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ENG

5-9

PISTON

E

1

2

3

4

5

6

1

E

Order

Job/Part

Q´ty

Remarks

Removing the piston

Remove the parts in the order listed.

Cylinder head
Cylinder

1

Piston pin clip

2

2

Piston pin

1

3

Piston

1

4

Top ring

1

5

2nd ring/expander ring

1/1

6

Connecting rod small end bearing

1

For installation, reverse the removal
procedure.

CYLINDER HEAD, CYLINDER AND PISTON

5PG-7-10   100

06.5.16, 17:43:47

Содержание PW50W 2007

Страница 1: ...SERVICE MANUAL 5PG 28197 10 LIT 11616 20 15 PW50W...

Страница 2: ......

Страница 3: ...otor Corporation U S A First edition May 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed...

Страница 4: ...intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all...

Страница 5: ...except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify proce...

Страница 6: ...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 indicate the types of lubricants and lubrication points u...

Страница 7: ...IFICATIONS TROUBLESHOOTING ELECTRICALSYSTEM CARBURETOR CHASSIS PERIODIC CHECKSAND ADJUSTMENTS GENERALINFORMATION GEN INFO TRBL SHTG ELEC CARB CHAS CHK ADJ SPEC TABLE OF CONTENTS 4 6 7 8 3 2 1 ENGINE E...

Страница 8: ......

Страница 9: ...NUMBER 1 1 ENGINE SERIAL NUMBER 1 1 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...

Страница 10: ...N VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The number 1 is stamped into the frame head pipe ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase NOTE Designs and s...

Страница 11: ...f the parts and place them in trays in the order of disassembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire 1 2 EAS000...

Страница 12: ...earing 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 e...

Страница 13: ...several times 3 Check 9 all connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect 9 lead 9 coupler 9 connector NOTE Make sure all connectio...

Страница 14: ...g tool This tool is necessary for removing and installing the rotor 90890 01252 Dial gauge and stand set These tools are for measuring the crankshaft runout Crankshaft instoller pot This tool is neces...

Страница 15: ...nkcase 90890 01362 YU 33270 90890 06754 YM 34487 Ignition checker This instrument is necessary for check ing the ignition system components 90890 01307 YM 01307 Hex wrench 22 mm This tool is needed fo...

Страница 16: ...FICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 2 ENGINE 2 2 CHASSIS 2 6 ELECTRICAL 2 10 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 11 DEFINITION OF UNITS 2 11 LUBRICATION POINTS AND LUBRICANT TYPES 2 12 E...

Страница 17: ...verall length 1245 mm 49 0 in Overall width 575 mm 22 6 in Overall height 715 mm 28 1 in Seat height 485 mm 19 1 in Wheelbase 855 mm 33 7 in Ground clearance 105 mm 4 13 in Minimum turning radius 1300...

Страница 18: ...uantity 0 30 L 0 32 US qt 0 26 Imp qt Transmission oil Type YAMALUBE 4 10W30 or SAE 10W30 Except for EUROPE SAE 10W30 For EUROPE API service SG type or higher JASO standard MA Total amount 0 35 L 0 37...

Страница 19: ...outside diameter 9 994 10 000 mm 0 3935 0 3937 in Limit 9 974 mm 0 3927 in Piston ring Top ring Ring type Keystone Dimensions B x T 1 50 x 1 80 mm 0 06 x 0 07 in End gap installed 0 15 0 35 mm 0 0059...

Страница 20: ...15 x 54 11 6 218 Kickstarter Kickstarter type Ratchet Kick clip friction force P 1 5 N 0 34 1 33 lbf 0 15 0 60 kgf Air filter Air filter oil grade Foam air filter oil or SAE10W30SE Carburetor Type x...

Страница 21: ...Muffler M8 x 1 25 1 18 1 8 13 Exhaust chamber protector M6 x 1 0 4 9 0 9 6 5 Bearing retainer Main axle M6 x 1 0 2 12 1 2 8 7 Middle driven pinion Screw M45 x 1 5 1 60 6 0 43 Left hand thread Plate b...

Страница 22: ...Rim size 10x1 50 Rim material Steel Wheel travel 50 0 mm 1 97 in Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Front tire Type With tube Size 2 50 10 4PR Manufactu...

Страница 23: ...rum inside diameter 80 0 mm 3 15 in Limit 80 5 mm 3 17 in Lining thickness 3 5 mm 0 14 in Limit 1 5 mm 0 06 in Shoe spring free length 44 5 mm 1 75 in Steering Steering bearing type Ball and race bear...

Страница 24: ...ar shock absorber assembly travel 30 0 mm 1 18 in Spring free length 153 mm 6 02 in Installed length 146 mm 5 75 in Spring rate K1 11 89 N mm 67 94 lb in 1 22 kgf mm Spring rate K2 33 4 N mm 190 71 lb...

Страница 25: ...R Engine Front M8 x 1 25 2 29 2 9 21 Bearing housing Rear M8 x 1 25 2 33 3 3 24 Front brake Cam shaft lever M5 x 0 8 1 4 0 4 2 9 Side cover Frame M6 x 1 0 2 7 0 7 5 1 Rear brake Cam shaft lever M5 x 0...

Страница 26: ...R B Source coil resistance 297 363 B R B CDI unit model manufacturer 3PT 00 YAMAHA Ignition coil Model manufacturer 2JN YAMAHA Primary coil resistance 0 32 0 48 Secondary coil resistance 5 68 8 52 k M...

Страница 27: ...clean dry threads Components should be at room tem perature Unit Read Definition Measure mm Millimeter 10 3 m Length cm Centimeter 10 2 m Length kg Kilogram 103 gram Weight N Newton 1 kg m sec2 Force...

Страница 28: ...Kickstarter gear inner surface Kickstarter shaft Crankcase mating surface Yamaha bond No 1215 CHASSIS Lubrication point Lubricant Front wheel oil seal lips Front brake camshaft Rear wheel oil seal lip...

Страница 29: ...overflow pipe w Oil delivery pipe e C D I magneto lead wire r C D I unit coupler t Fuel pipe y Control unit coupler u C D I unit lead i Switch cord band o Fuel pipe p Control unit lead Route it under...

Страница 30: ...and oil pipe Clamp with the switch cord band the wire harness throttle cable 2 oil pump cable and starter cable behind the igni tion coil lead Pass through the wire har ness stater cable rear brake c...

Страница 31: ...Clamp 7 Guide 2 front brake cable 8 Guide 1 Wire harness oil pipe starter cable 9 Oil pipe 0 Oil tank q Wire harness w Switch cord band Clamp the wire harness and starter cable Pass the front brake c...

Страница 32: ...E AUTOLUBE PUMP MINIMUM STROKE 3 7 AIR BLEEDING THE AUTOLUBE PUMP 3 9 CHECKING THE EXHAUST SYSTEM 3 10 CLEANING THE SPARK ARRESTER AND EXHAUST CHAMBER 3 11 CLEANING THE AIR FILTER ELEMENT 3 11 CHECKIN...

Страница 33: ...7 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYS TEM NOTE 9 From 18 months repeat the maintenance intervals starting from 6 months 9 Items marked with an asterisk should be performed by a Yam...

Страница 34: ...g bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease every 2 years 7 Middle and nal gear cases Check for grease leakage Check gears for damage and wear Lu...

Страница 35: ...6 7 Nm 0 7 m kg 5 1 ft lb Order Job Part Q ty Remarks Removing the side covers seat Remove the parts in the order listed and fuel tank 1 Flap 1 2 Side cover 1 3 Seat 1 4 Fuel cock 1 Set the fuel cock...

Страница 36: ...upright 2 Start the engine warms it up for several minutes and then turn it off 3 Place a container under the transmission 4 Remove 9 Oil filler cap 1 9 Transmission oil drain bolt 2 Completely drain...

Страница 37: ...warm up for several minutes 2 Install 9 Digital tachometer onto the spark plug lead 1 of cylinder 3 Check 9 Engine idling speed Out of specification Adjust the throttle stop screw 4 Adjust 9 Engine id...

Страница 38: ...LE e Loosen the locknut 1 handle grip side and then turn the adjusting nut 2 in direc tion a or b until the specified throttle cable free play is obtained f Tighten the locknut w After adjusting the t...

Страница 39: ...aligned Adjust ADJUSTING THE AUTOLUBE PUMP CABLE ADJUSTING THE AUTOLUBE PUMP MINIMUM STROKE 5 Adjust 9 Autolube pump alignment mark a Loosen the locknut 1 b Turn the adjust nut 2 until align the pin...

Страница 40: ...tolube pump minimum stroke a Measure the autolube pump stroke while turning the kick crank slowly b Loosen the locknut 1 and turn the adjust ing bolt 2 direction a or b for proper adjustment c Tighten...

Страница 41: ...ump cable slightly and keep the engine speed until all air bubbles flow out from the air bleed hole c When there are no air bubbles left tighten the air bleed screw AIR BLEEDING THE AUTOLUBE PUMP cC 9...

Страница 42: ...components 9 Do not start the engine when cleaning the exhaust system 1 Check 9 Exhaust chamber assembly 9 Muffler Cracks damage Replace Exhaust gas leaks Replace the gasket 2 Check 9 Tightening torq...

Страница 43: ...rester portion of the tail pipe 9 Tap the tail pipe lightly and remove the carbon deposits from the outside portion of the tail pipe 9 Exhaust chamber If the carbon deposit use the round scraper to re...

Страница 44: ...but not dripping 6 Install 9 Air filter element 9 Air filter case cover cC Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and m...

Страница 45: ...urn the adjuster 1 in direction a or b until the specified brake lever free play is obtained cC After adjusting the brake lever free play make sure there is no brake drag CHECKING THE FRONT AND REAR B...

Страница 46: ...nest portion CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the vehicle on a level surface w Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a s...

Страница 47: ...cket and check the upper and lower bearings Refer to STEERING in chapter 4 f Install the oil tank bracket washer and steering stem bolt and then tighten the steering stem bolt to specified torque 5 In...

Страница 48: ...pressure Out of specification Regulate w 9 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air tem perature 9 The tire pressure and the suspension m...

Страница 49: ...mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire w A...

Страница 50: ...LS The following procedure applies to both of the wheels 1 Check 9 Wheel Damage out of round Replace w Never attempt to make any repairs to the wheel NOTE After a tire or wheel has been changed or re...

Страница 51: ...nd ELECTRICAL CHECKING THE SPARK PLUG 1 Disconnect 9 Spark plug cap 1 Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease 2 Remove 9 Spark plug cC Before re...

Страница 52: ...b CHECKING THE SPARK PLUG 1 2 a 4 Check 9 Electrode 1 Damage wear Replace the spark plug 9 Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean 9 Spark plug wi...

Страница 53: ...THE HANDLEBAR 4 17 CHECKING THE HANDLEBAR 4 17 INSTALLING THE HANDLEBAR 4 18 FRONT FORK 4 20 REMOVING THE FRONT FORK LEGS 4 22 DISASSEMBLING THE FRONT FORK LEG 4 23 CHECKING THE FRONT FORK LEG 4 24 A...

Страница 54: ...4 0 m kg 29 ft lb Order Job Part Q ty Remarks Removing the front wheel Remove the parts in the order listed 1 Brake cable adjusting nut 1 2 Front brake cable 1 3 Pin 1 4 Spring 1 5 Axle nut washer 1 1...

Страница 55: ...AND BRAKE 4 2 2 2 3 4 1 Order Job Part Q ty Remarks Disassembling the front wheel Disassemble the parts in the order listed 1 Oil seal 1 2 Bearing 2 3 Spacer coller 1 1 4 Ring 1 1 For assembly revers...

Страница 56: ...ted 2 Remove 9 Brake cable adjusting nut 3 Disconnect 9 Front brake cable at the brake camshaft lever 4 Remove 9 Axle nut 9 Washer 9 Wheel axle 9 Front wheel 9 Brake shoe plate 9 Spacer 9 Coller CHECK...

Страница 57: ...e wheel bearings DISASSEMBLING THE FRONT WHEEL 1 Remove 9 Oil seals 9 Wheel bearings a Clean the outside of the front wheel hub b Remove the oil seal 1 with a flat head screwdriver NOTE To prevent dam...

Страница 58: ...4 or balls 5 Contact should be made only with the outer race 6 NOTE Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal INSTALLING THE FRONT WHEEL 1 Lubricate 9 Front...

Страница 59: ...tightening the wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Connect 9 Front brake cable at the brake camshaft lever 5 Install 9 Brake...

Страница 60: ...Nm 0 4 m kg 2 9 ft lb Order Job Part Q ty Remarks Disassembling the front wheel Disassemble the parts in the order listed 1 Brake shoe brake shoe spring 2 1 2 Nut 1 3 Bolt 1 4 Brake camshaft lever 1...

Страница 61: ...no danger of it falling over NOTE Place the vehicle on the mainstand so that the front wheel is elevated 2 Remove the front wheel Refer to REMOVING THE FRONT WHEEL 3 Remove 9 Brake shoe plate from th...

Страница 62: ...hoe and brake shoe spring as a set w Do not allow oil or grease to contact the brake shoes NOTE Replace the brake shoes as a set if either is worn to the wear limit 3 Measure 9 Brake drum inside diame...

Страница 63: ...e brake camshaft so its punch mark a is positioned as shown b Align the projection on the brake shoe wear indicator with the notch in the brake camshaft c Align the punch mark in the brake camshaft wi...

Страница 64: ...rder listed brake Side cover Refer to SIDE COVERS SEAT AND FUEL TANK in chapter 3 Muffler Refer to ENGINE REMOVAL in chapter 5 Rear shock absorber lower bolt Refer to REAR SHOCK ABSORBER right ASSEMBL...

Страница 65: ...RONT WHEEL REAR WHEEL AND BRAKE 4 12 6 Nm 0 6 m kg 4 3 ft lb 1 2 3 4 5 6 8 7 11 10 9 Order Job Part Q ty Remarks 10 Brake camshaft lever 1 11 Brake camshaft 1 For installation reverse the removal proc...

Страница 66: ...ENGINE REMOVAL in chapter 5 3 Remove 9 Swingarm Refer to REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 4 Remove 9 Brake cable adjusting bolt 1 9 Rear brake cable 2 9 Pin 3 9 Spring 4 at the brake camshaf...

Страница 67: ...er to CHECKING THE FRONT BRAKE 3 Measure 9 Brake drum inside diameter Refer to CHECKING THE FRONT BRAKE 4 Check 9 Brake drum inner surface Refer to CHECKING THE FRONT BRAKE 5 Check 9 Brake camshaft Re...

Страница 68: ...ly and muffler Refer to CLEANING THE SPARK ARRESTER AND MUFFLER in chapter 3 60 Nm 6 0 m kg 43 ft lb INSTALLING THE REAR WHEEL 1 Stand the vehicle on a level surface w Securely support the vehicle so...

Страница 69: ...r listed Front fender Refer to SIDE COVERS SEAT AND FUEL TANK in chapter 3 Oil tank Refer to STEERING 1 Handle protector 1 2 Rear brake cable 1 3 Rear brake lever 1 4 Front brake cable 1 5 Front brake...

Страница 70: ...le 9 Throttle grip 2 NOTE While removing the ignition control switch pull back the rubber cover 3 3 Disconnect 9 Rear brake lever 4 Remove 9 Grip 1 NOTE Blow compressed air between the left handle bar...

Страница 71: ...the handlebar grip until the rubber adhesive has fully dried INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface w Securely support the vehicle so that there is no danger of it falling ove...

Страница 72: ...y NOTE Align the same angle of the ignition control switch with left lever holder and then install the ignition control switch 7 Connect 9 Front brake cable 9 Rear brake cable 8 Install 9 Handle prote...

Страница 73: ...andlebar Refer to HANDLEBAR Oil tank Refer to STEERING 1 Band 1 2 Front brake cable 1 3 Cap bolt washer 2 2 4 Lower bracket pinch bolt 2 Loosen 5 Front fork 2 Do not disassemble the front fork right F...

Страница 74: ...4 21 1 2 3 4 5 1 2 3 4 5 6 7 8 9 32 Nm 3 2 m kg 23 ft lb 23 Nm 2 3 m kg 17 ft lb Order Job Part Q ty Remarks 6 Spring 1 7 Fork spring 1 8 Damper rubber 1 9 Outer tube 1 For assembly reverse the disass...

Страница 75: ...s no danger of it falling over 9 Place the vehicle on a suitable stand so that the front wheel is elevated 2 Remove 9 Handlebar Refer to REMOVING THE HANDLEBAR 3 Remove 9 Front wheel Refer to REMOVING...

Страница 76: ...a vise with soft jaws cC Do not scratch the inner tube c Remove the dust seal from outer tube d While pressing down on the front fork remove the circlip 2 Remove 9 Inner tube 1 9 Outer tube 2 a Hold t...

Страница 77: ...to straighten a bent inner tube as this may dangerously weaken it 2 Measure 9 Spring free length a Out of specification Replace 3 Check 9 Outer tube assembly 1 Damage wear Replace cC When disassembli...

Страница 78: ...o replace the following parts 9 Before assembling the front fork leg make sure all of the components are clean 2 Install 9 Damper rubber 1 9 Fork spring 2 9 Spring seat 3 1 Lubricate 9 Inner tube s ou...

Страница 79: ...ube INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install 9 Front fork 1 Temporarily tighten the lower bracket pinch bolt 2 Tighten 9 Lower bracket pi...

Страница 80: ...Remove the parts in the order listed Handlebar Refer to HANDLEBAR 1 Steering stem bolt cap bolt 1 2 2 Oil tank cap 1 3 Oil tank 1 Drain the engine oil 4 Oil tank bracket starter cable 1 1 5 Upper bra...

Страница 81: ...VING THE HANDLE BAR 3 Remove 9 Steering stem bolt 9 Washer 9 Upper bracket 9 Oil tank bracket 9 Ring nut 1 9 Upper ball bearing 9 Lower bracket 9 Lower ball bearing CHECKING THE STEERING HEAD 1 Wash 9...

Страница 82: ...pe could be damaged NOTE 9 Always replace the bearings and bearing races as a set 9 Whenever the steering head is disassem bled replace the rubber seal INSTALLING THE STEERING HEAD 1 Lubricate 9 Upper...

Страница 83: ...CHAS STEERING HEAD 4 30 3 Install 9 Oil tank 9 Upper bracket 9 Washer 1 9 Steering stem bolt 2 4 Bleed 9 Autolube pump Refer to AIR BLEEDING THE AUTOL UBE PUMP in chapter 3 1 2 32 Nm 3 2 m kg 23 ft lb...

Страница 84: ...t lb 1 29 Nm 2 9 m kg 21 ft lb G Order Job Part Q ty Remarks Removing the rear shock Remove the parts in the order listed absorber and swingarm Side cover Refer to SIDE COVERS SEAT AND FUEL TANK in ch...

Страница 85: ...assembly 1 2 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check 9 Rear shock absorber rod rear shock absorber assembly Damage wear Replace 9 Rear shock absorber Oil leaks Replace the rear shock absorb...

Страница 86: ...rm bolt rear 2 9 Swingarm bolt front 3 3 Loosen 9 Rear axle nut 4 NOTE While applying the rear brake loosen the rear axle nut 4 Remove 9 End cap 5 9 Rear axle nut 9 Swingarm 6 1 4 5 2 6 3 3 CHECKING T...

Страница 87: ...ear brake to tighten the rear axle nut 3 Install 9 Exhaust chamber assembly 9 Muffler Refer to ENGINE REMOVAL in chapter 5 29 Nm 2 9 m kg 21 ft lb 33 Nm 3 3 m kg 24 ft lb 60 Nm 6 0 m kg 43 ft lb 23Nm...

Страница 88: ...emarks Removing the shaft drive Remove the parts in the order listed Rear shock absorber Refer to REAR SHOCK ABSORBER left right ASSEMBLY AND SWINGARM Swingarm Rear wheel Refer to FRONT WHEEL REAR WHE...

Страница 89: ...3 14 15 9 Nm 0 9 m kg 6 5 ft lb 16 26 Nm 2 6 m kg 19 ft lb 26 Nm 2 6 m kg 19 ft lb 50 Nm 5 0 m kg 36 ft lb Order Job Part Q ty Remarks 12 Spacer 1 13 Screw 1 14 Bearing 1 15 Spacer 1 16 Drive pinion g...

Страница 90: ...ol 2 3 Remove 9 Spacer 9 Bearing 9 Shim cC The drive pinion gear should only be removed if ring gear replacement is neces sary NOTE Lightly tap on the end of the drive pinion gear with a soft hammer 1...

Страница 91: ...ean the contacting surface of rear arm ends before applying the sealant 2 Tighten 9 Rear arm bolt 2 Install 9 Drive pinion gear 9 Shim 9 Bearing 9 Spacer 9 Bearing 1 2 1 1 Hexagon wrench 90890 01307 Y...

Страница 92: ...ALVE 5 19 CHECKING THE REED VALVE 5 19 ASSEMBLING AND INSTALLING THE REED VALVE 5 20 CLUTCH 5 21 REMOVING THE CLUTCH 5 23 CHECKING THE PRIMARY DRIVE GEAR 5 24 CHECKING THE PRIMARY DRIVEN GEAR 5 24 CHE...

Страница 93: ...ENG CHECKING THE CRANKSHAFT 5 41 INSTALLING THE CRANKSHAFT 5 42 MIDDLE GEAR 5 44 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 5 46 CHECKING THE MEDDLE GEAR 5 46 INSTALLING THE MEDDLE GEAR 5 46...

Страница 94: ...m 0 9 m kg 6 5 ft lb 3 Order Job Part Q ty Remarks Removing the muffler and exhaust Remove the parts in the order listed chamber assembly 1 Muffler assembly 1 2 Exhaust chamber assembly 1 3 Gasket 1 P...

Страница 95: ...R ASSEMBLYAND SWINGARM in chapter 4 Swingarm Refer to SWINGARM in chapter 4 Rear brake cable Refer to REAR WHEEL in chapter 4 Oil hose autolube pump assembly Refer to AUTOLUBE PUMP Air filter case car...

Страница 96: ...vehicle on the mainstand so that the rear wheel is elevated 2 Remove 9 Side cover Refer to SIDE COVERS SEAT AND FUEL TANK in chapter 3 3 Remove 9 Air filter case assembly 1 4 Disconnect 9 Oil hose 9...

Страница 97: ...ASSEMBLY AND SWINARM in chapter 4 8 Remove 9 Brake cable adjusting nut 1 9 Rear brake cable 2 9 Pin 3 9 Spring 4 9 Remove 9 Autolube pump cover outer 1 10 Remove 9 Oil hose autolube pump cable 9 Autol...

Страница 98: ...le removing the engine pull out the pivot shaft and then remove the frame assembly 9 Be sure to check the wire cable and hose disconnected INSTALLING THE ENGINE w Securely support the engine assembly...

Страница 99: ...plug cap 1 3 Tighten 9 Pivot shaft nut 4 Connect 9 CDI magneto lead coupler connector 1 6 Install 9 Autolube pump assembly 1 With the autolube pump cover inner 2 9 Autolube pump cable oil hose 3 9 Aut...

Страница 100: ...kg 6 5 ft lb 18 Nm 1 8 m kg 13 ft lb 29 Nm 2 9 m kg 21 ft lb 33 Nm 3 3 m kg 24 ft lb 60 Nm 6 0 m kg 43 ft lb 23Nm 2 3 m kg 17 ft lb 18 Nm 1 8 m kg 13 ft lb 10 Install 9 Carburetor assembly Refer to CA...

Страница 101: ...Nm 1 0 m kg 7 2 ft lb 20 Nm 2 0 m kg 14 ft lb E Order Job Part Q ty Remarks Removing the cylinder Remove the parts in the order listed Exhaust chamber assembly Refer to ENGINE REMOVAL Spark plug cap...

Страница 102: ...piston Remove the parts in the order listed Cylinder head Cylinder 1 Piston pin clip 2 2 Piston pin 1 3 Piston 1 4 Top ring 1 5 2nd ring expander ring 1 1 6 Connecting rod small end bearing 1 For ins...

Страница 103: ...9 Cylinder 9 Gasket 1 REMOVING THE PISTON 1 Remove 9 Piston pin clips 1 9 Piston pin 2 9 Piston 3 cC Do not use a hammer to drive the piston pin out NOTE 9 Before removing the piston pin clip cover t...

Страница 104: ...THE CYLINDER HEAD 1 Eliminate 9 Combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid dam aging or scratching 9Spark plug bore threads 2 Eliminate 9 Exh...

Страница 105: ...head several times e After resurfacing out of specification Replace the cylinder head CHECKING THE CYLINDER AND PISTON 1 Check 9 Piston wall 9 Cylinder wall Vertical scratches Rebore or replace the cy...

Страница 106: ...n to cylinder clearance Cylinder bore C Piston skirt diameter D f If out of specification replace the cylinder and replace the piston and piston rings as set Diameter D 39 952 39 972 mm 1 5729 1 5737...

Страница 107: ...place the piston pin and small end bearing as a set Piston pin outside diameter 9 994 10 000 mm 0 3935 0 3937 in Limit 9 974 mm 0 3927 in CYLINDER HEAD CYLINDER AND PISTON a Install a piston ring into...

Страница 108: ...a set Piston pin to piston pin bore clearance Piston pin bore diameter b Piston pin outside diameter a Piston pin bore inside diameter 10 004 10 015 mm 0 3939 0 3943 in Limit 10 035 mm 0 3951 in Pist...

Страница 109: ...it 3 Install 9 Piston 1 9 Piston pin 9 Piston pin clips 2 NOTE 9 Apply engine oil the piston pin 9 Make sure the arrow mark a on the piston points towards the exhaust side of the cylin der 9 Before in...

Страница 110: ...cylinder with the other hand 9 Gasket 9 Cylinder head 4 Tighten 9 Cylinder head nut NOTE Tighten the cylinder head nut 2 stages and in a crisscross pattern 5 Install 9 Spark plug 6 Tighten 9 Spark pl...

Страница 111: ...valve Remove the parts in the order listed Side cover Refer to SIDE COVERS SEAT AND FUEL TANK in chapter 3 Engine Refer to ENGINE REMOVAL 1 Intake manifold 1 2 Upper valve seat gasket 1 3 Reed valve...

Страница 112: ...ower valve seat gasket CHECKING THE REED VALVE 1 Check 9 Reed valve assembly Cracks damage Replace the reed valve assembly 2 Check 9 Reed valve bending a Out of specification Replace the reed valve 3...

Страница 113: ...VALVE 1 Install 9 Reed valve 9 Reed valve stopper 2 Install 9 Lower valve seat gasket 1 9 Reed valve assembly 2 9 Upper valve seat gasket 3 9 Intake manifold 3 Install 9 Carburetor assembly 9 Air fil...

Страница 114: ...e parts in the order listed Side cover Refer to SIDE COVERS SEAT AND FUEL TANK in chapter 3 Engine Refer to ENGINE REMOVAL 1 Crankcase cover protector 1 2 Right crankcase cover 1 3 Gasket 1 4 Dowel pi...

Страница 115: ...5 6 7 8 9 11 10 9 Nm 0 9 m kg 6 5 ft lb 30 Nm 3 0 m kg 22 ft lb 13 14 12 8 Nm 0 8 m kg 5 8 ft lb 4 Order Job Part Q ty Remarks 12 Straight key 1 13 Thrust plate 1 14 Coller 1 For installation reverse...

Страница 116: ...SION OIL in chapter 3 3 Remove 9 Crankcase cover protector 1 9 Right crankcase cover 2 9 Gasket 9 Dowel pin 4 Remove 9 Circlip 1 9 Clutch housing 2 5 Remove 9 Primary drive gear nut 1 9 Washer 9 Clutc...

Страница 117: ...ary drive and clutch carri er assembly as a set CHECKING THE CLUTCH HOUSING 1 Check 9 Clutch housing Damage wear Replace the clutch hous ing 1 2 Measure 9 Clutch housing inside diameter Out of specifi...

Страница 118: ...34 5 mm 1 36 in Wear limit 35 5 mm 1 40 in INSTALLING THE CLUTCH 1 Install 9 Absorber large 1 9 Absorber small 2 NOTE Install the absorber large to L side a and install the absorber small to S side b...

Страница 119: ...6 CLUTCH 5 Install 9 Right crank case cover 1 9 Crankcase cover protector 2 6 Fill 9 Transmission oil Refer to CHANGING THE TRANSMIS SION OIL in chapter 3 1 2 8 Nm 0 8 m kg 5 8 ft lb 9 Nm 0 9 m kg 6 5...

Страница 120: ...er assembly Refer to ENGINE REMOVAL 1 Autolube pump cover outer 1 2 Oil delivery hose 1 3 Autolube pump cable 1 4 Oil hose 1 Be sure cap the oil hose by proper bolt to prevent the engine oil to spilt...

Страница 121: ...r outer 1 2 Remove 9 Autolube pump assembly 1 with autolube pump cover inner 2 3 Remove 9 Oil pump cable 1 9 Oil delivery hose 2 disconnect the autolube pump side 1 2 1 1 3 2 4 Disconnect 9 Oil hose 3...

Страница 122: ...r 2 9 Pin 3 9 O ring 4 9 Oil seal 5 CHECKING THE AUTOLUBE PUMP 1 Check 9 Autolube pump Damage cracks Replace the autolube pump assembly 2 Check 9 Worm wheel gear Worn damage Replace the oil pump drive...

Страница 123: ...PUMP 1 Install 9 Autolube pump assembly 1 with autolube pump cover inner 2 5 4 3 2 1 1 2 3 1 2 4 Install 9 Autolube pump cover outer 1 1 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 5 Install 9 Air...

Страница 124: ...in the order listed Side cover Refer to SIDE COVERS SEAT AND FUEL TANK in chapter 3 Engine Refer to ENGINE REMOVAL Clutch Refer to CLUTCH 1 Kick crank bolt 1 1 2 Pump drive gear 1 3 Torsion spring 1 4...

Страница 125: ...Unhook the torsion spring 1 from the stopper a in the crankcase 6 Remove 9 Kick pinion gear 9 Clip CHECKING THE KICK STARTER 1 Check 9 Kick shaft 1 Bend damage Replace the kick shaft 9 Kick gear toot...

Страница 126: ...ockwise and hook onto the stopper a in the crankcase 3 Install 9 Oil pump drive gear 3 NOTE Align the oil pump drive gear tooth with oil pump drive gear tooth and then install it 1 2 3 1 2 a 3 4 Insta...

Страница 127: ...moving the CDI magneto Remove the parts in the order listed Side cover Refer to SIDE COVERS SEAT AND FUEL TANK in chapter 3 1 Magneto cover 1 2 Rotor nut 1 3 Spring washer 1 4 Washer 1 5 CDI magneto r...

Страница 128: ...e rotor holding tool 2 3 Remove 9 Rotor nut 9 Spring washer 9 Washer 9 CDI magneto rotor 1 Use with the flywheel puller 2 9 Woodruff key 5 Remove 9 Stator assembly 1 1 2 1 1 2 1 Rotor holding tool 908...

Страница 129: ...ff key INSTALLING THE CDI MAGNETO 1 Install 9 Stator assembly 2 Tighten 9 Stator assembly screw 3 Install 9 Wooruff key 1 to install the crankshaft key way 4 Install 9 CDI magneto rotor 1 9 Washer 2 9...

Страница 130: ...ding tool 2 NOTE While holding the CDI magneto rotor with the rotor holding tool tighten the rotor nut 6 Install 9 Magneto cover 7 Connect 9 CDI magneto coupler connecter 2 1 43 Nm 4 3 m kg 31 ft lb R...

Страница 131: ...fer to SIDE COVERS SEAT AND FUEL TANK in chapter 3 Engine Refer to ENGINE REMOVAL Cylinder head cylinder piston Refer to CYLINDER HEAD CYLINDER AND PISTON Reed valve Refer to REED VALVE Clutch Refer t...

Страница 132: ...ANKSHAFT 1 2 3 3 4 5 6 6 7 7 8 Nm 0 8 m kg 5 8 ft lb 15 Nm 1 5 m kg 11 ft lb E E Order Job Part Q ty Remarks 4 Crankshaft assembly 1 5 Crankcase right 1 6 Bearing 2 7 Oil seal 2 For installation rever...

Страница 133: ...uller 2 a 95 mm 3 74 in NOTE 9 Fully tighten the tool holding bolts but make sure the tool body is parallel with the case If necessary one screw may be backed out slightly to level tool body 9 As pres...

Страница 134: ...nout a 9 Small end free play b 9 Connecting rod big end side clearance c 9 Crank width d Out of specification Replace the crank shaft assembly Use the dial gauge and thickness gauge 1 2 a a b c d Dial...

Страница 135: ...e crankshaft clean the contacting surface of crankcase 9 Apply the lithium soap base grease on the oil seal lip cC Do not use a hammer to drive in the crank shaft 2 Apply 9 Yamaha bond No 1215 Three B...

Страница 136: ...ankcase the connect ing rod should be positioned at TDC top dead center 4 Tighten 9 Screw crankcase NOTE Tighten the crankcase tightening screws in stage using a crisscross pattern 5 Remove 9 Sealant...

Страница 137: ...in the order listed Engine Refer to ENGINE REMOVAL Clutch Refer to CLUTCH Kick starter Refer to KICK STARTER Rear wheel Refer to FRONT WHEEL REAR WHEEL AND BRAKE in chapter 4 Shaft drive Refer to SHA...

Страница 138: ...5 45 MIDDLE GEAR 1 2 3 4 12 Nm 1 2 m kg 8 7 ft lb 6 5 9 8 7 60 Nm 6 0 m kg 43 ft lb G G Order Job Part Q ty Remarks 8 Main axle assembly 1 9 Pinion shim 1 For installation reverse the removal procedu...

Страница 139: ...9 Bearing 2 9 Driven pinion 3 9 Thrust shim 4 Hexagon wrench 90890 01306 YM 01306 1 2 1 2 3 4 1 2 CHECKING THE MEDDLE GEAR 1 Check 9 Main axle 1 Galling pitting wear Replace 2 Check 9 Driven pinion 2...

Страница 140: ...ENG 5 47 MIDDLE GEAR 2 Install 9 Screw 1 Attach the hexagon wrench 2 NOTE Tighten the screw counterclockwise 3 Install 9 Oil seal Hexagon wrench 90890 01306 YM 01306 1 2 60 Nm 6 0 m kg 43 ft lb...

Страница 141: ...CARB CHAPTER 6 CARBURETOR CARBURETOR 6 1 REMOVING THE CARBURETOR 6 3 DISASSEMBLING THE CARBURETOR 6 4 CHECKING THE CARBURETOR 6 4 ASSEMBLING THE CARBURETOR 6 6 INSTALLING THE CARBURETOR 6 8...

Страница 142: ...sted Side cover Refer to SIDE COVERS SEAT AND FUEL TANK in chapter 3 1 Air filter assembly 1 2 Fuel hose 1 Set the fuel cock to S 3 Oil delivery hose 1 4 Mixing chamber top 1 5 Carburetor clamp screw...

Страница 143: ...embling the carburetor Disassemble the parts in the order listed 1 Throttle stop screw set 1 2 Float chamber body 1 3 Float chamber gasket 1 4 Float pin 1 5 Float 1 6 Needle valve 1 7 Main jet 1 8 Mai...

Страница 144: ...9 Seat 9 Clip 9 Air filter assembly 1 2 Remove 9 Oil delivery hose 1 9 Fuel hose 2 3 Remove 9 Mixing chamber top 1 4 Loosen 9 Carburetor clamp screw 2 5 Remove 9 Carburetor assembly 3 6 Remove 9 Thro...

Страница 145: ...oat chamber body 1 2 Remove 9 Throttle stop screw set 1 3 Remove 9 Float chamber body 9 Float chamber gasket 2 3 1 4 Remove 9 Float pin 1 9 Float 2 9 Needle valve assembly 3 1 2 3 5 Remove 9 Main jet...

Страница 146: ...uretor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check 9 Float chamber body Dirt Clean 4 Check 9 Float Damage Replace 5 Check 9 Needle valve 9 Needle valve seat D...

Страница 147: ...ess Replace the throttle valve 9 Check 9 Starter plunger 9 Starter plunger spring Bends cracks damage Replace 10 Check 9 Fuel hose 9 Oil delivery hose Cracks damage wear Replace Obstruction Clean Blow...

Страница 148: ...wn position b Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE The float arm should be resting on the needle valve but not compre...

Страница 149: ...and then install them 6 Install 9 Throttle valve spring 1 9 Needle set 2 9 Throttle valve 3 9 Plunger spring 4 9 Starter plunger 5 1 3 2 4 5 INSTALLING THE CARBURETOR 1 Adjust 9 Engine idling speed R...

Страница 150: ...ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 7 1 CHECKING SWITCH CONTINUITY 7 2 CHECKING THE SWITCHES 7 3 IGNITION SYSTEM 7 4 CIRCUIT DIAGRAM 7 4 TROUBLESHOOTING 7 5...

Страница 151: ...ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1Ignition control switch 2Diode 3Control unit 4CDI unit 5Ignition coil 6Stater assembly 2 3 4 5 1 6 ELEC ELECTRICAL COMPONENTS 7 1...

Страница 152: ...ck et tester to 0 and to the 1 range 9 When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop swi...

Страница 153: ...NG THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the terminals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly conne...

Страница 154: ...W R W R W R W R W R B R B R B R B R B R B R B R B R B R B R B R Y W Y W Y W B B B W Y R R B Y W B W B B Y 1 2 3 4 5 6 7 8 1 Ignition control switch 2 Diode 3 Control unit 4 C D I magneto 5 C D I unit...

Страница 155: ...from the spark plug 9Connect the ignition checker 1 as shown 2 Spark plug cap 9Set the main switch to ON 9Crank the engine by pushing the start switch and gradually increase the spark gap until a mis...

Страница 156: ...probe terminal 1 Positive tester probe spark plug lead 2 9Measure the secondary coil resistance 9Is the ignition coil OK IGNITION SYSTEM 3 Spark plug cap resistance 9Remove the spark plug cap from th...

Страница 157: ...coil resistance 18 0 22 0 at 20 C 68 F between white red and black YES NO Replace the stator coil pickup coil assembly 6 Charge coil resistance 9Disconnect the charge coil coupler from the wire harne...

Страница 158: ...W R B R 1 2 Lighting coil resistance 0 57 0 69 at 20 C 68 F between white and black YES NO Replace the stator coil assembly 1 3 2 W R B R B B Y W B YES NO Replace the control unit assembly Control uni...

Страница 159: ...iring 9 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM 9 Is the ignition system wiring properly con nected and without defects YES NO Properly connect or repair the igni tion system...

Страница 160: ...E 8 2 FUEL SYSTEM 8 2 ELECTRICAL SYSTEM 8 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 3 ENGINE 8 3 FUEL SYSTEM 8 3 FAULTY CLUTCH 8 3 ENGINE OPERATES BUT VEHICLE WILL NOT MOVE 8 3 FUEL SYSTEM 8 3 ELECTR...

Страница 161: ...d piston ring 9 Seized piston ring 9 Seized or damaged piston Air filter 9 Improperly installed air filter 9 Clogged air filter element Crankcase and crankshaft 9 Improperly assembled crankcase 9 Seiz...

Страница 162: ...ded circuit 9 Loose connections ENGINE Air filter 9 Clogged air filter element FUEL SYSTEM Carburetor s 9 Faulty starter plunger 9 Loose or clogged pilot jet 9 Loose or clogged pilot air jet 9 Damaged...

Страница 163: ...ive CLUTCH SLIPS Clutch shoe spring s 9 Damaged loose or worn clutch shoe spring Clutch shoe s 9 Damaged or worn clutch shoe POOR STARTING PERFORMANCE Clutch shoe s 9 Bent damaged or worn clutch shoe...

Страница 164: ...correct grease viscosity EAS28660 FAULTY FRONT FORK LEGS Handlebar 9 Bent or improperly installed handlebar Steering head components 9 Improperly installed upper bracket 9 Improperly installed lower b...

Страница 165: ......

Страница 166: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A...

Страница 167: ...O Orange R Red W White W B White Black B Y Black Yellow B R Black Red W R White Red Y W Yellow White COLOR CODE RUN OFF START B B B B B B B B B B B B B B B Y R R R O O O W W B Y B Y B Y W B W B W W B...

Страница 168: ...2 Diode 3 Control unit 4 C D I magneto 5 C D I unit 6 Ignition coil 7 Spark plug 8 Ground PW50W 2007 WIRING DIAGRAM RUN OFF START 1 2 3 4 5 6 7 8 Black Orange Red White Black Yellow Black Red White Bl...

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