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Yamaha YJ50RN Service Manual

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YJ50RN
SERVICEMANUAL
LIT-11616-14-50
5LY-28197-E0

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  • Page 1 YJ50RN SERVICEMANUAL LIT-11616-14-50 5LY-28197-E0...
  • Page 2 EAS00001 YJ50RN SERVICE MANUAL ©2000 by Yamaha Motor Corporation, U.S.A. First edition, December, 2000 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-11616-14-50...
  • Page 3 EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 4 EAS00007 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 5 EAS00009 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 3 Periodic checks and adjustments 4 Engine 5 Carburetor(s) 6 Chassis 7 Electrical system CHAS CARB 8 Troubleshooting...
  • Page 6 EAS00011 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE CARBURETION CARB – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 MEMO...

  • Page 8: Table Of Contents

    CONTENTS CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION................1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL CODE...................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 ........1-2 BEARINGS AND OIL SEALS ..............1-3 CIRCLIPS ....................1-3 CHECKING THE CONNECTIONS ............1-4 SPECIAL TOOLS ....................1-5...

  • Page 9: Periodic Checks And

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 INFO PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ....3-1 SIDE COVERS AND FOOTREST BOARD .............3-3 SPEC FRONT PANEL AND LEG SHIELD ..............3-5 ADJUSTING THE ENGINE IDLING SPEED ..........3-7 ADJUSTING THE THROTTLE CABLE FREE PLAY.........3-8 BLEEDING THE AUTOLUBE PUMP............3-9 CHECKING THE SPARK PLUG..............3-10 MEASURING THE COMPRESSION PRESSURE ........3-11 CHECKING THE ENGINE OIL LEVEL ............3-13...
  • Page 10 CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE ................4-1 CHECKING THE FRONT WHEEL ............4-5 CHECKING THE SPEEDOMETER GEAR UNIT........4-6 CHECKING THE BRAKE ................4-7 ASSEMBLING THE BRAKE SHOE PLATE ..........4-8 INSTALLING THE FRONT WHEEL ............4-8 REAR WHEEL AND BRAKE.................4-10 CHECKING THE REAR WHEEL .............4-12 CHECKING THE BRAKE ................4-12 INSTALLING THE BRAKE SHOE PLATE ..........4-13 INSTALLING THE BRAKE SHOES ............4-14...
  • Page 11 CHAPTER 5 ENGINE ENGINE REMOVAL..................5-1 INSTALLING THE ENGINE ...............5-3 INFO CYLINDER HEAD, CYLINDER AND PISTON ..........5-4 REMOVING THE CYLINDER AND PISTON ..........5-6 CHECKING THE CYLINDER HEAD ............5-6 CHECKING THE CYLINDER AND PISTON..........5-7 SPEC CHECKING THE PISTON RINGS .............5-8 CHECKING THE PISTON PIN ..............5-9 INSTALLING THE PISTON AND CYLINDER .........5-11 KICKSTARTER....................5-13 SHEAVES COVER .................5-13...
  • Page 12 CRANKCASE ....................5-37 DISASSEMBLING THE CRANKCASE ............5-39 CHECKING THE CRANKCASE ..............5-39 CHECKING THE BEARINGS AND OIL SEALS ........5-40 CHECKING THE REED VALVE ..............5-40 ASSEMBLING THE CRANKCASE ............5-41 CRANKSHAFT ....................5-42 REMOVING THE CRANKSHAFT ASSEMBLY ........5-43 CHECKING THE CRANKSHAFT ............5-43 INSTALLING THE CRANKSHAFT ............5-44 CHAPTER 6 CARBURETION CARBURETOR....................6-1...
  • Page 13 STARTER MOTOR ..................7-17 CHECKING THE STARTER MOTOR .............7-19 ASSEMBLING THE STARTER MOTOR ..........7-20 CHARGING SYSTEM ..................7-21 CIRCUIT DIAGRAM ................7-21 TROUBLESHOOTING................7-22 INFO LIGHTING SYSTEM ..................7-24 CIRCUIT DIAGRAM ................7-24 TROUBLESHOOTING................7-25 SPEC CHECKING THE LIGHTING SYSTEM ............7-26 SIGNALING SYSTEM..................7-29 CIRCUIT DIAGRAM ................7-29 TROUBLESHOOTING................7-31 CHECKING THE SIGNALING SYSTEM ..........7-32 AUTO CHOKE SYSTEM ................7-39 CIRCUIT DIAGRAM ................7-39...
  • Page 14 OVERHEATING ....................8-3 ENGINE .....................8-3 FUEL SYSTEM ..................8-3 CHASSIS ....................8-3 ELECTRICAL SYSTEMS ................8-3 POOR BRAKING PERFORMANCE..............8-3 UNSTABLE HANDLING..................8-3 FAULTY LIGHTING OR SIGNALING SYSTEM..........8-4 HEADLIGHT DOES NOT LIGHT ...............8-4 HEADLIGHT BULB BURNT OUT ..............8-4 TAIL/BRAKE LIGHT DOES NOT LIGHT ...........8-4 TAIL/BRAKE LIGHT BULB BURNT OUT ..........8-4 TURN SIGNAL DOES NOT LIGHT ............8-4 TURN SIGNAL BLINKS SLOWLY .............8-4 TURN SIGNAL REMAINS LIT ..............8-4...

  • Page 15: General Information

    SCOOTER IDENTIFICATION INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL CODE The model code label 1 is affixed to the loca- tion shown in the figure. Record the informa- tion on this label in the space provided.

  • Page 16: 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 17: Bearings And Oil Seals

    IMPORTANT INFORMATION INFO EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium soap base grease. Oil bearings liberally when installing, if appro- priate.

  • Page 18: Checking The Connections

    IMPORTANT INFORMATION INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 19: Special Tools

    SPECIAL TOOLS INFO EAS00027 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 inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 20 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Sheave holder YU-01701 This tool is used to hold the clutch hous- ing when removing or installing the clutch housing nut. Pocket tester YU-03112 This tool is used to check the electrical system.
  • Page 21 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration ® Quick Gasket ACC-1100-15-01 This sealant is used to seal to mating surfaces (e.g., crankcase mating sur- faces). 1 - 7...

  • Page 22: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5LY1 ---- Dimensions Overall length 1,630 mm (64.1 in) ---- Overall width 630 mm (24.8 in) ---- Overall height 1,030 mm (40.5 in) ---- Seat height 715 mm (28.1 in) ---- Wheelbase 1,150 mm (45.3 in)

  • Page 23: Engine Specifications

    Unleaded fuel ---- Fuel tank capacity Total (including reserve) 6 L (5.3 Imp qt, 6.3 US qt) ---- Engine oil Lubrication system Separate lubrication (Yamaha autolube) ---- Oil type or grade Yamalube 2-cycle oil or ---- 2-stroke engine oil ---- Quantity Capacity 1.4 L (1.23 Imp qt, 1.48 US qt)
  • Page 24 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston Piston-to-cylinder clearance 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in) 0.10 mm (0.0039 in) Diameter D 39.952 ~ 39.969 mm (1.5729 ~ 1.5736 in) ---- Height H 5 mm (0.2 in) ---- Oversize 1st ---- ---- Oversize 2nd...
  • Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Limit Crankshaft Width A 37.90 ~ 37.95 mm (1.492 ~ 1.494 in) ---- Max. runout C ---- 0.03 mm (0.0012 in) Big end side clearance D 0.35 ~ 0.75 mm (0.0138 ~ 0.0295 in) 1.0 mm (0.0394 in) Big end radial clearance E 0.004 ~ 0.017 mm (0.00016 ~ 0.00067 in)
  • Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Limit Carburetor Model (manufacturer) × quantity Y14P/1 (TEIKEI) × 1 ---- Throttle cable free play 1.5 ~ 3.5 mm (0.06 ~ 0.14 in) ---- (at the flange of the throttle grip) ID mark 5LY1 00 ---- Main jet ----...

  • Page 27: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Steel tube underbone ---- Caster angle 25° ---- Trail 71 mm (2.8 in) ---- Front wheel Wheel type Panel wheel ---- 10 × 2.15 Size ---- Material Steel ---- Wheel travel 60 mm (2.36 in) ----...
  • Page 28 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front brake Brake type Drum brake ---- Operation Right-hand operation ---- Brake lever free play (at lever end) 10 ~ 20 mm (0.39 ~ 0.79 in) ---- Dram brake type Leading, trailing ---- Brake drum inside diameter 110 mm (4.33 in) 110.5 mm (4.35 in)
  • Page 29 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Unit swing ---- Rear shock absorber assembly type Coil spring/oil damper ---- Rear shock absorber assembly travel 45 mm (1.77 in) ---- Spring Free length 173.5 mm (6.83 in) 170.0 mm (6.69 in) Installed length 166.5 mm (6.56 in)

  • Page 30: Electrical Specifications

    14° BTDC at 5,000 r/min ---- Advancer type Fixed ---- 248 ~ 372 Ω/W/L–W/R Pickup coil resistance/color ---- CDI unit model (manufacturer) 5BM (YAMAHA) ---- Ignition coil Model (manufacturer) 2JN (YAMAHA) ---- Minimum ignition spark gap 6 mm (0.24 in) ---- 0.18 ~ 0.28 Ω...
  • Page 31 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) 5BM (YAMAHA) ---- Power output 0.14 kW ---- Brush Overall length 6.1 mm (0.24 in) 0.9 mm (0.04 in) Spring force 2.32 ~ 3.48 N ---- (236.5 ~ 355.0 gf, 8.35 ~ 12.53 oz)

  • Page 32: Conversion Table

    CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.

  • Page 33: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m·kgf ft·lb Spark plug Cylinder head Cylinder head Stud bolt Air shroud Screw Air shroud Screw Screw Autolube pump Bolt Air filter Screw...

  • Page 34: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks m·kgf ft·lb Engine mounting: Engine mounting bolt/nut Rear shock absorber and engine Engine bracket and frame Tail reinforcement Rear shock absorber and frame Lower handlebar holder bracket Upper race M45 (BCI) Upper steering stem ring nut...

  • Page 35: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Symbol Oil seal lips O-rings Bearings Piston surface Piston pin Cylinder Transmission case (bearing) Right crankcase (bearing retainer) Autolube pump Starter wheel gear Idle gear plate Secondary drive gear Kickstarter pinion gear Drive axle...

  • Page 36: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS Lubrication Point Symbol Oil seal lips O-rings Bearings Speedometer drive gear Front brake camshaft Front brake cable Throttle cable Tube guide (throttle grip) inner surface Upper steering stem ring nut Upper bearing outer race Lower bearing outer race Rear brake camshaft Centerstand...

  • Page 37: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Front brake cable È Push the brake cable flange in until it contacts 2 Rear brake cable the lever holder. 3 Front turn signal leads É Fasten the handlebar switch leads, brake light 4 Fuel level gauge coupler switch leads, meter light lead, speedometer 5 Flasher relay cable, brake cables and throttle cable with a...
  • Page 38 SPEC CABLE ROUTING 1 Front turn signal leads (left) C Crankcase breather hose 2 Headlight coupler D Ground lead 3 Fuel level gauge coupler E Carburetor overflow hose 4 Flasher relay lead F Rear brake cable 5 Horn lead G Throttle cable 6 Front turn signal leads (right) 7 Front brake cable È...
  • Page 39 SPEC CABLE ROUTING Ê Pass the front brake cable and speedometer Î Install the fuel tank so that the paint mark on the cable through the cable guide. fuel hose is facing up. Ë Pass the front brake cable and speedometer Ï...
  • Page 40 SPEC CABLE ROUTING 1 Tail/brake light coupler B Flasher relay lead 2 Oil level switch lead C Ignition coil lead 3 Battery leads D Spark plug lead 4 Battery E Oil hose 5 Starter motor coupler F Rear turn signal leads 6 AC magneto coupler G Wire harness 7 Auto choke coupler...
  • Page 41 SPEC CABLE ROUTING È Fasten the wire harness with a plastic locking Í Pass one end of a plastic clip through the hole of tie. the fuel tank flange, and then fasten the tail/ É Fasten the wire harness, throttle cable and rear brake light lead and rear turn signal light leads brake cable with plastic locking tie.
  • Page 42 SPEC CABLE ROUTING 1 Ignition coil lead A CDI unit 2 Ignition coil B Vacuum hose 3 Battery C Rectifier/regulator 4 Starter relay D Fuel hose 5 Oil hose E Auto choke lead 6 Oil level switch lead F Oil delivery hose 7 AC magneto lead G Throttle cable 8 Fuel sender lead...
  • Page 43 SPEC CABLE ROUTING È Fasten the wire harness at the white tape Ì Fasten the auto choke lead with a plastic clip. Í After connecting the AC magneto coupler and marker with a plastic locking tie. É Pass the spark plug lead through the bottom starter motor coupler, cover the couplers with cowling guide.

  • Page 44: Periodic Checks And Adjustments

    • Check operation. √ √ √ 15 * Centerstand • Repair if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice. ** Lithium soap base grease 3 - 1...
  • Page 45 PERIODIC MAINTENANCE AND LUBRICATION EAU00479 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. EAU03903 NOTE: From 6,000 mi (9,000 km) or 18 months, repeat the maintenance intervals starting from 2,000 mi (3,000 km) or 6 months.

  • Page 46: Side Covers And Footrest Board

    SIDE COVERS AND FOOTREST BOARD EAS00038 SIDE COVERS AND FOOTREST BOARD 15 Nm (1.5 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft •...
  • Page 47 SIDE COVERS AND FOOTREST BOARD 15 Nm (1.5 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • •...

  • Page 48: Front Panel And Leg Shield

    FRONT PANEL AND LEG SHIELD EAS00040 FRONT PANEL AND LEG SHIELD Order Job/Part Q’ty Remarks Removing the front panel and leg Remove the parts in the order listed. shield Footrest board Refer to “SIDE COVERS AND FOOT- REST BOARD”. Headlight cover Headlight coupler Disconnect.
  • Page 49 FRONT PANEL AND LEG SHIELD Order Job/Part Q’ty Remarks Fuel level gauge Main switch cover Leg shield For installation, reverse the removal procedure. 3 - 6...

  • Page 50: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00053 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor should be adjusted properly, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for sev- eral minutes.

  • Page 51: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 6. Adjust: • throttle cable free play a Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.5 mm (0.06 ~ 0.14 in) EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY...

  • Page 52: Bleeding The Autolube Pump

    BLEEDING THE AUTOLUBE PUMP BLEEDING THE AUTOLUBE PUMP NOTE: The Autolube pump and delivery lines must be bled on the following occasions. • Setting up a new scooter out of the crate. • Whenever the oil tank has run dry. •...

  • Page 53: Checking The Spark Plug

    BLEEDING THE AUTOLUBE PUMP/ CHECKING THE SPARK PLUG NOTE: • Check the bleed screw gasket, and if dam- aged, replace with a new one. • Place a oil pan under the autolube pump to catch oil. ▲ ▲▲▲ ▲ ▲▲▲ ▲...

  • Page 54: Measuring The Compression Pressure

    CHECKING THE SPARK PLUG/ MEASURING THE COMPRESSION PRESSURE 4. Check: • electrodes 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6.
  • Page 55 MEASURING THE COMPRESSION PRESSURE CAUTION: Before removing the spark plug, use com- pressed air to blow away any dirt accumu- lated in the spark plug well to prevent it from falling into the cylinder. 5. Install: • compression gauge 1 Compression gauge YU-33223 6.

  • Page 56: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL d. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than with-...

  • Page 57: Replacing The Transmission Oil

    CHECKING THE ENGINE OIL LEVEL/ REPLACING THE TRANSMISSION OIL 3. Remove: • oil tank cover Refer to “SIDE COVERS AND FOOTREST- BOARD”. • oil tank cap 1 4. Fill: • engine oil Make sure the engine oil is at the specified level.
  • Page 58 REPLACING THE TRANSMISSION OIL 5. Remove: • transmission oil drain bolt 1 • gasket 6. Drain: • transmission oil (completely from the transmission case) 7. Check: • O-ring Damage → Replace. 8. Install: • gasket 1 • transmission oil drain bolt 2 18 Nm (1.8 m ·...

  • Page 59: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT EAS00089 CLEANING THE AIR FILTER ELEMENT NOTE: On the bottom of the air filter case is a check hose 1. If dust or water or both collects in this hose, clean the air filter element and air filter case.

  • Page 60: Checking The Carburetor Joint

    CLEANING THE AIR FILTER ELEMENT/ CHECKING THE CARBURETOR JOINT/ CHECKING THE FUEL AND VACUUM HOSES 6. Install: • air filter element • air filter case cover CAUTION: Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.

  • Page 61: Checking The Crankcase Breather Hose

    CHECKING THE FUEL AND VACUUM HOSES/ CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 2. Check: • vacuum hose 1 • fuel hoses 2 Cracks/damage → Replace. Loose connection → Connect properly. 3. Install: • side cover (left) Refer to “SIDE COVERS AND FOOTREST BOARD”.

  • Page 62: Chassis

    ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EAS00109 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: • brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 10 ~ 20 mm (0.39 ~ 0.79 in) 2.

  • Page 63: Checking The Brake Shoes

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE SHOES/ CHECKING AND ADJUSTING THE STEERING HEAD 2. Adjust: • brake lever free play ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained.

  • Page 64: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Check: • steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness →...

  • Page 65: Checking The Front Shock Absorber

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT SHOCK ABSORBER/ CHECKING THE TIRES 5. Install: • Steering shaft bolt 5 42 Nm (4.2 m · kg, 30 ft · lb) 6. Install: • leg shield Refer to “FRONT PANEL AND LEG SHIELD”. •...

  • Page 66: Checking The Tires

    CHECKING THE TIRES WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider and acces- sories) and the anticipated riding speed.
  • Page 67 Tube or tubeless Tubeless wheel tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.

  • Page 68: Checking The Wheels

    CHECKING THE TIRES/CHECKING THE WHEELS Rear tire Manufacturer Model Size 80/90-10 INOUE MB38 (34J) 80/90-10 CHENG SHIN C-922 (34J) WARNING New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.

  • Page 69: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS/LUBRICATING THE CENTERSTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its movement.

  • Page 70: Electrical System

    CHECKING AND CHARGING THE BATTERY EAS00179 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 71 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 72 CHECKING AND CHARGING THE BATTERY b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% ▲...
  • Page 73 CHECKING AND CHARGING THE BATTERY • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery sta- bilizes about 30 minutes after charging has been completed.
  • Page 74 CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger 3 - 31...
  • Page 75 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger 3 - 32...
  • Page 76 CHECKING AND CHARGING THE BATTERY 6. Install: • battery 7. Connect: • battery lead coupler (to the battery terminals) 8. Check: • battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • battery terminal Recommended lubricant Dielectric grease 10.Install:...

  • Page 77: Checking The Fuse

    CHECKING THE FUSE EAS00181 CHECKING THE FUSE CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: • center cover Refer to “SIDE COVERS AND FOOTREST BOARD”. • battery Refer to “ENGINE REMOVAL”...
  • Page 78 CHECKING THE FUSE/REPLACING THE HEADLIGHT WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

  • Page 79: Replacing The Headlight Bulb

    REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 6. Install: • headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
  • Page 80 ADJUSTING THE HEADLIGHT BEAM 2. Adjust: • headlight beam (horizontally) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting knob 2 in direction a or Headlight beam moves Direction a to the right.

  • Page 81: Chassis

    CHAS FRONT WHEEL AND BRAKE EAS00517 CHASSIS FRONT WHEEL AND BRAKE 48 Nm (4.8 m kg, 35 ft • • Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
  • Page 82 CHAS FRONT WHEEL AND BRAKE 48 Nm (4.8 m kg, 35 ft • • Order Job/Part Q’ty Remarks Front brake shoe plate Spacer For installation, reverse the removal procedure. 4 - 2...
  • Page 83 CHAS FRONT WHEEL AND BRAKE Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal Wheel bearing (right) Refer to “CHECKING THE FRONT Spacer WHEEL”. Collar Wheel bearing (left) Dust seal For assembly, reverse the disassembly procedure.
  • Page 84 CHAS FRONT WHEEL AND BRAKE 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake shoe Remove the parts in the order listed. plate Brake shoe Brake shoe spring (pin side) Brake shoe spring (brake camshaft side) Bushing Speedometer drive gear...

  • Page 85: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE EAS00525 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent wheel axle. 2. Check: • tire •...

  • Page 86: Checking The Speedometer Gear Unit

    CHAS FRONT WHEEL AND BRAKE 5. Replace: • oil seal • wheel bearings ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the outside of the front wheel hub. b.

  • Page 87: Checking The Brake

    CHAS FRONT WHEEL AND BRAKE EAS00536 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: • brake shoe lining Glazed areas → Repair. Sand the glazed areas with course sandpa- per. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth.

  • Page 88: Assembling The Brake Shoe Plate

    CHAS FRONT WHEEL AND BRAKE EAS00537 ASSEMBLING THE BRAKE SHOE PLATE 1. Install: • brake camshaft 1 • spring • brake shoe wear indicator 2 • brake camshaft lever 3 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
  • Page 89 CHAS FRONT WHEEL AND BRAKE 5. Tighten: • wheel axle nut 48 Nm (4.8 m · kg, 35 ft · lb) WARNING Make sure the brake cable is routed prop- erly. CAUTION: Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly.

  • Page 90: Rear Wheel And Brake

    CHAS REAR WHEEL AND BRAKE EAS00551 REAR WHEEL AND BRAKE 13 Nm (1.3 m kg, 9.4 ft • • 28 Nm (2.8 m kg, 20 ft • • 105 Nm (10.5 m kg, 75 ft • • Order Job/Part Q’ty Remarks Removing the rear wheel and brake Remove the parts in the order listed.
  • Page 91 CHAS REAR WHEEL AND BRAKE 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the rear brake shoe plate Remove the parts in the order listed. Adjusting nut Rear brake cable Brake shoe Brake shoe spring (pin side) Brake shoe spring (brake camshaft side) Brake camshaft lever...

  • Page 92: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE EAS00565 CHECKING THE REAR WHEEL 1. Check: • rear wheel Refer “CHECKING FRONT WHEEL”. 2. Check: • tire • rear wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3.

  • Page 93: Installing The Brake Shoe Plate

    CHAS REAR WHEEL AND BRAKE 3. Measure: • brake drum inside diameter a Out of specification → Replace the wheel. Brake drum inside diameter limit (maximum) 110.5 mm (4.35 in) 4. Check: • brake drum inner surface Oil deposits → Clean. Remove the oil with a rag soaked in lacquer thinner or solvent.

  • Page 94: Installing The Brake Shoes

    CHAS REAR WHEEL AND BRAKE EAS00573 INSTALLING THE BRAKE SHOES 1. Install: • brake camshaft lever 1 NOTE: • Align the punch mark a in the brake cam- shaft with the mark b on the brake camshaft lever. • Lubricate the brake camshaft and pin with lithium soap base grease.

  • Page 95: Front Shock Absorber Assemblies

    CHAS FRONT SHOCK ABSORBER ASSEMBLIES EAS00647 FRONT SHOCK ABSORBER ASSEMBLIES Order Job/Part Q’ty Remarks Removing the front shock absorber Remove the parts in the order listed. assemblies The following procedure applies to both of the front shock absorbers. Front panel Refer to “FRONT PANEL AND LEG SHIELD”...

  • Page 96: Checking The Front Shock Absorber Assemblies

    CHAS FRONT SHOCK ABSORBER ASSEMBLIES CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both front shock absorber assemblies. 1. Check: • front shock absorber rod Bends/damage → Replace the front shock absorber assembly. • front shock absorber Oil leaks →...

  • Page 97: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR Order Job/Part Q’ty Remarks Removing the handlebar switches Remove the parts in the order listed. and handlebar grips Center cover Refer to “SIDE COVERS AND FOOT- REST BOARD” in chapter 3. Rear view mirror (left/right) Front brake cable Rear brake cable Throttle cable holder Loosen.
  • Page 98 CHAS HANDLEBAR Order Job/Part Q’ty Remarks Left handlebar switch Refer to “INSTALLING THE HANDLE- Upper handlebar holder BAR”. Handlebar Handlebar grip Refer to “REMOVING THE HANDLE- BAR”. For installation, reverse the removal procedure. 4 - 18...

  • Page 99: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: • handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

  • Page 100: Installing The Handlebar

    CHAS HANDLEBAR EAS00671 INSTALLING THE HANDLEBAR 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Install: • handlebar 1 • upper handlebar holders 2 10 Nm (1.0 m · kg, 7.2 ft · lb) CAUTION: •...
  • Page 101 CHAS HANDLEBAR 4. Install: • throttle grip • throttle cable NOTE: Lubricate the inside of the throttle grip with a thin coat of lithium soap base grease and install it onto the handlebar. 5. Install: • right handlebar switch 1 WARNING Make sure the throttle grip operates smoothly.

  • Page 102: Steering Head

    CHAS STEERING HEAD STEERING HEAD Order Job/Part Q’ty Remarks Removing the lower handlebar Remove the parts in the order listed. holder Footrest board Refer to “SIDE COVERS AND FOOT- REST BOARD” in chapter 3. Front panel/leg shield Refer to “FRONT PANEL AND LEG SHIELD”...
  • Page 103 CHAS STEERING HEAD Order Job/Part Q’ty Remarks Removing the fork Remove the parts in the order listed. Cover Upper steering stem ring nut Upper race Fork Upper bearing Lower bearing Upper bearing outer race Lower bearing outer race For installation, reverse the removal procedure.

  • Page 104: Removing The Fork

    CHAS STEERING HEAD EAS00680 REMOVING THE FORK 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: • upper steering stem ring nut 1 • upper race 2 NOTE: Hold the upper race with the steering nut wrench (45 mm), and then remove the upper...

  • Page 105: Installing The Steering Head

    CHAS STEERING HEAD 3. Replace: • bearings • bearing races ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b.

  • Page 106: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 30 Nm (3.0 m kg, 22 ft • • 15 Nm (1.5 m kg, 11 ft • • Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Side cover (left) Refer to “SIDE COVERS AND FOOT-...

  • Page 107: Removing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00692 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.

  • Page 108: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL 84 Nm (8.4 m kg, 61 ft • • 28 Nm (2.8 m kg, 20 ft • • 15 Nm (1.5 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft • •...
  • Page 109 ENGINE REMOVAL 84 Nm (8.4 m kg, 61 ft • • 28 Nm (2.8 m kg, 20 ft • • 15 Nm (1.5 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 11 Nm (1.1 m kg, 8.0 ft •...

  • Page 110: Installing The Engine

    ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: • engine mounting bolt/nut 1 84 Nm (8.4 m · kg, 61 ft · lb) • bolt (rear shock absorber-lower) 2 15 Nm (1.5 m · kg, 11 ft · lb) 2. Install: •...

  • Page 111: Cylinder Head, Cylinder And Piston

    CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD, CYLINDER AND PISTON 28 Nm (2.8 m kg, 20 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 12 11 20 Nm (2.0 m kg, 14 ft • • 14 Nm (1.4 m kg, 10 ft •...
  • Page 112 CYLINDER HEAD, CYLINDER AND PISTON 28 Nm (2.8 m kg, 20 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 12 11 20 Nm (2.0 m kg, 14 ft • • 14 Nm (1.4 m kg, 10 ft •...

  • Page 113: Removing The Cylinder And Piston

    CYLINDER HEAD, CYLINDER AND PISTON EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin clip 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out. NOTE: Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crank- case.

  • Page 114: Checking The Cylinder And Piston

    CYLINDER HEAD, CYLINDER AND PISTON ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c.

  • Page 115: Checking The Piston Rings

    CYLINDER HEAD, CYLINDER AND PISTON b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter “P” with the micrometer. a 5 mm (0.20 in) from the bottom edge of the pis- Piston size “P”...

  • Page 116: Checking The Piston Pin

    CYLINDER HEAD, CYLINDER AND PISTON Piston ring side clearance Top ring 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in) <Limit>: 0.10 mm (0.0039 in) 2nd ring 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in) <Limit>: 0.10 mm (0.0039 in) 2. Install: •...
  • Page 117 CYLINDER HEAD, CYLINDER AND PISTON 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in) <Limit>: 9.976 mm (0.3928 in) 3. Measure: •...

  • Page 118: Installing The Piston And Cylinder

    CYLINDER HEAD, CYLINDER AND PISTON EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: • top ring 1 • 2nd ring 2 NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers face up. • Before installing the cylinder, align the piston ring end gaps to the respective knock pins as shown.
  • Page 119 CYLINDER HEAD, CYLINDER AND PISTON 3. Install: • cylinder gasket 1 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) Recommended lubricant Yamalube 2-cycle oil or 2-stroke engine oil 5. Install: • cylinder 2 NOTE: While compressing the piston rings with one hand, install the cylinder with the other hand.

  • Page 120: Kickstarter

    KICKSTARTER EAS00338 KICKSTARTER SHEAVES COVER 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Part Q’ty Remarks Removing the sheave cover Remove the parts in the order listed. Air filter case assembly Refer to “CARBURETOR” in chapter 6. Transmission oil Drain.
  • Page 121 KICKSTARTER Order Job/Part Q’ty Remarks Disassembling the kickstarter shaft Remove the parts in the order listed. Kickstarter pinion gear Kickstarter pinion gear clip Circlip Washer Kickstarter shaft Kickstarter spring Spacer For assembly, reverse the disassembly procedure. 5 - 14...

  • Page 122: Checking The Kickstarter

    KICKSTARTER EAS00339 CHECKING THE KICKSTARTER 1. Check: • kickstarter shaft • kickstarter pinion gear Damage/wear → Replace. 2. Check: • kickstarter spring Damage/wear → Replace. 3. Measure: • kickstarter pinion gear clip force (with the spring gauge) Out of specification → Replace the kick- starter pinion gear clip.

  • Page 123: Belt Drive

    BELT DRIVE EAS00316 BELT DRIVE 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the V-belt, primary and Remove the parts in the order listed. secondary pulley Sheaves cover Refer to “KICK STARTER”.
  • Page 124 BELT DRIVE 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Collar Primary sliding sheave Slider Primary pulley weight Gasket For installation, reverse the removal procedure. 5 - 17...
  • Page 125 BELT DRIVE 50 Nm (5.0 m kg, 36 ft • • Order Job/Part Q’ty Remarks Disassembling the secondary pulley Remove the parts in the order listed. Clutch carrier nut Clutch carrier Clutch spring Spring Spring seat Secondary sliding sheave O-ring Oil seal Secondary fixed sheave For assembly, reverse the disassembly...

  • Page 126: Removing The Secondary Pulley And V-Belt

    BELT DRIVE EAS00318 REMOVING THE SECONDARY PULLEY AND V-BELT 1. Remove: • air shroud • fan Refer to “GENERATOR AND AUTOLUBE PUMP”. 2. Remove: • clutch housing nut 1 • clutch housing 2 NOTE: While holding the clutch housing with the sheave holder 3, loosen the clutch housing nut.

  • Page 127: Removing The Primary Sheave

    BELT DRIVE EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: • primary sheave nut 1 • conical spring washer • kickstarter one-way clutch • claw washer • primary fixed sheave 2 NOTE: While holding the generator rotor with the rotor holding tool 3, loosen the primary sheave nut. Rotor holding tool YU-01235 EAS00319...

  • Page 128: Checking The Secondary Pulley

    BELT DRIVE 2. Measure: • clutch shoe thickness Out of specification → Replace the clutch shoes as a set. Clutch shoe thickness 4.0 mm (0.157 in) <Limit>: 1.0 mm (0.039 in) 3. Check: • clutch housing inside diameter a Out of specification → Replace the clutch housing.

  • Page 129: Checking The V-Belt

    BELT DRIVE EAS00320 CHECKING THE V-BELT 1. Check: • V-belt 1 Cracks/damage/wear → Replace. Grease/oil → Check the primary and sec- ondary pulleys. 2. Measure: • V-belt width a Out of specification → Replace. V-belt width 16.6 mm (0.65 in) <Limit>: 15.0 mm (0.59 in) EAS00321 CHECKING THE PRIMARY PULLEY...

  • Page 130: Assembling The Secondary Pulley

    BELT DRIVE EAS00324 ASSEMBLING THE SECONDARY PULLEY 1. Lubricate: • secondary fixed sheave’s inner surface 1 • secondary sliding sheave’s inner surface 2 • oil seals (with the recommended lubricant) Recommended lubricant Lithium soap base grease 2. Install: • secondary sliding sheave 1 NOTE: Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal...

  • Page 131: Installing The Primary Pulley

    BELT DRIVE 5. Install: • secondary fixed sheave 1 • secondary sliding sheave 2 • spring • clutch carrier 3 NOTE: Attach the clutch spring holder 4 onto the sec- ondary pulley as shown. Then, compress the spring, and tighten the clutch carrier nut 5. Clutch spring holder YS-28891 EAS00323...

  • Page 132: Installing The Belt Drive

    BELT DRIVE 4. Install: • washer 7 • primary fixed sheave 8 • claw washer 9 • kickstarter one-way clutch 0 • conical spring washer A • primary sheave nut B 30 Nm (3.0 m · kg, 22 ft · lb) NOTE: •...
  • Page 133 BELT DRIVE 2. Install: • V-belt 1 • secondary pulley 2 CAUTION: Do not allow grease to contact the V-belt, secondary pulley or clutch assembly. NOTE: • The V-belt must be installed, with the arrow 3 forward. • Install the V-belt on the primary pulley, then install the secondary pulley 2 along with the V-belt 1.

  • Page 134: Starter Clutch And Starter Motor

    STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND STARTER MOTOR 13 Nm (1.3 m kg, 9.4 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks Removing the starter clutch and Remove the parts in the order listed. starter motor Sheaves cover Refer to “KICKSTARTER”.

  • Page 135: Checking The Starter Clutch

    STARTER CLUTCH AND STARTER MOTOR EAS00351 CHECKING THE STARTER CLUTCH 1. Check: • starter clutch rollers 1 • starter clutch spring caps 2 • starter clutch springs 3 Damage/wear → Replace. 2. Check: • starter wheel gear 1 Burrs/chips/roughness/wear → Replace the defective part(s).
  • Page 136 STARTER CLUTCH AND STARTER MOTOR 2. Install: • starter wheel gear 1 • starter clutch assembly 2 NOTE: Install the starter clutch assembly 1 while turning the starter wheel gear 2 clockwise. 5 - 29...

  • Page 137: Transmission

    TRANSMISSION EAS00419 TRANSMISSION 9 Nm (0.9 m kg, 6.5 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Transmission oil Drain. Rear wheel Refer to “REAR WHEEL AND BRAKE”...
  • Page 138 TRANSMISSION 9 Nm (0.9 m kg, 6.5 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Part Q’ty Remarks Circlip Bearing Oil seal For installation, reverse the removal procedure. 5 - 31...

  • Page 139: Checking The Transmission

    TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Check: • drive axle • main axle • secondary drive gear Damage/wear → Replace. 2. Check: • bearing Rough movement → Replace. 3. Check: • secondary drive gear movement Rough movement → Replace the defective part.

  • Page 140: Generator And Autolube Pump

    GENERATOR AND AUTOLUBE PUMP GENERATOR AND AUTOLUBE PUMP STATOR COIL ASSEMBLY 38 Nm (3.8 m kg, 27 ft • • Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Center cover, side cover (right) and Refer to “SIDE COVERS AND FOOT- footrest board REST BOARD”...

  • Page 141: Autolube Pump

    GENERATOR AND AUTOLUBE PUMP AUTOLUBE PUMP 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Removing the autolube pump Remove the parts in the order listed. Stator coil assembly Refer to “GENERATOR AND AUTOL- UBE PUMP”. Spark plug cap Cylinder head cover Circlip...

  • Page 142: Removing The Generator

    GENERATOR AND AUTOLUBE PUMP EAS00346 REMOVING THE GENERATOR 1. Remove: • generator rotor nut 1 • washer NOTE: While holding the generator rotor 2 with the rotor holding tool 3, loosen the generator rotor nut. Rotor holding tool YU-01235 2. Remove: •...

  • Page 143: Installing The Generator

    GENERATOR AND AUTOLUBE PUMP EAS00354 INSTALLING THE GENERATOR 1. Install: • gasket 1 • woodruff key • generator rotor 2 • washer • generator rotor nut NOTE: • Clean the tapered portion of the crankshaft and the generator rotor hub. •...

  • Page 144: Crankcase

    CRANKCASE CRANKCASE 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Rear wheel assembly Refer to “REAR WHEEL AND BRAKE”...
  • Page 145 CRANKCASE 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Part Q’ty Remarks Cover Intake manifold Reed valve assembly Valve seat gasket Bearing retainer Right crankcase Refer...

  • Page 146: Disassembling The Crankcase

    CRANKCASE EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: • crankcase screws 1 NOTE: Loosen each screw 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the screws are fully loosened, remove them. 2. Remove: •...

  • Page 147: Checking The Bearings And Oil Seals

    CRANKCASE EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: • bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace. 2. Check: • oil seals Damage/wear → Replace. CHECKING THE REED VALVE 1.

  • Page 148: Assembling The Crankcase

    CRANKCASE EAS00416 ASSEMBLING THE CRANKCASE 1. Apply: • sealant (onto the crankcase mating surfaces) ® Quick Gasket ACC-1100-15-01 NOTE: Do not allow any sealant to come into contact with the oil gallery. 2. Install: • dowel pins 1 3. Install: •...

  • Page 149: Crankshaft

    CRANKSHAFT EAS00381 CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Crankcase Separate. Refer to “CRANKCASE”. Crankshaft Bearing Oil seal Crankcase 1 For installation, reverse the removal procedure. 5 - 42...

  • Page 150: Removing The Crankshaft Assembly

    CRANKSHAFT EAS00388 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • crankshaft assembly 1 NOTE: • Remove the crankshaft assembly with the crankcase separating tool 2. • Make sure the crankcase separating tool is centered over the crankshaft assembly. Crankcase separating tool YU-01135 EAS00394 CHECKING THE CRANKSHAFT...

  • Page 151: Installing The Crankshaft

    CRANKSHAFT 4. Check: • bearing Cracks/damage/wear → Replace. EAS00408 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft installing tool Crankshaft installer pot 1 YU-90058 Crankshaft installer bolt 2 YU-90060 Crankshaft installer adapter (M10) 3 YU-90062 2. Install: • crankshaft assembly 4 (to the left crankcase 5) CAUTION: To avoid scratching the crankshaft and to...

  • Page 152: Carburetion

    CARB CARBURETOR CARBURETION CARBURETOR Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Center cover, side cover (left) and foot- Refer to “SIDE COVERS AND FOOT- rest board REST BOARD” in chapter 3. Air filter case assembly Clip Auto choke coupler Disconnect.
  • Page 153 CARB CARBURETOR Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot air screw is turned out from the seated position to its set position. Throttle cables Throttle valve Jet needle kit...
  • Page 154 CARB CARBURETOR Order Job/Part Q’ty Remarks O-ring Float pivot pin Float Needle valve Main jet Needle jet Pilot jet Carburetor body For assembly, reverse the disassembly procedure. 6 - 3...

  • Page 155: Checking The Carburetor

    CARB CARBURETOR EAS00485 CHECKING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot air screw is turned out from the seated position to its set position. 1. Check: • carburetor body • float chamber •...

  • Page 156: Assembling The Carburetor

    CARB CARBURETOR 7. Check: • throttle valve 1 Damage/scratches/wear→ Replace. 8. Check: • jet needle kit 1 • needle jet 2 • main jet 3 • pilot jet 4 Bends/damage/wear → Replace. Obstruction → Clean. Blow out the jets with compressed air. 9.

  • Page 157: Installing The Carburetor

    CARB CARBURETOR 2. Install: • needle valve 1 • float 2 • float pivot pin 3 • screw 4 3. Install: • float chamber 1 4. Install: • starter plunger kit 5. Install: • throttle valve • jet needle holder •...

  • Page 158: Measuring And Adjusting The Float Height

    CARB CARBURETOR EAS00499 MEASURING AND ADJUSTING THE FLOAT HEIGHT 1. Measure: • float height a Out of specification → Replace the needle valve. Float height 15 ~ 17 mm (0.59 ~ 0.67 in) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 159: Checking The Fuel Cock Operation

    CARB CARBURETOR Starter plunger Perform step (3). opens. Starter plunger Replace the auto- closes. choke assembly. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • autochoke assembly ▼ ▼▼▼...

  • Page 160: Electrical

    – ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 8 Battery 2 Starter relay 9 Spark plug cap 3 Fuel sender 0 Ignition coil 4 Oil level switch A Wire harness 5 CDI unit B Turn signal relay 6 Rectifier/regulator C Horn 7 Main fuse...

  • Page 161: Switches

    – ELEC SWITCHES EAS00730 SWITCHES “∞” “0” 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- “Ω×1” essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.

  • Page 162: Checking The Switches

    – ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 163 – ELEC CHECKING THE SWITCHES 1 Front brake light switch 2 Turn signal switch 3 Dimmer switch 4 Horn switch 5 Main switch 6 Rear brake light switch 7 Start switch 8 Engine stop switch 9 Main fuse 7 - 4...

  • Page 164: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.

  • Page 165: Checking The Condition Of The Bulbs

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 166: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester YU-03112 NOTE:...

  • Page 167: Ignition System

    – ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM 7 - 8...

  • Page 168: Troubleshooting

    – ELEC IGNITION SYSTEM EAS00736 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no • Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) 2.
  • Page 169 – ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance • Disconnect the spark plug cap from the • Remove the spark plug cap from the spark spark plug. plug lead. • Connect the pocket tester (“Ω × 1k” range) •...
  • Page 170 – ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Pickup coil resistance • Disconnect the ignition coil connectors • Disconnect the stator coil assembly cou- from the ignition coil terminals. pler from the wire harness. • Connect the pocket tester (Ω × 1) to the •...
  • Page 171 – ELEC IGNITION SYSTEM EAS00750 9. Engine stop switch • Check the engine stop switch for continu- ity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? Replace right handlebar switch. EAS00754 10.Wiring • Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”.

  • Page 172: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7 - 13...

  • Page 173: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) 3.
  • Page 174 – ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 4. Starter relay 6. Engine stop switch • Remove the starter relay from the wire • Check the engine stop switch for continu- harness. ity. • Connect the pocket tester (Ω × 1) and bat- Refer to “CHECKING THE SWITCHES”.
  • Page 175 – ELEC ELECTRIC STARTING SYSTEM 9. Rear brake light switch • Check the rear light switch for continuity. Refer to “CHECKING THE SWITCHES” • Is the rear brake light switch OK? Replace rear brake light switch. EAS00766 10.Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”.
  • Page 176 – ELEC STARTER MOTOR EAS00767 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Air shroud Refer to “CYLINDER HEAD, CYLINDER AND PISTON” in chapter 5. Starter motor coupler Starter motor assembly For installation, reverse the removal procedure.
  • Page 177 – ELEC STARTER MOTOR EAS00768 Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. O-ring Starter motor yoke Armature assembly Gasket Brush holder Starter motor cover For assembly, reverse the disassembly procedure. 7 - 18...

  • Page 178: Checking The Starter Motor

    – ELEC STARTER MOTOR EAS00769 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 14.8 mm (0.58 in) 3.

  • Page 179: Assembling The Starter Motor

    – ELEC STARTER MOTOR Armature coil Commutator resistance 1 0.065 ~ 0.079 Ω at 20 °C (68 °F) Insulation resistance 2 Above 1 MΩ at 20 °C (68 °F) b. If any resistance is out of specification, replace the starter motor. ▲...

  • Page 180: Charging System

    – ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM W/L B B W/L L/Y O L/W Br (BLACK) W/L W/L L/W R (BLACK) (BLACK) L/Y L/W (BLACK) Gy/B Br/W Br/W Gy/B Gy/B Br/W Br/W Br/W Br/W (RED) (RED) Br/W Br/W B Dg 2 Battery 3 Main fuse...

  • Page 181: Troubleshooting

    – ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 12.8 V or more at 20°C (68°F) 3.
  • Page 182 – ELEC CHARGING SYSTEM NOTE: Make sure the battery is fully charged. • Is the charging voltage within specifica- tion? The charging circuit is OK. EAS00779 4. Wiring • Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. •...

  • Page 183: Lighting System

    – ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 7 - 24...

  • Page 184: Troubleshooting

    – ELEC LIGHTING SYSTEM EAS00782 EAS00739 TROUBLESHOOTING 2. Battery Any of the following fail to light: Head- • Check the condition of the battery. light, high beam indicator light, taillight, Refer to “CHECKING AND CHARGING auxiliary light, and meter light. THE BATTERY”...

  • Page 185: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EAS00787 5. Wiring 2. Voltage • Check the entire lighting system’s wiring. • Connect the pocket tester (DC 20 V) to the Refer to “CIRCUIT DIAGRAM”. headlight and high beam indicator light • Is the lighting system’s wiring properly couplers as shown.
  • Page 186 – ELEC LIGHTING SYSTEM EAS00776 2. Voltage 4. Source coil resistance • Connect the pocket tester (20 V) to the • Disconnect the stator coil assembly cou- meter light coupler (wire harness side) as pler from the wire harness. • Connect the pocket tester (Ω × 1) to the shown.
  • Page 187 – ELEC LIGHTING SYSTEM 2. Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Positive tester probe → blue 1 Negative tester probe → black 2 • Set the main switch to “ON”. •...

  • Page 188: Signaling System

    – ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 7 - 29...
  • Page 189 – ELEC SIGNALING SYSTEM 1 Main switch 2 Battery 3 Main fuse E Rear brake light switch F Front brake light switch G Tail/brake light H Oil level gauge I Diode J Turn signal relay K Horn M Horn switch O Turn signal switch P Rear turn signal light Q Front turn signal light...

  • Page 190: Troubleshooting

    – ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: • Check the condition of the battery. Flasher light, brake light or an indicator Refer to “CHECKING AND CHARGING light. THE BATTERY” in chapter 3. •...

  • Page 191: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the pink connector at the horn terminal. 1. Horn switch • Connect a jumper lead 1 to the horn ter- • Check the horn switch for continuity. minal and ground the jumper lead.
  • Page 192 – ELEC SIGNALING SYSTEM 4. Voltage 2. Brake light switches • Connect the pocket tester (DC 20 V) to the • Check the brake light switches for continu- horn connector at the pink terminal as ity. shown. Refer to “CHECKING THE SWITCHES”. •...
  • Page 193 – ELEC SIGNALING SYSTEM EAS00799 3. Voltage 3. The turn signal light, turn signal indicator light or both fail to blink. • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness 1. Turn signal indicator light bulb and socket side) as shown.
  • Page 194 – ELEC SIGNALING SYSTEM 4. Voltage 5. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness turn signal light connector (wire harness side) as shown.
  • Page 195 – ELEC SIGNALING SYSTEM EAS00802 3. Diode 5. The oil level warning light fails to come on. • Remove the diode from the wire harness. 1. Oil level warning light bulb and socket • Connect the pocket tester (Ω × 1) to the •...
  • Page 196 – ELEC SIGNALING SYSTEM EAS00804 4. Voltage 2. Fuel sender • Connect the pocket tester (DC 20 V) to the • Remove the fuel sender from the fuel tank. meter assembly coupler (wire harness • Connect the pocket tester to the fuel side) as shown.
  • Page 197 – ELEC SIGNALING SYSTEM 3. Fuel level gauge 4. Voltage • Set the main switch to “ON”. • Connect the pocket tester (DC 20 V) to the • Move the float up 1 or down 2. fuel level gauge coupler (wire harness •...

  • Page 198: Auto Choke System

    – ELEC AUTO CHOKE SYSTEM AUTO CHOKE SYSTEM CIRCUIT DIAGRAM W/L B B W/L L/Y O L/W Br (BLACK) W/L W/L (BLACK) (BLACK) LACK) Gy/B 0 AC magneto A Auto choke Br/W 7 - 39...
  • Page 199 – ELEC AUTO CHOKE SYSTEM TROUBLESHOOTING 2. Source coil resistance The auto choke fails to operate • Disconnect the stator coil assembly cou- pler from wire harness. Check: • Connect the pocket tester (Ω × 1) to the 1. auto choke resistance source coil lead.
  • Page 200 – ELEC AUTO CHOKE SYSTEM 3. Voltage • Connect the pocket tester (AC 20 V) to the auto choke lead. Tester positive probe → yellow/red 1 Tester negative probe → black 2 • Set the main switch to “ON”. • Start the engine and accelerate to about 3,000 r/min •...

  • Page 201: Troubleshooting

    TRBL STARTING FAILURE/HARD STARTING SHTG EAS00845 TROUBLESHOOTING 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 man- ual for checks, adjustments, and replacement of parts.

  • Page 202: Incorrect Engine Idling Speed

    INCORRECT ENGINE IDLING SPEED/POOR MEDIUM- TRBL AND-HIGH-SPEED PERFORMANCE/FAULTY CLUTCH SHTG EAS00847 INCORRECT ENGINE IDLING SPEED ENGINE ELECTRICAL SYSTEMS Air filter Battery • Clogged air filter element • Discharged battery FUEL SYSTEM • Faulty battery Carburetor Spark plug • Faulty starter plunger •...

  • Page 203: Poor Braking Performance

    OVERHEATING/POOR BRAKING PERFORMANCE/ TRBL UNSTABLE HANDLING SHTG EAS00854 OVERHEATING ENGINE Cylinder head and piston Air filter • Heavy carbon buildup • Clogged air filter element Engine oil and transmission oil CHASSIS • Incorrect oil level Brake(s) • Incorrect oil viscosity •...
  • Page 204 TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT HORN DOES NOT SOUND • Wrong headlight bulb • Improperly adjusted horn • Too many electrical accessories • Damaged or faulty horn • Hard charging •...
  • Page 205 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

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