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Model : CE50T, CG50A, CG50U, CG50W
2YT281972000 *2YT281972000*
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CE50T |
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SERVICE |
MANUAL |
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©1986 by Yamaha |
Motor |
Co., Ltd. |
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1st Edition, November |
1986 |
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All rights reserved. |
Any reprinting or |
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unauthorized use without |
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permission of Yamaha Motor |
Co., Ltd. |
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is expressly |
prohibited. |
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D
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 manual, |
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 |
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use and/or unsafe. |
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Yamaha Motor |
Company, Ltd. is continually |
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striving to improve |
all models manufactured |
by Yamaha. |
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Modifications |
and significant changes in specifications |
or procedures will be forwarded |
to all Autho- |
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rized |
Yamaha |
dealers and will, |
where applicable, appear |
in future editions of this |
manual. |
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TECHNICAL |
PUBLICATIONS |
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SERVICE DIVISION |
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MOTORCYCLES OPERATIONS |
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CO., LTD. |
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YAMAHA MOTOR |
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HOW TO USE THiS |
MANUAL |
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PARTICULARLY |
iMPORTANT |
iNFORMATiON |
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NOTE: |
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A NOTE provides key information to make procedures easier or clearer. |
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ACAUTIONindicatesspecialprocedutrhesatmustbefollowedtoavoid |
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damage to the scooter. |
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A WARNING |
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indicates special procedures that must be followed to avoid injury |
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to a scooter operator or person inspecting or repairing the scooter. |
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MANUAL |
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FORMAT |
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All of the procedures |
in this manual are organized in a sequential, step-by-step format. |
The |
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tion |
has been compiled to provide the mechanic with |
an easy to read, handy reference that |
contains |
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comprehensive |
explanations of all disassembly, repair, assembly, and inspection |
operations. |
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In this revised format, |
the condition of a faulty component |
will precede an arrow symbol and the course |
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of |
action required will |
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Bearings |
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Pitting/Damage_ Replace. |
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EXPLODED |
DIAGRAM |
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Each chapter |
provides exploded |
diagrams before each disassembly section for ease in identifying cor- |
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rect disassembly and assembly |
procedures. |
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(9 |
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IGENINFO |
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ENG %_JDI |
IC OOL _i |
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ICARB[ |
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1 |
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_L_.._ |
iLLUSTRATED |
SYMBOLS |
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(Refer |
to the |
illustration) |
Illustrated |
symbols |
(_) to _) are designed as |
thumb tabs to indicate the chapter's number and content.
Periodic inspection and adjustment
General information
_ CoolingEngine system
_ Carburetion
@ Chassis
_(_)_; pter'nCdl'ces |
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Illustrated |
symbols |
( to (_) are used to identify |
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( ) |
Filling |
fluid |
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specifications |
appearing in the text. |
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the |
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Lubricant |
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Tightening |
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(_) |
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WearEnginelimit,speedclearance
Illustrated |
symbols |
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exploded |
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indicate grade |
of |
lubricant |
and |
location |
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of lubrication point. |
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®Apply engine o,1
®Apply gear oil
@(_Apply molybdenumwheel bearing disulfidegrease oil
_(_))Apply molybdenumlightweight lithiumdisulfide-soapgreasebase grease Apply locking agent (LOCTITE ®)
®
l
m
i
INDEX
GENERAL,NFORMAT,ON
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ENGINE OVERHAUL |
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CARBURETION |
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CHASSIS |
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ELECTRICAL
'_'%_
ENG _
CARB_,
CHAS_
L..,-.-----J
ELEC_
APPENDICES |
APPX_ |
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m
GEN
CHAPTER 1
GENERAL INFORMATNON
SCOOTER IDENTIFICATION |
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VEHICLE IDENTIFICATION |
NUMBER .............................. |
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ENGINE SERIAL NUMBER |
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IMPORTANT INFORMATION |
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ALl. REPLACEMENT PARTS ..................................... |
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GASKETS, OIL SEALS, AND O-RINGS |
............................ |
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LOCK WASHER/PLATES |
AND COTTER PINS ..................... |
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BEARINGS AND OIL SEALS ..................................... |
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CIRCLIPS ...................................................... |
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SPECIAL TOOLS |
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FOR TUNE-UP .................................................. |
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FOR ENGINE SERVICE |
.......................................... |
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FOR CHASSIS SERVICE ......................................... |
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FOR ELECTRICAL COMPONENTS ................................ |
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B-3 B-3 B-3
B-3 B-3 B-3 B-3 B-4 B-4
B-4 B-4 B-4 B-5 B-5
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INFO |
SCOOTER IDENTIFICATION |
G E N E R A L
I N F O R M A T I O N
SCOOTER IDENTIFICATION
VEHICLE IDENTIFICATIO N N U M B E R
The vehicle identification number (~ is stamped into the frame.
NOTE:
The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing outhority in your state.
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Starting Serial Number: |
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JYA2U G00-~ HA720101
ENGINE SERIAL N U M B E R
The engine serial number (~ is stamped into the crankcase.
.NOTE:
wwwThe 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
IMPORTANT INFORMATION I°E"INFO
1. Use only genuine Yamaha parts for all replacements. Use oil and/or grease recom- mended by Yamaha for assembly and adjust- ment. Other brands may be similar in func- tion and appearance, but inferior in quality.
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1. All gaskets, seals, |
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gasket surfaces, oil seal lips and O-rings must |
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2. Properly oil all mating parts and bearings dur- |
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ing reassembly. Apply grease to the oil seal |
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lips. |
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LOCK WASHERS/PLATES |
AND |
COTTER |
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PINS |
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Lock tab(s) should |
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(_ and cotter pins |
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1. All lock washers/Plates |
1-2
INFO |
iMPORTANT |
__) |
_ |
iNFORMATiON
manufacturer's marks or numbers facing outward. (In other words, the stamped letters
installing oil seal(s), apply a light coating of must be on the side exposed to view.) When 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
(_
_/._/7_/_////_
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(_ Bearing |
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CIRCLIPS |
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1. All circlips should be inspected carefully |
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clips after one use. Replace distorted circlips. |
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the sharp edged corner (_ |
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When |
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sectional view.
(_) Shaft
1-3
3 |
I GEN |
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SPECIAL TOOLS I |
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SPECIAL TOOLS |
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The proper special tools are necessary for com- |
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plete and accurate tune-up and assembly. Using |
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the correct special tool will help prevent damage |
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caused by the use of improper tools or improvis- |
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FOR TUNE-UP |
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1. Inductive Tachometer |
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P/N. YU-08036 |
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This tool is needed for detecting engine rpm. |
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2. Compression Gauge |
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P/N. YU-33223 |
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This gauge is used to measure engine compr- |
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ession. |
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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
I GEN
SPECIAL TOOLS
P
i . . . . . . . . . . . . . |
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3. Primary Sheave Holder P/N. YS-01880
This tool is used when holding the clutch hub.
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4. Clutch Spring Holder P/N. YS-28891
This tool is used to disassembly and assembly the
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5. |
Thickness Gauge |
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P/N. YU-03001 |
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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
I GEN |
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SPECIAL TOOLS I ,.Fol |
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8. Crankshaft Installation Set |
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P/N. YU-90050 . . . . . . . . . . . . . . . . . . . . . . |
(~) |
Adapter (M10) |
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P/N. YM-90062 . . . . . . . . . . . . . . . . . . . . . |
(~ |
Adapter (M12) |
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P/N. YM-90063 . . . . . . . . . . . . . . . . . . . . . |
~) |
These tools are used to install the crankshaft.
@
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9.Sealant (Quick Gasket~) P/N. ACC-11001-05-01
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This sealant (bond) is used for crankcase mating |
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FOR C H A S S I S SERVICE |
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1. Ring Nut Wrench |
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(~ |
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P/N. YU-01268 |
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P/N. YU-33975 . . . . . . . . . . . . . . . . . . . . . |
(~ |
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This tool is used to loosen and tighten the steer- |
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FOR ELECTRICAL C O M P O N E N T S
1. Pocket Tester P/N. YU-03112
This instrument is invaluable for electrical system inspection and §djustment.
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2. Electro Tester |
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P/N. YU-33260 |
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This instrument is necessary for ignition system |
inspection. |
1-6
INSP
CHAPTER 2
INTRODUCTION |
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PERIODIC MAINTENANCE/LUBRICATION |
INTERVALS ............ |
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TAIL COVER ..................................................... |
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REMOVAL |
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INSTALLATION ................................................ |
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FRONT FENDER, FRONT PANEL AND |
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REMOVAL |
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INSTALLATION |
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THROTTLE CABLE FREE PLAY ADJUSTMENT.ScooterTime................... |
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HANDLEBAR |
COVERS ........................................... |
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REMOVAL |
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INSTALLATION ................................................ |
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ENGINE .......................................................... |
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ENGINE IDLE SPEED ADJUSTMENT |
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AUTOLUBE |
PUMP CABLE ADJUSTMENT ........................ |
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AUTOLUBE |
PUMP AIR BLEEDING ............................... |
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AIR CLEANER ELEMENT CLEANINGwww............................. |
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FUEL COCK CLEANING |
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COMPRESSION |
PRESSURE MEASUREMENT ..................... |
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ENGINE OIL LEVEL INSPECTION ................................ |
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TRANSMISSION |
OIL REPLACEMENT .... ........................ |
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FUEL LINE INSPECTION ........................................
CHASSIS ........................................................
FRONT BRAKE LEVER FREE PLAY CHECK .......................
REAR BRAKE LEVER FREE PLAY CHECK .......................
FRONT AND REAR BRAKE LINING INSPECTION ................
TIRE AND WHEEL INSPECTION .................................
STEERING ADJUSTMENT ......................................
C-3
C-3
C-3
C-3
C-4
C-4 C-4 C°5
C-5
C-5
C-5
C-5
C-5
C-6
C-6
C°7
C-8
C-8
C-9
C-10 C-10 C-11
C-11 C-11 C-11 C-12 C-12 C-12
ELECTRICAL ..................................................... |
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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ADJ |
1 |
LUBRICATION |
iNTERVALS |
MAINTENANCE/ |
B |
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I INSPli |
INTRODUCTION/PERIODIC |
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PERIODIC |
INSPECTIONS |
AND |
ADJUSTMENTS |
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INTRODUCTION |
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This chapter includes all information |
necessary |
to perform recommended inspections and adjustments. |
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These preventiw, • maintenance procedures, if followed, |
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will ensure more reliable vehicle operation |
and |
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a longer service life. The need for |
costly overhaul work |
will be greatly reduced. |
This information |
ap- |
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plies to vehicles already |
in service |
as well as new vehicles that |
are being prepared |
for sale. All service |
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technicians should be familiar with this entire |
chapter. |
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PERIODIC |
MAINTENANCE/LUBRICATION |
INTERVALS |
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Unit: km (mi) |
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BREAK-IN |
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ITEM |
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REMARKS |
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ScooterTime |
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(300) |
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Spark plug |
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Check/Clean or replace. |
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Air |
filter |
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Clean. Replace if necessary. |
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Carburetor |
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Check/Adjust/idle speed, |
starter operation. |
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Fuel line |
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Check fuel |
hose for |
cracks or damage. |
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Transmission oil |
Replace (Warm engine before draining). |
Replace |
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Every 12,000 (8,000) or 24 months. |
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Autolube pump |
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Check/Adjust/Air bleeding. |
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Brake |
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Check operation. Adjust |
if necessary. |
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Wheels* |
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Check balance/damage/runout. |
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from |
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Wheel bearings |
Check bearings assembly for looseness/ |
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damage. Replace if damaged. |
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Check bearings assembly for looseness. |
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DownloadedReplace if |
necessary. |
12,000 (8,000) |
Check |
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Steering bearing |
Moderately |
repack |
every |
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or 24 months.** |
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Rear shock |
absorber |
Check |
operation. |
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Fittings/Fasteners |
Check |
all chassis fittings |
and fasteners. |
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Battery |
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Check specific gravity. Check breather pipe |
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for proper |
operation. |
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V-belt |
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Check damage and wear. |
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**: |
Medium |
weight wheel |
bearing |
grease. |
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EVERY
3,000 6,000
(2,000) or (4,000) or 6 months 12 months
©O
O |
© |
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© |
O |
O |
Check |
Check |
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O |
O |
O |
O |
O |
O |
O |
Check |
Check |
O |
O |
O |
O |
O |
O |
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O |
2-1
TAIL COVER ADJ
1.Open the seat lock.
2.Remove:
=Seat
3. Remove:
-Cover (_
_
Downloaded
from
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net |
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ScooterTime |
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4. Remove: |
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,Grab |
bar |
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www |
, Rear carrier |
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(With |
rear flasher lights and taillight) |
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5. Disconnect: |
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,Rear |
flasher light leads |
• Taillight leads
6.Remove:
®Side covers (Right and left)
NOTE:
When removing the side cover, unhook it at the front and slide it forward.
7.Remove: =Tail cover
:!!
2-2
INSP |
TA'LCOVER |
E |
ADJ _1 |
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When installing the tail cover, reverse the "REMOVAL" procedure.
Note the following points.
i_J_.
i__i
1.Install: ®Side covers
NOTE:
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net |
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After installing the side covers, make sure that |
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all hooks are securely fitted. |
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ScooterTime |
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2. Connect: |
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. |
eRear flasher light leads |
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www |
NOTE: |
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The leads of identical colors should be connected. |
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Downloaded |
from |
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31 install: ®Rear carrier
7Nm (0.7 m,kg, 5.1 ft-lb)
4.Install: eSeat
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m,kg, |
!_ |
7 Nm (0.7 |
5.1 ft,lb) |
2-3
- |
I |
FRONT FENDER, FRONT PANEL |
INSP |
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AND FOOTREST BOARD |
iADJ |
FRONT FENDER, FRONT PANEL
AND FOOTREST BOARD
REMOVAL 1. Remove:
-Tail cover
Refer to "TAIL COVER" section.
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2. Remove: |
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®Front fender |
_, |
NOTE: |
@ |
i:Q::!i!_-:: |
_N % |
- -_ - |
_iiiii:iiii__" |
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i:iiii!i!ilii_i |
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Downloaded
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Before removing |
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net |
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the fender, make sure that all |
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hooks are free. |
. |
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ScooterTime |
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3. Remove: |
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. |
,Main switch |
cap |
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Turn the cap counterclockwise. |
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from |
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4. Remove:
®Front panel
5.Remove:
, Footrest board
2-4
I INSP
FRONT FENDER, FRONT PANEL |
E |
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A N D FOOTREST B O A R D / H A N D L E B A R COVERS |
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IN S T A L L A T I O N
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.
Downloaded |
from |
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net |
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ScooterTime |
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HANDLEBAR COVERS |
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www |
R E M O V A L |
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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
ENGINE iDLE SPEED A D J U S T M E N T I A D J I
I N S T A L L A T I O N
1.Install:
oHandlebar cover (Rear) (~)
2.Connect:
• Leads
oSpeedometer cable (~)
Downloaded |
from |
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NOTE:
Position the cables as shown.
Front brake cable
(~)Throttle cable
(~)Rear brake cable
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net |
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ScooterTime |
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3. |
Connect: |
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eHeadlight lead and flasher ]~ght leads |
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Install: |
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www |
4. |
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® Handlebar cover (Front) |
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®Rear view mirror(s)
ENGIN E iDLE SPEED A D J U S T M E N T
1.Remove:
•Tail cover,.
Refer to " T A I L COVER" section.
2.Start the engine and warm it up before checking 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
I INSP
ENGINE IDLE SPEED A D J U S T M E N T / |
E |
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THROTTLE CABLE FREE PLAY A D J U S T M E N T |
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3.Attach:
®Inductive Tachometer (YU-08036)
4.Check:
eEngine idle speed
Out of specification-*Adjust.
Engine Idle Speed:
1,500-2,100 r/rnin
Downloaded |
from |
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Engine idle speed adjustment steps; |
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®Start the engine at idle speed. |
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eTurn the throttle stop screw (~ clockwise to |
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net |
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increase engine speed and counterclockwise |
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to decrease engine speed. |
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ScooterTime |
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5. Install: |
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. |
eTail cover |
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Refer to "TAIL COVER" section. |
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www |
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THROTTLE CABLE FREE PLAY
ADJUSTMENT
1.Check:
*Throttle cable free play (~ Out of specification-*Adjust.
[ ~ ThrottleCableFree 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
AUTOLUBE |
PUMP CABLE ADJUSTMENT |
ADJ |
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=Loosen the Iocknut (_. |
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oTurn the adjuster (_ |
in or out until the cor- |
!_:__...... |
rect free play is obtained. |
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=Tighten the Iocknut. |
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Downloaded |
from |
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AUTOLUBE PUMP |
CABLE ADJUSTMENT |
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NOTE: |
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net |
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Beforeadjustingthe pump cable, adjustthe throt- |
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tle cable free play. |
. |
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ScooterTime |
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1. Remove: |
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. |
=Tail cover |
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Refer to "TAIL |
COVER" section. |
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www |
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* Front fender |
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=Front panel eFootrest board
Refer to "FRONT FENDER, FRONT PANEL AND FOOTREST BOARD" section.
2. Check:
*Throttle cable free play (_ (at carburetor side)
Out of specification_Adjust.
..... 1.0 mm (0.04 in)
J_ Thrott,eCableFreePlay(_):
Throttle cable free play adjustment steps;
=Loosen the Iocknut (_.
=Turn the adjuster _ in or out until the cor- rect free play is obtained.
=Tighten the Iocknut.
2-8
Downloaded |
from |
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4. Close the throttle grip completely.
5. Check:
®Autolube pump pulley position (_
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net |
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Out of position-*Adjust. |
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ScooterTime |
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®: |
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(0.0-0.04 |
in) |
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0.0-1.0 |
mm |
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_ |
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Autolube |
Pump |
Pulley |
Position |
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Autolube |
pump pulley position |
adjustment |
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. |
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steps: |
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www |
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oLoosen the Iocknut _. |
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®Turn the adjuster (_ |
in or out until the pump |
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plunger pin (_ |
is aligned with the mark _) |
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on the pump pully. |
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eTighten the Iocknut. |
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6. |
Install: |
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oAutolube pump cover |
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oFootrest board |
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®Front |
panel |
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• Front fender |
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eTail cover |
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Refer to "FRONT |
FENDER, FRONT PANEL |
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AND |
FOOTREST |
BOARD" |
and "TAIL |
COVER" section.
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.
oIf the scooter lies on its side after falling over.
2-9
__ |
I,.sPl l |
AUTOLUBE PUMP AIR BLEEDING ADJ |
J
Downloaded
1. Remove:
=Tail cover
® Front fender
-Front panel
•Footrest board
Refer to "TAIL COVER" and "FRONT
FENDER, FRONT PANEL AND FOOTREST BOARD" section.
2.Remove:
®Autolube pump cover
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net |
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. |
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ScooterTime |
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3. Remove: |
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• Bleed screw |
@ |
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. |
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NOTE: |
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www |
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from |
Place a rag under the Autolube pump. |
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4. Start the engine at idle speed. |
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5. Air bleed: |
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Keep the oil |
running out until air bubbles |
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disappear. |
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NOTE: |
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Pull the pump cable all the way out to set the pump stroke to a maximum.
6.Inspect:
®Bleed screw gasket
Damage_Replace.
7.Install:
•,Bleed screw gasket
• Bleed screw
2-10
t ADJINSP
UTOLUBE PUMP AiR BLEEDING/
8.Keep the engine runningat about 2,000 r/min for two minutes or so, and both distributor
and delivery pipe can be completely bled.
NOTE:
It is difficult to bleed the distributor completely with the pump stroke at a minimum, and therefore the pump stroke should be set to a maximum.
;_
Downloaded
9. Install: |
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eAutolube |
pump cover |
• Footrest |
board |
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®Front |
panel |
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net |
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Front fender |
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. |
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oTail cover |
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ScooterTime |
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Refer to "FRONT PANEL, FRONT FENDER |
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ANT |
FOOTREST BOARD" and "TAIL |
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COVER" section. |
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AIR |
CLEANER ELEMENT CLEANING |
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. |
1. Remove: |
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®Side cover (Left) |
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www |
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NOTE: |
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When removing the side cover, unhook it at the |
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from |
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front and slide it forward. |
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2. |
Remove: |
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®Air cleaner case cover (_ |
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eAir cleaner element |
i i : i_iii i:i i_i!i !_i!i i_ ! |
i |
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Never operate the engine with |
the air cleaner |
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element |
removed. |
This will |
allow |
unfiltered |
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air to enter, |
causing |
rapid |
wear |
and possi- |
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ble engine |
damage. |
Additionally, |
operation |
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without |
the |
cleaner |
element will affect car- |
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buretor |
jetting |
with |
subsequent |
poor perfor- |
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mance |
and |
possible |
engine overheating. |
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Be careful |
not to |
have rags |
or the |
like block- |
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ing the |
intake |
area |
of the |
air |
cleaner. |
2-11
;'='8 I |
AiR CLEANER LEMENT CLEANHNG/ |
INSP |
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FUEL COCK CLEANING |
ADJ |
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3. Clean: |
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oAir cleaner element |
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Air cleaner element cleaning steps: |
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oWash the element gently, but thoroughly in |
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solvent. |
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Never use low flash point |
solvents such as |
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gasoline |
to clean the element. Such sol- |
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vent may |
lead to a fire |
or explosion. |
Downloaded
from
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oSqueeze the excess solvent out of the element |
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and let dry. |
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net |
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::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: |
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. |
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ScooterTime |
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when squeezing |
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Do not twist |
the element |
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the element. |
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4. Inspect: |
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oElement |
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. |
Damage- |
Replace. |
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5. Apply: |
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www |
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oFoam-air-filter |
oil or SAE 10W30 type SE |
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motor oil |
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Onto the element. |
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6. Squeeze out the excess |
oil. |
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NOTE: |
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The element should |
be wet |
but not dripping. |
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7. Install: |
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oAir cleaner element |
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®Air cleaner case cover |
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®Side coyer |
(Left) |
|
1.Remove: -Tail cover
Refer to "TAIL COVER" section.
2-12
I,NsP |
E |
|
ADJ |
FUEL COCK CLEANHNG |
|
2.Drain: =Fuel
FUEL IS HIGHLY FLAMMABLE:
__ |
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_k,_ |
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|
==_£ |
'=_ |
{ |
" |
(_ |
|
_,_/ |
(_) |
_* '!_ii!iiii_ |
_:::_ |
Downloaded |
=Take care not to spill any fuel on the engine ®Always turn off the engine when draining. or exhaust pipe/muffler when draining.
oNever drain fuel while smoking or in the
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vicinity |
of an open flame. |
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net |
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. |
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.ScooterTime®Filter ( |
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3. Remove: |
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*Cap |
( |
from |
www |
4. Clean: |
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Filter |
||
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oCap |
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Wash the filter and cap gently using solvent. |
5. Inspect:
• Filter oO-ring
Damage--* Replace.
6.Install: ®O-ring Filter
oCap
oTail cover
Refer to "TAIL COVER" section.
2-13