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CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS

……3-1

REAR BODYWORK AND MUDGUARD

………………………………………3-2

REMOVAL ………………………………………………………………………3-2
INSTALLATION …………………………………………………………………3-3

FRONT COWLING AND FOOTREST

…………………………………………3-4

REMOVAL ………………………………………………………………………3-4
INSTALLATION …………………………………………………………………3-5

HANDLEBAR COVERS

…………………………………………………………3-6

REMOVAL ………………………………………………………………………3-6
INSTALLATION …………………………………………………………………3-7

ENGINE

……………………………………………………………………………3-8

ADJUSTING THE ENGINE IDLING SPEED …………………………………3-8
ADJUSTING THE THROTTLE CABLE FREE PLAY ………………………3-9
CHECKING THE SPARK PLUG ……………………………………………3-10
CHECKING THE ENGINE OIL LEVEL  ……………………………………3-11
CHANGING THE TRANSMISSION OIL ……………………………………3-12
AUTOLUBE PUMP AIR BLEEDING ………………………………………3-12
CLEANING THE AIR FILTER ELEMENT……………………………………3-13
CHECKING THE COOLANT LEVEL (CS50Z only) ………………………3-14
CHANGING THE COOLANT (CS50Z only) ………………………………3-15

CHASSIS

…………………………………………………………………………3-18

ADJUSTMENT THE FRONT BRAKE LEVER………………………………3-18
ADJUSTMENT THE REAR BRAKE LEVER ………………………………3-18
CHECKING THE FRONT BRAKE PADS

…………………………………3-18

CHECKING THE REAR BRAKE SHOES …………………………………3-19
CHECKING THE BRAKE FLUID LEVEL……………………………………3-19
BLEEDING THE HYDRAULIC BRAKE SYSTEM …………………………3-20
CHECKING AND ADJUSTING THE STEERING HEAD …………………3-21
CHECKING THE TIRES

……………………………………………………3-23

CHECKING THE WHEELS …………………………………………………3-23
CHECKING THE FRONT FORK ……………………………………………3-23
REAR SHOCK ABSORBER INSPECTION…………………………………3-24

ELECTRICAL SYSTEM

…………………………………………………………3-25

CHECKING AND CHARGING THE BATTERY ……………………………3-25
CHECKING THE FUSE ………………………………………………………3-30
REPLACING THE HEADLIGHT BULB ……………………………………3-31
ADJUSTING THE HEADLIGHT BEAM ……………………………………3-31

CHK

ADJ

Summary of Contents for 2002 CS50

Page 1: ...2002 SERVICE MANUAL CS50 Z5RW1 AE1 ...

Page 2: ...E MANUAL 2002 by Yamaha Motor España S A 1st Edition September 2002 Any reprinting or use of this material without the prior authorisation of Yamaha Motor España S A is expressly prohibited Printed in Spain EAS00001 ...

Page 3: ...ts models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha MBK dealers and will appear in future editions of this manual where applicabe NOTE Designs and specifications are subject to change without notice EAS00005 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following The Safety Aler...

Page 4: ...ovide useful reference material which contains ample explanations of all disassembly repair assembly and inspection procedures A par ticularly important procedure is placed between a lines of asterisks with each procedure pre ceded by IMPORTANT CHARACTERISTICS Data and special tools are put in a box preceded by a corresponding symbol A number within a circle indicates the number of a part and a al...

Page 5: ...r in the text 10 Refill liquid 11 Lubricant 12 Special tool 13 Torque 14 Wear play limit 15 Motor speed 16 Ω V A The illustrated symbols from 17 to 24 of the detailed diagrams indicate the grade of lubri cant and the site of the lubrication point 17 Apply motor oil 18 Apply gear oil 19 Apply molybdenum disulphide oil 20 Apply wheel bearing grease 21 Apply lightweight lithium soap base grease 22 Ap...

Page 6: ...S CHK ADJ 3 PERIODIC CHECKS AND ADJUSTMENTS ENG 4 ENGINE COOL 5 COOLING SYSTEM CARB 6 CARBURETOR CHAS 7 CHASSIS ELEC 8 ELECTRICAL SYSTEM EAS00010 TABLE OF CONTENTS TRBL SHTG 9 TROUBLESHOOTING GENERAL INFORMATION GEN INFO 1 ...

Page 7: ...GEN INFO 1 ...

Page 8: ... IDENTIFICATION 1 1 FRAME SERIAL NUMBER 1 1 ENGINE SERIAL NUMBER 1 1 IMPORTANT INFORMATION 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 2 CIRCLIPS 1 3 SPECIAL TOOLS 1 4 ...

Page 9: ... chassis ENGINE SERIAL NUMBER The serial number of the engine is stamped on the raised portion of the rear left section of the transmission box NOTE The first three digits of these numbers are for identifying the model the remaining digits constitute the production number of the unit NOTE Designs and specifications are subject to change without notice ...

Page 10: ... the oil seal lips EAS00023 LOCK WASHERS PLATES AND COTTER PINS 1 Replace all lock washers plates and cot ter pins after removal Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification EAS00024 BEARINGS AND OIL SEALS 1 Install the bearings and oil stops with their manufacturer brands or numbers facing outwards In other words the stam ped letters should ...

Page 11: ...Check all circlips carefully before reas sembly Always replace piston pin clips after one use Replace distorted circlips When installing a circlip make sure that the sharp edged corner is positioned opposite the thrust it receives See sec tional view Shaft ...

Page 12: ...while holding the compression spring 90890 01274 Container of the crankshaft installer a 01275 Bolt of the crankshaft installer b 01277 Adapter c Spacer d 01288 These tools are used to install the crankshaft 90890 01362 Flywheel puller For removing the flywheel 90890 01135 Crankcase separation tool This tool is used to remove the crankshaft or separate the crankcase 90890 01384 Oil seal guide Prot...

Page 13: ...the left oil seal of the crankcase 90890 06754 Ignition checker This instrument is necessary to check the components of the ignition system 90890 85505 Yamaha bond No 1215 This bond sealant is used for crankcase mating surface etc 90890 01348 Locknut wrench This tool is used to loosen and tighten the secondary sheave nut 90890 01367 Front oil seals inserter 01400 Counterweight a Adapter b These to...

Page 14: ...SPEC 2 ...

Page 15: ...NCE SPECIFICATIONS 2 3 ENGINE 2 3 CHASSIS 2 5 ELECTRICAL SYSTEM 2 6 CONVERSION TABLE 2 7 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 7 TIGHTENING TORQUES 2 8 ENGINE TIGHTENING TORQUES 2 8 CHASSIS TIGHTENING TORQUES 2 9 COOLING SYSTEM CS50Z only 2 10 CABLE ROUTING 2 11 ...

Page 16: ...r grade Engine oil 2 strokes motor oil JASO grade FC Transmission oil SE type 10W30 SAE motor oil Oil capacity Oil tank motor oil 1 4 L Transmission fluid Periodic fluid change 0 10 L Total amount 0 11 L Cooling system capacity Total amount 0 910 L Air filter Wet type element Fuel Type Unleaded gasoline Fuel tank capacity 5 5 L Carburetor Type quantity PHVA12ZS 1 PY12 1 PHVA12ZS 1 Manufacturer DEL...

Page 17: ...ork Rear suspension Unit swing Shock absorber Front shock absorber Coil spring Oil damper Rear shock absorber Coil spring Oil damper Wheel travel Front wheel travel 70 mm Rear wheel travel 60 mm Electrical Ignition system DC CDI Generator system Magnetic flywheel Battery type or model Maintenance free Battery capacity 12V 4AH Type of headlamp Bulb Bulb wattage quantity Headlight 12V 35W 35Wx1 Tail...

Page 18: ...2 mm 39 957 39 997 mm Measuring point 5 mm Piston clearance 0 034 0 047 mm 0 029 0 042 mm On measurement 1st 40 25 mm Piston rings Cut away section BXT TYPE Top ring 1 5 x 1 8 mm Keystone 2nd ring 1 5 x 1 8 mm Keystone End gap installed Top ring 0 15 0 35 mm 2nd ring 0 15 0 35 mm Limit 0 6 mm Sice clearance Top ring 0 03 0 05 mm 2nd ring 0 03 0 05 mm Crankshaft Crank width A 37 90 37 95 mm Runout ...

Page 19: ...ccentricity limit 0 08 mm Drive axle eccentricity limit 0 08 mm Pedal starting Type Ratchet Strength of pedal spring 150 250 g Air filter oil grade For foam air filter or air cooled 2 stroke motor oil Carburetor Type Manufacturer Amount PHVA12ZS 1 PY12 1 PHVA12ZS 1 DELL ORTO GURTNER DELL ORTO Main jet Model M J 65 62 65 Jet needle J N A20 3 5 B10A 2 3 A35 4 5 Main air jet M A J ø 2 5 ø 2 0 ø 2 5 P...

Page 20: ...Type of rear wheel Alloy rim Size material of front tyre 2 75 x 12 aluminium Size material of rear tyre 3 00 x 12 aluminium Rim runout limit Radial 1 0 mm Lateral 1 0 mm Front disc brake Type Single Disc outside diameter x thickness ø 190 x 3 5 mm Pad thickness 4 5 mm Limit 0 5 mm Interior diameter of pump 11 mm Calliper interior diameter 30 mm Brake fluid type DOT 4 Rear drum brake Type Single ca...

Page 21: ...system Normal output 0 4 A or more 3 000 r min 1 0 A or less 8 000 r min Source coil resistance colour 0 288 0 432 Ω at 20 C 68 F White Black Lighting system Lighting output 12 V or more 3 000 r min 15 V or less 8 000 r min Lighting coil resistance colour 0 176 0 264 Ω at 20 C 68 F Yellow Red Black Battery Type GT4L BS Capacity 12V 4 Ah Electric starter system Type Constant mesh type Starter motor...

Page 22: ...ning Nut Bolt torques Nm m kg 10 mm 6 mm 6 0 6 12 mm 8 mm 15 1 5 14 mm 10 mm 30 3 0 17 mm 12 mm 55 5 5 19 mm 14 mm 85 8 5 22 mm 16 mm 130 13 0 EAS00028 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 Ex METRIC MULTIPLIER IMPERIAL mm x 0 03937 in 2 mm x 0 03937 0 08 in CONVERSION TABLE METRIC T...

Page 23: ...olt M 8 2 26 2 6 Exhaust pipe protector Bolt M 6 2 0 7 0 7 Exhaust pipe cover Bolt M 6 5 0 7 0 7 Crankcase Bolt M 6 6 10 1 0 Cover of crankcase 2 Bolt M 6 6 10 1 0 Cover of crankcase 1 Bolt M 6 12 12 1 2 Air conduct A C Screw M 6 2 7 0 7 Crankcase bracket Screw M 6 2 7 0 7 Drain bolt Bolt M 8 1 18 1 8 Oil plug Plug M 14 1 3 0 3 Intermediate gear plate Screw M 6 2 8 0 8 Kickstarter Bolt M 6 1 9 0 9...

Page 24: ... 25 axle guide Axle guide M25 x 1 00 75 7 5 See chapter 3 ADJUSTING THE STEERING HEAD Brake tube joint screw M10 x 1 25 23 2 3 Seats and related parts Seat lock unit M6 x 1 0 9 75 0 975 Hook bracket M6 x 1 0 8 0 8 Case M6 x 1 0 8 0 8 Covers and related parts Plastic parts plastic covers M5 1 5 0 15 Frame footrest plate M6 x 1 0 4 0 4 Leg protector 2 frame M6 x 1 0 4 0 4 Front and rear wheels Front...

Page 25: ...SPEC COOLING SYSTEM 2 10 COOLING SYSTEM L C VERSION ONLY Radiator Water pump Cylinder Reservoir tank ...

Page 26: ... L C 14 DC CDI 15 Coolant hoses Carburetor L C A Insert the three tubes through the clamp B Connect the oil hose to the carburettor C Set the intake hose under the reinforcement L C D Clamp the fuel pipe to the carburettor E Tighten together the ground cable and the starter motor F Clamp all the cables except the coolant hose L C without tightening G Clamp the intake hose to the air filter box L C...

Page 27: ...meter cable A Clamp the wire harness brake cable and throttle to the frame B Clamp the oil hose to the tank C Connect the oil hose to the pump D Tie both ends E Tighten together the ground cable and the ignition coil F Pass the speedometer cable through the guide G Insert the seat lock cable throught the orifi ce of the frame CABLE ROUTING ...

Page 28: ...nt brake switch Wire harness Throttle cable Rear brake cable Front brake hose A Throttle tension cable Cover then adjust B Connect the brake switch cables in this area C Do not pass the brake hose through the clamp CABLE ROUTING ...

Page 29: ...CHK ADJ 3 ...

Page 30: ...EEDING 3 12 CLEANING THE AIR FILTER ELEMENT 3 13 CHECKING THE COOLANT LEVEL CS50Z only 3 14 CHANGING THE COOLANT CS50Z only 3 15 CHASSIS 3 18 ADJUSTMENT THE FRONT BRAKE LEVER 3 18 ADJUSTMENT THE REAR BRAKE LEVER 3 18 CHECKING THE FRONT BRAKE PADS 3 18 CHECKING THE REAR BRAKE SHOES 3 19 CHECKING THE BRAKE FLUID LEVEL 3 19 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 20 CHECKING AND ADJUSTING THE STEERING ...

Page 31: ...rs 7 Wheels Check runout and for damage 8 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 9 Wheel Check bearing for looseness or damage bearings 10 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 24 000 km 11 Chassis fasteners Make sure that all nuts bolts and screws are properly tigh...

Page 32: ...BODYWORK MUDGUARD REMOVAL 1 Remove seat 2 Remove central panel NOTE Slide the panel to the front 3 Remove rear fender 4 Remove oil tank cap and grommet fuel tank cap and grommet passenger hand grap bolts and collars passenger hand grap o i l ...

Page 33: ...n side cover and tail light 6 Remove battery cover leads and battery oil tank fixing bolt NOTE Fix the oil tank to the frame with a band helmet box 7 Remove rear mudguard 4 bolts INSTALLATION Reverse the removal process NOTE After installing all plastic parts check that all hooks are properly attached ...

Page 34: ...LING AND FOOTREST 3 4 FRONT COWLING AND FOOTREST REMOVAL 1 Remove front upper cowling NOTE Disconect front light and indicator light cou plers 2 Remove front middle cowling 3 Remove lower cowling 4 Remove under cowling ...

Page 35: ...REST 3 5 5 Remove legshield NOTE Remove first the main switch cover 6 Remove hook bracket 7 Remove footrest INSTALLATION Reverse the removal process NOTE After installing all plastic parts check that all hooks are properly attached ...

Page 36: ...handlebar cover NOTE Disconect panel meter couplers 2 Remove front master cylinder 2 bolts handlebar switch couplers stop switch couplers rear brake wire from lever side throttle wire from throttle grip 3 Remove handlebar fixing bolt 4 Remove lower handlebar cover bolts ...

Page 37: ...6 Remove the wiring harness rubber band from the handlebar 7 Remove handlebar lower handlebar cover INSTALLATION Reverse the removal process NOTE For handlebar installation refer to chapter 7 After installing all plastic parts check that all hooks are properly attached ...

Page 38: ... b Turn the pilot air screw in or out until it is lightly seated c Turn the pilot screw out the specified num ber of turns d Turn the throttle stop screw in direction a or b until the specified engine idling speed is obtained e Install the center panel 5 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Engine tachometer 90890 03113 Pilot air screw setting CS50 Dellor...

Page 39: ...ified throttle cable free play cannot be obtained on the carburetor side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the locknut b Turn the adjusting nut in direction a or b until the specified throttle cable freey play is obtained c Thighten the loknut s s WARNING After adjusting the throttle cable free play start the engine and turn the handlebar to the right...

Page 40: ...rect Change 4 Check electrode Damage wear Replace the spark plug insulator 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 Measure spark plug gap a with a wire Thickness gauge Out of specification Regap 7 Install spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 8 Connect s...

Page 41: ...not lit Inspect for defective electric circuit bulbs etc The OIL CAUTION indicator light is lit Place the main switch in position f The OIL CAUTION indicator light is not lit The OIL CAUTION indicator light is lit Supply engine oil The OIL CAUTION indicator light is lit The engine oil level and electric circuit are in good condition NOTE After filling the oil tank close it with the cap and close t...

Page 42: ...ase AUTOLUBE PUMP AIR BLEEDING The air bleeding must be done always the oil tank is empty when the intake lube is discon nected or the tank is disassembled NOTE The air bleeding must be done after filling the oil tank 1 Remove fan cover CS50 crankcase cover right CS50Z 2 Remove drain screw Let the oil flow out until the air bubbles have been removed Drain bolt 18 Nm 1 8 m kg Transmission oil 10W30...

Page 43: ...rformance and the possible overheating of the engine Be careful not to block the inlet area of the air filter with cloths or rags 3 Inspect damaged element Change 4 Clean air filter Steps for cleaning air filter Wash the filter carefully but completely with solvent s s WARNING Never use solvents with a low flammability point such as petrol to clean the filter Such solvents may cause fire or explos...

Page 44: ...minimum level mark Remove the front upper cowling and add the recom mended coolant to the proper level CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if disti lled water is not available soft water may be used 3 Start ...

Page 45: ...er pump cover 2 Drain coolant from the engine and radiator 3 Check o ring water pump cover Damage Replace 4 Install water pump cover 5 Fill coolant reservoir with the specified amount of the recom mended coolant NOTE While start the engine fill the coolant until spe cified amount 7 Nm 0 7 m kg Recommended antifreeze High quality ethylene glycol anti freeze containing corrosion inhi bitors for alum...

Page 46: ...with soap and water If coolant is swallowed induce vomiting and get immediate medical attention CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if disti lled water is not available soft water may be used If coolant come...

Page 47: ...Refer to CHECKING THE COOLANT LEVEL NOTE Before checking the coolant level wait a few minutes until the coolant has settled NOTE For a quick air bleeding lift up the front wheel 1metre with the engine at idle speed This will provide a effective and air quick blee ding from the head cylinder to the radiator 9 Install front upper cowling ...

Page 48: ...y and may cause loss of control and accidents Inspect and bleed the system if it is necessary EAS00114 ADJUSTMENT THE REAR BRAKE LEVER 1 Check free play of rear brake lever a Outside specified value Adjust Steps for adjusting the free play of the rear brake lever Turn the adjuster inwards or outwards until the correct free play is obtained EAS00117 CHECKING THE FRONT BRAKE PADS 1 Inspect brake pad...

Page 49: ...to correct level CAUTION The fluid may corrode painted surfaces or plastic parts Always clean any spilt fluid immediately s s WARNING Only use fluid of the designated quality Otherwise the rubber seals may deterio rate due to leakages and poor performan ce of the brakes Refill with the same type of fluid The mix ture of fluids may cause a damaging che mical reaction which may cause the poor perfor...

Page 50: ... it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed brake fluid Steps for air bleeding a Add the appropriate amount of brake fluid to the sump b Install the diaphragm Take care not to spill fluid or to let the sump overflow c Connect the clean plastic tube d Place the other end of the tube in a ...

Page 51: ...ork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove front upper cowling front middle cowling legshield 4 Adjust steering head a Remove the upper ring nut the lock washer the center ring nut and the rubber washer b Loosen the lower ring nut and then tigh ten it to specification with the ring nut wrench c Loosen the lower ring nut 1 2 turn counter clockwise t...

Page 52: ... center ring nut then align the slots of both ring nuts If neces sary hold the lower ring nut and tighten the center ring nut until their slots are aligned h Install the lock washer NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b i Hold the lower and center ring nuts with a ring nut wrench and tighten the upper ring nut with a steering nut wrench 5 Install legshield fro...

Page 53: ... both of the wheels 1 Check wheel Damage out of round Replace s s WARNING Never attempt to make any repairs to the wheel NOTE After a tire or wheel has been changed or replaced always balance the wheel EAS00151 CHECKING THE FRONT FORK 1 Inspect front fork Bent Damaged Fork bar Change Oil leaks Seals Replace Rough operation Fork assembly Replace 158 3 kg CS50Z Maximum load 161 5 kg CS50 Pressure co...

Page 54: ...DJ REAR SHOCK ABSORBER INSPECTION 3 24 REAR SHOCK ABSORBER INSPECTION 1 Inspect rear shock absorber Oil leaks Damage Replace 2 Check tightening torque Upper nut 31 5 Nm 3 15 m kg Lower bolt 17 5 Nm 1 75 m kg ...

Page 55: ...rolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION This is a sealed battery Never remove the sealing cap...

Page 56: ...nd then the positive battery lead 3 Remove battery 4 Check battery charge a Connect a pocket tester to the battery ter minals NOTE The charge state of an MF battery can be checked by measuring its open circuit vol tage i e the voltage when the positive ter minal is disconnected No charging is necessary when the open circuit voltage equals or exceeds 12 8 V b Check the charge of the battery as show...

Page 57: ...e the chance of sparks do not plug in the battery charger until the bat tery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A corroded battery charger lead clip may generat...

Page 58: ...e for the open circuit voltage Refer to Battery condition checking steps If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Cha...

Page 59: ...attery Charge the battery until the battery s charging voltage is 15 V This type of battery charger cannot charge the MF battery A variable voltage charger is recommended Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery NOTE Voltage should be ...

Page 60: ...HE FUSE 1 Remove the battery cover See the FRONT BODYWORK section 2 Inspect fuse Defective Replace Steps to be taken for blown fuses Disconnect the ignition and circuit Install a new fuse of the correct amperage Connect the switches to check the correct operation of the electrical device If the fuse blows immediately after check the circuit concerned s s WARNING Do not use fuses of a higher ampera...

Page 61: ...h 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 If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 5 Install headlight bulb holder 6 Install front upper cowling EAS00...

Page 62: ...ENG 4 ...

Page 63: ...ARING 4 15 CHECKING THE KICKSTARTER 4 16 TRANSMISSION 4 16 AUTOLUBE OIL PUMP 4 17 CHECKING THE CRANKSHAFT 4 17 CHECKING THE BEARINGS 4 18 CHECKING THE PRIMARY SHEAVE 4 18 CHECKING THE SECONDARY SHEAVE 4 19 CHECKING THE V BELT 4 20 STARTER CLUTCH AND GEARS 4 21 ENGINE ASSEMBLY AND ADJUSTMENT 4 22 CRANKSHAFT AND CRANKCASE 4 22 INSTALLING THE CRANKSHAF 4 23 AUTOLUBE OIL PUMP AND DC CDI MAGNETO 4 24 I...

Page 64: ...mp cover Drain the coolant coolant hose on cylinder head CABLES LEADS AND HOSES 1 Loosen rear axle nut 2 Disconnect rear brake cable 3 Disconnect starter motor leads positive negative leads 4 Disconnect DC CDI magneto lead spark plug cap temperature sensor lead on the cylinder head autochoke lead throttle cable with throttle valve vaccum hose fuel hose 5 Disconnect oil hose delivery oil tank oil p...

Page 65: ... 4 2 ENGINE REMOVAL 1 Place a suitable stand under the frame 2 Remove rear shock absorber bolt lower engine mounting bolt 3 Remove engine NOTE Lift up the frame and remove the engine 4 Place the frame on a suitable stand ...

Page 66: ...S50Z only cylinder head cylinder head gasket NOTE Before loosening the cylinder head loosen the spark plug The position nuts of the cylinder head should be loosened by 1 2 a turn each time and then removed 2 Remove coolant hose on cylinder CS50Z only cylinder cylinder gasket REMOVING THE PISTON PIN AND PISTON 1 Remove piston pin clip NOTE Before removing the piston pin clip cover the crankcase wit...

Page 67: ... a hammer to take out the piston pin REMOVING THE KICKSTARTER SYSTEM 1 Remove clamp air filter air filter 2 Remove oil hose delivery carburator 3 Remove kick crank crankcase cover left 4 Remove kick pinion gear NOTE When the kick pinion gear removed move the pedal axle 5 Unhook return spring ...

Page 68: ... CS50 only right cranckcase cover CS50Z only 2 Remove nut primary sheave NOTE To loos nut primary sheave support the mag netic flywheel using Fly wheel holder 3 Remove conical spring washer one way clutch special washer fixed primary sheave shim v belt 4 Remove hub primary sheave assembly Fly wheel holder 90890 01235 ...

Page 69: ...ve crankcase cover gasket dowel pins 3 Attach sheave holder nut spanner 41 mm 4 Loosen clutch securing nut CAUTION Do not remove the clutch positioning nut yet 5 Attach clutch spring compressor 6 Remove clutch securing nut 7 Remove clutch assembly secondary sheave spring spring seat guide pins secondary sliding sheave Sheave holder 90870 01701 Sheave holder 90870 01701 Clutch spring compressor 908...

Page 70: ...h assembly starter wheel gear 2 Remove spacer bearing washer starter motor TRANSMISSION 1 Remove transmission box cover gasket dowel pins NOTE Before proceeding to disassemble the trans mission cover empty the oil 2 Remove main shaft drive shaft flat washer conical spring washer 3 Remove oil seal bearing secondary sheave axle ...

Page 71: ...otor flat washer NOTE Support the rotor to loosen the nut with the engine flywheel holder 3 Remove rotor woodruff key Use the flywheel puller stator assembly gasket NOTE Attach the flywheel puller using the flywheel thread holes Flywheel holder 90890 01235 Flywheel puller 90890 01362 ...

Page 72: ... pin circlip 3 Remove carburetor joint reed valve reed valve gasket REMOVING THE CENTERSTAND 1 Remove clip rubber washer axle spring central stand DISASSEMBLING THE CRANKCASE AND CRANKSHAFT 1 Remove oil seal stopper screws crankcase NOTE Loosen each screw 1 4 of a turn and remove them after loosening them ...

Page 73: ...ool 3 Remove crankcase right As pressure is applied keep taping care fully on the engine mounting bosses CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly 4 Attach crankcase puller 5 Remove crankshaft Crankcase puller 9089...

Page 74: ...cket CS50Z only Mineral deposits ruts Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a tickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sa...

Page 75: ...its Use a rounde scraper 2 Inspect cylinder wall Wear striping Rectify or change 3 Eliminate carbon deposits From the piston crown and ring groovers 4 Remove cracking marks and carbon deposits on piston sides 5 Inspect piston wall Wear striping damage Replace 6 Measure piston to cylinder clearance ...

Page 76: ... replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set Piston size P Standard CS50 39 952 39 972 mm CS50Z 39 957 39 977 mm Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance CS50 0 034...

Page 77: ...carbon deposits from the piston ring grooves and piston rings 2 Install piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown a 20 mm 3 Measure piston ring end gap Out of specification Replace the piston ring Use a Feeler Gauge Piston ring side clearance Top ring 0 03 0 05 mm Limit 0 1 mm 2nd ring 0 03 0 05 mm Limit 0 1 mm Piston ring end gap Top ring 0 1...

Page 78: ...n outside diameter a Out of specification Replace the piston pin 3 Calculate piston pin to piston clearance Out of specification Replace the piston pin and piston as a set 4 Inspect bearing piston pin Pitting Damage Change Piston pin outside diameter 9 996 10 000 mm Piston pin to piston clearance 0 004 0 017 mm Limit 0 07 mm Piston pin to piston clearance Piston pin bore diameter b Piston pin outs...

Page 79: ...nion gear clip force with the spring gauge Out of specification Replace the kickstarter pinion gear clip TRANSMISSION 1 Inspect main axle drive axle secondary sheave axle Burrs Chips Non uniformity Wear Replace 2 Inspect secondary sheave axle bearing drive axle bearing main axle bearing Pivot the inner guide of the bearing Excessive play Non uniformity Replace Pitting Damage Replace Kickstarter pi...

Page 80: ... the autolube oil pump gear teeth driven by autolube oil pump Pitting Wear Damage Replace EAS00394 CHECKING THE CRANKSHAFT 1 Measure crankshaft runout C Out of specification Replace the cranks haft bearing or both NOTE Turn the crankshaft slowly 2 Measure big end side clearance D Out of specification Replace the big end bearing crankshaft pin or connecting rod 3 Measure crankshaft width A Out of s...

Page 81: ... 1 Inspect primary sliding pulley wheel primary fixed pulley wheel Wear Crackjs Striping Damage Replace 2 Check free movement Insert the collar in the primary sliding sheave and check if there is free move ment If it catches or there is excessive play Replace the pulley wheel or the bushing 3 Measure external diameter collar Outside specified value Replace Primary sheave weight outside diameter 15...

Page 82: ...lace as a set o ring Damaged Replace 3 Measure clutch spring free length Outside specified value Replace 4 Inspect clutch housing inner surface Oil Striping Clean 5 Measure internal diameter of the clutch hub a Outside of specification Replace Clutch spring free length 121 7 mm Limit 106 7 mm Oil Use a cloth dampened with dissolvent Striping Use sand paper polish lightly and uniformly Clutch housi...

Page 83: ...rticles with a cloth 7 Measure clutch shoe thickness a Outside specified value Replace EAS00320 CHECKING THE V BELT 1 Check v belt Cracks damage wear Replace Grease oil Clean the primary and secondary sheave 2 Measure v belt width a Out of specification Replace Clutch shoe thickness 2 0 mm Wear limit 1 0 mm V belt width 16 5 mm Limit 15 7 mm ...

Page 84: ...ect starter clutch Press the conical pin in the direction of the arrow Unsmooth operaton Replace starter clutch assembly 2 Inspect starter wheel gear teeth idle gear teeth Burrs Spalling Non uniformity Wear Replace bearing starter wheel gear Pitting Damage Replace ...

Page 85: ...l seal Oil seal catch Crankcase right Dowel pin Bearing Crankshaft right Bearing Crankshaft pin Connecting rod Crankshaft left Bearing Engine mounting spacer Crankcase left Oil seal Crankshaft A 37 90 37 95 mm C 0 03 mm D 0 2 0 5 mm E 0 004 0 017 mm F 0 4 0 8 mm 9 Nm 0 9 m kg 13 Nm 1 3 m kg 17 5 Nm 1 75 m kg ...

Page 86: ...l 6 Install right crankcase 7 Tighten crankcase positioning screws NOTE Tigten the crankcase positioning screws in stages using a crossed method for tightening 8 Check rotation of crankshaft rough turning Repair 9 Install oil seal catch plate Crankshaft installation tool 90890 01411 90890 01274 90890 01275 90890 01277 Yamaha Nº 1215 adhesive 90890 85505 Crankshaft installation tool 90890 01411 908...

Page 87: ...tor assembly Charge coil Lighting coil Pickup coil Stator plate Oil seal Gasket Oil hose Oil delivery hose Bushing Autolube pump O ring Circlip Oil pump drive gear Pin EAS00360 AUTOLUBE OIL PUMP AND DC CDI MAGNETO 7 Nm 0 7 m kg 43 Nm 4 3 m kg 9 Nm 0 9 m kg 4 Nm 0 4 m kg ...

Page 88: ...grease with lithium soap base on the autolubrication pump gear INSTALLING THE DC CDI MAGNETO 1 Install gasket 2 Apply grease with lithium soap base on the oil seal 3 Pass the wheel cable through the crankca se orifice 4 Install stator assembly 5 Install woodruff key rotor plain washer nut Screw autolubrication pump 4 Nm 0 4 m kg Lithium soap base grease 15 cc 0 92 cu in Screw stator assembly 8 5 N...

Page 89: ...ENG ENGINE ASSEMBLY AND ADJUSTMENT 4 26 6 Tighten nut magneto rotor Use the flywheel holding tool Flywheel holding tool 90890 01235 Nut Flywheel magneto 43 Nm 4 3 m kg ...

Page 90: ...DJUSTMENT 4 27 EAS00419 TRANSMISSION 9 Nm 0 9 m kg Circlip Bearing Oil seal Drive axle Bearing Main axle Conical spring washer Flat washer Secondary sheave axle Bearing Dowel pin Gasket Transmission case cover Bearing Oil seal ...

Page 91: ... case cover 3 Install circlip oil seal NOTE Apply grease with lithium soap based onto the oil seal lips 4 Check rotation of secondary sheave axle Rough rotation Repair 5 Apply SE type 10W30 engine oil on bearing of main axle and drive axle bea ring 6 Install drive axle main axle conical spring washer flat washer 7 Install gasket dowel pins transmission case cover Screw case cover 9 Nm 0 9 m kg ...

Page 92: ...ENG ENGINE ASSEMBLY AND ADJUSTMENT 4 29 STARTER SYSTEM 8 Nm 0 8 m kg 13 Nm 1 3 m kg Collar Starter wheel gear Bearing Starter clutch Plate Shaft Flat washer Idle gear O ring Starter motor ...

Page 93: ...se on the bearing Apply molybdenum disulphide oil on the pin starter clutch 2 Install flat washer idle gear flat washer plate intermediate gear NOTE Apply engine oil on the intermediate gear 3 Install starter motor NOTE Apply grease with a lithium soap base on the o ring of the starter motor Screw intermediate gear plate 8 Nm 0 8 m kg Screw starter motor 13 Nm 1 3 m kg ...

Page 94: ... Secondary fixed sheave Conical washer One way clutch Special washer Primary fixed sheave Shim Collar Primary sliding sheave Weight 21 Slider 22 Cam Apply assembly lube 50 Nm 5 0 m kg 40 Nm 4 0 m kg 33 Nm 3 3 m kg Free length limit of spring 29 9 mm Waste limit of clutch housing 107 4 mm Waste limit of clutch shoes 1 0 mm Trapezoidal belt waste limit 15 7 mm Variator roller limit 14 5 mm ...

Page 95: ...ENG ENGINE ASSEMBLY AND ADJUSTMENT 4 32 EAS00338 KICKSTARTER 10 Nm 1 0 m kg Kick shaft Return spring Collar Flat washer Circlip Kick crank Kick pinion gear clip Kick pinion gear 150 250 g ...

Page 96: ...ot turn when the pulley wheel is installed 3 Install guide pin 4 Lubricate guide pin groove oil seal with the recommended lubricant 5 Install secondary sheave complete spring clutch carrier spacer diameter 30 mm thickness 2 3 mm NOTE Attach the clutch spring holder and clutch spring holder arm onto the secondary she ave as shown Then compress the spring and tighten the clutch securing nut Recommen...

Page 97: ...EMBLING THE PRIMARY SHEAVE 1 Clean primary sliding sheave face primary fixed sheave face collar primary sheave weights primary sliding sheave cam surface 2 Install primary sheave weights cam slider collar NOTE Before installing the primary sheave weights lubricate the inside and outside of each weight Sheave holder 90890 01701 Clutch securing nut 50 Nm 5 0 m kg Sheave holder 90890 01701 Nut second...

Page 98: ...elt should be installed with the arrow facing towards the front 6 Install shim primary fixed sheave special washer one way clutch conical spring washer nut 7 Tighten nut primary sheave NOTE When the nut is tightened primary sheave support the magnetic flywheel using the engi ne wheel support tool Flywheel holding 90890 01235 Nut Primary sheave 33 Nm 3 3 m kg ...

Page 99: ...ll fan CS50 only Side right INSTALLING THE KICKSTARTER 1 Install return spring kick shaft collar flat washer circlip 2 Hook on return spring on kick gear and hub 3 Install kick pinion gear 4 Install crankcase cover 5 Install kick crank Screw fan 7 Nm 0 7 m kg Screw crankcase cover 9 Nm 0 9 m kg Bolt kick crank 10 Nm 1 0 m kg ...

Page 100: ...on rings Piston Piston pin Piston pin clips Bearing Piston to cylinder clearance 0 034 0 047 mm Limit 0 1 mm End gap installed Top ring 0 15 0 35 mm Limit 0 60 mm Second ring 0 15 0 35 mm Limit 0 60 mm Ring side clearance Top ring 0 03 0 05 mm Second ring 0 03 0 05 mm Spark plug Type manufacturer BR8HS NGK Spark plug gap 0 6 0 7 mm CS50 11 Nm 1 1 m kg 14 Nm 1 4 m kg 20 Nm 2 0 m kg ...

Page 101: ... Piston pin clips Bearing Thermo switch Thermostat Piston to cylinder clearance 0 029 0 042 mm Limit 0 1 mm End gap installed Top ring 0 15 0 35 mm Limit 0 60 mm Second ring 0 15 0 35 mm Limit 0 60 mm Ring side clearance Top ring 0 03 0 05 mm Second ring 0 03 0 05 mm Spark plug Type manufacturer BR8HS NGK Spark plug gap 0 6 0 7 mm CS50Z 11 Nm 1 1 m kg 5 Nm 0 5 m kg 20 Nm 2 0 m kg 14 Nm 1 4 m kg 16...

Page 102: ... circlips NOTE The arrow of the piston should point to the exhaust side Before installing the piston circlip cover the crankcase with a towel or clean cloth so that the circlip and other materials do not accidentally fall into the crankcase Always use new piston circlips CYLINDER AND CYLINDER HEAD 1 Install cylinder gasket Use a new gasket 2 Check piston rings NOTE Ensure that the ends of the ring...

Page 103: ...only 4 Install cylinder head gasket new gasket 5 Install thermostat CS50Z only on cylinder head cylinder head spark plug air covers CS50 only NOTE The arrow EX from the cylinder head should point to the exhaust side Tighten the cylinder head positioning nuts in several steps using a cris cross pattern right crankcase cover CS50Z only Cylinder head positioning nuts 14 Nm 1 4 m kg Spark plug 20 Nm 2...

Page 104: ...bolt lower 2 Install carburetor oil supply pipe fuel pipe autochoke lead air filter box assembly water pipes of carburator CS50Z only NOTE Align the projection of the carburetor with the projections of the carburator joint Before installing the oil supply pipe fill it with oil 3 Install oil pipe oil tank head cylinder coolant pipe CS50Z only spark plug cap NOTE Pass the oil supply pipe and the oil...

Page 105: ...r CS50Z only Refill coolant and bleed the air Refer to chapter 5 7 Apply transmission oil Refer to CHANCHING TRANSMISSION OIL in chapter 3 8 Adjust free play of brake levers Refer to ADJUSTMENT OF FREE PLAY OF FRONT REAR BRAKE LEVER in chapter 3 free play of throttle cable Refer to ADJUSTMENT OF FREE PLAY OF ACCELERATOR CABLE in chapter 3 9 Install helmet box center cover Refer to REAR BODYWORK MU...

Page 106: ......

Page 107: ...COOL 5 ...

Page 108: ...OVING THE RADIATOR 5 2 REMOVING THE WATER PUMP 5 2 CHECKING THE RADIATOR 5 3 CHECKING THE WATER PUMP 5 3 INSTALLING THE WATER PUMP 5 4 INSTALLING THE RADIATOR 5 5 THERMOSTAT 5 5 REMOVING THE THERMOSTAT 5 5 CHECKING THE THERMOSTAT 5 6 INSTALLING THE THERMOSTAT 5 6 COOL ...

Page 109: ...iator Radiator inlet hose Radiator outlet hose Carburetor inlet hose Carburetor outlet hose Impeller Water pump cover Water pump outlet hose O ring 10 Reservoir tank 11 Reservoir tank hose 12 Thermostatic valve 13 Thermo switch 11 10 9 Nm 0 9 m kg 7 Nm 0 7 m kg 16 Nm 1 6 m kg 13 5 Nm 0 5 m kg 12 ...

Page 110: ...e clamp with a thin flatted head screwdirver 4 Remove radiator hoses radiator EAS00470 REMOVING THE WATER PUMP 1 Drain coolant from cooling system Refer to CHANGING THE COOLANT in chapter 3 2 Remove water pump cover crankcase cover right 3 Remove circlip water pump drive pulley pin impeller 4 Remove bearings NOTE Remove the bearing and oil seal from the out side of the crankcase cover right 5 Remo...

Page 111: ...Repair or replace NOTE Straighten any flattened fins with a thin flathe ad screwdriver 2 Check radiator hoses radiator pipes Cracks damage Replace EAS00473 CHECKING THE WATER PUMP 1 Check crankcase cover right water pump cover impeller pin o ring water pump drive pulley water pump seal Cracks damage wear Replace circlip 2 Check bearings Rough movement Replace ...

Page 112: ...ump assembly 1 Install impeller pin water pump drive pulley circlip NOTE After installation check that the impeller shaft rotates smoothly 2 Install crankcase cover right 3 Install o ring NOTE Lubricate the O ring with a thin coat of lithium soap based grease 4 Install water pump cover New New 7 Nm 0 7 m kg ...

Page 113: ...amp with a pliers 2 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part THERMOSTAT REMOVING THE THERMOSTAT 1 Drain coolant Refer to CHANGING COOLANT in chap ter 3 2 Remove cylinder head thermostat ...

Page 114: ...eter s indicated tem perature Thermostat Container Thermometer Water A Fully closed B Fully open NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause serious overheating or overcooling EAS00466 INSTALLING THE THERMOSTAT 1 Install thermostat cylinder head 2 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLAN...

Page 115: ......

Page 116: ...CARB 6 ...

Page 117: ... CARBURETOR 6 2 CHECKING THE CARBURETOR 6 3 ASSEMBLING THE CARBURETOR 6 5 CHECKING THE AUTOCHOKE UNIT 6 6 INSTALLING THE CARBURETOR 6 7 FUEL COCK 6 7 CHECKING THE FUEL COCK 6 7 REED VALVE 6 8 REMOVING THE REED VALVE 6 8 CHECKING THE REED VALVE 6 8 INSTALLING THE REED VALVE 6 9 CARB ...

Page 118: ...eedle valve 14 Float chamber Main jet 62 Jet needle B10 A 2 3 Main air jet ø 2 0 Pilot jet 38 Starter jet 42 Pilot air screw 1 3 4 2 Idling speed 1 800 150 r min 13 11 14 10 12 carburetor dell orto CS50 CS50Z carburetor gurtner CS50 only 15 13 11 14 10 Main jet 65 Jet needle A20 3 5 A35 4 5 CS50Z Main air jet ø 2 5 Pilot jet 36 Starter jet 50 Pilot air screw 1 3 4 1 8 CS50Z 2 1 4 Idling speed 1 80...

Page 119: ... screw coolant Refer to CHANGING THE COOLANT in chapter 3 3 Disconnect autochoke lead coupler coolant hoses fuel hose vacuum hose oil delivery hose throttle cable with throttle valve clamp fixing clip 4 Remove carburetor DISASSEMBLING THE CARBURETOR 1 Remove float chamber 2 Remove float pin float needle valve 3 Remove pilot jet main jet needle jet ...

Page 120: ... needle throttle valve throttle valve spring EAS00485 CHECKING THE CARBURETOR 1 Check carburetor body Dirty Clean NOTE For cleaning use a petrol based solvent Clean the pipes and jets with compressed air 2 Check main jet needle jet pilot jet Dirty Clean 3 Check needle valve Wear Dirty Clean float Damage Change gasket Damage Change ...

Page 121: ...r screw jet needle starter plunger Wear Damage Change 7 Measure Float height a Outside specifications Check valve float and valve seat Steps for measuring the height of the float Assemble the valve float and axle on the carburettor body Turn the carburettor upside down Using a vernier caliper measure the distance between the plane of the bowl gasket wit hout the gasket and the upper part of the fl...

Page 122: ...d in the fac tory Do not try to modify it under any cir cumstances EAS00487 ASSEMBLING THE CARBURETOR The assembly of the carburetor is carried out following the reverse procedure to DISAS SEMBLY Bear in mind the following points CAUTION Before assembling the carburetor wash all of the parts in a petroleum based sol vent Always use new gaskets 1 Install jet needle clip throttle valve spring seat s...

Page 123: ...r plunger is open air should come out of the other side of the starter air passage 3 Check autochoke unit a Connect the autochoke unit leads to a 12 0 V battery for five minutes b Connect a 3 3 mm hose to the starter air passage and blow into the hose Starter plunger Perform step 3 opens Starter plunger Replace the auto closes choke unit Positive batter lead yellow red Negtive battery lead black S...

Page 124: ...BODYWORK MUDGUARD section 3 Inspect fuel cock Steps for inspecting fuel cock Disconnect the fuel hose Place a receptacle under the end of the fuel hose Disconnect the vacum hose and suction to create a vacuum If the fuel comes out of the fuel hose as a result of applying a vacuum and stops when the vacuum is stopped the cock is in good condition If not clean or replace the vacuum hose the fuel hos...

Page 125: ...carburetor See section REMOVING THE CARBURE TOR 3 Remove carburetor joint reed valve assembly CHECKING THE REED VALVE 1 Inspect carburetor joint Damage Cracks Change reed valve Fatigue Cracks Change Inspection steps Visually inspect the reed valve If there is any doubt on how to seal apply suction on the carburettor side Leaks should be light or moderate ...

Page 126: ...lace the reed valve INSTALLING THE REED VALVE When the reed valve assembly is installed reverse the removal procedure Bear in mind the following points 1 Install gasket 2 Tighten tighten the bolts for reed valve NOTE Tighten each bolt gradually to avoid it being deformed Height of valve stopper 6 0 6 4 mm Clearance of reed valve Less than 0 2 mm Reed valve 11 Nm 1 1 m kg New ...

Page 127: ...CHAS 7 ...

Page 128: ...7 13 REMOVING THE REAR WHEEL 7 14 CHECKING THE REAR WHEEL 7 14 ASSEMBLING THE BRAKE SHOES 7 15 INSTALLING THE REAR WHEEL 7 16 FRONT FORK 7 17 REMOVING THE FRONT FORK LEGS 7 18 DISASSEMBLING THE FRONT FORK LEGS 7 18 CHECKING THE FRONT FORK LEGS 7 19 ASSEMBLING THE FRONT FORK LEGS 7 20 INSTALLING THE FRONT FORK LEGS 7 22 HANDLEBAR AND STEERING 7 23 REMOVING THE HANDLEBAR 7 24 REMOVING THE LOWER BRAC...

Page 129: ...HASSIS FRONT WHEEL Wheel axle Speed sensor unit Bearing Collar Valve Tyre Front rim Oil seal Spacer 10 Nut Tyre Size 110 70 12 Type 47 L Rim runout limit Vertical 1 0 mm Lateral 1 0 mm Wheel axle bend limit 0 25 mm 47 5 Nm 4 75 m kg ...

Page 130: ...here is no danger of it falling over NOTE Place the scooter on a suitable stand so that the front wheel is elevated 2 Remove brake caliper axle nut NOTE Do not apply the brake lever when removing the brake caliper 3 Elevate front wheel NOTE Place the scooter on a suitable stand so that the front wheel is elevated 4 Remove axle speed sensor unit ...

Page 131: ...imits Replace 4 Check wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings oil seals Damage wear Replace 5 Replace wheel bearings oil seals a Clean the outside of the front wheel hub b Remove the oil seals with a flat head screwdriver NOTE To prevent damaging the wheel place a rag between the screwdriver and the wheel surfa ce c Remove the wheel bearings with a gene ral ...

Page 132: ...28 CHECKING THE BRAKE DISC 1 Check brake disc Damage galling Replace 2 Measure brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the scooter on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflection turn the handlebar to the left or right to ensure that the front wheel is statio nary c Rem...

Page 133: ... bolt hole c Install the brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern d Measure the brake disc deflection e If out of specification repeat the adjust ment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc Brake disc thickness limit mini mum 3 0 mm Brake dis...

Page 134: ...ions engaged into the flat surface of the wheel 3 Install front wheel NOTE Make sure the slot in the speed sensor unit fits over the stopper on the outer tube 4 Tighten wheel axle brake caliper bolts s s WARNING Make sure the brake hose is routed pro perly CAUTION Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smo othly Recom...

Page 135: ...ake pad cover Brake disc Master cylinder cap 10 Diaphragm 11 Brake hose 12 Brake pump assy 13 Front brake lever 14 Copper washers 15 Union bolt 16 Brake light switch cable Type of brake fluid DOT 4 Wear limit of brake pads 0 5 mm Wear limit of brake disc 3 0 mm 15 13 14 11 10 16 12 23 Nm 2 3 m kg 23 Nm 2 3 m kg 23 Nm 2 3 m kg ...

Page 136: ...fication Replace the brake pads as a set 4 Install brake pad shims onto the brake pads brake pads brake pad spring NOTE Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose tightly to the bleed screw Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with you...

Page 137: ... spring must point in the direction of disc rotation 5 Install brake pad pins brake pad clips brake pad cover 6 Check brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapte...

Page 138: ...e brake hose drain the brake fluid from the entire brake system 1 Remove union bolt copper washers brake hose NOTE To collect any remaining brake fluid place a container under the end of the brake hose CHECKING THE BRAKE HOSE 1 Check brake hoses cracks damage wear Replace ...

Page 139: ... safe scooter operation Refer to CABLE ROUTING NOTE While holding the brake hose tighten the union bolt Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 2 Fill brake master cylinder reservoir with the specified amount of the recom mended brake fluid Recommended brake fluid DOT 4 23 Nm 2 3 m kg New Rec...

Page 140: ...linder reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Below the minimum level mark Add the recommended brake fl...

Page 141: ...Brake camshaft Wear indicator Bolt 10 Brake camshaft lever 11 Axle 12 O ring 13 Nut Tyre Size 130 70 12 Type 56 L Size 120 70 12 Type 51 L Spain Brake drum wear limit 110 5 mm Brake shoe wear limit 2 0 mm Wheel runout limit Vertical 1 0 mm Lateral 1 0 mm 11 12 13 10 13 Nm 1 3 m kg 12 Nm 1 2 m kg ...

Page 142: ...ake shoes plain washer EAS00565 CHECKING THE REAR WHEEL 1 Inspect wheel See CHECKING THE FRONT WHEEL section 2 Measure wheel runout See CHECKING THE FRONT WHEEL section 3 Check wheel bearings See CHECKING THE FRONT WHEEL section 4 Inspect brake shoes Crystallisation Polish with sand paper NOTE After using sand paper clean the polished par ticles with a cloth Rim runout limits Vertical 1 0 mm Later...

Page 143: ... bled reverse the removal procedure Bear in mind the following points 1 Install brake cam NOTE Apply Grease with a lithium soap base on the brake cam and pin CAUTION After installing the brake cam remove excess grease 2 Install brake shoes return spring NOTE Install with the mark outwards 3 Install wear indicator cam lever NOTE Align the projection of the wear indicator with the line as shown Alig...

Page 144: ...procedure The following points should be remembered 1 Install rear wheel plain washer nut 2 Install muffler 3 Adjust free play of rear brake lever Refer to CHECKING FREE PLAY OF REAR BRAKE LEVER in chapter 3 Bolt cam lever 10 Nm 1 0 m kg Nut Rear wheel axle 125Nm 12 5 m kg Bolt exhaust pipe side 9 Nm 0 9 m kg Bolt muffler side 26 Nm 2 6 m kg ...

Page 145: ... O ring Collar Dust seal Oil seal circlip 10 Oil seal 11 Spring 12 Piston 13 Rebound spring 14 Circlip 15 Inner tube 16 Oil lock piece 17 Outer tube 18 Washer 19 Bolt Fork spring free lenght 224 mm Fork oil capacity 45 cc 1 cc Oil grade SAE 10 W oil fork or equivalent 13 14 15 16 17 18 19 10 11 12 ...

Page 146: ...r to FRONT BRAKE REMOVAL sec tion 3 Remove front fender front wheel See FRONT WHEEL REMOVAL section 4 Remove front upper cowling Refer to FRONT BODYWORK MUD GUARD in chapter 3 5 Loosen pinch bolt fork 6 Remove circlip front fork EAS00652 DISASSEMBLING THE FRONT FORK LEGS 1 Remove rubber cap circlip spring stopper collar fork spring 2 Drain fork oil 3 Remove dust seal circlip ...

Page 147: ...eal outer tube EAS00657 CHECKING THE FRONT FORK LEGS 1 Check outer tube inner tube piston hydraulic rod Striping Warping Wear Damage Replace s s WARNING Do not try to straighten an outer tube or an inner tube as this may dangerously weaken the tube 2 Measure fork spring Above specified limit Replace 3 Inspect oil lock piece o ring spring stopper Wear Damage Replace T handle 90890 01326 Support 908...

Page 148: ...pper washer new bolt hydraulic rod NOTE Tighten the bolt hydraulic rod while suppor ting the outer tube with the T handle and the support 2 Install oil seal Use a counterbalance for installing fork seals and an adaptor NOTE Before installing the oil seal apply grease with a lithium soap base on the edges of same CAUTION Ensure that the numbered side of the seal is facing upwards Bolt hydraulic rod...

Page 149: ...tall fork spring collar spring stopper circlip rubber cap NOTE Before installing the spring stopper apply grease to the o ring Couple the circlip correctly on the inner tube groove Quantity each front fork leg 45 cc Recommended oil SAE 10W or equivalent From fork leg oil level from the top of the inner tube with the inner tube fully compressed and without the fork spring 105 mm ...

Page 150: ...ont fork circlip NOTE Attach the circlip correctly on the inner tube groove 2 Tighten pinch bolt steering bracket 3 Install front wheel brake calliper brake hose holder speed sensor coupler See FRONT WHEEL section front mudguard Refer to FRONT BODYWORK MUD GUARD in chapter 3 Pinch bolt steering bracket 30 Nm 3 0 m kg Wheel axle 47 5 Nm 4 75 m kg ...

Page 151: ...hrottle grip Throttle grip guide Grip Nut Bolt Throttle cable Brake cable 10 Upper ring nut 11 Lock washer 12 Center ring nut 13 Rubber washer 14 Lower ring nut 15 Bearing cover 16 Upper bearing race 17 Bearing cage 18 Bearing race 19 Lower bracket 10 11 13 15 17 16 18 19 12 14 16 18 17 ...

Page 152: ...middle cowling legshield handlebar cover upper 3 Disconnect meter coupler flasher relay 4 Disconnect handlebar switch couplers left and right brake switch connectors front and rear rear brake cable 5 Remove handlebar switch right 6 Disconnect throttle cable 7 Remove throttle grip 8 Loosen handlebar securing nut 9 Remove screws lower handlebar cover 10 Remove wire harness fixed strap 11 Remove hand...

Page 153: ...ver 2 Remove handlebar 3 Remove brake caliper brake hose holder 4 Disconnect speed sensor coupler 5 Remove clamp 6 Remove ring nut upper with the ring nut wrench 7 Remove lock washer ring nut center rubber washer ring nut lower s s WARNING Securely support the lower bracket so that there is no danger of it falling 8 Remove lower bracket with wheel and front forks Ring nut wrench 90890 01403 ...

Page 154: ...ong rod and hammer b Remove the bearing race from the lower bracket with a floor chisel and hammer c Install a new dust seal and new bearing races CAUTION If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearing balls and bea ring races as a set Whenever the steering head is disassem bled replace the dust seal 4 Check lower bracket along...

Page 155: ...er the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag s s WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried EAS00684 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races 2 Install lower bracket lower ring nut rubber washer center ring nut lock washer upper ring nut Refer to CHECKING THE STEERING HEAD in...

Page 156: ...tch throttle cable throttle grip NOTE Lubricate the inside of the throttle grip with a thin coat of lithium soap based grease and install it onto the handlebar NOTE Align the projection on the right handlebar switch with the hole on the handlebar s s WARNING Make sure the throttle grip operates smo othly 5 Fasten wire harness fixed to steering head with a strap 6 Adjust throttle cable free play Re...

Page 157: ......

Page 158: ...ELEC 8 ...

Page 159: ...TING 8 9 ELECTRIC STARTING SYSTEM 8 12 CIRCUIT DIAGRAM 8 12 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8 13 TROUBLESHOOTING 8 14 STARTER MOTOR 8 16 REMOVING THE STARTER MOTOR 8 17 CHECKING THE STARTER MOTOR 8 17 ASSEMBLING THE STARTER MOTOR 8 18 CHARGING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 20 LIGHTING SYSTEM 8 22 CIRCUIT DIAGRAM 8 22 TROUBLESHOOTING 8 23 CHECKING THE LIGHTING SYSTEM ...

Page 160: ...ICAL COMPONENTS Wire harness Starter motor DC CDI Unit Engine oil level gauge Starter relay Fuel sender gauge Battery Ignition coil Temperature sender CS50Z only Ignition coil Primary coil resistance 0 56 0 84 Ω at 20 C Secondary coil resistance 5 68 8 52 Ω at 20 C ...

Page 161: ...ELEC ELECTRICAL COMPONENTS 8 2 Main switch seat closure Indicator relay Rectifier regulator Horn ...

Page 162: ...o the Ωx1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE indicates a conti...

Page 163: ...UITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch OFF PUSH P B HI LO G L Y G L R Y Br Ch Dg W P B L N R Br Ch Dg W LOCK OPEN OFF CHECK ON G Y Br R B B R G Br Y B W OFF START B L W TOP VIEW SIDE VIEW Horn switch Dimmer switch Turn signal switch Front brake switch Rear brake switch Star switch Main switch Fuse Oil level switch ...

Page 164: ...majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulbs c is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bulbs d and e are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out CHECKING THE CONDITI...

Page 165: ... a Connect the positive tester probe to termi nal and the negative tester probe to ter minal and check the continuity b Connect the positive tester probe to termi nal and the negative tester probe to ter minal and check the continuity c If either of the readings indicate no conti nuity replace the bulb CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb so...

Page 166: ...HE BULBS AND BULB SOCKETS 8 7 b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity repla ce the bulb socket ...

Page 167: ...ELEC IGNITION SYSTEM 8 8 EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM DC CDI magneto pickup coil DC CDI unit Ignition coil Spark plug Main switch Fuse Battery ...

Page 168: ...ch and gradually increase the spark gap until a misfire occurs Minimum ignition spark gap 6 0 mm Is there a spark and is the spark gap within specification ELEC IGNITION SYSTEM 8 9 EAS00736 TROUBLESHOOTING Check 1 Spark plug 2 Ignition spark gap 3 Spark plug cap resistance 4 Ignition coil resistance 5 Main switch 6 Pickup coil resistance 7 Main fuse 8 Battery 9 Wiring connections of the entire ign...

Page 169: ... 1 to the ignition coil as shown Positive tester probe red black Negative tester probe orange gray Measure the primary coil resistance Primary coil resistance 0 56 0 84 at 20 C Connect the pocket tester Ω x 1k to the ignition coil as shown Negative tester probe spark plug lead Positive tester probe ground Measure the secondary coil resistance Secondary coil resistance 5 68 8 52 kΩ at 20 C Is the i...

Page 170: ...for continuity Refer to CHECKING THE FUSES in chapter 3 Is the fuse OK EAS00739 8 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C Is the battery OK EAS00754 9 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly con nected and without ...

Page 171: ...ELEC ELECTRIC STARTING SYSTEM 8 12 EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Fuse Battery Starter relay Starter motor Start switch Front brake switch Rear brake switch ...

Page 172: ...motor can only operate if at least one of the following conditions is met The front brake switch is ON The rear brake switch is ON When at least one of the above conditions has been met the starter relay is closed and the engine can be started by pressing the starter switch Battery Fuse Main switch Front brake switch Rear brake switch Starter relay Start switch Starter motor ...

Page 173: ...Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C Is the battery OK EAS00758 3 Starter motor Connect the positive battery terminal and starter motor lead with a jumper lead s s WARNING A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead otherwise th...

Page 174: ... 5 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK EAS00764 6 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK EAS00766 7 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly connected and without defects G Y R R L W 4 3 2 1 Rep...

Page 175: ...TEM 8 16 EAS00767 STARTER MOTOR O ring Starter motor front cover Rubber seal Brush holder brushes Armature assembly Starter motor rear cover Wiring Brush wear limit 0 9 mm Commutator wear limit 14 8 mm Mica lower cut off 1 15 mm ...

Page 176: ...ature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification replace the starter motor 4 Measure brush length a Out of specification Replace the brushes as a set Commutator wear limit 14 8 mm Pocket tester 90890 03112 Armature coil Commutator resist...

Page 177: ...NG THE STARTER MOTOR 1 Install brush set rubber seal starter motor front cover 2 Install starter motor rear cover 3 Install Starter motor bolts NOTE When install the starter motor the ground ter minal a is installed with upper side bolt 13 Nm 1 3 m kg a ...

Page 178: ...ELEC CHARGING SYSTEM 8 19 EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM DC CDI Magneto Main fuse Battery Rectifier regulator ...

Page 179: ...ng voltage Charging voltage 12 V or more at 3000 r min 15 V or less at 8000 r min NOTE Make sure the battery is fully charged Is the charging voltage within specification EAS00738 2 Main fuse Check the fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 Is the fuse OK EAS00739 3 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum ope...

Page 180: ... 0 432 Ω at 20 C Is the charging coil OK EAS00779 5 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s wiring properly connected and without defects Replace the char ging coil assembly Properly connect or repair the charging system s wiring Replace the rectifier regulator YES NO YES NO ...

Page 181: ... SYSTEM 8 22 EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM DC CDI magneto lighting coil Tail brake light License light for UK only Auxiliary light 24 Dimmer switch 25 Headlight 35 High beam indicator light 37 Meter light ...

Page 182: ...sistance 0 116 0 264 Ω at 20 C Is the lighting coil OK EAS00784 2 Dimmer switch Check the dimmer switch for continuity Refer to CHECKING THE SWITCHES Is the dimmer switch OK EAS00787 3 Wiring Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM Is the lighting system s wiring properly con nected and without defects Pocket tester 90890 03112 Any of the following fail to light head lig...

Page 183: ...Start the engine Set the dimmer switch to HI or LO Measure the voltage DC 12 V of yellow or green on the headlight coupler wire harness side Is the voltage within specification EAS00789 2 The meter light fails to come on 1 Meter light bulb and socket Check the meter light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the meter light bulb and socket OK 2 Voltage Co...

Page 184: ...e on the tail brake light coupler tail brake light side Is the voltage within specification EAS00791 4 The position light fails to come on 1 Position light bulb and socket Check the position light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the position light bulb and socket OK 2 Voltage Connect the pocket tester DC 20 V to the position light coupler wire harnes...

Page 185: ...rt the engine Measure the voltage DC 12 V of blue on the position light coupler positionlight side Is the voltage within specification Wiring circuit from the main switch to the position light coupler is faulty and must be repaired This circuit is OK YES NO ...

Page 186: ...turn signal light left 21 Front turn signal light right 22 Rear turn signal light left 23 Rear turn signal light right 26 Horn 27 Horn switch 28 Fuel sender 29 Thermo switch CS50Z only 30 Engine oil level switch 31 Water temperature warning light CS50Z only 32 Fuel meter 33 Right turn signal indicator light 34 Left turn signal indicator light 36 Oil level warning light 38 Clock 39 Speedometer 40 S...

Page 187: ...y Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C Is the battery OK EAS00749 3 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK EAS00795 4 Wiring Check the entire signal system s wiring Refer to CIRCUIT DIAGRAM Is the signaling system s wiring properly...

Page 188: ...terminal Connect a jumper lead to the horn terminal and ground the jumper lead Set the main switch to ON Does the horn sound 4 Voltage Disconnect the pink and brown connectors at the horn terminal Connect the pocket tester DC 20 V to the horn connectors as shown Positive tester probe brown Negative tester probe pink Set the main switch to ON Push horn switch Measure the voltage DC 12 V of pink at ...

Page 189: ... green yellow on the tail brake light cou pler wire harness side Is the voltage within specification EAS00799 3 The turn signal light turn signal indicator light or both fail to blink 1 Turn signal indicator light bulb and socket Check the turn signal light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the turn signal light bulb and socket OK 2 Turn signal switch ...

Page 190: ...h to L or R Measure the voltage DC 12 V on brown white at the turn signal relay cou pler wire harness side Is the voltage within specification 5 Voltage Connect the pocket tester DC 20 V to the turn signal light connector or meter coupler wire harness side as shown Turn signal light Turn signal indicator light Left turn signal light Positive tester probe chocolate Negative tester probe ground Righ...

Page 191: ...DC 20 V to the meter coupler wire harness side as shown Positive tester probe green yellow Negative tester probe black Set the main switch to ON Measure the voltage DC 12 V of green yellow and black at the meter coupler Is the voltage within specification EAS00804 5 The fuel level gauge fails to operate 1 Fuel sender Remove the fuel sender from the fuel tank Connect the pocket tester to the fuel s...

Page 192: ...nts of the fuel level gauge increase or decrease to E or F NOTE Before reading the fuel level gauge leave the float in one position either up or down for at least three minutes Does the fuel level gauge needle move appropriately 4 Wiring Check the entire signaling system s wiring EAS00806 6 The speedometer fails to come on 1 Voltage Connect the pocket tester DC 20 V to the multi function meter soc...

Page 193: ...arning light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the water temperature warning light bulb and socket OK EAS00811 2 Thermo switch Remove the thermo switch from the cylin der head Connect the pocket tester Ω x 1 to the thermo switch as shown Immerse the thermo switch in a container filled with coolant Place a thermometer in the coolant Slowly heat the cool...

Page 194: ...t the pocket tester DC 20 V to the meter coupler wire harness side as shown Positive tester probe brown Negative tester probe green red Set the main switch to ON Measure the voltage DC 12 V of brown and green red at the meter coupler Is the voltage within specification Replace the thermo switch The wiring circuit from the main switch to the meter coupler is faulty and must be repaired L Y Br Ch Dg...

Page 195: ...TRBL SHTG 9 ...

Page 196: ...RMANCE 9 3 OVERHEATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEM 9 4 OVERCOOLING CS50Z only 9 4 COOLING SYSTEM 9 4 POOR BRAKING PERFORMANCE 9 4 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 5 MALFUNCTION 9 5 UNSTABLE HANDLING 9 5 FAULTY LIGHTING OR SIGNALING SYSTEM 9 6 HEADLIGHT DOES NOT COME ON 9 6 HEADLIGHT BULB BURNT OUT 9 6 TAIL BRAKE LIGHT DOES NOT COME ON 9 6...

Page 197: ...n ring Seized or damaged piston Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel tank cap breather hole Deteriorated or contaminated fuel Clogged or damaged fuel hose Fuel pump Faulty fuel pump Faulty fuel pump relay Damaged vacuum hose Improperly routed...

Page 198: ...arting circuit cut off relay Faulty starter clutch 9 2 TRBL SHTG STARTING FAILURE HARD STARTING INCORRECT ENGINE IDLING SPEED ENGINE Cylinder s and cylinder head s Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Carburetor s Faulty starter plunger Loose or clogged pilot jet Loose or clogged pilot air jet Damaged or loose carburetor joint I...

Page 199: ... Damaged clutch spring Transmission gear s Damaged transmission gear CLUTCH SLIPS Clutch shoe spring s Damaged loose or worn clutch shoe spring Clutch shoe s Damaged or worn clutch shoe Primary sliding sheave Seized primary sliding sheave POOR STARTING PERFORMANCE V belt V belt slips Oil or grease on the V belt Primary sliding sheave Faulty operation Worn pin groove Worn pin Clutch shoe s Bent dam...

Page 200: ...nt CHASSIS Brake s Dragging brake ELECTRICAL SYSTEMS Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Ignition system Faulty ignitor unit 9 4 TRBL SHTG OVERHEATING OVERCOOLING POOR BRAKING PERFORMANCE EAS00856 OVERCOOLING CS50Z only COOLING SYSTEM Thermostat Thermostat stays open EAS00859 POOR BRAKING PERFORMANCE Disc brake Worn brake pad Worn brake disc Air in hydraulic brake...

Page 201: ...lled handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring both front fork legs Broken fork spring Bent or damaged inner tube Bent or damaged outer tube Swingarm Worn bearing o...

Page 202: ...ULB BURNT OUT Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired TURN SIGNAL DOES NOT COME ON Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY Fau...

Page 203: ......

Page 204: ... Headlight 26 Horn 27 Horn switch 28 Fuel sender 29 Thermo switch for CS50Z only 30 Oil level switch 31 Water temperature warning light for CS50Z only 32 Fuel meter 33 Turn signal indicator light right 34 Turn signal indicator light left 35 High beam indicator light 36 Oil level warning light 37 Meter light 38 Clock 39 Speedometer 40 Speed sensor COLOR CODE B BLACK R RED L BLUE G GREEN O ORANGE Y ...

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