Note the following points. 1. Lubricate: • Front wheel axle • Bearings • Oil seal (lips) - Drive/driven gear (speedometer) _ Disc ® Bolt _ Caliper _ Piston @ Piston seals _ Air bleed screw Lithium soap base grease I D_ _ NOTE: _ Pad spring ® Pad retainer _) Brake pads _i_O. ring @ Bolt @ Mounting bolt Be sure to install the pads correctly. 3.
MASTER CYLINDER DISASSEMBLY Master cylinder ® Master cylinder piston ass'y Diaphragm Master cylinder cap Screw Master cylinder bracket • Disc brake components _ Brake hose _ Bolt @ Bolt _ Copper washer Drain completely before removing the master cylinder, assembly. Do not disassemble components unless absolutely necessary. If any hydraulic connection is disconnected, the entire system must be disassembled, drained, cleaned, and then properly filled and bled after reassembly.
F.O.TB.,KE E'I .O.TB,,KE IC"'S 4. Install: o Brake pads ....................................................... Removal steps: oAxle 'oo_ Pad spring • Pin _ Be careful to install the brake pads correctly. _'_' _ ing to force out the piston from the caliper _J_O\_y_/Z _ '\ _ _ _ Blow compressed air into the hosejoint openbody. • Never try to pry • Cover the piston the piston does expelled from the _,_o. 5.
.O.TB,,KE IC"'S 1E-81 F.O.TB.,K IC"'S o Master cylinder dust boot 0 • Master cylinder kit (_) _ , Brake hose (_) CrackslWearlDamage .._Replace. 4. Remove: _ 3. Check: 34700e 34e014 INSPECTION AND REPAIR /_._ \ 4. Measure: schedule: Brake pads Piston seal, Dust seal Out of specification _ Inspect wheel runout. If wheel runout is good, replace the brake disc.
.O.TB IC"'S .E E-'] 2. Install: I<_1 .O.TB IC"'SI .E _'_" 23 (brake Nm (2,3 m.kg, 17 ft.lb) Bolt caliper): 1. Install: 'I:CAUTiONil install the master cylinder holder with the arrow mark pointing upwards. • Tightenthe upperboltfirst,thenthelower bolt. ! 3. Install: • Caliper body (_) • Brake caliper ___o I_J 4. Install: /'/_ ' J _\ /_ Bolt (master cylinder 9 Nm (0.9 m.kg, 6.5 holder): ft.lb) I • Brake hose ® o7. • Copper washers ® • Brake lever 23 Nm (2.3 m.kg, 17 ft.
.--.EEL IC--I IE'101 --W.EEL IC"'S REAR WHEEL Rear wheel ass'y Tire Valve (_ Axle Nut REMOVAL 1. Remove: _ _ (_ (_ _ O-ring Brake shoe Spring Brake camshaft Brake camshaft lever _ Wear indicator _ Bolt _ Washer _ Nut _ Washer • Muffler ass'y A TIRE SIZE: B 130/90 - 10 DRUM BRAKE WEAR LIMIT." 110.5 mm (4.40 in) 11o5Nm (10.5 \ LININGS REPLACE BRAKE • __ II _)} ) )) )/ (_)"-_'_ I I SPRING.._. AND SASASET NOTE: 2PullLoosen the rear brake to loosen the axle nut.
IC"ASIIE'111 .E,.W,EE" whee earn0s Br keshoesO Refer to the section "FRONT WHEEL IN- • Return spring (_) SPECTION". NOTE: 4. Check: The arrow mark ® must point outwards. • Brake lining surface Glazed spots _ Eliminate with sandpaper. ...... CAUTION_ When installing the springs and the brake shoes, takecarenotto damage thesprings lo NOTE: After sanding the brake lining remove dust parti- • Wear indicator (_ • Camshaft lever 0 cesoeresoewieanco nt 5.
REARWHEEL I CHAS (_r'(g] IE-121 .u,,.r Wh.--, ..ONT FO. 105 Nm (10.5 m.kg, 76 ft.lb) _ Steering bracket Bolt _ Circlip _ Tube cap Oil seal @ Inner fork tube (right) @ Inner fork tube (left) _ Dust boot _ Retainer _ Oil seal I (_ Circlip _ Outer fork tube (right) I _ Washer ® Plunger Oil seal guide _ @ Brake _ Outer fork Brake hosetube bracket (left) _ hose bracket _ Bolt (_ Steering race set 3. Install: • Muffler I_ i I Bolt (exhaust pipe): Bolt 9 Nm (muffler): 26 Nm(0.9 (2.6m.kg, m.kg,6.
ICH' ®l IE-131 FRONTFORK 1. Remove: Securely support the scooter under the engine. REMOVAL with a stand • Rubber plug (D • Circlip (_ DISASSEMBLY _ 1. Disconnect: Place the scooter on an even surface. 2. • Spring (_) • Speedometer cable 3. Remove: • Front wheel Refer to "FRONT WHEEL".
.O.TO.K IC"'SI [E-I'] F.O.TO.K INSPECTION 3. Install: • Inner fork tube and fork components • Drain bolt • Outer fork tube Wear/Scratches/Damage --, Replace. NOTE: Tighten the drain boltO while holding the piston _'1._ Never attempt to straighten a bent fork tube as this may dangerously weaken the tube. 1. Check: with the T-handle _ and holder (_. i _i_ 2. Measure: (_) I_> Right 206 free mm length: (8.11 in) Front forkside: spring Left side: 225 mm (8.
STEERING HEAD AND HANDLEBAR _ IE-151 STEERING HEAD AND STEERING HEAD AND HANDLEBAR _) Handlebar Nut _) Bolt Grip Throttle grip Throttle cable Screw Brake cable Starter cable HANDLEBAR STEERING HEAD AND HANDLEBAR REMOVAL Securely support thescooter sothereisno danger of it falling over. 1, Place the scooter on an even surface. 2. Remove: • Front fender • Upper handlebarin cover Refer to "COVERS" CHAPTER 3. 3. Drain: ° Front brake system Refer to "FRONT BRAKE".
10. Remove: Ic.As IE-lel JA STEE.,.O.EAOA.O...O **......... • Ring nut 0 • Washer Drive out the bearing race from the steering tube by hitting on it in several places. Remove the bearing race on the steering shaft with a hammer and a chisel Q as shown. NOTE: Use the Ring Nut Wrench (_) to loosen the ring nut. • Securing nut Drive in the new bearing races evenly by Bearing race replacement steps: I<_ Ring wrench:90890-01268 Nut I Support the front fork so that it may not fall down. ....
IC"'S [I S.EE.,.O.E.O..O...O. C"'S 3. Install: • Steering shaft • Upper bearing race (Top) (D • Bearing race cover (_) 9. Clamp: • Speedometer cable ° Front brake cable (to head pipe with the band) ° Washer • Ring nut NOTE: NOTE: Refer to "CABLE ROUTING" in CHAPTER 2. Hold the steering column until it is secured. 10. Apply: • Lithium soap base grease 4. Tighten: • Ring nut (to throttle cable end and handlebar right end). 11.
RE,RS.OCK,BSOR_ER IC"'S_II F'2I REAR SHOCK ABSORBER REMOVAL 1. Place the scooter on its centerstand 2. Remove: • Mole Refer to "COVERS" in CHAPTER 3. ;' - • Rear shock absorber 0 = _ 3. Remove: INSPECTION 1. Inspect: • Rear shock absorber Oil leaks/Damage _ Replace. INSTALLATION When installing the rear shock absorber, reverse the removal procedure. Note the following points. 1. Install: • Rear shock absorber I 6- 29 31.5 Nm 13.15 m.kg, 22.8 lt.lb) I Rear Shock Absorber Bolt (Lower): I 17.
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IELEC _1 I F-S IE_EC _ I CHAPTER 7. ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS ..................................................................... F-6 SWITCH INSPECTION ................................................................................. F-6 SWITCH INSPECTION ........................................................................... F-6 SWITCH CONTINUITY INSPECTION .................................................... F-7 CIRCUIT DIAGRAM ...................................................
E'ECT..C.LCO.PO.E.TS IE' c I F'6I SW,TO.,.SPEOT IE'Ec ELECTRICAL SWITCH INSPECTION ELECTRICAL COMPONENTS Flasher relay Wire harness Oil sender (_ Starter relay _ _ _ _ _)®Ignition cOilcDi unit _ Main switch "0" ,,,, SWITCH INSPECTION Battery Fuel sender Horn Rectifier/regulator Use a pocket tester to check the terminals for continuity. If the continuity is faulty as any point, replace the switch. I_l Pocket tester:90890.
SW,.C"'"S"ECT'O" IE'EC ------I F'_I SWITCH CONTINUITY INSPECTION Refer to "SWITCH INSPECTION" and check for continuity between lead terminals. Poor connection, no continuity _ Correct or replace. * The coupler locations are circled. L ...... i® ® /" z" _, / Horn switch Dimmer switch Turn switch Main switch Start switch Engine stop switch Front stop switch Rear stop switch Fuse Oil lever gauge @ Fuel sender SW..C.,.S.ECT, _ @_ /i _ _ @ (_ i@o I .....
c,.co,To..o... IELEc '11 -8 CIRCUIT DIAGRAM [_ _ _ _ ' _) ® _i _ _ _ , GY ° __'' ° __ _ Left front flasher light _ Right front flasher light @ Left rear flasher light @ Right rear flasher light _ Tail/Stop light @ Horn L_ Flasher relay _ Front stop switch @ Rear stop switch _ Starting motor _ Right handle switch _ Left handle switch _ Oil level gauge _ Meter _ Sender @ :_i COLOR CODE _ _ '_[_ : _ C.D.I Magneto C.D.
.O.,T.O...OST..T,.OSYSTE. IE'EC -----I 1_"9I ,O.,T,O...OST..T,.OS IE'EC " I IGNITION AND STARTING SYSTEM IGNITION ANDSTARTING SYSTEMCIRCUIT DIAGRAM CIRCUIT DIAGRAM (_ C,D.I magneto _) C.D.
IE'Ec TROUBLESHOOTING 3.Spark plugcapresistance: (NO SPARK OR IRREGULAR THE STARTING SYSTEM DOES SPARKS). NOT WORK I IELEc [F-10I •• Connect thethe pocket Disconnect sparktester plug (_ cap.x 1 k) to the spark plug cap. NOTE: • Check the resistance of the spark plug cap. Remove the following parts before proceeding with the troubleshooting: 1) Mole For accurate troubleshooting use the following special tools: I_=_ IgnitiOn checker:90890-06754 1.Spark plug: I '_ _ _ POcket tastar:90890-03112 _.
'O"'T'O"'"OSTA.T,.OSYSTE. IE'EC ------I [F-11 'O"'T'O"'"OST..T,.O 5. Pickup -0- I coil resistance: • Check the pickup coil resistance. •° pickup Pocket Disconnect Connect tester teeter coil. thethe (+) (') pocket lead pickup leadtester (_ (!)c_oil --_(Q coupler.
STARTER MOTOR 4. Starter relay: • Disconnect the Blue/White lead from the wire harness. • Connect the (-) _ terminal of the battery to the Blue/White lead. • Check the starter motor operation. (_ _ _ _ O-ring Brush Armature coil O-ring A COMMUTATOR UNDER CUT: DOES NOT WORK 1.15 mm (0.045 in) B COMMUTATOR DIAMETER WEAR LIMIT: - --I::>uw I Replace the starter relay. 37_ I, C 15.0 mm (0.60LIMIT: in) BRUSH WEAR 5.3 mm (0.21 in) _ CORRECT _::_::::_ I Refer to "SWITCH INSPECTION".
,ON,T,ON.NOST.RT,NOSYSTEM IE'Ec ['131 ,ON,T,ON.NOST.RT IE' C • Commutator Dirty _ Clean it with #600 grit sandpaper. 2. Measure: • Commutator diameter @ Out of specification _ Replace starter motor 1. Inspect: REMOVAL 15.0 mm (0.60 _ Commutator wearin)limit: I 3. Measure: @/_ @ Out of specification --, Replace. Brush length limit@: 5.30 mm (0.21 in) _ - Brush length @ 5. Measure: 6.
CHARGING SYSTEM C...O,.OS*STEM IE'ECIF'141 TROUBLESHOOTING CIRCUIT DIAGRAM I C...O,.OS*STE. THE BATTERY ISNOT CHARGED I NOTE: • Remove the following parts before proceeding with the troubleshooting : 1 ) Mole. • For accurate troubleshooting use the following special tools : I<_ 90890-03113 Inductive tachometer: Refer to "SWITCH _@i_ INSPECTION". ,_ I I<_ 90890-03112 Pocket tester: INOC CONTINUITY I Reptace fuse. I 2. Battery OUT OF SPECIFICATION • Check the condition of the battery.
C.A.O,.OSY.TEM 1'151 4.Charging coil resistance .,O.T,.OSYSTE IE'"c LIGHTING • Disconnect the CDI magneto coupler from the wire harness. ,_L-_ _ SYSTEM CIRCUITDIAGRAM • Connect the pocket tester (_ x 1) to the charging coil. • Check the charging coil resistance Tester (+) lead --, White O Tester (-) lead ---,Ground Q I_ I Charging coil resistance : 0.48 ~ 0.72 E2at 20°C (68°F) _ 15"C°nnections OUT OF SPECIFICATION .._ SPECIFICATION MEETS I Replace charging coil.
TROUBLESHOOTING LIGHTING SYSTEM INSPECTION 1. Headlight, headlight indicator or meter light do not work. I THE HEADLIGHT, HEADLIGHT LIGHT DOINDICATOR, NOT WORKTAlL LIGHT OR METER NOTE: Remove the following I 1. Bulb and socket I I I " Check the bulb and socket for continuity.
',°.T,.°S*STEM IG'II 3. The tail light does not work. 1. Bulb and socket j • Check the bulb and socket for continuity. I NO CONTINUITY _ [ CONTINUITY 2. Voltage _, c-_-_ - _=_ • Connectthe pocket tester (AC20V)to the ,,__ .... taillight coupler. Pocket tester (+) lead --* Blue (_ Pocket tester (-) lead _ Black (_) ',_) [_ ',0 , , ', J • Setthemainswitch to"ON". [ i 8 • Start the engine. • Check the voltage (12V) between the headlight coupler leads "Blue" and "Black". ".
S,O..LSYSTE. IELECG'2 TROUBLESHOOTING I HORN DOES NOTWARNING SOUND LIGHT DO NOT WORK FLASHER LIGHTS, BRAKE LIGHT, "OIL" I NOTE: Remove the following parts before proceeding with the troubleshooting: ..O.ALSYSTEM IELEC SIGNAL SYSTEM CHECK 1. Horn does not sound I 1. "HORN" switch I I I I Refer to "SWITCH iNSPECTION". •" boardHandlebar Mole and footrest cover ,_ INCORRECT CONTINUITY I Replace left handlebar switch. I For accurate troubleshooting use the following special tools: 2.
S,O..LSYSTEM IE'Ec G-3I 2. The tail light does not work. 3. Flasher does not work I1. Refer INCORREcTBrake to.SWiTCH switch ,NSPECT,ON.. .J_ S,O..LSYSTEM IE'Ec Ii Refer 1. "TURN" switch INSPECTION.. to .SWITCH I CORRECT .J_ CORRECT • Connect the pocket tester (DC20V) to the socket, • Connect the pocket tester (DC20V) to the flasher relay.
S.O.ALSY.TE. IE'EC [G'41 ,_ S,O.ALSYSTE. I'Eo-----J 4. The "OIL" indicator light does not work. m 4.Voltage Flasher light Turnindicator light flasher bulb : Pocket tester (+) lead _ Chocolate (_) Pocket tester (-) lead _ Ground I 1.Bulb and socket I I J_. Replace bulb or socket. 2. Oil level switch Cllg Left Connect flasher connector. the bulb pocket Right flasher : tester (DC2OV)to the Pocket tester (+) lead _ Dark green (_) _ I= • Disconnect Check the bulb and continuity...
c,-Ju ............ u lull= ..................
I TRBL CHAPTER 8. TROUBLESHOOTING STARTING FAILURE/HARD STARTING .................................................... FUEL SYSTEM ....................................................................................... ELECTRICAL SYSTEM .......................................................................... COMPRESSION SYSTEM ..................................................................... G-8 G-8 G-8 G-8 POOR IDLE SPEED PERFORMANCE ........................................................
STARTING FAILURE/HARD STARTING TROUBLESHOOTING SHTG ITRBL _ NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.
POOR MEDIUM AND HIGH SPEED PERFORMANCE I SHTG TRBL L _• POOR MEDIUM AND HIGH SPEED PERFORMANCE FUEL SYSTEM Fuel tank Carburetor - Clogged fuel filter • Deteriorated fuel, fuel containing water or • Deteriorated fuel or fuel containing water or foreign material foreign material • Sucked-in air • Clogged fuel tank cap • Deformed float Fuel cook • Groove-worm needle valve • Clogged fuel hose Air cleaner ° Clogged air cleaner • Improperly sealed valve seat • Improperly set clip position of jet needle
I TRBL IMPROPER KICKING/FAULTY BRAKE I IMPROPER KICKING Cylinder, piston and piston ring • Damaged or seized cylinder • Damaged or seized piston • Damaged or seized piston ring FAULTY SIGNALAND LIGHTING SYSTEM Ii TRBL INSTABLE HANDLING Transmission oil o Improper quality (low viscosity) • Deterioration Worn or damaged kick gear Damaged kick clip Kick clip coming off Damaged kick clip stopper HARD KICKING Kick axle assembly • High tension of kick clip • Seized kick gear " INSTABLE HANDLING SLIPPING
FAULTY SIGNAL AND LIGHTING SYSTEM/ OVERHEATING I TRBL Flasher winks slower Horn is inoperative • • • • • Faulty battery o Faulty fuse • Faulty main and/or horn switch • Improperly adjusted horn • Faulty horn • Broken wirehamess Faulty flasher relay Insufficient battery capacity (nearly discharged) Improper bulb Faulty main and/or flasher switch Flasher winks quicker • Improper bulb • Faulty flasher relay OVERHEATING OVERHEATING Ignition system • Improper spark plug gap • Improper spark plug heat ran
IG-12 I WIRING DIAGRAM ® _(_c,_ _:: i [_ r_ ....... _!_] _i_'_ _ -- _::1_ .... r- _ C.D.I Unit Ignition coil _ I _-I_1 @ Rectifier/regulator @Starter motor -, ' • _ L...... _B i-_-i i _ i _ _ Right handle switch @ Lefthandle switch ........ _-_ _6"_-__ ......... i --L_; ...................... __ _ _ L_, I_ L_ _ 'i__ ............. _ E _} i' ' _ " ',-_-_B_ _ @ ' ] ," ............... .ORN _,._ER _ ......._.E.
Yamaha Motor Canada Ltd.
