Yamaha 1999 CW50L, Service Manual

Page 1: ...1999 2002 MOTORCYCLE SERVICE MANUAL Model CW50L CW50M CW50N CW50P 4RW281972K00 4RW281972K00 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 2: ...YAMAHA dealers and will where applicable appear in future editions of this manual DOCUMENTATION TECHNIQUE MBK INDUSTRIE PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation _ The safetyAlert Symbol meansATTENTION BECOMEALERT YOUR SAFETY IS INVOLVED r IIY 1 I_11_ 1 Failure to follow WARNING instructions could result in severe injury or death to the scooter ope...

Page 3: ...ial tools are framed in a box preceded by a relevant symbol _ _ Illustrated symbols _ to _ are used to identify An encircled numeral indicates a part name and an encircled alphabetical letter data for an _ alignments mark Q the others being indicated by an alphabetical letter in a box_ the specifications appearing in the text A condition of a faulty component will precede an arrow symbol and the c...

Page 4: ...A 4 I INDEX SPECIFICATIONS PERIODIC INSPECTION I _ I AND ADJUSTMENT I sP ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 5: ...1 I1 II I D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 6: ...INFORMATION A 8 ALL REPLACEMENT PARTS A 8 GASKETS OIL SEALS AND O RINGS A 8 LOCK WASHERS PLATES AND CO I I ER PINS A 8 BEARINGS AND OIL SEALS A 8 CIRCLIPS A 9 SPECIAL TOOLS A 9 FOR TUNE UP A 9 FOR ENGINE SERVICE A 9 FOR CHASSIS SERVICE A 10 FOR ELECTRICAL COMPONENTS A 10 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 7: ...01301 ing reassembly Apply grease to the oil seal lips The engine serial number is stamped into the PINS _ crankcase _ 1 All lock washers plates _ and cotter pins must be replaced when they are removed NOTE _ Lock tab s should be bent along the boltor nut The first three digits of these numbers are for _MHr IH flat s after the bolt or nut has been properly model identifications the remaining digit...

Page 8: ...S 90890 01135 90890_0t_ _ f _ The proper special tools are necessary for com _ _ _ plete and accurate tune up and assembly Us ing the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques Inductive tachometer Crankshaft installing tool set Clutch serving nut wrenc_ 90890 03113 1 90890 01274 _ _ _ 90890 01348 __ 90890 01275 _ 90890 01277 _ _ FOR ...

Page 9: ...68 _ _ _ 90890 01403 _ FOR CHASSIS SERVICE Damper rod holder T Handle 90890o01294 90890 01326 Oil seal guide Oil seal guide adapter 90890 01184 90890 01186 Pocket Tester FOR COMPONENT ELECTRICAL 90890 03112 _ 1 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 10: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 11: ... ___ Ill J D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 12: ...1 IsPEc _1 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS A 14 MAINTENANCE SPECIFICATIONS A 15 ENGINE A 15 CHASSIS A 16 ELECTRICAL B 1 CABLE ROUTING B 2 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 13: ...lectric and kick starter MICHELIN REGGAE TL Lubricationsystem Separatelubrication Yamaha Autolube Tire pressure cold tire Maximumload exceptscooter 152kg 335Ibs Oil type or grade Up to 90 kg 198 Ibs load Engine oil Semi synthetic oil in accordance to the Front 100 kPa 1 00 kgf cm2 15 psi API TC TS C3 standard Rear 125 kPa 1 25 kgf cm2 18 psi Transmission oil SAE 10W30 type SE motor oil 90 kg 198 I...

Page 14: ...antity Limit 40 1 mm 1 579 in OIL 12V 3W x 1 Taper limit 0 006 mm 0 0002 in TURN 12V 3W x 1 Piston HIGH BEAM 12V 3W x 1 MeasuringPiSt n size point _ _ 39 952 39 9725 0 mmmm 0 2 1 573in 1 574 in Piston clearance 0 034 0 047 mm 0 0013 0 0018 in Limit 0 1 mm 0 004 in Piston pin bore size 10 004 10 015 mm 0 3938 0 3943 in Piston pin Outside diameter 9 996 10 000 mm 0 3935 0 3937 in Piston ring Section...

Page 15: ... wheel type Cast wheel Kick clip tension 150 250 g 5 3 8 8 oz Rear wheel type Cast wheel Carburetor Front wheel size MT 3 50 xl0 I D mark PHBN12HS Material Aluminium Main jet M J 93 Front wheel size MT 3 50 xl0 Main air jet M A J 2 0 Material Aluminium Jet needle J N A21 3 5 Rim runout limit Needle jet N J 2 110 Front 2 0 mm 0 08 in Cutaway C A 4 0 Rear 2 0 mm 0 08 in Pilot jet P J 36 Front disk b...

Page 16: ...resistance 5 68 8 52 Qk at 20 C 68 F Mica undercut 1 15 mm 0 045 in Spark plug cap Starter relay Resistance 5 k Qat 20 C 68 F Amperage rating 20 A CDI Magneto Coil resistance 54 66 _ at 20 C 68 F Lighting coil resistance 0 32 0 48 Q at 20 C 68 F Yellow Red Black Horn Lighting coil resistance 0 48 0 72 Q at 20 C 68 F White Black Type Quantity Plain type 1 pc Voltage regulator Rectifier Model Manufa...

Page 17: ... With a band tie the choke cable the throotle cable and the rear _ Speedometer cable speedometer Throttle cable brake cable to the left side the wire harness to the right side of _ Throttle cable The left handlebar switch leads must pass along the underside of Wire harness the frame Lower handlebar cover the handlebar then in front of the boss on the lower handlebar Speedometer cable 9 Front brake...

Page 18: ...the wire harness to the side of the main switch bracket with a band Horn The wire harness must run straight no loops between the two bands Steedng tube Attach the wire hamess with a band to the steedng tube just above the Lower cover wire bracket The speedometer cable must pass through the hole in the front fender The speedometer cable must pass through the hole in the lower fender The horn leads ...

Page 19: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 20: ...11 AIR CLEANER ELEMENT CLEANING B 12 CHASSIS B 12 FRONT BRAKE LEVER FREE PLAY ADJUSTMENT B 12 REAR BRAKE LEVER FREE PLAY ADJUSTMENT B 12 BRAKE PADS INSPECTION B 12 BRAKE SHOES INSPECTION B 13 AIR BLEEDING HYDRAULIC BRAKE SYSTEM B 13 STEERING HEAD ADJUSTMENT B 14 TIRE INSPECTION S 14 WHEEL INSPECTION B 15 CABLE INSPECTION AND LUBRICATION B 15 LEVER LUBRICATION B 15 CENTERSTAND LUBRICATION B 15 REAR...

Page 21: ... Front brake system Check operation fluid leakage See NOTE Page 9 3 Correct if necessary O O O Check operation __ 8 Rear brake system Adjust if necessary O O 9 Wheels Check damage runout tightening torque Replace tighten if necessary O 1 Wheel bearings Check bearing assembly for looseness damage Check Replace if damaged operation O _ _ 5 Remove Check bearing assembly for looseness 11 Steering bear...

Page 22: ...able Insert the projection a of central cover into the Couplers l_ _ _ _ _ _ slot b of footrest board NOTE _ D Correct routing of cables and wires is essential for a safe operation of this scooter Refer to 2 CABLEInstaIt ROUTING in Chapter 2 ___ _ _ __ 8 Install Rear carrier D Helmet holder Handlebar cover _ Seat NOTE NOTE Be careful not to pinch any wires with the covers After connecting the tail...

Page 23: ...11_ I First step Loosen the Iocknut _ on the throttle cable For safety reasons place the scooter on Turn the adjuster _ in or out until the speci the center stand before starting the engine fled free play is obtained 4 Attach Turn in Free play increased Inductive tachometer to the spark plug lead Turn out Free play decreased ndu t vetac meter ef 0 03t 1 I T0 tent e _WARNING After adjusting turn th...

Page 24: ...lrun until there are no more air bubbles 4 Measure __ init Plug gap When there are no more bubbles tighten the Out of specification Adjust gap bleed screw Use a wire gauge or feeler gauge NOTE I_ Spark plug gap Check the condition of the bleed screw gasket 0 5 0 7 mm 0 020 0 028 in If it is damaged replace it with a new one 5 Tighten Start the engine Spark plug Let the engine run two or three minu...

Page 25: ...light 4 Fill Transmission case IT rn a n switch r m on o to ON SAE 10W30 type SE motor oil i Capacity I Periodic replacement _ 0 11 L 0 10 Imp qt 0 12 US qt I OIL indicatorgoes_ _ OIL indicator Total amount stays on I 0 13 L 0 11 Imp qt 0 13 US qt _ NOTE I InspectFaulW Engine oil level Add oil J electricalcircuit and electric circuit Wipe off any oil spilt on the crankcase tire or I Light bulb etc...

Page 26: ... an accident Inspect and bleed the system _ if necessary r Cleaning steps Wash the element gently but thoroughly in REAR BRAKE LEVER FREE PLAY AD solvent _ __ JUSTMENT 1 Check _l liW _l l_ll_ Hll __ _ Rear brake lever free play Never use low flashpoint solvents such as ___ r _ xIOutof specification Adjust I gasoline to clean the element Such solvents h may lead to fire or explosion _ Free play 10 ...

Page 27: ... g Loosen the bleed screw and pull the lever all the way _ _ _ 3 6co_ h When the lever is completely pulled tighten the bleed screw then release the lever J _ _ 1 Inspect i Repeat steps e to h until allair bubbles have Brake fluid level been removed from the system Brake fluid level is under LOWER level line j Add brake fluid to proper level D Fill to proper level b j_ _ _ _ i _l Recommended brake...

Page 28: ...nut until no play can be seen even injury Install the securing nut _re pressure oald Front Rear Tighten the securing nut _ Upto 90kg 100kPa 125kPa 1 00kgf cm 1 25kgflcm I_ I Securing nut I 15psi 18psi 22 5 Nm 2 25 m kg 16 2 ft lb 90 kg maximum 100kPa 150kPa load 1 0O kgflcm _ 1 50kgflcm z NOTE 15psi 21 psi Set the torque wrench _ to the ring nut wrench Maximum load 152kg 335Ib SOthat they form a r...

Page 29: ...UBRICATION F _ _ ___ REAR SHOCK ABSORBER 1 Check VIIYL I I_II_ tt Rear shock absorber D A damaged cable sheath will rapidly corrode Oil leaks Damage _ Replace As a result the cable cannot move smoothly 2 Check inside the sheath Since this situation is Tightening torque dangerous replace a damaged cable Upper bolt immediately 31 5 Nm 3 t 5 m kg 22 8 ft lb Lower bolt I 1 Check I 17 5 Nm 1 75 m kg 12...

Page 30: ...e quantities of water or milk Breather hose Followwith milkof magnesia beaten egg Obstruction _ Remove or vegetable oil Get immediate medical 3 Inspect attention Batteries generate explosive hydrogen gas Battery Always follow these preventive measures Charge batteries in a well ventilated area Replace the battery if Keep batteries away from fire sparks or Batteryvoltagewillnotrisetoaspecificvalue ...

Page 31: ...lectric 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 Main circuit 7A HEADLIGHT BEAM ADJUSTMENT 1 Adjust Headlight beam Higher Turn out screw O Lower Turn In screw _ 3 21 3 22 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e ...

Page 32: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 33: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 34: ...CTION AND REPAIR C 10 CYLINDER HEAD C 10 CYLINDER AND PISTON C 10 PISTON RINGS C 11 PISTON PIN AND PISTON PIN BEARING C 11 KICK STARTER C 12 TRANSMISSION C 12 AUTOLUBE PUMP C 12 CRANKSHAFT C 12 PRIMARY SHEAVE C 12 SECONDARY SHEAVE C 13 V BELT C 13 STARTER CLUTCH AND GEARS C 14 ENGINE ASSEMBLY AND ADJUSTMENT C 14 CRANKSHAFT AND CRANKCASE C 14 AUTOLUBE PUMP C 16 CDI MAGNETO C 16 TRANSMISSION D I STA...

Page 35: ..._____ __ 2 Disconnect 1 Remove Earth ground lead Air cleaner case assembly _ Spark plug cap 0 Starter motor lead _ CDI magneto lead _ Carburetor cover _ _ _ Rear brake cable _ Hoses __ Carburetor top __ 3 Remove Carburetor _ _ 4 Remove __ Exhaust protector Air shroud _ _ Muffler assembly _ 5 Loosen o Rear axle nut _ NOTE Apply the rear brake while loosening the rear axle nut 4 1 4 2 D o w n l o a ...

Page 36: ... _ 4 Place the frame on a suitable stand Center stand _ 358 O1 1 Remove Air shroud Cylinder head C Cylinder head gasket S NOTE 3o_c_s Beforeloosening the cylinder head nuts loosen the spark plug Loosen the cylinder head nuts crosswise 1 4 of _ _ 2 a Rem ve tUrnCylinder Cylinder each before _gasket removing _ them PISTON PIN AND PISTON 1 Remove Piston pin clip _ NOTE Before removing the piston pin ...

Page 37: ... _ _V _ J _ _ _ _F_ Kick crank o o _ _T_ Transmission cover O teft 2 _ _ pinion gear D Ratchet _ NOTE Washer _ To remove the kick pinion gear push down the Fixed primary sheave _ kick crank Washer _ 3 Unhook V belt _ Kick return spring _ 3 goo cirdi0s_ _ __ S0_cer_ Plate washer _ Primary sliding sheave _ Kick shaft _ 317O02 SECONDARY SHEAVE _ 1 Remove c c c NOTE Nut 0 secondary sheave Hold the sec...

Page 38: ...r _ NOTE _ t _ _ __ _ _ Conicalspring Compressthe secondary sheave using the clutch _ _ _ spring holder _ _ Clutch spring holder ____ ____ _ _ _o_ 90890 01337 3 Remove 6 Remove _ Oil seal _ Clutch securing nut Secondary sheave axle _ Clutch assembly _ Clutch spring _ Spring seat _ Guide pin _ 3_ o_ Secondary sliding sheave _ CDI MAGNETO Nut O rotor STARTER SYSTEM Plate washer _ _ ___ _ 1 Remove St...

Page 39: ... separate evenly If one end hangs up take the pressure off the push screw realign the cases and the tool and start again If the cases do not separate at all check for a remaining case screw or fitting Do not force 314001 eove Pin _ Crankcase separating tool Circlip _ 90890 01135 _ _ Remove Crankshaft _ 3140C_ 3O04 _ 1 CRANKCASEANDCRANKsHAFT1 Remove Oil seal stopper _ Screws crankcase NOTE Loosen e...

Page 40: ...re If the warpage is out of specification resur face the cylinder head P _ X Standard Wear limit NOTE Cylinder 39 993 49 912mm 40 10 mm Rotate the head several times to avoid removing 3 too much material from one side 3o7oos Bore C 1 574 1 575in 1 579 in Taper _ 0 006 mm CYLINDER AND PISTON T 0 0002in 1 Eliminate C Maximum D Carbon deposits T Maximum D1 D3or Ds Use a rounded scraper C Maximum D2 D...

Page 41: ...sure Outside diameter piston pin Side clearance Out of specification Replace Out of specification Replace piston and or Outside diameter piston pin rings 9 996 10 000 mm Use a Feeler Gauge D 0 3935 0 3937 in S ar mt 307OO7 3O7OO9 Top 0 03 0 05 mm 0 10 mm ring 0 0012 0 0020 in 0 004 in __ 3 Measure Piston pin to piston clearance 2nd 0 03 0 05 mm 0 10 mm Out of specification _ Replace piston ring 0 ...

Page 42: ... pinion gear C __ 1 Measure __ Out of specification _ Replace oCrankshaft width A i i i i i I Use a spring balance c_ Runout limit C Connecting rod big end side clearance D _ Standard tension I _ Use V blocks dial gauge and thickness gauge 150 250 g 5 3 8 8 oz D _ Crankshaft width A 37 90 37 95 mm 317007 _oo_ 1 492 1 494 in Runout limit C TRANSMISSION 0 03 mm 0 0012 in 1 Inspect Connecting rod big...

Page 43: ...19008 319012 SECONDARY SHEAVE 6 Inspect 1 Inspect Clutch shoes __ Secondary fixed sheave _ Glazed parts _ Sand with coarse sandpa oSecondary sliding sheave _ per Scratch Crack Damage _ Replace as a set Oil seal _ NOTE After using the sand paper clean off the pol Damage _ Replace ished particles with a cloth 319009 o Torque cam groove 0 Clutch shoe thickness oGuide pin _ Out of specification _ Repl...

Page 44: ... _ Oil seal STARTER CLUTCH AND GEARS 9 Nm 0 9 m kg 6 5 ft lb I J13Nm 1 3 m kg 9 4 ft lb I A CRANKSHAFT 1 Inspect _ _ _ _ Crank width o Starter clutch 37 90 37 95 mm Push the dowel pin in arrow direction _ _ 1 492 1 492 in Unsmooth operation _ Replace starter clutch Runout limit assembly 0 03 ram 0 0012 in Big end side clearance 3_oo8 0 2 0 5 mm 0 008 0 020 in 2 Inspect _ _ _ Starter wheel gear tee...

Page 45: ...1 3O8OO2 2 Install _ 7 Tighten Crankshaft _ Crankcase holding screws to left crankcase NOTE NOTE Tighten the crankcase holding screws in stages Hold the connecting rod at top dead center with using a crisscross pattern one hand while tightening the nut of the installa tion tool with the other Tighten the installation I _l Crankcase holding screw tool until the crankshaft bottoms against the 13 Nm ...

Page 46: ..._ _ _ to O ring 3 Install _ _ _ _ Autolube pump _ 4 Nm 0 4 m kg 2 9 ft lb _ __ _ Screw autolube pump 4 Apply to autolube pump gear _ _b_6 5 Nm 0 65 m kg 4 7 ft lb _ _ I_ _ O 0_ _ _ _ 314006 CDI MAGNETO 1 Install _ _ _ J _ _ _ _ i_ Gasket Lithium soap base grease to oil seal 321001 3 Pass the CDI magneto lead through the J _ crankcase hole _ _ 4 Install Stator assembly 8Nm 0 8 m kg 5 8 _ b I I _ I ...

Page 47: ...cover When installing the magneto rotor make sure _ Conical spring washer _ Oil seal the woodruff key is properly seated in the key Plain washer _1_ way of the crankshaft Apply a light coating of lithium soap base grease to the tapered portion of the crankshaft end __ Tighten __ Nut D magneto rotor 0 Z Use the flywheel holding tool _ Flywheel holding tool 90890 01235 I _ oo 37 5 Nm 3 75 m kg 27 1 ...

Page 48: ...ase grease onto the oil seal lips 319O14 i 4 Check Secondary sheave axle operation Unsmooth operation _ Repair _ 5 Apply 10W30 type SE Motor oil to main axle bearing and drive axle bearing 6 Install _ _ _ __ Drive axle C Main axle _ Conical spring washer _ 113 Nm 1 3 m kg 9 4 ft lb l P n Apply lithium soap base grease onto the oilseal _b L lips _ ii s19o16 Always use a new gasket _ __ _ 7 Install ...

Page 49: ...t sheave ing Guide pin _Clutch weights _ __3 1 starter Apply molybdenum disulfide oil to the shaft clutch _Secondary fixed sheave _f _ 50Nm 50 2 ft lb I _ _ I m kg 36 17O11 2 Install __ Plain washer D j tq _ o Idle gear _ _3_4 _ Plain washer _ ____ t _g _ Plate E idle gear I 1Screw idle gear plate I ___ 8 Nm 0 8 m kg 5 8 ft lb NOTE _ _ Apply engine oil to the idle gear _ _ _ _ __ _ 3 Install _ _ _...

Page 50: ...sheave to avoid turning over the oil seal lips when installing the sheave 319019 t_ __ __ 3 Install Pin _ J _ 4 Apply _ __ BEL RAY Assembly Lube to the torque cam grooves and O rings 5 Check Sliding sheave 31_o2o Unsmooth operation _Repair Remove excessive grease _ _ 6 Install Clutch securing nut clutch spring holder 112 Nm 12mkg 87ftIb I _ I_c utch h _r I 90890 01337 319021 f J 7 Tighten 18 5 Nm ...

Page 51: ... Primary fixed sheave c c c Sheave holder Washer _ PIN 90890 01701 One way clutch _ Washer _ I_ I Nut secondary sheave I Nut _ 40 Nm 4 0 m kg 28 9 ft lb 31_o_ PRIMARY SHEAVE 7 Tighten _ _ _ _ _l_ 1 Clean Nut O primary sheave Primary sliding sheave face D i_ 1 Primary fixed sheave face _ Nut primary sheave Collar _ 30 Nm 3 0 m kg 21 7 ft tb Weight _ Primary sliding sheave cam surface _ NOTE When ti...

Page 52: ...spring __ _ _ _ _ 3 to the kick gear and boSS lnstall ___ __ Kick pinion gear D _ _ _ _ _ _ _ _o _ Install the spring as shown 4 Install _L_ f_ _ _J _L _ _ _J Transmission case C _ _ A Pistonclearance _ 0 034 0 047mm 0 0013 0 0018in B Piston rings end gap 3_9o_ 0 15 0 30mm 0 006 0 012 in _ C Pistonrings side clearance Kick crank _ D Sparkplug Bolt kick crank Manufacturer NGK 8 5 Nm 6 85 m kg 6 15 ...

Page 53: ...ence crankcase with a clean towel or rag so you will The arrow on the cylinder head must point to not accidentally drop the pin clip and material the front into the crankcase J t u c o r o The ends of the piston pin clip must not 10 Nm 1 0 m kg 7 2 ft lb i Spark plug come together at the slot in the piston 20 Nm 2 0 m kg 14 0 ft lb groove Always use a new piston pin clip c__c_ ns 1 Install _ Cente...

Page 54: ...HAPTER 3 1 Install 8 Adjust Engine mounting bolt 0 Brake lever free play Rear shock absorber bolt _ lower Refer to FRONT REAR BRAKE LEVER FREE Theseboltsshouldbetemporarily secured PLAYADJUSTMENT in CHAPTER 3 2 Tighten Engine idle speed Engine mounting bolt Throttle cable free play Rear shock absorber bolt lower Refer to THROTTLE CABLE FREE PLAY AD I ll I usTNT an OL _ Engine mounting bolt JUSTMEN...

Page 55: ...ply tU D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 56: ...ARBURETOR D 12 REMOVAL D 12 DISASSEMBLY D 12 INSPECTION D 13 ASSEMBLY D 14 INSTALLATION D 14 FUEL COCK D 15 INSPECTION D 15 REED VALVE D 15 REMOVAL D 15 INSPECTION D 15 INSTALLATION D 16 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 57: ... jet M A J 2 0 _ J Oil hose _ Jet needle J N A21 3 5 _ 3 Remove Needle jet N J 2 110 Carburetor top 0ElL LO_O Cutaway C A 4 0 Pilot jet P J 36 _ Throttle valve Bypass B P 1 0 8 ___322_ Starter plunger top Pilot air screw A S 1 5 8 _ 1 4out Starter plunger Valve seat size V S 1 2 ___ Starter jet G S 1 40 Carburetor Float height F H 15 17 mm _ Fuel height F L 20 5 22 5 turn ___ 0 59 0 67in _ DISASSE...

Page 58: ...nt for cleaning Blow out all passages and jets with compressed air _2o18 2 Inspect 7 Measure _ oMainjetC I Float height Main nozzle _ Iill Out of specification inspect needle valve _ Pilot jet _ I _ float and valve seat Starter jet Contamination _ Clean _ Float height 15 0 17 0 mm 0 59 0 67 In 322012 322017 3 Check Needle valve 0 Float height measurement steps Wear Contamination Replace Install th...

Page 59: ...OTE Air hose _ The float height is factory adjusted Never try to Pass the air hose through the hole _ in the adjust it yourself carburetor cover ASSEMBLY 2 Adjust Reversethe DISASSEMBLY procedures Note Throttle cable free play Refer to q HROTTLE CABLE FREE PLAY AD the following points JUSTMENT in CHAPTER 3 o Before reassembling the carburetor wash all its components in clean gasoline Always use ne...

Page 60: ...on If not clean or replace the fuel cock Disconnect the vacuum hose and breathe in __ _r _ _ _r _ through the hose to create a vacuum in the I 2 Measure Valve stopper height C fuel cock _ Out of specification _ Replace valve stop If fuel flows out of the fuel hose when vacuum is applied and stops flowing when vacuum _ per stops the fuel cock is in good condition _ _ I If not clean or replace the v...

Page 61: ...te 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 5 9 5 10 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 62: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 63: ...I wuu M _m mmm J_ I pv v D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 64: ...8 MASTER CYLINDER ASSEMBLY E 9 REAR WHEEL E 10 REMOVAL E 10 INSPECTION E 10 ASSEMBLY E 11 INSTALLATION E 11 FRONT FORK E 12 REMOVAL E 13 DISASSEMBLY E 13 INSPECTION E 14 ASSEMBLY E 14 INSTALLATION E 14 STEERING HEAD AND HANDLEBAR E 15 REMOVAL E 15 INSPECTION E 16 ASSEMBLY AND INSTALLATION E 16 REAR SHOCK ABSORBER F 2 REMOVAL F 2 INSPECTION F 2 INSTALLATION F 2 D o w n l o a d e d f r o m w w w S c...

Page 65: ...5in INSPECTION LATERAL 2 0 mm 0 08in _1_ 1 Inspect oFront axle runout 0 25mm 0 01in Out of specification Replace _ Axle runout limit I _oo_ 0 25 mm 0 01 in Do not attempt to straighten a bent axle 1_ 2 Measure Wheel runout Out of specification Replace _ _ Rim runout limit I Radial 2 0 mm 0 08 in __ __ __I_ _ _ _ 34 ii 7 13 Inspect Tire Laterah 2 0 mm 0 08 in _ _ _J_ _ 4 oWear Cracks Warpage Replac...

Page 66: ... C NOTE _ _ _ Be sure that the two projections at the gear unit I _ _ _ I 21 SNm 2 15m kg 16ft lb l mesh with the two slots on the wheel hub _ _ 00_ _ ___ 3 Install t _ Front wheel 0 Front caliper _ _ _i k_ _ l NOTE Be sure that the slot torque stopper of the gear unit housing is positioned correctly 4 Tighten Front wheel axle o Front caliper mounting botts I_ I Front wheel axle 4v 47 Nm 4 7 m kg ...

Page 67: ...lft lb _ tort Use only clean brake fluid for cleaning ____ Use care with brake fluid Never allow brake fluid tocome incontact with eyes the Brake _ _tl 110 8Nm 1 08 m kg 8 ft lb tic fluid can damage painted su parts rfaces and plas I BRAKE PAD REPLACEMENT It is not necessary to disassemble the brake L caliper and brake hose to replace the brake pads 1 Remove Pin D BRAKE FLUID _ Axle _ A DOT 3 or D...

Page 68: ... the front brake master cylinder drain all brake fluid from the brake hose master cylinder brake caliper and reser voir tank 1 Remove CALIPER DISASSEMBLY Upper handlebar cover j _ _ _ NOTE __ _ _ Before disassembling the front brake caliper 2 Remove drain all brake fluid from the brake hose master Brake switch _ cylinder brake caliperand tank Brake lever __t Union bolt 1 Remove Union bolt _ NOTE _...

Page 69: ...uid only Donotusesolventsasthey _ Bolt brakedisc will cause seals to swell and distort 23 Nm 2 3 m kg 17 ft lb LOCTITE 1 Inspect CALIPER ASSEMBLY Caliper piston C __ _ Scratches Rust Wear _ Replace caliper _ y11 i L 1 l_ll_ assembly All internal parts should be cleaned in new Caliper body _ brake fluid only Wear Scratches Cracks Damage_Reptace Internal parts should be lubricated with caliper assem...

Page 70: ...nstall the caliper Brake hose oCopper washers o Union bolts Proper hose routing is essential to insure Brake switch safe operation Referto CABLE ROUTING I _1 Union bolt I Always use new copper washers 23 Nm 2 3 m kg 17 ft lb MASTER CYLINDER ASSEMBLY _ lV_Vl_ l _11_ eE All internal parts should be cleaned in new _1 w_ 1 1_11_ 11 brake fluid only Internal parts should be lubricated with Proper hose ...

Page 71: ...KE L N N_ WEAR L M _ _ _ _ _ _ 2 0 mm 0 08 in Rear wheel 11o5 Nm 10 5 Kg m 76 ft lb D RIM RUNOUT LIMIT _ VERTICAL 2 0 mm 0 08in _o_ _ REPLACE BRAKE LININGS 7 _ 4 Remove Brake cable __ II J Brake shoes _ I I AND SPRING _ SASASET _ _ _ _ Plain washer _ a4r_l_ INSPECTION 1 Check Rear wheel __L _ I 7 Kg m 5 ft Ib I 2 SPECTION Measure Refer to the section FRONT WHEEL IN _ _ _ Wheel runout __ ___ _ d __...

Page 72: ...imit 11 2 0 mm 0 08 in I_ 1 Camshaft Lever Bolt 6 Check 7 Nm 0 7 m kg 5 1 ft lb Brake drum inner surfaca __ Oil Scratches _ Repair _ 4 Install Plain washer C 7 Measure Brake drum inside diameter t Brake cable Out of specification _ Replace C _ Brake Drum Wear limit I t10 5 mm 4 35 in 34S006 _012 ASSEMBLY INSTALLATION _L___ Reverse the REMOVAL procedure Reverse the REMOVAL procedure Notethefollowin...

Page 73: ... right 9 Nm 0 9 m kg 6 5 ft lb I _ Plunger guide Outer fork tube left i Bolt muffler Oil seal _ Brake hose bracket 26 Nm 2 6 m kg 19 ft lb _ Washer _ Brake hose bracket 4 Adjust _ Bolt _ Steering race set o Rear brake lever free play A FRONT FORK TUBE CAPACITY I Refer to REAR BRAKE LEVER FREE PLAY i B 48 cc 1 69 Imp oz 1 62 US oz l ADJUSTMENT in CHAPTER 3 FRONT FORK OIL GRADE J _ SO 3743 4 LHV46 _...

Page 74: ...older _ BAR 6 Remove Securing nut _ _ T handle for front fork Ring nut C I 90890 01326 Holder NOTE 90890 01294 Usethe Ring Nut Wrench _ to loosenthe ring nut I I_l Ring Nut Wrench 90790 0t 268 Support the steering shaft to prevent it from falling 7 Remove 3 Remove Washer _ _ Inner fork tube _ _ _ _ Upper bearing race top _ _ _ Piston _ Steering collumn Spring _ Bearings Spring seat _ Take care not...

Page 75: ...Fork oil _2o ISO 674314 LHV 46 i Amount per fork tube ASSEMBLY 48 cc 1 69 Imp oz 1 62 US oz Reverse the DISASSEMBLY procedure Note the following points 5 Install NOTE Spring When reassembling the front fork make sure Spring seat you use following new parts Circlip Oil seals Rubber plug Circlips and retainers Make sure that all components are clean be fore reassembling INSTALLATION Reverse the REMO...

Page 76: ...e 2 Remove Front fender __ Inner panels Upper handlebar cover Refer to COVERS in CHAPTER 3 3 Drain Front brake system Refer to FRONT BRAKE _ 60 Nm 6 0 m kg 43 ff lb l 4 Remove Front brake master cylinder __ 5 Refer Remove to FRONT BRAKE Front brake caliper mounting bolts 6 Remove Front wheel Refer to FRONT BRAKE _ 7 Remove Rear brake cable D Throttle grip 8 Disconnect Ground wire All couplers Wire...

Page 77: ...ing balls Upper _0o8 22 pieces Lower 22 pieces INSPECTION _ 4 Check 1 Check Steering shaft Handlebar O _ Bend Damage Replace Bends Cracks Damage _ Replace VTI_ 7_ E_Tr_ Never attempt to straighten a bent steering 2 Wash the bearing balls in solvent shaft 354OO9 3 Check ASSEMBLY AND INSTALLATION Bearing races _ Reverse the REMOVAL and DISASSEMBLY _ _ _ Pitting Damage Replace procedure Bearing balls...

Page 78: ...r switch leads NOTE Brake switch lead Fit the handlebar bridge _ into the steering column notcher _ 13 Install Front fender NOTE Refer to CABLE ROUTING in CHAPTER 2 for NOTE proper cable and lead routing Refer to COVERS in CHAPTER 3 13 Adjust Front brake free play Before installing the handlebar wipe the oil Rear brake lever free play off the insertion portion using thinner etc Throttle free play ...

Page 79: ...er 0 INSPECTION 1 Inspect Rear shock absorber Oil leaks Damage _ Replace INSTALLATION When installing the rear shock absorber re verse the removal procedure Note the following points 1 Install Rear shock absorber 31 5 Nm 13 15 m kg 22 8 lt lb I Rear Shock Absorber Bolt Lower I I 17 5 Nm 1 75 m kg 12 6 ft lb I 6 29 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 80: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 81: ... D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 82: ...AM F 8 IGNITION AND STARTING SYSTEM F g CIRCUIT DIAGRAM F 9 IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM F 9 TROUBLESHOOTING F IO CHARGING SYSTEM F 14 CIRCUIT DIAGRAM F 14 TROUBLESHOOTING F 14 LIGHTING SYSTEM F 15 CIRCUIT DIAGRAM F 15 TROUBLESHOOTING F 16 SIGNAL SYSTEM G 1 WIRING DIAGRAM G 1 TROUBLESHOOTING G 2 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 83: ...I Q range when testing the switch for continuity Turn the switch on and off a few times when checking it INSPECTING ASWITCH SHOWN IN THE I_1 I I I_1 _ MANUAL switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors inthe top row ____ For each switch position 0 0 ind...

Page 84: ...etween lead terminals _ Dimmer switch Poor connection no continuity _ Correct or replace Turn switch The coupler locations are circled _ Main switch Start switch Engine stop switch Front stop switch Rear stop switch Fuse Oil lever gauge Fuel sender L i z _ _ i o i I 7 3 7 4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 85: ...ter relay Rear stop switch _ _ _ Starting motor _ Oil level gauge _ _ _ Right handle switch _ Meter _ _ Left handle switch _ Sender _i _ _ _ Head light _ GY __ _i COLOR CODE __ __ I _ R Red L Blue B Black Y R Yellow Red _ W White L W Blue White _ _ Y Yellow G Y Green Yellow _ _ _ I Br Brown B W Black White _ Gy Gray B R Black Red O Orange W R White Red Ch Chocolate Br W Brown White Dg Darkgreen Y ...

Page 86: ...andle switch Pickup coil Ignition coil _ Front brake switch Wave shape shaping circuit Spark plug _ Rear brake switch Condenser Main switch Diode Fuse SCR Battery To oil level switch Starter relay o_ 4 _ _ _ B W LOCK 00_0 OFF O0 CHECK O0 ON _ _ _ R _ T B Current flow in ignition control circuit Current flow in starter motor control circuit 7 7 7 8 D o w n l o a d e d f r o m w w w S c o o t e r T ...

Page 87: ... plug _ Connect the pocket tester _ x 1 to the BR8HS NGK ignition coil _ Spark plug gap I Replace or adjust the spark plug gap I Ignition coil 0 5 0 7 mm 0 020 0 027 in Pocket tester lead _ Orange Pocket tester lead _Ground CORRECT Check the primary coil resistance 3720_ 2 Spark check _ Primary coil resistance Remove the spark plug cap _1 0 56 0 84 E_ at 20 C 68 F Connect the ignition checkerO Con...

Page 88: ...o BATTERY INSPECTION in I Pocket tester lead C Black Red CHAPTER 3 I OUT OF SPECIFICATION Pocket tester lead _ Ground _ _ J Open circuit voltage I H 12 8 Y or more at b 20 C 68 F I Check the source coil resistance r _l S urcs c il resistance _ CORRECT J Clean battery terminals I I 640 960 _ at 20 C 68 F OUT OF SPECIFICATION Charge or replace the battery 3 Starter motor MEETS _ Use ajumper lead _ t...

Page 89: ...WEAR LIMIT 5 3 mm 0 21 in _ CORRECT _ _ _ _3 _ I 5 Main switch J INCORRECT _ _ _m_ I Refer to SWITCH INSPECTION _ kg 9 4 _ _ CORRECT I Replace the main switch I I 6 Engine stop switch I INCORRECT ___ I Refer to SWITCH INSPECTION 8 _ CORRECT I Replace right handlebar switch I 17 Startersw tc INCORRECT _ _ _ Refer to SWITCH INSPECTION _ _ CORRECT i Replace right handlebar switch I ___ 8 Connections ...

Page 90: ...lace as a proper measurement use a hacksaw blade set which has been grounded to fit the commu tator _ Brush spring force 150 650 gr 5 29 22 92 oz _ Micaundercut I 1 15 mm 0 045 in NOTE 7 Inspect The mica insulation of the commutator must be Bearing undercut to ensure proper operation of Roughness Replace commutator O rings Wear damage _ Replace 4 Inspect Armature coil resistance _ii_ Defect Replac...

Page 91: ...n circuit v ltage i Clean battery terminals I _ i _ _ i t2 8 V or_more at 20 C 68 F Charge or replace the battery L JL_ _ _ _ _ _ CORRECT _f _ E 3 Charging voltage __ _ Connecttheenginetachometertothespark plug lead _ L_ _ Connect the pocket tester DC20V to the ___ battery terminals ___ _ i_ _ _ I _ Pockettester lead_ Battery terminal _r_ _ _j_ Pocket tester lead _ Battery terminal _ _ _ _ _ Start...

Page 92: ...nce Tester lead White O Tester lead Ground Q I_ I Charging coil resistance OUT OF SPECIFICATION 0 48 0 72 E2at 20 C 68 F _ _ MEETS SPECIFICATION I Replace charging coil I 15 C nnections I POOR CONNECTIONS _ Z _ _ i_ _ _ _ii_ I Check allconnections in the charging system _ E _ _ I Refer to CIRCUIT DIAGRAM I _ _ llv CORRECT IRepair I i I Replace the rectifier regulator I 7 19 7 20 D o w n l o a d e ...

Page 93: ...ter lead _ Yellow _ testerindicator lead _ Black _ _ _ _ __ 2 Lighting coil resistance Pocket tester lead Yellow _ f Disconnect the lighting coil coupler from the Pocket tester lead _ Black _ __ wire ms r Connect the pocket tester _ x 1 to the Pocket tester lead _ Blue _ lighting coil R Pocket tester lead Black _ Check the lighting coil resistance Start the engine _ _ Tester lead _ Yellow I Red D ...

Page 94: ...the pocket tester AC20V to the _ _ taillight coupler _ _ J i 0 Pocket tester lead Blue _ Pocket tester lead _ Black _ Setthemain switch to ON 8 Start the engine Check the voltage 12V between the head _E_ _ light coupler leads Blue and Black OUT OF SPECIFICATION SPECIFICATION JWiring circuit between C DJ magneto and JThe circuit is good I I taillight coupler Repair I 7 23 7 24 D o w n l o a d e d f...

Page 95: ...2 _ LBattery INCORRECT _ Check the condition of the battery m _ SPECIFICATIoNMEETS Wiring circuiffrom main switch to horn isfaulty I I Refer to BAI rERY INSPECTION in _ I Repair I CHAPTER 3 I Vo a0e Battery voltage Charge or replace the battery T t2 8 V or more at 2O C 68 F Connect the pocket tester DC20V to the Br Pink lead _ Pocket tester lead Pink _ CORRECT Pocket tester lead Ground 3 Main swit...

Page 96: ... Pull the brake lever Check the voltage 12V between the Brown Check the voltage 12V between Green lead and the ground UT OF SPECIFICATION Yellow _ and Black _ n MEETS SPECIFICATIONS _ _ 3 Voltage I Wiring circuit from main switch to flasher relay I Y I connector is faulty Replair I L Connect the pocket tester DC2OV to the flasher relay Pocket tester lead _ Brown White O B OUT OF SPECIFICATION Pock...

Page 97: ... voltage 12V between Choco Pocket tester lead _Terminal _ late and the ground then Dark green and OUTOF SPECIFICATION 37_s the ground Check the switch for continuity Float Good Bad MEETS position condition condition SPECIFICATION I Wiring circuit from turn switch to bulb socket i HIGH X O xJ O I Thiscircuit isgo d I I connector is faulty Repair I LOW O X X O OUT OF SPECIFICATION O Continuity X No ...

Page 98: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 99: ...A I ii u lull c Ju D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 100: ...ENGINE IS OPERATING G 9 CLUTCH OUT FAILURE G 9 POOR STANDING START LOW CLIMBING ABILITY G 9 POOR ACCELERATION POOR HIGH SPEED G 9 IMPROPER KICKING G 10 SLIPPING G 10 HARD KICKING G 10 KICK CRANK NOT RETURNING G 10 FAULTY BRAKE G 4 POOR BRAKING EFFECT G 4 MALFUNCTION G 4 FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION G 10 OIL LEAKAGE G 10 MALFUNCTION G 10 INSTABLE HANDLING G 10 INSTABLE HANDLING...

Page 101: ...en gasket Clogged fuel filter foreign material Seized or damaged piston Broken reed valve Deteriorated fuel or fuel containing water or Clogged pilot jet foreign material Clogged pilot air passage Clogged fuel tank cap Sucked in air Fuel cock Deformed float Clogged fuel hose Groove worm needle valve Air cleaner Improperly sealed valve seat POOR IDLE SPEED PERFORMANCE Clogged air filter Improperly ...

Page 102: ...in nozzle POOR STANDING START LOW CLIMBING ABILITY ELECTRICAL SYSTEM V belt Secondary sheave Spark plug CDI unit system Worn damaged or slipped v belt Fatigued compression spring Improper plug gap Faulty CDI unit Primary sheave Improperoperation of secondarysliding sheave Worm electrodes Faulty source coil Worn or improper operation of weight Wire between terminals broken Faulty pick up coil impro...

Page 103: ...ND LIGHTING SYSTEM FAULTY BRAKE Headlight dark Flasher does not light POOR BRAKING EFFECT Improper bulb Improperly grounded Disc brake Drum brake Too many electric accessories Discharged battery Worn nbrake pads Worn brake shoe Hard charging broken charging coil Faulty flasher switch Worn disc Worn or rusty brake drum Incorrect connection Faulty flasher relay Air in brake fluid Improperly adjusted...

Page 104: ...horn Broken wirehamess Flasher winks quicker Improper bulb Faulty flasher relay OVERHEATING OVERHEATING Ignition system Compression system Improper spark plug gap Heavy carbon buildup Improper spark plug heat range Improper ignition timing Faulty system Cooling fan Improper carburetor main jet Improper setting Damaged cooling fan Clogged air cleaner element Damaged air shrouds Lean mixture faulty ...

Page 105: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 106: ...lasher light L_ L_ L_ i__ _ _ i _ Leftrearflasherlight __ _ _ Right rear flasher light E _ Tail Stop light _ _ _ Flasher relay _ _B_ _ _ Front stop switch _ Rear stop switch _ Oil level gauge ORN _ _ER _ _ E _ _ _ Meter _ _ _ _i _ Sender t i t ii iiiiii Bown Gre __ _ _o Y _ Yo o_ _ _c_ _ Ch Chocolate Y R YellowlRed I_ _____ _ _____ __ i Dg Dark green Br Y Brown Yellow I_ _ _ __ _ B R BlacldRed Br ...

Page 107: ...Yamaha Motor Canada Ltd 480 Gordon Baker Road Toronto ON M2H 3B4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...