YAMAHA JOG Diagram

Page 1
1987 - 1990
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MOTORCYCLE
SERVICE MANUAL
Model : CE50T, CG50A, CG50U, CG50W
2YT281972000
*2YT281972000*
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INFO
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SCOOTER IDENTIFICATION
GENERAL
INFORMATION
SCOOTER IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number (~ is stamped into the frame.
NOTE:
The vehicle identification number is used to iden- tify your scooter and may be used to register your scooter with the licensing outhority in your state.
Starting Serial Number:
JYA2U G00-~ H A720101
ENGINE SERIAL NUMBER
The engine serial number (~ is stamped into the crankcase.
NOTE:
The first three digits of these numbers are for
model identifications; the remaining digits are the unit production number.
Starting Serial Number:
14T-720101
NOTE:
Designs and specifications are subject to change
without notice.
1-1
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GEN
I
SPECIAL TOOLS I SPECIAL TOOLS
The proper special tools are necessary for com- plete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvis- ed techniques.
FOR TUNE-UP
1. Inductive Tachometer P/N. YU-08036
This tool is needed for detecting engine rpm.
2. Compression Gauge P/N. YU-33223
This gauge is used to measure engine compr- ession.
FOR ENGINE SERVICE
1. Flywheel Holding Tool P/N. YU-01235
This tool is used to the hold the flywheel magneto
and clutch assembly when removing or installing the securing nut.
2. Flywheel Magneto Puller
P/N.
YM-01189
This tool is used to remove the flywheel.
1-4
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I GEN
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SPECIAL TOOLS
i ............. ir
3. Primary Sheave Holder
P/N.
YS-01880
This tool is used when holding the clutch hub.
4. Clutch Spring Holder
P/N.
YS-28891 This tool is used to disassembly and assembly the secondary sheave.
P
5.
Thickness Gauge P/N. YU-03001
6.
Universal Puller Set
P/N. YU-33270
This tool is used to remove the crankshaft from the crankcase.
7. Crankcase Separating Tool P/N. YU-01135
This tool is used to remove the crankshaft or separate the crankcase.
1-5
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GEN
SPECIAL TOOLS I
8. Crankshaft Installation Set
P/N. YU-90050 ...................... (~)
Adapter (M10)
P/N. YM-90062 ..................... (~
Adapter (M12)
P/N. YM-90063 ..................... ~)
These tools are used to install the crankshaft.
9. Sealant (Quick Gasket ~) P/N. ACC-11001-05-01
This sealant (bond) is used for crankcase mating surfaces.
,.Fol l
@
!J
FOR CHASSIS SERVICE
1. Ring Nut Wrench P/N. YU-01268 (~
P/N. YU-33975 ..................... (~
This tool is used to loosen and tighten the steer- ing ring nut.
FOR ELECTRICAL COMPONENTS
1. Pocket Tester P/N. YU-03112
This instrument is invaluable for electrical system
inspection and §djustment.
2. Electro Tester P/N. YU-33260
This instrument is necessary for ignition system
inspection.
1-6
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I INSP
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FRONT FENDER, FRONT PANEL
AND FOOTREST BOARD/HANDLEBAR COVERS
I
NSTALLATION
Reverse the "REMOVAL" procedure. Note the following points,
1. Install: ® Front fender
NOTE:
After installing the front fender, make sure that all hooks are securely fitted.
E
HANDLEBAR COVERS
REMOVAL
1. Remove: =Screws (Handlebar cover -- Front) =Rear view mirror(s)
2. Disconnect:
-Headlight lead and flasher light leads
3. Remove:
-Handlebar cover (Front) (~
4. Disconnect: ® Leads
-Speedometer cable (~
5. Remove: ®Handlebar cover (Rear) (~
2-5
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ENGINE iDLE SPEED ADJUSTMENT I ADJ
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INSTALLATION
1. Install: oHandlebar cover (Rear) (~)
2. Connect:
Leads oSpeedometer cable (~)
NOTE:
Position the cables as shown.
Front brake cable (~) Throttle cable (~) Rear brake cable
I
3. Connect: eHeadlight lead and flasher ]~ght leads
4. Install: ® Handlebar cover (Front) ®Rear view mirror(s)
ENGINE
ENGINE iDLE SPEED ADJUSTMENT
1. Remove:
Tail cover,.
Refer to "TAIL COVER" section.
2. Start the engine and warm it up before check- ing the idle speed.
NOTE:
A warm engine is defined as one which had been operated for about 3 minutes at 3,000 r/min with no load.
2-6
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I INSP
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ENGINE IDLE SPEED ADJUSTMENT/
THROTTLE CABLE FREE PLAY ADJUSTMENT
3. Attach: ®Inductive Tachometer (YU-08036)
4. Check: eEngine idle speed
Out of specification-*Adjust.
Engine Idle Speed:
1,500-2,100 r/rnin
Engine idle speed adjustment steps; ®Start the engine at idle speed.
eTurn the throttle stop screw (~ clockwise to
increase engine speed and counterclockwise to decrease engine speed.
E
5. Install: eTail cover
Refer to "TAIL COVER" section.
THROTTLE CABLE FREE PLAY
ADJUSTMENT
1. Check: *Throttle cable free play (~
Out of specification-*Adjust.
[~ Throttle Cable Free Play (~):
3.0-7.0 mm (0.12-0.28 in)
Throttle cable free play adjustment steps;
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
2-7
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INSP
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STEERING ADJUSTMENT/BATTERY
2. Check: =Steering assembly bearings
Grasp the bottom of the forks and gently rock the rock assembly back and forth.
Looseness-*Adjust.
Steering head adjustment steps: =Remove the front fender and front panel.
Refer to "FRONT FENDER, FRONT PANEL
AND FOOTREST BOARD" section.
=Tighten the ring nut ~ to specification us-
ing the Ring Nut Wrench (YU-33975).
Ring Nut (~:
30 Nm (3.0 m okg, 22 ftolb)
NOTE: Set the torque wrench to the ring nut wrench
so that they form right angle.
*Move the handlebar up and down, and/or
back and forth. If handlebar free play is ex- cess, tighten the bolt (~ to specification.
Bolt (~:
60 Nm (6.0 m-kg, 43 ft-lb)
=Install the front fender and front panel.
ELECTRICAL
BATTERY
1. Check: = Fluid level
Incorrect-* Refill. Fluid level should be between upper and lower level marks.
(~ Upper level (~) Lower level
iiii!!ii i ii i iiiii!iii!!i
Refill with distilled water only; tap water
contains minerals harmful to a battery.
2-21
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I INSP
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SPARK PLUG INSPECTION/ HEADLIGHT BEAM ADJUSTMENT/IGNITION TIMING
3. Measure: ePlug gap (~
Out of specification--* Regap. Use a Wire Gauge or Feeler Gauge.
I~ Spark Plug Gap (~: ]
0.9-1.0 mm (0.035-0.039 in)
4. Clean the plug with a spark plug cleaner if necessary.
5. Tighten: Before installing a spark plug, clean the gasket and plug surfaces.
NOTE:
Finger,tighten the spark plug before torquing to
specification.
Spark Plug:
20 Nm (2.0 m-kg, 14 ft.ib)
HEADLIGHT BEAM ADJUSTMENT
1. Adjust:
Headlight (Vertically) Vertical adjustment
Higher Loosen the adjusters (~) Lower Tighten the adjusters (~)
Headlight (Horizontal)
Horizontal adjustment
Right the adjuster (~) Left
Loosen the adjuster (~) or tighten Loosen the adjuster (~) or tighten
the adjuster (~)
IGNITION TIMING
Adjustment free.
2-25
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CHAPTER 3
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ENGINE OVERHAUL

I ENG
ri
ENGINE REMOVAL .
PREPARATION FOR REMOVAL ................................. D-3
TAIL COVER .................................................. D-3
FRONT FENDER, FRONT PANEL AND FOOTREST BOARD ........ D-3
CARBURETOR ................................................. D-3
CABLES, LEADS AND PIPES ................................... D-4
ENGINE REMOVAL ............................................. D-4
DISASSEMBLY
MUFFLER ..................................................... D-5
CYLINDER HEAD .............................................. D-5
CYLINDER .................................................... D-6
PISTON PIN AND PISTON ...................................... D-6
PRIMARY AND SECONDARY SHEAVE ........................... D-6
STARTER SYSTEM ............................................ D-7
C.D.I. MAGNETO .............................................. D-8
AUTOLUBE PUMP ............................................. D-8
TRANSMISSION ............................................... D-8
CRANKCASE AND CRANKSHAFT ............................... D-9
INSPECTION AND REPAIR ....................................... D-10
CYLINDER HEAD .............................................. D-10
CYLINDER AND PISTON ....................................... D-10
PISTON PIN AND PISTON PIN BEARING ........................ D-12
AUTOLUBE PUMP ............................................. D-12
CRANKSHAFT ................................................. D-12
TRANSMISSION ............................................... D-13
PRIMARY SHEAVE ................... ~ ......................... D-13
SECONDARY SHEAVE ......................................... D-13
V-BELT ....................................................... D-15
STARTER CLUTCH AND GEARS ................................ D-15
............................................. D-3
.................................................. D-5
ENGINE ASSEMBLY AND ADJUSTMENT
CRANKSHAFT AND CRANKCASE ............................... D-16
TRANSMISSION ............................................... E-1
AUTOLUBE PUMP ............................................. E-3
C.D.I. MAGNETO .............................................. E-4
STARTER SYSTEM ............................................ E-5
PRIMARY AND SECONDARY SHEAVE ........................... E-6
PISTON PIN AND PISTON ...................................... E-8
CYLINDER AND CYLINDER HEAD ............................... E-9
MUFFLER ..................................................... E-10
REMOUNTING ENGINE ......................................... E-10
......................... D-16
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ENG %-j]
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ENGINE REMOVAL
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE:
It is necessary to remove the engine in order to remove the following components. oCylinder head
Cylinder
Piston ®CDI magneto ®Starter motor ®Primary and secondary sheave
PREPARATION FOR REMOVAL
1. Remove all dirt, mud, dust and foreign material before removal and disassembly.
2. Use proper tools and cleaning equipment. Refer to "CHAPTER 1. GENERAL INFOR- MATION-SPECIAL TOOLS" section.
NOTE:
When disassembling the engine, keep mated parts together. This includes gears, cylinder, piston and other parts that have been " mated" through nor- mal wear. Mated parts must be reused as an assembly or replaced.
3-1
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ENGINE REMOVAL
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.
During engine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled in the engine.
.
Drain the transmission oil completely.
Refer to "CHAPTER 2.--TRANSMISSION
OIL REPLACEMENT" section.
I E.o I, .l
TAIL COVER
1. Remove: .Seat
Tail cover
Rear carrier
Refer to "CHAPTER 2.--TAIL COVER" section.
FRONT FENDER, FRONT PANEL AND FOOTREST BOARD
1. Remove: ® Front fender ® Front panel = Footrest board
Refer to "CHAPTER 2.--FRONT FENDER, FRONT PANEL AND FOOTREST BOARD"
section.
CARBURETOR
1. Remove:
-Air cleaner case
3-2
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O,SASSEMB. ! I' .1
j ii
.Z ; !;;~!!
3. Remove: eStarter wheel gear (~)
® Bearing (~ ®Washers (~ oldie gear (~)
4. Remove: ®Stay (~ oCollar (~)
5. Remove:
oStarter motor (~
6. Remove: ®Kick crank (~
7. Remove: oKick torsion spring (~
3-10
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ENGr
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DISASSEMBLY
I-q
2. Unhook: = Spring (Centerstand)
3, Remove:
Clip (~
Centerstand
4. Remove:
Transmission case cover (~
Gasket (~)
®
~ii!ii~:~ :~!!~:ii ~:~¸:: ! ~~:~ / ~ !iii~i~i~ii~ ~ii~ O
...... ....
5. Remove: =Main axle (~
Drive axle (~
-Washer (~ (Main axle)
Washer (~ (Drive axle)
6. Remove: ®Oil seal oCirclip (~
7. Remove:
Secondary sheave axle (~
3-13
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[ENoI
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DISASSEMBLY/INSPECTION AND REPAIR
pressure off the push screw, realign,
start
over. If the cases do not
check
Do not force.
NOTE:
Use the following bolts available on the market. Lenght: 160 mm (6.3 in)
Thread: 6 mm (0.24 in)
for a remaining case screw or fitting.
5. Remove: = Crankshaft
Use Universal Puller Set (YU-33270) (~.
Pitch: 1.25 mm
and
separate,
INSPECTION AND REPAIR
CYLINDER HEAD
1. Remove: =Carbon deposits
Use a rounded scraper (~.
NOTE:
Take care to avoid damaging the spark plug threads. Do not use a sharp instrument. Avoid scratching the aluminum.
2. Inspect:
=Cylinder head warpage
Out of specification ~ Re-su rface.
Warpage measurement and re-surface- ment steps: =Attach a straight edge and a thickness gauge
on the cylinder head.
=Measure the warpage limit.
3-15
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F ~
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y
,' If l! !f
2. Inspect: oTorque cam groove (~)
oGuide pin (~
Wear/Damage-*Replace as a set. ®Oil seals (~ oO-rings (~)
Damage-* Replace.
3. Measure: ®Clutch spring free length (~
Out of specification-* Replace.
Clutch Spring Free Length:
109.6 mm (4.31 in)
< Limit > :
94.0 mm (3.70 in)
4. Inspect: ®Clutch housing inner surface
Oil/Scratches-* Remove.
Oil
Scratches
5. Measure: oClutch housing inside diameter (~)
Ouf of specification-*Replace.
Clutch Housing Inside Diameter:
<Wear
Use a rag soaked in lacquer
thinner or solvent.
Use an emery cloth (lightly and evenly polishing).
105.0 mm (4.13 in) Limit> :
105.4 mm (4.15 in)
r
6. Inspect: oClutch shoes
Glazed parts-* Sand with coarse sandpaper.
NOTE:
After using the sand paper, clean of the polished
particles with cloth.
3-23
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INSPECTION AND REPAIR
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7. Measure: oClutch shoe thickness (~
Out of specification-* Replace.
Clutch Shoe Thickness:
4.0 mm (0.16 in)
<Wear Limit> :
2.5 mm (0.10 in)
Assembly
When assemblying the secondary sheave, reverse the disassembly procedure. Note the following
points.
1. Apply: +BEL-RAY Assembly Lube ®
(to the inside of the sliding sheave)
I ENG
,!:,.~ .... ~+~iii,si= ~. .......
~; ++.
+.;+!:i:~!
2. Install:
Sliding sheave
NOTE:
Be careful so that the oil seal lips are not turned over when installing the sheave.
3. Apply: eBEL-RAY Assembly Lube ®
(to the torque cam grooves and O-rings)
4. Check:
Sliding sheave Unsmooth operation-* Repair.
3-24
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ENGINE ASSEMBLY AND ADJUSTMENT
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ENGINE ASSEMBLY AND ADJUSTMENT
CRANKSHAFT AND CRANKCASE
i!!i,!!iii!~!i!ii~!!ii:i!i:ii!!i!i:i~i~i~i!i:i~i!~ii!~i:i~i!~!i~i!ii~!~:~!~i~i~!!i~iii~i~ii
To protect the crankshaft against scratches
or to facilitate the operation of the installation. Apply the grease to the oil seal lips, and app- ly the engine oil to each bearing.
1. Attach: oCrankshaft Installing Tool
(YU-90050 (~, YM-90062 (~)
2. Install: ® Crankshaft
To left crankcase.
NOTE:
Hold the connecting rod at top dead center with one hand while turning the nut of the Installing Tool with the other. Operate the Installing Tool
until the crankshaft bottoms against the bearing.
3. Apply: ®Sealant (Quick Gasket ® )
(ACC-11001-30-00) To the mating surfaces of both case halves.
4. Install:
®Dowel pins (~) oSpacer (~)
5. Install: ®Right crankcase
Use crankshaft Installing Tool (YU-90050
(~, YM-90063 (~)).
3-27
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ENG
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STARTER SYSTEM
(~) Kick shaft (~) Kick torsion spring (~) Kick crank @ Idle gear ~ ollar
Stay
ENGINE ASSEMBLY AND ADJUSTMENT
(~) Bearing
Starter wheel gear (~) Starter clutch assembly (~ Kick pinion gear
0 Nm (1.0 mokg. 7.2 ft°lb) I
/ ~J
/
/ ~ ~
®
"~v / ~ /
® @
(~
I °kg' 5"8 ft°lb) I
I CLIP STANDARD TENSION:
A 250-300 g (8.83-10.6 oz)
3-39
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ENGINE
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ASSEMB'YA.OIA.OSTME°T IENO
eCylinder head gasket (New gasket)
7. Install: oCylinder head (~ oSpark plug (~
NOTE:
Tighten the cylinder head holding nuts in stage, using a crisscross pattern.
~, 4:. ,~, ~:.
Q
Cylinder Head Holding
10 Nm (1.0 m.kg, 7.2 ftolb)
Spark Plug:
20 Nm (2.0 m°kg, 14 ftolb)
8. Install: eAir shroud
Bolt (Air Shroud):
l~
8 Nm (0.8 m-kg, 5.8 ft.lb)
Nuts:
9.
Install: ® Fan cover
Screw (Fan cover):
l~
8 Nm (0.8 m.kg, 5.8 ft.lb)
3-46
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[ ENGI &~] ENGINE ASSEMBLY AND
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CYLINDER AND CYLINDER HEAD
(~) Spark plug (~) Cylinder head ® Gasket @ Cylinder ® Gasket
ADJUSTMENT
120 Nm (2.0 14 l~
®
m.kg, ft-lb) A
C
PISTON TO CYLINDER CLEARANCE:
0.034-0.047 mm (0.0013-0.0018 in)
CYLINDER HEAD WARPAGE LIMIT:
0.02 mm (0.0008 in)
SPARK PLUG:
BPR6HS (N.G.K,)
GAP: 0.9-1.0 mm (0.035-0.039 in)
@
®
3-47
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ENGINE ASSEMBLY AND ADJUSTMENT
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MUFFLER
1. Install: ®Muffler
Bolt (Muffler):
27 Nm (2.7 m.kg, 19 ft.lb)
Bolt (Exhaust pipe):
8 Nrn (0.8 m.kg, 5.8 ftolb)
I ENG
i~!?i~:i!i:~i;:~i)!::
!iiiiiiiiiiii~i
REMOUNTING ENGINE
When remounting the engine, reverse the removal
procedure.
1. Install: ®Engine mounting bolts
These bolts should be temporarily secured.
2. Tighten: oEngine mounting bolts
Bolt
~--]:
42 Nm (4.2 rn.kg, 30 ft.lb)
Bolt r-~:
17 Nm (1:7 m°kg, 12 ft-lb)
3.
Install: ® Carburetor ®Carburetor top together with throttle valve
NOTE:
When installing the throttle valve into the car-
buretor, align the groove (~ of the throttle valve
with the projection (~) of the carburetor.
3-48
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AUTO CHOKE SYSTEM
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CARBURETION
AUTO CHOKE SYSTEM
CONSTITUENTS The electric auto-choke consists of the Positive Temperature Coefficient (P.T.C.) thermistor, wax element and starter plunger.
~ P.T.C. thermistor
Wax element O-ring
(~) Starter plunger
r-i
®
I P.T.C.
When electric current flows in this thermistor, it
begins to be heated up to a specified temperature.
This specified temperature is then reained.
I Wax
The wax element changes its volume according to a varying temperature of the thermistor, thereby causing the starter plunger to operate.
I Starter
The starter plunger opens or closes the starter
passage according to changes in the volume of the wax element,
WIRING SCHEMATIC
Power source is provided by the C.D.I. magneto
lighting coil.
thermistor I
element I
plunger I
(~) C.D.I. magneto
(~) Rectifier/Regulator
(~ Auto choke unit
m
®
±
4-1
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