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Yamaha YW50AP, Service Manual

The Yamaha YW50AP Service Manual is a comprehensive guide that enables users to efficiently maintain and repair their Yamaha YW50AP. This manual can be easily downloaded for free from manualshive.com, providing users with detailed instructions and invaluable insights to ensure optimal performance and longevity for their Yamaha YW50AP.

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4-25

ENG

Order

6
7
8
9

10
11

Job name/Part name

Gear boss
Bearing
Starter wheel gear
Plate washer
Starter motor
Starter motor coupler

Q’ty

1
1
1
1
1
2

Remarks

Reverse  the  removal  procedure  for
instalation

STARTER CLUTCH AND STARTER MOTOR

11

10

8

7

6

5

4

3

2

1

New

13Nm(1.3m.kg, 9.4 ft.lb)

T

 

R

.

.

8Nm(0.8m.kg, 5.8 ft.lb)

T

 

R

.

.

9

LS

Summary of Contents for YW50AP

Page 1: ...YW50AP 5PJ F8197 10 LIT 11616 15 39 ...

Page 2: ... 2001 by Yamaha Motor Corporation U S A First edition November 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited P N LIT 11616 15 39 ...

Page 3: ...ll of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety A...

Page 4: ...p of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub sec tion title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indi c...

Page 5: ...0 Filling fluid q Lubricant w Special tool e Tightening torque r Wear limit clearance t Engine speed y Electrical data Symbols u to s in the exploded diagrams in dicate the types of lubricants and lubrication points u Engine oil i Gear oil o Molybdenum disulfide oil p Wheel bearing grease a Lithium soap base grease s Molybdenum disulfide grease Symbols d to f in the exploded diagrams indicate the ...

Page 6: ...INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING 1 2 3 4 5 6 7 8 ...

Page 7: ...IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING OF CONNECTIONS 1 4 HOW TO USE THE CONVERSION TABLE 1 5 CONVERSION TABLE 1 5 SPECIAL TOOLS 1 6 ...

Page 8: ...NE 2 4 TIGHTENING TORQUES 2 6 ENGINE 2 6 MAINTENANCE SPECIFICATION 2 7 CHASSIS 2 7 TIGHTENING TORQUES 2 8 CHASSIS 2 8 MAINTENANCE SPECIFICATION 2 9 ELECTRICAL 2 9 GENERAL TORQUE SPECIFICATIONS 2 11 LUBRICATION POINTS AND LUBRICATION TYPE 2 12 ENGINE 2 12 CHASSIS 2 13 CABLE ROUTING 2 14 ...

Page 9: ...ASSIS 3 15 FRONT BRAKE LEVER FREE PLAY CHECK 3 15 REAR BRAKE LEVER FREE PLAY CHECK 3 15 BRAKE PAD INSPECTION 3 15 BRAKE SHOE INSPECTION 3 16 BRAKE FLUID LEVEL INSPECTION 3 16 AIR BLEEDING HYDRAULIC BRAKE SYSTEM 3 17 STEERING ADJUSTMENT 3 18 TIRE INSPECTION 3 19 WHEEL INSPECTION 3 22 FRONT FORK INSPECTION 3 22 REAR SHOCK ABSORBER INSPECTION 3 22 SEAT LOCK CABLE ADJUSTMENT 3 22 CABLE CHECKING AND LU...

Page 10: ...SHEAVE REMOVAL 4 16 CLUTCH INSPECTION 4 17 V BELT INSPECTION 4 18 PRIMARY SHEAVE INSPECTION 4 19 SECONDARY SHEAVE 4 20 SECONDARY SHEAVE INSTALLATION 4 21 PRIMARY SHEAVE 4 22 STARTER CLUTCH AND STARTER MOTOR 4 24 STARTER CLUTCH AND STARTER MOTOR 4 24 STARTER CLUTCH AND GEARS INSPECTION 4 26 C D I MAGNET 4 27 C D I MAGNETO 4 27 C D I MAGNETO REMOVAL 4 28 C D I MAGNETO INSTALLATION 4 28 AUTOLUBE PUMP...

Page 11: ...HAPTER 5 CARBURETION CARBURETION 5 1 CARBURETOR 5 1 CABURETOR DISASSEMBLY 5 2 CABURETOR INSPECTION 5 3 CARBURETOR ASSEMBLY 5 5 FUEL LEVEL ADJUSTMENT 5 6 AUTO CHOKE INSPECTION 5 7 FUEL COCK INSPECTION 5 8 ...

Page 12: ...INSTALLATION 6 15 CALIPER 6 17 CALIPER DISASSEMBLY 6 18 BRAKE CALIPER DISASSEMBLY 6 19 CALIPER INSPECTION 6 19 BRAKE CALIPER ASSEMBLY 6 20 BRAKE CALIPER INSTALLATION 6 20 REAR WHEEL AND REAR BRAKE 6 21 REAR WHEEL 6 21 REAR BRAKE 6 22 REAR WHEEL INSPECTION 6 23 REAR BRAKE INSPECTION 6 23 REAR BRAKE INSTALLATION 6 24 HANDLEBAR 6 25 HANDLEBAR 6 25 HANDLEBAR INSTALLATION 6 27 STEERING 6 29 STEERING 6 ...

Page 13: ...7 CHECKING THE CONDITION OF THE BULB SOCKETS 7 8 IGNITION SYSTEM 7 9 CIRCUIT DIAGRAM 7 9 TROUBLESHOOTING 7 10 CHARGING SYSTEM 7 14 CIRCUIT DIAGRAM 7 14 TROUBLESHOOTING 7 15 ELECTRIC STARTING SYSTEM 7 18 CIRCUIT DIAGRAM 7 18 TROUBLESHOOTING 7 19 STARTER MOTOR 7 22 STARTER MOTOR DISASSEMBLY 7 23 INSPECTION AND REPAIR 7 24 LIGHTING SYSTEM 7 26 CIRCUIT DIAGRAM 7 26 TROUBLESHOOTING 7 27 LIGHTING SYSTEM...

Page 14: ...8 4 CLUTCH OUT FAILURE 8 4 POOR STANDING START LOW CLIMBING ABILITY 8 4 POOR ACCELERATION POOR HIGH SPEED 8 4 OVER HEAT 8 5 OVERHEAT 8 5 POOR SPEED 8 5 POOR SPEED 8 5 IMPROPER KICKING 8 6 SLIPPING 8 6 HARD KICKING 8 6 KICK CRANK NOT RETURNING 8 6 FAULTY BRAKE 8 7 POOR BRAKING EFFECT 8 7 MALFUNCTION 8 7 INSTABLE HANDLING 8 8 INSTABLE HANDLING 8 8 FAULTY SIGNAL AND LIGHTING SYSTEM 8 9 HEADLIGHT DARK...

Page 15: ...VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame EAS00018 MODEL CODE The model code label 1 is affixed to the loca tion shown in the figure Record the informa tion on this label in the space provided This information will be needed to order spare parts 1 1 ...

Page 16: ...nd allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS00022 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace a...

Page 17: ... Oil bearings liberally when installing if appro priate 1 Oil seal cC Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned ...

Page 18: ... that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the con nector 6 Connect 8 Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE 8 If there is no continuity clean the termi nals 8 Be sure to perform the steps 1 to 7 listed above when checking the wireharness 8 For a field remedy use a contact revitalizer a...

Page 19: ...C TO IMP Known Multiplier Result 7 233 86 794 0 0723 0 8679 2 205 0 03527 0 6214 0 6214 3 281 1 094 0 3937 0 03937 0 03527 0 06102 0 8799 0 2199 55 997 14 2234 9 5 C 32 ft lb in lb ft lb in lb lb oz mph mi ft yd in in oz IMP liq cu in qt IMP liq gal IMP liq lb in psi lb in2 Fahrenheit F Torque Weight Distance Volume Capacity Miscellaneous m kg m kg cm kg cm kg kg g km h km m m cm mm cc cm3 cc cm3 ...

Page 20: ...ssem bly the secondary pulley Crankshaft Installation set 1 Adapter 2 These tools are used to install the crank shaft Flywheel puller This tool is used for removing the rotor Crankcase Separating tool This tool is used to remove the crankshaft or separate the crankcase Oil seal guide This tool is used for protecting the oil seal lip when installing the secondary sliding sheave Steering nut wrench ...

Page 21: ...alant is used to seal to mating sur faces e g crankcase mating sur faces Locknut wrench This tool is used to loosen and tighten the clutch carrier locknut of the secondary sheave Front fork seal driver Weight 1 Adapter 2 These tools are used when installing the fork seal T handle 1 Damper rod holder 2 These tools are needed to loosen and tighten the damper rod holding bolt Fuel level gauge This ga...

Page 22: ...lmp qt 0 12 US qt 0 13 L 0 11 lmp qt 0 13 US qt Wet type element Regular unleaded gasoline 5 7 L 1 25 lmp gal 1 5 US gal Y14P 1 TEIKEI GENERAL SPECIFICATION SPECIFICATION GENERAL SPECIFICATION Model Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight With oil and full fuel tank Engine Engine type Cylin...

Page 23: ...shock absorber Rear shock absorber Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Generator system Battery type Battery capacity YW50A BPR7HS NGK 0 6 0 7 mm 0 02 0 03 in Dry Centrifugal automatic Helical gear 4 000 Supur gear 3 666 V belt Automatic Steel tube underbone 26 5 93mm 3 7 in Tubeless 120 90 10 130 90 10 CHENG SHIN CHENG SHIN 56J 59J 143 kg 315 lb 200kpa 2 0...

Page 24: ...tity Headlight Tail brake light Flasher light Licence plate light Meter light High beam indicator light Oil indicator light Turn indicator light YW50A Bulb 12V 35W 35W 2 12 V 5W 21W 1 10W 4 5W 1 3 4W 1 1 7W 1 1 7W 1 1 7W 1 1 7W 1 GENERAL SPECIFICATION ...

Page 25: ...NTENANCE SPECIFICATION ENGINE Item Cylinder head Warp limit Lines indicate straightedge measurement Cylinder Bore size Taper limit Out of round limit Piston Piston to cylinder clearance Piston size D Measuring point H Piston pin bore inside diameter Piston pin outside diameter Piston Ring Sectional Sketch B T Type Top Ring 2nd Ring End Gap Installed Top Ring 2nd Ring Side Clearance Installed Top R...

Page 26: ...e V S Starter Jet G S Float Height Fuel level height Engine Idling Speed Reed Valve Thickness Valve Stopper Height Valve bending limit Standard 37 90 37 95 mm 1 49 1 49 in 0 03 mm 0 0012 in 0 2 0 5 mm 0 0029 0 020 in 0 4 0 8 mm 0 016 0 031 in 4 0 mm 0 16 in 105 mm 4 13 in 94 mm 3 7 in 3 300 3 700 r min 5 500 6 500 r min 16 6 mm 0 65 in Ratchet type 1 5 2 5 N 0 15 0 25 kgf 0 34 0 56 lb 5DA 01 80 2 ...

Page 27: ... cover 1 left Bolt case2 Crankcase cover2 left Drain bolt Oil plug Idle gear plate Kick crank Starter motor Clutch housing Clutch weight Magnet base C D I rotor Nut Stud bolt Screw Screw Screw Screw Bolt Screw Screw Screw Bolt Bolt Screw Bolt Bolt Bolt Screw Bolt Bolt Plug Screw Bolt Bolt Nut Nut Screw Nut M 14 M 7 M 7 M 6 6 0 M 6 M 5 M 6 M 6 M 4 M 6 M 8 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 8 M 14 M 6 M ...

Page 28: ...ide diameter Brake fluid type Rear drum brake Type Drum inside diameter Shoe thickness Brake lever Brake lever free play front at lever side Brake lever free play rear Throttle cable free play Standard Ball and race bearing 22 pcs 19 pcs 70 mm 2 8 in 236 6 mm 9 31 in 212 1 mm 8 35 in 15 68 Nm mm 1 6 kg mm 90lb in 23 5 Nm mm 2 43 kg mm 136lb in 55 mm 2 2 in 281 8 mm 11 1 in 159 8 mm 6 29 in 71 15 N...

Page 29: ...ng shaft Brake hose and master cylinder Fuel tank Fuel cock Fuel sender Box Seat lock assembly Plastic parts cover Footrest board Front wheel axle and nut Rear wheel axle and nut Rear brake cam lever Front brake caliper and front fork Brake disc and hub Brake hose and caliper Brake caliper and bleed screw M 12 M 10 M 6 M 10 M 8 M 25 M 10 M 8 M 6 M 6 M 5 M 6 M 6 M 5 M 6 M 10 M 14 M 6 M 8 M10 M 8 M ...

Page 30: ... timing Ignition timing B T D C Advanced type C D I Pickup coil resistance color Source coil resistance color C D I unit model manufacturer Ignition coil Model manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Spark plug cap Type Resistance Charging System Type C D I Magneto Model Manufacturer Nominal output Charging current Charging voltage Charging Coil Resis...

Page 31: ...Flasher frequency Fuel gage Model manufacturer Sender unit resistance full empty Oil level gauge Model manufacturer Circuit breaker Type MAIN Standard 4KP Asian 1 5A Capacitor 60 120 Cycle min 4VP San Chu 4 10 Ω 90 100 Ω 4VP Lun Ping Fuse 7Ax1pc limit MAINTENANCE SPECIFICATION ...

Page 32: ...sections of this book To avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specified torque specifica tions call for clean dry threads Components should be at room temperature A Distance across flats B Outside thread diameter A B A Nut 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm B Bolt 6 mm 8 mm 10 mm 12 mm 14 mm 16 ...

Page 33: ...ant Type LS LS LS E E G G G M Lubrication Point Oil seal lips O rings Bearings Piston surface Piston pin Cylinder Transmission case bearing Autolube pump Starter wheel gear Idle gear plate Secondary drive gear Kickstarter pinion gear Drive axle Pump drive gear Main axle Main axle bearing E E LS LS M LS G ...

Page 34: ...ips O rings Bearings Speedometer drive gear Front brake camshaft Front brake cable Throttle cable Tube guide throttle grip inner surface Upper steering stem ring nut Upper bearing outer race Lower bearing outer race Rear brake camshaft Centerstand CHASSIS LS LS LS LS LS LS LS LS LS LS LS LS LS ...

Page 35: ...f front fender then through the guide B Pass the wire harness through the inside of ignition coil C Secure the ground lead and the ignition coil base to the ignition coil stay D Pass the wire harness through the inside of oil tank E Pass the seat cable through the inside of frame F Align the clip with the white brand G Clamp the wire harness H Insert the seat cable through the frame tube I Clamp w...

Page 36: ... Flasher relay 9 Fuel tank breather hose 0 Fuel hose q Breather hose A Pass the brake hose through the holder B Insert the fuel overflowhose bottom C Pass the fuel overflowhose through the rear fender hole D Pass the fuel overflowhose through the holder E Hold the fuel overflowhose with a clamp F Pass the brake cable through the holder 6 0 q 2 1 5 4 7 3 9 8 ...

Page 37: ...Brake hose 2 Front fender 3 Front fork assembly 4 Nut 5 Plate washer 6 Brake hose holder 7 Flange bolt 8 Bolt 9 Brake hose holder 0 Flange bolt A Pass the brake hose through the holder 1 2 3 3 7 5 4 5 6 8 6 1 9 0 3 1 7 5 1 5 4 A ...

Page 38: ...ter securing starter relay leads C Pass the seat lock cable through the hole of bracket D Pass the fuel tank breath hose over seat lock cable E Clamp carburetor vacuum hose fuel hose and fuel cock vacuum hose F Clamp autochoke leads and autolube hose on to carbure tor throttle cable G Pass the battery leads over frame member H Put fuse box on to footrest board holder I Pass throttle cable1 3 wireh...

Page 39: ...rottle cable1 9 Throttle cable 3 0 Front flasher leads A Pass brake cable through the slot of bracket B Avoid clamping front flasher leads when in stalling handlebar covers C Pass throttle cable1 3 through between handlebar and wireharness D Hang the wireharness bind on to the bracket CABLE ROUTING 1 8 9 6 5 D C 2 3 0 4 A B 7 5 6 7 9 8 3 ...

Page 40: ...eck operation fluide level and vehicle for fluid leakage Replace brake pads Check operation Adjust brake lever free play Replace brake shoes Check balance runout and for damage Replace if necessary Check tread depth and for damage Replace if necesssary Check air pressure Correct if necessary Check Bearing for looseness or damage Replace if necessary Check bearing play and steering for roughness Lu...

Page 41: ...ever comes first 3 000 km 2 000 mi or 6 months whichever comes first NO INITIAL 1 000 km 600 mi Every 12 000 km 8 000 mi or 24 months whichever occurs first Every 9 000 km 6 000 mi Check operation Lubricate with lithium soap base greese all purpose grease Check operation and for oil leakage Check operation and shock ab sorber for oil leakage Replace shock absorber assembly if necessary Check engin...

Page 42: ...r Right side cover Center cover COVER AND PANEL SIDECOVER AND SEAT Remarks Remove the parts in order NOTE Insert the screwdriver into the slot of battery cover and pickup then remove Reverse the removal procedure for instal lation Order 1 2 3 4 5 6 7 8 Q ty 1 1 1 1 1 1 1 1 COVER AND PANEL 2 7 8 1 6 4 3 5 T R 13Nm 1 3 m kg 9 4ft lb ...

Page 43: ...b name part name Lower cowling upper cover leg shield 1 2 and footrest board re moval Lower cowling Upper cover Leg shield 1 Main switch cover leg shield 2 Battery Footrest board Remarks Remove the parts in order Reverse the removal procedure for instal lation COVER AND PANEL 3 2 4 5 6 1 T R 7Nm 0 7m kg 5 1ft lb ...

Page 44: ... Q ty 2 1 1 1 1 Job name Part name Handlebar cover Front and Rear re moval Mirrors Front handlebar cover Rear handlebar cover Flasher light Left Right Remarks Remove the part in order Reverse the removal procedure for instal lation COVER AND PANEL 1 4 2 4 3 1 ...

Page 45: ...enterstand for safety 3 Attach 8 Inductive tachometer 1 To the spark plug lead Inductive tachometer YU 8036 A 4 Check 8 Engine idle speed Out of specification Adjust Engine idle speed 1 750 1 850 r min 5 Adjust 8 Engine idle speed Adjustment steps 8 Turn the throttle stop screw 1 in or out until specified idle speed is obtained Turn in Idle speed becomes higher Turn out Idle speed becomes lower ...

Page 46: ... adjuster cover 1 8 Loosen the locknut 2 on the throttle cable 8 Turn the adjuster 3 in or out until the speci fied free play is obtained Turning in Free play is increased Turning out Free play is decreased 8 Tighten the locknuts 8 Install the adjuster cover w After adjusting the throttle cable free play start the engine and turn the handlebar to the right and to the left to ensure that this does ...

Page 47: ...g out until air bubbles dis appear 8 When air bubbles are expelled completely tighten the bleed screw NOTE Check the bleed screw gasket If damaged re place with a new one Place a oil pan under the autolube pump to catch oil 3 Air bleeding 8 Pump distributor and or delivery hose Air bleeding steps 8 Start the engine 8 Run the engine for 2 3 minutes at 2000 r min This will completely remove autolube...

Page 48: ...ect 8 Electrode 1 Wear Damage Replace 8 Insulator 2 Abnormal color Replace Normal color is a medium to light tan color 4 Clean the spark plug with a spark plug cleaner or wire brush 5 Measure 8 Plug gap a Use a wire gauge or feeler gauge Out of specification Regap Spark plug gap 0 6 0 7 mm 0 02 0 03 in 6 Tighten 8 Spark plug 20 Nm 2 0 m kg 14 ft lb 7 Install 8 Battery box cover ...

Page 49: ... 23 lmp qt 1 48 US qt NOTE Install the oil tank filler cap 1 and push it fully into the filler Engine oil level visual inspection steps Turn main switch to position OIL indicator light does not comes on Inspect faulty electrical circuit light bulbs etc OIL indicator light comes on Turn main switch to ON position OIL indicator light does not come on Engine oil level and elec trical circuit are OK O...

Page 50: ...nstall 8 Drain bolt 18 Nm 1 8 m kg 13 ft lb 6 Fill 8 Transmission case Recommended oil Yamalube 4 SAE 10W 30SE or GL gear oil Oil capacity Total amount 0 13 L 0 11 lmp qt 0 13 US qt Periodic oil change 0 11 L 0 096 lmp qt 0 12 US qt cC 8 Always use the same type of oil mixing oils may result in a harmful chemical re action and lead to poor performance 8 Do not allow foreign material to enters the ...

Page 51: ... air to enter causing rapid wear and possible en gine damage Additionally operation without the cleaner element will affect carburetor jet ting with subsequent poor performance and possible engine overheating Be careful not to have rags or the like blocking the intake area of the air filter 5 Inspect 8 Element 1 Damage Replace 6 Clean 8 Air filter element Air filter element cleaning steps 8 Wash t...

Page 52: ...or explosion 8 Squeeze the excess solvent out of the ele ment and let dry cC Do not twist the element when squeezing the element 8 Apply the foam air filter oil or engine oil 8 Squeeze out the excess oil NOTE The element should be wet but not dripping 7 Install 8 Air filter 8 Battery box cover AIR FILTER ELEMENT CLEANING ...

Page 53: ...mary and second ary sheaves Refer to ENGINE OVERHAUL INSPEC TION AND REPAIR section in the CHAP TER 4 3 Measure 8 V belt width a Out of specification Replace Refer to ENGINE OVERHAUL section in the CHAPTER 4 V belt width 16 6 mm 0 65 in Limit 14 6 mm 0 57 in NOTE Measure the V belt width on several points 4 Install 8 Crankcase cover 1 left 12Nm 1 2m kg 8 4 ft lb 8 Air cleaner 9Nm 0 9m kg 6 5 ft lb...

Page 54: ...ident Inspect and bleed the system if necessary FRONT BRAKE LEVER FREE PLAY CHECK REAR BRAKE LEVER FREE PLAY CHECK BRAKE PAD INSPECTION a 1 1 1 3 2 REAR BRAKE LEVER FREE PLAY CHECK 1 Check 8 Rear brake lever free play a Out of specification Adjust 10 20 mm 0 39 0 79 in Rear brake lever free play adjustment steps 8 Turn the adjuster 1 in or out until the cor rect free play is obtained BRAKE PAD INS...

Page 55: ...y corrode painted surfaces or plas tic parts Always clean up spilled fluid imme diately w 8Use only the designated quality fluid Other wise the rubberseals may deteriorate caus ing leakage and poor brake performance 8Refill with the same type of fluid Mixing flu ids may result in a harmful chemical reaction leading to poor brake performance 8Be careful that water does not enter the mas ter cylinde...

Page 56: ...e other end of the tube into a con tainer e Slowly apply the brake lever several times f Pull the lever in Hold the lever in posi tion g Loosen the bleed screw and allow the le ver to travel towards its limit h Tighten the bleed screw when the limit has been reached then release the lever i Repeat steps e to h until the air bubbles have been removed from the system j Add brake fluid to proper leve...

Page 57: ... so that they form a right angle 8 Loosen the ring nut 3 1 1 4 turn 8 Install rubber ring 2 and ring nut 2 3 then tighten the ring nut 2 until it contacts with rubber ring cC Aligning the slot of ring nut 2 with the slot of ring nut 3 If not slightly tighten ring nut 2 un til the slots alignment 8 Install special washer 4 NOTE Insert the projections of special washer into the slots of ring nut 3 2...

Page 58: ...OOTER TIRE INSPECTION Basic weight with oil and a full uel tank Maximum load Cold tire pres sure Total of cargo rider passenger and acces sories w It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit re place the tire immediately FRONT Manufacturec Size Type CHENG SHIN 120 90 10 56J REAR Manufacturec Size Type CHENG SHIN 130 90 10 59J Front 200 kpa 2 0 kgf cm2 29...

Page 59: ...atching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replace ment A Tire B Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire 8 After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by ...

Page 60: ...til they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 8 Install the tire with the mark pointing in the direction of wheel rotation 8 Align the mark 2 with the valve installation point ...

Page 61: ...e Replace inner tube comp fork ass y Grease leakage Replace inner tube comp fork ass y Unsmooth operation Replace fork ass y REAR SHOCK ABSORBER INSPECTION 1 Inspection 8 Rear shock absorber1 Oil leaks Damage Replace 2 Check 8 Tightening torque Upper nut 30Nm 3 0 m kg 22ft lb Lower bolt 16 Nm 1 6 m kg 12ft lb SEAT LOCK CABLE ADJUSTMENT 1 Remove 8 Upper cover Refer to COVER AND PANEL section 2 Adju...

Page 62: ...mmended lubricant Engine oil or a suitable cable lubri cant NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device EAS00171 LEVERS LUBRICATING Lubricate the pivoting point and metal to metal moving parts of the levers Recommended lubricant Lithium soap base grease EAS00173 CENTERSTAND LUBRICATING Lubricate the pivoting point and...

Page 63: ...to operate regularly 8The charging time charging current and charging voltage for the MF battery is differ ent than general type batteries The MF battery should be charged as in structed in the Charging method Should the battery be overcharged the electrolyte level will lower extremely Therefore use special care when charging the battery 8Avoid using any electrolyte other than speci fied The speci...

Page 64: ...n Wash with water 8 Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL 8 Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion 3 Check 8 Battery condition Battery condition checking steps 8 Connect a digital volt meter to the battery ter minals Tester lead Battery terminal Tester lead Batt...

Page 65: ... it from the motorcycle If charging has to be done with the battery mounted on the motorcycle for some reason be sure to dis connect the wire at the negative terminal 8Never remove the sealing plug from the MF battery 8Use special care so that charging clips are in a full contact with the terminal and that they are not shorted A corroded clip of the charger may cause the battery to generate heat a...

Page 66: ... check if the standard charging current is reached If current does not exceed stan dard charging current after 5 minutes replace the battery In case that charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current NOTE Voltage should be measured 30 minu...

Page 67: ...rd charging current written on the battery Charge the battery until the battery s charging voltage is 15 volts Check the open circuit voltage after hav ing left the battery for 30 minutes after charging 12 8 V or more Charging is complete 12 7 V or less Recharging is neces sary Under 12 V Replace the battery This type of battery charger Can not charge the MF battery A variable voltage charger is r...

Page 68: ... question w Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the lighting and ignition systems to mal function and could possibly cause a fire Description Amperage Quantity Main 7A 1 4 Install 8 Fuse 8 Battery box cover 4 Inspect 8 Battery terminal Dirty terminal ...

Page 69: ...PLACEMENT 1 Remove 8 Upper cover Refer to COVER AND PANEL section HEADLIGHT BEAM ADJUSTMENT HEADLIGHT BULB REPLACEMENT 1 2 Disconnect 8 Headlight coupler 1 3 Remove 8 Bulb holder cover 2 1 2 2 1 2 4 Remove 8 Headlight bulb holder 1 Turn the bulb holder counterclockwise to remove it 5 Remove 8 Bulb defective 2 w Since the headlight bulb gets extremely hot keep flammable products and your hands away...

Page 70: ...ead light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely af fected If the headlight bulb gets soiled thor oughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Install 8 Bulb holder 8 Turn the bulb holder clockwise to install it 8 Install 8 Bulb holder cover 9 Connect 8 Headlight coupler 10 Insta...

Page 71: ...EPLACEMENT 1 Remove 8 Screws 1 8 Lens 2 2 Replace 8 Bulb defective 3 3 Install 8 Lens 2 8 Screws 1 cC Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely af fected If the headlight bulb gets soiled thor oughly clean it with a cloth moistened with alcohol or lacquer thinner...

Page 72: ...CHAPTER 3 Refer to CARBURETOR section in CHAPTER 6 Job name Part name Wireharness and cables removal Rear carrier Tail cover Left side panel Right side panel Battery box cover Center cowling Air filter case Carburetor Air shroud 1 Autolube delivery hose Order 1 2 Q ty 1 1 45Nm 4 5 m kg 31ft lb T R 12 1 8 4 3 5 13 2 6 10 9 11 7 120Nm 12 0 m kg 87 ft lb T R ...

Page 73: ...s coupler Starter motor leads coupler Rear wheel nut Rear brake adjuster Rear brake cable Pin Bolt Engine mount bolt Engine Q ty 1 1 1 1 1 1 1 1 1 1 1 Remarks NOTE Loosen the rear wheel nut Reverse the removal procesure for instal lation 45Nm 4 5 m kg 31ft lb T R 12 1 8 4 3 5 13 2 6 10 9 11 7 120Nm 12 0 m kg 87 ft lb T R ...

Page 74: ...t Cylinder Piston pin clip Piston pin Bearing Piston Piston ring set Cylinder gasket Remarks Remove the parts in the order Refer to the ENGINE REMOVAL sec tion Reverse the removal procedure for in stallation Order 1 2 3 4 5 6 7 8 9 10 Q ty 1 1 1 1 1 1 1 2 1 1 1 1 1 4 5 6 7 10 1 2 3 26Nm 2 6 m kg 18 2 ft lb T R 14Nm 1 4 m kg 10 ft lb T R 9Nm 0 9 m kg 6 5 ft lb T R New New New E 8 9 CYLINDER HEAD CY...

Page 75: ... out CYLINDER HEAD INSPECTION 1 Eliminate 8 Carbon deposits Use a rounded scrapper 1 2 Inspect 8 Cylinder head warpage Out of specification Re surface Warpage measurement and re surfacement steps 8 Attach a straight edge 1 and a thickness gauge 2 on the cylinder head 8 Measure the warpage limit Warpage limit 0 03 mm 0 0012 in 8 If the warpage is out of specification reface the cylinder head NOTE R...

Page 76: ...rkes and lacquer deposits From the sides of piston 5 Inspect 8 Piston wall Wear Scratches Damage Replace 6 Measure 8 Piston to cylinder clearance Piston to cylinder clearance measurement steps First step 8 Measure the cylinder bore C with a cylin der bore gauge NOTE Measure the cylinder bore C in parallel to and at right angles to the crankshaft Then find the average of the measurements CYLINDER A...

Page 77: ...ameter p with a micrometer a 10 mm from the piston bottom edge Piston size P 39 958 39 972 mm 1 5731 1 5737 in 8 If out of specification replace piston and pis ton rings as a set 3rd step 8 Calculate the piston to cylinder clearance with following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter p 8 If out of specification rebore or replace cyl inder and replace piston an...

Page 78: ...ication Replace piston and or rings Use a feeler gauge 1 Top ring 0 03 0 05 mm 0 1 mm 0 0012 0 002 in 0 0039 in 2nd ring 0 03 0 05 mm 0 1 mm 0 0012 0 002 in 0 0039 in Standard Limit 2 Install 8 Piston ring Into the cylinder Push the ring with the piston crown 3 Measure 8 End gap Out of specification Replace rings as a set Use a feeler gauge 1 a Top ring 0 15 0 35 mm 0 6 mm 0 005 0 01 in 0 02 in 2n...

Page 79: ...de diameter piston pin Piston pin to piston clearance 0 004 0 019 mm 0 0016 0 00075 in Limit 0 07 mm 0 003 in 4 Inspect 8 Bearing piston pin Pitting Damage Replace PISTON PIN AND PISTON INSTALLATION 1 Apply 8 Engine oil to the crankshaft bearing connecting rod big end bearing small end bearing piston pin piston ring grooves and pis ton skirt areas 2 Install 8 Reed valve gasket 8 Reed valve 8 Carbu...

Page 80: ...drop the pin clip mate rial into the crankcase 8 Always use a new piston pin clip CYLINDER AND CYLINDER HEAD 1 Install 8 Cylinder gasket new gasket 2 Check 8 Piston rings 1 1st ring 2 2nd ring NOTE Make sure the ring ends 1 are properly fitted around the ring locating pins 3 in the piston grooves CYLINDER HEAD CYLINDER AND PISTON 3 Install 8 Cylinder 1 NOTE Install the cylinder with one hand while...

Page 81: ...sket new gasket 5 Install 8 Cylinder head 1 14Nm 1 4m kg 10ft lb 8 Spark plug 2 20Nm 2 0m kg 14ft lb 8 Air shroud NOTE Tighten the cylinder head holding nuts in stage using a crisscross pattern 1 2 T R T R CYLINDER HEAD CYLINDER AND PISTON ...

Page 82: ... name Kick starter and crankcase cover left removal Kick starter Crankcase cover 2 left Crankcase cover 1 left Gasket Pin V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE KICK STARTER AND CRANKCASE COVER LEFT 1 12Nm 1 2m kg 8 4 ft lb T R 3 4 5 New 90Nm 0 9m kg 6 5 ft lb T R 2 7Nm 0 7m kg 5 1 ft lb T R ...

Page 83: ...ND SECONDARY PRIMARY SHEAVE Job name Part name Kick starter removal Crankcase cover 1 left removal Kickstarter pinion gear Kickstarter pinion gear clip Circlip Plain washer Kickstarter segment gear Return spring Collar Remarks Remove the parts in order Reverse the removal procedure for in stallation New 1 2 4 5 3 6 LS ...

Page 84: ... 3 8 Plain washer 4 8 Circlip 5 Installation steps a Install return spring 6 and segment gear 7 as shown b Install clip 5 c Hook the spring onto the crankcase pro jection 8 d Install the kick starter pinion gear 9 and the kick starter 2 1 5 3 4 7 6 2 5 8 9 6 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE ...

Page 85: ...PRIMARY SHEAVE REMOVAL ASSEMBLY section Reverse the removal procedure for in stallation Job name Part name V belt clutch and secondary primary sheave removal Lower cowling Air shroud 3 Crankcase cover left Clutch housing Secondary sheave assembly V belt Conical washer One way clutch Crow washer Primary fixed sheave Collar Washer Primary sliding sheave Cam Slider Weight V BELT CLUTCH AND SECONDARY ...

Page 86: ...ATION section Refer to SECONDARY SHEAVE IN STALLATION section Reverse the disassembly procedure for assembly Job name Part name Secondary sheave disassembly Nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O ring Oil seal Secondary fixed sheave V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE 1 2 3 4 5 6 7 8 9 0 New LS LS 9 50Nm 5 0m kg 36ft lb T R ...

Page 87: ...move 8 Conical spring washer 1 8 One way clutch 2 8 Washer 3 8 Primary fixed sheave 4 8 Shim 5 8 V Belt 4 Remove 8 Collar 1 8 Primary sheave assembly 2 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE SECONDARY SHEAVE REMOVAL 1 Remove 8 Nut 1 secondary sheave NOTE Hold the secondary sheave using sheave holder 2 Sheave holder YU 01701 2 Remove 8 Clutch housing 8 Secondary sheave assembly 8 Dowel pins 1 2...

Page 88: ...pect 8 Clutch shoes Glazed parts Sand with coarse sand paper NOTE After using the sand paper clean of the pol ished particles with cloth 3 Loosen 8 Nut Clutch carrier 1 NOTE Install the secondary sheave to primary drive shaft as shown and hold the secondary sheave by Universal Roter Holder 2 to loosen the nut 1 Roter holding tool YU 01235 cC Do not remove the clutch securing nut yet If the nut is ...

Page 89: ... 0 16 in Wear limit 2 5 mm 0 1 in V BELT INSPECTION 1 Inspect 8 V belt1 Crack Replace NOTE Replace the V belt smeared with a lot of oil or grease 2 Measure 8 V belt width a Out of specification Replace V belt width 16 6 mm 0 65 in Wear limit 14 6 mm 0 57 in a V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE ...

Page 90: ...heave 2 Wear Cracks Scratch Damage Replace 2 Check 8 Free movement Insert the collar 1into the primary slid ing sheave2 and check for free move ment Stick or excessive play Replace the sheave or collar 3 Measure 8 Out side diameter 1 weight Out of specification Replace Out side diameter weight 15 0 mm 0 59 in Limit 14 5 mm 0 57 in 1 ...

Page 91: ... 8 O rings 3 Damage Replace 3 Measure 8 Clutch spring free length Out of specification Replace Clutch spring free length 94 mm 3 7 in Limit 91 mm 3 58 in 4 Inspect 8 Clutch housing inner surface Oil Scratches Remove 5 Measure 8 Clutch housing inside diameter a Out of specification Replace Clutch housing inside diameter 105 mm 4 13 in Wear limit 105 5 mm 4 15 in Use a rag soaked in lacquer thinner ...

Page 92: ... Sliding sheave 1 NOTE Be careful so that the oil seal 2 lips are not turned over when installing the sheave 3 Apply 8 Lithium soap base grease to the torque cam grooves and O rings 4 Install 8 Guide pin 1 5 Check 8 Sliding sheave Unsmooth operation Repair 6 Install 8 Clutch securing nut 1 Use clutch spring holder 2 Clutch spring holder YS 28891 7 Tighten 8 Clutch securing nut 1 50 Nm 5 0 m kg 36 ...

Page 93: ... face 1 8 Primary fixed sheave face 2 8 Collar 3 8 Weight 4 8 Primary sliding sheave cam surface 5 2 Install 8 Weight 1 8 Cam 2 8 Slider 3 8 Collar 4 3 Check 8 Cam operation Not smooth Repair 4 Install 8 Primary sheave assembly 1 8 Collar 2 5 Install 8 V belt 8 Install 8 Secondary sheave assembly 8 Clutch housing 1 8 V belt 2 NOTE The V belt must be installed with the arrow frontward T R 2 1 1 2 2...

Page 94: ...pring washer 5 8 Nut 6 7 Tighten 8 Nut 1 primary sheave 45 Nm 4 5 m kg 31ft lb NOTE When tightening the nut primary sheave hold the C D I magneto using Flywheel Holding Tool 2 Rotor holding tool YU 01235 8 Adjust 8 V belt 1 Tense the V belt by turning the primary sheave several times 9 Install 8 Fan 7 Nm 0 7 m kg 5 1 ft lb T R 1 2 T R 1 ...

Page 95: ...n in chap ter 6 Refer to KICKER STARTER section Refer to V BELT PRIMARY SHEAVE section Job name Part name Starter clutch and starter motor re moval Left Right side cover Center cover Lower cowling Air shroud 3 Cooling fan Rear wheel Crankcase cover left 1 2 Primary sheave Plate Plain washer Idle gear Plain washer Starter clutch 11 10 8 7 6 5 4 3 2 1 New 13Nm 1 3m kg 9 4 ft lb T R 8Nm 0 8m kg 5 8 f...

Page 96: ...aring Starter wheel gear Plate washer Starter motor Starter motor coupler Q ty 1 1 1 1 1 2 Remarks Reverse the removal procedure for instalation STARTER CLUTCH AND STARTER MOTOR 11 10 8 7 6 5 4 3 2 1 New 13Nm 1 3m kg 9 4 ft lb T R 8Nm 0 8m kg 5 8 ft lb T R 9 LS ...

Page 97: ...spect 8 Starter clutch operation Clutch operation checking steps 8 Install the starter wheel gear to the starter clutch and hold the starter clutch 8 When turning the wheel gear clockwise A the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it 8 When turning the wheel gear counter clock wise B the wheel gear should turn freely If not the starter clu...

Page 98: ... for in stallation Job name Part name C D I magneto removal Rear carrier Tail cover Left side cover Right side cover Center cover Lower cowling Air shroud 1 Fan O ring Magneto rotor Bind Couplers magneto leads Stator coil Woodruff key Gasket Magneto cover 1 2 3 4 5 6 7 8 New 38Nm 3 8 m kg 27 ft lb T R 8Nm 0 8m kg 5 8ft lb T R C D I MAGNETO 7Nm 0 7m kg 5 1ft lb T R 7Nm 0 7 m kg 5 1 ft lb T R ...

Page 99: ...thium soap base grease to oil seal 3 Pass the C D I magneto lead through the crankcase hole 4 Install 8 Stator assembly 8 Nm 0 8 m kg 5 8 ft lb 5 Install 8 Woodruff key 8 C D I magneto Rotor 2 8 Plain washer 8 Nut 38Nm 3 8 m kg 31 1ft lb NOTE 8 Clean the tapered portion of the crankshaft and the magneto rotor hub 8 When installing the magneto rotor make sure the woodruff key is properly seated in ...

Page 100: ...er to C D I magneto section Refer to Autolube pump installation section Reverse the removal procedure for in stallation Job name Part name Autolube pump removal C D I magneto Air shroud 2 Circlip Pump drive gear Pin Oil hose Oil delivery hose Autolube pump ass y 1 2 3 4 5 6 7 4Nm 0 4m kg 2 8ft lb T R AUTOLUBE PUMP ...

Page 101: ...ube pump it must be bleeded 1 Install 8 Pin 1 8 Pump drive gear 2 8 Circlip 3 New 2 Apply 8 Lithium soap base grease to O ring 3 Install 8 Autolube pump 1 4 Nm 0 4m kg 2 8ft lb 4 Apply 8 Lithium soap base grease to autolube pump gear 2 3 15 cc 0 92 cu in 1 2 3 1 3 2 LS T R New ...

Page 102: ...ARY PRIMARY SHEAVE section Refer to TRANSMISSION OIL RE PLACEMENT section in chapter 3 Job name Part name Transmission removal Rear wheel Secondary sheave Drain the transmission oil Transmission case cover Gasket transmission case cover Dowel pin Primary drive gear Drive gear Circlip Main axle New New 18Nm 1 8 m kg 13ft lb T R 12Nm 1 2 m kg 8 4ft lb T R 1 2 3 4 5 6 7 8 LS TRANSMISSION New ...

Page 103: ...32 ENG TRANSMISSION Order 8 Job name Part name Drive axle Q ty 1 Remarks Reverse the removal procedure for in stallation New New 18Nm 1 8 m kg 13ft lb T R 12Nm 1 2 m kg 8 4ft lb T R 1 2 3 4 5 6 7 8 LS New ...

Page 104: ...OVER LEFT section Refer to V BELT CLUTCH AND SEC ONDARY PRIMARY SHEAVE section Refer to C D I MAGNETO section Refer to STARTOR CLUTCH AND STARTOR MOTOR section Refer to AUTOLUBE PUMP section Refer to REAR WHEEL AND REAR BRAKE section in chapter 6 Refer to TRANSMISSION section Job name Part name Crankcase and Reed valve removal Engine removal Cylinder head cylinder piston Crankcase cover left V bel...

Page 105: ... Reed valve Valve seat gasket Stopper Crankcase 2 Dowel pin Engine mount spacer Circlip Bearing Oil seal Q ty 1 1 1 1 1 2 1 1 1 1 Remarks Reverse the removal procedure for in stallation New New New 9Nm 0 9m kg 6 5ft lb T R 12Nm 1 2m kg 8 4ft lb T R 3 4 1 2 6 5 7 8 10 9 LS 11Nm 1 1m kg 8ft lb T R ...

Page 106: ...emove 8 Oil seal stopper 1 8 Screws crankcase 9Nm 0 9 m kg 6 5ft lb NOTE Loosen each screw 1 4 turn and remove them after all are loosened T R CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check 8 crankcase Cracks damage Replace 8 oil delivery passages Obstruction Blow out with com pressed ...

Page 107: ...Reed valve clearance 2 Less than 0 2 mm 0 0079 in CRANKCASE AND REED VALVE CRANKCASE RIGHT INSTALLATION 1 Install 8 Dowel pins 1 8 Engine mount spacer 2 2 Apply 8 Sealant 3 To the mating surfaces of both case helves Quick gasket ACC 1100 15 01 NOTE Do not allow any sealant to come into contact with the oil galley 3 Attach 8 Crankshaft installing tool 1 2 Crankshaft installation set 1 YU 90050 Cran...

Page 108: ...screws in stage using a crisscross pattern 5 Check 8 Crankshaft operation Unsmnoth operation Repair 6 Install 8 Oil seal right crank case 1 New Apply grease on to oil seal lip T R 7 Install 8 Oil seal stopper plate 1 9 Nm 0 9 m kg 6 5 ft lb New LS 8 Install 8 Gasket 8 Reed valve 8 Intake manifold 1 11 Nm 1 1 m kg 8 ft lb T R 1 T R ...

Page 109: ...the parts in order Refer to CRANK CASE AND REED VALVE section Reverse the removal procedure for in stallation Job name Part name Crankshaft removal Right crankcase removal Crankshaft Bearing Oil seal Crankcase cover left CRANKSHAFT 1 2 3 4 2 3 E E LS CRANKSHAFT LS ...

Page 110: ... 1 Measure 8 Runout limit C 8 Connecting rod big end side clearance D 8 Small 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 clear ance D 0 2 0 5 mm 0 0079 0 020 in Small end free play F 0 4 0 8 mm 0 016 0 031 in 2 Inspect 8 Bearings crankshaft Spin the bearing inner race Excessive play Rou...

Page 111: ...guide 2 and seal driver 3 to install the oil seal Oil seal driver YM 1410 Oil seal guide YM 1409 New 3 4 1 2 3 1 cC To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with grease and each bear ing with engine oil NOTE Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installing tool with the other...

Page 112: ...EL section in CHAPTER 3 Reverse the removal procedure for instal lation Job name Part name Carburetor removal Battery box cover Grip End cover Left Right cover Center cover Air cleaner case assembly Auto choke lead coupler Fuel hose vacuum hose Oil delivery pipe assembly Carburetor Throttle cable T R 9Nm 0 9 m kg 6 5 ft lb 1 2 3 4 6 5 ...

Page 113: ...verse the removal procedure for in stallation Job name Part name Carburetor disassembly Throttle cable Throttle valve Needle set Carburetor top cover o ring Throttle stop screw Auto choke unit assembly Float chamber Seal ring Float pin Float Needle valve Main jet Pilot jet Main nozzle Carburetor body CARBURETOR 1 5 6 e 9 8 7 0 w q 3 2 4 ...

Page 114: ... based solvent Do not use any caustic carbure tor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check 8 Float chamber body Dirt Clean 4 Check 8 Float chamber rubber gasket Cracks damage wear Replace 5 Check 8 Float Damage Replace 6 Check 8 Needle valve 1 Damage obstruction wear Replace the needle valve 7 Check 8 Throttle valve 1 Damage scratches wear Replace 1 1 ...

Page 115: ...Check 8 Vacuum hose 8 Fuel hose Cracks damage wear Replace Obstruction Clean Blow out the hoses with compressed air 1 2 3 4 11 Measure 8 Float height a Out of specification Inspect needle valve float and valve seat Float height 15 17 mm 0 59 0 67 in Float height measurement steps 8 Install the needle valve float and float pin to the carburetor body 8 Hold the carburetor in an upside down posi tion...

Page 116: ...ication inspect the needle valve float and valve seat 8 If it is worn replace it NOTE ThefloatheightisproperlyadjustedattheYamaha factory Never attempt to adjust it CARBURETOR ASSEMBLY To assemble the carburetor reverse the disas sembly procedures Note the following points cC 8 Before reassembling wash all parts in clean gasoline 8 Always use a new gasket ...

Page 117: ... carburetor is positioned verti cally 8 Connect the fuel level gauge 1 to the drain pipe 2 Fuel level gauge YM 01312 A 8 Loosen the drain screw 3 8 Measure the fuel level a with the gauge 8 If the fuel level is incorrect adjust the fuel level 8 Remove the float chamber float and the needle valve 8 Inspect the needle valve 8 If it is worn replace it 1 Install 8 Throttle cable 1 2 Install 8 Carburet...

Page 118: ...th the mouth etc Possible Good condition Impossible Replace auto choke unit 3 Inspect 8 Auto choke unit with battery Inspection and adjustment steps 8 Connect auto choke unit leads to the 12 V battery for 5 minutes Black terminal 12 V battery 1 Black terminal 12 V battery 2 8 Connect a suitable hose 4 to the starter 3 and blow it with the mouth etc Possible Replace auto choke unit Impossible Good ...

Page 119: ...er the fuel hose end 8 If fuel stops flowing out in a few seconds the fuel cock is in good condition If not clean or replace the fuel cock 8 Disconnect the vacuum hose 2 and breathe in the vacuum hose with the mouth etc for vacuum 8 If fuel flows out of the fuel hose under vacuum and stops under non vacuum the fuel cock is in good condition If not clean or replace the vacuum hose fuel hose and fue...

Page 120: ...o FRONT WHEEL INSTALLA TION section Refer to FRONT WHEEL ASSEMBLY section Reverse the removal procedure for in stallation Job name Part name Front wheel and brake disc removal Speedometer cable Front brake hose holder Brake caliper Wheel axle Front wheel assembly Gear unit assembly Collar Brake disc T R 7Nm 0 7 m kg 5 1ft lb T R 23Nm 2 3 m kg 16 6ft lb T R 70Nm 7 m kg 51ft lb T R 20Nm 2 0 m kg 14 ...

Page 121: ...Y FRONT WHEEL AND BRAKE DISC Remarks Remove the parts in order Refer to FRONT WHEEL DISASSEM BLY ASSEMBLY section Reverse the removal procedure for in stallation Job name Part name Front wheel disassembly Oil seal Bearing Collar Spacer Bearing 1 2 3 4 5 New L S LS ...

Page 122: ...ce Bends Replace w Do not attempt to straighten a bent wheel axle Wheel axle bending limit 0 25 mm 0 0098 in 2 Inspect 8 Front tire Wear damage Replace Refer to TIRE INSPECTION in CHAP TER 3 8 Front wheel Refer to WHEEL INSPECTION in CHAPTER 3 3 Measure 8 Front wheel runout Over the specified limits Replace Front wheel runout limits Radial 1 1 0 mm 0 04 in Lateral 2 1 0 mm 0 04 in 4 Inspect 8 Fron...

Page 123: ... Grooved wear Replace the collar and the oil seal as a set YP FRONT WHEEL ASSEMBLY 1 Install 8 Bearing 1 8 Collar 2 8 Spacer 3 8 Bearing 4 8 Oil seal 5 NOTE 8 Apply the lithium soap base grease on the bearing and oil seal lip when installing 8 Use a socket that matches the outside diam eter of the race of the bearing 8 Always use a new oil seal 8 Install the oil seal with its manufacturer s marks ...

Page 124: ...installed with the three projections meshed into the two slots T R 2 Install 8 Brake disc 1 20 Nm 2 0 m kg 14 ft lb NOTE Tighten the bolts brake disc in stage using a crisscross pattern 3 Install 8 Front wheel NOTE Make sure that the slot in the speedometer gear unit fits over the stopper on the front fork outer tube 4 Tighten 8 Front wheel axle 1 8 Axle nut front wheel axle 70 Nm 7 0 m kg 51 ft l...

Page 125: ...eel s bottom spot c Turn the wheel so that the X1 mark is 90 up d Release the wheel and wait for it to rest Put an X2 mark on the wheel s bottom spot e Repeat the above b c and d several times until all marks come to the same spot f This spot is the wheel s heavy spot X 4 Adjust 8 Wheel static balance Adjusting steps 8 Instail a balancing weight 1 on the rim ex actly opposite to the heavy spot X N...

Page 126: ... AND BRAKE DISC 5 Check 8 Wheel static balance Checking steps 8 Turn the wheel so that it comes to each point as shown 8 Check that the wheel is at rest at each point If not readjust the front wheel static balance X X X X ...

Page 127: ...rks Remove the parts in order Refer to BRAKE PAD REPLACEMENT section Reverse the removal procedure for in stallation Job name Part name Brake pad removal Caliper support bolt Caliper Brake pad Pad spring T R 23Nm 2 3 m kg 16 6 ft lb LS LS 1 2 3 4 T R 23Nm 2 3 m kg 16 6 ft lb ...

Page 128: ... damage may oc cur 8 Disconnect any hydraulic connection other wise the entire system must be disas sembled drained cleaned and then prop erly filled and bled after reassembly 1 2 3 1 2 a BRAKE PAD REPLACEMENT NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Loosen 8 Retaining bolt 1 2 Remove 8 Brake caliper 2 8 Holder brake hose 3 3 Remove 8 Ret...

Page 129: ... 3 into the caliper by your finger 8 Tighten the capliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb 8 Install the pad spring new and brake pad new 4 8 Tighten retaining bolt 5 23 Nm 2 3 m kg 16 6 ft lb 8 Install brake hose holder 6 7 Nm 0 7 m kg 5 15 ft lb 8 Install caliper 7 23 Nm 2 3 m kg 16 6 ft lb 5 Inspect 8 Brake fluid level Refer to the BRAKE FLUID INSPEC TION section in the CHAPTER 3 1 LOWER lev...

Page 130: ...6 11 CHAS FRONT BRAKE 6 Check 8 Brake lever operation A softy or spongy feeling Bleed brake system Refer to AIR BLEEDING section in the CHAPTER 3 ...

Page 131: ...APTER 3 Refer to MASTER CYLINDER INSTAL LATION section Reverse the removal procedure for in stallation Job name Part name Master cylinder removal Drain the brake fluid Brake lever compression spring Brake switch Union bolt Copper washer Brake hose Master cylinder bracket Master cylinder New T R 9Nm 0 9 m kg 6 5 ft lb T R 20Nm 2 0 m kg 14 ft lb LS 1 2 5 4 7 3 6 ...

Page 132: ...SSEMBLY FRONT BRAKE Remarks Remove the parts in order Refer to MASTER CYLINDER ASSEM BLY section Reverse the disassembly procedure for assembly Job name Part name Master cylinder disassembly Master cylinder boot Circlip Master cylinder kit Spring 2 1 4 3 New ...

Page 133: ...id only before installation Recommended brake fluid DOT 4 or DOT 3 8 Replace the piston seals and dust seals whenever a master cylinder is disassembled 1 Install 8 Cylinder cup 1 8 Master cylinder piston 2 Install cylinder cup 1 by using cylinder cup installer 3 Cylinder cup installer set 90890 01996 YP702040 MASTER CYLINDER INSPECTION 1 Inspect 8 Master cylinder kit 1 Wear scratches Replace the m...

Page 134: ... circlip securely into the mas ter cylinder groove 8 Master cylinder boot 2 YP MASTER CYLINDER INSTALLATION 1 Install 8 Master cylinder 1 8 Master cylinder bracket 2 9 Nm 0 9 m kg 6 5 ft lb cC 8 Install the master cylinder bracket 2 with the UP mark a facing upward 8 Align the end of the holder with the punch mark b on the handle bar New T R New START ENGINE STOP 1 2 a b 1 2 ...

Page 135: ...s may deteriorate causing leakage and poor brake perforrmance 8 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemi cal reaction and lead to poor perforrmance 8 Be careful that water does not enter the sig nificantly lower the boiling point of the fluid may result in vapor lock 3 Inspect 8 Brake operation FRONT BRAKE ...

Page 136: ...ion in CHAPTER 3 Refer to CALIPER INSTALLATION sec tion Reverse the removal procedure for in stallation Job name Part name Caliper removal Drain the brake fluid Union bolt Copper washer Brake hose Caliper support bolt Caliper assembly T R 23Nm 2 3 m kg 16 6 ft lb T R 23Nm 2 3 m kg 16 6 ft lb 1 2 3 4 5 New T R 23Nm 2 3 m kg 16 6 ft lb ...

Page 137: ...ve the parts in order Refer to BRAKE CALIPER DISASSEM BLY ASSEMBLY section Reverse the disassembly procedure for assembly Job name Part name Caliper disassembly Caliper bracket Brake pad Pad spring Caliper piston Dust seal Piston seal Bleed screw T R 6Nm 0 6 m kg 4 3 ft lb New LS 1 2 3 4 5 6 7 ...

Page 138: ... brake caliper body w 8 Never try to pry out the caliper piston 8 Cover the caliper piston with a rag Be care ful not to get injured when the piston is ex pelled from the master cylinder cC Carefully remove the caliper piston to prevent damage 2 Remove 8 Dust seal 1 8 Piston seal 2 When removing push the seals by your finger cC 8 Do not use a sharp instrument Remove seals by your finger 8 Do not r...

Page 139: ...eal 1 New 8 Dust seal 2 New FRONT BRAKE 2 Install 8 Caliper piston 1 Apply brake fluid to the outer surface and install cC 8 Do not force 8 Use care to prevent damage on caliper pis ton YP BRAKE CALIPER INSTALLATION 1 Install 8 Caliper 1 8 Caliper support bolt 23Nm 2 3m kg 16 6ft lb 8 Brake hose 2 8 Copper washer 3 New 8 Union bolt 4 25Nm 2 5 m kg 18ft lb cC When installing the brake hose to the c...

Page 140: ...ooter on a suitable atand so that the rear wheel is elevated Reverse the disassembly procedure for installation Job name Part name Rear wheel and rear brake removal Muffler assembly Gasket Nut Plain washer Rear wheel assembly Plain washer T R 9Nm 0 9 m kg 6 5 ft lb T R 26Nm 2 6 m kg 18 2 ft lb T R 120Nm 12 m kg 87 ft lb New 2 1 4 3 REAR WHEEL ...

Page 141: ...8 Q ty 1 1 1 1 1 1 1 1 Remarks Reverse the removal procedure for in stallation Job name Part name Adjuster Brake cable Pin Return spring Brake shoe Camshaft lever Wear indicator Brake camshaft T R 10Nm 1 0 m kg 7 2 ft lb New 5 8 2 4 1 3 7 6 REAR BRAKE LS LS ...

Page 142: ...Glazed areas Polish Use coarse sand paper NOTE After polishing wipe the polished particles with a cloth 2 Measure 8 Brake lining thickness a Brake lining thickness a Standard 4 mm 0 16 in Limit 2 mm 0 08 in Out of specification Replace Measuring points M NOTE Replace the brake shoes as a set if either is worn to the wear limit 3 Measure 8 Brake drum inside diameter a Out of specification Replace t...

Page 143: ...pill oil or grease on the brake lining YP REAR BRAKE INSTALLATION 1 Install 8 Camshaft 1 8 Indicator plate 2 Installation steps 8 Set the camshaft with its punched mark a facing the direction as shown 8 Align the projection b on the indicator plate with the camshaft notch and install 8 Check the proper position of the brake shoe 2 Install 8 Camshaft lever 1 10Nm 1 0 m kg 7 2ft lb NOTE Set the cams...

Page 144: ...e Handlebar removal Left Right bake mirror Front protector bar Upper cover Front Rear handlebar cover Left Right flasher Brake master cylinder Front brake switch Handlebar switch Right Throttle cable Right grip Brake cable Rear brake switch Handlebar switch Left Bind HANDLEBAR LS T R 9Nm 0 9 m kg 6 5 ft lb T R 43Nm 4 3 m kg 37 ft lb 1 2 3 4 6 7 8 9 11 12 5 13 LS LS 10 ...

Page 145: ...Part name Wire harness strap Brake hose Handlebar comp Left grip Q ty 1 1 1 1 1 Remarks Reverse the removal procedure for in stallation HANDLEBAR LS T R 9Nm 0 9 m kg 6 5 ft lb T R 43Nm 4 3 m kg 37 ft lb 1 2 3 4 6 7 8 9 11 12 5 13 LS LS 10 ...

Page 146: ...8 Nut 43Nm 4 3 m kg 37ft lb NOTE Match the bolt 2 on to the steering column dent a cC There must be a space b after tighting bolt 2 3 Install 8 Band NOTE Clamp the wire harness 4 Apply 8 Lithium soap base grease to throttle cable end and handlebar right end T R 5 Install 8 Handlebar switch right 1 NOTE Insert the projection a into the hole b on the handlebar comp a a 1 2 1 a b M b ...

Page 147: ... Install 8 Handlebar switch left 1 NOTE Insert the projection a into the hole b on the handlebar comp HANDLEBAR b 1 a 7 Install 8 Master cylinder NOTE Match the slot with the punched mark b on the handlebar comp b ...

Page 148: ...TAL LATION section Reverse the removal procedure for in stallation Job name Part name Steering removal Handlebar Front wheel Ring nut 1 Special washer Ring nut 2 Rubber washer Ring nut 3 Under bracket Front fork Left Right Bearing cover Ball race Ball Upper Lower Ball race T R 38Nm 3 8 m kg 27ft lb T R 40Nm 4 0 m kg 29 ft lb LS LS 1 2 3 4 5 6 7 8 9 9 8 9 STEERING 22Nm 2 2 m kg 16 ft lb T R T R 66N...

Page 149: ... Remove the ring nuts by steering nut wrench Steering nut wrench 0 YU 33975 8 Hold the lower bracket by hand then remove by using the steering nut wrench 0 8 Do not loss the balls Upper 22 pcs Lower 19 pcs 2 Remove 8 Front fork assembly Refer to FRONT FORK section 3 Remove 8 Ball race Ball race replacement steps 8 Remove the ball races on the head pipe us ing long rod 1 and the harmmer as shown 8 ...

Page 150: ...s may dangerously weaken the under bracket STEERING INSTALLATION 1 Install 8 Ball 1 NOTE Upper 22 pcs Lower 19 pcs 2 Lubricate 8 Ball 8 Ball race Lithium soap base grease STEERING INSPECTION 1 Wash the bearing races with a solvent 2 Inspect 8 Ball race 8 Ball Pitting Damage Replace NOTE Always replace bearings and races as set 1 1 ...

Page 151: ...he ring nut wrench 1 22 Nm 2 2 m kg 16 ft lb Steering mut wrench YU 33975 NOTE Set the torque wrench 3 to ring nut wrench 1 so that they form right angle w Do not over tightening 8 Loosen the ring nut 3 2 1 4 turn 8 Check the front fork by turning it lock to lock If there is any binding remove the front fork assembly and inspect the steering ball bear ings and ball races 8 Install rubber washer 4 ...

Page 152: ...hould be align If not turn the ring nut 2 towards tighten direction until slots alignment 8 Install special washer 6 NOTE Insert the projections of the special washer into the slots 8 Install ring nut 1 7 and tighten 66Nm 6 6 m kg 47 8 ft lb STEERING T R ...

Page 153: ...er Refer to Steering section Refer to FRONT FORK REMOVAL IN STALLATION section Reverse the removal procedure for in stallation Job name Part name Front fork removal Steering Under fender Speedometer cable holder Cap bolt Pinch bolt Front fork T R 40Nm 4 0 m kg 29 ft lb 2 3 1 5 4 T R 38Nm 3 8 m kg 27 ft lb ...

Page 154: ...IN STALLATION section Refer to FRONT FORK DISASSEMBLY ASSEMBLY section Reverse the disassembly procedure for assembly Job name Part name Front fork disassembly Fork spring Band Front fork boot Bolt Copper washer Inner tube Damper rod Rebound spring Oil lock piece Oil seal clip Oil seal Outer tube T R 23Nm 2 3 m kg 16 6 ft lb LT New New New New 1 2 3 4 5 6 7 8 9 0 ...

Page 155: ...Securely support the scooter so there is no danger of it falling over 8 Stand the scooter on a level surface 8 Stand the scooter on its centerstand 1 Remove 8 Under fender 1 1 1 1 2 3 1 2 3 YP703020 FRONT FORK DISASSEMBLY 1 Remove 8 Bolt damper rod 1 Loosen the bolt damper rod 1 while holding the damper rod with T handle 3 and holder 2 T handle YM 1326 Holder YM 01300 1 ...

Page 156: ...SPECTION 1 Inspect 8 Inner tube bending Inner tube bending limit 0 2 mm 0 008 in Scratches bends damage Replace w Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube YP FRONT FORK ASSEMBLY Reverse the DISASSEMBLY procedure Note the following points 1 Install 8 Damper rod 1 8 Rebound spring 2 8 Oil lock piece 3 8 Inner tube 4 1 3 4 2 New 4 1 2 3 ...

Page 157: ... 2 3 Install 8 Plain washer 1 New 8 Bolt damper rod 2 New 1 2 LT T R 5 Install 8 Oil seal 1 New 8 Retaining clip Use the fork seal driver weight 2 and the attachment 3 NOTE 8 Before installing the oil seal 1 apply lithium soap base grease onto the oil seal lips 8 Adjust the retaining clip so that it fits into the outer tube groove cC Make sure that the oil seal numbered side faces upward Fork seal...

Page 158: ...l 8 Front fork spring 1 NOTE 8 Install the fork spring with its smaller pitcha upward 8 Before installing the cap bolt apply grease to the O ring 8 Temporarily tighten the cap bolt 1 a EB703050 FRONT FORK INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Install 8 Front fork 1 NOTE Apply grease onto cap bolt O ring before in stalling cap bolt 2 Tighten 8 Cap bolts 2 38Nm 3 8 m...

Page 159: ...LECTRICAL COMPONENTS 1 Main switch 2 Flasher relay 3 Oil level gauge 4 C D I UNIT 5 Fuel level gauge 6 Starter relay 7 Fuse ELECTRICAL COMPONENTS 8 Battery 9 Ignition coil 0 Rectifier Regulator q Horn 1 2 3 4 5 6 7 8 9 0 q ...

Page 160: ...G Y Ch Dg G Y W Y R Y R B B B B B Ch Dg G Y G Y G Y Br Br B Or Or B B W B R Br Gy Gy Br Y Y Ch Dg B G G B 1 3 2 4 n b g l k 6 5 s 7 9 8 q a o i e w d W R B Y R m h z x c v 0 f j I B B G B G B Y B Y B G Y B Ch Br Dg Br Dg Ch Br Dg G Y B Ch Br G Y Br G Y Br G Y Br G Y B W B B W L W B W B W B B W B B W L W L W GY R R L W Y R W Y R Ch Br W Dg G W W L W R B R G W W L W R 12V 7A R B R B L L P B B Br W B...

Page 161: ...Head light for high beam a Head light for low beam s Flasher relay d Horn f Handlebar switch left g Horn switch h Dimmer switch j Turn switch k Fuel sender l Meter Fuel gauge z Oil indicator light x Meter light c High beam indicator light v Turn indicator light b Oil level gauge n Handlebar switch right m Starter switch Engine stop switch B Br Ch Dg G L Or Sb P R COLOR CODE Gy Y W B R Br W G R G Y...

Page 162: ...ocket tester selector to 1 Ω SWITCH CONNECTION AS SHOWN IN THIS MANUAL This manual contains connection charts like the one shown on the left showing the termi nal connections of switches e g the main switch handlebar switch brake switch light ing switch etc The column on the extreme left indicates the different switch positions the top line indicates the colors of the leads connected to the termi ...

Page 163: ...cording to the color combi nations shown in the chart Poor connection fault Repair or replace CHECKING SWITCHES Rear brake switch Horn switch Dimmer switch Turn switch Main switch Front brake switch Start switch Engine stop switch Fuse B R Gy Br LOCK OPEN OFF ON Gy Br R B B W Ch L Br W P Dg B Release Push in Y G P B G L Y 4 6 Ch Br W Dg Release Push in L W L G OFF RUN B W B W L G B B W B W B L W ...

Page 164: ...e bulbs used on this scooter are shown in the illustration on the left 8 Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The ma jority of these types of bulbs can be removed from their respective socket by turning them counterclockwise 8 Bulbs C are used for turn signal and tail brake lights and can be removed from the socket b...

Page 165: ...er wise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check 8 bulb for continuity with the pocket tester No continuity Replace Pocket tester YU 03112 NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a...

Page 166: ...ester No continuity Replace Pocket tester YU 03112 NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity re place the bulb soc...

Page 167: ... L W B L W R GY R B W Y R R B Br P Br Br W P B G Y Ch Dg G Y W Y R Y R B B B B B Ch Dg G Y G Y G Y Br Br B Or Or B B W B R Br Gy Gy Br Y Y Ch Dg B G G B 1 3 2 4 n b g l k 6 5 s 7 9 8 q a o i e w d W R B Y R m h z x c v 0 f j I B B G B G B Y B Y B G Y B Ch Br Dg Br Dg Ch Br Dg G Y B Ch Br G Y Br G Y Br G Y Br G Y B W B B W L W B W B W B B W B B W L W L W GY R R L W Y R W Y R Ch Br W Dg G W W L W R ...

Page 168: ...ntil misfire occurs Minimum spark gap 6 0 mm 0 24 in OUT OF SPECIFI CATION OR NO SPARK IGNITION SYSTEM TROUBLESHOOTING IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE NO SPARK OR INTERMITTENT SPARK NOTE 8 Remove the following parts before troubleshooting 1 Battery box cover 4 Tail cover 2 Center cowling 5 Side cover right 3 Rear carrier 6 Handlebar cover front 8 Use the following special tools in thi...

Page 169: ...ster Ω 1 to the ignition coil Ignition coil Tester lead Terminal 1 Tester lead Coil base 2 8 Check the primary coil for specification resistance Primary coil resistance 0 32 0 48 Ω at 20 C 68 F 8 Connect the pocket tester Ω 1 k to the ignition coil Tester lead Spark plug lead 1 Tester lead Coil base 2 8 Check the secondary coil for specificated resistance Secondary coil resistance 5 68 8 52 k Ω at...

Page 170: ...istance 8 Disconnect the source coil coupler from the wireharness 8 Connect the pocket tester Ω 100 to the source coil terminal Tester lead Black Red lead 1 Tester lead Green White 2 8 Check the source coil for specificated re sistance Source coil resistance 640 960 Ω at 20 C 68 F Black Red Green White MEET SPECIFICATION 7 Main switch Refer to CHECKING SWITCHS section CONTINUITY OUT OF SPECIFICATI...

Page 171: ...fer to CHECKING SWITCHS section CONTINUITY 9 Wiring connection Check the entire ignition system for connec tions Refer to the WIRING DIAGRAM section CORRECT Replace CDI unit NO CONTINUITY Engine stop switch is faulty replace it POOR CONNECTION Correct ...

Page 172: ... R GY R B W Y R R B Br P Br Br W P B G Y Ch Dg G Y W Y R Y R B B B B B Ch Dg G Y G Y G Y Br Br B Or Or B B W B R Br Gy Gy Br Y Y Ch Dg B G G B 1 3 2 4 n b g l k 6 5 s 7 9 8 q a o i e w d W R B Y R m h z x c v 0 f j I B B G B G B Y B Y B G Y B Ch Br Dg Br Dg Ch Br Dg G Y B Ch Br G Y Br G Y Br G Y Br G Y B W B B W L W B W B W B B W B B W L W L W GY R R L W Y R W Y R Ch Br W Dg G W W L W R B R G W W ...

Page 173: ...c tion in the CHAPTER 3 Open circuit voltage 12 8V or more at 20 C 68 F CORRECT TROUBLESHOOTING THE BATTERY IS NOT CHARGED NOTE 8 Remove the following parts before troubleshooting 1 Front protector bar 4 Tail cover 2 Upper cover 5 Right side cover 3 Rear carrier 8 Use the following special tool s in this trobleshooting Pocket tester YU 03112 NO CONTINUITY Fuse is faulty replace it INCORRECT 8 Clea...

Page 174: ... lighting coil resistance 8 Disconnect the charging coil coupler from the wireharness 8 Connect the pocket tester Ω 1 to the charging coils 8 Measure the charging coil and lighting coil resistance Charging coil resistance Tester lead White lead 1 Tester lead Earth Lighting coil resistance Tester lead Yellow Red 2 Tester lead Earth Charging coil resistance 0 48 0 72 Ω at 20 C 68 F Lighting coil res...

Page 175: ...7 17 ELEC 5 Wiring connection Check the entire ignition system for con nections Refer to the WIRING DIAGRAM section OK Replace rectifier regulator POOR CONNECTION Correct CHARGING SYSTEM ...

Page 176: ... PUSH 4 N 6 Or B Or B Gy Br R B B W R R R R L W B L W R GY R B W Y R R B Br P Br Br W P B G Y Ch Dg G Y W Y R Y R B B B B B Ch Dg G Y G Y G Y Br Br B Or Or B B W B R Br Gy Gy Br Y Y Ch Dg B G G B 1 3 2 4 n b g l k 6 5 s 7 9 8 q a o i e w d W R B Y R m h z x c v 0 f j I B B G B G B Y B Y B G Y B Ch Br Dg Br Dg Ch Br Dg G Y B Ch Br G Y Br G Y Br G Y Br G Y B W B B W L W B W B W B B W B B W L W L W G...

Page 177: ...SHOOTING STARTER MOTOR DOES NOT OPERATE NOTE 8 Remove the following parts before troubleshooting 1 Battery box cover 4 Side covers left and right 2 Rear carrier 5 Trunk 3 Tail cover 6 Handlebar cover front 8 Use the following special tool in this troubleshooting NO CONTINUITY Fuse is faulty replace it INCORRECT 8 Clean battery terminals 8 Recharge or replace battery w 8 A wire for the jumper lead ...

Page 178: ...heck the starter relay for continuity Tester lead 3 terminal Tester lead 4 terminal CONTINUITY 5 Main switch Refer to CHECKING SWITCHS section CONTINUITY 6 START switch Refer to CHECKING SWITCHS section CONTINUITY 7 Engine stop switch Refer to CHECKING SWITCHS section CONTINUITY NO CONTINUITY Replace the starter relay NO CONTINUITY Main switch is faulty replace it NO CONTINUITY START switch is fau...

Page 179: ...witch leads 8 Check the brake switch for continuity Switch Position Good condition Bad condition Brake is applied Brake is not applied Continuity No continuity BAD CONDITION Replace brake switch es CONTINUITY GOOD CONDITION Br G Y 1 2 9 Wiring connection 8 Check the entire electrical starting system for connections Refer to WIRING DIAGRAM section POOR CONNECTION Correct ...

Page 180: ...EEL AND REAR BRAKE section in CHAPTER 6 Refer to ENGINE REMOVAL section chapter 4 Reverse the removal procedure for in stallation Job name Part name Starter motor removal Rear carrier Tail cover Battery box cover Left Right side cover Center cowling Muffler Rear wheel Air shroud 3 Starter motor coupler Starter motor T R 13Nm 1 3 m kg 9 4 ft lb 1 2 3 4 5 2 1 LS ...

Page 181: ...r motor disassembly O ring Rear bracket Armature ass y Ring Brush holder set Q ty 1 1 1 1 1 Remarks Disassembly the parts in order Refer to Starter motor assembly Reverse the disassembly procedure for assembly ELECTRIC STARTING SYSTEM T R 13Nm 1 3 m kg 9 4 ft lb 1 2 3 4 5 2 1 LS ...

Page 182: ...ut a Mica undercut 1 05 mm 0 04 in Out of specification Scrape the mica to the proper value a hacksaw blade can be ground to fit NOTE The mica insulation of the commutator must be undercut to ensure proper operation of com mutator 4 Inspect 8 Armature coil resistances installation continuity Defects Replace the starter motor If commutator is dirty clean it with sand paper O Continuity x No continu...

Page 183: ... ELEC 5 Measure 8 Brush length a Out of specification Replace Brush length wear limit 3 0 mm 0 012 in 6 Measure 8 Brush spring force Fatigue out of specification Replace as a set ELECTRIC STARTING SYSTEM a ...

Page 184: ...B Dg B Dg B OFF PUSH 4 N 6 Or B Or B Gy Br R B B W R R R R L W B L W R GY R B W Y R R B Br P Br Br W P B G Y Ch Dg G Y W Y R Y R B B B B B Ch Dg G Y G Y G Y Br Br B Or Or B B W B R Br Gy Gy Br Y Y Ch Dg B G G B 1 3 2 4 n b g l k 6 5 s 7 9 8 q a o i e w d W R B Y R m h z x c v 0 f j I B B G B G B Y B Y B G Y B Ch Br Dg Br Dg Ch Br Dg G Y B Ch Br G Y Br G Y Br G Y Br G Y B W B B W L W B W B W B B W ...

Page 185: ...t handlebar cover 2 Rear carrier 3 Right side cover 8 Use the special tools specified in the troubleshooting section Pocket tester YU 03112 YP 1 Fuse Refer to CHECKING SWITCHES section CONTINUITY YP 2 Battery 8 Check the battery condition Refer to BATTERY INSPECTION section in CHAPTER 3 CORRECT YP 3 Main switch Refer to CHECKING SWITCHES section CONTINUITY NO CONTINUITY Replace the fuse IN CORRECT...

Page 186: ...coil coupler from the wireharness 8 Connect the pocket tester Ω x 1 to the lighting coils 8 Measure the lighting coil resistances Tester lead Yellow Red lead 1 Tester lead Earth Lighting coil resistance 0 4 0 6 Ω at 20 C 68 F MEET SPECIFICATION NO CONTINUITY Replace the left handlebar switch OUT OF SPECIFICATION Lighting coil is faulty replace it ...

Page 187: ...r to CHECKING SWITCHES section CONTINUITY 2 Voltage 8 Connect the pocket tester DC20V to the headlight and high beam indicator light couplers A When the dimmer switch is on low beam B When dimmer switch is on high beam Headlight low beam Tester lead Green 1 lead Tester lead Black 2 lead Headlight high beam Tester lead Yellow 3 lead Tester lead Black 4 lead High beam indicator light Tester lead Yel...

Page 188: ...UITY 2 Voltage 8 Connect the pocket tester DC20V to the bulb socket coupler Tester lead Blue terminal 1 Tester lead Black terminal 2 8 Turn the main switch to on 8 Start the engine 8 Check the voltage 12V of the leads on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to bulb socket connector is faulty Repair NO ...

Page 189: ... bulb socket connector Tester lead Brown 1 lead Tester lead Black 2 lead 8 Turn the main switch to on 8 Check the voltage 12V on the Brown lead at the bulb socket connector MEETS SPECIFICATION 12V This circuit is not faulty NO CONTINUITY Bulb and or bulb socket are faulty replace OUT OF SPECIFICATION Wiring circuit from main switch to bulb socket connector is faulty Repair 1 2 Br Dg G Y B Ch ...

Page 190: ...ocket connector Tester lead Brown terminal 1 Tester lead Black terminal 2 8 Turn the main switch to on 8 Check the voltage 12V on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty LIGHTING SYSTEM NO CONTINUITY Replace the bulb and or bulb socket OUT OF SPECIFICATION The wiring circuit from main switch to bulb connector is faulty Repair 1 2 Br Dg G Y B Ch ...

Page 191: ...Gy Br Br G Br G Dg Ch Dg Ch L Gy B L Gy B G B G B L P B Ch Br W Dg Y G Y G Ch B Ch B Dg B Dg B OFF PUSH 4 N 6 Or B Or B Gy Br R B B W R R R R L W B L W R GY R B W Y R R B Br P Br Br W P B G Y Ch Dg G Y W Y R Y R B B B B B Ch Dg G Y G Y G Y Br Br B Or Or B B W B R Br Gy Gy Br Y Y Ch Dg B G G B 1 3 2 4 n b g l k 6 5 s 7 9 8 q a o i e w d W R B Y R m h z x c v 0 f j I B B G B G B Y B Y B G Y B Ch Br ...

Page 192: ...IL TO COME ON IF THE HORN FAILS TO SOUND Procedure Check 1 Fuse Main 3 Main switch 2 Battery 4 Wiring connection entire signal system NOTE 8 Remove the following parts before troubleshooting 1 Battery box cover 5 Tail cover 2 Front protector bar 6 Side covers Left Right 3 Upper cover 7 Center cover 4 Rear carrier 8 Use the special tools in the troubleshooting section NO CONTINUITY Replace the fuse...

Page 193: ...arness 8 Check the connections of the entire sig nal system Refer to CIRCUIT SYSTEM WIRING DIA GRAM section CONTINUITY Check condition of each of the signal system s circuits Refer to SIGNAL SYSTEM CHECK sec tion POOR CONNECTION Correct ...

Page 194: ... voltage 12V on the Brown lead at the horn terminal MEETS SPECIFICATION 3 Horn 8 Connect the pocket tester DC20V to the horn at the Pink terminal Tester lead Pink 1 terminal Tester lead Frame ground 8 Turn the main switch to on 8 Check for voltage on the Pink lead at the horn terminal CONTINUITY Adjust or replace horn NO CONTINUITY Replace the left handlebar switch OUT OF SPECIFICATION The wiring ...

Page 195: ...nal 1 Tester leadGBlack terminal 2 8 Turn the main switch to on 8 The brake lever is pulled in 8 Check for voltage 12V of the Green Yel low lead on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty SIGNAL SYSTEM NO CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY Replace brake switch OUT OF SPECIFICATION 4 Wiring connection 8 Wiring circuit from the main switch t...

Page 196: ... of the Brown lead at the flasher relay terminal MEETS SPECIFICATION 4 Voltage 8 Connect the pocket tester DC20V to the flasher relay coupler Tester lead Brown White lead 1 Tester lead Black lead2 8 Turn the main switch to on 8 Check for voltage 12V on the Brown White lead at the flasher relay terminal MEETS SPECIFICATION NO CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY Replace the ...

Page 197: ...ome on 1 Bulb and bulb socket 8 Check the bulb and bulb socket for conti nuity CONTINUITY 2 Oil level switch 8 Remove the oil level switch from the oil tank 8 Connect the Pocket Tester Ω x 1 to the oil level switch Tester Lead Brown 1 Tester Lead Gray 2 8 Check the oil level gauge for continuity GOODCONDITION OUT OF SPECIFICATION 6 Wiring connection 8 Wiring circuit from the turn switch to bulb so...

Page 198: ...emove the fuel sender from the fuel tank 8 Disconnect the fuel sender coupler from the wireharness Connect the pocket tester Ω 10 to the fuel sender coupler lead Tester lead Green terminal 1 Tester lead Black terminal 2 8 Check the fuel sender for specificated re sistance BOTH MEET SPECIFICATION OUT OF SPECIFICATION 4 Wiring connection 8 Check the entire signal system for connec tions Refer to the...

Page 199: ...to wireharness 8 Move the float to UP 1 or DOWN 2 8 Turn the main switch to ON 8 Check the fuel gauge needle moves F or E Float position Needle moves Float UP 1 F Float DOWN 2 E MOVES This circuit is not faulty OUT OF SPECIFICATION Check the connection of the entire signal sys tem Refer to CHECKING OF CONNECTIONS Refer to CIRCUIT DIAGRAM NOTE Before reading the meter stay put the float for more th...

Page 200: ...Y R R B Br P Br Br W P B G Y Ch Dg G Y W Y R Y R B B B B B Ch Dg G Y G Y G Y Br Br B Or Or B B W B R Br Gy Gy Br Y Y Ch Dg B G G B 1 3 2 4 n b g l k 6 5 s 7 9 8 q a o i e w d W R B Y R m h z x c v 0 f j I B B G B G B Y B Y B G Y B Ch Br Dg Br Dg Ch Br Dg G Y B Ch Br G Y Br G Y Br G Y Br G Y B W B B W L W B W B W B B W B B W L W L W GY R R L W Y R W Y R Ch Br W Dg G W W L W R B R G W W L W R 12V 7A...

Page 201: ...ighting coil resistance 0 4 0 6 Ω 20 C 68 F MEETS SPECIFICATION AUTO CHOKE SYSTEM YP TROUBLESHOOTING IF THE AUTO CHOKE FAILS TO OPERATE Procedure Check 1 Lighting coil resistance 2 Auto choke unit resistance 3 Wiring connection entire auto choke system NOTE 8 Remove the following parts before troubleshooting 1 Battery box cover 2 Rear carrier 3 Tail cover 4 Right side cover 8 Use the special tools...

Page 202: ...r Ωx1 to the auto choke unit coupler lead Tester lead Black terminal 1 Tester lead Black terminal 2 Auto choke unit resistance 8 12Ω at 20 C 68 F MEETS SPECIFICATION 3 Wiring connection 8 Check the connection of the entire auto choke system Refer to CIRCUIT DIAGRAM section OUT OF SPECIFICATION Replace the auto choke unit POOR CONNECTION Correct B B ...

Page 203: ...el or fuel containing water or foreign material 8Clogged fuel tank cap 8Clogged fuel hose 8Clogged fuel cock 8Faulty fuel cock operation 8Broken or disconnected fuel cock 8Deteriorated fuel fuel containing water or foreign material 8Clogged pilot jet 8Clogged pilot air passage 8Sucked in air 8Deformed float 8Groove worn needle valve 8Improperly sealed valve seat 8Improperly adjusted fuel level 8Im...

Page 204: ...itch 8 Broken or shorted wiring COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston rings Crankcase and crankshaft Reed valve PROBABLE CAUSE 8Loose spark plug 8Loose cylinder head or cylinder 8Broken cylinder head gasket 8Broken cylinder gasket 8Worn damaged or seized cylinder 8Improperly installed piston ring 8Worn fatigued or broken piston ring 8Seized piston ring 8Seized or damaged ...

Page 205: ...rter plunger malfunction 8Wax malfunction 8Faulty thermister 8Clogged air cleaner 8Faulty spark plug 8Faulty spark plug read 8Faulty C D I unit 8Faulty source coil 8Faulty ignition coil POOR MEDIUM AND HIGH SPEED PERFOR MANCE Carburetor Air cleaner Muffler PROBABLE CAUSE 8 Refer to starting failure Hard starting item Fuel system Ignition system compression system 8 Clogged or loose main nozzle 8 C...

Page 206: ...belt 8Worn damaged 8Damaged 8Damaged 8 Damaged 8 Pealed lining 8 Seized primary sliding sheave and collar POOR STANDING START LOW CLIMBING ABILITY V belt Primary sheave Compression spring Secondary sheave Clutch shoe POOR ACCELERATION POOR HIGH SPEED V belt Weight Primary Secondary seave PROBABLE CAUSE 8 Worn or slipped V belt 8 Improper operation 8 Damaged 8 Damaged 8 Improper operation 8 Worn gu...

Page 207: ...er head 8 Clogged 8 Refer to FAULTY AUTOMATIC 8 Drag OVER HEAT POOR SPEED OVERHEAT OVER HEAT Ignition system Fuel system Compression system Muffler Exhaust pipe Oil pimp Brake Cooling system PROBABLE CAUSE 8Improper plug gap 8Improper spark plug heat range 8Faulty C D I unit 8Improper carburetor setting 8Clogged air filter 8Carbon accumulation of cylinder head 8Clogged 8Faulty oil pump 8Faulty oil...

Page 208: ...maged kick clip 8Kick clip coming off 8Damaged kick clip stopper 8Improper quality Low viscosity 8Deterioration PROBABLE CAUSE 8High tension of kick clip 8Seized kick gear 8Damaged or seized cylinder 8Damaged or seized piston 8Damaged or seized piston ring 8Improperly seated crankcase 8Improperly seated crankshaft 8Damaged or seized crankshaft 8Damaged or seized crankshaft bearing PROBABLE CAUSE 8...

Page 209: ...return spring 8Oily or greasy brake shoe 8Oily or greasy brake drum 8Broken brake cable 8Worn brake pad 8Worn brake disc 8Air in brake fluid 8Leaking brake fluid 8Faulty master cylinder kit 8Faulty caliper seal kit 8Loose union bolt 8Broken brake hose 8Oily or greasy brake pad 8Oily or greasy brake disc PROBABLE CAUSE 8Bent deformed or damaged inner tube 8Bent or deformed outer tube 8Damaged fork ...

Page 210: ... installed steering column Improperly tightened ringnut 8Bent steering column 8Damaged ball bearing or bearing race 8Broken spring 8Bonded front forks 8Uneven tire pressures on both sides 8Incorrect tire pressure 8Unevenly worn tires 8Damaged bearing 8Bent or loose wheel axle 8Excessive wheel run out 8Twisted 8Damaged head pipe 8Improperly installed bearing race 8Bent or damaged 8Fatigued spring 8...

Page 211: ...ection 8Improperly grounded 8Poor contacts main or light switch 8Bulb life expires PROBABLE CAUSE 8Improper bulb 8Improperly grounded 8Faulty main and or light switch 8Bulb life expires PROBABLE CAUSE 8Improperly grounded 8Discharged battery 8Faulty flasher switch 8Faulty flasher relay 8Broken wireharness 8Loosely connected coupler 8Bulb burnt out 8Faulty fuse PROBABLE CAUSE 8Faulty flasher relay ...

Page 212: ...BABLE CAUSE 8Faulty flasher relay 8Insufficient battery capacity nearly discharged 8Improper bulb 8Faulty main and or flasher switch PROBABLE CAUSE 8Improper bulb 8Faulty flasher relay PROBABLE CAUSE 8Faulty battery 8Faulty fuse 8Faulty main and or horn switch 8Improperly adjusted horn 8Faulty horn 8Broken wireharness ...

Page 213: ...nk Red Gray Yellow White Black Red Brown White Green Red Green Yellow Blue Black Blue Yellow Blue White Blue Red Red Black Red Yellow Red white Yellow White White Green Green White White Red Blue Green LOCK OPEN OFF CHECK ON B Gy R Br R Br B Gy OFF START B B Y R B Gy Br Gy Br Br G Br G Dg Ch Dg Ch L Gy B L Gy B G B G B L P B Ch Br W Dg Y G Y G Ch B Ch B Dg B Dg B OFF PUSH Or B Or B Gy Br R B B W R...

Page 214: ...YAMAHA MOTOR TAIWAN CO LTD ...

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