Page 1
1987 - 1990
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MOTORCYCLE
SERVICE MANUAL
Model : CE50T, CG50A, CG50U, CG50W
2YT281972000
*2YT281972000*
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CE50T
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SERVICE MANUAL
©1 986 by Yamaha Motor Co., Ltd.
1st Edition, Nov e mb e r 1986
All rights reserv e d. A n y r e printing or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibit e d.
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Page 4
N O TICE
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This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to put an entire mechanic's education into one manu a l,
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha scooter
have a basic understanding of the mechanical concepts and procedures inherent in scooter repair tech-
nology. Without: such knowledge, attempted repairs or service to this model may render it unfit to
use and / or unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all Autho-
rized Yamaha dealers and will, where applicable , appear in future editions of this manual.
TECHNICAL PUBLICATIONS
SER V ICE DI VIS I O N
M OTORCYCLES OPER A TIONS
YAM A H A MOT O R CO., L TD.
HO W T O USE THiS M ANU AL
PA RTIC ULARL Y iM P O RTANT iN FORMA TiON
This m aterial is dist i nguished b y the f ollowing notat i on.
D
NOTE: A NOTE prov i des k e y i n for m ation to ma k e procedures easier or clearer.
ili i i i iiil A CAUTION indicates special procedu r es t h at must be followed t o avo i d
da m ag e to th e scoote r .
A WARNING indicates special procedu r es that m ust be f ollowed to avoid injur y
to a scoot e r op e rator or p e r son insp e ct in g or r e pairing th e scoot e r.
MA N UAL FO R M A T
All of the procedures in this manual are organized in a sequential, step-by-step format . The info r ma-
tion has been compiled to provide the mechanic with an easy to r ead, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course
of a ction requir e d will follow the symbol, e.g.,
• Bearings
Pitting / Damage_ Replace.
EXPLODED D I AGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
Page 5
( 9 ® iLLUSTRATED SYMBOLS
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IGENI NFO (R efer to the illust r ation)
Illustrated symbols (_) to _) are designed as
thumb tabs to indicat e t h e chapter's nu m b e r and
(_ (_) content .
E N G OOL P eriodic inspection and adjustment
(_ (_) _ Carburetion
ICARB[ ] _ 1 _"AS1_I _(_) _; pter 'nCdl 'c es
® ®
® ® _ Illustrated symbols (_ t o (_) are used to identify
% _ J DI I C _i General information
_ Engine Cooling syst e m
Chassis
@
6_ _ the specifications appearing in t he text.
(_) Filling fluid
(_ Lubricant
(_) Tightening
_Wear limit, clearance (_) (_) -- E ngine speed
@ @
® ®
. ,1 _ j diagram indicate grade of lubricant and location
- _ = of lubrication point .
_ _ ® Apply engine o,1
@ (_ (_ @(_ App l y molybdenum disulfide o i l Apply wheel bearing grease
_ _ _ _L _.._ _(_)) Apply lightweigh t lithium-soap base grease
@
Illustrated symbols (_ to (_ in the exploded
® Apply gear oil
Apply molybdenum disulfide grease
Apply locking agent (LOCTITE ®)
®
l
m
i
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I N DEX
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GENERAL ,NFORMAT, ON
ENGI N E OVERHAUL ' _ ' %_
ENG _
CARB U RET I ON
CAR B _ ,
CHASS I S CHAS_
L. .,-. -----J
ELEC T R I CAL ELEC_
APP END I CES APPX _
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!
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1
p,
Page 8
GEN
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CH AP TER 1
GENERAL INFOR M ATNON
S C OOTER IDEN T I F IC A TION ....................................... B-3
VEHICLE IDENTIFICATION NUMBER .............................. B-3
ENGINE SERIAL NUMBER ....................................... B-3
I MPORTANT INFORMATION ...................................... B-3
ALl. REPLACEMENT PARTS ..................................... B-3
GASKETS, OIL SEALS , AND O-RINGS ............................ B-3
LO C K WASHER / PLATES AND COTTER PINS ..................... B-3
BEARINGS AND OIL SEALS ..................................... B-4
CIRCLIPS ...................................................... B-4
SPECIAL TOOLS .................................................. B-4
FOR TUNE-UP .................................................. B-4
FOR ENGINE SERVICE .......................................... B-4
FOR CHASSIS SERVICE ......................................... B-5
FOR ELECTRICAL COMPONENTS ................................ B-5
m
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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
Page 11
I MPO RTA NT IN F O R M ATI ON INFO
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I °E"
IMPORT ANT INFO R M A TION
ALL REP L ACEMENT PARTS
1 . U s e o n l y g e n ui n e Ya m a h a part s f o r all
r ep lac e m e n ts. U s e oil and / or gr e a s e r e co m -
m e nd e d by Y a m a h a f or a ss e mbly and adju s t-
me n t. O t her brand s m a y b e s i m ilar in f unc -
tio n and app e a ra nce , b ut inferior in qual i t y .
GA SKE T S, O I L S EA LS , AND O- RING S
1. All gaskets, seals, and O-rings should be
replaced when an engine is overhauled. A l l
gasket su r faces , oil seal lips and O-rings must
be cleaned.
2. Properly oil all mating parts and bearings dur-
ing r eassembly. Apply grease to the o i l seal
lips .
LOCK WASHERS / PLATES AND COTTER
P I NS
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been pro-
perly tightened.
1 . All lock w ashers / Plates ( _ and cotter pins
1-2
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I N FO i M P O R TANT i N F O R MA T i O N
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BE A RI NG S AND OIL S E ALS
manufacturer's marks or numbers facing out-
ward. (In other words, the stamped letters
__) _ must be on the side exposed to view.) When
(_ i n gs dr y. This caus e s da ma ge t o t he b e a r i ng
_ / ._ /7 _ / _ //// _ When installing a ci re lip (_, make su re th at
/ J sectional view .
installing oil seal(s), apply a light coating of
i. Install the bearing(s) and oil seal(s) with their
lip(s). Oil the bearings liberally when installing.
light-weight lithium base grease to the seal
(_ Oil seal
Do not use compressed air to spin the bear-
sur f ac e s.
(_ Beari n g
CI R CLIPS
1 . A ll c i rcl i ps should be in sp ected car e f ull y
clips after one use. Replace distorted circlips.
e ore reas e reo ace O ton
the sharp edged corner (_ is positioned op-
posite to the thrust (_) it receives. See the
(_) (_) Shaft
1-3
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3
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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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I
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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
Page 16
INSP
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CHAPTER 2
PERiODiC iNSPECTiONS AND ADJUSTMENTS
INT R O DU C T IO N ................................................. C-3
PERIOD I C M AINTENA N CE / LUBRICAT I O N INTERVALS ............ C-3
TAIL COVER ..................................................... C-3
REMOVAL .................................................... C-3
INSTALLATION ................................................ C-4
FRONT FENDER, FRO N T PA N EL AND FOOTREST B OAR D ......... C-4
REMOVAL .................................................... C-4
INSTALLATION ................................................ C°5
HANDLEBAR COVERS ........................................... C-5
REMOVAL ..................................................... C-5
INSTALLATION ................................................ C-5
E NGINE .......................................................... C-5
ENGINE IDLE SPEED ADJUSTMENT ............................. C-5
THROTTLE CABLE FREE PLAY ADJUSTMENT ................... C-6
AUTOLUBE PUMP CABLE ADJUSTMENT ........................ C-6
AUTOLUBE PUMP AIR BLEEDING ............................... C°7
AIR CLEANER ELEMENT CLEANING ............................. C-8
FUEL COCK CLEANING ........................................ C-8
COMPRESSION PRESSURE MEASUREMENT ..................... C-9
ENGINE OIL LEVEL INSPECTION ................................ C-10
TRANSMISSION OIL REPLACEMENT .... ........................ C-10
FUEL LINE INSPECTION ........................................ C-11
CHA S SIS ........................................................ C-11
FRONT BRAKE LEVER FREE PLAY CHECK ....................... C-11
REAR BRAKE LEVER FREE PLAY CHECK ....................... C-11
FRONT AND REAR BRAKE LINING INSPECTION ................ C-12
TIRE AND WHEEL INSPECTION ................................. C-12
STEERING ADJUSTMENT ...................................... C-12
ELEC T RICAL ..................................................... C-13
BATTERY ..................................................... C-13
FUSE INSPECTION ............................................. C-14
SPARK PLUG INSPECTION ..................................... C-14
HEADLIGHT BEAM ADJUSTMENT .............................. C-15
IGNITION TIMING ......................................... ..... C-15
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Page 18
ADJ LUBRICATION iNTERVALS
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I INSPli 1 INTRODU CTI O N / PE R I O DIC M A INTEN A NCE / B
PERIODI C I NSPECT I ONS A ND A DJUSTME N TS
I NT R OD U C T IO N
T h is chapte r i n cl u des a ll i nf or m atio n ne ces s ar y to p e rf or m r e co mm e n d e d ins p ectio ns and adju s t m e n t s.
Th e s e pr e v e nti w , • m ai n t e nanc e proc e dur e s , i f f ollow e d, will e nsur e m or e r e liabl e vehicl e op e r atio n a n d
a longer servic e li f e. The n e ed for co s tl y overhaul w o rk w i l l be greatl y reduced. T hi s i nf or m ation ap-
p l i e s to vehicles a l read y i n s erv i ce a s wel l as new vehicles tha t are bei n g p repared f or s ale. A ll se r v i c e
t e ch n i c ia n s s ho u ld b e famil ia r wit h t his e n tire c h a p ter.
PER I OD IC MAI NTEN A NCE / LUBRIC AT I O N INTER VA LS
Uni t: km ( mi )
BRE A K-I N
ITEM RE MA RK S 5 00 3,0 0 0 6 , 0 0 0
( 300) ( 2,000 ) or (4,000) or
Spark plug Check / Clean or replace. O © O
Air filter Clean. Replace if necessary . O ©
Carb u retor Check / Ad j ust / i dle speed, starter o peration . © ©
F uel l ine Check fuel hose f o r cracks or damage. O O
Transmission oil Replace (Warm engine before draining). Replace Check Check
Autolube pump Check / Adjust / Air bleeding. O O
Brake Check o peration . Adjust if necessary. O O
Wheels* Check balance / damage / runout. O O
Wheel bearings damage. Replace if damaged.
Steering bearing Moderately repack every 12,000 (8,000) Check Check Check
Rear shock absorber Check operation. O O
Fittings / Fas t eners Check all chassis fittings and fasteners. O O O
Battery for proper operation.
Every 12,000 (8,000) or 24 months.
Check bearings assembly for looseness / O O
Check bearings assembly for looseness.
or 24 months.**
Check spec i f i c gravity . Check breather pipe O O
E V ER Y
6 month s 12 months
V - belt Check damage and w ear. O
**: Medium weight wheel bearing grease.
2- 1
Replace if necessary.
Page 19
TA I L COV E R ADJ
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TAIL COVE R
RE M OVAL
1. Open the seat lock .
2. Remove:
=Seat
3 . Remove:
-Cover (_
4. Rem o ve:
,Grab bar
_ , Rear carrier
(With rear flasher lights and taillight)
5. Disconnect:
,Rear flasher light leads
• Taillight leads
6. Remove:
®Side covers (Right and left)
N OTE:
When removing the side cover, unhook it at the
front and slide it forward.
7. Remove:
=Tail cover
: !!
2-2
Page 20
INSP E
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A DJ _1 T A ' L COVER
I N STALLATIO N
When installing the tail cover , reverse the
"REMOVAL" procedure.
Note the following points.
1. Install:
®Side covers
NOTE:
After installing the side covers, make sure that
all hooks are securely fitted.
2. Connect:
e Rear flasher light leads
N OTE:
The leads of identical colors should be connected.
31 install :
i_J_. ® Rear carrier
i__i 7Nm (0.7 m , kg, 5.1 ft-lb)
4. Install:
e Seat
!_ 7 Nm (0.7 5.1 ft,lb)
2-3
m,kg ,
Page 21
I FRO NT FEN D ER , FRO N T PA NE L IN SP
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- i
A N D FOOT R E ST BOA R D ADJ
F R ON T F EN D ER, F R O NT P A N EL
AND FOOTREST BOARD
REMOVAL
1. Remove:
-Tail cover
Refer to "TAIL COVER" section.
2 . Remove:
® Front fender
_, N OT E :
@ i: Q::!i hooks are free.
_N % - -_ - 3. Remove:
_iiiii:iiii_ __" ,Main switch cap
i:iiii! i!il ii_i i Turn the cap counterclockwise.
!_-::
Before removing the fender, make sure that all
4. Remove:
® Front panel
5. Remove:
, Footrest board
2-4
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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
Page 23
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
Page 24
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
Page 25
AUTOLUBE PUMP CABLE ADJUST M ENT A D J
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= Loos e n th e Ioc kn ut (_ .
o Turn the adjuster (_ in or o ut until the cor-
!_:__ ...... rect free play is obtained.
=Tighten the Iocknut.
AUTOLUBE PUMP CABLE ADJUSTMENT
NOTE:
Before adjusting t h e pump cable , adjust t h e t hrot-
tle cable free play.
1 . Remove :
=Tail cover
Refer t o "TAIL COVER" sect i on.
* Front fender
= Front panel
e Footrest board
Refer to "FRONT FENDER, FRONT PANEL
AND FOOTREST BOARD" section.
2 . Check :
*Throttle cable free p l ay (_
(at carburetor side)
Out of specification_Adjust.
..... 1. 0 m m (0. 0 4 in)
J _ T hr o t t,eCabl e FreePlay (_) :
Throttle cable free play adjustment steps;
= Loosen th e Ioc k nut (_ .
= Turn the adjuster _ in or ou t until the cor-
rect free play is obtained.
=Tighten the Iocknut.
2- 8
Page 26
4. Close the throttle grip completely.
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5. Check:
®Autolube pump pulley position (_
Out of position-*Adjust.
®:
0.0-1.0 mm (0.0- 0 .04 i n)
_ Aut o lub e P ump P ulley Posi tion
A u t olub e pu m p pull ey pos it io n ad jus t m ent
s t e ps:
o Loo s e n t h e Ioc kn ut _ .
® Tur n the adju st er (_ in o r out until the p u m p
plun g er p in (_ i s a l ig n ed wit h t h e m ar k _)
o n t h e pu mp p ull y .
eTig ht e n th e Ioc k nut .
6 . Install:
oAut o lube pump cover
o F ootrest board
® Front panel
• Front fender
eTail cover
Refer to "FRONT FENDER, FRONT PANEL
AND FOOTREST BOARD" and "TAIL
COVER" section.
A U TOLU BE PUMP AI R BL EEDIN G
The Autolube pump and delivery lines must be
bled on the following occasions:
• ,Whenever the Autolube tank has run dry .
oWhenever any portion of the Autolube
system is disconnected.
o If the scooter lies on its side after falling over.
2-9
Page 27
__ AUT O LUBE PUMP A IR BLEEDING A DJ
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1 . Remove:
= Tail cover
® Front f ender
- Front pan e l
• Footrest board
Refer to " TAIL COVER " and " FRONT
FENDER , FRONT PANEL AN D FOOTREST
BOARD " s e ction .
2. Remove:
®Autolube pump cover
J
I,.sPl l
3. Remove:
• Bleed screw @
N OT E:
Plac e a rag und e r the A utolu b e p u m p.
4 . Start the engine at idle speed.
5 . Air bleed :
K eep the oil running out until air bubbles
disappear .
N OTE:
Pull the pump cable all the way out to set the
pump stroke to a maximum.
6. I nspect :
®Bleed scre w gasket
Damage_Replace .
7. Install:
• ,Bleed screw gasket
• Bleed screw
2-10
Page 28
ADJ AiR CL EANER E L EMENT CLEANING
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t INSP A UT OL UBE PUM P A iR B L EEDING /
8. Keep th e engine runn i ng at a b out 2, 00 0 r / m in
for two min utes or so , a nd bot h d i str ib utor
and deliver y pipe ca n be co mp le t e ly b led.
NOTE:
It is d iff icult t o b l ee d th e di s tri but or co mp l e t e l y
w ith the pu mp s tro k e a t a m ini m u m , and t h ere f ore
th e pu m p st r o k e s h ould b e s e t to a m axi m u m .
9. Install:
eAutolube pump cover
• Footrest board
® Front panel
Front fender
oTail cover
Refer to "FRONT PANEL, FRONT FENDER
ANT FOOTREST BOARD" a nd "TAIL
COVER" section.
A IR CLE A NE R EL EMENT C L EANIN G
1. Remove :
®Side cover (Left)
;_ NOTE:
W h en re m ovi ng t h e si de c ove r , unhoo k i t at t h e
fron t and sl id e it f o r wa r d.
2 . Remove:
®Air cleaner case cover (_
e Air cleaner element
i i : i_iii i : i i_i!i !_i!i i_ ! i
N ever o perate the e ngine w ith th e air cl e a n e r
e lement r e moved . This will allo w unfiltere d
a i r t o enter, causi n g r apid wear and po s si-
b l e engine d am a ge. A dditionally , o per a tion
withou t the cl e aner e lement w i ll affect car-
buretor jettin g with subsequent poor perfor-
mance and possibl e eng i ne ov e rheat i ng.
B e careful no t to hav e rags or the like bloc k -
ing the intake area of the air clea n e r .
2-11
Page 29
;' = ' 8 I A iR CLEA N ER E L EMEN T CLEA NHNG / INSP
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FUEL COCK CLEANING ADJ
3. Clean:
oAir cleaner element
Air cleane r elemen t cleaning ste p s:
oWash the element gently , but thoroughly in
solvent.
Never use low flash point solvents such as
g a soline to clean t he e lemen t . Such sol-
vent may l ead t o a f i re or explosion.
o Squeeze the excess solvent out of the element
and let dry.
: : ::: :::: :: : : : : ::: : : : : :: : : :: ::::::: : : : :::: : : : : : ::: : : : :::::::::: : :: : : : : :: : ::::::: : :: : :::::
D o not twist the element when squeezing
t h e element.
4. Inspect:
oElement
Damage-_ Replace .
5. Apply:
oFoam-air-filter oil or SAE 10W30 type SE
motor oil
Onto the element.
6. Squeeze out the excess oil.
N OTE:
The element should be wet but not dripping.
7 . Install:
oAir cleaner element
®Air cleaner case cover
®Side coyer (Left)
FUEL COCK CLEANING
1. Remove:
- Tail cover
Refer to "TAIL COVER" section.
2-12
Page 30
ADJ FUEL COCK C L EAN H NG
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I ,NsP E
2. Drain:
= Fuel
FUEL IS HIGHLY FLAMMABLE:
__ _k , _ ®Al w ays t u rn o ff t h e e n g i ne wh e n dra in i n g .
==_£ or exhaust pipe / muffler when draining.
' =_ { " o N ever dr ain f uel w hil e s mok i ng o r in t h e
(_ *Cap (_
_, _ / (_) ®Filter (_
_* _'!_ii! _iiii_ _: : :_ 4 . Clean:
= Take care not to spill any f uel on th e engine
vic i nity o f an open f la m e .
3. Remove:
Filter
oCap
Wash the filter and cap gently using solvent .
2 - 13
5. Inspect:
• Filter
oO-ring
Damage- - * Replace.
6. Install:
®O-ring
Filter
oCap
oTail cover
Refer to "TAIL COVER" section.
Page 31
COM PRE SS I O N P RESS U RE MEASUREM E NT ADJ
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• ;!i ...... COMPRESSION PRESSURE
Insufficient compress i on pressure w il l result in
performance loss and may indicate worn or
__4 A damaged piston rings.
1. Remove:
®Cover (_
2 . Warm up engine for serveral minutes, then
stop the engine.
........ _ 3 . Remove :
I eSpark plugs
4. Connect:
®Compression Gauge (YU-33223) (_
INSP
_ "" :::: :::: ........ • C o m press i o n
_. . ._ : _ :: ,. 5 . Measure:
NOTE:
Start the starter motor and throttle valve wide-
open until the pressure indicated on gauge can
rise no further. Compression should be within the
specified levels.
Compression Pressure (at sea level):
Standard ....... 800 kPa (8.0 kg / cm 2,
Minimum ...... 640 kPa (6.4 kg / cm 2,
Whe n crank i ng engine , g round spark plu g
wires to prevent sparking.
Compression test st e ps (below minimum
l e vels):
oS quirt a fe w drop s o f oil i n to c y li n d e r.
e Measure compress i on again .
114 psi)
91 p s i )
R e ading Di a gnosis
Hi g her than piston and piston
with o ut o il
Same as ring(s) , valve(s) and
with o ut oil
Compr e ssion t e st st e ps (abov e st a ndard
levels):
eCheck cylinder head or piston crown for car-
bon deposits.
®Worn cyli n der,
rings
® D efective piston ,
cylinder head gasket
2-14
Page 32
I iN S P ADJ J_l ENGINE OI L LEVEL INSPECTION
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E NGINE O i L L E V E L INSP E CTION
1 . Pl a c e t he s coo ter o n the l eve l p lac e .
NOT E :
Be s ure t he s coo ter i s p o s itio ned s t ra ti gh t up and
o n b ot h w hee l s w hen i nspe cti ng t he oil l eve l ,
":":%_{iii_ 2 . Inspect :
...... ":<_ o Engine oil level
__:_-_ .... " ............ - 0il leve l l ow - , Add sufficient oil by the
" _ f o llow i ng inspecti o n s t eps.
(_) "OIL" indicator light
_ 3 N _ 0- _ _$ E O NLY
En gi n e oil l e vel visual i n spection steps:
position.
I T urn m a in s witch to "_" I
l
does not :ome on. c o mes on.
I "OlL"indicat o rlight I I "OlL"indicat o rlight I
+
"ON" position.
I urn main switch to
I
"OIL" indicator light _ i"OIL" indicator light I
d o es not come o n. ?1 iomeson i
e,ec- 1 en0ine o"'eve'" e'ec- I Su 0' eat'he °"'l I trical circuit, trical circuit are OK.
I
2-15
Page 33
E N G IN E O i L LEVEL iNSP EC Ti O N / l l NSPI _ I _ I TRANS M ISS I O N Oi L RE P L ACEM E NT ADJ
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_ Recommended O i l:
NOTE:
Instal l the o i l tank filler cap (_ and push it fully
into the filler .
Always use the same typ e of engine oi l ; mix-
ing oils may r esult i n a h_rmful chemical
r e action and l e ad t o po o r p e rformance.
Yamalu b e 2 o r Air Coo le d 2
Stroke Engin e Oil
Oil Capac i ty:
Total:
0 . 8 L (0.7 I m p qt, 0 .84 US qt)
TRA N S M IS S IO N O I L R EPL A CE M ENT
1. Warm up the engine at idle speed, then stop
it.
2. Place the oil pan under the drain hole.
3. Remove:
oDrain bolt (_
Drain the transmission oil .
oOil filler plug
2-16
Page 34
ADJ FUEL Li N E i NS PEC Ti O N
Downloaded from www.ScooterTime.net
t I NSPt_ I T R AN S MI SS I ON OIL R E P LAC EME N T /
4 . Inspect:
®Gasket (Drain bolt)
• O-ring (Oil filler plug)
Damage_ Replace.
5. Install:
• Gasket
Drain bolt
I_ D ra in Bol t :
6. Fill:
• Transmission case
___ Tr a n smission O il :
N OTE :
Wipe off any oil split on the crankcase, tire or
wheel .
7. Install:
• Oil filler plug
18 Nm (1 . 8 m . kg , 13 ft . lb)
Yamalube 4 or SAE 10W30 Type
S E M o tor Oi l
Capacity:
0 . 1 L ( 0 . 0 9 Imp qt, 0.11 U S qt)
FUEL LINE I N SPECT I O N
1. Remove:
eTail cover
Refer to "TAIL COVER" section.
2-17
Page 35
RE A R B R A KE LE V ER FR E E P LAY C H E C K ADJ
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F.ONT B LEVE. F.EE P.A C.ECK/ I,.SP[ I
_ 2 . I nspect:
o Fuel pipe (_
Cracks / Damage -_ Replace.
3. Install:
oTail cover
Refer to "TAIL COVER" section.
FRO N T BRAK E LEVER F R EE PLAY CHECK
1. Check:
oFront brake lever free play
C H ASSI S
Out of specification-_Adjust.
, 0- 0 l
F ro nt b rake lever f ree p | a¥ adjus tm e nt
steps:
oTurn the adjuster (_ in or out until the cor-
rec t fr ee pla y is obtained.
R E AR BR A K E LEV ER FREE P L AY CH E CK
1. Check:
®Rear brake lever free play (_
Ou t of sP , ecif i cation_ Adjus t .
'_ 10- 2 0 mm ( 0 . 4-0 .8 in)
R ea r brake lever f ree p la y adjustm en t
steps;
® Tur n t h e adjuster (_ i n o r out u n til t h e c or-
r ec t f ree p la y i s obtaine d .
2-18
Page 36
ADJ TIRE AND WHE E L i N S PECTI O N
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I INSP I (i_ F R O NT AND REAR BR A K E L N N I N G I N S P ECTIO N / l
[] _. FRONT AN D RE A R BRAKE LINING
) 1 . Activate the brake lever .
2. Inspect:
- _ ; ®Wear indicator (_
Indicator at wear limit line (_Replace
brake shoes.
!
_; T i RE AND WHEE L I NS P ECTI O N
1 . M e as ur e :
®Ai r p r e ss ure
Out of sp e cifi c atio n - _A dju s t.
Cold t ire
Front 1 25 kPa (1.25 kg / crn 2 , 18 psi)
Rear 225 k Pa (2.25 kg / crn 2 , 32 psi)
Prop e r loading of your scooter is i m portant
for the h a n dling, braking, a n d ot h e r perfor-
ma n ce and saf e ty charact e ristics o f your
scooter. Do not carry l oosely pack e d it e ms
that can shift. S ecurely pack your h eavi e st
it e m s clos e to th e center o f the scooter, and
d estribute the wei g ht ev e nl y f rom s i d e to
side. And ch e ck the co n dit i on and pr e ssur e
of yo u r tir e s. NEVER OVE R LOA D YOUR
SCOOTER. Mak e sure the to t al w e ight to the
cargo, r ider, passenger, and accessories (fai r -
ing, saddl e bags, e tc. if approved f o r this
mod e l) does not e xce e d the ma x imum l o ad
of t h e scoot e r. Operation of an ov e rloaded
scoo t e r could cause tire damag e , an acci-
d e n t, or ev e n inju r y.
pressure
2 - 1 9
Page 37
" STEERING ADJUSTMENT ADJ
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2. Ins pe ct :
'_._=q _ o Tire surface
__ , _ : ._\1 Wear / Damage / Cracks / R o ad ha z ards-- *
" -" +Aluminum wheels
Damage / Bends--* Replace.
Never attempt even small repairs to the
wheel.
__._ ii. Replace.
Ride c ons e rv at ivel y aft e r ins ta lli n g a t i re t o
allow it to seat itself properly on th e rim.
(]_) 3. Measure:
(_ _ Mi n imu m Tire T read Depth:
®Tire tread depth
Out of specification_Replace.
(front and r e ar)
0 .8 mm (0. 0 3 in)
(_) Tread depth
Wear indicator
Side wall
ST EER I N G A DJ U S T MEN T
1 . Plac e th e scoo t e r o n it s c e nters t an d, th e n
e l e vat e t h e fr ont w h ee l.
2-20
Page 38
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
Page 39
BATTER * L'NSP1 IAOJ
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2. inspect:
• Breather hose
Obstruction_ Remove.
Damage-* Replace.
3. Inspect:
® Battery
Replace the battery if:
Battery voltage will not rise to a specific value
or bubbles fail to rise even after many hours
of charging.
®Sulfation of one or more cells occurs, as in-
dicated by the plates turning white, or an ac-
cumulation of material exists in the bottom
of the cell.
®Specific gravity readings after a long , slow
charge indicate one cell to be lower than the
rest.
®Warpage or buckling of plates or insulators
• is evident.
®Specific gravity:
Less than 1.280-*Recharge battery.
Charging Current:
_ 4. Measure:
0.4 amps / 10 hrs
Specific Gravity:
1.280 at 20°C (68°F)
2-22
Page 40
I INSP
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A DJ l ( l B A TTE RY / F USE INSPE C TI O N
Always charge a new batt e ry b e for e using
it to ensure maximum p e rformance.
Battery electrolyte is dangerous; it contains
sulfuric acid and ther e fore is poisonous and
highly caustic.
__ , === A l w a y s f o l low th es e p r eve ntiv e me asu r e s:
_\_J -- _ 9 / - S KIN -- F lush with wa te r.
____= '_ "_ c an ca u s e server e burns or pe r man e n t e y e
oAv o id bodily contact w ith electrolyte as it
inju r y.
=W ear protective eye gear when handling or
working near batte r ies.
Antidote (EXTERNAL):
®EYES -- F l ush w i th water for 15 minut e s and
get imm e diate medical attent i o n .
Antidote (INTERNAL):
eDrink lar g e quantities of water or m i lk
follow with milk of magnesia) beaten e gg,
or veget a bl e oil. Get i mmediate medical
attentio n .
B atteries also g e n e rate explosive hyd r ogen
g as, ther e f o re you should a l ways f o llow
these preventive measures:
e Charge bat t eries in a w ell-ventilated ar e a .
® Kee p b att e ri e s away f r om fi r e, sp a rks, or
open flames (e.g., w e lding equipment,
lighted cigarettes, e t c.)
= DO NOT SMOKE w hen c harging or ha n dl-
ing batteries.
KEEP B A T T ERIES A ND ELECTROLYTE OUT
OF REACH OF CHI L DREN.
FUSE I NSPECTI O N
1 . Open the seat l ock .
2-23
Page 41
FUS E iN S PECTI O N / SPARK PLUG iN S PECTi O N ADJ
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2. Insp e ct:
e F use C)
Defective-- * Replace.
B lown f use p ro c edure s t eps:
=Turn off ignit io n and the circuit .
= Install a n e w fus e o f pro p e r a mp e ra g e.
= Tur n o n swi tch e s to v e r ify ope r at i on o f e l e c -
t ric al d e v i ce.
® If f u s e blows i mm e d iat e l y a g ai n , c h e c k ci rcu i t
in que st io n .
D o not us e fuses o f higher amperage rating
t han recommended. Extensive el e ctrical
syst e m damage and fire could r esult fro m
substitution o f a fuse of i m p c op e r a m perage:
i = Cover @
_i_:_ - =Spark plug ,
0 H_
" - -?: i
Descrip t ion Am p e rage Quantity
M ain 7 A 1
SPARK PLUG INSPECTION
1 . Re m ove:
2. Inspect :
= Electr o de _)
W ear / Damage-- , Replace.
=Insulator (_
Abnormal Color_ Replace.
@ @ St a n da r d Spar k P lug:
"
BPR6HS (N.G.K.)
2-24
Page 42
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
Page 43
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Page 44
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
Page 45
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Page 46
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
Page 47
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
Page 48
[ENO EOO,NE.EMO V A, Fi
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2. Remove:
oFuel pipe (_
oOil delivery pipe (_)
®Vacuum pipe (_)
®Auto choke unit lead
3. Remove:
_, ®Carburetor top cover
oCarburetor
NOTE:
Cover the carburetor with a clean rag to prevent
dirt or foreign matter into the carburetor.
i 1. Remove :
_i CA BLE S , LE A DS A ND PI P E S
i
- Autolube pump cover @
2 . Remove:
oOil pump cable (_
oOil pipe (_)
N OTE:
Plug the oil pipe so the oil will not run out of the
oil tank .
3. Remove:
• Battery negative lead (_
3-3
Page 49
4 E NG I N E R E MO V AL ENG %_
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4 . R em o ve:
® S park p l ug c ap
5 . Remove:
.Earth lead (_
]
6. Remove:
• Rear brake cable (_
7 . Disconnect:
• C.D . I . magnet o leads
• Starter mot o r l eads
+,
E N G IN E RE M OV AL
1 . Remove:
• Air shroud (_
3-4
Page 50
[ENG ENGI NEREMO V AL / D I SASSEMBLY
Downloaded from www.ScooterTime.net
2. Rem o ve:
o Eng i ne m o unt i n g b olt s
3. Remove:
®Engine
Lift up the frame and remove the engine .
4 . P lace the frame on a suitable stand .
DISASSEMBLY
MUFFLE R
1. Rem o ve:
oExhaust p i pe
3-5
Page 51
O'SASSEMB' I EN°
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2. Remove:
`" Muffler
CYLINDER HEAD
1. Remove:
`" Fan cover
2. Remove:
" _::_:_ ®Air shroud
3. Remove:
(_,
........ ::: : _ ,,Cylinder head (_
®Cylinder head gasket
NOTE:
`" Before loosening the cylinder head, loosen the
spark plug _).
• The cylinder head holding nuts should be loosen-
ed 1 / 2 turn each time , and remove.
3-6
Page 52
O,SASSEMBL * E
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CYL I ND ER
1 . Remove:
• Cylinder (_
i_ • Cylinder gasket
2. Remove:
®Carburetor joint (_
oReed valve assembly
P IS T O N PI N A N D PI S T O N
1 . Remove:
®Piston pin clip (_
N OTE:
Before removing the piston pin clip , cover the
crankcase with a clean rag so you will not acciden-
tally drop the clip into the crankcase.
2. Remove:
o Piston pin (_
® Piston (_)
®Piston pin bearing
NOTE:
Before removing the piston pin, deburr the clip
groove and pin hole area. If the piston pin groove
is deburred and piston pin is still difficult to
remove, use Piston Pin Puller (YU-01304).
Do not use a hammer to drive the piston pin
out.
3-7
Page 53
PR I MARY AN D SECON D ARY SHEAVE
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1 . Remove:
*Crankcase cover (Left)
* Dowel pins
2. Remove:
*Fan (_
;i 4 _! '- __ 3. Remove:
*Nut @ (Primary sheave)
NOT E :
- - . ..... the C.D . I. magneto using Flywheel Holding Tool
_ (YU-01235) . •
- *Conical spring washer (_
_ . _,. *Primary fixed sheave _)
"_'_ , ,,V-Belt
When loosening the nut (primary sheave), hold
4 . Remove:
*One-way clutch (_
3-8
Page 54
_ !_ :. _ STAR T ER SY S TEM
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/ ' ;_-_- : _ ........ 1 Remove:
3-9
• Starter clutch assembly (_
2. Remove:
-Plate (_ (Idle gear)
Page 55
q
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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
Page 56
9. Remove:
Downloaded from www.ScooterTime.net
oCirclip (_
o Plain washer (_
C.D.I. MAGNETO
1. Remove:
.... _ oNut (_ (C.D.I. magneto)
Use Flywheel Holding Tool (YU-01235) (_).
._ ii;_ 2. Remove:
3-11
_- __..9 ® C. D.I. magneto
Use Flywheel Magneto Puller (YM-01189)
oWoodruff key
Page 57
O'SASSEMB' I E"O t
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_ 3. Remove:
eStator assembly (_
4. Remove:
®Gasket @
AUTOLUBE PUMP
1 . Remove:
*Autolube pump @
2. Remove:
®Circlip (_
*Shim (_)
-,Wave washer. (_)
\. ®Pump drive gear @
_0\ 0 "Pin @
TRANSMISSION
1. Remove:
• Rear wheel
oBrake shoe plate
3-12
Page 58
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
Page 59
O,SASSEMO LY [ ENOL
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_zi;ili_:_ _- CRAN K C A S E A ND CR ANK S H AFT
: : e Oil seal stopper (_)
"'_ 2. Remove:
1. Remove:
® Circlip (_)
o Screws (Crankcase)
NOTE:
Loosen each screw 1 / 4 turn, and remove them
after all are loosened.
_, 3. Attach:
_ _i __:i: _ : .....
_ : ? . _
oCrankcase Separating Tool (YU-01135) (_
_ N O T E:
Fu ll y tighten the-tool h ol ding b o lts , but make s ure
the t ool b o dy is para ll e l w ith the c ase. I f
ne c essary , one s c re w may be ba c ked o ut s l ight -
ly t o l evel t ool b o dy .
4 . Remove:
e Crankcase (Left)
"::" - i ": " " ! : i . :: • "
U se s o ft hamme r t o tap o n the c ase h a lf. T ap
o nly o n reinf o r c ed p o rti o ns o f case . Do n o t
t a p o n gasket m a ting su r face . Wo rk s lowl y
and c a re f u l l y . Ma ke sur e t h e c a se hal ves
separate evenly. If one end "hangs up", take
As pressure is applied, alternately tap on the
engine mounting bosses.
3-14
Page 60
[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
Page 61
oq .os ONANO.EPA.. I E"O I .l
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/ 1 . E l iminate :
-_ _ ( /
_ Warpage Limit:
olf the warpage is out of specification, reface
the cylinder head.
oPlace a 400-600 grit wet sandpaper on the
surface plate, and re-surface the head using
a figure-eight sanding pattern.
NOTE:
Rotate the head several times to avoid remov-
ing too much material from one side.
CY LI N D E R AND PIS T ON
0.02 mm (0.0008 in)
From the piston crown and ring grooves.
< \ ._ . .,. 2 . Eliminate:
- _ / _ 1 _ -Carbon deposits
-- _ N OT E:
_ _ Sand in a crisscross pattern. Do not sand exces-
i+:_ ,!+++ ,
®Score marks and lacquer deposits
From the sides of piston.
Use a 600-800 grit wet sandpaper.
3. I nspect: + '
• Piston wall
Wear / Scratches / Damage_ Replace.
sively.
4. Eliminate:
® Carbon deposits
Use a rounded scraper (_ .
3-16
Page 62
5 . Inspect:
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oCylinder wall
Wear / Scratches -_Rebore or replace .
6. Measure:
i_± ® Piston-to-cylinder clearance
::_ ......... _ (_ Piston-to-cylinder clearance measurement
s te ps:
First st e p:
:_ D _ Bore Gauge .
. - , _ r __ _ - ,._ _ ...... Measure the cylinder bore "C" in par a llel to and
/
_- _ at right angles to the crankshaft. Then, find the
-- _ . _ - -_ --=_" average of the measurements .
® Measure the cylinder bore "' C" with a Cylinder
NOTE:
_ S t a ndard W e ar L imit
C yl ind e r bore 4 0.00 - 40.0 2 mm 40 . 50 mm
"C" (1.575-1.583 in) (1.594 in)
T a per " ' T "
Out of round 0 . 0 1 tur n
"'R " (0.000 4 in)
C= M a xi m u m D
T=(Maximum Dz or D 2 ) -
( M a x i m u m D s or D 6 )
R=( M aximu m D 1 , D 3 or D s ) -
( M inimum D 2 , D 4 or D 6 )
e l f out o f s peci f ic a t i on , re b or e or re pl ace
c y l in der, and r e p lac e piston and p i s to n r i ng s
as a set.
0.05 mm
(0.0019 in)
_ / ®Measure the piston skirt diameter "P" with
__ 2nd step :
307, 000
3-17
a micrometer .
Page 63
I NSPECTION A ND REPAI R ENG]
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_ . _ Piston Size P
Standard
Oversize 1 40.25 mm (1.585 in)
Oversize 2 40.50 mm (1.594 in)
elf out of specification, replace piston and
piston rings as a set.
3rd step:
• Calculate the piston-to-cylinder clearance with
following formula:
Pis t on- t o-cyli n der Cle a ra n ce =
C y linder bore " C " -
Piston s k irt di a meter " P "
o l f out o f speci f icat i on, r ebor e or replace
c y l in de r , a n d rep l ace p i sto n and pisto n ring s
a s a s e t.
40.05 - 40,07 mm
( 1 .577 - 1.578 in)
_ Pi ston-to-cylind e r Clearance:
.... i;:i 7 . Measure :
oEnd gap
_:i ___ Standard Li m i t
Top ring (0. 0 06 - 0 . 0 12 in) ( 0 .0 2 8 in)
2nd ring ( 0 .006 -0 . 0 12 in) (0. 0 28 in)
Measuring Point 20 mm (0 . 8 in)
0.034-0. 047 m m
(0.0013- 0.0018 i n)
L imit : 0.1 mm (0.004 i n)
Out of spe c ificati o n--* Replace rings as a set.
Use a Feeler Gauge (_.
0 .15 - 0.30 mm 0 . 7 0 mm
0.15 - 0.30 mm 0 .7 0 m m
3-18
Page 64
,°SPEOT,ONANO.EPA,.
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8. Oversize piston ring size:
Ring size is stamped on top of the ring.
Oversize piston ring
Oversize 1 25
Oversize 2 50
PISTON PIN AND PISTON PIN BEARING
1. Apply:
e2 cycle oil
To the piston pin and bearing.
2. Install:
o Piston pin
®Piston pin bearing
Into the small end of the connecting rod.
3 . Check:
/ There should be no noticeable for the play.
__ . _]]_ .Free play
_. ¢ _ / for wear / Replace the pin and / or connecting
(___j_ Into the piston pin hole.
Free play exists_ Inspect the connecting rod
rod as required.
4. Install:
o Piston
5. Check:
o Free play (when the piston pin is in place in
the piston)
There should be no noticeable for the play.
Free play exists--* Replace piston pin and / or
piston.
6. Inspect:
oPiston pin and bearing
Signs of heat discoloration-_Replace.
pin
3-19
Page 65
'OSPEOT'ON AOO"EPA'" I ENo
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AUTOLUBE PUMP
Wear or an internal malfunction may cause pump
output to vary from the factory setting . This situa-
tion is , however, extremely rare. If improper out-
put is suspected, inspect the following:
1. Inspect:
® Delivery line
Obstructions_ Blow out.
cO-ring
Wear / Damag e _ Replace.
2. Inspect:
_ ®Autolube pump drive gear teeth (_ .._ I_ oAutolube pump driven gear teeth (_
_i_?!i:!_!i !_ Pitting / Wear / Damage--* Replace.
F CRANKSHAFT
-= =- 1. Measure:
eRunout limit "C"
oSmall end free play limit "' F"
Out of Specification_Replace.
_Connecting rod big end side clearance "D"
Use V-Blocks, Dial Gauge and thickness
gauge.
Runo ut Li m i t "'C " :
Conn e cti n g Rod Big End Side
Clearanc e " D " :
Small E n d Fr e e Play:
2. Inspect:
o Bearings (Crankshaft)
Spin the bearing inner race.
Excessive play / Roughness_ Replace.
Pitting / Damage_ Replace.
0.03 m m ( 0 .0 0 12 in)
0.2 -0 , 5 mm (0.0 0 8 -0 . 0 2 i n )
0 . 4 -0 .8 mm ( 0 . 0 15 -0 .031 in)
3-20
Page 66
[ENG ,NSPEOT, OO AND.EPA,.
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TRANSMISSION
m
_ , _ , :;_ .Primary drive gear teeth (_
_ , _ 4_ ,_i_ , , / . Primary driven gear teeth (_)
, _;_; _!_#_, _ , _, / '_ *Secondary drive gear teeth
/ / ......... _i .Secondary driven gear teeth _)
@ / ® / Burrs / Chips / Roughness / Wear_ Replace .
_i!!i_i Spin the bearing inner race .
(_) Pitting / Damage--* Replace .
.... • Primary sliding sheave (_
1. Inspect:
2. Inspect:
• Drive gear bearing (_
• Main axle bearing (_)
QSecondary sheave axle bearing (_)
Excessive play / Roughness-* Replace.
1. Inspect :
PRIMARY S HEAVE
®Primary fixed sheave (_
• Collar (_)
Wear / Cracks / Scratch / Damage--* Replace.
®
2. Check:
® Free movement
Insert the collar into the primary sliding
sheave, and check for free movement.
..... Stick or excessive play-* Replace the sheave
or collar.
_ _:_; _ _<;_.- . ...... S E CO N DA RY S H E A V E
_ : _ ;;_ .... Disa s sembl y
1. Attach:
_ - -_ _ ,Primary Sheave Holder (YS-01880) (_)
• Socket Wrench (41 mm) (_
: , _. , _ _Clutch securing nut
,oose :
_i_ i _:.:. :.
D o not r e m ove th e clutch s e cur i n g nut ye t.
3 -21
Page 67
3q ,osPEoT,oN AOO.EPA,. l ENO I' .i
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3. Attach:
oClutch Spring Holder (YS-28891) (_
NOTE:
Use the following bolt (_ available on the
market.
Thread: 10 mm (0.39 in)
Pitch: 1.25 mm
4 . Remove:
®Clutch securing nut (_
5. Remove:
®Clutch spring (_
.... _ - _[_,, ® Spring seat (_
(_ . __ ®Clutch assembly @
. - ::5 * "
6. Remove:
,Guide pins @
7. Remove:
oSecondary sliding sheave (_
I n sp e ction
(_ 1 . Inspect:
............... oSecondary sliding sheave (_)
%
i_ Scratch / Crack / Damage--* Replace as a set.
_Secondary fixed sheave (_
3-22
Page 68
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
Page 69
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
Page 70
5 . I nstall:
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®Clutch securing nut
Use Clutch Spring Holder (_) (YS-28891) .
_z,_ , _._ ......... 6 . Tighten:
oCtutch securing nut
Use Sheave Holder (_ (YS-01880) and
Wrench (41 mm).
[_ 50 Nm (5 . 0 m,kg, 36 ft°lb)
V-BELT
1 . Inspect:
oV-belt
Crack / Wear-_ Replace.
NOTE:
Replace the V-belt smeared with a lot of oil or
grease.
2. Measure:
oV-belt width (_
Out of specification_Replace.
1 5 .0 m m 10 . 5 9 i n )
1 3 . 5 mm ( 0 .53 in)
Push the dowel pin to arrow direction .
Unsmooth operation-_Replacce starter
clutch assembly.
3 -25
/
a
I <We a r L i m it> :
_ V-Belt Width:
STARTER CLUTCH A N D GEARS
1. Inspect:
- Starter clutch
Page 71
,os ooAoo.EPA,. ! ENO I I
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2. Inspect:
oStarter wheel gear teeth (_
oldie gear teeth (_)
Burrs / Chips / Roughness / Wear-* Replace.
3. Inspect:
_Z(_ oBearing (_) (Starter wheel gear)
_ ®Kick gear teeth (_
(_ Burrs / Chips / Roughness / Wear-* Replace .
/
; /
Pitting / Damage--* Replace.
4. Inspect:
o Kick pinion gear teeth (_)
5. Inspect:
o Mating dogs (Kick pinion gear and one-way
clutch)
Rounded edges / Damage_ Replace.
6. Measure:
eClip tension (Kick pinion gear)
Out of spedification-*Replace.
f , ] _ _ :_ Use a spring balance.
Standard Tension:
250- 300 g (8.83- 10.6 oz)
3 -26
Page 72
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
Page 73
NOTE:
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Tighten the crankcase holding screws in stage,
using a crisscross pattern.
7 . Check:
oCrankshaft operation
Unsmooth operation-* Repair.
8 . Install:
®Oil seal stopper plate (_
®Circlip (_)
S c re w ( O il S e al S toppe r P l a t e) :
13 Nm (1.3 m=kg, 9.4 f t.l b )
3-28
Page 74
m
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E.oI I EOO,NE ASSEMB, ANO AOJOSTMENT
CRANKSHAFT A: 3 7 . 9 0 - 3 7 . 9 5 mm
0 Oil s e al F (1.492-1.494 in)
Crank (Right) D: 0.2-0.5 mm
@ Crank pin (0.008-0 . 020 in)
Bearing F: 0.4-0.8 mm
Connecting rod (0.015-0.031 in)
_ Bearing __ C: 0. 0 3mm(0 . oe12in)
_ Crank ([.eft)
(_) Oil seal
(_ Bearing _D
!
®
3-29
Page 75
q Eoo.NE AssEMB,Y Aoo AOJOSTMEOT I ENO I'..
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TRANSMISSION
J, 1 . Apply:
o10W30 Type SE Motor oil
(to transmission case cover bearing)
2 . Install:
®Secondary sheave axle (_
(to transmission case cover)
3. Install:
®Circlip @
®Oil seal
NOTE:
i_i_i Apply lithium soap base grease onto the oil seal
_,_i . % lips .
4. Apply:
®10W30 type SE Motor oil
(to main axle bearing and drive axle bearing)
_ '_{_ ...... 5 . I nstall:
®Drive axle (_
®Main axle (_)
,Washer (_) (Main axle)
(_) ,Washer @ (Drive axle)
3-30
Page 76
ENG _ ENGIN E ASSEMBLY AND ADJUSTMENT
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7 . I n stall:
_ ..... : _: ' _: : _! ..... i_ii_ii: (_ *Transmission case c o ver (_
_iii:_;_;_ !ilili;_ _ _ Screw (Case cover):
ii;_ili! ! 'i _ 8 N m (0.8 m , kg, 5.8 ft , lb)
8. Install:
i: ._i_ ' * Centerstand
9. Install:
*Brake shoe plate @
1 8 Nm ( 1.8 m ° k g , 1 3 f t,lb )
- t S oe P'ate ' :
10. Install:
*Plain washer (_
®Rear wheel (_)
(_ * P lain washer _)
t I_ LI 93 N m (9"3 m'k g" 67 f t' i b) I
®Nut @
3-31
Page 77
TRANSMISS I ON
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Bearing
Oil seal
Drive axle
(_ Bearing
q_) Main axle
(_) Plain washer
_ econdary sheave axle Bearing
(_ C i rclip
(_ Oil seal
EOO,NE ASSEMB L ANO AOJ U STM OT "OJ
G
3-32
Page 78
3-33
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Page 79
o oo,oE Aoo AOJOSTMENT I E"OI I
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AUT OL U B E PUM P
( _ Auto l ube pump
(_ Pin
(_ Circlip
@ Shim
(_) Wave washer
(_) Pump drive gear
(_ Circlip
3-34
Page 80
[ E N G ' _®_D] ENGINE ASSEMBLY AND AD J USTMENT h
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C.D.I. MAGNETO
1 . Install:
eGasket (_
• ,. ,_*'_
, . : . : z , . : .,
2. Pass the C.D.I. magneto lead through the
crankcase hole.
'"_ 3. Install:
_ 8 N m (0.8 m, k g, 5.8 ftolb)
_ .......... ®Woodruff key
_, *C . D .I. magneto
_" _:_ . _, 5 . Tighten :
,i:_ ®Nut (C.D .I. magneto)
_ 4 . Install :
e Stator assembly (_)
!_ Screw (Sta t ° r A sse m b ' y ) : I
• Plain washer
, _Spring washer
_Nut
NOTE:
When installing the C.D.I. magneto, make sure
the woodruff key is properly seated in the key way
of the crankshaft. Apply a light coating of lithium
soap base grease to the tapered portion of the
crankshaft end.
Use Flywheel Holding Tool (YU-01235) (_.
43 Nm 1 4 .3 m °k g, 3 1 f t ° lb)
...... 141 I
3-35
Page 81
EOO , OE ASSEMB L ANO AOJOSTMEOT
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C.D.I. MAGNETO
(_ F an
(_ C.D.I. magne to
Sta tor assemb l y
G aske t
(_ Woo dru ff key
[ 8 N m ( 0 8 ___.kg , 5. 8 ft . _b) }
• >%'--.
43 Nm 14.3 mokg, 31 ft-lb) ! __._
8 N m 1 0 .8 m,kg, 5. 8 f t ,lb )
I
I
3 - 36
Page 82
ENG _ E N G IN E A S S E MBLY AND AD JU STM E NT [
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STAR T ER SYSTEM
1 . Install:
oC ollar (_
• Kick shaft (_)
@
3-37
4. Install:
• Kick torsion spring (_
NOTE:
Set the kick torsion spring to the spring hook.
Page 83
_=_ ENGI N E ASSEM BL Y A N D A DJ U ST M ENT ENG
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_. 6 . Ins t all :
oStarter motor (_
8 Nm 1 0 .8 m,kg, 5.8 ft-lb)
NOTE:
A p p l y lith i u m s oa p ba s e g r ea s e to t h e O - ring o f
(_ the starter motor.
7 . Install"
® Stay (_
:' ............. " ............. oCollar (_)
8 Nm 10.8 m ok g, 5 . 8 f t olb )
, :_._:_.., . '_ . , _ ,:; ' &: - "_, _ ' :: , ::!:i::':_!:! " _ i_i:::_:_
@_:!_i_: :_:_"_ ( -_ -Apply lithium soap base grease to the bearing
_: _'_ " - :;: ' ._'_t ............ 8 . Install :
" _:: ,-_i:_,, :i_ .... * Plain washers (_
....... :_::_i:{:;:_i-_ - _::;:_;___ "Starter wheel gear (_
_ = -_) - Apply Yamalube 2 cycle oil to the idle gear (_.
ii:i 9. , sta,"
.:..:.:,._ ®Plate (_D (Idle gear)
I _ S cr e w ( ' die G ea r P late ) :
10. Install:
8 N m ( 0 .8 m okg, 5.8 f t-lb)
eStarter clutch assembly (_
3-38
Page 84
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
Page 85
Eoo,oE ASSEMB L ANO AO U STMEOT E"O I' . I
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PRIMA R Y AND SEC O ND A RY SHEA V E
1 . Install "
- S eco n dar y sheave a ss e m bl y
=C lutch hou si n g ( _
i
2. Tighten :
• Nut (Secondary sheave)
Use Sheave Holder (_ (YS-01880) .
[_ 40 Nm ( 4 .0 m,k g, 29 ft o lb) ]
3. Install:
cO-ring
I 4 . Apply:
• Lithium soap base grease
L>
...... :_;- ..,_::-_,,_ , : - : ,:_ :_ - :_ ...... ., , ., ,_:: ; 5. Install:
iiiiiiii_iii_i_iiii -Primary sheave assembly (_
_i: : !!i i_iiiii_iiii i_i -Collar (_
_;;!_ : ! : _!_ : ililili_i!_iii_i_i _ - Shim (_ .,
6 . Install:
_V-belt
Place the V-belt around the secondary
sheave, and compress the secondary sheave
spring hard so that the V-belt moves toward
the clutch hub.
N OT E:
The V- be lt mus t be i n st a ll ed wit h t he arr ow
': frontward.
3-40
Page 86
I ENG ENGINE ASSE N I BLY AND ADJUSTMENT E
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7 . Install:
e Prima ry fi x ed sheave (_
® One-wa y clutch (_)
• Conical spring washer @
oNut
_ ::_ -- _;_ 8 . Tighten :
®Nut (primary sheave) (_
3 0 Nm (3 .0 m,k g , 22 ft,lb )
NOTE:
When tightening the nut (primary sheave), hold
the C . D.I. magneto using Flywheel Holding Tool
(YU-01235).
9. install:
oFan (_
[_ S cr e w (Fa n ): ] ii_ 8 Nm ( 0 .8 m-kg, 5 .8 ft -l b)
10. Install:
® Dowel pins
oCrankcase cover (Left)
8 Nm (0 . 8 m , kg, 5.8 ft , lb)
Sc r ew (Crankcase Cover): ]
3-41
Page 87
q Eoo NE AssEMB. , Aoo AOJOSTMEOT [ ENO l
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PRIMARY AND SEC O N D ARY S H EA V E
Secondary fixed sheave (_) Clutch assembly
(_ Oil seal (_ C lutc h h ousing
(_ S econdar y s li di n g sheave (_ O-ring
(_ O - ring O Primary sheave assembly
(_) Oil seal (_ V-belt
(_) Spring seat (_ Primary fixed sheave
(_ Clutch spring (_) One-way clutch
*Apply BEL-RAY Assembly Lube ®
C L U T CH S PRING FREE L ENGTH L IMI T :
A
94.0 r n rn (3.70 in)
C L UTCH HOUSING WEAR L I M IT:
B
1 0 5,4 mr n (4. 1 5 in)
CLUTCH SH O E WEAR LI M IT : / _ " _ • ,
C 2 . 5mm (0.10 in) _ / 1 50 N m (5.0 m k g, 3 6ft . l b ) I
V BELT _, L ,_, T / _% /
O 135 mm ( 0 .53 _ n l __ / / _
_ r/// % : _ / / ®
@
t e
3-42
Page 88
I ENG ENGINE ASSEMBLY AND ADJUSTMENT
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PISTON PIN AND PISTO N
1 . Apply:
o Ya m alube 2 cycle o il
To the piston pin, bearing, piston ring
grooves and piston skirt areas.
2 . Install :
• Small end bearing
• Piston
Piston pin
®Piston pin clip
NOTE:
= Th e arrow ( _ on t h e p i s to n m ust p oi n t to th e
fro n t o f the e n gine.
- Before installing the pist o n pin clip, cover the
crankcase with a clean towel or rag so you will
not accidentally drop the pin clip and material
into the crankcase.
®Always use a new piston pin clip.
3-43
Page 89
E N G IN E A SS EMBL Y A N D ADJU S T M ENT E N G
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P IS TO N P IN A N D P IS TO N
(_ Piston ring (1st, 2nd)
(_) Piston
(_ Piston pin clip
@ Piston pin
_ Piston pin clip Small end bearing
PIST O N RING SIDE C L EARANCE:
A 0 . 0 3- 0. 0 5 mm ( 0.0 0 12- 0 . 0020 i n)
< LIMIT>: 0 . 1 0 m m (0.0 0 4 in)
B 0.015 - 0.03 mm (0.0 0 6 - 0. 0 12 in)
< LIMIT > : 0.7 mm (0.028 in)
I
. ®
3- 44
Page 90
_i C Y L I ND ER AND CYLIND ER HE AD
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_; 1 . I nsta ll :
®Cylinder gasket (New gasket)
2. Offset the piston ring end gaps as shown .
( _ 1st ring
_) 2nd ring
NOTE:
oBe sure to check the manufacturer's marks or
numbers stamped on the rings are on the top
side of the rings.
oBefore installing the cylinder, apply a liberal
coating of 2-stroke to the pisotn rings.
3. Install:
• Reed valve
oCarburetor joint (_
B°'t ( Ca r b u r e t°r J°in t) : I
;_i_ ; _ J 4 . I nstall:
• C y l inder (_
; _ N OTE :
I nsta ll the cyli nder wi th o ne hand w hi l e co mpress -
ing t he pis to n r i ngs w ith the ot her hand .
5 . P ass the o i l de l ivery pipe as sh ow n,
8 N m ( 0.8 m o k g, 5.8 f t.lb)
3 -45
Page 91
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
Page 92
[ 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
Page 93
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
Page 94
ENG ENGINE ASSEMBLY AND ADJUSTMENT
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4. A ir bleeding:
®A utolub e pump
Refer to "C H A PTER 2-- A UTOLUBE PUMP
A IR BLEE D I NG" section.
5. A p p ly:
• Transmission oil
Refer to "CHAPTER 2--TRANSMISSION
OIL REPLACEMENT" section.
6. Adjust:
,Brake lever free play
Refer to "CHAPTER 2--BRAKE LEVER
FREE PLAY ADJUSTMENT" section.
• Autolube pump cable
Refer to "CHAPTER 2--AUTOLUBE PUMP
CABLE ADJUSTMENT" section .
• Throttle cable free play
Refer to "THROTTLE CABLE FREE PLAY
ADJUSTMENT" section.
3-49
Page 95
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Page 96
C H APT E R 4
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CA RBU RE T I O N
AUTO CHOKE S YSTE M .......................................... F - 3
CONSTITUENTS ................................................ F-3
WIRING SCHEMATIC .......................................... F-3
OPERATION ................................................... F-3
CARBURETOR ................................................... F-4
SECTION VIEW ................................................ F-5
REMOVAL .................................................... F-5
DISASSEMBLY ................................................ F-5
INSPECTION .................................................. F-6
ASSEMBLY ................................................... F-7
INSTALLATION ................................................ F-7
AUTO CHOKE UNIT CHECK .................................... F-8
REED V A LVE ........................... . ........................ F-8
REMOVAL .................................................... F-8
INSPECTION .................................................. F-8
INSTALLATION ................................................ F-9
Page 97
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Page 98
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
Page 99
AOTO C . OKE S , STEM [OA"
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O PER A TI O N
j Cold engine J
On the cold engine the wax element changes
(reduces) its volume according to the ambient
temperature.
In this state the starter plunger is at the top,
thereby opening the starter plunger .
: Air
_==J= • Fuel
J Running engine J
When the engine is started, the heated P.T.C .
thermistor expands the wax element, gradually
pushing the starter plunger and controlling the
opening of the starter passage. The further heated
thermistor expands the wax element to a com-
plete extent, thereby fully closing the starter
passage.
This in turn causes the engine r.p.m, to change
(be reduced) with time, finally coming to specified
idling.
The wax element expands during the ride as well
by means of the P.T.C. thermistor, thereby keep-
ing the starter passage fully closed .
: Air
_" Fuel
4-2
Page 100
J CARB [ AUTO CHOKE SYSTEM E
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j R e starting after e ngine warm-up J
1 . Restarting right a f ter ride:
The wax element is fully expanded, so the
start e r passag e is f ully clos e d by th e start e r
plung e r.
2. Restarting after leaving engine for a pa rt icula r
tim e :
The wax e le m e n t b e gins t o r e duc e its volum e
according to the ambient temperature , per-
mitting the starter plunger to open the
passage to meet the engine requirement.
4 -3