Yamaha CE50T Service Manual Download Page 1

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1987 - 1990

MOTORCYCLE

SERVICE MANUAL

Model : CE50T, CG50A, CG50U, CG50W

2YT281972000

*2YT281972000*

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Summary of Contents for CE50T

Page 1: ...1987 1990 MOTORCYCLE SERVICE MANUAL Model CE50T CG50A CG50U CG50W 2YT281972000 2YT281972000 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 2: ...a Motor Co Ltd 1st Edition November 1986 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 3: ...3 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 4: ...CULARLY iMPORTANT iNFORMATiON This material is distinguished by the following notation NOTE A NOTE provides key information to make procedures easier or clearer ili ii i iiil ACAUTION indicates special procedures that must be followed toavoid damage to the scooter A WARNING indicates special procedures that must be followed to avoid injury to a scooter operator or person inspecting or repairing th...

Page 5: ...re used to identify 6_ _ the specifications appearing in the text _ Filling fluid _ Lubricant _ Tightening _Wear limit clearance _ _ Engine speed Illustrated symbols _ to _ in the exploded 1 _ j diagram indicate grade of lubricant and location _ of lubrication point _ _ Apply engine o 1 Apply gear oil _ _ _ Apply molybdenum disulfide oil Apply wheel bearing grease _ _ _ _L_ _ _ _ Apply lightweight...

Page 6: ...INDEX GENERAL NFORMAT ON ENGINE OVERHAUL _ _ ENG _ CARBURETION CARB_ CHASSIS CHAS_ L J ELECTRICAL ELEC_ APPENDICES APPX_ D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 7: ...i i i 1 p D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 8: ...NT INFORMATION B 3 ALl REPLACEMENT PARTS B 3 GASKETS OIL SEALS AND O RINGS B 3 LOCK WASHER PLATES AND COTTER PINS B 3 BEARINGS AND OIL SEALS B 4 CIRCLIPS B 4 SPECIAL TOOLS B 4 FOR TUNE UP B 4 FOR ENGINE SERVICE B 4 FOR CHASSIS SERVICE B 5 FOR ELECTRICAL COMPONENTS B 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

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

Page 10: ...r scooter with the licensing outhority in your state Starting Serial Number JYA2U G00 HA720101 ENGINE SERIAL NUMBER The engine serial number is stamped into the crankcase NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number Starting Serial Number 14T 720101 NOTE Designs and specifications are subject to change without notice...

Page 11: ...skets seals and O rings should be replaced when an engine is overhauled All gasket surfaces oil seal lips and O rings must be cleaned 2 Properly oil all mating parts and bearings dur ing reassembly Apply grease to the oil seal lips LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers Plates _ and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut f...

Page 12: ...p s Oil the bearings liberally when installing _ Oil seal Do not use compressed air to spin the bear _ ings dry This causes damage to the bearing surfaces _ Bearing CIRCLIPS 1 All circlips should be inspected carefully e ore reas e reo ace O ton clips after one use Replace distorted circlips _ _ 7_ _ _ When installing a cirelip _ make sure th at the sharp edged corner _ is positioned op posite to ...

Page 13: ...Tachometer P N YU 08036 This tool is needed for detecting engine rpm 2 Compression Gauge P N YU 33223 This gauge is used to measure engine compr ession FOR ENGINE SERVICE 1 Flywheel Holding Tool P N YU 01235 This tool is usedto the hold the flywheel magneto and clutch assembly when removing or installing the securing nut 2 Flywheel Magneto Puller P N YM 01189 This tool is used to remove the flywhe...

Page 14: ... used to disassembly and assembly the secondary sheave 5 Thickness Gauge P N YU 03001 6 Universal Puller Set P N YU 33270 This tool is used to remove the crankshaft from the crankcase 7 Crankcase Separating Tool P N YU 01135 This tool is used to remove the crankshaft or separate the crankcase 1 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 15: ...crankcase mating surfaces FOR CHASSIS SERVICE 1 Ring Nut Wrench P N YU 01268 P N YU 33975 This tool is used to loosen and tighten the steer ing ring nut FOR ELECTRICAL COMPONENTS 1 Pocket Tester P N YU 03112 This instrument is invaluable for electrical system inspection and djustment J 2 Electro Tester P N YU 33260 This instrument is necessary for ignition system inspection 1 6 D o w n l o a d e d...

Page 16: ... C 6 AUTOLUBE PUMP AIR BLEEDING C 7 AIR CLEANER ELEMENT CLEANING C 8 FUEL COCK CLEANING C 8 COMPRESSION PRESSURE MEASUREMENT C 9 ENGINE OIL LEVEL INSPECTION C 10 TRANSMISSION OIL REPLACEMENT C 10 FUEL LINE INSPECTION C 11 CHASSIS C 11 FRONT BRAKE LEVER FREE PLAY CHECK C 11 REAR BRAKE LEVER FREE PLAY CHECK C 11 FRONT AND REAR BRAKE LINING INSPECTION C 12 TIRE AND WHEEL INSPECTION C 12 STEERING ADJU...

Page 17: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 18: ... Clean or replace O O Air filter Clean Replace if necessary O Carburetor Check Adjust idle speed starter operation Fuel line Check fuel hose for cracks or damage O O Transmission oil Replace Warm engine before draining Replace Check Check Every 12 000 8 000 or 24 months Autolube pump Check Adjust Air bleeding O O Brake Check operation Adjust if necessary O O Wheels Check balance damage runout O O ...

Page 19: ... Rear carrier With rear flasher lights and taillight 5 Disconnect Rear flasher light leads Taillight leads 6 Remove Side covers Right and left NOTE When removing the side cover unhook it at the front and slide it forward 7 Remove Tail cover 2 2 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 20: ...vers NOTE After installing the side covers make sure that all hooks are securely fitted 2 Connect eRear flasher light leads NOTE The leadsof identical colors should be connected 31 install i_J_ Rear carrier i__i 7Nm 0 7 m kg 5 1 ft lb 4 Install eSeat _ 7 Nm 0 7 5 1 ft lb m kg 2 3 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 21: ... Refer to TAIL COVER section 2 Remove Front fender _ NOTE Before removing the fender make sure that all _ i Q i hooks are free _N _ 3 Remove _iiiii iiii_ __ Main switch cap i iiii i ilii_i i Turn the cap counterclockwise 4 Remove Front panel 5 Remove Footrest board 2 4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 22: ...installing the front fender make sure that all hooks are securely fitted E HANDLEBAR COVERS REMOVAL 1 Remove Screws Handlebar cover Front Rear view mirror s 2 Disconnect Headlight lead and flasher light leads 3 Remove Handlebar cover Front 4 Disconnect Leads Speedometer cable 5 Remove Handlebar cover Rear 2 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 23: ...eHeadlight lead and flasher ght leads 4 Install Handlebar cover Front Rear view mirror s ENGINE ENGINE iDLE SPEED ADJUSTMENT 1 Remove Tail cover Refer to TAIL COVER section 2 Start the engine and warm it up before check ing the idle speed NOTE A warm engine is defined as one which had been operated for about 3 minutes at 3 000 r min with no load 2 6 D o w n l o a d e d f r o m w w w S c o o t e r ...

Page 24: ...le stop screw clockwise to increase engine speed and counterclockwise to decrease engine speed 5 Install eTail cover Refer to TAIL COVER section THROTTLE CABLE FREE PLAY ADJUSTMENT 1 Check Throttle cable free play Out of specification Adjust ThrottleCableFreePlay 3 0 7 0 mm 0 12 0 28 in Throttle cable free play adjustment steps NOTE Before adjusting the throttle cable free play the engine idle spe...

Page 25: ...r Refer to TAIL COVER section Front fender Front panel eFootrest board Refer to FRONT FENDER FRONT PANEL AND FOOTREST BOARD section 2 Check Throttle cable free play _ at carburetor side Out of specification_Adjust J_ Thrott eCableFreePlay _ 1 0 mm 0 04 in Throttle cable free play adjustment steps Loosen the Iocknut _ Turn the adjuster _ in or out until the cor rect free play is obtained Tighten th...

Page 26: ...e pump pully eTighten the Iocknut 6 Install oAutolube pump cover oFootrest board Front panel Front fender eTail cover Refer to FRONT FENDER FRONT PANEL AND FOOTREST BOARD and TAIL COVER section AUTOLUBE PUMP AIR BLEEDING The Autolube pump and delivery lines must be bled on the following occasions Whenever the Autolube tank has run dry oWhenever any portion of the Autolube system is disconnected oI...

Page 27: ...mp cover J 3 Remove Bleed screw NOTE Place a rag under the Autolube pump 4 Start the engine at idle speed 5 Air bleed Keep the oil running out until air bubbles disappear NOTE Pull the pump cable all the way out to set the pump stroke to a maximum 6 Inspect Bleed screw gasket Damage_Replace 7 Install Bleed screw gasket Bleed screw 2 10 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 28: ...AIL COVER section AIR CLEANER ELEMENT CLEANING 1 Remove Side cover Left _ NOTE When removing the side cover unhook it at the front and slide it forward 2 Remove Air cleaner case cover _ eAir cleaner element i i i_iii i i i_i i _i i i_ i Never operate the engine with the air cleaner element removed This will allow unfiltered air to enter causing rapid wear and possi ble engine damage Additionally o...

Page 29: ...ueeze the excess solvent out of the element and let dry Do not twist the element when squeezing the element 4 Inspect oElement Damage _ Replace 5 Apply oFoam air filter oil or SAE 10W30 type SE motor oil Onto the element 6 Squeeze out the excess oil NOTE The element should be wet but not dripping 7 Install oAir cleaner element Air cleaner case cover Side coyer Left FUEL COCK CLEANING 1 Remove Tail...

Page 30: ...muffler when draining _ oNever drain fuel while smoking or in the vicinity of an open flame 3 Remove _ Cap _ _ _ _ Filter _ _ _ _ii _iiii_ _ _ 4 Clean Filter oCap Wash the filter and cap gently using solvent 5 Inspect Filter oO ring Damage Replace 6 Install O ring Filter oCap oTail cover Refer to TAIL COVER section 2 13 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 31: ...rther Compression should be within the specified levels Compression Pressure at sea level Standard 800 kPa 8 0 kg cm 2 114 psi Minimum 640 kPa 6 4 kg cm 2 91 psi When cranking engine ground spark plug wires to prevent sparking Compression test steps below minimum levels oSquirt a few drops of oil into cylinder eMeasure compression again Reading Diagnosis Worn cylinder Higher than piston and piston...

Page 32: ...il by the _ following inspection steps _ OIL indicator light _3N _0 _ _ E ONLY Engine oil level visual inspection steps I Turn main switch to _ I position l I OlL indicatorlight I I OlL indicatorlight I does not ome on comes on I urn main switch to ON position I OIL indicator light _ i OIL indicator light I does not come on 1 iomeson i I e ec 1en0ine o eve e ec I Su 0 eat he l I trical circuit tri...

Page 33: ...r cap _ and push it fully into the filler Always use the same type of engine oil mix ing oils may result in a h_rmful chemical reaction and lead to poor performance TRANSMISSION OIL REPLACEMENT 1 Warm up the engine at idle speed then stop it 2 Place the oil pan under the drain hole 3 Remove oDrain bolt _ Drain the transmission oil oOil filler plug 2 16 D o w n l o a d e d f r o m w w w S c o o t e...

Page 34: ...t 18 Nm 1 8 m kg 13 ft lb 6 Fill Transmission case ___ Transmission Oil Yamalube 4 or SAE 10W30 Type SE Motor Oil Capacity 0 1 L 0 09 Imp qt 0 11 US qt NOTE Wipe off any oil split on the crankcase tire or wheel 7 Install Oil filler plug FUEL LINE INSPECTION 1 Remove eTail cover Refer to TAIL COVER section 2 17 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 35: ...ut of specification _Adjust 0 0 l Front brake lever free p a adjustment steps oTurn the adjuster _ in or out until the cor rect free play is obtained REAR BRAKE LEVER FREE PLAY CHECK 1 Check Rear brake lever free play _ Out of sP ecification_ Adjust _ 10 20 mm 0 4 0 8 in Rear brake lever free play adjustment steps Turn the adjuster _ in or out until the cor rect free play is obtained 2 18 D o w n ...

Page 36: ...g braking and other perfor mance and safety characteristics of your scooter Do not carry loosely packed items that can shift Securely pack your heaviest items close to the center of the scooter and destribute the weight evenly from side to side And check the condition and pressure of your tires NEVER OVERLOAD YOUR SCOOTER Make sure the total weight to the cargo rider passenger and accessories fair...

Page 37: ...ide conservatively after installing a tire to allow it to seat itself properly on the rim _ 3 Measure Tire tread depth Out of specification_Replace _ _ Minimum Tire Tread Depth front and rear 0 8 mm 0 03 in _ Tread depth Side wall Wear indicator STEERING ADJUSTMENT 1 Place the scooter on its centerstand then elevate the front wheel 2 20 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 38: ...okg 22 ftolb NOTE Set the torque wrench to the ring nut wrench so that they form right angle Move the handlebar up and down and or back and forth If handlebar free play is ex cess tighten the bolt to specification Bolt 60 Nm 6 0 m kg 43 ft lb Install the front fender and front panel ELECTRICAL BATTERY 1 Check Fluid level Incorrect Refill Fluid level should be between upper and lower level marks Up...

Page 39: ...urs as in dicated by the plates turning white or an ac cumulation of material exists in the bottom of the cell Specific gravity readings after a long slow charge indicate one cell to be lower than the rest Warpage or buckling of plates or insulators is evident _ 4 Measure Specific gravity Less than 1 280 Recharge battery Charging Current 0 4 amps 10 hrs Specific Gravity 1 280 at 20 C 68 F 2 22 D o...

Page 40: ...EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL eDrink large quantities of water or milk follow with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these preventive measures eCharge batteries in a well ventilated area Keep batteries away from fi...

Page 41: ...heck circuit in question Do not use fuses of higher amperage rating than recommended Extensive electrical system damage and fire could result from substitution of a fuse of impcoper amperage Description Amperage Quantity Main 7A 1 SPARK PLUG INSPECTION 1 Remove i Cover _i_ _ Spark plug 0 H_ i 2 Inspect Electrode _ Wear Damage Replace Insulator _ Abnormal Color_ Replace Standard Spark Plug BPR6HS N...

Page 42: ...gasket and plug surfaces NOTE Finger tighten the spark plug before torquing to specification Spark Plug 20 Nm 2 0 m kg 14 ft ib HEADLIGHT BEAM ADJUSTMENT 1 Adjust Headlight Vertically Vertical adjustment Higher Loosenthe adjusters Lower Tighten the adjusters Headlight Horizontal Horizontal adjustment Loosen the adjuster or tighten Right the adjuster Loosen the adjuster or tighten Left the adjuster...

Page 43: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 44: ...CASE AND CRANKSHAFT D 9 INSPECTION AND REPAIR D 10 CYLINDER HEAD D 10 CYLINDER AND PISTON D 10 PISTON PIN AND PISTON PIN BEARING D 12 AUTOLUBE PUMP D 12 CRANKSHAFT D 12 TRANSMISSION D 13 PRIMARY SHEAVE D 13 SECONDARY SHEAVE D 13 V BELT D 15 STARTER CLUTCH AND GEARS D 15 ENGINE ASSEMBLY AND ADJUSTMENT D 16 CRANKSHAFT AND CRANKCASE D 16 TRANSMISSION E 1 AUTOLUBE PUMP E 3 C D I MAGNETO E 4 STARTER SY...

Page 45: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 46: ...move all dirt mud dust and foreign material before removal and disassembly 2 Use proper tools and cleaning equipment Refer to CHAPTER 1 GENERAL INFOR MATION SPECIAL TOOLS section NOTE When disassembling the engine keep mated parts together This includes gears cylinder piston and other parts that have been mated through nor mal wear Mated parts must be reused as an assembly or replaced 3 1 D o w n ...

Page 47: ...ransmission oil completely Refer to CHAPTER 2 TRANSMISSION OIL REPLACEMENT section TAIL COVER 1 Remove Seat Tail cover Rear carrier Refer to CHAPTER 2 TAIL COVER section FRONT FENDER FRONT PANEL AND FOOTREST BOARD 1 Remove Front fender Front panel Footrest board Refer to CHAPTER 2 FRONT FENDER FRONT PANEL AND FOOTREST BOARD section CARBURETOR 1 Remove Air cleaner case 3 2 D o w n l o a d e d f r o...

Page 48: ...er the carburetor with a clean rag to prevent dirt or foreign matter into the carburetor _i CABLES LEADS AND PIPES i 1 Remove Autolube pump cover i 2 Remove oOil pump cable _ oOil pipe _ NOTE Plug the oil pipe so the oil will not run out of the oil tank 3 Remove Battery negative lead _ 3 3 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 49: ...Remove Spark plug cap 5 Remove Earth lead _ 6 Remove Rear brake cable _ 7 Disconnect C D I magneto leads Starter motor leads ENGINE REMOVAL 1 Remove Air shroud _ 3 4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 50: ... Remove oEngine mounting bolts 3 Remove Engine Lift up the frame and remove the engine 4 Place the frame on a suitable stand DISASSEMBLY MUFFLER 1 Remove oExhaust pipe 3 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 51: ... _ _ Air shroud 3 Remove _ Cylinder head _ _ Cylinder head gasket NOTE Before loosening the cylinder head loosen the spark plug _ The cylinder head holding nuts should be loosen ed 1 2 turn each time and remove 3 6 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 52: ... clean rag so you will not acciden tally drop the clip into the crankcase 2 Remove oPiston pin _ Piston _ Piston pin bearing NOTE Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and piston pin is still difficult to remove use Piston Pin Puller YU 01304 Do not use a hammer to drive the piston pin out 3 7 D o w n l o a d e d f r o m w w w ...

Page 53: ... __ 3 Remove Nut Primary sheave NOTE When loosening the nut primary sheave hold the C D I magneto using Flywheel Holding Tool _ YU 01235 4 Remove Conical spring washer _ One way clutch _ _ _ Primary fixed sheave _ _ _ V Belt 3 8 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 54: ..._ _ _ STARTER SYSTEM _ _ _ 1 Remove Starter clutch assembly _ 2 Remove Plate _ Idle gear 3 9 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 55: ... Z 3 Remove eStarter wheel gear Bearing Washers oldie gear 4 Remove Stay oCollar 5 Remove oStarter motor 6 Remove Kick crank 7 Remove oKick torsion spring 3 10 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 56: ...C D I MAGNETO 1 Remove _ oNut _ C D I magneto Use Flywheel Holding Tool YU 01235 _ _ ii _ 2 Remove _ __ 9 C D I magneto Use Flywheel Magneto Puller YM 01189 oWoodruff key 3 11 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 57: ...mbly _ 4 Remove Gasket AUTOLUBE PUMP 1 Remove Autolube pump 2 Remove Circlip _ Shim _ Wave washer _ Pump drive gear _0 0 Pin TRANSMISSION 1 Remove Rear wheel oBrake shoe plate 3 12 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 58: ...rstand I q 4 Remove Transmission case cover Gasket 5 Remove Main axle Drive axle Washer Main axle Washer Drive axle ii ii ii iii i i ii ii O 6 Remove Oil seal oCirclip 7 Remove Secondary sheave axle 3 13 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 59: ... the tool body is parallel with the case If necessary one screw may be backed out slight ly to level tool body _ _i __ i _ _ _ 4 Remove eCrankcase Left As pressure is applied alternately tap on the engine mounting bosses i i Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separat...

Page 60: ...n Thread 6 mm 0 24 in Pitch 1 25 mm INSPECTION AND REPAIR CYLINDER HEAD 1 Remove Carbon deposits Use a rounded scraper NOTE Take care to avoid damaging the spark plug threads Do not use a sharp instrument Avoid scratching the aluminum 2 Inspect Cylinder head warpage Out of specification Re su rface Warpage measurement and re surface ment steps Attach a straight edge and a thickness gauge on the cy...

Page 61: ...remov ing too much material from one side CYLINDER AND PISTON 1 Eliminate _ _ _ _ 1 _ Carbon deposits From the piston crown and ring grooves _ 2 Eliminate Score marks and lacquer deposits From the sides of piston Use a 600 800 grit wet sandpaper _ NOTE _ _ Sand in a crisscross pattern Do not sand exces sively 3 Inspect Piston wall Wear Scratches Damage_ Replace 4 Eliminate Carbon deposits Use a ro...

Page 62: ... Then find the _ _ _ _ average of the measurements _ Standard Wear Limit Cylinder bore 40 00 40 02 mm 40 50 mm C 1 575 1 583 in 1 594 in 0 05 mm Taper T 0 0019 in Out of round 0 01 turn R 0 0004 in C Maximum D T Maximum Dz or D2 Maximum Ds or D6 R Maximum D1 D3 or Ds Minimum D2 D4 or D6 elf out of specification rebore or replace cylinder and replace piston and piston rings as a set __ 2nd step _ M...

Page 63: ...e C Piston skirt diameter P olf out of specification rebore or replace cylinder and replace piston and piston rings as a set _ Piston to cylinder Clearance 0 034 0 047 mm 0 0013 0 0018 in Limit 0 1 mm 0 004 in i i 7 Measure oEnd gap Out of specification Replace rings as a set Use a Feeler Gauge _ _ i ___ Standard Limit 0 15 0 30 mm 0 70 mm Top ring 0 006 0 012 in 0 028 in 0 15 0 30 mm 0 70 mm 2nd ...

Page 64: ... _ _ Free play There should be no noticeable for the play Freeplay exists_ Inspect the connecting rod _ _ for wear Replace the pin and or connecting rod as required 4 Install oPiston pin ___j_ Into the piston pin hole 5 Check oFree play when the piston pin is in place in the piston There should be no noticeable for the play Free play exists Replace piston pin and or piston 6 Inspect oPiston pin an...

Page 65: ...iven gear teeth _ _i_ i _ i _ Pitting Wear Damage Replace F CRANKSHAFT 1 Measure eRunout limit C _Connecting rod big end side clearance D oSmall end free play limit F Out of Specification_Replace Use V Blocks Dial Gauge and thickness gauge Runout Limit C 0 03 mm 0 0012 in Connecting Rod Big End Side Clearance D 0 2 0 5 mm 0 008 0 02 in Small End Free Play 0 4 0 8 mm 0 015 0 031 in 2 Inspect oBeari...

Page 66: ...hness Replace _ Pitting Damage Replace PRIMARY SHEAVE 1 Inspect Primary sliding sheave _ Primary fixed sheave _ Collar _ Wear Cracks Scratch Damage Replace 2 Check Free movement Insert the collar into the primary sliding sheave and check for free movement Stick or excessive play Replacethe sheave or collar __ _ _ _ _ SECONDA RY SH EAVE _ _ _ Disassembly 1 Attach _ _ _ Primary Sheave Holder YS 0188...

Page 67: ...ch 1 25 mm 4 Remove Clutch securing nut _ 5 Remove _ __ Clutch assembly Clutch spring _ _ _ _ Spring seat _ 6 Remove Guide pins 7 Remove oSecondary sliding sheave _ 5 Inspection _ 1 Inspect _Secondary fixed sheave _ oSecondary sliding sheave _ i_ Scratch Crack Damage Replace as a set 3 22 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 68: ...Oil Scratches Remove Use a rag soaked in lacquer Oil thinner or solvent Use an emery cloth Scratches lightly and evenly polishing 5 Measure oClutch housing inside diameter Ouf of specification Replace r Clutch Housing Inside Diameter 105 0 mm 4 13 in Wear Limit 105 4 mm 4 15 in 6 Inspect oClutch shoes Glazed parts Sand with coarse sandpaper NOTE After using the sand paper clean of the polished par...

Page 69: ...ssembly procedure Note the following points 1 Apply BEL RAY Assembly Lube to the inside of the sliding sheave iii si i 2 Install Sliding sheave NOTE Be careful so that the oil seal lips are not turned over when installing the sheave 3 Apply eBEL RAY Assembly Lube to the torque cam grooves and O rings 4 Check Sliding sheave Unsmooth operation Repair 3 24 D o w n l o a d e d f r o m w w w S c o o t ...

Page 70: ...rack Wear _ Replace NOTE Replace the V belt smeared with a lot of oil or grease 2 Measure oV belt width _ Out of specification_Replace _ V Belt Width 15 0 mm 10 59 in a I Wear Limit 13 5 mm 0 53 in STARTER CLUTCH AND GEARS 1 Inspect Starter clutch Push the dowel pin to arrow direction Unsmooth operation _Replacce starter clutch assembly 3 25 D o w n l o a d e d f r o m w w w S c o o t e r T i m e ...

Page 71: ...Inspect _ Kick gear teeth _ oKick pinion gear teeth _ _ Burrs Chips Roughness Wear Replace 5 Inspect oMating dogs Kick pinion gear and one way clutch Rounded edges Damage_ Replace 6 Measure eClip tension Kick pinion gear Out of spedification Replace f _ _ _ Use a spring balance Standard Tension 250 300 g 8 83 10 6 oz 3 26 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 72: ... oCrankshaft Installing Tool YU 90050 YM 90062 2 Install Crankshaft To left crankcase NOTE Hold the connecting rod at top dead center with one hand while turning the nut of the Installing Tool with the other Operate the Installing Tool until the crankshaft bottoms against the bearing 3 Apply Sealant Quick Gasket ACC 11001 30 00 To the mating surfaces of both case halves 4 Install Dowel pins oSpace...

Page 73: ...e using a crisscross pattern 7 Check oCrankshaft operation Unsmooth operation Repair 8 Install Oil seal stopper plate _ Circlip _ Screw Oil Seal Stopper Plate 13 Nm 1 3 m kg 9 4 ft lb 3 28 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 74: ... 0 Oil seal F 1 492 1 494 in _ Bearing __ C 0 03mm 0 oe12in Crank Right D 0 2 0 5 mm Crank pin 0 008 0 020 in Bearing F 0 4 0 8 mm _ Crank eft Connecting rod 0 015 0 031 in _ Bearing _D _ Oil seal 3 29 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 75: ...xle _ to transmission case cover 3 Install Circlip Oil seal NOTE i_i_i Apply lithium soap base grease onto the oil seal _ _i lips 4 Apply 10W30 type SE Motor oil to main axle bearing and drive axle bearing _ _ _ 5 Install Drive axle _ Main axle _ Washer _ Main axle _ Washer Drive axle 3 30 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 76: ... _ _ Screw Case cover ii _ili i _ 8 Nm 0 8 m kg 5 8 ft lb 8 Install i _i_ Centerstand 9 Install Brake shoe plate t Soe P ate 18 Nm 1 8 m kg 13 ft lb 10 Install Plain washer _ Rear wheel _ _ Plain washer _ Nut t I_LI 93 Nm 9 3 m kg 67 ft ib I 3 31 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 77: ...ANO AOJUSTM OT OJ TRANSMISSION Bearing Oil seal Drive axle _ Bearing q_ Main axle _ Plain washer _ econdary sheave axle Bearing _ Circlip _ Oil seal G 3 32 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 78: ...3 33 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 79: ...o oo oE Aoo AOJOSTMEN IE OI I AUTOLUBE PUMP _ Autolube pump _ Pin _ Circlip Shim _ Wave washer _ Pump drive gear _ Circlip 3 34 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 80: ...uff key _ C D I magneto Plain washer _Spring washer _Nut NOTE When installing the C D I magneto make sure the woodruff key is properly seated in the key way of the crankshaft Apply a light coating of lithium soap base grease to the tapered portion of the crankshaft end _ _ _ _ 5 Tighten i _ Nut C D I magneto Use Flywheel Holding Tool YU 01235 _ 141 I 43 Nm 14 3 m kg 31 ft lb 3 35 D o w n l o a d e...

Page 81: ...TMEO C D I MAGNETO _ Fan _ C D I magneto Stator assembly Gasket _ Woodruff key 8Nm 08___ kg 5 8 ft _b I I 43 Nm 14 3mokg 31 ft lb __ _ 8 Nm 10 8m kg 5 8 ft lb 3 36 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 82: ...MBLY AND ADJUSTMENT STARTER SYSTEM 1 Install oCollar _ Kick shaft _ 4 Install Kick torsion spring _ NOTE Set the kick torsion spring to the spring hook 3 37 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 83: ...tolb _ _ _ _ _t 8 Install _ _ _ _ _ _ _ i _ _ i_i _ _ _ _i _ i_ Plain washers _ _ _i _i _ _ _ ___ Starter wheel gear _ _ _ Apply Yamalube 2 cycle oil to the idle gear _ _ _i_ _ _ _ _ Apply lithium soap base grease to the bearing ii i 9 sta _ Plate _D Idle gear I _ Screw die Gear Plate 8 Nm 0 8 m okg 5 8 ft lb 10 Install eStarter clutch assembly _ 3 38 D o w n l o a d e d f r o m w w w S c o o t e ...

Page 84: ... ollar Stay ENGINE ASSEMBLY AND ADJUSTMENT Bearing Starterwheelgear Starterclutchassembly Kickpiniongear 0 Nm 1 0 mokg 7 2 ft lb I J v I kg 5 8 ft lb I I CLIP STANDARD TENSION A 250 300 g 8 83 10 6 oz 3 39 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 85: ...m soap base grease L _ _ _ _ _ _ _ _ 5 Install iiiiiiii_iii_i_iiii Primary sheave assembly _ _i i i_iiiii_iiii i_i Collar _ _ _ _ _ ililili_i _iii_i_i _ Shim _ 6 Install _V belt Place the V belt around the secondary sheave and compress the secondary sheave spring hard so that the V belt moves toward the clutch hub NOTE The V belt must be installed with the arrow frontward 3 40 D o w n l o a d e d ...

Page 86: ...sheave _ 30 Nm 3 0 m kg 22 ft lb NOTE When tightening the nut primary sheave hold the C D I magneto using Flywheel Holding Tool YU 01235 9 install oFan _ _ Screw Fan ii_ 8 Nm 0 8 m kg 5 8 ft lb 10 Install Dowel pins oCrankcase cover Left Screw Crankcase Cover 8 Nm 0 8 m kg 5 8 ft lb 3 41 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 87: ...ly _ Oil seal _ V belt _ Spring seat _ Primary fixed sheave _ Clutch spring _ One way clutch Apply BEL RAY Assembly Lube CLUTCH SPRING FREE LENGTH LIMIT A 94 0 rnrn 3 70 in CLUTCH HOUSING WEAR LIMIT B 105 4 mrn 4 15 in CLUTCH SHOE WEAR LIMIT _ _ C 2 5mm 0 10 in _ 150 Nm 5 0 m kg 36ft lb I VBELT_ L _ T _ O 135 mm 0 53 _nl __ _ _r _ t e 3 42 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n ...

Page 88: ...nd bearing Piston Piston pin Piston pin clip NOTE The arrow _ on the piston must point to the front of the engine Before installing the piston pin clip cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and material into the crankcase Always use a new piston pin clip 3 43 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 89: ...d _ Piston _ Piston pin clip Piston pin _ Piston pin clip Small end bearing PISTON RING SIDE CLEARANCE A 0 03 0 05 mm 0 0012 0 0020 in LIMIT 0 10 mm 0 004 in B 0 015 0 03 mm 0 006 0 012 in LIMIT 0 7 mm 0 028 in I 3 44 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 90: ...p side of the rings oBefore installing the cylinder apply a liberal coating of 2 stroke to the pisotn rings 3 Install Reed valve oCarburetor joint _ B t Carburet r J int I 8 Nm 0 8 m okg 5 8 ft lb _i_ _ J 4 Install Cylinder _ _ NOTE Install the cylinder with one hand while compress ing the piston rings with the other hand 5 Pass the oil delivery pipe as shown 3 45 D o w n l o a d e d f r o m w w w...

Page 91: ...d holding nuts in stage using a crisscross pattern Cylinder Head Holding Nuts 10 Nm 1 0 m kg 7 2 ftolb Spark Plug 20 Nm 2 0 m kg 14 ftolb Q 4 8 Install eAir shroud l Bolt Air Shroud 8 Nm 0 8 m kg 5 8 ft lb 9 Install Fan cover l Screw Fan cover 8 Nm 0 8 m kg 5 8 ft lb 3 46 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 92: ... Cylinder Gasket ADJUSTMENT 120 Nm 2 0 14 l m kg ft lb A C PISTONTO CYLINDERCLEARANCE 0 034 0 047 mm 0 0013 0 0018in CYLINDER HEAD WARPAGE LIMIT 0 02 mm 0 0008in SPARK PLUG BPR6HS N G K GAP 0 9 1 0 mm 0 035 0 039in 3 47 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 93: ...ure 1 Install Engine mounting bolts These bolts should be temporarily secured 2 Tighten oEngine mounting bolts Bolt 42 Nm 4 2 rn kg 30 ft lb Bolt r 17 Nm 1 7 m kg 12 ft lb 3 Install Carburetor Carburetor top together with throttle valve NOTE When installing the throttle valve into the car buretor align the groove of the throttle valve with the projection of the carburetor 3 48 D o w n l o a d e d ...

Page 94: ...TER 2 TRANSMISSION OIL REPLACEMENT section 6 Adjust Brake lever free play Refer to CHAPTER 2 BRAKE LEVER FREE PLAY ADJUSTMENT section Autolube pump cable Refer to CHAPTER 2 AUTOLUBE PUMP CABLE ADJUSTMENT section Throttle cable free play Refer to THROTTLE CABLE FREE PLAY ADJUSTMENT section 3 49 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 95: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 96: ...ATIC F 3 OPERATION F 3 CARBURETOR F 4 SECTION VIEW F 5 REMOVAL F 5 DISASSEMBLY F 5 INSPECTION F 6 ASSEMBLY F 7 INSTALLATION F 7 AUTO CHOKE UNIT CHECK F 8 REED VALVE F 8 REMOVAL F 8 INSPECTION F 8 INSTALLATION F 9 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 97: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 98: ...fied temperature This specified temperature is then reained I Wax element I The wax element changes its volume according to a varying temperature of the thermistor thereby causing the starter plunger to operate I Starter plunger I The starter plunger opens or closes the starter passage according to changes in the volume of the wax element r i m WIRING SCHEMATIC Power source is provided by the C D ...

Page 99: ...wax element gradually pushing the starter plunger and controlling the opening of the starter passage The further heated thermistor expands the wax element to a com plete extent thereby fully closing the starter passage This in turn causes the engine r p m to change be reduced with time finally coming to specified idling The wax element expands during the ride as well by means of the P T C thermist...

Page 100: ... starter passage is fully closed by the starter plunger 2 Restartingafter leavingenginefor a particular time The wax element beginsto reduceitsvolume according to the ambient temperature per mitting the starter plunger to open the passage to meet the engine requirement 4 3 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 101: ... Drain screw _ Pilot air jet Auto choke unit _ Pilot jet 1_ O ring Main nozzle Starter jet needle Main jet Starter plunger j_ME _ SPECIFICATIONS IN JET 82 NEEDLE 3S30 4 5 IN AIR JET _2 0 _ PILOT JET 42 _ _ _ e FLOAT HEIGHT 15 0 17 0 mm _ 0 59 0 67 in ENGINE IDLE SPEED 1 500 2 100 r rain 4 4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 102: ...lve _ Starter jet needle Slow metering system _ Main nozzle _ Starter needle jet Starter metering system _ Main jet _ Starter jet Fuel metering system _ Pilot air jet _ Needle valve Air _ Pilot jet _ Float Mixture Auto choke unit Fuel 4 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 103: ...r case _ 2 Disconnect _ oFuel pipe _ Vacuum pipe _ oOil delivery pipe _ 3 Remove Carburetor top _ 4 Remove Carburetor assembly 5 Disconnect oAuto choke unit leads _ DISASSEMBLY _ 1 Remove _ _ _ i Float chamber _ iii_ _ _ _ Gasket _ 4 6 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 104: ...ove oFIoat pin stop screw _ Float pin oFloat oNeedle valve _ 4 Remove Throttle stop screw _ oSpring _ Throttle stop screw 6 Remove Auto choke unit _ O ring _ 4 7 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 105: ...th compressed air 2 Inspect _ Float _ _ Damage Replace Gasket _ Damage Replace 3 Inspect oNeedle valve _ Wear Contamination Replace I 4 Inspect Throttle valve _ Wear Damage Replace 5 Check Free movement Stick Replace Insert the throttle valve into the carburetor body and check for free movement 4 8 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 106: ...place O _ _ 8 Inspect Starter plunger _ Wear Damage _ Replace 9 Measure Float height Out of specification Inspect needle valve float and valve seat 15 0 17 0 mm 10 59 0 67 in Float height measurement steps Install the needle valve float and float pin to the carburetor body Hold the carburetor in an upside down position 4 9 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 107: ... i If it is worn replace it NOTE The float height is properly adjusted at the Yamaha factory Never attempt to adjust it ASSEMBLY To assemble the carburetor reverse the dis assembly procedures Note the following points Before reassembling wash all parts in clean gasoline Always use a new gasket 1 Install Throttle valve _ NOTE Align the groove _ of the throttle valve with the projection _ of the car...

Page 108: ... room temperature If both measurements are the same auto choke unit is defective Replace it For reference below is a table of plunger heights at respective temperature Temperature Plunger height 5 C 23 5 F 16 1 0 3 mm 0 63 0 01 in 10 C 50 5 F 17 8 0 3 mm 0 70 0 01 in 20 C 68 5 F 18 8 0 3 mm 0 74 0 01 in 30 C 86 5 F 19 7 0 3 mm 0 78 0 01 in 40 C 104 5 F 20 1 0 3 mm 0 79 0 01 in NOTE In the above ta...

Page 109: ...e assembly INSPECTION 1 Inspect Carburetor joint Damage Cracks_ Replace eReed valve Fatigue Cracks Replace Inspection steps eVisually inspect the reed valve NOTE Correct reed valve should fit flush or nearly flush against valve seat elf in doubt asto sealing ability apply suction to carburetor side of assembly eLeakage should be slight to moderate 4 12 D o w n l o a d e d f r o m w w w S c o o t e...

Page 110: ...e stopper 3 Measure Reedvalve clearance Out of specification Replace reed valve Reed Valve Clearance Less than 0 2 mm 0 008 in iNSTALLATION When installing the reedvalve assembly reverse the removalprocedure Notethe following points 1 Install oGasket New 2 Tighten Reedvalve securing bolts 9 Nm 0 9 m kg 6 5 ft lb NOTE Tighten each bolt gradually to avoid warping 4 13 D o w n l o a d e d f r o m w w...

Page 111: ...91 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 112: ... WHEEL G 6 REMOVAL G 6 INSPECTION G 7 ASSEMBLY BRAKE SHOE PLATE G 7 INSTALLATION G 7 FRONT FORK AND STEERING G 8 REMOVAL G 9 DISASSEMBLY G 10 INSPECTION G 10 ASSEMBLY AND INSTALLATION G 10 REAR SHOCK ABSORBER G 12 REMOVAL G 13 INSPECTION G 13 INSTALLATION G 13 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 113: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 114: ...ain washer _ Bearing _ Brake shoe plate _ Speedometer driven gear _ Speedometer drive gear _ Wear indicator TIRE SIZE A 2 75 10 4PR RIM RUNOUT LIMIT _ B RADIAL 2 0 mm 0 08 in __ LATERAL 2 0 mm 0 08 in C BRAKE DRUM WEAR LIMIT 80 5 mm 3 17 in D BRAKE SHOE WEAR LIMIT 2 0 mm 0 08 in WHEEL AXLE RUNOUT LIMIT 0 25 mm 0 01 in J _ I 35 Nm 13 5 m kg 25 ft lb I 5 1 D o w n l o a d e d f r o m w w w S c o o t...

Page 115: ...e runout Out of specification Replace _ _ I_ h_ Wheel Axle Run ut Limit L_ILI_ 0 25 mm 0 01 in I Do not attempt to straighten a bent axle 2 Measure w ee nout Out of specification Replace _ Runout Limit f _ Radial 2 0mmlO O8in Lateral 2 0 mm 0 08 in 3 Inspect oWheel Cracks Bends Warpage _ Replace 5 2 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 116: ...hes the outside diameter of the race of the bearing Do not strike the inner race of balls of the bearing Contact should be made only with the outer race _j 5 Inspect Brake shoes Glazed parts Sand with coarse sandpaper NOTE After using the sand paper clean of the polished particles with cloth 6 Measure Brake shoe thickness _ Out of specification Replace _ Brake Shoe Thickness S T D 3 5 mm 0 14 in L...

Page 117: ...rum Wear Limit 80 5 mm 3 17 in ASSEMBLY BRAKE SHOE PLATE When assembling the brake shoe plate reverse _ _ili the disassembly procedure _i_i _ _ _ Note the following points 1 Apply _ oLithium soap base grease to speedometer driven gear 2 Apply Lithium soap base grease to speedometer drive gear 3 Install Dust seal New NOTE Install the dust seal with their manufacturer s marks or numbers facing outwa...

Page 118: ...n installing the front wheel reverse the removal procedure Note the following points W 1 Install oBrake shoe plate _ NOTE Make sure the projections inside the gear unit are meshed with the flats in the wheel hub iT _ _i i _ 2 Install Front wheel NOTE Be sure the boss on the front fork correctly engages with the locating slot on the brake shoe plate assembly 5 5 D o w n l o a d e d f r o m w w w S ...

Page 119: ...FROOT WNEEL iOHAS I 3 Tighten oAxle nut 5 6 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 120: ...ear indicator Camshaft lever TIRE SIZE A 2 75 10 4PR _ BRAKE DRUM WEAR LIMIT I B 95 5 mm 3 76 in rn kg 67 ft lb BRAKE SHOE WEAR LIMIT 2 0 mm 0 08 in WHEEL RUNOUT LIMIT RADIAL 2 0 mm 0 08 in LATERAL 2 0 mm 0 08 in I _ I 18 Nm 11 8 m kg 13 ftolb I 6 Nm 0 6 n3okg 4 3 ft lb 5 7 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 121: ...Remove Fan cover _ 3 Remove Exhaust pipe Muffler 4 Remove Rear axle nut NOTE _ When loosening axle nut apply the rear brake i i 5 Remove eRear wheel 6 Remove oAdjuster Rear brake cable _ oBrake shoe plate 5 8 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 122: ... sandpaper NOTE After using the sand paper clean of the polished _ particles with cloth 4 Measure Brake shoe thickness _ Out of specification Replace Brake Shoe Thickness S T D 3 0 mm 0 12 in Limit 2 0 mm 0 08 in 5 Inspect Brake drum inner surface Oil Scratches_ Remove Use a rag soaked in lacquer Oil thinner or solvent Use an emery cloth Scratches lightly and evenly polishing 5 9 D o w n l o a d e...

Page 123: ...bly procedure Note the following points _ii 4_ 1 Apply oLithium_soap base grease _ii_ _ _i_ to the brake camshaft _ _ i_ 2 Install Brake camshaft Camshaft lever _ NOTE Align the camshaft mark _ with the lever mark INSTALLATION When installing the rear wheel reverse the removal procedure Note the following points 1 Install Brake shoe plate 5 10 D o w n l o a d e d f r o m w w w S c o o t e r T i m ...

Page 124: ...9 3 m kg 67 ft lb i NOTE Make sure the splines on the wheel hub fit the rear drive axle 3 Install Muffler oExhaust pipe Muffler 18 Nm 1 8 m kg 13 ft lb Exhaust pipe 8 Nm 0 8 m kg 5 8 ft lb 5 11 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 125: ...ring _ Washer _ Rubber Left side only _ Upper bearing race Top _ Spring seat _ Bearings _ Inner tube Right and left _ Upper bearing race Bottom BEARING SIZE A 5 32 in FORK SPRING FREE __ LENGTH STANDARD L B 92 mm 3 62 in LIMIT 87 mm 3 42 in _k_ Ic us _o _ i o _ _wo I 30 Nm 13 0 m kg 22 ft lb 15 32inx26j_ _ _ _ _ _ k _ _ _ _ 5 12 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 126: ...L section 3 Remove Front fender Front panel Refer to CHAPTER 2 FRONT FENDER FRONT PANEL AND FOOTREST BOARD section 4 Remove Handlebar cover Refer to CHAPTER 2 HANDLEBAR COVER section 5 Remove oFront brake cable Rear brake cable 6 Remove Handlebar switch Right Front brake lever assembly Bracket Throttle cable Throttle grip 5 13 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 127: ...Remove Ring nut _ Using the Ring Nut Wrench _ YU 01268 NOTE Support the steering column so that it may not fall down 11 Remove _ i Washer _ Upper bearing race Top _ Turn it counterclockwise Steering column Bearings NOTE Take care not to lose the bearings Upper 26 pieces Lower 26 pieces 5 14 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 128: ...eft side only Front fork spring INSPECTION 1 Wash the bearings in solvent 2 Inspect Bearing races _ill Pitting Damage Replace oBearings Pitting Damage Replace NOTE Always replace the bearing and race as a set Bearing Size Upper 5 32 in Lower 5 32 in Bearing Quantity Upper 25 pcs Lower 26 pcs 5 15 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 129: ... column eDo not hit the face of the ball race 3 Inspect _ _ Steering column _ _ _ _ _ Inner fork tube _ _ _ Bends Damage Replace _ Do not attempt to straighten a bent fork tube 4 Measure _ _ Fork spring free length i _ O_t of specification_ Replace Fork Spring Free Length _ Standard 92 mm 3 62 in Limit 87 mm 3 42 in Q _ ASSEMBLY AND INSTALLATION Reverse the disassembly and removal steps Note the f...

Page 130: ...tube oCirclip _ oOil seal _ 3 Check Front fork operation Unsmooth operation Repairl 4 APply Wheel bearing grease _ To upper bearings and lower bearings 5 install Steering column i i i Upper bearing race Top Turn it clockwise completely Washer _ Ring nut Hold the steering column until it is secured 5 17 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 131: ...ring nut 8 Install oHandlebar _ oBolt _ New Nut _ New NOTE Fit the handlebar bridge into the steering column notcher _ Before installing the handlebar wipe the oil off the insertion portion _ using thinner etc olnstall the bolt _ from the right as shown Make sure that the slit _ has enough clearance after tightening the nut _ i Always use a new bolt _ and nut _ _ I_ B ltlHandlebar I 60 Nm 6 0 m kg...

Page 132: ... Right _ _ 13 Install Front brake cable _ Rear brake cable _ NOTE _s___ Apply lithium soap basegrease onto the cable end pivot 14 Install Handlebar covers Front and rear Speedometer cable Front panel Front fender Refer to CHAPTER 2 FRONT FENDER FRONT PANEL AND FOOTREST BOARD and HANDLEBAR COVERS section 15 Adjust Front and rear brake lever free play Throttle cable free play Refer to CHAPTER 2 sect...

Page 133: ...i EA s ocK BE REAR SHOCK ABSORBER _ Rear shock absorber 32 Nm 3 2 mokg 23 ftolb i _ _ _ 118 Nm 1 8 m kg 13 ft lb 5 20 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 134: ...emove Rear shock absorber INSPECTION 1 Inspect Rear shock absorber Q _ _ Oil leaks Damage aeplace INSTALLATION When installing the rear shock absorber reverse the removal procedure Note the following points 1 Instal eRear shock absorber p Upper 32 Nm 13 2 m kg 23 ft lb Lower 18 Nm 1 8 m kg 13 ft ib 5 21 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 135: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 136: ... DIAGRAM H 11 TROUBLESHOOTING CHART H 12 CHARGING SYSTEM H 15 CIRCUIT DIAGRAM H 15 TROUBLESHOOTING CHART H 16 LIGHTING SYSTEM I 2 CIRCUIT DIAGRAM I 2 TROUBLESHOOTING CHART I 3 SIGNAL SYSTEM I 5 CIRCUIT DIAGRAM I 5 TROUBLESHOOTING CHART I 6 SIGNAL SYSTEM TEST AND CHECKS I 7 AUTO CHOKE SYSTEM I 9 CIRCUIT DIAGRAM I 9 TROUBLESHOOTING CHART 1 10 AUTO CHOKE UNIT TEST 1 10 D o w n l o a d e d f r o m w w...

Page 137: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 138: ... LO 001 _ Hi C_ __ E o o_ v J _ i_o __ Y _ _E o _l l k_ __LOCK __Gy_ d2 1 OFF L LI Br L_ x C ON CO 0 zB _ R_ Gy Br Gy_ Gy I B W_ zB _I GY Y r it B R _ O oo _ B W r I 2 W R w I B Oh Br W Dg L R 3 0 N 0 L B _ L 0 0 2 e T 6 I D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 139: ...lasher light Front and rear TURN indicator light Horn Horn switch Oil level gauge OIL indicator light Front brake switch Rear brake switch Tail Brake light LIGHTS switch Dimmer Headlight HIGH BEAM indicator light Meter light Auto choke unit COLOR CODE R B W Y Br Gy O Ch Dg Red P Pink Black L Blue White Y R Yellow Red Yellow L W Blue White Brown G Y Green Yellow Gray B W Black White Orange B R Blac...

Page 140: ...RY _ Oil level gauge A TYPE GM4 3B _ Ignition coil SPECIFIC GRAVITY 1 280 _ Battery C D I unit IGNITION COIL RE 1 TANCE _ Starter relay B PRIMARY 0 21 0 25 at 20 C 68 F SECONDARY 4 5 6 7kft at 20 C 68 F f 6 3 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 141: ...ELECT OA COMPOOEN E ECl Main switch _ lasher light relay Horn Rectifier Regulator 6 4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 142: ...ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows starter circuit D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 143: ...LSTARTING SYSTElVl ELECI_ 1 _ Starter motor _ Starter relay _ START switch _ Main switch _ Fuse _ Battery _ Front brake switch _ Rear brake switch 6 6 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 144: ...evel should be between upper _ and lower _ level mark Incorrect I Refill battery fluid Refill with distilled water on ly tap water contains minerals harmful to a battery J L C rrect Dirty or poor connection _Clean battery terminals using Check battery terminals r wire brush NOTE After cleaning terminals apply grease lightly to both terminals OK oConnect battery leads correctly 6 7 D o w n l o a d ...

Page 145: ...ble oil Call a physician turning white or an accumula immediately tion of materiad exists in the bot Eyes Flush with water for 15 minutes and tom of the cell get prompt medical attention Batteries Specific gravity readings after a produce explosive gases Keep sparks long slow charge indicate on cell flame cigarettes etc away Ventilate to be lower than the rest when charging or using in an enclosed...

Page 146: ...ead Tester lead Brown lead 4 Turn main switch to ON position Continuity START switch conduct check 1 Disconnect handlebarswitch Right leads No 2 Set Pocket Tester YU 03112 selector to Continuity _ 1 _ 1 position Replace handlebarswitch 3 Connect tester leadsto START switch Right leads Black lead Blue White lead Tester lead _Blue White lead Tester lead Black lead 4 Push on START switch IF Continuit...

Page 147: ...llow lead Tester lead Brown lead Tester lead Green Yellow lead 4 Apply front or rear brake TI 1 I J Continuity Starter relay conduct check No 1 Remove starter relay Continuity 2 Connect 12V battery to starter relay ter minals as shows _ Replace starter relay l NOTE Use full charge battery 3 Set Pocket Tester YU 03112 selector to _ 1 position 4 Connect tester leads to starter relay ter 7 minals as ...

Page 148: ...electricalstartingsystemfor _ _ 1 Correct I connections Refer to WIRING DIAGRAM _U7OK Poor Check starter motor condition Refer to conamon _ Replace starter motor _ STARTER MOTOR CHECK section 6 11 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 149: ... 81800 50 YAMAHA So check which type in fitted before main tenance Data for YAMAHA s starter motor are shown in brackets A COMMUTATOR UNDER CUT 1 0 mm 0 039 in 1 15 rnm 0 045 in COMMUTATOR DIAMETER WEAR B LIMIT _ 14 5 mm 0 57 in 14 8 mm 0 58 in __ _ BRUSH WEAR LIMIT C 2 5 mm 0 10 in 0 9 rnm 0 04 in i 6 12 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 150: ...Remove Yoke assembly 3 Remove Armature Inspection and Repair 1 Measure Brush length Each Out of specification Replace the starter motor assembly _ Minimum Brush Length 2 5 mm 0 10 in 0 9 mm 0 04 in 2 Inspect eBrush spring Wear Damage Replace the starter motor _ _ assembly 6 13 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 151: ... 8 turn 0 58 in 5 Measure oMica undercut Out of specification Scrape mica using a hacksaw blade 1 Mica Undercut 1 0 rnm 0 039 in 1 15 mm 0 045 in NOTE The mica insulation of the commutator must be undercut to ensure proper operation of the commutator i i iii i iii iii iiiiiiiiiii iii i iil jiil i ili iiiiiii i i 6 Measure oArmature coil resistance Out of specification Replace the starter motor ass...

Page 152: ... 9 1K position Continuity Replace the starter motor as sembly Assembly Reverse the removal procedure Note the following points 1 Install Brush Brush spring Using a thin screw driver 2 Install oArmature coil assembly 3 Install O ring New 6 15 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 153: ...Align the projection on the cover with the groove on the housing 5 Install Bolts eO rings New O 6 Install O ring New NOTE Apply a grease lightly Installation 1 Install Starter motor I 9 Nm 0 9mokg 6o5fteib 6 16 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 154: ...ELEC J IGNITIONSYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows ignition circuit 6 17 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 155: ... Main switch ENGINE STOP switch C D I magneto Source coil pick up coil C D I unit gnitioncoil Spark plug IGNITION SYSTEM I ELEC o l 6 18 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 156: ...LUG INSPECTION section Plug Gap 0 9 1 0 mm 0 035 0 039 in Ignition spark test 1 Install spark plug to plug cap 2 Ground spark plug to air shroud 3 Start starter motor No good j Replace or regap spark plug v Spark 1 Ignition circuit is good I Ignition spark gap test 1 Remove spark plug and plug cap 2 Hold spark plug lead 5 mm 0 20 in from air shroud 3 Start starter motor S ark I Replace spark plug ...

Page 157: ...4 Turn main switch to ON position Jv Continuity ENGINE STOP switch conduct check 1 Disconnect handlebar switch Right leads 2 Set Pocket Tester YU 03112 selector to 9 x 1 position 3 Connect tester leads to ENGINE STOP switch leads Tester lead Black Red lead Tester lead Black lead 4 Turn ENGINE STOP switch to RUN position No continuity 1 Replace main switch Continuity 1 Replace handlebar switch Righ...

Page 158: ...oil base Set Pocket Tester YU 03112 selector to x 1 position oSecondary coil resistance r Orange lead Spark plug lead Set Pocket Tester selector to 9 x 1K position Primary Coil Resistance 0 21 0 25 at 20 C 68 F Secondary Coil Resistance 4 5 6 7k t at 20 C 68 F Out of i Replace ignition coil 6 21 JL OK D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 159: ...4 Measure eSource coil resistance 216 264 3 at 20 C 68 F v OK Pick up coil resistance test 1 Set Pocket Tester YU 03112 selector to G 10 position 2 Connect tester leadsto pick up coil leads Tester lead White Red lead Tester lead Black lead 3 Measure Pick up coil resistance 27 33 at 20 C 68 F Out of 1 Replace s urce c il I Out of specification 1 Replace pick up coil 6 22 D o w n l o a d e d f r o m...

Page 160: ...ON SYSTEM __LOK Poor Check entire ignition system for connections connection 1 Refer to WIRING DIAGRAM _l Correct I CD unit is faulty replace it I 6 23 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 161: ... iGNITION SYSTEM ELEC 6 24 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 162: ..._L___1CHARO NO SYSTEM i_ CHARGING SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows charging circuit 6 25 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 163: ...CHARGING SYSTEM ELEC E_ _ C D I magneto Lighting coil charging coil _ Rectifier Regulator _ Fuse _ Battery 6 26 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 164: ...n upper _ and lower _ level mark oRefill battery fluid Incorrect Refill with distilled water on ly tap water contains minerals harmful to a battery _ _Correct Dirty or poor nnnp c tinn I Check _ oClean battery terminals using battery terminals I v wire brush NOTE After cleaning terminals apply OK grease lightly to both terminals Connect battery leads correctly i I t 6 27 D o w n l o a d e d f r o ...

Page 165: ...hysi turning white or an accumula clan immediately tion of material exists in the bot Eyes Flush with water for 15 minutes and tom of the cell get prompt medical attention Batteries oSpecific gravity readings after a produce explosive gases Keep sparks long slow charge indicate on cell flame cigarettes etc away Ventilate to be lower than the rest when charging or using in an enclosed Warpage or bu...

Page 166: ...ead _ terminal _1 _1 Replace battery 4 Start engine and accelerate to about 4 000 r rain 5 Measure Charging voltage 12 5 17 5V at 4 000 r min Out of specification Charging coil resistance test 1 Disconnect C D I magneto leads 2 Set Pocket Tester YU 03112 selector to _ 1 position 3 Connect tester leads to charging coil leads Tester lead White lead Tester lead Black lead 6 29 D o w n l o a d e d f r...

Page 167: ... I_ I 0 63_ 0 77_ at 20 C 68 F Out of specification Replace charging coil I OK Poor Check entire chargingDiAGRAM system for connections _ I Correct I Refer to WIRING _1 I Replace rectifier regulator 6 30 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 168: ...ELEC I LIGHTING LiGHTiNG SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows lighting circuit SYSTEM r 6 31 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 169: ...NG SYSTEM C D I magneto Lighting coil charging coil Rectifier Regulator LIGHTS switch Dimmer Headlight HIGH BEAM indicator light Meter light 6 32 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 170: ...r continuity Tester lead Terminal 1 Tester lead Terminal 3 Tester lead Terminal 2 Tester lead Terminal 3 Continuity does not exist on j Replace headlight lens unit P ists uit Lighting voltage test 1 Set Pocket Tester YU 03112 Selector to AC20V position 2 Turn LIGHTS switch to HI position 3 Connect tester leads to headlight leads Tester lead Yellow lead Tester lead Black lead 6 33 D o w n l o a d e...

Page 171: ...andlebar switch lead 2 Set Pocket Tester YU 03112 selector to x 1 position 3 Connect tester leads to LIGHTS switch leads If If switch is turned to LO position Tester lead Blue lead Tester lead Green lead switch is turned to HI position Tester lead Blue lead Tester lead Yellow lead Continuity exists on both circuits Continuity does not exist on one circuit 1 Replace left handlebar switch 6 34 D o w...

Page 172: ...hting coil leads Tester lead Yellow Red lead Tester lead Black lead 4 Measure Lighting coil resistance 1 0 27 0 33G at 20 C 68 F Out of specification IReplace lighting coil 13 Check entire lighting system for connections Refer to WIRING DIAGRAM L OK I Replace rectifier regulator Poor connection Correct 6 35 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 173: ...i LiGHTiNG SYSTEM ELEC 6 36 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 174: ...E EcE 1 s ooAL S STEM I SIGNAL SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows signal circuit 6 37 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 175: ... gauge _ Flasher light relay OIL indicator light _ TURN switch _ Front brake switch _ Left flasher light Front and rear _ Rear brake switch _ Right flasher light Front and rear _ Tail Brake light TURN indicator light I 6 38 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 176: ...el should be between upper _ and lower _ level mark Incorrect oRefill battery fluid Refill with distilled water on ly tap water contains minerals harmful to a battery Correct Dirty or poor I I connection L Check battery terminals _ oClean battery terminals using I wire brush NOTE After cleaning terminals apply OK grease lightly to both terminals Connect battery leads correctly 7 6 39 D o w n l o a...

Page 177: ... turning white or an accumula clan immediately tion of material exists in the bot Eyes Flush with water for 15 minutes and tom of the cell get prompt medical attention Batteries oSpecific gravity readings after a produce explosive gases Keep sparks long slow charge indicate on cell flame cigarettes etc away Ventilate to be lower than the rest when charging or using in an enclosed Warpage or buckli...

Page 178: ...rn main switch to ON position Poor condition Check bulb conditions of flasher lights in _1 Replace bulb s dicator lights and tail brake light Poor Check entire signal system for connections I connection _l I Refer to WIRING DIAGRAM section I IF Correct i Jv L K Poor Check condition of each circuit for signal ____ l __ system Refer to SIGNAL SYSTEM TEST _i Replace poor condition electrical AND CHEC...

Page 179: ... v ltage 12V n Br lead at fr nt I_1 Wiring circuit fr m fuse t fr ntswitch connector repair brake switch connector is faulty i No voltage _ I Wiring circuit from fuse to rear Check for voltage 112V on Br lead at rear v brake switch connector is faulty brake switch connector i repair Checkfor voltage 12V on G Y lead at front I No voltage _ I Front brake switch is faulty brake switch connector while...

Page 180: ...repair J _o_ Check for voltage 12V on Ch and or Dg I No voltage _ TURN switch is faulty replace lead at TURN switch connector J_o_ I Flasher light bulb socket is faulty replace it 3 Horn does not work Check for voltage 12V on Br lead at horn No voltage _ I Wiring circuit from fuse to horn terminal r I terminal is faulty repair _o_ No voltage i Check for voltage 12V on P lead at I l HORN switch con...

Page 181: ...t bulb socket is faul indicator light connector ty replace it Oil level gauge check 1 Disconnect eOil level gauge leads 2 Remove Oil level gauge 3 Connect Pocket Tester YU 03112 Set the tester selector to 9 x 1 position _ i_ 4 Check Oil level gauge conduct Refer to following table _ Not per result Replace Float position Good Up _ No continuity Down _ Continuity 5 Taillight does not work Check for ...

Page 182: ... ELEC _I AUTO CHOKE SYSTEM F _ AUTO CHOKE SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows auto choke circuit 6 45 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 183: ...AUTO CHOKE SYSTEM ELECI_ _ C D I magneto Charging coil lighting coil _ Auto choke unit 6 46 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 184: ... lighting coil leads Out of Tester lead _Yellow Red lead specificati n _ I I Tester lead Black lead Replace lighting coil 4 Measure oLighting coil resistance _ 0 27 0 33_ at 20 C 68 F F OK Poor Check entire auto Choke system for connec I connection I b tions v l Correct Refer to WIRING DIAGRAM Check auto choke condition Refer to AUTO CHOKE UNIT TEST section 6 47 D o w n l o a d e d f r o m w w w S...

Page 185: ...VER section 2 Remove eAir cleaner case 3 Disconnect oAuto choke unit leads 4 Connect oPocket tester YU 03112 Set the tester selector to _ x 1 position 5 Measure oAuto choke unit resistance Out of specification_Replace I 0oc o I 6 48 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 186: ...ICATIONS J 3 GENERAL SPECIFICATIONS J 3 MAINTENANCE SPECIFICATIONS J 4 GENERAL TORQUE SPECIFICATIONS J 8 DEFINITION OF UNITS J 8 CABLE ROUTING J 8 CES0S WIRING DIAGRAM D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 187: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 188: ...angement Single cylinder Forward inclined Displacement 49 cm 3 Bore x Stroke 40 0 x 39 2 mm 1 57 x 1 54 in Compression Ratio 7 2 1 Starting System Electric and Kick Starter Lubrication System Separate lubrication Yamaha Autolube Oil Type or Grade Engine Oil Yamalube 2 cycle oil or Air cooled 2 stroke engine oil Transmission Oil Yamalube 4 cycle oil or SAE 10W30 type SE motor oil or GL gear oil Oil...

Page 189: ... Type Steel Tube Underbone Caster Angle 25 Trail 62 mm 2 44 in Tire Size F 2 75 10 4PR Size R 2 75 10 4PR Tire Pressure Cold tire Front 125 kPa 1 25 kg cm 2 18 psi Rear 225 kPa 2 25 kg cm 2 32 psi Brake Front Brake Type Drum brake Operation Right hand operation Rear Brake Type Drum brake Operation Left hand operation Suspension Front Suspension Telescopic Fork Rear Suspension Unit Swing Shock Abso...

Page 190: ...ity 12V 4AH Headlight Type Shealed Beam Bulb Wattege x Quantity Headlight 12V 25W 25W x 1 Tail Brake light 12V 5W 21Wx 1 Flasher light 12V 10Wx4 Licence Light 12V 5Wx 1 Meter light 12V 3 4Wx 1 Indicator Light Wattage x Quantity TURN 12V 1 7Wx 1 HIGH BEAM 12V 1 7Wxl OIL 12V 3 4Wx 1 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 191: ...1 585 in 2nd 40 50 mm 1 594 in Piston Ring Sectional Sketch BxT Top Ring t _ i B 1 2x 1 6 mm 0 047x0 063 in 2nd Ring L_____JJ__ __ 1 2 x 1 6 mm 0 047 x 0 063 in End Gap Installed Top Ring 0 15 0 30 mm 0 006 0 012 in 2nd Ring 0 15 0 30 mm 0 006 0 012 in Side Clearance Installed Top Ring 0 03 0 05 mm 0 0012 0 0020 in 2nd Ring 0 03 0 05 mm 0 0012 0 0020 in Crankshaft F Crank Width A 37 90 37 95 mm 1 ...

Page 192: ...het Type Kick Clip Tension 250 300 g 8 83 10 6 oz Carburetor I D Mark 1UV00 Main jet M J 82 Jet Needle clip Position J N 3S30 4 5 Main Air Jet M A J 2 0 Cutaway C A 3 0 Pilot Jet P J 42 Pilot Ait Jet P A J _1 04 Valve Seat Size V S 1 5 Starter Jet G S 46 Float Height 15 0 17 0 mm 0 59 0 67 in Engine Idling speed 1 500 2 100 r min Reed Valve Thickness 0 15 mm 0 006 in Valve Stopper Height 3 0 3 4 m...

Page 193: ...Case M 6x 1 0 2 8 0 8 5 8 Exhaust pipe M 6x 1 0 2 8 0 8 5 8 Muffler M 8x 1 25 2 27 2 7 19 M 6xl 0 2 8 0 8 5 8 Muffler protector Crankcase M 6 x 1 0 6 8 0 8 5 8 Transmission case cover M 6 x 1 0 5 8 0 8 5 8 Crankcase cover M 6x 1 0 10 8 0 8 5 Transmission oil drain bolt M 8x 1 25 1 18 1 8 13 Autolube pump cover M 6x 1 0 2 8 0 8 5 8 Stay starter clutch M 6x 1 0 3 8 0 8 5 8 Kick crank M 6x 1 0 1 10 1...

Page 194: ... mm 269 9 Ib in K3 72 6 N mm 7 4 kg mm 407 6 Ib in Stroke K1 0 0 25 mm 0 0 0 98 in K2 25 40 mm 0 98 1 57 in K3 40 45 mm 1 57 1 77 in Optional Spring No Wheel Front Wheel Type Disc wheel Rear Wheel Type Disc wheel Front Rim Size Material 1 50x 10 DC Steel Rear Rim Size Material 1 50 10 DC Steel Rim Runout Limit Vertical 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in Front Drum Brake Type Leading Trailing Dr...

Page 195: ...eering column M 8 x 1 25 1 29 2 9 21 Ring nut Steering column M25 1 30 3 0 22 Front wheel axle MIO 1 25 1 35 3 5 25 Front brake cam lever M 5x 0 8 1 4 0 4 2 9 Rear brake cable holder M 6x 1 0 1 7 0 7 5 1 Rear brake cam lever M 5x 0 8 1 6 0 6 4 3 Rear wheel axle M14x 1 5 1 93 9 3 67 Rear brake shoe plate M 8x 1 25 3 18 1 8 13 Rear stay M 6x1 0 4 10 1 0 7 2 Seat bracket and seat M 6x 1 0 2 7 0 7 5 1...

Page 196: ... Winding Resistance 4 5 6 7kft at 20 C 68 F Charging System Type Flywheel Magneto C D I Magneto Model Manufacturer F 1HH YAMAHA Pickup Coil Resistance Color 27 33_ at 20 C 68 F White Red Black Charging Voltage 13 0 17 5V at 4 000 r min Lighting Voltage 11 5 13 5V at 4 000 r min Source Coil Resistance Color 216 264_ at 20 C 68 F Black Red Black Charging Coil Resistance Color 0 63 0 77_ at 20 C 68 F...

Page 197: ...mm 0 15 in Wear Limit 2 5 mm 0 10 in 0 9 mm 0 03 in Commutator Diameter 15 5 mm 0 61 in 15 8 mm 0 62 in Wear Limit 14 5 mm 0 57 in 14 8 mm 0 58 in Mica Undercut 1 0 mm 0 039 in 1 15 mm 0 045 in Starter Relay Model Manufacturer 27V TATEISHI Amperage Rating 20A Coil Resistance 54 66_ Horn Type Quantity Plain type Model M anufactu rer GF 12 NIKKO Maximum Amperage 1 5A Flasher Relay Type Condenser typ...

Page 198: ...re A Nut B Bolt 10 mm 6 mm 12 mm 8 mm 14 mm 10 mm 17 mm 12 mm 19 mm 14 mm 22 mm 16 mm General torque specifications Nm mokg ftolb 6 0 6 4 3 15 1 5 11 30 3 0 22 55 5 5 40 85 8 5 61 130 13 0 94 A Distance cross flats B Outside thread diameter DEFINITION OF UNITS Unit Read Definition Measure mm millimeter 10 3meter Length cm centimeter 10 2meter Length kg kilogram 103gram Weight N Newton 1 kg x m sec...

Page 199: ...ield bracket frame Rear brake cable Route wire harness along left side of leg shield _ Throttle cable bracket and then along left side of frame _ Carrier stay 2 down tube Horn Wire harness should be on the left side _ Rectifier Regulator 7 12 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 200: ...between rear stay and fuel _ Oil level gauge tank _ Breather hose Insert fuse case wire harness assembly into _ Band holder integrated with battery casel Route wire harness over frame Route breather hose along engine protector slit Route wire harness under back stay 7 13 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 201: ...n coil Meter cable and front brake cable should be _ Fuel pipe tank to cock free of twists _ Clamp Clamp rear brake cable _ Band Be sure the casing cap of brake cable is com _ Auto choke unit lead pletely in crankcase Clamp wire harness only 7 14 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 202: ...pipe Fuel tank Fuel cock Oil tank Starter relay Clamp Band CABLE ROUTING Push the projecting portion of clamp into the mounting hole on the stay side 1 7 15 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 203: ... flasher lead through holes in flasher stay _ Exhaust pipe and carrier 2 _ Clamp As shown after connecting the taillight and _ Starter motor lead flasher leads push the connections completely _ Carrier 2 into the tail cover _ Taillight assembly No coupler and connector are allowed to be Tail cover assembly outside the case License bracket _ Flasher stay _ Cap _ Flasher light assembly 7 16 D o w n ...

Page 204: ...tk_U c _ r _ _ y Gv I J I indicator ligh t_ J JGv 1 _4L_L U _ _1_ _ B Meter light 0 B _ HIGH BEAM f_ T y C _Z Y _ indicat r light _ L B Headlight _ P light Left _ 8_ s L2 j_ B _ G L Y B B P G Y Br relay J B L2L I 8 ___ OFF LO O _ N LIGHTS Horn R 0 0 Dimmer switch TURN Rear brake Horn switch switch switch Handlebar switch Left D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 205: ... R l COLOR CODE R B Black 8 R S L Blue O Orange R P Pink Y Yellow R Red G Green Br Brown O _ Gy Gray Ch Chocolate Dg Dark green o choke CDI magneto CDI unit Battery Starter Starter W White t relay motor B R Black Red L W Blue White Y R Yellow Red G Y Green Yellow Br W Brown White W R White Red B W Black White D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 206: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 207: ...YAM liiA 2YT AE1 UPPLEM ENTARY RViCE MANUAL D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 208: ...ther with following manual I CE50T Service Manual 2UG IVIE1 I TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO LTD CG50U SUPPLEM ENTARY SERVICE MANUAL 1987 by Yamaha Motor Co Ltd 1st Edition November 1987 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited D o w n l o a d e d f r o m w w w S c ...

Page 209: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 210: ...aterial is distinguished by the following notation NOTE A NOTE provides key information to make procedures easier or clearer A CAUTION indicates special procedures that must be followed to avoid damage to the scooter A WARNING indicates special procedures that must be followed to avoid injury to a scooter operator or person inspecting or repairing the scooter MANUAL FORMAT All of the procedures in...

Page 211: ...lustrated symbols to are used to identify the specifications appearing in the text Filling fluid Lubricant Tightening Wear limit clearance Engine speed 0 V A Illustrated symbels to in the exploded diagram indicate grade of lubricant and location of lubrication point Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium soap base grease ...

Page 212: ...EST BOARD L 7 HANDLEBAR COVERS L 8 ENGINE L 8 ENGINE OIL LEVEL INSPECTION L 8 AUTOLUBE PUMP AIR BLEEDING L 9 ELECTRICAL L 10 CGEOU CIRCUIT DIAGRAM L 10 ELECTRICAL COMPONENTS L 11 SIGNAL SYSTEM L 12 CIRCUIT DIAGRAM L 12 TROUBLESHOOTING L 13 APPENDICES L 14 SPECIFICATIONS L 14 GENERAL SPECIFICATIONS L 14 MAINTENANCE SPECIFICATIONS L 16 GENERAL TORQUE SPECiFiCATIONS M 3 DEFINITION OF UNITS M 3 CABLE ...

Page 213: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 214: ...our scooter with the licensing authority in your state Starting Serial Number JYA2YTN0 JA000101 ENGINE SERIAL NUMBER The engine serial number is stamped into the crankcase NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number Starting Serial Number 2YT 000101 NOTE Designs and specifications are subject to change without notic...

Page 215: ...y i Check fuel hose for cracks or damage Fuel line Replace if necessary i Check oil leakage Correct if necessary Transmission oil Replace every 12 000 8 000 or 24 months REPLACE Warm engine before draining I Check operation Correct if necessary Autolube pump Air bleeding i Brake Check operation Adjust if necessary I Wheels Check damage runout Repair if necessary i Check bearings assembly for loose...

Page 216: ...move Moles Left and right NOTE Unhook the pawl out of groove of the footrest board oSlide the mole backward and unhook the pawl out of groove of the tail cover 4 Disconnect oTaillight leads oRear flasher light leads 5 Remove Carrier assembly 6 Remove Cover 3 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 217: ...il cover 4 2 Install Cover NOTE Install the projection into the opening 3 Install Carrier assembly Nut Carrier 7 Nm 0 7 m kg 5 1 ft lb Bolt Carrier 7 Nm 0 7 m kg 5 1 ft lb 4 Connect Taillight leads Rear flasher light leads D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 218: ...l onto the opening 6 Install Seat Helmet holder Nut Seat 7 Nm 0 7 m kg 5 1 ft lb FRONT PANEL LEG SHIELD AND FOOTREST BOARD Removal 1 Remove Covers Left and right NOTE Unhook the projection by pulling up the cover 2 Remove Front panel NOTE Unhook the projection by pulling up the front panel 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 219: ... TAIL COVERS AND MOLES section 5 Remove Footrest board installation 1 Install Footrest board 2 Install Tail cover Refer to TAIL section COVER AND MOLES 3 Install Leg shield 4 Install Front panel NOTE Install the projection into the slot 6 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 220: ...her light leads 3 Remove Handlebar cover Front WARNING 4 Disconnect Leads Speedometer cable 5 Remove Rear view mirror Handlebar cover Rear Installation 1 Install Handlebar cover Rear Rear view mirror 2 Connect Leads Speedometer cable 7 Proper cable and lead routing is essential to insure safe scooter operation Refer to CA BLE ROUTING section D o w n l o a d e d f r o m w w w S c o o t e r T i m e ...

Page 221: ...ient oil Recommended Oil Yamalube 2 or Air Cooled 2 Stroke Engine Oil Oil Tank Capacity 0 8 L 0 70 Imp qt 0 84 US qt OIL LEVEL AND OIL INDICATOR LIGHT CHECKING METHOD I Turn main switch to ON I I OIL indicator light I does not come on I OIL indicator light goes off I I Engline oil level and electrical I circuit are OK Refer to ELECTRICAL I I SIGNAL SYSTEM I OIL indicator light I comes on I Wait a ...

Page 222: ...P AIR BLEEDING The oil pump and delivery line must be bled on the following occasions Any portion of the oil system has been dis connected The scooter has been turned on its side Whenever the oil tank has been run empty eDuring predelivery 1 Remove oTail cover Refer to TAIL COVERS AND MOLES section ePump cover 2 Fill Oil tank Recommended Oil Yamalube 2 or Air cooled 2 Stroke Engine Oil 3 Place a r...

Page 223: ...Disconnect oOil delivery hose From the carburetor 9 Feed the engine oil into the oil delivery hose using a oil can from complete air bleeding Then connect the oil delivery hose to the car buretor NOTE Thoroughly clean the engine exterior of oil 1 0 Install oTail cover Refer to TAIL COVERS AND MOLES section 10 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 224: ...GRAM IELEC I E B L B R B W R B R 1 B R _ B W J _ Y R Y R J S J S g B _J _ G Y L W L L G Y B B B T I J __ J J L __L 2 F N IotO B B _L _L LOCK OFF ON B Wi B o m T B 2 RIBr Sr Gy 1 b B 2_ N 11 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 225: ...relay TURN switch TURN indicatorlight Left flasher light Front Left flasher light Rear Right flasher light Front Right flasher light Rear Horn HORN switch Front brake switch Rear brake switch OIL indicatorlight Oil level gauge COLOR CODE R Red B Black W White Y Yellow Br Brown Gy Gray O Orange Ch Chocolate Dg Dark green G Green P L Y R L W G Y B W B R W R Br W Pink Blue Yellow Red Blue White Green...

Page 226: ...nder Ignitioncoil Battery tarterrelay Oil level gauge CDI unit A BAI rERY TYPE YB4L B SPECIFIC GRAVITY 1 280 B IGNITION COIL RESISTANCE PRIMARY 0 56 0 84 3 at 20 C 68 F SECONDARY 5 68 8 52k at 20oc 68OF L 6 13 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 227: ...ELECTRICAL COMPONENTS Horn Main switch Rectifier Regulator Flasher relay IELECI tj S 14 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 228: ...SIGNAL SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows signal system SIGNAL SYSTEM ELEC 15 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 229: ... fuel sender added and the oil level gauge changed This signal system explains the checking of only such addition and change SIGNAL SYSTEM ELEC Main switch Fuse Battery Fuel meter Fuel sender OIL indicatorlight Oil level gauge i 16 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 230: ...r lead at fuel meter connector JvL OK Check for voltage 12V on G lead at fuel meter connector J OK Check for voltage 6 12V on G lead at fuel sender connector J OK Check for condition of fuel sender and fuel meter Refer to FUEL SENDER CHECK and FUEL METER CHECK NO VOLTAGE NO VOLTAGE Y NO VOLTAGE Wiring circuit from fuse to fuel meter connector is faulty repair Check for condition of fuel meter If f...

Page 231: ...tance Up 4 10 Down 90 100 NOTE Check from top to bottom Fuel Meter Check 1 Connect Fuel sender lead 2 Turn the main switch to ON 3 Check Fuel meter Refer to following table Not per result Replace Float position Fuel meter position Up F Down E NOTE Before reading the meter stay put the float for more than three minutes respectively at and 18 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n...

Page 232: ...ircuit from OIL indicator level gauge connector F light to oil level gauge is faulty repair Check for condition of oil level gauge Refer to OIL LEVEL GAUGE CHECK Oil Level Gauge Check 1 Remove oOil level gauge _ NOTE Do not disconnect the oil level gauge lead 2 Turn the main switch to ON 3 Check oOil level gauge Refer to follOwing table Not per result Replace Oil level gauge OIL indicator light po...

Page 233: ...tion Cylinder Arrangement Single cylinder Forward inclined Displacement 49 cm3 Borex Stroke 40 0 x 39 2 mm 1 575x 1 543 in Compression Ratio 6 7 1 Starting System Electric and kick starter Lubrication System Separate lubrication Yamaha Autolube Oil Type or Grade Engine Oil Yamalube 2 or Air cooled 2 stroke engine oil Transmission Oil Yamalube 4 or SAE 10W30 type SE motor oil Oil Capacity Oil Tank ...

Page 234: ... Chassis Frame Type Steel tube underbone Caster Angle 26 5 Trail 72 mm 2 83 in Tire Size F 3 00 10 4PR Size R 3 00 10 4PR Tire Pressure Cold tire Front 125 kPa 1 25 kg cm 2 18 psi Rear 200 kPa 2 00 kg cm 2 28 psi Brake Front Brake Type Drum brake Operation Right hand operation Rear Brake Type Drum brake Operation Left hand operation Suspension Front Suspension Telescopic fork Rear Suspension Unit ...

Page 235: ...ery Capacity 12V 4AH Headlight Type Semi sealed beam Bulb Wattege Quantity Headlight 12V 25W 25W 1 Tail Brake light 12V 5W 21W x 1 Flasher light 12V 10W x 4 Meter light 12W 3 4W x 1 Indicator Light Wattage x Quantity TURN 12V 1 7Wx 1 HIGH BEAM 12V 1 7W 1 OIL 12V 3 4W 1 22 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 236: ...ize 2nd 40 50 mm 1 594 in Piston Ring Sectional Sketch B x T Type Top Ring _ _ _B 1 5x1 8 mm 0 059 0 071 in Keystone 2nd Ring _ 4 1 5 x 1 8 mm 0 059 0 071 in Keystone End Gap Installed Top Ring 0 15 0 35 mm 0 006 0 014 in 2nd Ring 0 15 0 35 mm 0 006 0 014 in Side Clearance Installed Top Ring 0 03 0 05 mm 0 0012 0 0020 in 2nd Ring 0 03 0 05 mm 0 0012 0 0020 in Crankshaft F Crank Width A 37 90 37 95...

Page 237: ...in Drive Axle Runout Limit 0 08 mm 0 003 in Kick Starter Type Ratchet type Kick Clip Tension 150 250 g 5 3 8 8 oz Carburetor I D Mark 2YR00 Main jet M J 90 Jet Needle clip Position J N 3P01 4 5 Main Air Jet M A J _2 0 Cutaway C A 2 5 Pilot Jet P J 42 Pilot Air Screw A S 1 and 3 4 turns out Valve Seat Size V S _1 8 Starter Jet G S 48 Float Height 15 0 17 0 mm 0 59 0 67 in Engine Idling speed 1 800 ...

Page 238: ...er Case M 6 x 1 0 2 9 0 9 6 5 Exhaust pipe M 6 1 0 2 9 0 9 6 5 Muffler M 8 1 25 2 33 3 3 24 Muffler protector M 6 x 1 0 2 9 0 9 6 5 Crankcase M 6 x 1 0 6 9 0 9 6 5 Transmission case cover M 6 x 1 0 5 8 0 8 5 8 Crankcase cover M 6xl 0 10 9 0 9 6 5 Transmission oil drain bolt M 8x 1 25 1 18 1 8 13 Autolube pump cover M 6 1 0 2 9 0 9 6 5 Starter motor M 6x 1 0 2 13 1 3 9 4 Kick crank M 6x 1 0 1 10 1 ...

Page 239: ... 9 kg mm 269 9 Ib in K3 74 0 N mm 7 4 kg mm 407 6 Ib in Stroke K1 Zero 20 mm Zero 0 79 in K2 20 35 mm 0 79 1 38 in K3 35 45 mm 1 38 1 77 in Optional Spring No Wheel Front Wheel Type Panel wheel Rear Wheel Type Panel wheel Front Rim Size Material 1 85x 10 DC Steel Rear Rim Size Material 1 85x 10 DC Steel Rim Runout Limit Vertical 2 0 mm 0 08 in o Lateral 2 0 mm 0 08 in Front Drum Brake Type Leading...

Page 240: ...nd steering column MIO 1 25 1 60 6 0 43 Ring nut Steering column M25 1 30 3 0 22 Front wheel axle MIOx 1 25 1 35 3 5 25 Front brake cam lever M 5x 0 8 1 4 0 4 2 9 Rear brake cable holder M 6 1 0 1 9 0 9 6 5 Rear brake cam lever M 5x 0 8 1 4 0 4 2 9 Rear wheel axle M14x 1 5 1 95 9 5 68 Rear brake shoe plate M 8 1 25 3 18 1 8 13 Rear stay M 6 1 0 4 10 1 0 7 2 Seat bracket and seat M 6 1 0 2 7 0 7 5 ...

Page 241: ...YAMAHA 0 56 0 84 at 20 C 68 F 5 68 8 52k at 20 C 68 F Charging System Type Flywheel magneto C D I Magneto Model Manufacturer Charging Coil Resistance Color Charging Current Full Charged Battery 1 280 Half Charged Battery 1 180 Charging Voltage Lighting Coil Resistance Color Lighting Voltage Voltage Regulator Type Model Manufacturer No Load Regulated Voltage F2JA YAMAHA 0 48 0 72fl at 20 C 68 F Whi...

Page 242: ...ameter 15 5 mm 0 61 in 15 8 mm 0 62 in Wear Limit 14 5 mm 0 57 in 14 8 mm 0 58 in Mica Undercut 0 9 1 2 mm 1 15 mm 0 045 in 0 035 0 047 in Starter Relay Model Manufacturer 27V OMRON 27V MATSUSHITA Amperage Rating 20A 20A Coil Resistance 54 66_ at 20 C 68 F 72 88_ at 20 C 68 F Horn Type Quantity Plain typeZ1 pc Model Manufacturer GF 12 NIKKO Maximum Amperage 1 5A Flasher Relay Type Condenser type M...

Page 243: ...m 14 mm 85 8 5 61 gressive stages until full torque is reached Unless 22 mm 16 mm 130 13 0 94 otherwise specified torque specifications call for clean dry threads Components should be at room temperature A Distance cross flats B Outside thread diameter DEFINITION OF UNITS U nit Read Definition Measure mm millimeter 10 3meter Length cm centimeter 10 2meter Length kg kilogram 103gram Weight _ N Newt...

Page 244: ... ROUTING _ Front brake cable _ Flasher relay _ Rear brake cable Speedometer cable _ Throttle cable _ Band Main switch Horn _ Rectifier Regulator 31 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 245: ...X 1 _ Rear brake cable i Throttle cable Band Wireharness Starter relay CDI unit Oil level gauge Battery positive lead Fuse _ Fuel sender _ Clamp 000 000 32 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 246: ...Front brake cable _ peedometer cable Rectifier Regulator _ Throttle cable _ Fuel hose _ Vacuum hose _ Ignition coil _ Rear brake cable _ Band 33 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 247: ...OOT 0 APP _ Battery breather pipe _ CDI unit _ Oil level gauge _ Fuse _ Auto choke unit _ hrottle cable Starter motor lead _ CDI magneto lead J 34 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 248: ...Y t r y v v v _ _ r _ _8 _ _ _ ICI _ o _ o _ _ _ _ _ _ E _ 3o_ _ _ _ r _z _ u_ F oo 0 0 _ D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 249: ...Yamaha Motor Canada Ltd 480 Gordon Baker Road Toronto ON M2H 3B4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

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