Yamaha QT 50F Service Manual Download | Manualshive

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Summary of Contents for QT 50F

Page 1: ...1 ...

Page 2: ...ations are therefore inevitable and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha Dealers and will where applicable appear in future editions of this manual Particularly important information is distinguished in this manual by the following notations NOTE A NOTE provides key information to make procedures easier or clearer CAUTION A CAUTION indicate...

Page 3: ...SECTION INDEX V GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENTS ENGINE OVERHAUL j CARBURETlON CHASSIS ELECTRICAL v Vys APPENDICES i a j L _ _ _ i 3 iH ...

Page 4: ...i MS CHAPTER 1 GENERAL INFORMATION 1 1 MACHINE IDENTIFICATION 1 2 1 2 SPECIAL TOOLS 1 2 ...

Page 5: ... identify the production number of the unit POCKET TESTER Tool No 90890 03096 FLYWHEEL HOLDING TOOL Tool No 90890 01235 The engine serial number is located on a raised boss on the lower left side of the engine Engine identification follows the same code as frame identification 1 Engine serial number ft J u I a 4W m sB wmmB LM ELECTRO TESTER Tool No 90890 03021 DIAL GAUGE Tool No 90890 03110 FLYWHE...

Page 6: ...e set 2 Torque wrench 3 Tire pressure gauge 4 Fluid measuring cup 5 Micrometer 6 Vernier caliper 7 Cylinder gauge 8 Magnetic stand 9 10 11 12 13 14 15 BOLT Tool No 90890 01305 CRANK INSTALLER BOLT Tool No 90890 01275 HEXAGON WRENCH Toll No 90890 01306 25 90890 01307 22 Grease gun Yamalube 4 cycle oil Yamalube 2 cycle oil Wheel bearing grease Yamaha bond No 4 Yamaha Chain and Cable Lube Lithium bas...

Page 7: ...ervals 2 2 B Lubrication Intervals 2 3 ENGINE 2 3 A Carburetor 2 3 B Air Cleaner 2 4 C Autolube Pump 2 4 D Engine and Transmission Oil 2 5 E Cylinder Head 2 6 CHASSIS 2 6 A Brake and Wheel Front Rear 2 6 B Steering and Suspension 2 7 ELECTRICAL 2 8 A Ignition Timing 2 8 B Spark Plug 2 8 C Battery 2 9 D Headlight Beam Adjustment 2 10 ...

Page 8: ...he motorcycle is continually operated in an area of high humidity then all parts must be lubricated much more fre quently that shown on the chart to avoid damage caused by water to metal parts A Mainter cioj Cylinder head Spark plug Air filter Carburetor Autolube purr Brake system Wheels and t Suspension s Fuel petcock Battery Lights Signal ance Intervals tern Exhaust system P complete res stem I ...

Page 9: ... O 3 months Check O O o 6 months O O O 0 0 Check Thereafter every 6 months O O 0 1 year O O 2 years 2 years O 2 years 2 3 ENGIN A Carburetcir 1 Pilot air screw Turn air adjusting screw until it lightly seats then back it out to specification This adjustment can be made with engine stopped Air screw Turns out 1 3 4 1 1 2 After engine serial No 3L5 702401 2 Start the bngine and let it warm up 3 Thro...

Page 10: ...ent maintenance is performed check the air inlet to the cleaner case of obstructions Check the air cleaner joint rubber to the carburetor and manifold fittings for an air tight seal Tighten all fit tings throughly to avoid the possibility of un filtered air entering the engine r CAUTION Never operate the engine with the air cleaner element removed This will allow unfiltered air to enter causing ra...

Page 11: ...for proper adjustment Turning the adjusting bolt clockwise decreases the plunger stroke while turning counterclockwise increases the plunger stroke c When the correct stroke is attained tighten the lock nut Minimum stroke Maximum stroke Pulley color code Pulley adjust mark 0 20 0 25 mm 0 008 0 010 in 0 95 1 10 mm 0 037 0 043 in Yellow 7777777f 7777777 D Engine and Transmission Oil 1 Engine oil Aut...

Page 12: ...ft lb Transmission oil quantity Total dry 350 cc 0 37 US qt Exchange 300 cc 0 32 US qt E Cylinder Head Check torque of cylinder head holding nuts Tighten in a crisscross pattern Cylinder head nut torque 1 0m kg 7 0ft lb 2 4 CHASSIS A Brake and Wheel Front Rear 1 Inspection and adjustment of brakes Check the free play of both brake lever If the free play is off the specification make an adjustment ...

Page 13: ...hoe bring the punch mark on the camshaft lever to align with the punch mark on the camshaft When installing the rear brake be sure to align the projection on the drive shaft housing with the center of the camshaft lever 1 Indicator set position 2 Punch mark 3 Set position 4 Front axle Check axle nut Front axle nut torque 5 5 m kg 40 ft lb 5 Rear axle Check axle nut Rear axle nut tome 6 m kg 43 ft ...

Page 14: ...g the ignition timing Using a timing light check to see that the stationary pointer and mark on the magneto flywheel are aligned a Remove the crankcase cover L b Connect the timing light to the spark plug lead wire c Start the engine and keep it running at the specified speed Use a tachometer for checking Timing checking speed 5 000 r min d While running the engine at the spe cified speed check to...

Page 15: ...S lighting Torque 2 0m kg 14ft lb C Battery A poorly maintained battery will deteriorate quickly The battery fluid should be checked at least once a month 1 The level should be between the upper and lower level marks Use only distilled water for refilling Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water 2 Always make sure the connections ...

Page 16: ...es KEEP OUTOF REACH OF CHILDREN D Headlight Beam Adjustment When necessary adjust the headlight beam as follows 1 About horizontally by tightening or loosening the adjusting screw as in the illustration To adjust to the right tighten the screw To adjust to the left loosen the screw 2 Adjust vertically by moving the head light body Hi m m its w 1 Adjusting screw 2 10 ...

Page 17: ...e Gear and Kick Pinion Gear 3 5 K Transmission 3 5 L Crankcase 3 6 M Crankshaft 3 6 3 3 INSPECTION AND REPAIR 3 7 A Cylinder Head 3 7 B Cylinder 3 7 C Piston Pin and Bearing 3 7 D Piston 3 7 E Piston Rings 3 8 F Autolube Pump 3 8 G Clutch 3 9 H Kick Starter 3 9 I Transmission 3 9 J Crankshaft 3 10 K Bearing and Oil Seals 3 10 L Crankcase 3 10 3 4 ENGINE ASSEMBLING AND ADJUSTMENT 3 10 A Crankshaft ...

Page 18: ...ition coil and coil bracket 2 Disconnect the magneto lead wire 3 Remove the rear fender 4 Remove the rear brake cable from shaft drive housing 5 Remove the nut and rear wheel from shaft drive housing NOTE Immediately when the rear wheel is removed from the housing place a wooden frame or block under the rear carrier to keep the ma chine upright 6 Remove air cleaner joint and clip air cleaner case ...

Page 19: ... hold ing screws and reed valve assembly 1 Reed valve assembly 2 Reed valve 3 Reed valve stopper 4 Panhead screw 5 Spring washer 6 Reed valve plate 7 Valve seat packing 1 8 Valve seat packing 2 9 Manifold 10 Panhead screw C Kick Crank Kick Starter Remove kick crank securing bolt and kick crank D Drive Shaft Rear Arm Comp Remove rear arm comp from engine E Magneto 1 Remove left crankcase cover scre...

Page 20: ...plug before loosening cylinder head 1 Cylinder head 2 Cylinder head gasket 3 Sparkplug 4 Cylinder body 5 Cylinder gasket 6 Stud bolt 7 Plate washer 8 Hexagon nut Piston Pin and Piston Remove piston pin clip from piston NOTE Before removing the piston pin clip cover the crankcase with a clean rag so you will not accidentally drop the clip into the crank case 2 Push piston pin from opposite side the...

Page 21: ...n nut Circlip 11 Plate washer 12 Clutch carrier assembly 13 Clutch weight shaft 14 Spring 15 Washer 16 Circlip 17 Clutch weight damper 18 Clutch housing comp 19 Circlip J Kick Shaft Assembly Drive Gear and Kick Pinion Gear 1 Remove the circlip drive gear and kick pinion gear 2 Remove the kick shaft assembly K Transmission 1 Main axle comp 2 Pinion shim 3 Cover plate 4 Stopper 5 Bolt 6 Middle drive...

Page 22: ... if 1 Screw 2 Hexagon wrench 3 Remove the distance collar bearing driven pinion and thrust shim form the rebore to next over size L Crankcase 1 Working in a crisscross pattern loosen each screw 1 4 turn Remove screws after all are loosened 2 As illustrated below remove the crank case right by tapping it with a soft faced hammer oVOycC E f p v2 iv_ aT Wti 0 M Crankshaft Remove crankshaft assembly w...

Page 23: ...der Mea sure front to rear and side to side at top center and bottom just above ex haust port Compare minimum and maximum measurements If over toler ance and not correctable by honing rebore to next over size Max allowable taper d a 0 05 mm 0 0020 in Max allowable out of round B A o r A B 0 01 mm 0 0004 in Wear limit 40 10 mm 1 579 in at a position C Piston Pin and Bearing Apply a light film of oi...

Page 24: ...earance _ Top Second Minimum 0 03 mm 0 0012 in Maximum 0 05 mm 0 0020 in F Autolube pump 1 Troubleshooting and repair a Wear or an internal malfunction may cause pump output to vary from the factory setting This situation is how ever extremely rare If output is sus pect check the following 1 Obstructions in delivery line to pump or from pump to carburetor 2 Worn or damaged pump body seal or crankc...

Page 25: ...kness S T D 1 0 mm 0 040 in Wear limit 0 7 mm 0 03 in 2 Measure each clutch shoes spring If beyond tolerance replace _ _ _ Clutch shoe spring free length New 34 5 mm 1 36 in Limit 35 5 mm 1 39 in Wm H Kick Starter Check the ratchet teeth on the kick gear and drive gear The matching edges should fit flush against each other If there is severe rounding off replace as a set Kick gear and drive gear I...

Page 26: ... 2 Check oil seal lips for damage wear Replace as required 3 Always replace crankshaft oil seals whenever the crankshaft is removed 4 Installation Install bearing s and oil seal s with their manufacture marks or numbers facing outward That is you can see its marks or numbers easily L Crankcase 1 Visually inspect case halves for any cranks damage etc 2 If bearing s have been removed check their sea...

Page 27: ... mating surfaces It is advisable that the right hand case mat ing surface be coated Set the crankcase right half onto the shafts and tap lightly on the case with a soft hammer to assemble C Transmission Installation 1 Check to see that all parts move freely and that all loose shims are in place Make sure all shafts are fully seated 1 Main axle comp 2 Pinion shim 3 Cover plate 4 Stopper 5 Bolt 6 Mi...

Page 28: ... Cover Right Install crankcase cover G Piston 1 During reassembly coat the piston ring grooves piston skirt areas piston pin and bearing with two stroke oil 2 Install new piston pin clips and make sure they are fully seated in their grooves NOTE Take care during installation to avoid damag ing the piston skirts against the crankcase as the cylinder is installed Note the two induc tion holes in the...

Page 29: ...l engine mounting bolt with proper tightening torque Tightening torque 5 0 m kg 36 ft lb 6 Install air cleaner assembly and carbure tor assembly adjust 7 Install rear fender and rear wheel Rear wheel axle nut torque 6 0 m kg 43 ft lb 8 Install oil pump wire and carburetor 9 Install muffler and footrest Exhaust pipe holding bolt torque 1 0 m kg 7 ft lb 3 13 ...

Page 30: ... z CHAPTER 4 CARBURETIOIM 4 1 CARBURETOR A Inspection and Repair 4 2 REED VALVE ASSEMBLY A Inspection 4 3 4 3 4 3 4 3 ...

Page 31: ...ain jet Needle jet Pilot jet Pan head screw Mixing chamber gasket Mixing chamber top Wire adjusting screw Wire adjusting nut Cap Float Needle valve Float pin Throttle valve Spring seat Jet needle Throttle valve spring Clip Throttle stop spring Throttle stop screw Starter plunger Plunger spring Panhead screw Pilot air screw spring Pilot air screw Nut Panhead screw Hose 4 2 ...

Page 32: ...ve and needle assem bly in carburetor mixing chamber 10 Install mixing chamber top 11 Re install carburetor Check position and routing of all tubes Check tight ness of all fittings Make sure carburetor is mounted in a level position Refer to CABLE ROUTING DIAGRAM 12 After installation readjust throttle cable and Autolube pump cable See direc tions in Chapter 2 Section 2 3 A and 2 3 C 4 2 REED VALV...

Page 33: ... in NOTE If clearance a is larger than specified the valve will be broken If smaller engine per formance can be impaired Valve stopper screw torque 0 08 m kg 0 6 ft lb 5 Reed valve a Place the reed valve on a surface plate with the reverse side down and measure the amount of warpage If measured more than the limit the reed valve should be replaced 0 8 mm 0 03 in Surface Plate Warpage limit 0 8 mm ...

Page 34: ...6 Manifold Check distortion of manifold surface If theZn IS Ut f mlt r6SUrface the 600 wet sandpaper 1 Manifold 2 Sandpaper 600 ...

Page 35: ...el 5 3 5 2 REAR WHEEL 5 3 A Removal 5 3 B Rear Wheel Inspection 5 3 C Brake Shoe Wear Inspection 5 3 D Rear Drum Inspection 5 3 E Brake Shoe Plate Inspection 5 3 F Installing Rear Wheel 5 3 5 3 SHAFT DRIVE 5 5 A Removal 5 5 B Shaft Drive Inspection 5 7 5 4 FRONT FORKS 5 8 A Disassembly 5 8 B Inspection 5 9 C Reassembly 5 9 5 5 STEERING HEAD 5 10 A Inspection 5 10 5 6 CABLES AND FITTING 5 10 A Cabl...

Page 36: ...eeds tolerance check wheel bearing or replace wheel as re quired Rim run out limits Vertical Lateral 0 7 mrr 1 3 mm 0 028 in 0 051 in f 1 h w II rTi D w 1 Vertical 2 Lateral D Brake Shoe Wear Inspection 1 Measure the brake shoe thickness at 3 or 4 points If beyond wear limits re place brake shoe Brake shoe wear limit 2 mm 0 08 in 2 Remove any glazed areas from brake shoes using coarse sandpaper E ...

Page 37: ...nts 1 Lightly grease lips of front wheel oil seals and gear teeth of speedometer drive and driven gears Use light weight lithium soap base grease 2 Check for proper engagement of the boss on the outer fork tube with the locating slot on brake shoe plate 3 Always secure the front wheel axle as follows a Torque the front axle nut Axle nut torque 4 0 m kg 30 ft lb b Install a new cotter pin 5 2 REAR ...

Page 38: ...16 Camshaft 17 Hexagon bolt 18 Hexagon nut 19 Indicator 20 Bearing 21 Front rim 22 Front spoke set 23 Stop ring 24 Wheel axle 25 Collar 26 Castle nut 27 Cotter pin 28 Plain washer 29 Ring 30 O ring 1 Rear hub 2 Rear tire 3 Rear tube 4 Rim band 5 Rear rim 6 Rear spoke set 7 Brake shoe comp 8 Shoe return spring 9 Camshaft 10 Camshaft lever 11 Hexagon bolt 12 Lock washer 13 Self locking nut 14 Plate ...

Page 39: ...g gear A Removal 1 Remove the six bolts shown in the figure below te r f mm 2 Using the special tool remove the screw turning to left spacer bearings and shim together with the drive pinion 3 Remove the screw securing the housing cover to the drive housing and remove the O ring together with the housing cover 4 Remove the ring gear from the drive housing 1 Screw 2 Hexagon wrench 5 5 ...

Page 40: ...ression spring 14 Spring retainer 15 Circlip 16 Hexagon bolt 17 Spring washer 18 Rear arm comp 19 Screw 20 Bearing 21 Spacer 22 Bearing 23 Drive pinion shim 24 Drive pinion assembly 25 Rear cushion bushing 26 Bearing 27 Shaft drive housing 28 Bearing spacer 29 Bearing 30 Cover plate 31 Hexagon bolt 32 Ring gear comp 33 0 ring 34 Housing cover 35 Plate washer 36 Panhead screw 5 6 ...

Page 41: ...als Every 2 years Grease the shaded areas in particular Grease the drive pinion at least up to the center line 2 Ring gear complete Measure the deflection of ring gear complete using a dial gauge Deflection limit 0 08 mm 0 0031 in 4 Drive shaft bearing and shaft drive housing bearing checking Check bearing for wear damage If necessary replace them 5 Greacing the bearing Before installing the beari...

Page 42: ...in the groove on the cover 1 O ring 5 4 FRONT FORKS A Disassembly 1 Remove the rear brake cable and starter wire from the handlebars 2 Remove the headlight unit and front panel 1 and disconnect lead wires 3 Remove front panel 2 plate front carri er and ball race cover 4 Loosen the fitting nuts two pieces Loosen the handlebar fitting bolt re move the handlebar complete by tap ping the bolt with a s...

Page 43: ...rk spring 6 Rubber 7 Spring under seat 8 Outer panel 9 Ball race 1 10 Ball race 2 11 Ball race 3 12 Ball 13 Fitting nut 14 Ball race cover 15 Panhead tapping screw 16 Front carrier 17 Panhead screw 18 Plate washer 19 Front panel 1 20 Front panel 2 2J Carrier bracket 22 Plate B Inspection 1 Check if there is no catch when the dust seal slide metal collar and spring slide up and down 2 Check the inn...

Page 44: ...es 5 32 in Lower 26 pes 5 32 in Examine dust seal under lowest race and replace if damaged Grease the lower ball race of the upper and lower assembly and arrange the balls around it Then apply more grease and the top race into place 5 6 CABLES AND FITTINGS A Cable Maintenance NOTE See Maintenance and Lubrication Intervals charts for additional information Cable maintenance is primarily concerned w...

Page 45: ...ase grease and reassemble NOTE Tighten housing screws evenly to maintain an even gap between the two halves 5 Check for smooth throttle operation and quick spring return when released and make certain that housing does not rotate on handlebar C Cable Junction Maintenance The throttle cable cylinder junction point for Autolube control cable must be periodically maintained 1 Remove throttle cable 1 ...

Page 46: ... Charge Coil and Pulser Coil 6 3 D Ignition Timing 6 3 E Spark Gap Test 6 3 F Ignition Coil 6 4 G Spark Plug 6 4 6 2 CHARGING SYSTEM 6 5 A Charging Circuit Test 6 5 B Checking Silicon Rectifier 6 6 C Battery 6 6 6 3 LIGHTING AND SIGNAL SYSTEMS 6 7 A Lighting Tests and Checks A C Circuit 6 7 B Lighting Tests and Checks D C Circuit 6 8 ...

Page 47: ...generates a high surge of voltage in the secondary winding of the ignition coil thus causing a spark to jump 1 Charge coil 2 Pulser coil 3 Condenser 4 Ignition coil 5 Sparkplug 2 Generation of pulses A magnetic circuit is produced by using the magnet on the rotor and pulses are generated according to the magnitude of voltage produced in the pulser coil by the variations in the magnetic flux The ma...

Page 48: ...il should be installed in the specified positions If position is to be changed a dry and air place should be selected Keep free from mud and water c To remove the rotor be sure to use the flywheel magneto puller Avoid using a hammer or the rotor may be damaged d Handle the C D I unit with special care If you should drop it the incorporated electronic components will be damaged C Checking the Magne...

Page 49: ...68 F G Spark Plug The life of a spark plug and its discoloring vary according to the habits of the rider At each periodic inspection replace burned or fouled plugs with suitable ones determined by the color and condition of the bad plugs One machine may be ridden only in urban areas at low speeds another may be ridden for hours at high speed Confirm what the present plugs indicate by asking the ri...

Page 50: ...1 Rectifier 2 Fuse 3 Battery 4 Set the tester in DC VCjLTAGE position b Turn ignition switch to ON position start engine and note voltage and amperage readings c Switch to night time lights on and note voltage and amperage readings 1 Changing current A 2 Battery voltage V 0 2 T 1 2 3 4 5 3 7 8 Engine speed x 1 000 r min If the indicated voltage and amperage cannot be reached perform the tests in s...

Page 51: ...ier test must be checked with both normal and reversed connections C Battery 1 Checking a If battery sulfation white accumula tions occurs on plates due to lack of battery electrolyte the battery should be rplaced b If the bottoms of the cells are filled with corrosive material falling off the plates the battery should be replaced c If the battery shows the following de fects it should be replaced...

Page 52: ...et Tester to AC20V posi tion Connect positive test lead to blue Connection and negative test lead to a good ground Start engine tuirn on lights and check y oltage at each engine speed If measured vo tage is too high or too low check for pad connections dam aged wires burned out bulbs or bulb capacities that are too large throughout the A C lighting circuit 3 Pi Blue Headlight Pocket tester Set tes...

Page 53: ...d charging system Also check fuse condition Replace open blown fuses 1 Horm does not work a Check for 6V on brown wire to horn b Check for good grounding of horn pink wire when horn button is pressed a b c 4 a b Brake light does not work Check bulb Check for 6V on yellow wire to brake light Check for 6V on brown wire to each brake light switch front brake switches Tail light does not work Check bu...

Page 54: ...evel gauge side 2 Br E on the main switch side and Br B on the level gauge side 3 R A and R E between wire har nesses In any one of the above connections there should be continuity the tester reading is zero If not wires are con sider to be broken Oil level gauge Hold the level gauge in a vertical posi tin and lower the float to the lowest position With the float in this position there should be c...

Page 55: ...CHAPTER 7 APPENDICES 7 1 GENERAL SPECIFICATIONS 7 2 A General 7 2 B Engine 7 2 C Chassis 7 4 D Electrical 7 5 E Tightening Torque 7 6 7 2 CABLE ROUTING 7 7 7 3 WIRING DIAGRAM 7 11 ...

Page 56: ...d valve 3L5 49 cc 3 0 cu in 40 0 mm x 39 2 mm 1 575 in x 1 543 in 6 0 1 Kick C D I Separate lubrication Yamaha Autolube Cylinder head Volume with spark plug 7 0 cc 0 43 cu in Cylinder Material Bore Size Taper Limit Out of Round Limit Special cast iron 40 mm 1 57 in 0 05 mm 0 002 in 0 01 mm 0 0004 in Piston Piston Clearance Piston Over Size 0 035 0 047 mm 0 0 0 1 4 0 0019 in 40 25 mm 40 50 mm 1 585...

Page 57: ...tor Type Manufacturer I D Mark Main Jet M J Air Jet Jet Needle cli Needle Jet Cutaway Pilot Jet Air Screw tur Starter Jet Fuel Level A J p Position J N N J C A PJ nsout A S G S F L Engine Idling Speed 38 _ 0 0 5 mm 1 50 _0 0 02 in 0 03 mm 0 0012 in 0 3 5 0 55 mm 0 0 1 4 0 021 in 0 4 0 8 mm 0 016 0 031 in 6203 C3 6203 C3 SD17 35 7 SD23 35 7 Wet Centrifugal automatic 63 33 1 909 gear 1 0 mm 0 040 in...

Page 58: ...Spring Free Length Set Length Spring Constant Wire Diameter x Winding Outside Diameter Fuel Tank Capacity Fuel Grade Wheel Tire Size Front Rear Tire Pressure ffront Rear Rim Size Fronw Rear Rim Run Out Liinit Front Rear Vertical Lateral Drive Shaft Lubricating Grease Grade 1 Quantity 1 1 h Steel tube underbone 25 7 5 mm 2 95 in 26 pes 5 32 in 26 pes 5 32 in 100 Telescopic fork Coil spring 45 mm 1 ...

Page 59: ...ndary Winding Resistance Diode Spark Plug Type Mar ufacture Spark Pluij Gap C D I Unit Model Manufacturer C D I Magneto Model Me nufacturer Charging Systor Flywheel Magneto Charging Output Charge Coil Resistance Black White Lighting Oijtput Lighting Cojl Resistance Black Blue Rectifier Type Capacity Withstand Voltage Rating Battery Model Manufacture Capacity Charging Specific Gravity Rate F3L6 Yam...

Page 60: ...7 ft lb Reed valve Manifold M6 0 9 m kg 6 5 ft b Generator Rqtor M12 4 0 m kg 30 ft lb Generator Stator M6 0 9 m kg 6 5 ft b Exhaust pipe M6 1 0 m kg 7 ft lb Cover plate Iv ain axle M6 1 0 m kg 7 ft lb Screw Middle driven pinion M45 6 0 m kg 43 ft lb Cover plate R ng gear M6 1 0 m kg 7 ft lb Screw Drive r inion M35 5 0 m kg 36 ft lb Chassis Front wheell slhaft nut M10 4 0 m kg 30 ft lb Rear wheel ...

Page 61: ...7 2 CABLE ROUTIIMG Starter wire Rear brake wire Wire harness u ftl ...

Page 62: ...Stop switch lead wire Stop switch lead wire Wire harness ass y Headlight Wire harness ass y Main switch Route wire harness behind horn Headlight unit 7 8 ...

Page 63: ...e Wire harness ass y Battery lead wire Battery After connecting wires put coupler lead wires and rectifier inside side cover 3 so that wires are not pinched by cover Housing Oil delivery pipe fmmmBmmmmmwmsm w m r ...

Page 64: ... Switch cord band Clamp wire to upper part of front carrier so that it is not pulled when handlebars are turned fully to left Wire harness ass y High tension lead wire ...

Page 65: ...R LIGHT C p J 1 TAIL STOP LIGHT 6V25W FRONT FLASHER LIGHT L 6V17W REAR STOP SWITCH REAR FLASHER LIGHT L 6V17W i CO m 2 Q D O FLASHER r SWITCH HORN SWITCH C D I MAGNETO COLOR CODE R Red L Blue B Black P Pink Y Yellow G Green 0 Orange W White Dg Dark green Ch Dark brown Gy Gray Br Brown G Y Green Yellow B R Black Red W R White Red Br W Brown White L W Blue White ...

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