Yamaha YSR50T Service Manual Download Page 96

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Summary of Contents for YSR50T

Page 2: ...maha Motor Corporation U S A 1st Edition March 1987 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Prin...

Page 3: ...LTD HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation NOTE A NOTE provides key information to make procedures easier or clearer A CAUTI...

Page 4: ...ing Illustrated symbols to are used to identify the specifications appearing in the text Filling fluid Lubricant Special tool Tightening Wear limit clearance Engine speed 9 v A Illustrated symbols 0to...

Page 5: ...INDEX GENERAL INFORMATION m GEN INFO SPECIFICATIONS Pf ENGINE OVERHAUL o PERIODIC INSPECTION AND ADJUSTMENT CHASSIS O em INSP ADJ ELECTRICAL E l ELEC TROUBLESHOOTING 0...

Page 6: ...S AND O RINGS 1 3 LOCK WASHERSIPLATE AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 ClRCLlPS 1 4 SPECIAL TOOLS 1 4 FOR TUNE UP 1 4 FOR ENGINE SERVICE 1 5 FOR CHASSIS SERVICE 1 6 FOR ELECTRICAL COMPONE...

Page 7: ...ECTION 3 11 TRANSMISSION OIL REPLACEMENT 3 12 CLUTCH ADJUSTMENT 3 13 AIR FILTER CLEANING 3 14 CARBURETOR JOINT INSPECTOIN 3 16 FUEL LINE INSPECTION 3 17 Y E I S HOSE INSPECTION 3 17 EXHAUST SYSTEM INS...

Page 8: ...E DISASSEMBLY 4 5 CYLINDER HEAD CYLINDER AND PISTON 4 5 CLUTCH AND PRIMARY DRIVE GEAR 4 6 KICK AXLE 4 8 SHIFT SHAFT 4 9 CDI MAGNETO 4 9 CRANKCASE 4 10 TRANSMISSION SHIFTER AND CRANKSHAFT 4 11 INSPECTI...

Page 9: ...LVE 5 8 REMOVAL 5 8 INSPECTION 5 8 INSTALLATION 5 9 CHAPTER 6 CHASSIS FRONT WHEEL 6 1 REMOVAL 6 2 INSPECTION 6 2 INSTALLATION 6 4 REAR WHEEL 6 5 REMOVAL 6 6 INSPECTION 6 6 INSTALLATION 6 8 FRONT BRAKE...

Page 10: ...GRAM 7 1 COLOR CODE 7 2 ELECTRICAL COMPONENTS 7 3 IGNITION AND STARTING SYSTEM 7 4 IGNITION CONTROL CIRCUIT OPERATION 7 6 TROUBLESHOOTING 7 7 CHARGING SYSTEM 7 16 TROUBLESHOOTING 7 18 LIGHTING SYSTEM...

Page 11: ...7 pqm INFO IMPROPER KICKING 8 8 SLIPPING 8 8 HARD KICKING 8 8 KICK CRANK NOT RETURNING 8 8 FAULTY BRAKE 8 9 POOR BRAKING EFFECT 8 9 FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION 8 9 OIL LEAKAGE 8...

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Page 13: ...your state IAL N The engine serial num left side sf the en cThe first three di ts sf these numbers are for model identificat ns heremainin duction number specifications are su without notice...

Page 14: ...OL 3 When disassembling the motorcycle keep mated parts together This includes gears cylinders pistons and other mated partsthat have been mated through normal wear Mated parts must be reused as an as...

Page 15: ...HERSIPLATES AND COlTER PINS 1 All lock washers1Plates and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has been prope...

Page 16: ...t receives See the sectional view I Shaft SPECIAL TOOLS The proper special tools are necessary for com plete and accurate tune up and assembly Using the correct special tool will help prevent damage c...

Page 17: ...s used to hold the clutch when loosen ing or tightening the clutch boss locknut 2 Universal Rotor Holder PIN YU 01235 This tool is used when loosening or tightening the flywheel magneto securing bolt...

Page 18: ...se 6 Crankshaft Installing Tool 0 PIN YU 90050 Adapter 0 PIN YM 90063 These tools are used to install the crankshaft FOR CHASSIS SERVICE 1 Front Fork Seal Driver Weight PIN YM 33963 Adapter PIN YM 332...

Page 19: ...w l FOR ELECTRICAL COMPONENTS 1 Coil Tester PIN YU 33261 This tester is necessary for checking the ignition system components 2 Pocket Tester PIN YU 03112 This tester is invaluable for checking the e...

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Page 21: ...TYpe Engine Oil Type Transmission Oil Type Oil Capacity Engine Oil Oil Tank Transmission Oil Periodic Oil Change Total Amount Air Filter Type 1 630 mm 64 2 in 635 mm 25 0 in 930 mm 36 6 in 660 mm 26 0...

Page 22: ...hassis Frame Type Caster Angle Trail Tire TYpe Size Front Rear Tire Pressure Cold Tire Basic Weight With Oil and Full Fuel Tank Maximum Load Cold Tire Pressure Zero Maximum Load Regular gasoline 8 0 L...

Page 23: ...tem Generator System Battery Type Capacity Headlight TYpe Bulb Wattage Quantity Headlight TailIBrake Light Flasher Light Licence Light Meter Light NEUTRAL lndicator Light HIGH BEAM lndicator Light TUR...

Page 24: ...talled Top Ring 2nd Ring Side Clearance Top Ring 2nd Ring 0 02 mm 0 001 in Lines indicate straightedge measurement 40 00 40 02 mm 1 575 1 576 in 0 05 mm 0 002 in 0 01 mm 0 0004 in 39 96 39 98 mm 1 573...

Page 25: ...thod Push Rod Bending Limit Transmission Main Axle Runout Limit Drive Axle Runout Limit Shifter TYpe Guide Bar Bending Limit Kick Starter TYpe 37 90 37 95 mm 1 492 1 494 in 0 03 mm 0 0012 in 0 2 0 7 m...

Page 26: ...Valve Bending Limit Lubrication System Autolube Pump Color Code Minimum Stroke Maximum Stroke Minimum Output Maximum Output Pulley Adjusting Mark Foam Air Filter oil or Yamalube 2 2AL 01 120 42 5 3621...

Page 27: ...nifold Muffler Front Muffler Rear Crankcase Crankcase cover Transmission oil drain bolt Autolube pump cover Kick crank assembly Primary drive gear Clutch boss Pressure plate Stopper plate Bearing Stop...

Page 28: ...l TYpe Rim Size Rim Material Rim Runout Limit Vertical Lateral Ball Bearing 90 mm 3 54 in 374 2 mm 14 7 in 367 mm 14 4 in 8 2 Nlmm 0 83 kglmm 46 6 Iblin 0 0 90 0 mm 0 0 3 5 in No LEFT 126 cm3 4 44 Imp...

Page 29: ...mit Shoe Spring Free Length Lining Thickness Limit Brake Lever and Brake Pedal Brake Lever Free Play Brake Pedal Free Play Clutch Lever Free Play Throttle Cable Free Play Panel wheel MT2 50 x 12 Steel...

Page 30: ...Brake cam lever and camshaft Rear wheel sprocket and wheel hub Tension bar and platelframe Rear wheel axle and nut Rear view mirror and stay Brake hose union bolt Footrest and frame Cowling stay and f...

Page 31: ...Manufacturer Pickup Coil Resistance Color Source Coil Resistance Color Ignition Coil ModelIManufacturer Minimum Spark Gap Primary Coil Resistance Secondary Coil Resistance Spark Plug Cap TYpe Plug Ca...

Page 32: ...White Black 7 4 8 2V at 5 000 rlmin Lighting Coil Resistance Color Standard Output Engine Speed x 1 000 rlmin IVoltage Regulator ModelIManufacturer Rectifier ModelIManufacturer Capacity Withstand Vol...

Page 33: ...del Flasher Relay Type ModelIManufacturer Self Cancelling Device Flasher Frequency Wattage Oil Level Switch ModelIManufacturer Curcuit Breaker Type Curcuit Fuse MAIN Condenser Type FZ636SDlNIPPON DENS...

Page 34: ...Unless otherwise specified torque specifications call for clean dry threads Components should be at room tem perature I A Distance across flats B Outside thread diameter DEFINITION OF UNITS General to...

Page 35: ...drivenldrive gear Push rod a A I Guide bar Shift fork PinionIWheel gears Collar Drive axle 4 la CHASSIS Shift shaft Shift cam Lubrication Points Part name 1 Lubricant Type I la a Steering UpperlLower...

Page 36: ...CABLE ROUTING ISPEC p9I CABLE ROUTING aHandlebar switch Right lead Main switch lead Clutch cable Handlebar switch Left lead Clamp Throttle cable aFront brake hose...

Page 37: ...ING ISPEC Ip9I CABLE ROUTING Headlight lead Spark plug lead Clutch cable Horn lead Sidestand switch lead Band aCable holder Speedometer cable Meter light lead Pass the speedometer cable through the ca...

Page 38: ...brake hose Clamp Carburetor air vent hose 1Si Pass the battery breather hose through the Cable guide 0CDl magneto lead hole on the rear fender Oil hose Battery breather hose Oil pump cable Rear brake...

Page 39: ...Throttle cable 0Sidestand switch lead IB Pass the main switch and brake switch lead in Front brake hose Handlebar switch Left lead side of the oil tank cap Brake switch lead Spark plug lead Pass the...

Page 40: ...Right lead Taillight lead Rear flasher light Left lead Battery negative lead aBattery positive lead Battery Flasher relay CDI unit Pass the wireharness flasher light lead and battery breather hose th...

Page 41: ...ACE 0 0 Correct if necessary Replace every 12 000 8 000 or 24 months Warm engine before draining Check operation Correct if necessary Air bleeding Check operation fluid IeakageISee NOTE Correct if nec...

Page 42: ...r caliper cylinder replace the brake fluid Normally check the brake fluid level and add the fluid as required 2 We recommend that on the inner parts of the master cylinder and caliper cylinder replace...

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Page 44: ...Front seat Side cover everse removal ste a and warm it up Engine idle speed ut of specification Adjust Engineidle speed p screw in or out un...

Page 45: ...tall efore adjusting throttle ca le free play engine idle speed should be adjusted 1 Check Throttlecable free play 2 Adjust Turn the adjuster or out until the cor tle cable free pl 1 Remove Lower cowl...

Page 46: ...e pump cover a Check Aiignmeni mark r out until the ali 9Tighten the locknut P p P 5 Install autol lube pum Lowercowling...

Page 47: ...fully gine the moment that the adjus moves out to its limit 5 Measure ut of speci3icatioi Adjus t Measure hegap with the Thickness gauge between the raised boss on the pump adjusting pulley an the adj...

Page 48: ...Install the adjustin locknut 7 Install Air bleed appear Whenair bubbles are expelled completely tighten the bleed screw damaged replace with a new one...

Page 49: ...4 Air bleed ump distributor andlor delivery hose 4 It is difficult to bleed the distri urnp stroke at a rn maximum 5 Install Q Lower cowlin PA 1 Remove...

Page 50: ...brus Measure auge or Feeler Gau ut sf specification Wegap 7 Tighten efore installing a s ark plug clean the gasket and plug surfaces OTE Finger tighten the spark d u g befcwe rorquing to specificscis...

Page 51: ...OIL warning indicator light A 1 Place the motorcycle on a level surface and warm up the engine for several minutes 2 Stop the engine and remove the oil filler cap...

Page 52: ...false readings 4 Inspect il level should b A he engine for several minutes an stop the engine 2 Place an oil pan under the engine rain the engine oil...

Page 53: ...Install Fill 7 Install Loosen the locknuts adjusters in or out until the free play is obtained 5 14 ten the locknuts...

Page 54: ...lutcch push lever free play tighten the locknut while hoiding the ad juster 5 Install Flywheel magneto cover Lower cowling 6 Adjust Clutchcable free play efer to Free play adjustment section Front sea...

Page 55: ...er ever operate the en ine with the air filter element removed This will alisw unfiltered air t o enter causin id wear and possi withaut the filter will affect cavbu uewt poor perfor ne overheating Cl...

Page 56: ...of the element and let dry r filter oil or Vamalu to the element out the excess oil The element should be wet ut not dripping Air filter case cover 4 1 Install Fuel tank Front seat cSide cover 2 Insp...

Page 57: ...Lower cowl bowercowling Install lowercowling 1 Check rake lever free play ut of specification lnspect the brake section...

Page 58: ...r out until the spsci fied free play is obtained i BRAKE FLUID 1 Make sure the r top i shorimontaal by turning the handlebars 2 1nspecr oBrake fluid level Fluid lwei is under L WER level line a e p l...

Page 59: ...ake shoes AICE LIGHT SbVITCH ADJUSTMENT TE The brake light switch is operated by movemenu of the brake pe Proper adjustment is achieved when the bralee light comes on just before the brake begins to t...

Page 60: ...andlor adjust the chain slack with the rear wheel in this tightest I Check rive chain slack ut of specification tAdjcest slack is obtained alignment...

Page 61: ...nut ear wheel axle Insert a new cotter pin center rollers 2 To clean the chain remove he machine dip it in solvent an 9 Remove bower cowling 2 Elevate the front wheel by placing a suitable 3 21 under...

Page 62: ...3 Check Grasp the bottom o the forks and gently rock the fork assembly back and forth seness Adjust steerin oRstighten re ring nut using the Ring Nclr Avoid over tightening r 5 Install Lower cowling...

Page 63: ...hecked and adjusted when the temperature of the tire equals the ambient air temperature Tire in flation pressure must be adjusted according to total weight of cargo rider passenger and accessories fai...

Page 64: ...J Never attempt even small repairs t o the wheel 2 Tighten Valve stem locknut Ride conservatively after installing a tire t o allow it to seat itself properly on the rim CABLE INSPECTION AND LUBRICATI...

Page 65: ...ube or SAE 10W30 Motor Oil NOTE Hold cable end high and apply several drops of lubricant to cable LEVER AND PEDAL LUBRICATION Lubricate pivoting parts of each lever and pedal Recommended Lubricant Yam...

Page 66: ...terminal Dirty terminal Clean with wire brush Poor connection Correct After cleaning the terminals apply grease lightly to the terminals 4 Connect Breatherhose Be sure the hose is properly attached a...

Page 67: ...id and therefore is poisonous and highly caustic Always follow these preventive measures Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury Wear protective eye...

Page 68: ...t for continuity Set the tester selector to Q x 1 position elf the tester is indicated at a The fuse is blown replace it 4 Replace Blown fuse Turnoff ignition and the circuit elnstall a new fuse of pr...

Page 69: ...T Lowercowling 2 3 Flasher lights Left and right sflasher light stay Refer to COWLINGS section Remove Headlight Install Headlight New Install Flasherlight stay Flasherlights Left and right Lowercowlin...

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Page 71: ...Autolube pump Transmissionoil section Frontseat section 1 Turn the fuel cock to FF position and dis connect the fuel hose 2 Remove Fuel tank...

Page 72: ...VAL U Autolubepump cover Autolubepump cable Oilhose a Plug the oil hose end with a suitable screw...

Page 73: ...eNecatral switch leads crankcase cover Left a oGasket Crankcase cover Left RBVEcwim Loosen adjuster 2 Push forward t e rear wheel to loosen the drive chain...

Page 74: ...Place a suitable stand under the engine...

Page 75: ...Q Lower cowlin 0Muffler 2 Remove Gaske Cylinder head cylinder J gasket Cylinder Intake rnanifoid pin circlip cover crank ing into crankcase cavity...

Page 76: ...out CLUTCH AND PRIMARY TE Bower cowl 2 IYsi xve 8 Boles Pressure plate Springs Pressure plats...

Page 77: ...4 Remove Use the Universal Clutch Holder the clutch boss imary drive gear lace a folded rag abetween the teeth of the primary drive gear and driven gear...

Page 78: ...m mounted the kick axle and kick maintained by removing the fol owing parts cable and hoses 1 Unhook the sprin Kickaxle assembly a...

Page 79: ...NOTE With the engine mounted the CDB ma be mainlained by removing the fcallo Lower covviiiyj 1 Remove Rotor Holder ato hold...

Page 80: ...Use the Flywheel Puller ato remove the rotor hift cam stopper ttern loosen all screws them after all are loosened...

Page 81: ...s and shift cam Use soft hammer to tap on the casehalf Tap only on asinforced ortiona of case Do not tap sn gasket mati g surface Wdwk s owOy a qd carsffuiiy Make sure the ease hahes separate evenly I...

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Page 83: ...a thickness gauge on the cylinder head Measure the warpage If the warpage is out of specification resur face the cylinder head Place a 400 600 grit wet sandpaper on the surface plate and resurface the...

Page 84: ...o and at right angles to the crankshaft Then find the average of the measurements Standard Wear Limit C 0 05 mm TaperJ1T 1 10 0019 in ut of Round 0 01 mm R 1 1 10 0004 in1 C Maximum D T Maximum Dl or...

Page 85: ...on to cylinderclearance with following formula Piston to cylinder Clearance Cylinder Bore C Piston Skirt Diameter P If out of specification rebore or replace cylinder and replace piston and piston rin...

Page 86: ...06 0 014 in1 I 0 15 0 35 mrn 0 006 0 014 in Oversize Piston Ring Oversize 1 Oversize 2 PISTON PIN AND BEARING 1 Lubricate Piston pin Lightly 2 Install Small end bearing Piston pin lnto the small end o...

Page 87: ...Inspect Friction plate Damage Wear Replace friction plate as a set 2 Measure Friction plate thickness Out of specification Replace friction plate as a set Measure at all four points 3 Inspect Clutch p...

Page 88: ...age Deburr or replace Clutch housing bearing ScoringlWear Damage Replace clutch housing NOTE Scoring on the clutch housing dogs will cause erratic operation 8 Inspect Clutch boss splines Scoring1Wear...

Page 89: ...primary drive gear teeth Prirnsry driven gear teeth KICK STARTER 1 Inspect Measure ick clip Pension u l of specification Use a spring balance a Do not try t s bend the dip SHBFT SHAFT 4 Inspect...

Page 90: ...foliower 2 Inspect fork movement Unsrnooth speratiois Repface shiftfork andlor guide bar uide bar on a flat surface Do not attempt to strai Rten a bent gui bas Measure se centering device UT of specif...

Page 91: ...ends Replace CRANKSHAFT 1 Measure Runout Use a centering device and Dial Gauge Out of specification Replace or repair Runout Limit 0 03 mm 0 0012 in 2 Measure Small end free play a Use a Dial Gauge Ou...

Page 92: ...mating surfaces thoroughly 3 Inspect Crankcase Cracks Damage Replace Oil delivery passages Clog Blow out with compressed air AUTOLUBE PUMP Wear or an internal malfunction may cause pump output to vary...

Page 93: ...e d t of specification A 4 Inspect...

Page 94: ...rankshaft Installing Tool Adaptera Installing Tool 2 Install other Operate the 3 Install heck lifteroperation Transmission operation eration Repair...

Page 95: ...ase onto the left case Tap iightly on the case with a soft hammer Before instaliin t h e crankease ewm be sure to check whether ission is ff uwctioning properly by manually rotating the shift cam eith...

Page 96: ...Forced out on the cylinder hole 7 Check Install...

Page 97: ...Bearing Connecting rod 0Piston pin clip Big end bearing Small end bearing Crank pin Woodruff key aBearing Collai...

Page 98: ...Main axle 4th pinion gear 4th wheel gear Circlip 3rd wheel gear 3rd pinion gear 2nd wheel gear 2nd pinion gear 5th wheel gear Oil seal 0Drive sprocket Circlip...

Page 99: ...Guide bar Shift fork 8Shift cam assembly Shift fork 2 Shift cam plate Shift fork 3 Shift cam stopper Pin Q Spring Circlip 5011 Shift fork 1 Circlip aCotter pin Segment...

Page 100: ...witch lead 2 Install When installing the rotor make sure the woodruff key is properly seated in the keyway of the crankshaft Clean the tapered ortion of the cranks with a cloth 3 Tighten o Er Holder a...

Page 101: ...aRotor Stator assembly Charge coil Lighting coil Pickup coil...

Page 102: ...hift lever correctly en KlCK AXLE I Install Kickaxle assembly 1 eMake sure that the kick stopper is sto n epf the crankcase at the kick clip is engaged with the crankcase hole 2 Hook the kick spring 3...

Page 103: ...Circlip Kick crank Shift lever Return spring Rotor 0Collar Return spring Kick axle Pin Kick idle gear 0Oil seal...

Page 104: ...the conical spring was as shown oApply the transmission oil onto the collars 2 Tighten oNuk Primary drive gear NOTE etween the teeth of the 3 Install Thrust washer a Clutchboss Q e sure to install th...

Page 105: ...per Q and f r i c t i n plate alter friction plate and second clutch damper Install NOTE Tighten the bolts in stages using a crisscross pattern Gasket Crankcase cover New Tighten the screws in stages...

Page 106: ...utch boss Primary drive gear 0Clutch damper Conical spring washer Friction plate Push rod 2 Clutch plate Ball Cushion spring Thrust washer Conical spring washer aCollar Push rod 1 O ring 0Pressure pla...

Page 107: ...To the small end bearin bearing the crankcase Asways use a new piston pin dip 4 Install askets Cylinder...

Page 108: ...5 Install Installthe cylinder with one ha d while compress ing the piston rings wit the other hand Tighten the nuts in stages using a crisscross 7 Install...

Page 109: ...Vkl A aCylinder head Gasket Cylinder head Spark plug Cylinder Gasket Cylinder...

Page 110: ...Note the following points 1 Install Q Engine assembly efore installing t e drive sprocket loosen the rear wheel axle and push forward the rear wheel...

Page 111: ...Tighten the screws in stages using a crisscross pattern p P rive chain slack ENT section 9 Adjust Throttle cable free play...

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Page 113: ...Spring Throttle valve Jet needle assembly Main jet Throttle valve Valve seat assembly Throttle stop screw 0Float Pilot screw Pin Float Starter plunger Float chamber aPilot jet Drain screw Float height...

Page 114: ...screw 0 Lower cowling Refer s o CHA sectioja 2 Turn the fuel cock to OFF piaskion and dis connect the fuel hose a 3 Loosen Screws Carburetor joint 4 Eernove srburetor assembly a DiSASSEMBL 4 Remove Th...

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Page 116: ...not use any caustic carburetor cleaning solution low out all passages and jets with com pressed air P 2 Inspect Float amage Replace Inspect o Needle va ve Valveseat Gasket amage Wear Contamination Re...

Page 117: ...throttle valve into the carburetor body and check for free movement Inspect Clipposition 7 Inspect Starterplunger Throttle stop screw everse the disassemby procedure Note the following points 1 Measur...

Page 118: ...at height is nor within specification insped the valve seat and needle valve Ifeither is worn Ifboth are fine Q Recheck the float height _ _ _ _ Y _ _ Y V _ _ _ L _ _ iT_ BfqSTALLATIOM Reverse the rem...

Page 119: ...ed veskecaliy 3 Attach the Fuel Level Gauge to h e iioet 4 Loosen the drain screw a and warm up the engine for sevehai minuies 5 Pdeasure oFdel level ut of specification Adjust I elow the Carburetor A...

Page 120: ...I Measure Valvestopper hei ut of specification Replace 2 Measure eed valve bending Installthe reed valves New...

Page 121: ...REED VALVE I INSTALLATION Reverse the removal procedure Note following points 1 Tighten Carburetor joint b Bolt Carburetor Joint 8 Nrn 0 8 rn kg 5 8 ft lbl...

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Page 123: ...Cotter pin Load is the total weight of cargo rider and accessories...

Page 124: ...a efer t o CHA Nut Front wheel axle Elevate the front el by placing a suitable Collar ofront wheel axle ny corrosion from parts 2 Inspect Frontaxle oll the axle on a flat surface ten a bent axle Inspe...

Page 125: ...aReplace lean the out side o ernove the bearing puller se a socket that matche ameter of the race of the bearing Do not strike t e inner race of houid be made only with the outer race e esnservatiwel...

Page 126: ...val procedure Roae the follow 2 Install Make sure the projections insi the flats in the Install sys use a new cotter end the end sf cotter pin...

Page 127: ...Brake cam shaft Brake shoes Bearing Collar Bearing Joint Rear wheel axle...

Page 128: ...lacing a suitable nd remove ce drive chain a Wear wheel I Ti8 1 Inspect Wear wheel axle EEL INSPECTI section 2 Inspect 6 section...

Page 129: ...and paper A can of the polished articles with cloth _ Je _ _ 7 Measure brake lining Ihiclcness 9u h of specification Replace aMeasuring points Brake Lining Th1cknsss 4 mim 0 16 in I Wear L i r i t 111...

Page 130: ...te the follow ing points A p p l y the Bi ri7ium soap base grease onto the brake cam shaft align the slot on the bake cam shaft with the projection on the wear indicator 2 Install rake cam lever Insta...

Page 131: ...rake sb oes _ __ r r _ Z _ _ _ _ _Xg____ 5 Apply Lithiurn base grease rease to uhe oil seal lips Adjust rive chain slack Refer to CHAPTER 3 DRIVE CHAIN A JUST hRfiT section Install Colterpin Always us...

Page 132: ...Brake hose Union bolt 0Copper washer Brake pads aster cylinder kit Bust seal Piston seal Brake disc...

Page 133: ...8 1is not necessa to disassemble the brake caliper and brake hose to replace the brake pads worn to the wear limit a suitable hose eed screw Then this hose into an open container...

Page 134: ...4 Loosen the cali istons into the calipe NOTE 7 Install Calipercoves a LOWER level line lever operation A softy or spongy fillin...

Page 135: ...P sassembig ing the brake caliper drain the rake system of the brake fluid section...

Page 136: ...emre disassemblyingthe front master cylinders drain the brake syste of the brake flui Mastercylinder boot eCirclip Mastercylinder kit P...

Page 137: ...2 Measure rake pad thickness ut of specification et if either is found to be 4 Inspect Mastercylinder body Mastercylinder kit...

Page 138: ...t of specification 0All internal parts should be cleaned in new brake fluid only be lubricated with Replaee the piston seals whenever a caliper is disassembled NOTE ly the lithium soap piston seal cal...

Page 139: ...3 Install Pad springs E section 4 Install 5 Install bracket with the mark facing upward...

Page 140: ...8 Install Air From brake system section 8 Install Q Master cylinder cap...

Page 141: ...e reservoir fluid or allow the r plastic tube 4 5 mm htly to the caliper d Place the other end of the tube into a con tainer e Slowly apply the rake lever several times f Pull the lever in old the lev...

Page 142: ...Cap bolt Fork spring Circlip lain washer il seal lick metal Inner tube Outer tube...

Page 143: ...VAL Remove ofron l fender 4 Loosen inch bolt bower a Frontfork seat a Left si ring Left si...

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Page 145: ...rk rube a T m p s Do i 2 0 t a ta8 ip t tr aigB7y ef i9 b i3 2 inpier 2 Inspect oDusl seal Reverse the disassern Note the following poin s NOTE 7 A 2 i n e sure all components are clean before as semb...

Page 146: ...n e r tube To outer tube apply the lithium soap base grease onto the oil seal lip before installing the oil seal e sure oil seal numbered side face upward 4 Press the oil seal into the inner tube with...

Page 147: ...wly pump the front Car up and down to distri 7 Measure ert of specification Add or reduce oil Left 146 mm 5 74 in Right 51 mm 2 Qli aj From the top o f the inner fork 1 rubs f d l y compressed without...

Page 148: ...1 Install Q front fork 2 Install 0TE Apply the lithium soap base rease onto the ring...

Page 149: ...Bottom all 114 i n 4 9 pcs earing race Lower Bop earing race Upper all 3116 in 22 pcs earing race Upper Top earing race cover ing nut A Handle crown Steering stembolt Handlebar Left Q Cap Throttle ho...

Page 150: ...otorcyele ss there is Lower cowling Q Upper cowling ofront wheel section Front forks section j F emove S l e e r i g stern bolt washer 2 handle crown...

Page 151: ...all bearings and bearing races with a solvent Inspect Dnstall the new dust seal and races...

Page 152: ...G HEAD A A ote the follow bower balls To bearing race bower Bottom rrange the bearings around race and ap 3 Install H iloldthe under bracket until 6 8 i s secured ring nut using the...

Page 153: ...et the torque wrench to the ring nut wrench Loosen the rin Avoid over tightening handle crown NOTE a porary tighten the steering fitting bolt a 6 Install front forks section 7 Tighten...

Page 154: ...Install Install Frontbrake master cylin Install the master cylinder bracket with the ht coat of lithium soap base grease onto 11 Install section...

Page 155: ...ear shock absorber Cotter pin Swingarm Push Spacer Chain support Chain cover...

Page 156: ...g over Wear Shock Absorber 4 Remove 0 Lower cowling section 2 Place a jack under e engine and elevate the motorcycle 3 Remove Q C O pin oPBain washer Q Pin Rear shock absorber Lower a SscureBy support...

Page 157: ...Remove DISASSEMBLY oChain guide tension bar 1 Wash the bushes and swingarm pivot in a solvent...

Page 158: ...5 Inspect A 1 Install Apply the lithium soap base grease onto the pivot 2 Install ear shock absorber Lower Cotterpin...

Page 159: ...3 Install section 1 Install ear shock absorber Apply the lithium soap base grease onto t bolt and oil seal lip...

Page 160: ...2 Clean lace it in solvent and brush off as much ble Then remove the chain from the solvent and lean and oil the chain an trated lace drive chain...

Page 161: ...Roller Slip off BnstalI a new driven sprocket and Is Always use new lock was I end the lock washer tabs alsn I INSTALLATION everse the removal steps ate the following points 1 Install rear wheel Refer...

Page 162: ...NOTE During reassern ly the master link clip must be installed with the rounded en facing the direc tion sf travel aTurning direction 4 Lubricate o5rive chain Chain Lube Yemaha Chain Lube or NOTE Alig...

Page 163: ...YSRSOT CIRCUIT DIAGRAM IELEC I I ELECTRICAL YSR50T CIRCUIT DIAGRAM la...

Page 164: ...Battery Oil level switch LIGHTS Dimmer switch NEUTRAL indicator light HIGH BEAM indicator light Neutral switch Headlight a Front brake switch Meter light Rear brake switch Sidestand switch TailIBrake...

Page 165: ...witch Main switch Neutral switch Ignition control unit lgnition coil Oil level switch CDl unit Rectifier Regulator Flasher relay Horn Battery Rear brake switch Fuse BATTERY I CAPACITY 6V 4AH 1 SPECIFI...

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Page 167: ...ITION AND STARTING SYSTEM IELEC 1 I S I For the color codes see page 7 2 Spark plug Ignition coil CDI magneto CDI unit ENGINE STOP switch Main switch Sidestand switch Ignition control unit Neutral swi...

Page 168: ...utral the neutral switch is on 2 The sidestand is up the sidestand switch is on I I Transmission I Sidestand Isparkt Neutral switch Sidestand switch plug Neutral close Neutral Down open IN gear close...

Page 169: ...esistance Wiring connection Entire ignition system NOTE Remove the following parts before troubleshooting 1 Lower cowling 2 Upper cowling 3 Seat 4 Side cover 5 Fuel tank Use the following special tool...

Page 170: ...PECIFICATION Ignition system is good Start the engine and increase the spark gap until misfire occurs Minimum Spark Gap 6 mm 0 24 in OUT OF SPECIFICATION OR NO SPARK I 3 Ignition circuit I Disconnect...

Page 171: ...ester 1 Lead Black White Lead Tester 1 Lead Black Lead Turn the main switch to ON and OFF Check the main switch for continuity Switch position 1 condition Oood 1 Bad condition OFF 0 x x 0 ON x 0 x 0 0...

Page 172: ...White and Black from the wire harness Connect the PocketTester 2 x 1 to the EN GINE STOP switch Tester 1 Lead Black Whie Lead Tester 1 Lead Black Lead Turn the ENGINE STOP switch to 0FF and RUN Check...

Page 173: ...Lead tSpark Plug Lead Tester Lead lgnition Coil Base J Check the secondary coil for specificated resistance 1 Secondary Coil Resistance Spark Plug Lead Coil Base 1 I BOTH MEET SPECIFICATIONS 8 Pickup...

Page 174: ...N Pickup coil is faulty replace it Disconnect the CDI magneto lead Black Red and coupler Sky blue White Black and YellowIRed from the wireharness Connect the Pocket Tester Qx100 to the source coil lea...

Page 175: ...unit is faulty replace it I section I Procedure 2 Check 1 Sidestand switch 2 Neutral switch 3 Wiring connection Entire starting system Correct I 1 Sidestand switch CORRECT Disconnect the sidestand sw...

Page 176: ...nnect the Pocket Tester 52x 1 to the neu tral switch leads Tester 1 Lead Sky blue aLead Tester 1 Lead Black Lead Bad condition Sidestand position Shift the transmission in neutral and gear Check the n...

Page 177: ...AND STARTING SYSTEM x 3 Wiring connection POOR CONNECTION Check the entire starting system for connec tions Refer to the WIRING DIAGRAM section Correct I I UCORRECT Ignition control unit is faulty re...

Page 178: ...T elow circuit diagram shows chargin...

Page 179: ...CHARGING SYSTEM IELEC I I NOTE For the color codes see page 7 2 CDl magneto RectifierIRegulator Fuse Battery...

Page 180: ...emove the following parts before troubleshooting 1 Side cover Use the following special tool s in this troubleshooting INCORRECT 1 Fuse NOCONTINUITY Connect the Pocket Tester M x 1 to the fuse Check t...

Page 181: ...3 Charging voltage Connect the Engine Tachometer to the s plug lead battery attery Ter attery B 1 Ter charging coil leads...

Page 182: ...Checkthe charging coil for speci icated resistance...

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Page 184: ......

Page 185: ...CDI magneto tifierlRegulator n switch Fuse Headlight TailIBrake light...

Page 186: ...ove the following arrs before trou ecial tool s1 in this roubleshootin Checkthe headlight for continuity...

Page 187: ...Yellow Lead When turning LIGHTS Dimmer switch to LO Tester Lead Yellow Red Lead Tester Lead Green Lead Turn the LIGHTS Dimmer switch to the HI and LO Check the LIGHTS Dimmer switch for continuity Swit...

Page 188: ...conds Standard Output a 62 7 2 at 3 000 rlmin or more OUT OF SPECIFICATION 4 Lighting coil resistance Disconnect the CDI magneto coupler Sky blue White Black and YellowIRed from the wireharness Connec...

Page 189: ...ulty replace it I POOR CONNECTION IRectifier Regulator is faulty replace it TROUBLESHOOTING 2 TAILLIGHT DOES NOT COME ON Procedure 1 Fuse 2 Battery 3 TailJBrake light bulb 4 Main switch 5 Wiring conne...

Page 190: ...llbrake light bulb Connect the Pocket Tester Oxl k to the taillbrake light bulb Tester Lead Terminal Tester Lead Terminal Tester 1 e a d e r m i n a l Tester Lead Terminal Check the taillbrake light b...

Page 191: ...Bad condition position condition GOOD CONDITION 0 OFF 5 Wiring connection I x 1 0 1 x 10 BAD CONDITION 0 Continuity x Nocontinuity Main switch is faulty replace it Check the entire lighting system fo...

Page 192: ...slow circuit diagram shows si...

Page 193: ...OTE For the color code see page 7 2 aMain switch Fuse Battery Flasher relay 0 TURN switch Flasher light Left Flasher light Right C Horn HORN switch Front brake switch Rear brake switch TailIBrake ligh...

Page 194: ...se I Remove the fuse NOCONTINUITY Connect the PocketTester Qx 1 to the fuse Check the fuse for continuity CONTINUITY Fuse is faulty replace it 2 Battery Check the battery condition Refer to the BATTER...

Page 195: ...witch I Good I Bad condition position condition OFF 1 x I O x I O 0 Continuity x Nocontinuity GOOD CONDITION BAD CONDITION IMain switch is faulty replace it I I INCORRECT 4 Wiring connection Check the...

Page 196: ...t the Pocket Tester Qx I to the HORN switch Tester 1 Lead Pink Lead Tester Lead Black Lead Check the HORN switch for continity Bad condition q Switch position HORN switch is pushed HORN switch is not...

Page 197: ...rn termi 3 Horn check II I MEETS disconnect the Pink lead at the horn terminal connect a jumper lead to the horn termi nal and ground the jumper lead nal is faulty repair HORN IS NOT SOUNDED 4 Voltage...

Page 198: ...erminal Horn is faulty replace it Tester LeadjTerminal Tester LeadjTerminal Adjust or replace horn I Check the bulb for continuity CONTINUITY EXISTS BOTH CIRCUITS CONTINUITY DOES NOT EXIST ON ONE CIRC...

Page 199: ...GOOD CONDITION 3 Voltage check Connectthe Pocket Tester DC20V to the front brake switch Tester Lead Brown Lead Tester Lead Frame Ground Check for voltage 6V on the Brown lead at the brake switch coup...

Page 200: ...to the brake switch lead Check the brake switch for continuity Switch position 1 c o n I Bad condition Rear brake is applied Rear brake X is not applied O X 0 0 Continuity x Nocontinuity 5 Voltage che...

Page 201: ...tch connector is faulty repair Check the bulb for continuity CONTINUITY TailIBrake light bulb socket is faulty replace taillbrake light assembly 2 Bulb socket check Install the bulb to the socket Disc...

Page 202: ...the TURN switch leads When turning TURN switch to R Tester Lead BrownIWhite Lead Tester 1 Lead Dark green Lead Bulb socket is faulty replace flasher light as sembly When turning TURN switch to L Teste...

Page 203: ...Tester 1 Lead tBrown Lead Tester 1 Lead Frame Ground b 0 f DCZOV u Check for voltage 6V on the Brown lead at the flasher relay terminal I I OUT OF SPECIFICATION Wiring circuit from main switch to fla...

Page 204: ......

Page 205: ...gneto RectifierIRegulator aMain switch Fuse Battery LIGHTS Dimmer switch 0 HIGH BEAM indicator light Meter light Ignition control unit Flasher relay 0 TURN switch TURN indicator light I OIL warning in...

Page 206: ...nection NOTE Remove the following parts before troubleshooting 1 Seat 2 Side cover Use the following special tool s in this troubleshooting 1 Meter light and HIGH BEAM indicator light Pocket Tester YU...

Page 207: ...ellow Lead When turning LIGHTS Dimmer switch to LO Tester Lead tYellowIRed Lead Tester Lead t Green Lead Turn the LIGHTS Dimmer switch to the HI and LO Check the LIGHTS Dimmer switch for continuity Sw...

Page 208: ...rlmin for more than 1 or 2 seconds Check the lighting coil for specificated resistance MEETS SPECIFICATION 0 Bulb socket is faulty replace it 4 Lighting coil resistance Disconnect the CDI magneto cou...

Page 209: ...PECIFICATION 0 16 0 24 at 20 C 68OF I I MEETS 1 5 Wiring connection YellowIRed Black I Lighting coil is faulty replace it Check the entire display system for connec tions Refer to the WIRING DIAGRAM s...

Page 210: ...1 Fuse I NOCONTINUITY Remove the fuse Connect the Pocket Tester Qx 1 to the fuse i Check the fuse for continuity Fuse is faulty replace it CONTINUITY 1 2 Battery I Check the battery condition Refer to...

Page 211: ...tch I Oood I Bad condition position condition IGOOD CONDITION ON OFF 4 Wiring connection Check the entire display system for connec tions Refer to the WIRING DIAGRAM section CORRECT BAD CONDITION 0 Co...

Page 212: ...x l k to the bulb Tester Lead Terminal Tester 1 Lead Terminal Check the bulb for continuity 2 Neutral switch check Disconnect the CDI magneto coupler Sky blue White Black and YellowIRed from the wireh...

Page 213: ...is faulty replace it I I Tester 1 LeadhBrown Lead Tester Lead Frame Ground Gear Q 1EVT2 S b Y B B Y Sb D Ch L L Ch Dg x 1 0 1 x 0 BAD CONDITION Bad condition 0 Continuity x Nocontinuity 3 Wireharness...

Page 214: ...he meter coupler Battery Lead Brown Lead Battery 1 Lead Black Red Lead I1INDICATOR LIGHT I I COMES ON 2 Oil level switch check 1 Remove the oil level switch from the oil tank Connect the Pocket Tester...

Page 215: ...for continuity Switch position Good 1 Bad condition condition Upright position Up side down position 0 Continuity x Nocontinuity II GOOD 4 V CONDITION 4 Voltage check Connect the Pocket Tester DC2OV t...

Page 216: ...t from main switch to OIL warn ing indicator light connecter is faulty repair Check the bulb for continuity I I Wiring connection is faulty correct I 2 TURN switch check Disconnect the handlebar switc...

Page 217: ...ck Connect the Pocket Tester DC20V to the flasher relay Tester Lead Brown Lead Tester Lead Frame Ground u Check for voltage 6V on the Brown lead at the flasher relay terminal MEET SPECIFICATION 6V BAD...

Page 218: ......

Page 219: ...BLE CAUSE rlanky Empty Clogged fuel filter Clogged air passage Fuel tank cap Deteriorated fuel or fuel containing water or foreign material tFuel cock Clogged fuel hose Deteriorated fuel fuel containi...

Page 220: ...ulty spark plug cap Ignition coil Broken or shorted primarylsecondary Faulty spark plug lead Broken body C D I unit system 7 Faulty C D I unit Faulty source coil Faulty pick up coil Broken woodruff ke...

Page 221: ...ing Seized piston ring Seized or damaged piston tCrankcase and crankshaft Improperly seated crankcase Improperly sealed crankcase Damagedoil seal Seized crankshaft Reed valve Deformed reed valve stopp...

Page 222: ...er or foreign material Sucked in air Deformed float Groove worn needle valve Improperly sealed valve seat Improperly set clip position of jet needle Improperly adjusted fuel level Clogged or loose mai...

Page 223: ...zed cylinder Piston and piston ring Improperly installed piston ring Worn fatigued or broken piston ring Seized piston ring Seized or damaged piston Crankcase and crankshaft Improperly seated crankcas...

Page 224: ...gh viscosity Deterioration CHANGE PEDAL DOES NOT MOVE PROBABLE CAUSE tShift shaft Improperly adjusted shift rod Bent shift shaft tShift cam and shift fork Groove jammed with impurities Seized shift fo...

Page 225: ...Transmission oil Low oil level Improper quality Low viscosity Deterioration CLUTCH DRAGGING I Clutch PROBABLE CAUSE Improperly adjusted clutch cable Improperly adjusted pull lever position elmproper e...

Page 226: ...ick clip Seized kick gear Seized kick idle gear tTransmission oil Improper quality High viscosity Deterioration Cylinder piston and piston ring T Damaged or seized cylinder Damaged or seized piston Da...

Page 227: ...position Improper brake shoe position Fatigued orldamaged return spring Oily or greasy brake shoe Rusty oily or greasy brake drum Broken brake cable FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION O...

Page 228: ...ng adjuster position Broken spring Twisted front forks Tires tr Uneven tire pressures on both sides Incorrect tire pressure Unevenly worn tires Wheels T rlncorrect wheel balance Deformed cast wheel Lo...

Page 229: ...light switch Bulb life expired BULB BURNT OUT PROBABLE CAUSE Improper bulb Faulty battery Faulty rectifierlregulator Improperly grounded Faulty main and or light switch Bulb life expired FLASHER DOES...

Page 230: ...nsufficient battery capacity nearly discharged Improper bulb Faulty main and or flasher switch PROBABLE CAUSE FLASHER WINKS QUICKER Improper bulb Faulty flasher relay HORN IS INOPERATIVE PROBABLE CAUS...

Page 231: ...it Fuel system Improper carburetor main jet Improper setting Improperly adjusted fuel height Clogged air cleaner element Lean mixture Faulty autolube pump settings tCompression system Heavy carbon bui...

Page 232: ......

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Yamaha YSR50T, Service Manual

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