Page 1 YW50AP LIT-11616-15-39 5PJ-F8197-10...
Page 2 EB000000 YW50AP SERVICE MANUAL ©2001 by Yamaha Motor Corporation U.S.A. First edition, November 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. P/N LIT-11616-15-39...
Page 3 EB001000 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 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. The manual is divided into chapters.
Page 5: General Information
EAS00009 SYMBOLS SPEC The following symbols are not relevant to ev- INFO ery vehicle. Symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number and content. INSP 1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine CHAS 5 Carburetor(s)
Page 6 INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS – ELECTRICAL TROUBLESHOOTING...
Page 7: Table Of Contents
CHAPTER 1. GENERAL INFORMATION SCOOTER INDENTIFICATION ......................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 ......................
Page 8 CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATION ....................... 2-1 MAINTENANCE SPECIFICATION ..................... 2-4 ENGINE ............................2-4 TIGHTENING TORQUES ....................... 2-6 ENGINE ............................2-6 MAINTENANCE SPECIFICATION ..................... 2-7 CHASSIS ............................2-7 TIGHTENING TORQUES ....................... 2-8 CHASSIS ............................2-8 MAINTENANCE SPECIFICATION ..................... 2-9 ELECTRICAL ........................... 2-9 GENERAL TORQUE SPECIFICATIONS ...................
Page 9 CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENTS INTRODUCTION ..........................3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ..............3-1 COVER AND PANEL .......................... 3-3 SIDECOVER AND SEAT ........................ 3-3 LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD ..... 3-4 HANDLEBAR COVER(FRONT AND REAR) ................... 3-5 ENGINE ..............................
Page 10 CHAPTER 4. ENGINE ENGINE OVERHAUL ......................... 4-1 WIREHARNESS AND CABLES ...................... 4-1 CYLINDER HEAD, CYLINDER AND PISTON ..................4-3 CYLINDER HEAD, CYLINDER AND PISTON ................4-3 PISTON PIN AND PISTON REMOVAL ..................4-4 CYLINDER HEAD INSPECTION ..................... 4-4 CYLINDER AND PISTON INSPECTION ..................4-5 PISTON RINGS INSPECTION ......................
Page 11 CHAPTER 5 CARBURETION CARBURETION ..........................5-1 CARBURETOR ..........................5-1 CABURETOR DISASSEMBLY ....................... 5-2 CABURETOR INSPECTION ......................5-3 CARBURETOR ASSEMBLY ......................5-5 FUEL LEVEL ADJUSTMENT ......................5-6 AUTO CHOKE INSPECTION ......................5-7 FUEL COCK INSPECTION ......................5-8...
Page 12 CHAPTER 6 CHASSIS FRONT WHEEL AND BRAKE DISC ....................6-1 FRONT WHEEL AND BRAKE DISC ....................6-1 FRONT WHEEL DISASSEMBLY ....................6-2 FRONT WHEEL DISASSEMBLY ....................6-3 FRONT WHEEL INSPECTION ......................6-3 BRAKE DISC INSPECTION ......................6-4 FRONT WHEEL ASSEMBLY ......................6-4 FRONT WHEEL INSTALLATION ....................
Page 13 CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS ......................7-1 ELECTRICAL COMPONENTS ......................7-1 CIRCUIT DIAGRAM ........................7-2 CHECKING SWITCHES ........................7-4 CHECKING STEPS ......................... 7-4 SWITCH CONNECTION AS SHOWN IN THIS MANUAL............. 7-4 SWITCH POSITION AND TERMINAL CONNECTION ..............7-5 CHECKING THE BLUBS AND BULB SOCKETS ................7-5 CHECKING THE BULBS AND BULB SOCKETS ................
Page 14 CHAPTER 8 TROUBLESHOOTING STARTING FAILURE/HARD STARTING ................... 8-1 FUEL SYSTEM ..........................8-1 IGNITION SYSTEM ........................8-2 COMPRESSION SYSTEM ......................8-2 POOR IDLE SPEED PERFORMANCE ....................8-3 POOR IDLE SPEED PERFORMANCE .................... 8-3 POOR MIDIUM AND HIGH SPEED PERFORMANCE ............... 8-3 POOR MIDIUM AND HIGH SPEED PERFORMANCE ..............
Page 15: General Information
SCOOTER INDENTIFICATION 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 replace- ments. 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 Of Connections
IMPORTANT INFORMATION INFO EB801000 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: 8 Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three. 4. Pull the read to check that it will not come off.
Page 19: How To Use The Conversion Table
HOW TO USE THE CONVERSION TABLE INFO EB201000 HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULTIPLIER ×...
Page 20: Special Tools
SPECIAL TOOLS INFO EE102000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this Will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.
Page 21 SPECIAL TOOLS INFO Tool No. Tool name / Function Illustration YU-03112 Pocket tester This tool is used to check the electrical sys- tem. YM-1409 Oil seal guide This tool is used to install the left side crank- case oil seal. YM-1410 Oil seal driver This tool is used to install the left side crank-...
Page 22: General Specification
Electric and kick starter Lubrication system: Separate lubrication Oil Type or Grade: Engine Oil For YAMAHA brand: Yamalube 2 or Air cooled 2-stroke engine oil (ISO EG-C, EG-D grade) Transmission Oil Yamalube 4 SAE 10W/30 SE or GL gear oil...
Page 23 SPEC GENERAL SPECIFICATION Model YW50A Spark Plug: Type/Manufacturer BPR7HS/NGK 0.6 ~ 0.7 mm(0.02 ~ 0.03 in) Clutch Type Dry, Centrifugal automatic Transmission: Primary Reduction System Helical gear Primary Reduction Ratio 4.000 Secondary Reduction System Supur gear Secondary Reduction Ratio 3.666 Transmission Type V-belt Operation...
Page 24 SPEC GENERAL SPECIFICATION Model YW50A Headlight type: Bulb Bulb wattage x quantity: Headlight 12V 35W/35W×2 Tail/brake light 12 V 5W/21W×1 Flasher light 10W×4 Licence plate light 5W×1 Meter light 3.4W×1/1.7W×1 High beam indicator light 1.7W×1 Oil indicator light 1.7W×1 Turn indicator light 1.7W×1...
Page 25: Maintenance Specification
SPEC MAINTENANCE SPECIFICATION MAINTENANCE SPECIFICATION ENGINE Item Standard Limit Cylinder head: Warp limit 0.03 mm (0.0012 in) *Lines indicate straightedge measurement Cylinder: Bore size 40.000~40.014mm 40.10 mm (1.5748~1.5754 in) (1.5787 in) Taper limit 0.05 mm (0.0020 in) Out of round limit 0.03 mm (0.0012 in) Piston:...
Page 26 SPEC MAINTENANCE SPECIFICATION Item Standard Limit Crankshaft: Crank Width “A” 37.90~37.95 mm(1.49~1.49 in) Run Out Limit “C” 0.03 mm(0.0012 in) Connecting Rod Big End Side Clearance “D” 0.2~0.5 mm 1.0 mm(0.04 in) (0.0029~0.020 in) Small End Free Play “F” 0.4~0.8 mm (0.016~0.031 in) Automatic centrifugal clutch: Clutch shoe thickness...
Page 27: Tightening Torques
SPEC MAINTENANCE SPECIFICATION TIGHTENING TORQUES ENGINE Tightening Thread torque Part to be tightened Part name Q’ty Remarks size Nm m•kg ft•lb Spark plug — M 14 Cylinder head and cylinder Cylinder Stud bolt Air shroud 1 Screw Air shroud 1×2 Screw Screw Autolube pump...
Page 28: Maintenance Specification
SPEC MAINTENANCE SPECIFICATION CHASSIS Item Standard Limit Steering system: Steering bearing type Ball and race bearing No /size of steel balls: Upper 22 pcs Lower 19 pcs Front suspension: Front fork travel 70 mm(2.8 in) Fork spring free length 236.6 mm(9.31 in) 233.6 mm Fork length (Installed) 212.1 mm(8.35 in)
Page 29: Tightening Torques
SPEC MAINTENANCE SPECIFICATION TIGHTENING TORQUES CHASSIS Tightening Thread torque Part to be tightened Remarks size m•kg ft•lb Frame and engine bracket M 12 Engine bracket, compression rod and engine M 10 Rear carrier Rear shock absorber and frame M 10 Rear shock absorber and engine Steering ring nut M 25...
Page 30: Electrical
SPEC MAINTENANCE SPECIFICATION ELECTRICAL Item Standard limit Ignition timing: Ignition timing (B.T.D.C.) 14˚ at 5,000 r/min Advanced type Fixed C.D.I.: Pickup coil resistance/color 248 ~ 372Ω at 20˚C (68˚F) (W/R-W/L) 640 ~ 960 Ω at 20˚C (68˚F) Source coil resistance/color (B/ R-G/W) C.D.I.
Page 31 SPEC MAINTENANCE SPECIFICATION Item Standard limit Horn: Model/manufacturer 4KP/Asian Maximum amperage 1.5A Flasher relay: Type Capacitor Flasher frequency 60~120 Cycle/min Fuel gage: Model/manufacturer 4VP/San Chu 4~10 Ω Sender unit resistance - full 90~100 Ω - empty Oil level gauge: Model/manufacturer 4VP/Lun Ping Circuit breaker: Type...
Page 32: General Torque Specifications
SPEC GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE General torque specifications SPECIFICATIONS (Nut) (Bolt) m•kg ft•lb This chart specifies torque for standard fasten- 10 mm 6 mm ers with standard I.S.O. pitch threads. Torque 12 mm 8 mm specifications for special components or as- 14 mm 10 mm semblies are included in the applicable sections...
Page 33: Lubrication Points And Lubrication Type
SPEC LUBRICATION POINTS AND LUBRICATION TYPE LUBRICATION POINTS AND LUBRICATION TYPE ENGINE Lubrication Point Lublicant Type Oil seal lips O-rings Bearings Piston surface Piston pin Cylinder Transmission case (bearing) Autolube pump Starter wheel gear Idle gear plate Secondary drive gear Kickstarter pinion gear Drive axle Pump drive gear...
Page 34: Chassis
SPEC LUBRICATION POINTS AND LUBRICATION TYPE CHASSIS Lubrication Point Lubricant Type 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 35: Cable Routing
SPEC CABLE ROUTING t Wire harness CABLE ROUTING brand. A Pass the speedometer cable G Clamp the wire harness. 1 Horn H Insert the seat cable through through the right hole of front 2 Rectifier regulator fender, then through the the frame tube.
Page 36 SPEC CABLE ROUTING 1 Brake cable A Pass the brake hose through the holder. 2 Speedometer cable B Insert the fuel overflowhose bottom. 3 Fuel tank overflow hose C Pass the fuel overflowhose through the rear 4 Brake cable holder fender hole.
Page 37 SPEC CABLE ROUTING 1 Brake hose A Pass the brake hose through the holder. 2 Front fender 3 Front fork assembly 4 Nut 5 Plate washer 6 Brake hose holder 7 Flange bolt 8 Bolt 9 Brake hose holder 0 Flange bolt 2-16...
Page 38 SPEC CABLE ROUTING 1 Ignition coil r Battery(+)lead and autolube hose on to carbure- 2 Spark plug lead A Pass battery leads through tor throttle cable. 3 Starter relay leads G Pass the battery leads over frame the slot of footrestboard. 4 Auto choke leads B Cover them after securing member.
Page 39 SPEC CABLE ROUTING 1 Handlebar switch(right) A Pass brake cable through the slot of bracket. 2 Speedometer B Avoid clamping front flasher leads when in- 3 Wire brake stalling handlebar covers. 4 Handlebar switch(left) C Pass throttle cable1,3 through between 5 Wire harness handlebar and wireharness.
Page 40: Periodic Inspection And Adjustments
INTRODUCTION/ INSP PERIODICMAINTENANCE/LUBLICATION INTERVALS EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being pre- pared for sale.
Page 41 Every 9,000 km(6,000 mi) Items marked with an asterisk (*) require special tools, data and technical skills for servicing. Take the scooter to a Yamaha dealer. NOTE: •The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Page 42: Cover And Panel
INSP COVER AND PANEL COVER AND PANEL SIDECOVER AND SEAT 13Nm(1.3 m.kg, 9.4ft.lb) Order Job name/Part name Q’ty Remarks Sidecover and seat removal Remove the parts in order. Battery box cover NOTE: Insert the (-) screwdriver into the slot of battery cover and pickup then remove.
Page 43: Lower Cowling, Upper Cover, Leg Shield 1, 2 And Footrest Board
INSP COVER AND PANEL LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD 7Nm(0.7m.kg, 5.1ft.lb) Order Job name/ part name Q’ty Remarks Lower cowling, upper cover, leg Remove the parts in order. shield 1,2 and footrest board re- moval Lower cowling Upper cover...
Page 44: Handlebar Cover(Front And Rear)
INSP COVER AND PANEL HANDLEBAR COVER(FRONT AND REAR) Order Job name / Part name Q’ty Remarks Handlebar cover(Front and Rear) re- Remove the part in order. moval. Mirrors Front handlebar cover Rear handlebar cover Flasher light(Left/Right) Reverse the removal procedure for instal- lation.
Page 45: Engine
INSP ENGINE IDLE SPEED ADJUSTMENT ENGINE IDLE SPEED ADJUSTMENT 1. Remove 8 Battery box cover 1 2. Start the engine and let it warm up. Before starting the engine, be sure to use the centerstand for safety. 3. Attach: 8 Inductive tachometer 1 To the spark plug lead Inductive tachometer: YU-8036-A...
Page 46: Throttle Cable Free Adjustment
INSP THROTTLE CABLE FREE ADJUSTMENT THROTTLE CABLE FREE ADJUSTMENT 1. Check: 8 Throttle cable free play a Out of specification→Adjust. Free play: 3 ~ 5 mm(0.12 ~ 0.20 in) *************************************** Throttle cable free play adjustment steps; NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted.
Page 47: Autolube Pump Air Bleeding
INSP AUTOLUBE PUMP AIR BLEEDING AUTOLUBE PUMP AIR BLEEDING 1. Remove 8 Lower cowling 8 Air shroud 1 1 2. Air bleeding: 8 Pump case and / or oil hose. *********************************** Air bleeding steps: 8 Place a rag under the autolube pump to catch the oil.
Page 48: Spark Plug Inspection
INSP SPARK PLUG INSPECTION SPARK PLUG INSPECTION 1. Remove: 8 Battery box cover 2. Inspect: 8 Spark plug type Incorrect→Replace. Standard spark plug: BPR7HS/NGK 3. Inspect: 8 Electrode 1 Wear/Damage→Replace. 8 Insulator 2 Abnormal color→Replace. Normal color is a medium-to-light tan color.
Page 49: Engine Oil Level Inspection
Engine oil level and elec- Supply engine oil. circuit, light bulbs etc. trical circuit are OK. “OIL” indicator light comes on. Recommended oil: For Yamaha: Yamalube 2 or 2-stroke engine oil (ISO EG-C, EG-D grade) Total: 1.4L(1.23 lmp.qt, 1.48 US.qt) NOTE: Install the oil tank filler cap 1 and push it fully into the filler.
Page 50: Transmission Oil Replacement
INSP TRANSMISSION OIL REPLACEMENT TRANSMISSION OIL REPLACEMENT 1. Warm up the engine for several minutes, then stop the engine. 2. Place a container under the drain hole. 3. Remove: 8 Oil filler plug 1 8 Drain bolt (with gasket) 2 NOTE: Drain the transmission oil completely.
Page 51: Air Filter Element Cleaning
INSP AIR FILTER ELEMENT CLEANING AIR FILTER ELEMENT CLEANING 1. Remove: 8 Battery box cover 2. Remove: 8 Caburetor jont clamp 1 3. Remove: 8 Screw 12 8 Air filter 3 4. Remove: 8 Air filter case 1 8 Air filter element Never operate the engine with the air filter el- ement removed.
Page 52 INSP AIR FILTER ELEMENT CLEANING Never use low flash point solvents such as gasoline to clean the element. Such solvent may lead to a fire or explosion. 8 Squeeze the excess solvent out of the ele- ment and let dry. Do not twist the element when squeezing the element.
Page 53: V-Belt Inspection
INSP V-BELT INSPECTION V-BELT INSPECTION 1. Remove: 8 Kick crank 1 8 Screws 2 8 Crankcase cover 2(left) 3 8 Screws(Air cleaner and left crankcase cover 4 8 Crankcase cover 1(left) 5 2. Inspect 8 V-belt 1 Cracks/Wear/Damage→Replace. Oil or grease adhere to the V-belt→Check the primary and second- ary sheaves.
Page 54: Chassis
FRONT BRAKE LEVER FREE PLAY CHECK/REAR BRAKE INSP LEVER FREE PLAY CHECK/BRAKE PAD INSPECTION CHASSIS FRONT BRAKE LEVER FREE PLAY CHECK 1. Check: 8 Front brake lever free play 2~5 mm(0.08~0.20 in) A soft or spongy feeling in the brake lever can indicate the presence of air in the brake sys- tem.
Page 55: Brake Shoe Inspection
BRAKE SHOE INSPECTION/ INSP BRAKE FLUID LEVEL INSPECTION BRAKE SHOE INSPECTION 1. Activate the brake lever. 2. Inspect: 8 Wear indicator 1 Indicator at wear limit line 2→Replace brake shoes. BRAKE FLUID LEVEL INSPECTION NOTE: Position the scooter straight up when inspect- ing the fluid level.
Page 56: Air Bleeding (Hydraulic Brake System)
INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 1. Bleed: 8 Brake fluid *************************************** Air bleeding steps: a. Add proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow.
Page 57: Steering Adjustment
INSP STEERING ADJUSTMENT STEERING ADJUSTMENT 1. Check: 8 Steering assembly bearings Gap the bottom of the forks and gently rock the fork assembly back and forth. Loosen→Adjust. *************************************** Adjustment steps: 8 Remove upper cover, lower cowling, leg shield 1,2. refer to “COVER AND PANEL” sec- tion.
Page 58: Tire Inspection
INSP TIRE INSPECTION FRONT TIRE INSPECTION Manufacturec Size Type 8 The tire pressure should only be checked and CHENG SHIN 120/90-10 regulated when the tire temperature equals REAR the ambient air temperature. Manufacturec Size Type 8 The tire pressure must be adjusted accord- ing to the total weight (including cargo, rider CHENG SHIN 130/90-10...
Page 59 Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con- cerning han-dling characteristics can be given if a tire combination other than one approved by Yamaha is used on this scooter. 3-20...
Page 60 INSP CHECKING THE TIRES/CHECKING THE WHEELS 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. NOTE: For tires with a direction of rotation mark 1: 8 Install the tire with the mark pointing in the...
Page 61: Wheel Inspection
WHEEL INSPECTION/FRONT FORK INSPECTION INSP REAR SHOCK ABSORBER INSPECTION/SEAT LOCK CABLEADJUSTMENT WHEEL INSPECTION 1. Inspect: 8 wheels Damage/Bends→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. FRONT FORK INSPECTION 1.
Page 62: Cable Checking And Lubricating
CABLE CHECKING AND LUBRICATING / LEVERS LUBRICATING / INSP CENTERSTAND LUBRICATING EAS00170 CABLE CHECKING AND LUBRICATING The following procedure applies to all of the cable sheaths and cables. Damaged cable sheaths may cause the cable to corrode and interfere with its movement. Replace damaged cable sheaths and cables as soon as possible.
Page 63: Electrical
INSP BATTERY INSPECTION ELECTRICAL BATTERY INSPECTION NOTE: Since the MF battery is of a sealed-type con- struction, it is impossible to measure the spe- cific gravity of the electrolyte in order to check the state of charge in the battery. Therefore, to check the state of charge in the battery, volt- age must be measured at the battery terminals.
Page 64 INSP BATTERY INSPECTION Batteries generate explosive hydrogen gas and contain electrolyte which is made of poison- ous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: 8 Wear protective eye gear when handling or working near batteries. 8 Charge batteries in a well-ventilated area. 8 Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
Page 65 INSP BATTERY INSPECTION Open circuit voltage Charging time Ambient temperature 20°C 12.8 v or more No charging is necessary. 8 Check the battery condition using figures. EXAMPLE: Open circuit voltage = 12.0v Charging time = 6.5 hours 30 25 20 Condition of charge in battery = 20 ~ 30% Condition of charge in battery(%) ***************************************...
Page 66 INSP BATTERY INSPECTION Charging method using a variable-current (voltage) type charger Charger NOTE: meter Measure the open-circuit volt- Voltage should be measured age prier to charging. 30 minutes after the machine is stopped. NOTE: Connect a charger and AMP Set the changing voltage at meter to the battery and start 16-17 V.
Page 67 INSP BATTERY INSPECTION Charging method using a constant-voltage type charger NOTE: Measure the open-circuit volt- Voltage should be measured 30 min- Charger utes after the machine is stopped. age prier to charging. AMP meter Volt meter Connect a charger and AMP meter to the battery, and start charging.
Page 68: Fuse Inspection
INSP FUSE INSPECTION 4. Inspect: 8 Battery terminal Dirty terminal→Clean with wire brush. Poor connection→Correct. NOTE: After cleaning terminals, apply lightly to the terminals. 5. Install 8 Battery 8 Battery box cover FUSE INSPECTION 1. Remove: 8 Battery box cover Refer to “COVER AND PANEL”...
Page 69: Headlight Beam Adjustment
HEADLIGHT BEAM ADJUSTMENT INSP /HEADLIGHT BULB REPLACEMENT HEAD LIGHT BEAM ADJUSTMENT 1. Adjust: 8 Head light (vertically) Turn the adjusting screw1 in or out to adjust headlight beam. 8 Head light (Horizontal) Turn the adjusting screw2 in or out to adjust headlight beam.
Page 70 INSP HEADLIGHT BULB / TURN SIGNAL BULB REPLACEMENT Install: 8 Bulb(new) 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 af- fected.
Page 71: Taillight Bulb Replacement
INSP TAILLIGHT BULB / LICENCE LIGHT BULB REPLACEMENT 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 af- fected.
Page 72: Engine Overhaul
ENGINE REMOVAL EB400000 ENGINE OVERHAUL ENGINE REMOVAL WIREHARNESS AND CABLES 120Nm(12.0 m.kg, 87 ft.lb) 45Nm(4.5 m.kg, 31ft.lb) Order Job name/Part name Q’ty Remarks Wireharness and cables removal Remove the parts in order. Rear carrier Tail cover Refer to “COVER AND PANEL” section Left side panel in CHAPTER 3.
Page 73: Engine Removal
ENGINE REMOVAL 120Nm(12.0 m.kg, 87 ft.lb) 45Nm(4.5 m.kg, 31ft.lb) Order Job name/Part name Q’ty Remarks Spark plug cap Battery (-) lead C.D.I magneto leads coupler Starter motor leads coupler Rear wheel nut NOTE: Loosen the rear wheel nut. Rear brake adjuster Rear brake cable Bolt Engine mount bolt...
Page 74: Cylinder Head, Cylinder And Piston
CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD, CYLINDER AND PISTON 26Nm(2.6 m.kg, 18.2 ft.lb) 9Nm(0.9 m.kg,6.5 ft.lb) 14Nm(1.4 m.kg, 10 ft.lb) Order Job name/Part name Q’ty Remarks Cylinder head, Cylinder and piston Remove the parts in the order. removal Engine Refer to the “ENGINE REMOVAL”...
Page 75: Piston Pin And Piston Removal
CYLINDER HEAD, CYLINDER, PISTON PISTON PIN AND PISTON REMOVAL 1. Remove: 8 Piston pin clip 1 NOTE: Before removing the piston pin clip, cover the crankcase with a clean rag so you will not acci- dentally drop the clip into the crankcase. 2.
Page 76: Cylinder And Piston Inspection
CYLINDER AND PISTON INSPECTION CYLINDER AND PISTON INSPECTION 1. Eliminate: 8 Carbon deposits Use a rounded scraper 1. 2. Inspect: 8 Cylinder wall Wear/Scratches→Rebore or replace. 3. Eliminate: 8 Carbon deposits 1 From the piston crown and ring grooves. 4. Remove: 8 Score markes and lacquer deposits From the sides of piston.
Page 77 CYLINDER HEAD, CYLINDER AND PISTON Standard Wear limit Cylinder bore 40.10 mm 40.000~40.014mm (1.5748~1.5754 in) (1.5787 in) “C” 0.05 mm – Taper “T” (0.0020 in) Out of round – 0.03 mm (0.0012 in) “R” C = Maximum D T=( Maximum D1 or D2 ) - ( Maximum D5 or D6 ) R=( Maximum D1 D3 or D5 ) - ( Maximum D2 D4 or D6 )
Page 78: Piston Rings Inspection
CYLINDER HEAD, CYLINDER AND PISTON PISTON RINGS INSPECTION 1. Measure: 8 Side clearance Out of specification→Replace piston and/or rings. Use a feeler gauge 1 Standard Limit Top ring 0.03 ~ 0.05 mm 0.1 mm (0.0012 ~ 0.002 in) (0.0039 in) 2nd ring 0.03 ~ 0.05 mm 0.1 mm (0.0012 ~ 0.002 in)
Page 79: Piston Pin And Piston Installation
CYLINDER HEAD, CYLINDER AND PISTON 2. Measure: 8 Outside diameter a (piston pin) Out of specification→Replace. Out side diameter (piston pin): 9.996~10.000 mm(0.3935~0.3937in) 3. Measure: → a ← 8 Piston pin-to-piston clearance Out of specification→Replace piston. Piston pin-to-piston clearance = Bore size (piston pin) Outside diameter (piston pin) Piston pin-to-piston clearance:...
Page 80: Cylinder And Cylinder Head
CYLINDER HEAD, CYLINDER AND PISTON 3. Install: 8 Small end bearing 8 Piston 1 8 Piston pin 2 8 Piston pin clip 3 NOTE: 8 The arrow a on the piston to the exhaust side. 8 Before installing the piston pin clip, cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip mate- rial into the crankcase.
Page 81 CYLINDER HEAD, CYLINDER AND PISTON 4. Install: 8 Cylinder head gasket (new gasket) 5. Install: 8 Cylinder head 1 14Nm(1.4m.kg,10ft.lb) 8 Spark plug 2 20Nm(2.0m.kg,14ft.lb) 8 Air shroud NOTE: Tighten the cylinder head holding nuts in stage, using a crisscross pattern. 4-10...
Page 82: V-Belt, Clutch And Secondary/Primary Sheave
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE KICK STARTER AND CRANKCASE COVER (LEFT) 12Nm(1.2m.kg, 8.4 ft.lb) 7Nm(0.7m.kg, 5.1 ft.lb) 90Nm(0.9m.kg, 6.5 ft.lb) Order Job name/Part name Q’ty Remarks Kick starter and crankcase cover (left) Remove the parts in order. removal Kick starter Crankcase cover 2 (left)
Page 83: Kick Starter
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE KICK STARTER Order Job name/Part name Q’ty Remarks Kick starter removal Remove the parts in order. Crankcase cover 1 (left) removal Kickstarter pinion gear Kickstarter pinion gear clip Circlip/Plain washer Kickstarter segment gear Return spring Collar...
Page 84: Kick Starter Installation
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE KICK STARTER INSTALLATION 1. Install: 8 Return spring 1 8 Kickstarter segment gear 2 8 Collar 3 8 Plain washer 4 8 Circlip 5 *************************************** Installation steps: a. Install return spring 6 and segment gear 7 as shown.
Page 85: V-Belt, Clutch And Secondary/Primary Sheave
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 40Nm(4.0m.kg,29ft.lb) 45Nm(4.5m.kg,33ft.lb) Order Job name/Part name Q’ty Remarks V-belt, clutch and secondary/primary Remove the parts in order. sheave removal Lower cowling Refer to “COVER AND PANEL” section Air shroud 3 in chapter 3.
Page 86: Secondary Sheave
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE SECONDARY SHEAVE 50Nm(5.0m.kg, 36ft.lb) Order Job name/Part name Q’ty Remarks Secondary sheave disassembly Disassemble the parts in order. Refer to “SECONDARY SHEAVE DISAS- Clutch carrier SEMBLY” section. Clutch shoe spring Refer to “SECONDARY SHEAVE IN- Compression spring STALLATION”...
Page 87: Primary Sheave Removal
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE PRIMARY SHEAVE REMOVAL 1. Remove: 8 Fan 2. Remove: 8 Nut 1 (primary sheave) NOTE: When loosening the nut (primary sheave), hold the C.D.I. magneto using flywheel holding tool Rotor holding tool: YU-01235 3. Remove: 8 Conical spring washer 1 8 One-way clutch 2 8 Washer 3...
Page 88: Clutch Inspection
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 3. Loosen: 8 Nut(Clutch carrier)1 NOTE: Install the secondary sheave to primary drive shaft as shown, and hold the secondary sheave by Universal Roter Holder 2 to loosen the nut Roter holding tool: YU-01235 Do not remove the clutch securing nut yet. If the nut is removed without compressiong the secondary sheave.
Page 89: V-Belt Inspection
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 2. Measure: 8 Clutch shoe thickness a Out of specification→Replace. Clutch shoe thickness: 4 mm (0.16 in) < Wear limit>: 2.5 mm (0.1 in) V-BELT INSPECTION 1. Inspect: 8 V-belt1 Crack→Replace. NOTE: Replace the V-belt smeared with a lot of oil or grease.
Page 90: Primary Sheave Inspection
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE PRIMARY SHEAVE INSPECTION 1. Inspect: 8 Primary sliding sheave 1 8 Primary fixed sheave 2 Wear/Cracks/Scratch/Damage →Replace. 2. Check: 8 Free movement Insert the collar 1into the primary slid- ing sheave2, and check for free move- ment.
Page 91: Secondary Sheave
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE SECONDARY SHEAVE 1. Inspect: 8 Secondary fixed sheave 1 8 Secondary sliding sheave 2 Scratch/Crack/Damage→Replace as a set. 8 Oil seal 3 Damage→Replace 2. Inspect: 8 Torque cam grove 1 8 Guide pin 2 Wear/Damage→Replace as a set. 8 O-rings 3 Damage→Replace.
Page 92: Secondary Sheave Installation
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE SECONDARY SHEAVE INSTALLATION When assembling the secondary sheave, re- verse the disassembly procedure. Note the fol- lowing points. 1. Apply: 8 Lithium soap base grease (to the inside of the sliding/fixed sheave) 2. Install: 8 Sliding sheave 1 NOTE: Be careful so that the oil seal 2 lips are not turned over when installing the sheave.
Page 93: Primary Sheave
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 8. Install: 8 Secondary sheave assembly 8 Clutch housing 1 8 V-belt 2 NOTE: The V-belt must be installed with the arrow frontward. 9. Tighten: 8 Nut 1 (secondary sheave) 40 Nm(4.0 m.kg, 29 ft.lb) Use sheaveholder 2 Sheave holder: YU-01701...
Page 94 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 6. Install: 8 Shim 1 8 Primary fixed sheave 2 8 Washer 3 8 One-way clutch 4 8 Conical spring washer 5 8 Nut 6 7. Tighten: 8 Nut 1 (primary sheave) 45 Nm(4.5 m.kg, 31ft.lb) NOTE: When tightening the nut (primary sheave), hold the C.D.I.
Page 95: Starter Clutch And Starter Motor
STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND STARTER MOTOR 13Nm(1.3m.kg, 9.4 ft.lb) 8Nm(0.8m.kg, 5.8 ft.lb) Order Job name/Part name Q’ty Remarks Starter clutch and starter motor re- Remove the parts in order. moval Left/Right side cover Refer to “COVERS AND PANEL”...
Page 96 STARTER CLUTCH AND STARTER MOTOR 13Nm(1.3m.kg, 9.4 ft.lb) 8Nm(0.8m.kg, 5.8 ft.lb) Order Job name/Part name Q’ty Remarks Gear boss Bearing Starter wheel gear Plate washer Starter motor Starter motor coupler Reverse the removal procedure for instalation 4-25...
Page 97: Starter Clutch And Gears Inspection
STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND GEARS INSPECTION 1. Inspect: 8 Starter clutch Push the dowel pin to arrow direction. Unsmooth operation→Replace starter clutch assembly. 2. Inspect: 8 Starter wheel gear teeth 1 8 Idle gear teeth 2 Burrs/Chips/Roughness/Wear→Replace.
Page 98: Magnet
C.D.I. MAGNETO C.D.I. MAGNETO C.D.I. MAGNETO 8Nm(0.8m.kg, 5.8ft.lb) 38Nm(3.8 m.kg, 27 ft.lb) 7Nm(0.7 m.kg, 5.1 ft.lb) 7Nm(0.7m.kg, 5.1ft.lb) Order Job name/Part name Q’ty Remarks C.D.I. magneto removal Remove the parts in order. Rear carrier Tail cover Left side cover Refer to “COVER AND PANEL” section Right side cover in chapter 3.
Page 99: C.d.i. Magneto Removal
C.D.I. MAGNETO C.D.I. MAGNETO REMOVAL 1. Remove: 8 Nut 1(rotor) 8 Plain washer NOTE: Hold the rotor to loosen the nut by the flywheel holding tool 2. Rotor holding tool: YU-01235 2. Remove: 8 Rotor 1 8 Woodruff key Use the flywheel magneto puller 2. Flywheel puller: YU-01189 8 Stator assembly...
Page 100: Autolube Pump
AUTOLUBE PUMP AUTOLUBE PUMP AUTOLUBE PUMP 4Nm(0.4m.kg, 2.8ft.lb) Order Job name/Part name Q’ty Remarks Autolube pump removal Remove the parts in order. C.D.I. magneto Refer to “C.D.I. magneto” section. Air shroud 2. Circlip Pump drive gear Oil hose Oil delivery hose Autolube pump ass’y Refer to “Autolube pump installation”...
Page 101: Autolube Pump Installation
AUTOLUBE PUMP AUTOLUBE PUMP INSTALLATION After installing autolube pump, it must be bleeded. 1. Install 8 Pin 1 8 Pump drive gear 2 8 Circlip 3 2. Apply: 8 Lithium soap base grease (to O-ring) 3. Install: 8 Autolube pump 1 4 Nm(0.4m.kg, 2.8ft.lb) 4.
Page 102: Transmission
TRANSMISSION TRANSMISSION TRANSMISSION 12Nm(1.2 m.kg, 8.4ft.lb) 18Nm(1.8 m.kg, 13ft.lb) Order Job name/Part name Q’ty Remarks Transmission removal Remove the parts in order. Rear wheel Refer to “REAR WHEEL/REAR BRAKE ” section in chapter 7. Secondary sheave Refer to “V-BELT, CLUTCH, SECOND- ARY/ PRIMARY SHEAVE”...
Page 103 TRANSMISSION 12Nm(1.2 m.kg, 8.4ft.lb) 18Nm(1.8 m.kg, 13ft.lb) Order Job name/Part name Q’ty Remarks Drive axle Reverse the removal procedure for in- stallation. 4-32...
Page 104: Crankcase And Reed Valve
CRANKCASE AND REED VALVE CRANKCASE AND REED VALVE CRANKCASE AND REED VALVE 9Nm(0.9m.kg,6.5ft.lb) 12Nm(1.2m.kg, 8.4ft.lb) 11Nm(1.1m.kg,8ft.lb) Order Job name/Part name Q’ty Remarks Crankcase and Reed valve removal Remove the parts in order. Engine removal Refer to “ENGINE REMOVAL” section. Cylinder head, cylinder, piston Refer to “CYLINDER HEAD CYLINDER AND PISTON”...
Page 105 CRANKCASE AND REED VALVE 9Nm(0.9m.kg,6.5ft.lb) 12Nm(1.2m.kg, 8.4ft.lb) 11Nm(1.1m.kg,8ft.lb) Order Job name/Part name Q’ty Remarks Intake manifold Reed valve Valve seat gasket Stopper Crankcase 2 Dowel pin Engine mount spacer Circlip Bearing Oil seal Reverse the removal procedure for in- stallation. 4-34...
Page 106: Crankcase(Right) Removal
CRANKCASE AND REED VALVE CRANKCASE(RIGHT) REMOVAL 1. Remove: 8 Oil seal stopper 1 8 Screws (crankcase) 9Nm(0.9 m.kg,6.5ft.lb) NOTE: Loosen each screw 1/4 turn, and remove them after all are loosened. 2. Attach: 8 Crankcase separating tool 1 Crankcase separating tool: YU-01135 NOTE: Fully tighten the tool holding bolts, but make...
Page 107: Reed Valve Inspection
CRANKCASE AND REED VALVE REED VALVE INSPECTION 1. Measure: 8 Valve stopper height 1 Out of specification→Adjust stopper/Re- place valve stopper. Valve stopper height 1 6.0~6.4 mm(0.24~0.25 in) 2. Measure: 8 Reed valve clearance 2 Out of specification→Replace reed valve. Reed valve clearance 2 Less than 0.2 mm(0.0079 in) CRANKCASE (RIGHT) INSTALLATION...
Page 108 CRANKCASE AND REED VALVE 4. Tighten: 8 Crankcase holding screws 12 Nm(1.2 m.kg, 8.4 ft.lb) NOTE: Tighten the crankcase holding screws in stage, using a crisscross pattern. 5. Check: 8 Crankshaft operation Unsmnoth operation Repair. 6. Install: 8 Oil seal (right crank case) 1 Apply grease on to oil seal lip.
Page 109: Crankshaft
CRANKSHAFT CRANKSHAFT CRANKSHAFT Order Job name/Part name Q’ty Remarks Crankshaft removal Remove the parts in order. Right crankcase removal Refer to “CRANK CASE AND REED VALVE” section. Crankshaft Bearing Oil seal Crankcase cover (left) Reverse the removal procedure for in- stallation.
Page 110: Crankshaft Removal
CRANKSHAFT CRANKSHAFT REMOVAL 1. Attach: 8 Crankcase separating tool 1 Crankcase separating tool: YU-01135-A 2. Remove: 8 Crankshaft 2 NOTE: Make sure the crankcase separating tool is cen- tered over the crankshaft assembly. CRANKSHAFT INSPECTION 1. Measure: 8 Runout limit “ C” 8 Connecting rod big end side clearance “D”...
Page 111: Crankshaft Installation
CRANKSHAFT CRANKSHAFT INSTALLATION 1. Attach: 8 Crankshaft Installing Tool Crankshaft installation set 1 YU-90050 Crankshaft installer adapter (M10) 2 YU-90062 2. Install: 8 Crankshaft 3 (to the crankcase 4) To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with grease and each bear-ing with engine oil.
Page 112: Carburetion
CARB CARBURETOR CARBURETION CARBURETOR 9Nm(0.9 m.kg, 6.5 ft.lb) Order Job name/Part name Q’ty Remarks Carburetor removal Remove the parts in order. Battery box cover Grip End cover Refer to “COVER AND PANEL” section Left/Right cover in CHAPTER 3. Center cover Air cleaner case assembly Auto choke lead coupler Fuel hose/vacuum hose...
Page 113: Caburetor Disassembly
CARB CARBURETOR CABURETOR DISASSEMBLY Order Job name/Part name Q’ty Remarks Carburetor disassembly Disassemble the parts in order. Throttle cable Throttle valve Needle set Carburetor top cover/o-ring Throttle stop screw Auto choke unit assembly Float chamber/Seal ring Float pin Float/Needle valve Main jet Pilot jet Main nozzle...
Page 114: Caburetor Inspection
CARB CARBURETOR CABURETOR INSPECTION 1. Check: 8 Carburetor body 8 Float chamber 8 Jet housing Cracks/damage → Replace. 2. Check: 8 Fuel passages Obstruction → Clean. *************************************** a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carbure- tor cleaning solution.
Page 115 CARB CARBURETOR 8. Check: 8 Jet needle kit 1 8 Main nozzle 2 8 Main jet 3 8 Pilot jet 4 Bends/damage/wear → Replace. Obstruction → Clean. Blow out the jets with compressed air. 9. Check: 8 Throttle valve movement Insert the throttle valve into the carbu- retor Body and move it up and down.
Page 116: Carburetor Assembly
8 If it is worn, replace it. ************************************* NOTE: The float height is properly adjusted at the Yamaha factory. Never attempt to adjust it. CARBURETOR ASSEMBLY To assemble the carburetor, reverse the disas- sembly procedures.
Page 117: Fuel Level Adjustment
CARB CARBURETOR 1. Install: 8 Throttle cable 1 2. Install: 8 Carburetor assembly NOTE: Align the projection a with the projections b. FUEL LEVEL ADJUSTMENT 1. Measure: 8 Fuel level a Out of specifications→Adjust. Fuel level a: 3.0~4.0 mm(0.12~0.16 in) (Below the float chamber line) ↓...
Page 118: Auto Choke Inspection
CARB CARBURETOR 8 Install the carburetor. 8 Recheck the fuel level. *************************************** AUTO CHOKE INSPECTION (Ambient temperature lower than 45°C) 1. Remove: 8 Carburetor 2. Inspect: 8 Autochoke unit Connect a suitable hose 2 to the starter 1, and blow it with the mouth etc. Possible→Good condition.
Page 119: Fuel Cock Inspection
CARB CARBURETOR FUEL COCK INSPECTION 1. Stop the engine. 2. Remove: 8 Rear carrier 8 Tail cover 8 Left side cover 8 Battery box cover Refer to “COVER AND PANEL” section in chapter 3. 3. Inspect: 8 Fuel cock *************************************** Fuel cock inspection steps: 8 Disconnect the fuel hose 1.
Page 120: Front Wheel And Brake Disc
CHAS FRONT WHEEL AND BRAKE DISC CHASSIS FRONT WHEEL AND BRAKE DISC 7Nm(0.7 m.kg, 5.1ft.lb) 23Nm(2.3 m.kg, 16.6ft.lb) 70Nm(7 m.kg, 51ft.lb) 20Nm(2.0 m.kg, 14.5ft.lb) Order Job name/Part name Q’ty Remarks Front wheel and brake disc removal Remove the parts in order. Securely support the scooter so there is no danger of it falling over.
Page 121: Front Wheel Disassembly
CHAS FRONT WHEEL AND BRAKE DISC FRONT WHEEL DISASSEMBLY Order Job name/Part name Q’ty Remarks Front wheel disassembly Remove the parts in order. Oil seal Refer to “FRONT WHEEL DISASSEM- Bearing BLY/ASSEMBLY” section. Collar Spacer Bearing Reverse the removal procedure for in- stallation.
Page 122: Front Wheel Inspection
CHAS FRONT WHEEL AND BRAKE DISC YP ..FRONT WHEEL DISASSEMBLY 1. Remove: 8 Bearing 1 8 Spacer Remove the bearing using a general bearing puller 2. Handle the wheel with care not to damage the brake disc. If the brake disc is damaged, re- place.
Page 123: Brake Disc Inspection
CHAS FRONT WHEEL AND BRAKE DISC 4. Inspect: 8 Collar Grooved wear→Replace the collar and the oil seal as a set. YP..BRAKE DISC INSPECTION 1. Measure: 8 Brake disc deflection1 Maximum deflection: 0.15 mm (0.0059 in) Out of specification→Replace. 2.
Page 124: Front Wheel Installation
CHAS FRONT WHEEL AND BRAKE DISC 2. Install: 8 Brake disc 1 20 Nm(2.0 m.kg, 14 ft.lb) NOTE: Tighten the bolts (brake disc) in stage using a crisscross pattern. EB700030 FRONT WHEEL INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.
Page 125: Wheel Static Balance Adjustment
CHAS FRONT WHEEL AND BRAKE DISC YP700040 WHEEL STATIC BALANCE ADJUSTMENT NOTE: 8 After replacing the tire and/or rim, the wheel static balance should be adjusted. 8 Adjust the front wheel static balance with the brake disc installed. 1. Remove: 8 Balancing weight 2.
Page 126 CHAS FRONT WHEEL AND BRAKE DISC 5. Check: 8 Wheel static balance *************************************** Checking steps: 8 Turn the wheel so that it comes to each point as shown. 8 Check that the wheel is at rest at each point. If not, readjust the front wheel static balance. ***************************************...
Page 127: Front Brake
CHAS FRONT BRAKE FRONT BRAKE BRAKE PAD 23Nm(2.3 m.kg, 16.6 ft.lb) 23Nm(2.3 m.kg, 16.6 ft.lb) Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in order. Caliper support bolt Refer to “ BRAKE PAD REPLACEMENT Caliper “ section . Brake pad Pad spring Reverse the removal procedure for in-...
Page 128: Brake Pad Replacement
CHAS FRONT BRAKE Disc brake components rarely require disas- sembly. DO NOT: 8 Disassembly components unless absolutely necessary. 8 Use solvents in internal brake component. 8 Use contaminated brake fluid for cleaning. 8 Use only clean fluid. 8 Allow brake fluid to come in contact with the eyes otherwise eye injury may occur.
Page 129 CHAS FRONT BRAKE 4. Install: 8 Pad springs 8 Brake pads (new) *************************************** Installation steps: 8 Connect a suitable hose 1 tightly to the cali- per bleed screw 2. Then, place the other end of this hose into an open container. 8 Loosen the caliper bleed screw and push the piston 3 into the caliper by your finger.
Page 130 CHAS FRONT BRAKE 6. Check: 8 Brake lever operation A softy or spongy feeling Bleed→brake system. Refer to “ AIR BLEEDING ” section in the CHAPTER 3. 6-11...
Page 131: Master Cylinder
CHAS FRONT BRAKE MASTER CYLINDER 9Nm(0.9 m.kg, 6.5 ft.lb) 20Nm(2.0 m.kg, 14 ft.lb) Order Job name/Part name Q’ty Remarks Master cylinder removal Remove the parts in order. Drain the brake fluid Refer to “BRAKE FLUID REPLACE- MENT” section in CHAPTER 3. Brake lever/compression spring Brake switch Union bolt...
Page 132: Master Cylinder Disassembly
CHAS FRONT BRAKE MASTER CYLINDER DISASSEMBLY Order Job name/Part name Q’ty Remarks Master cylinder disassembly Remove the parts in order. Master cylinder boot Circlip Refer to “MASTER CYLINDER ASSEM- Master cylinder kit BLY” section. Spring Reverse the disassembly procedure for assembly.
Page 133: Master Cylinder Inspection
CHAS FRONT BRAKE YP702040 MASTER CYLINDER INSPECTION 1. Inspect: 8 Master cylinder kit 1 Wear/scratches→Replace the master cylinder assembly. 8 Master cylinder boot Cracks/damage→Replace. 2. Inspect: 8 Master cylinder 1 8 Scratches/wear/damage→Replace the master cylinder assembly. 3. Inspect: 8 Diaphragm 1 Wear/damage→Replace.
Page 134: Master Cylinder Installation
CHAS FRONT BRAKE 2. Install: 8 Spring 1 Install the spring with its smaller diam- eter to the master cylinder piston. 8 Master cylinder kit 2 3. Install: 8 Circlip 1 Install the circlip securely into the mas- ter cylinder groove. 8 Master cylinder boot 2 YP..
Page 135 CHAS FRONT BRAKE 2. Air bleed: 8 Brake system Refer to “AIR BLEEDING” section in CHAPTER 3. 8 Use only designated quality brake fluid: Otherwise, the rubber seals may deteriorate, causing leakage poor brake perforrmance. 8 Refill with the same type of brake fluid: Mixing fluids may result in a harmful chemi- cal reaction and lead to poor perforrmance.
Page 136: Caliper
CHAS FRONT BRAKE CALIPER 23Nm(2.3 m.kg, 16.6 ft.lb) 23Nm(2.3 m.kg, 16.6 ft.lb) 23Nm(2.3 m.kg, 16.6 ft.lb) Order Job name/Part name Q’ty Remarks Caliper removal Remove the parts in order. Drain the brake fluid Refer to “BRAKE FLUID REPLACE- MENT” section in CHAPTER 3. Union bolt Copper washer Refer to “CALIPER INSTALLATION”...
Page 137: Caliper Disassembly
CHAS FRONT BRAKE CALIPER DISASSEMBLY 6Nm(0.6 m.kg, 4.3 ft.lb) Order Job name/Part name Q’ty Remarks Caliper disassembly Remove the parts in order. Caliper bracket Brake pad Pad spring Refer to “BRAKE CALIPER DISASSEM- Caliper piston BLY/ASSEMBLY” section. Dust seal Piston seal Bleed screw Reverse the disassembly procedure for assembly.
Page 138: Brake Caliper Disassembly
CHAS FRONT BRAKE YP702020 BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling either brake caliper, drain the brake fluid from the brake hose, master cylinder, brake caliper and reservoir tank. 1. Remove: 8 Brake caliper piston *************************************** Removal steps: 8 Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body.
Page 139: Brake Caliper Assembly
CHAS FRONT BRAKE EB702050 BRAKE CALIPER ASSEMBLY 8 All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid: DOT #4(or DOT #3) 8 Replace the caliper piston seals whenever a brake caliper is disassembled. 1.
Page 140: Rear Wheel And Rear Brake
CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL AND REAR BRAKE REAR WHEEL 120Nm(12 m.kg, 87 ft.lb) 26Nm(2.6 m.kg, 18.2 ft.lb) 9Nm(0.9 m.kg, 6.5 ft.lb) Order Job name/Part name Q’ty Remarks Rear wheel and rear brake removal Remove the parts in order. NOTE: Place the scooter on a suitable atand so that the rear wheel is elevated.
Page 141: Rear Brake
CHAS REAR WHEEL AND REAR BRAKE REAR BRAKE 10Nm(1.0 m.kg, 7.2 ft.lb) Order Job name/Part name Q’ty Remarks Adjuster Brake cable Return spring Brake shoe Camshaft lever Wear indicator Brake camshaft Reverse the removal procedure for in- stallation. 6-22...
Page 142: Rear Wheel Inspection
CHAS REAR WHEEL AND REAR BRAKE EB701020 REAR WHEEL INSPECTION Inspect: 8 Rear wheel axle 8 Rear wheel 8 Rear wheel bearings 8 Oil seals Refer to “FRONT WHEEL”. 2. Measure: 8 Rear wheel runout Refer to “FRONT WHEEL”. EB701021 REAR BRAKE INSPECTION 1.
Page 143: Rear Brake Installation
CHAS REAR WHEEL AND REAR BRAKE 4. Inspect: 8 Brake drum inner surface 8 Oil/scratches→Repair. 8 Oil Use a rag soaked in lacquer thinner or solvent. 8 Scratches Use an emery cloth (lightly and evenly polishing) 5. Inspect: 8 Cam shaft face. Wear→Replace.
Page 144: Handlebar
CHAS HANDLEBAR HANDLEBAR HANDLEBAR 9Nm(0.9 m.kg, 6.5 ft.lb) 43Nm(4.3 m.kg, 37 ft.lb) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in order. Left/Right bake mirror Front protector bar Refer to “COVERS AND PANEL” IN Upper cover CHAPTER 3. Front/Rear handlebar cover Left/Right flasher Brake master cylinder...
Page 145 CHAS HANDLEBAR 9Nm(0.9 m.kg, 6.5 ft.lb) 43Nm(4.3 m.kg, 37 ft.lb) Order Job name/Part name Q’ty Remarks Wire harness strap Brake hose Handlebar comp. Left grip Reverse the removal procedure for in- stallation. 6-26...
Page 146: Handlebar Installation
CHAS HANDLEBAR HANDLEBAR INSTALLATION 1. Clean: 8 Steering shaft a Proper cables and leads routing is essential to issue safe scooter operation. 2. Install: 8 Handlebar 1 8 Bolt 2 8 Nut 43Nm(4.3 m.kg, 37ft.lb) NOTE: Match the bolt 2 on to the steering column dent a.
Page 147 CHAS HANDLEBAR 6. Install: 8 Handlebar switch (left) 1 NOTE: Insert the projection a into the hole b on the handlebar comp. 7. Install: 8 Master cylinder NOTE: Match the slot with the punched mark b on the handlebar comp. 6-28...
Page 148: Steering
CHAS STEERING STEERING STEERING 66Nm(6.6 m.kg, 47.8 ft.lb) 22Nm(2.2 m.kg, 16 ft.lb) 38Nm(3.8 m.kg, 27ft.lb) 40Nm(4.0 m.kg, 29 ft.lb) Order Job name/Part name Q’ty Remarks Steering removal Remove the parts in order Handlebar Refer to “HANDLEBAR” section. Front wheel Refer to “FRONT WHEEL AND BRAKE DISC”...
Page 149: Steering Removal
CHAS STEERING STEERING REMOVAL 8 Securely support the scooter so that there is no danger of it falling over. 8 Stand the scooter on a level surface. 1. Removal: 8 Ring nut 1 1 8 Special washer 2 8 Ring nut 2 3 8 Rubber washer 4 8 Ring nut 3 5 8 Bearing cover 6...
Page 150: Steering Inspction
CHAS STEERING STEERING INSPECTION 1. Wash the bearing races with a solvent. 2. Inspect: 8 Ball race 8 Ball Pitting/Damage→Replace. NOTE: Always replace bearings and races as set. 3. Inspect: 8 Under bracket 1 Crack/Bend/Damage→Replace. Do not attempt to straighten a bent under bracket as this may dangerously weaken the under bracket.
Page 151 CHAS STEERING 3. Install: 8 Front fork assembly 1 8 Ball race (Upper) 2 8 Bearing cover 3 8 Ring nut 3 4 8 Rubber washer 5 8 Ring nut 2 6 8 Special washer 7 8 Ring nut 1 8 NOTE: Securely support the steering shaft so that there is no danger of it falling down.
Page 152 CHAS STEERING Slots on the ring nut 2 and ring nut 3 should be align. If not, turn the ring nut 2 towards tighten direction until slots alignment. 8 Install special washer 6 NOTE: Insert the projections of the special washer into the slots.
Page 153: Front Fork
CHAS FRONT FORK FRONT FORK FRONT FORK 40Nm(4.0 m.kg, 29 ft.lb) 38Nm(3.8 m.kg,27 ft.lb) Order Job name/Part name Q’ty Remarks Front fork removal Remove the parts in order. Steering Refer to “Steering” section. Under fender Speedometer cable holder Cap bolt Pinch bolt Refer to “FRONT FORK REMOVAL/IN- Front fork...
Page 154: Front Fork Disassembly
CHAS FRONT FORK FRONT FORK DISASSEMBLY 23Nm(2.3 m.kg, 16.6 ft.lb) Order Job name/Part name Q’ty Remarks Front fork disassembly Remove the parts in order. Fork spring Refer to “FRONT FORK REMOVAL/IN- STALLATION” section. Band/Front fork boot Bolt/Copper washer Inner tube Damper rod Refer to “...
Page 155: Front Fork Removal
CHAS FRONT FORK YP..FRONT FORK REMOVAL 8 Securely support the scooter so there is no danger of it falling over. 8 Stand the scooter on a level surface. 8 Stand the scooter on its centerstand. 1. Remove: 8 Under fender 1 2.
Page 156: Front Fork Inspection
CHAS FRONT FORK 2. Remove: 8 Inner tube 1 8 Oil lock pice 2 8 Damper rod 3 8 Rebound spring 4 3. Remove: 8 Oil seal 1 Never reuse the oil seal. 2 Rag YP703030 FRONT FORK INSPECTION 1. Inspect: 8 Inner tube bending Inner tube bending limit: 0.2 mm(0.008 in)
Page 157 CHAS FRONT FORK 2. Install: 8 Inner tube 1 Into outer tube 2. 3. Install: 8 Plain washer 1 8 Bolt (damper rod) 2 4. Tighten: 8 Bolt (damper rod) 1 23Nm(2.3 m.kg, 16.6ft.lb) NOTE: Tighten the damper rod bolt 1 while holding the damper rod with a T-handle 2 and holder 3.
Page 158: Front Fork Installation
CHAS FRONT FORK 6. Inspect: 8 Inner tube operation Unsmooth operation→Disassembly and recheck. 7. Fill: 8 Fork oil 1 Oil quantity: 88 cc Recommended oil: Fork oil 10 W or equivalent 8. After filling up, slowly pump the fork up and down to distribute the fork oil.
Page 159: Electrical
– ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 8 Battery 2 Flasher relay 9 Ignition coil 3 Oil level gauge 0 Rectifier/Regulator 4 C.D.I. UNIT q Horn 5 Fuel level gauge 6 Starter relay 7 Fuse...
Page 160: Circuit Diagram
– ELEC CIRCUIT DIAGRAM CIRCUIT DIAGRAM LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH...
Page 161 – ELEC CIRCUIT DIAGRAM 1 Main switch a Head light(for low beam) 2 Main fuse s Flasher relay 3 Battery d Horn 4 Starter relay f Handlebar switch (left) 5 Starter motor g Horn switch 6 Rectifier regulator h Dimmer switch 7 Auto choke j Turn switch 8 C.D.I.
Page 162: Checking Switches
– ELEC CHECKING SWITCHES YP-N CHECKING SWITCHES “0” “∞” CHECKING STEPS Using pocket tester, check switches for conti- nuity between their terminals to determine whether they are correctly connected. “Ω×1” Replace the switch component if any of the combinations does not produce the correct reading.
Page 163: Switch Position And Terminal Connection
– ELEC CHECKING SWITCHES SWITCH POSITION AND TERMINAL CONNECTION Before checking a switch refer to the check- Main switch ing switches as shown in the left page and Gy Br R B B/W check for the correct terminal connections LOCK (closed circuit) according to the color combi- OPEN nations shown in the chart.
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: 8 bulb 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: 8 bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester YU-03112 NOTE:...
Page 167: Ignition System
– ELEC IGNITION SYSTEM CIRCUIT DIAGRAM LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH 1 Main switch 8 C.D.I. magneto 9 C.D.I. unit 0 Ignition coil q Spark plug m Engine stop switch...
Page 168: Troubleshooting
– ELEC IGNITION SYSTEM TROUBLESHOOTING IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE (NO SPARK OR INTERMITTENT SPARK) NOTE: 8 Remove the following parts before troubleshooting. 1) Battery box cover 4) Tail cover 2) Center cowling 5) Side cover (right) 3) Rear carrier 6) Handlebar cover (front) 8 Use the following special tools in this troubleshooting.
Page 169 – ELEC IGNITION SYSTEM 3. Spark plug cap resistance 8 Remove the spark plug cap. Ω×1k 8 Connect the pocket tester (Ω × 1k) to the spark plug cap. 8 Check the spark plug cap for specificated resistance. Spark plug cap resistance: 5kΩ...
Page 170 – ELEC IGNITION SYSTEM 5. Pickup coil resistance 8 Disconnect the pickup coil coupler from the wireharness. 8 Connect the pocket tester (Ω × 100) to the pickup coil terminal. Magneto Tester (+) lead→White/Red lead 1 Tester (-) lead→White/Blue 2 8 Check the pickup coil for specificated re- OUT OF SPECIFICATION sistance.
Page 171 – ELEC IGNITION SYSTEM NO CONTINUITY 8. Engine stop switch Refer to “CHECKING SWITCHS” section. Engine stop switch is faulty, replace it. CONTINUITY POOR CONNECTION 9. Wiring connection Check the entire ignition system for connec- tions. Refer to the “WIRING DIAGRAM” section. Correct.
Page 172: Charging System
– ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH 2 Main fuse 3 Battery 6 Rectifier Regulator 8 CDI magnet 7-14...
Page 173: Troubleshooting
– ELEC CHARGING SYSTEM TROUBLESHOOTING THE BATTERY IS NOT CHARGED. NOTE: 8 Remove the following parts before troubleshooting. 1) Front protector bar 4) Tail cover 2) Upper cover 5) Right side cover 3) Rear carrier 8 Use the following special tool (s) in this trobleshooting. Inductive tachometer: Pocket tester: YU-8036-A...
Page 174 – ELEC CHARGING SYSTEM 3. Charging voltage 8 Connect the inductive tachometer to the spark plug lead. 8 Connect the pocket tester (DC20V) to the battery. Tester (+) lead→Battery (+) terminal Tester (-) lead→Battery (–) terminal 8 Start the engine and accelerate to about 5,000 r/min.
Page 175 – ELEC CHARGING SYSTEM 5. Wiring connection Check the entire ignition system for con- POOR CONNECTION nections. Refer to the “WIRING DIAGRAM” section. Correct. Replace rectifier regulator. 7-17...
Page 176: Electric Starting System
– ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH 1 Main switch e Front brake switch 2 Main fuse m Engine stop switch 3 Battery , Starter switch 4 Starter relay 5 Starter motor w Rear brake switch 7-18...
Page 177: Troubleshooting
– ELEC ELECTRIC STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. NOTE: 8 Remove the following parts before troubleshooting. 1)Battery box cover 4)Side covers (left and right) 2)Rear carrier 5)Trunk 3)Tail cover 6)Handlebar cover (front) 8 Use the following special tool in this troubleshooting. Pocket tester: YU-03112 1.
Page 178 – ELEC ELECTRIC STARTING SYSTEM 4. Starter relay 8 Disconnect the relay unit coupler from the wire harness. 8 Connect the pocket tester(Ω × 1)and battery(12V) to the relay unit coupler ter- minals. Battery(+)lead→ Blue/White terminal 1 Battery(–)lead→ Green/Yellow terminal 2 8 Check the starter relay for continuity.
Page 179 – ELEC ELECTRIC STARTING SYSTEM CONTINUITY 8. Brake switches (front and rear) 8 Disconnect the brake switch leads from the wire harness. 8 Connect the pocket tester (Ω × 1 )to the brake switch leads. 8 Check the brake switch for continuity Switch Good Bad condition...
Page 180: Starter Motor
– ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 13Nm(1.3 m.kg, 9.4 ft.lb) Order Q’ty Remarks Job name/Part name Remove the parts in order. Starter motor removal Rear carrier Refer to “COVER PANEL” section in Tail cover CHAPTER 3. Battery box cover Left/Right side cover Center cowling Refer to “REAR WHEEL AND REAR...
Page 181: Starter Motor Disassembly
– ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR DISASSEMBLY 13Nm(1.3 m.kg, 9.4 ft.lb) Order Job name/Part name Q’ty Remarks Starter motor disassembly Disassembly the parts in order. O-ring Rear bracket Armature ass’y Refer to “Starter motor assembly” Ring Brush holder set Reverse the disassembly procedure for assembly.
Page 182: Inspection And Repair
– ELEC ELECTRIC STARTING SYSTEM YP803034 INSPECTION AND REPAIR 1. Inspect: 8 Commutator Dirt→Clean it with #600 grit sandpaper. 2. Measure: 8 Commutator diameter a Commutator wear limit: 15.1 mm (0.59 in) Out of specification→Replace the starter motor 3. Measure: 8 Mica undercut a Mica undercut: 1.05 mm (0.04 in)
Page 183 – ELEC ELECTRIC STARTING SYSTEM 5. Measure: 8 Brush length a Out of specification→Replace. Brush length wear limit 3.0 mm (0.012 in) 6. Measure: 8 Brush spring force Fatigue/out of specification→Replace as a set. 7-25...
Page 184: Lighting System
– ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH 1 Main switch p Head light(for high beam) 2 Fuse a Head light(for low beam) 3 Battery j Light dimmer switch 8 C.D.I. magneto x Meter light r Tail light c High beam indicator light...
Page 185: Troubleshooting
– ELEC LIGHTING SYSTEM YP805010 TROUBLESHOOTING IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT AND/OR METER LIGHT FAIL TO COME ON. Procedure Check: 1. Lights switch 2. Dimmer switch 3. Wiring connection (entire lighting system) NOTE: 8 Remove the following parts before troubleshooting. 1) Front handlebar cover 2) Rear carrier 3) Right side cover...
Page 186 – ELEC NO CONTINUITY YP ..4. Dimmer switch Refer to “CHECKING SWITCHES” section. CONTINUITY Replace the left handlebar switch. 5. Lighting coil resistance 8 Disconnect the lighting coil coupler from the wireharness. 8 Connect the pocket tester “ Ω x 1 “ to the lighting coils.
Page 187: Lighting System Check
– ELEC LIGHTING SYSTEM YP..6. Wiring connection POOR CONNECTIONS 8 Check the connections of the entire light- ing system. Refer to “WIRING DIAGRAM”. Correct. Check the condition of each of the lighting system’s circuits. Refer to “LIGHTING SYSTEM CHECK” YP805020 LIGHTING SYSTEM CHECK 1.
Page 188 – ELEC LIGHTING SYSTEM 8 Turn the main switch to on. OUT OF SPECIFICATION 8 Start the engine. 8 Turn the dimmer switch to low beam or high beam. 8 Check for voltage (12V) on the lead at bulb socket connectors. The wiring circuit from the main switch to bulb socket connector is faulty.
Page 189 – ELEC LIGHTING SYSTEM 3. Licence light does not come on. 1. Bulb and bulb socket NO CONTINUITY 8 Check the bulb and bulb socket for conti- nuity CONTINUITY Bulb and/or bulb socket are faulty, replace. 2. Voltage 8 Connect the pocket tester (DC20V) to the bulb socket connector.
Page 190 – ELEC LIGHTING SYSTEM YP805022 3. The taillight fails to come on. NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. CONTINUITY Replace the bulb and/or bulb socket. 2. Voltage 8 Connect the pocket tester (DC20V) to the bulb socket connector.
Page 191: Signal System
– ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH 1 Main switch y Rear flasher light(left) j Turn switch 2 Main fuse i Front flasher light(right) k Fuel sender 3 Battery o Front flasher light(left) ;...
Page 192: Troubleshooting
– ELEC SIGNAL SYSTEM YP806010 TROUBLESHOOTING IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON. IF THE HORN FAILS TO SOUND. Procedure Check: 1. Fuse (Main) 3.Main switch 2. Battery 4.Wiring connection (entire signal system) NOTE: 8 Remove the following parts before troubleshooting.
Page 193 – ELEC SIGNAL SYSTEM YP..4. Wireharness POOR CONNECTION 8 Check the connections of the entire sig- nal system. Refer to “CIRCUIT SYSTEM WIRING DIA- GRAM” section. Correct. CONTINUITY Check condition of each of the signal system’s circuits. Refer to “SIGNAL SYSTEM CHECK” sec- tion.
Page 194: Signal System Check
– ELEC SIGNAL SYSTEM YP806020 SIGNAL SYSTEM CHECK 1. If the horn fails to sound. NO CONTINUITY 1. HORN switch Refer to “CHECKING SWITCHES” section. Replace the left handlebar switch. CONTINUITY 2. Voltage 8 Connect the pocket tester (DC20V) to the horn lead.
Page 195 – ELEC SIGNAL SYSTEM YP806022 2. If the brake light fails to come on: NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2. Brake switch (Front/Rear) Refer to “CHECKING SWITCHES” section. CONTINUITY Replace brake switch.
Page 196 – ELEC SIGNAL SYSTEM YP806023 3. If the flasher light and/or turn indicator light fails to blink. NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2. Turn switch Refer to “CHECKING SWITCHES”...
Page 197 – ELEC SIGNAL SYSTEM 5. Voltage 8 Connect the pocket tester (DC20V) to the bulb socket connector. At flasher light (left) Ch B Tester (+) lead→Chocolate lead 1 Dg B Tester (-) lead→Black terminal 3 Ch B Dg B At flasher light (right) Tester (+) lead→Dark green lead 2 Tester (-) lead→Black terminal 3 OUT OF SPECIFICATION...
Page 198 – ELEC SIGNAL SYSTEM 3. Voltage 8 Connect the Pocket Tester (DC20V) to the bulb socket connector. Tester (+) Lead→Gray lead 1 Tester (-) Lead→Black lead 2 B Gy L 8 Turn the main switch to “*” 8 Check for voltage (12V) on the “Gray” lead at bulb socket connector.
Page 199 – ELEC SIGNAL SYSTEM 2. Voltage 8 Connect the pocket tester (DC20V) to the fuel gauge coupler. Tester (+) lead→Brown terminal 1 Tester (-) lead→Frame ground Gy B 8 Turn the main switch to “ON”. 8 Check for voltage (12V) of the “Brown” OUT OF SPECIFICATION lead on the fuel sender lead.
Page 200: Auto Choke System
– ELEC AUTO CHOKE SYSTEM AUTO CHOKE SYSTEM CIRCUIT DIAGRAM LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH 7 Auto choke 8 C.D.I. magneto 7-42...
Page 201 – ELEC AUTO CHOKE SYSTEM YP..TROUBLESHOOTING IF THE AUTO CHOKE FAILS TO OPERATE. Procedure Check: 1. Lighting coil resistance 2. Auto choke unit resistance 3. Wiring connection (entire auto choke system) NOTE: 8 Remove the following parts before troubleshooting. 1.
Page 202 – ELEC AUTO CHOKE SYSTEM YP... 2. Auto choke unit resistance 8 Disconnect the auto choke unit coupler from the wireharness. 8 Connect the pocket tester (Ωx1) to the auto choke unit coupler lead. Tester (+) lead→Black terminal 1 OUT OF SPECIFICATION Tester (-) lead→Black terminal 2 Auto choke unit resistance: 8~12Ω...
Page 203: Troubleshooting
TRBL STARTING FAILURE/HARD STARTING SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM PROBABLE CAUSE...
Page 204: Ignition System
TRBL STARTING FAILURE/HARD STARTING SHTG IGNITION SYSTEM PROBABLE CAUSE 8 Improper plug gap Spark plug 8 Worn electrodes 8 Wire between terminals broken 8 Improper heat range 8 Faulty spark plug cap 8 Broken or shorted primary/secondary coil Ignition coil 8 Faulty spark plug lead 8 Broken body 8 Faulty CD I unit...
Page 205: Poor Idle Speed Performance
POOR IDLE SPEED PERFORMANCE TRBL POOR MIDIUM AND HIGH SPEED PERFORMANCE SHTG POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE PROBABLE CAUSE 8 Improperly returned starter plunger Carburetor 8 Clogged or loose pilot jet 8 Clogged pilot air jet 8 Improperly adjusted idle speed (Throttle stop screw) 8 Improper throttle cable play 8 Flooded carburetor...
Page 206: Fulty Automatic(V-Belt Type)
TRBL POOR MIDIUM AND HIGH SPEED PERFORMANCE SHTG FAULTY AUTOMATIC(V-BELT TYPE) PROBABLE CAUSE SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING 8 Worn, damaged or slipped V-belt V-belt 8 Worn, damaged Cam, slider 8 Damaged Compression spring 8 Damaged Transmission CLUTCH OUT FAILURE 8 Damaged Clutch weight spring...
Page 207: Overheat
TRBL OVER HEAT / POOR SPEED SHTG OVERHEAT OVER HEAT PROBABLE CAUSE Ignition system 8 Improper plug gap 8 Improper spark plug heat range 8 Faulty C.D.I. unit 8 Improper carburetor setting Fuel system 8 Clogged air filter 8 Carbon accumulation of cylinder head Compression system 8 Clogged Muffler, Exhaust pipe...
Page 208: Improper Kicking
TRBL IMPROPER KICKING SHTG IMPROPER KICKING SLIPPING PROBABLE CAUSE Kick axle assembly 8 Low tension of kick clip 8 Worn kick axle 8 Worn or damaged kick gear 8 Damaged kick clip 8 Kick clip coming off 8 Damaged kick clip stopper Transmission oil 8 Improper quality (Low viscosity) 8 Deterioration...
Page 209: Faulty Brake
TRBL FAULTY BRAKE SHTG FAULTY BRAKE PROBABLE CAUSE POOR BRAKING EFFECT 8 Worn brake shoe Drum brake 8 Worn or rusty brake drum 8 Improperly adjusted brake free play 8 Improper brake cam lever position 8 Improper brake shoe position 8 Fatigue/Damaged return spring 8 Oily or greasy brake shoe 8 Oily or greasy brake drum...
Page 210: Instable Handling
TRBL INSTABLE HANDLING SHTG UNSTABLE HANDLING PROBABLE CAUSE INSTABLE HANDLING 8 Improperly installed or bent Handlebar 8 Improperly installed steering column Steering (Improperly tightened ringnut) 8 Bent steering column 8 Damaged ball bearing or bearing race 8 Broken spring Front forks 8 Bonded front forks 8 Uneven tire pressures on both sides Tires...
Page 211: Faulty Signal And Lighting System
TRBL FAULTY SIGNAL AND LIGHTING SYSTEM SHTG FAULTY SIGNAL AND LIGHTING SYSTEM PROBABLE CAUSE HEADLIGHT DARK 8 Improper bulb 8 Too many electric accessories 8 Hard charging (Broken charging coil) 8 Incorrect connection 8 Improperly grounded 8 Poor contacts (main or light switch) 8 Bulb life expires PROBABLE CAUSE BULB BURNT OUT...
Page 212: Flasher Blinks Slower
TRBL FAULTY SIGNAL AND LIGHTING SYSTEM SHTG FLASHER BLINKS SLOWER PROBABLE CAUSE 8 Faulty flasher relay 8 Insufficient battery capacity (nearly discharged) 8 Improper bulb 8 Faulty main and/or flasher switch FLASHER BLINKS QUICKER PROBABLE CAUSE 8 Improper bulb 8 Faulty flasher relay HORN DOES NOT SOUND PROBABLE CAUSE 8 Faulty battery...
Page 213: Wiring Diagram
1 Main switch Black WIRING DIAGRAM 2 Main fuse Brown 3 Battery Chocolate 4 Starter relay Dark Green 5 Starter motor Green 6 Rectifier regulator Blue LOCK OPEN 7 Auto choke Orange CHECK 8 C.D.I. magneto Sky blue 9 C.D.I. unit Pink 0 Ignition q Spark plug...
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Yamaha YW50AP Service Manual

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7 Electrical

Chapter 8

Quick Links

Troubleshooting

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Summary of Contents for Yamaha YW50AP