Yamaha PW50W 2007 Service Manual
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Yamaha PW50W 2007 Service Manual

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PW50W
SERVICE MANUAL
5PG-28197-10
LIT-11616-20-15

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Summary of Contents for Yamaha PW50W 2007

  • Page 1 PW50W SERVICE MANUAL 5PG-28197-10 LIT-11616-20-15...
  • Page 3 EAS00000 PW50W SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First edition, May 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-20-15...
  • Page 4 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 5 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.

  • Page 6: General Information

    SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Carburetor 7 Electrical system CARB 8 Troubleshooting Symbols 9 to y indicate the following.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE CARBURETOR CARB ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 9: Gen Info

    INFO CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION ................1-1 VEHICLE IDENTIFICATION NUMBER ............1-1 ENGINE SERIAL NUMBER .................1-1 IMPORTANT INFORMATION................1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-2 REPLACEMENT PARTS ................1-2 GASKETS, OIL SEALS AND O-RINGS ............1-2 LOCK WASHERS/PLATES AND COTTER PINS ........1-3 BEARINGS AND OIL SEALS ..............1-3 CIRCLIPS ....................1-3 CHECKING THE CONNECTIONS ..............1-4 SPECIAL TOOLS .....................1-5...

  • Page 10: General Information

    VEHICLE IDENTIFICATION INFO GENERAL INFORMATION VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The number 1 is stamped into the frame head pipe. ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase. NOTE: Designs and specifications are subject to change without notice.

  • Page 11: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 12: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. 300-000 BEARINGS AND OIL SEALS Install bearings and oil seals so that the man-...

  • Page 13: Checking The Connections

    CHECKING THE CONNECTIONS INFO CHECKING THE CONNECTIONS Check the leads, couplers, and connecters for stains, rust, moisture, etc. 1. Disconnect: 9 lead 9 coupler 9 connector 2. Check: 9 lead 9 coupler 9 connector → Dry with compressed air. Moisture Rust/stains →...

  • Page 14: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappro- priate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 15 This tool is needed for observing engine r/min. Ignition checker 90890-06754 YM-34487 This instrument is necessary for check- ing the ignition system components. Yamaha bond No.1215   (Three bond No.1215 90890-85505 This bond is used on crankcase mating surfaces,etc.

  • Page 16: Spec

    SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................. 2-1 MAINTENANCE SPECIFICATIONS ..............2-2 ENGINE ...................... 2-2 CHASSIS ..................... 2-6 ELECTRICAL ....................2-10 GENERAL TIGHTENING TORQUE SPECIFICATIONS ........2-11 DEFINITION OF UNITS ..................2-11 LUBRICATION POINTS AND LUBRICANT TYPES ........2-12 ENGINE ...................... 2-12 CHASSIS .....................

  • Page 17: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: PW50W (Except for EUROPE) PW50 (For EUROPE) Model code number: 5PGD (Except for EUROPE) 5PGE (For EUROPE) Dimensions: Overall length 1245 mm (49.0 in) Overall width 575 mm (22.6 in) Overall height 715 mm (28.1 in) Seat height 485 mm (19.1 in)

  • Page 18: Maintenance Specifications

    Unleaded gasoline only (Except for CANADA,EUROPE) Fuel tank capacity 2.0 L (0.53 US gal) (0.44 Imp.gal) Engine oil: Lubrication system Separate lubrication (Yamaha autolube) Type YAMALUBE 2 or 2-stroke engine oil Engine oil quantity Quantity 0.30 L (0.32 US qt) (0.26 Imp.qt)
  • Page 19 SPEC MAINTENANCE SPECIFICATIONS Item PW50 Cylinder head: Volume 6.80 cm (0.41 cu.in) Warpage limit 0.03 mm (0.0012 in) Cylinder: Bore 39.993-40.012 mm (1.5745-1.5753 in) Wear limit 40.100 mm (1.5787 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.010 mm (0.0004 in) Piston: Piston-to-cylinder clearance...
  • Page 20 SPEC MAINTENANCE SPECIFICATIONS Item PW50 Automatic centrifugal clutch: Clutch type Wet, centrifugal automatic Clutch housing inside diameter 105 mm (4.13 in) Wear limit 106 mm (4.17 in) Clutch shoe thickness 1.0 mm (0.04 in) Wear limit 0.7 mm (0.03 in) Clutch shoe spring free length 34.5 mm (1.36 in) Llimit...
  • Page 21 Middle driven pinion (Screw) M45 x 1.5 43 Left hand thread Plate bearing cover (Ring gear) M6 x 1.0 Crankcase M6 x 1.0 Yamaha bond No.1215 Crankcase cover (Right) M6 x 1.0 Transmission oil drain bolt M8 x 1.25 Oil plug M14 x 1.5...

  • Page 22: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item PW50 Chassis: Frame type Steel tube backbone Caster angle 25.50 degree Trail 50.0 mm (1.97 in) Front wheel: Wheel type Panel wheel Rim size 10x1.50 Rim material Steel Wheel travel 60.0 mm (2.36 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in)
  • Page 23 SPEC MAINTENANCE SPECIFICATIONS Item PW50 Front brake: Type Drum brake Operation Right hand operation Front brake lever free play 10.0-20.0 mm (0.39-0.79 in) Front drum brake Drum brake type Leading, trailing Brake drum inside diameter 80.0 mm (3.15 in) Limit 80.5 mm (3.17 in) Lining thickness 3.5 mm (0.14 in)
  • Page 24 SPEC MAINTENANCE SPECIFICATIONS Item PW50 Rear suspension: Type Unit swing Spring/shock absorber type Coil spring/oil damper Rear shock absorber assembly travel 30.0 mm (1.18 in) Spring free length 153 mm (6.02 in) Installed length 146 mm (5.75 in) Spring rate K1 11.89 N/mm (67.94 lb/in) (1.22 kgf/mm) Spring rate K2 33.4 N/mm (190.71 lb/in) (3.40 kgf/mm)
  • Page 25 Rear shock — upper M6 x 1.0 — lower M8 x 1.25 Swing arm (L) — Engine (Front) M8 x 1.25 Yamaha bond No.1215 — Gear housing (Rear) M8 x 1.25 Yamaha bond No.1215 Swing arm (R) — Engine (Front) M8 x 1.25...

  • Page 26: Electrical

    Item PW50 Ignition system: Ignition system Advancer type Fixed Ignition timing (B.T.D.C.) 16.0 degree/5000 r/min CDI: Magneto model/manufacturer F3L6/YAMAHA Pickup coil resistance 18.0-22.0 Ω W/R-B Source coil resistance 297-363 Ω B/R-B CDI unit model/manufacturer 3PT-00/YAMAHA Ignition coil: Model/manufacturer 2JN/YAMAHA Primary coil resistance 0.32-0.48 Ω...

  • Page 27: General Tightening Torque Specifications

    GENERAL TIGHTENING TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assem- blies in a crisscross pattern and progressive stages until the specified tightening torque is...

  • Page 28: Lubrication Points And Lubricant Types

    Main axle Drive and driven pinion teeth Drive axle Shaft drive spline Kickstarter gear inner surface Kickstarter shaft Crankcase mating surface Yamaha bond No.1215 CHASSIS Lubrication point Lubricant Front wheel oil seal lips Front brake camshaft Rear wheel oil seal lips...

  • Page 29: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Spark plug lead e C.D.I. magneto lead wire ç Clamp the lead wire to the 2 Ignition coil r C.D.I. unit coupler frame. 3 Ground t Fuel pipe ∂ Clamp the coupler lead under 4 Wire cylinder y Control unit coupler the throttle cable 2 and starter...
  • Page 30 SPEC CABLE ROUTING 1 Throttle cable 1 å Clamp the oil pump cable on ∂ Fuel tank cap→ between the 2 Throttle cable 2 top of all of the wire harness, handlebar protector and front 3 Oil pump cable starter cable, throttle cable 2 brake cable→...
  • Page 31 SPEC CABLE ROUTING 1 Throttle cable 1 å Clamp the wire harness and 2 Front brake cable starter cable. 3 Fuel tank breather hose ∫ Pass the front brake cable. 4 Rear brake cable ç Clamp the wire harness to the 5 Starter cable handlebar.
  • Page 32 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ....................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ......................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-2 SIDE COVERS, SEAT AND FUEL TANK ............3-3 ENGINE ......................3-4 CHANGING THE TRANSMISSION OIL ............3-4 CHECKING THE ENGINE IDLING SPEED ..........

  • Page 33: Periodic Checks And Adjustments

    PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYS- NOTE: 9 From 18 months, repeat the maintenance intervals starting from 6 months. 9 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. THEREAFTER...

  • Page 34: General Maintenance And Lubrication Chart

    Shock absorber Check operation and for oil leakage. assemblies Replace if necessary. Apply Yamaha chain and cable lube or engine oil Control cable 10W-30 lightly. Check operation and free play. Throttle grip housing Apply Yamaha chain and cable lube or engine oil and cable 10W-30 lightly.

  • Page 35: Side Covers, Seat And Fuel Tank

    SIDE COVERS, SEAT AND FUEL TANK SIDE COVERS, SEAT AND FUEL TANK 7 Nm (0.7 m•kg,5.1 ft•lb) Order Job/Part Q´ty Remarks Removing the side covers, seat Remove the parts in the order listed. and fuel tank Flap Side cover Seat Fuel cock Set the fuel cock to “S”.

  • Page 36: Engine

    CHANGING THE TRANSMISSION OIL ENGINE CHANGING THE TRANSMISSION OIL 1. Stand the vehicle on a level surface. NOTE: 9 Place the vehicle on the mainstand. 9 Make sure the vehicle is upright. 2. Start the engine, warms it up for several minutes, and then turn it off.

  • Page 37: Checking The Engine Idling Speed

    CHANGING THE ENGINE IDLING SPEED CHECKING THE ENGINE IDLING SPEED NOTE: Prior to checking the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes.

  • Page 38: Adjusting The Throttle Cable Free Play

    ADJUSTING THE THROTTLE CABLE FREE PLAY ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Check: 9 Throttle cable free play a Out of specification → Adjust. Throttle cable free play 1.5-3.5 mm (0.06-0.14 in) 2.

  • Page 39: Adjusting The Autolube Pump Cable

    ADJUSTING THE AUTOLUBE PUMP CABLE/ ADJUSTING THE AUTOLUBE PUMP MINIMUM STROKE ADJUSTING THE AUTOLUBE PUMP CABLE 1. Remove: 9 Muffler 9 Exhaust chamber assembly 2. Start the engine and turn the throttle grip slowly until slack off the pump cable. 3.
  • Page 40 ADJUSTING THE AUTOLUBE PUMP MINIMUM STROKE 2. Remove: 9 Autolube pump cover (outer) 1 3. Install: 9 Dial gauge 1 Install the dial gauge to the autolube pump plunger, so that the top end is attached. Dial gauge and stand set 90890-01252 4.

  • Page 41: Air Bleeding The Autolube Pump

    AIR BLEEDING THE AUTOLUBE PUMP AIR BLEEDING THE AUTOLUBE PUMP Whenever remove the autolube pump or oil hose, be sure to air bleed the autol- ube pump. 9 Make sure that the engine oil is filled in the engine oil tank. 9 If the engine oil is not in the engine oil tank, fill the engine oil tank.

  • Page 42: Chk Adj

    CHECKING THE EXHAUST SYSTEM CHECKING THE EXHAUST SYSTEM 9 Always let the exhaust system cool prior to touching exhaust components. 9 Do not start the engine when cleaning the exhaust system. 1. Check 9 Exhaust chamber assembly 9 Muffler Cracks/damage → Replace. Exhaust gas leaks →...

  • Page 43: Cleaning The Spark Arrester And Exhaust Chamber

    CLEANING THE SPARK ARRESTER AND EXHAUST CHAMBER/ CLEANING THE AIR FILTER ELEMENT CLEANING THE SPARK ARRESTER AND EXHAUST CHAMBER 1. Remove: 9 Tail pipe 1 9 Muffler 9 Exhaust chamber assembly 9 Gasket 2. Check: 9 Tail pipe NOTE: 9 Use a wire brush to remove any carbon deposits from the spark arrester portion of the tail pipe.
  • Page 44 CLEANING THE AIR FILTER ELEMENT 3. Clean: 9 Air filter element Clean them with solvent. NOTE: After cleaning, remove the remaining solvent by squeezing the element. 4. Check: 9 Air filter element 5. Apply: 9 Foam-air-filter oil or equivalent oil To the element.

  • Page 45: Checking The Fuel Hose

    CHECKING THE FUEL HOSE/ADJUSTING THE FRONT AND REAR BRAKE/ CHECKING THE FRONT AND REAR BRAKE SHOES CHECKING THE FUEL HOSE 1. Check: 9 Fuel hose 1 Clack/Damage → Replace CHASSIS FRONT ADJUSTING THE FRONT AND REAR BRAKE 1. Check: 9 Brake lever free play a Out of specification →...

  • Page 46: Checking The Front And Rear Brake Shoes

    CHECKING THE FRONT AND REAR BRAKE SHOES/ CHECKING AND ADJUSTING THE STEERING HEAD 2. Check: REAR 9 Wear indicator If the lining thickness of a brake shoe is less than 1.5 mm (0.06 in)→ Replace the front or rear brake shoes as a set. Refer to “FRONT WHEEL, REAR WHEEL AND BRAKE “in chapter 4.

  • Page 47: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK b. Tighten the steering nut 5 with a wrench. Steering nut (1st) 10 Nm (1.0 m·kg, 7.2 ft·lb) c. Lock to lock the steering head a few times. d. Fully loosen the steering nut and then tighten the steering nut to specified torque.
  • Page 48 CHECKING THE FRONT FORK/CHECKING THE TIRES 2. Check: 9 Inner tube Damage/scratches → Replace. Refer to “FRONT FORK” in chapter 4. 3. Hold the vehicle upright and apply the front brake. 4. Check: 9 Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly.

  • Page 49: Checking The Tires

    No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehicle. After a tire has been repaired or replaced, be sure to tighten the tire air valve stem nut 1 to specification.

  • Page 50: Checking The Wheels

    CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: 9 Wheel Damage/out-of-round → Replace. Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or re- placed, always balance the wheel.

  • Page 51: Lubricating The Lever

    LUBRICATING THE LEVER/LUBRICATING THE MAINSTAND/ CHECKING THE SPARK PLUG LUBRICATING THE LEVER Lubricate the pivoting point and metal-to- metal moving parts of the lever. Recommended lubricant Lithium-soap-based grease LUBRICATING THE MAINSTAND Lubricate the pivoting point and metal-to- metal moving parts of the mainstand. Recommended lubricant Lithium-soap-based grease ELECTRICAL...
  • Page 52 CHECKING THE SPARK PLUG 4. Check: 9 Electrode 1 Damage/wear → Replace the spark plug. 9 Insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: 9 Spark plug (with a spark plug cleaner or wire brush) 6.

  • Page 53: Chas

    CHAS CHAPTER 4 CHASSIS FRONT WHEEL, REAR WHEEL AND BRAKE ..........4-1 FRONT WHEEL ..................4-1 REMOVING THE FRONT WHEEL ............. 4-3 CHECKING THE FRONT WHEEL ............. 4-3 DISASSEMBLING THE FRONT WHEEL ........... 4-4 ASSEMBLING THE FRONT WHEEL ............4-5 INSTALLING THE FRONT WHEEL ............

  • Page 54: Chassis

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE CHASSIS FRONT WHEEL, REAR WHEEL AND BRAKE FRONT WHEEL 40 Nm (4.0 m•kg,29 ft•lb) Order Job/Part Q´ty Remarks Removing the front wheel Remove the parts in the order listed. Brake cable adjusting nut Front brake cable Spring Axle nut/washer...
  • Page 55 CHAS FRONT WHEEL, REAR WHEEL AND BRAKE Order Job/Part Q´ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Oil seal Bearing Spacer/coller Ring 1 For assembly, reverse the disassembly procedure.

  • Page 56: Removing The Front Wheel

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on the mainstand so that the front wheel is elevated.

  • Page 57: Disassembling The Front Wheel

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE 3. Measure: 9 Radial wheel runout 9 Lateral wheel runout b Over the specified limits → Replace the wheel. Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) 4.

  • Page 58: Assembling The Front Wheel

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE ASSEMBLING THE FRONT WHEEL 1. Install: 9 Wheel bearings 9 Oil seal MMMMMMMMMMMMMMMMMMMMMMM a. Install the new wheel bearings and oil seal in the reverse order of disassembly. Do not contact the wheel bearing inner or balls 5.
  • Page 59 CHAS FRONT WHEEL, REAR WHEEL AND BRAKE 3. Tighten: 9 Front wheel axle nut 40 Nm (4.0 m·kg, 29 ft·lb) Make sure the brake cable is routed prop- erly. Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly.

  • Page 60: Front Brake

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE FRONT BRAKE 4 Nm (0.4 m•kg,2.9 ft•lb) Order Job/Part Q´ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Brake shoe/brake shoe spring Bolt Brake camshaft lever Brake camshaft For assembly, reverse the disassembly procedure.

  • Page 61: Removing The Front Brake

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE REMOVING THE FRONT BRAKE 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on the mainstand so that the front wheel is elevated.

  • Page 62: Checking The Front Brake

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE CHECKING THE FRONT BRAKE 1. Check: 9 Brake shoe lining Glazed areas → Repair. Sand the glazed areas with course sand- paper. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth. 2.

  • Page 63: Assembling The Front Brake Shoe Plate

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE 5. Check: 9 Brake camshaft Damage/wear → Replace the brake camshaft ASSEMBLING THE FRONT BRAKE SHOE PLATE 1. Install: 9 Brake camshaft 1 9 Brake camshaft lever 2 4 Nm (0.4 m·kg, 2.9 ft·lb) MMMMMMMMMMMMMMMMMMMMMMM a.

  • Page 64: Rear Wheel And Brake

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE REAR WHEEL AND BRAKE 6 Nm (0.6 m•kg,4.3 ft•lb) Order Job/Part Q´ty Remarks Removing the rear wheel and Remove the parts in the order listed. brake Side cover Refer to “SIDE COVERS, SEAT AND FUEL TANK”...
  • Page 65 CHAS FRONT WHEEL, REAR WHEEL AND BRAKE 6 Nm (0.6 m•kg,4.3 ft•lb) Order Job/Part Q´ty Remarks Brake camshaft lever Brake camshaft For installation, reverse the removal procedure. 4-12...

  • Page 66: Removing The Rear Wheel

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on the mainstand so that the rear wheel is elevated.

  • Page 67: Disassembling The Rear Brake

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE DISASSEMBLING THE REAR BRAKE 1. Remove: 9 Brake shoe 1 9 Brake shoe spring 2 9 Brake camshaft lever 3 9 Lockwasher 4 9 Brake camshaft 5 CHECKING THE REAR BRAKE 1. Check: 9 Brake shoe lining Refer “CHECKING...

  • Page 68: Installing The Rear Wheel

    CHAS FRONT WHEEL, REAR WHEEL AND BRAKE b. Check that the brake shoes are properly positioned. LLLLLLLLLLLLLLLLLLLLLLL INSTALLING THE REAR WHEEL 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on the mainstand so that the rear wheel is elevated.

  • Page 69: Handlebar

    CHAS HANDLEBAR HANDLEBAR 19 Nm (1.9 m•kg,13 ft•lb) Order Job/Part Q´ty Remarks Removing the handlebar Remove the parts in the order listed. Front fender Refer to “SIDE COVERS, SEAT AND FUEL TANK” in chapter 3. Oil tank Refer to “STEERING”. Handle protector Rear brake cable Rear brake lever...

  • Page 70: Removing The Handlebar

    CHAS HANDLEBAR REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9 Handle protector 9 Ignition control switch 1 9 Throttle cable 9 Throttle grip 2 NOTE: While removing the ignition control switch, pull...

  • Page 71: Installing The Handlebar

    CHAS HANDLEBAR INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Install: 9 Handlebar 3. Tighten: 9 Handlebar 19 Nm (1.9 m·kg, 13 ft·lb) 4.
  • Page 72 CHAS HANDLEBAR 6. Install: 9 Ignition control switch Make sure the throttle grip operates smoothly. NOTE: Align the same angle of the ignition control switch with left lever holder, and then install the ignition control switch. 7. Connect: 9 Front brake cable 9 Rear brake cable 8.

  • Page 73: Front Fork

    CHAS FRONT FORK FRONT FORK 32 Nm (3.2 m•kg,23 ft•lb) 23 Nm (2.3 m•kg,17 ft•lb) Order Job/Part Q´ty Remarks Removing the front fork Remove the parts in the order listed. Handlebar Refer to “HANDLEBAR”. Oil tank Refer to “STEERING” Band Front brake cable Cap bolt/washer Lower bracket pinch bolt...
  • Page 74 CHAS FRONT FORK 32 Nm (3.2 m•kg,23 ft•lb) 23 Nm (2.3 m•kg,17 ft•lb) Order Job/Part Q´ty Remarks Spring Fork spring Damper rubber Outer tube For assembly, reverse the disassembly procedure. 4-21...

  • Page 75: Removing The Front Fork Legs

    CHAS FRONT FORK REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 9 Place the vehicle on a suitable stand so that the front wheel is elevated.

  • Page 76: Disassembling The Front Fork Leg

    CHAS FRONT FORK DISASSEMBLING THE FRONT FORK LEG The following procedure applies to the front fork leg. Do not disassembly the right front fork leg. 1. Remove: 9 Dust seal 1 9 Circlip 2 MMMMMMMMMMMMMMMMMMMMMMM a. Hold the inner tube vertically. b.

  • Page 77: Checking The Front Fork Leg

    CHAS FRONT FORK CHECKING THE FRONT FORK LEG The following procedure applies to the front fork leg. 1. Check: 9 Inner tube assembly Bends/damage/scratches → Replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2.

  • Page 78: Assembling The Front Fork Leg

    CHAS FRONT FORK ASSEMBLING THE FRONT FORK LEG The following procedure applies to the front fork leg. NOTE: 9 When assembling the front fork leg, be sure to replace the following parts: 9 Before assembling the front fork leg, make sure all of the components are clean.

  • Page 79: Installing The Front Fork Legs

    CHAS FRONT FORK 4. Install: 9 Circlip Always use a new circlip. NOTE: 9 Fully compress the front fork leg, and then install the circlip. 9 When installing the circlip 1, make sure the sharp-edged corner 2 is positioned oppo- site the thrust that the circlip receives.

  • Page 80: Steering Head

    CHAS STEERING HEAD STEERING HEAD 32 Nm (3.2 m•kg,23 ft•lb) 1st: 10 Nm (1.0 m•kg, 7.2 ft•lb ) 2nd: 0.7 Nm (0.07 m•kg, 0.5 ft•lb ) Order Job/Part Q´ty Remarks Removing the steering head Remove the parts in the order listed. Handlebar Refer to “HANDLEBAR”.

  • Page 81: Removing The Lower Bracket

    CHAS STEERING HEAD REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9 Handlebar Refer to “REMOVING THE HANDLE- BAR”. 3. Remove: 9 Steering stem bolt 9 Washer 9 Upper bracket...

  • Page 82: Installing The Steering Head

    CHAS STEERING HEAD b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new bearing races. If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: 9 Always replace the bearings and bearing races as a set.
  • Page 83 CHAS STEERING HEAD 3. Install: 9 Oil tank 9 Upper bracket 9 Washer 1 9 Steering stem bolt 2 32 Nm (3.2 m·kg, 23 ft·lb) 4. Bleed: 9 Autolube pump Refer to “AIR BLEEDING THE AUTOL- UBE PUMP” in chapter 3. 4-30...

  • Page 84: Rear Shock Absorber Assembly And Swingarm

    CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 60 Nm (6.0 m•kg,43 ft•lb) 11 Nm (1.1 m•kg,8.0 ft•lb) 29 Nm (2.9 m•kg,21 ft•lb) 33 Nm (3.3 m•kg,24 ft•lb) 23 Nm (2.3 m•kg,17 ft•lb) Order Job/Part Q´ty Remarks Removing the rear shock...

  • Page 85: Removing The Rear Shock Absorber Assemblies

    CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 86: Removing The Swingarm

    CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM REMOVING THE SWINGARM 1. Remove: 9 Rear shock absorber bolt (lower/right) 1 2. Loosen: 9 Swingarm bolt (rear) 2 9 Swingarm bolt (front) 3 3. Loosen: 9 Rear axle nut 4 NOTE: While applying the rear brake, loosen the rear axle nut.

  • Page 87: Installing The Swingarm

    CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM INSTALLING THE SWINGARM 1. Install: 9 Oil seal 9 Swingarm 9 Rear axle nut 9 Swingarm bolt (front) 9 End cap 9 Swingarm bolt (rear) 9 Rear shock absorber bolt (lower/right) 2. Tighten 9 Swingarm bolt (front) 29 Nm (2.9 m·kg, 21 ft·lb) 9 Swingarm bolt (rear)

  • Page 88: Shaft Drive

    CHAS SHAFT DRIVE SHAFT DRIVE 50 Nm (5.0 m•kg,36 ft•lb) 26 Nm (2.6 m•kg,19 ft•lb) 9 Nm (0.9 m•kg,6.5 ft•lb) 26 Nm (2.6 m•kg,19 ft•lb) Order Job/Part Q´ty Remarks Removing the shaft drive Remove the parts in the order listed. Rear shock absorber Refer to “REAR SHOCK ABSORBER (left/right)
  • Page 89 CHAS SHAFT DRIVE 50 Nm (5.0 m•kg,36 ft•lb) 26 Nm (2.6 m•kg,19 ft•lb) 9 Nm (0.9 m•kg,6.5 ft•lb) 26 Nm (2.6 m•kg,19 ft•lb) Order Job/Part Q´ty Remarks Spacer Screw Bearing Spacer Drive pinion gear For installation, reverse the removal procedure. 4-36...

  • Page 90: Disassembling The Shaft Drive Assembly

    CHAS SHAFT DRIVE DISASSEMBLING THE SHAFT DRIVE ASSEMBLY 1. Remove: 9 Housing cover 9 O-ring 9 Ring gear NOTE: 1/4 of a turn. After all of the bolts are fully loos- ened, remove them. 2. Remove: 9 Screw 1 (with the special tool 2) Hexagon wrench: 90890-01307, YM-01307 3.

  • Page 91: Assembling The Shaft Drive Assembly

    9 Ring gear 9 O-ring 9 Housing cover INSTALLING THE REAR ARM 1. Apply: 9 Yamaha bond No. 1215 (Three Bond No. 1215  ) 1 (to the mating surfaces of both arm ends) Yamaha bond No. 1215  ...

  • Page 92: Eng

    CHAPTER 5 ENGINE ENGINE REMOVAL ..................5-1 MUFFLER AND EXHAUST CHAMBER ASSEMBLY ........5-1 ENGINE .......................5-2 REMOVING THE ENGINE ................5-3 INSTALLING THE ENGINE ................. 5-5 CYLINDER HEAD, CYLINDER AND PISTON ..........5-8 CYLINDER HEAD AND CYLINDER ............5-8 PISTON ....................... 5-9 REMOVING THE CYLINDER HEAD ............
  • Page 93 CHECKING THE CRANKSHAFT ..............5-41 INSTALLING THE CRANKSHAFT .............. 5-42 MIDDLE GEAR ....................5-44 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY ......5-46 CHECKING THE MEDDLE GEAR .............. 5-46 INSTALLING THE MEDDLE GEAR ............5-46...

  • Page 94: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL MUFFLER AND EXHAUST CHAMBER ASSEMBLY 9 Nm (0.9 m•kg,6.5 ft•lb) 18 Nm (1.8 m•kg,13 ft•lb) Order Job/Part Q´ty Remarks Removing the muffler and exhaust Remove the parts in the order listed. chamber assembly Muffler assembly Exhaust chamber assembly Gasket (Power reduction plate)

  • Page 95: Engine

    ENGINE REMOVAL ENGINE 48 Nm (4.8 m•kg,35 ft•lb) Order Job/Part Q´ty Remarks Removing the engine Remove the parts in the order listed. Side cover Refer to “SIDE COVERS, SEAT AND FUEL TANK” in chapter 3. Rear shock absorber bolt (lower) Refer to “REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM”...

  • Page 96: Removing The Engine

    ENGINE REMOVAL REMOVING THE ENGINE 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on the mainstand so that the rear wheel is elevated. 2.
  • Page 97 ENGINE REMOVAL 6. Remove: 9 Muffler assembly 9 Exhaust chamber assembly 7. Remove: 9 Rear shock absorber bolt (lower/right side) 9 Rear axle nut 9 Rear shock absorber arm Refer “REAR SHOCK ABSORBER ASSEMBLY AND SWINARM” in chapter 8. Remove: 9 Brake cable adjusting nut 1 9 Rear brake cable 2 9 Pin 3...

  • Page 98: Installing The Engine

    ENGINE REMOVAL 11. Remove: 9 Spark plug cap 1 9 Rear shock absorber bolt (lower/left) 12. Disconnect: 9 CDI magneto lead coupler/connector 1 13. Remove: 9 Pivot shaft 1 NOTE: 9 While removing the engine, pull out the pivot shaft, and then remove the frame assembly. 9 Be sure to check the wire, cable and hose disconnected.
  • Page 99 ENGINE REMOVAL 2. Install: 9 Pivot shaft 1 9 Pivot shaft nut NOTE: Install the pivot shaft to temporarily. 3. Tighten: 9 Pivot shaft nut 48 Nm (4.8 m·kg, 35 ft·lb) 4. Connect: 9 CDI magneto lead coupler/connector 1 5. Install: 9 Rear shock absorber bolt (lower/left) 23 Nm (2.3 m·kg, 17 ft·lb) 9 Spark plug cap 1...
  • Page 100 ENGINE REMOVAL 8. Install 9 Swingarm bolt (front) 29 Nm (2.9 m·kg, 21 ft·lb) 9 Swingarm bolt (rear) 33 Nm (3.3 m·kg, 24 ft·lb) 9 Rear axle nut 60 Nm (6.0 m·kg, 43 ft·lb) 9 Rear shock absorber bolt (lower/right) 23Nm (2.3 m·kg, 17 ft·lb) NOTE: While apply the rear brake to tighten the rear...

  • Page 101: Cylinder Head, Cylinder And Piston

    CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD AND CYLINDER 10 Nm (1.0 m•kg,7.2 ft•lb) 20 Nm (2.0 m•kg,14 ft•lb) Order Job/Part Q´ty Remarks Removing the cylinder Remove the parts in the order listed. Exhaust chamber assembly Refer to “ENGINE REMOVAL.

  • Page 102: Piston

    CYLINDER HEAD, CYLINDER AND PISTON PISTON Order Job/Part Q´ty Remarks Removing the piston Remove the parts in the order listed. Cylinder head Cylinder Piston pin clip Piston pin Piston Top ring 2nd ring/expander ring Connecting rod small end bearing For installation, reverse the removal procedure.

  • Page 103: Removing The Cylinder Head

    CYLINDER HEAD, CYLINDER AND PISTON REMOVING THE CYLINDER HEAD 1. Remove: 9 Exhaust chamber assembly 9 Spark plug cap 1 9 Spark plug 2. Remove: 9 Cylinder head 9 Gasket NOTE: Loosen the nut to in the crisscross pattern and 2 or 3 stages as shown.

  • Page 104: Checking The Cylinder Head

    CYLINDER HEAD, CYLINDER AND PISTON 2. Remove: 9 Top ring 9 Second ring (with expander ring) NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. CHECKING THE CYLINDER HEAD 1.

  • Page 105: Checking The Cylinder And Piston

    CYLINDER HEAD, CYLINDER AND PISTON MMMMMMMMMMMMMMMMMMMMMMM a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c. If the limit is exceeded, resurface the cylinder head as follows. d. Place a 400-600 grit wet sandpaper on the surface plate and resurface the cylin- der head using a figure-eight sanding pat- tern.

  • Page 106: Checking The Piston Rings

    CYLINDER HEAD, CYLINDER AND PISTON “C”= maximum of D –D “T”= (maximum of D or D )-(maximum of D or D b. If out of specification, replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter “D” with the micrometer.

  • Page 107: Checking The Piston Pin And Small End Bearings

    CYLINDER HEAD, CYLINDER AND PISTON 2. Measure: 9 Piston ring end gap Out of specification → Replace the piston ring and cylinder as a set. Piston ring end gap 0.15-0.35 mm (0.0059-0.0138 in) Limit 0.50 mm (0.0197 in) MMMMMMMMMMMMMMMMMMMMMMM a. Install a piston ring into the cylinder. NOTE: Level the piston ring into the cylinder with the piston crown.

  • Page 108: Installing The Piston Ring And Piston

    CYLINDER HEAD, CYLINDER AND PISTON 4. Measure: 9 Piston pin bore diameter b Out of specification → Replace the piston, piston pin and small end bearing as a set. Piston pin bore inside diameter 10.004-10.015 mm (0.3939-0.3943 in) Limit 10.035 mm (0.3951 in) 5.

  • Page 109: Installing The Cylinder And Cylinder Head

    CYLINDER HEAD, CYLINDER AND PISTON 2. Install: 9 Top ring 1 9 2nd ring 2 (with expander ring 3) NOTE: 9 Be sure to install the top ring and 2nd ring so that the manufacturer’s marks or numbers face up. 9 Align the piston ring gap with the pin 4.
  • Page 110 CYLINDER HEAD, CYLINDER AND PISTON 3. Install: 9 Cylinder 1 NOTE: While compressing the piston rings with one hand, install the cylinder with the other hand. 9 Gasket 9 Cylinder head 4. Tighten: 9 Cylinder head nut 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the cylinder head nut 2 stages and in a crisscross pattern.

  • Page 111: Reed Valve

    REED VALVE REED VALVE 8 Nm (0.8 m•kg,5.8 ft•lb) Order Job/Part Q´ty Remarks Removing the reed valve Remove the parts in the order listed. Side cover Refer to “SIDE COVERS, SEAT AND FUEL TANK” in chapter 3. Engine Refer to “ENGINE REMOVAL”. Intake manifold Upper valve seat gasket Reed valve assembly...

  • Page 112: Removing The Reed Valve

    REED VALVE REMOVING THE REED VALVE 1. Remove: 9 Air filter case assembly 9 Carburetor assembly Refer to “REMOVING THE ENGINE” 2. Remove: 9 Intake manifold 9 Upper valve seat gasket 9 Reed valve assembly 9 Lower valve seat gasket CHECKING THE REED VALVE 1.

  • Page 113: Assembling And Installing The Reed Valve

    REED VALVE ASSEMBLING AND INSTALLING THE REED VALVE 1. Install: 9 Reed valve 9 Reed valve stopper 2. Install: 9 Lower valve seat gasket 9 Reed valve assembly 2 9 Upper valve seat gasket 9 Intake manifold 3. Install: 9 Carburetor assembly 9 Air filter case assembly Refer to “INSTALLING THE ENGINE”...

  • Page 114: Clutch

    CLUTCH CLUTCH 9 Nm (0.9 m•kg,6.5 ft•lb) 8 Nm (0.8 m•kg,5.8 ft•lb) 30 Nm (3.0 m•kg,22 ft•lb) Order Job/Part Q´ty Remarks Removing the clutch Remove the parts in the order listed. Side cover Refer to “SIDE COVERS, SEAT AND FUEL TANK” in chapter 3. Engine Refer to “ENGINE REMOVAL”.
  • Page 115 CLUTCH 9 Nm (0.9 m•kg,6.5 ft•lb) 8 Nm (0.8 m•kg,5.8 ft•lb) 30 Nm (3.0 m•kg,22 ft•lb) Order Job/Part Q´ty Remarks Straight key Thrust plate Coller For installation, reverse the removal procedure. 5-22...

  • Page 116: Removing The Clutch

    CLUTCH REMOVING THE CLUTCH 1. Remove: 9 Engine. Refer to “REMOVING THE ENGINE”. 2. Drain: 9 Transmission oil (from the crankcase) Refer to “CHANGING THE TRANSMIS- SION OIL” in chapter 3. 3. Remove: 9 Crankcase cover protector 1 9 Right crankcase cover 2 9 Gasket 9 Dowel pin 4.

  • Page 117: Checking The Primary Drive Gear

    CLUTCH CHECKING THE PRIMARY DRIVE GEAR 1. Check: 9 Primary drive gear 1 Damage/wear → Replace the primary drive and clutch carrier assembly. Excessive noise during operation → Replace the primary drive and clutch carri- er assembly as a set. CHECKING THE PRIMARY DRIVEN GEAR 1.

  • Page 118: Installing The Clutch

    CLUTCH 2. Measure: 9 Clutch shoe thickness Out of specification → Replace the clutch shoes and springs as a set. Clutch shoe thickness 1.0 mm (0.04 in) Wear limit 0.7 mm (0.03 in) 3. Measure: 9 Clutch shoe spring free length Out of specification →...
  • Page 119 CLUTCH 5. Install: 9 Right crank case cover 1 8 Nm (0.8 m•kg, 5.8 ft•lb) 9 Crankcase cover protector 2 9 Nm (0.9 m•kg, 6.5 ft•lb) 6. Fill: 9 Transmission oil Refer to “CHANGING THE TRANSMIS- SION OIL” in chapter 3. 5-26...

  • Page 120: Autolube Pump

    AUTOLUBE PUMP AUTOLUBE PUMP 4 Nm (0.4 m•kg,2.9 ft•lb) 4 Nm (0.4 m•kg,2.9 ft•lb) Order Job/Part Q´ty Remarks Removing the autolube pump Remove the parts in the order listed. Muffler/exhaust chamber assembly Refer to “ENGINE REMOVAL”. Autolube pump cover (outer) Oil delivery hose Autolube pump cable Oil hose...

  • Page 121: Removing The Autolube Pump

    AUTOLUBE PUMP REMOVING THE AUTOLUBE PUMP 1. Remove: 9 Muffler assembly 9 Exhaust chamber assembly Refer to “ENGINE REMOVAL”. 9 Autolube pump cover (outer) 1 2. Remove: 9 Autolube pump assembly 1 (with autolube pump cover (inner) 2) 3. Remove: 9 Oil pump cable 1 9 Oil delivery hose 2 (disconnect the autolube pump side)

  • Page 122: Disassembling The Autolube Pump

    AUTOLUBE PUMP DISASSEMBLING THE AUTOLUBE PUMP 1. Remove: 9 Circlip 1 9 Worm wheel gear 2 9 Pin 3 9 O-ring 4 9 Oil seal 5 CHECKING THE AUTOLUBE PUMP 1. Check: 9 Autolube pump Damage/cracks → Replace the autolube pump assembly.

  • Page 123: Assembling The Autolube Pump

    AUTOLUBE PUMP ASSEMBLING THE AUTOLUBE PUMP 1. Install: 9 Oil seal 1 9 O-ring 2 9 Pin 3 9 Worm wheel gear 4 9 Circlip 5 INSTALLING THE AUTOLUBE PUMP 1. Install: 9 Autolube pump assembly 1 (with autolube pump cover (inner) 2) 4 Nm (0.4 m•kg, 2.9 ft•lb) 2.

  • Page 124: Kick Starter

    KICK STARTER KICK STARTER 10 Nm (1.0 m•kg,7.2 ft•lb) Order Job/Part Q´ty Remarks Removing the kick starter Remove the parts in the order listed. Side cover Refer to “SIDE COVERS, SEAT AND FUEL TANK” in chapter 3. Engine Refer to “ENGINE REMOVAL”. Clutch Refer to “CLUTCH”.

  • Page 125: Removing The Kick Starter

    KICK STARTER REMOVING THE KICK STARTER 1. Remove 9 Engine Refer to “REMOVING THE ENGINE”. 2. Remove: 9 Clutch assembly. Refer to “REMOVING THE CLUTCH”. 3. Remove: 9 Oil pump drive gear 4. Remove: 9 Kick crank 1 5. Remove: 9 Torsion spring 1 9 Spring guide 2 9 Kick shaft 3...

  • Page 126: Installing The Kick Starter

    KICK STARTER INSTALLING THE KICK STARTER 1. Install: 9 Clip 1 9 Kick pinion gear 2 9 Kick shaft 3 2. Install: 9 Torsion spring 1 9 Spring guide 2 NOTE: Turn the torsion spring clockwise and hook onto the stopper a in the crankcase. 3.

  • Page 127: Cdi Magneto

    CDI MAGNETO CDI MAGNETO 9 Nm (0.9 m•kg,6.5 ft•lb) 43 Nm (4.3 m•kg,31 ft•lb) 4 Nm (0.4 m•kg,2.9 ft•lb) Order Job/Part Q´ty Remarks Removing the CDI magneto Remove the parts in the order listed. Side cover Refer to “SIDE COVERS, SEAT AND FUEL TANK”...

  • Page 128: Removing The Cdi Magneto

    CDI MAGNETO REMOVING THE CDI MAGNETO 1. Remove: 9 Magneto cover 1 2. Loosen: 9 Rotor nut 1 Use with the rotor holding tool 2. Rotor holding tool 90890-01235, YU-01235 3. Remove: 9 Rotor nut 9 Spring washer 9 Washer 9 CDI magneto rotor 1 Use with the flywheel puller 2.

  • Page 129: Checking The Cdi Magneto

    CDI MAGNETO CHECKING THE CDI MAGNETO 1. Check: 9 Magneto rotor inner surface 9 Stator outer surface Damage → Check the crankshaft runout and crankshaft bearing. If necessary, replace CDI magneto and/or stator. 2. Check: 9 Woodruff key Damage → Replace the woodruff key. INSTALLING THE CDI MAGNETO 1.
  • Page 130 CDI MAGNETO 5. Tighten: 9 Rotor nut 1 Use the rotor holding tool 2 43 Nm (4.3 m·kg, 31 ft·lb) NOTE: While holding the CDI magneto rotor with the rotor holding tool, tighten the rotor nut. Rotor holding tool 90890-01235, YU-01235 6.

  • Page 131: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT 15 Nm (1.5 m•kg,11 ft•lb) 8 Nm (0.8 m•kg,5.8 ft•lb) Order Job/Part Q´ty Remarks Separating the crankcase and Remove the parts in the order listed. removing the crankshaft Side cover Refer to “SIDE COVERS, SEAT AND FUEL TANK”...
  • Page 132 CRANKCASE AND CRANKSHAFT 15 Nm (1.5 m•kg,11 ft•lb) 8 Nm (0.8 m•kg,5.8 ft•lb) Order Job/Part Q´ty Remarks Crankshaft assembly Crankcase (right) Bearing Oil seal For installation, reverse the removal procedure. 5-39...

  • Page 133: Removing The Crankcase

    CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE 1. Remove: 9 Crankcase screw NOTE: Loosen each screw 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the screw are fully loosened, remove them. 2. Separate: 9 Crankcase (left) Use the bolts (M8×1.25, length 95 mm (3.74 in)) 1 and a flywheel puller 2.

  • Page 134: Checking The Crankshaft

    CRANKCASE AND CRANKSHAFT 3. Check: 9 Crankcase (left) 1 9 Crankcase (right) 2 → Cracks/damage Replace crankcase. 4. Check: 9 Bearing Unsmooth operation → Replace the bearing. CHECKING THE CRANKSHAFT 1. Measure: 9 Runout a 9 Small end free play b 9 Connecting rod big end side clearance c 9 Crank width d Out of specification →...

  • Page 135: Installing The Crankshaft

    Do not use a hammer to drive in the crank- shaft. 2. Apply: 9 Yamaha bond No. 1215 (Three Bond No. 1215  ) 1 (to the mating surfaces of both case halves) Yamaha bond No. 1215 (Three Bond No.
  • Page 136 CRANKCASE AND CRANKSHAFT 3. Install: 9 Dowel pin 9 Right crankcase To the left crankcase. NOTE: 9 Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer. 9 When installing the crankcase, the connect- ing rod should be positioned at TDC (top dead center).

  • Page 137: Middle Gear

    MIDDLE GEAR MIDDLE GEAR 12 Nm (1.2 m•kg,8.7 ft•lb) 60 Nm (6.0 m•kg,43 ft•lb) Order Job/Part Q´ty Remarks Removing the middle gear Remove the parts in the order listed. Engine Refer to “ENGINE REMOVAL”. Clutch Refer to “CLUTCH”. Kick starter Refer to “KICK STARTER”.
  • Page 138 MIDDLE GEAR 12 Nm (1.2 m•kg,8.7 ft•lb) 60 Nm (6.0 m•kg,43 ft•lb) Order Job/Part Q´ty Remarks Main axle assembly Pinion shim For installation, reverse the removal procedure. 5-45...

  • Page 139: Removing The Middle Drive Shaft Assembly

    MIDDLE GEAR REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Remove: 9 Oil seal 9 Screw 1 Attach the hexagon wrench 2. Hexagon wrench 90890-01306, YM-01306 NOTE: Loosen the screw clockwise. 2. Remove: 9 Distance coller 1 9 Bearing 2 9 Driven pinion 3 9 Thrust shim 4 CHECKING THE MEDDLE GEAR 1.
  • Page 140 MIDDLE GEAR 2. Install: 9 Screw 1 Attach the hexagon wrench 2. 60 Nm (6.0 m•kg, 43 ft•lb) Hexagon wrench 90890-01306, YM-01306 NOTE: Tighten the screw counterclockwise. 3. Install: 9 Oil seal 5-47...

  • Page 141: Carb

    CARB CHAPTER 6 CARBURETOR CARBURETOR ....................6-1 REMOVING THE CARBURETOR ...............6-3 DISASSEMBLING THE CARBURETOR............6-4 CHECKING THE CARBURETOR ..............6-4 ASSEMBLING THE CARBURETOR............6-6 INSTALLING THE CARBURETOR ..............6-8...
  • Page 142 CARB CARBURETOR CARBURETOR CARBURETOR " & 8 Nm (0.8 m•kg,5.8 ft•lb) Order Job/Part Q´ty Remarks Removing the carburetor Remove the parts in the order listed. Side cover Refer to “SIDE COVERS, SEAT AND FUEL TANK” in chapter 3. Air filter assembly Fuel hose Set the fuel cock to “S”.
  • Page 143 CARB CARBURETOR Order Job/Part Q´ty Remarks Disassembling the carburetor Disassemble the parts in the order listed. Throttle stop screw set Float chamber body Float chamber gasket Float pin Float Needle valve Main jet Main nozzle Pilot jet For assembly, reverse the disassembly procedure.
  • Page 144 CARB CARBURETOR REMOVING THE CARBURETOR 1. Remove: 9 Side cover 9 Seat 9 Clip 9 Air filter assembly 1 2. Remove: 9 Oil delivery hose 1 9 Fuel hose 2 3. Remove: 9 Mixing chamber top 1 4. Loosen: 9 Carburetor clamp screw 2 5.
  • Page 145 CARB CARBURETOR DISASSEMBLING THE CARBURETOR 1. Loosen the drain plug, and then drain the fuel from float chamber body. 2. Remove: 9 Throttle stop screw set 1 3. Remove: 9 Float chamber body 9 Float chamber gasket 4. Remove: 9 Float pin 1 9 Float 2 9 Needle valve assembly 3 5.
  • Page 146 CARB CARBURETOR 2. Check: 9 Fuel passages Obstruction → Clean. MMMMMMMMMMMMMMMMMMMMMMM a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air. LLLLLLLLLLLLLLLLLLLLLLL 3.
  • Page 147 CARB CARBURETOR 7. Check: 9 Main jet 1 9 Main nozzle 2 9 Pilot jet 3 Blow out the jets with compressed air. 8. Check: 9 Throttle valve movement Insert the throttle valve into the carburetor body and move it up and down. Tightness →...
  • Page 148 CARB CARBURETOR 2. Install: 9 Needle valve 1 9 Float 2 9 Float pin 3 NOTE: Install the float pin as shown. 3. Measure: 9 Float height a Out of specification → Replace the needle valve and the float Float height 15.5-17.5 mm (0.61-0.69 in) MMMMMMMMMMMMMMMMMMMMMMM a.
  • Page 149 CARB CARBURETOR 6. Install: 9 Throttle valve spring 1 9 Needle set 2 9 Throttle valve 3 9 Plunger spring 4 9 Starter plunger 5 7. Install: 9 Gasket 9 Mixing chamber top 2 NOTE: Align the slot on the throttle valve with projec- tion of the mixing chamber top, and then install them.

  • Page 150: Elec

    ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ................ 7-1 CHECKING SWITCH CONTINUITY ..............7-2 CHECKING THE SWITCHES ................7-3 IGNITION SYSTEM ..................7-4 CIRCUIT DIAGRAM ..................7-4 TROUBLESHOOTING ................7-5...

  • Page 151: Electrical System

    ELEC ELECTRICAL COMPONENTS ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1Ignition control switch 6Stater assembly 2Diode 3Control unit 4CDI unit 5Ignition coil...

  • Page 152: Checking Switch Continuity

    ELEC CHECKING SWITCH CONTINUITY CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. Never insert the tester probes into the 1 .

  • Page 153: Checking The Switches

    ELEC CHECKING THE SWITCHES CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch. Ignition control switch...

  • Page 154: Ignition System

    ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM...
  • Page 155 ELEC IGNITION SYSTEM TROUBLESHOOTING 9Is the spark plug in good condition, is it of The ignition system fails to operate (no the correct type, and is its gap within spark or intermittent spark). specification? Check: 1.Spark plug 2.Ignition spark gap 3.Spark plug cap resistance Re-gap or replace 4.Ignition coil resistance...
  • Page 156 ELEC IGNITION SYSTEM 3. Spark plug cap resistance 4. Ignition coil resistance 9Remove the spark plug cap from the spark 9Disconnect the ignition coil connector from plug lead. the ignition coil terminal. 9Connect the pocket tester (“Ω × 1k” range) 9Connect the pocket tester (“Ω...
  • Page 157 ELEC IGNITION SYSTEM 5. Pickup coil resistance 6. Charge coil resistance 9Disconnect the pickup coil coupler from 9Disconnect the charge coil coupler from the wire harness. the wire harness. 9Connect the pocket tester (“Ω×1” range) to 9Connect the pocket tester (“Ω×100” range) the pickup coil terminal as shown.
  • Page 158 ELEC IGNITION SYSTEM 7. Lighting coil resistance 9. Control unit resistance 9Disconnect the lighting coil coupler from 9Disconnect the control unit 1 coupler the wire harness. from the wire harness. 9Connect the pocket tester (“Ω×1” range) to 9Connect the pocket tester (“Ω×1k” range) the lighting coil terminal as shown.
  • Page 159 ELEC IGNITION SYSTEM 10. Wiring 9 Check the entire ignition system wiring. Refer to “CIRCUIT DIAGRAM”. 9 Is the ignition system wiring properly con- nected and without defects? Properly connect Replace the C.D.I. or repair the igni- unit. tion system wiring.

  • Page 160: Trbl Shtg

    TRBL SHTG CHAPTER 8 TROUBLESHOOTING GENERAL INFORMATION ................8-1 STARTING FAILURES ..................8-1 ENGINE ...................... 8-1 FUEL SYSTEM ................... 8-1 ELECTRICAL SYSTEM ................8-2 INCORRECT ENGINE IDLING SPEED ............8-2 ENGINE ...................... 8-2 FUEL SYSTEM ................... 8-2 ELECTRICAL SYSTEM ................8-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........
  • Page 161 TRBL GENERAL INFORMATION/STARTING FAILURES SHTG EAS28450 TROUBLESHOOTING EAS28460 GENERAL INFORMATION NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
  • Page 162 STARTING FAILURES/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEM Spark plug(s) Ignition system 9 Incorrect spark plug gap 9 Faulty CDI unit 9 Incorrect spark plug heat range 9 Faulty pickup coil 9 Fouled spark plug 9 Faulty charge coil 9 Worn or damaged electrode 9 Faulty lighting coil 9 Worn or damaged insulator...
  • Page 163 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY CLUTCH/OVERHEATING SHTG EAS28510 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”. FUEL SYSTEM ENGINE Carburetor(s) 9 Incorrect fuel level Autolube pump 9 Faulty autolube pump 9 Loose or clogged main jet Air filter 9 Clogged air filter element Exhaust system 9 Carbon buildup EAS28580...
  • Page 164 POOR BRAKING PERFORMANCE/ TRBL FAULTY FRONT FORK LEGS/UNSTABLE HANDLING SHTG EAS28630 POOR BRAKING PERFORMANCE 9 Worn brake shoe 9 Incorrect brake shoe position 9 Worn or rusty brake drum 9 Damaged or fatigued brake shoe spring 9 Incorrect brake pedal position (above the 9 Oil or grease on the brake shoe 9 Oil or grease on the brake drum top of the rider footrest)
  • Page 166 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 167 PW50W WIRING DIAGRAM 1 Safety switch 2 Diode 3 Control unit 4 C. D. I. magneto 5 C. D. I. unit 6 Ignition coil 7 Spark plug 8 Ground COLOR CODE B....Black W....White B/ R ....Black/ Red O....Orange W/ B ...White/ Black W/ R....White/ Red R ....Red B/ Y ....Black/ Yellow...
  • Page 168 PW50W 2007 WIRING DIAGRAM 1 Ignition control switch 2 Diode 3 Control unit 4 C. D. I. magneto 5 C. D. I. unit 6 Ignition coil 7 Spark plug 8 Ground Black Black Yellow Black Orange White White Yellow White...

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