YAMAHA JOG Diagram

0 (0)
YAMAHA JOG Diagram

1987 - 1990

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MOTORCYCLE

 

 

 

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SERVICE MANUAL

 

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Model : CE50T, CG50A, CG50U, CG50W

2YT281972000 *2YT281972000*

 

 

 

 

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CE50T

 

 

SERVICE

MANUAL

 

©1986 by Yamaha

Motor

Co., Ltd.

1st Edition, November

1986

All rights reserved.

Any reprinting or

unauthorized use without

the

written

permission of Yamaha Motor

Co., Ltd.

is expressly

prohibited.

 

3

 

 

 

 

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D

NOTICE

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

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

 

 

 

 

 

 

 

 

 

 

 

 

 

SERVICE DIVISION

 

 

 

 

 

 

 

 

 

 

 

 

 

net

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTORCYCLES OPERATIONS

 

 

 

 

 

 

 

 

 

 

 

 

.

 

CO., LTD.

 

 

 

 

 

 

 

 

 

 

 

 

YAMAHA MOTOR

 

 

 

 

 

 

 

 

 

 

ScooterTime

 

 

 

 

 

 

 

 

 

HOW TO USE THiS

MANUAL

 

 

 

 

PARTICULARLY

iMPORTANT

iNFORMATiON

 

 

 

 

 

This

material is distinguished by the following notation.

 

 

 

 

 

 

NOTE:

 

 

 

 

 

 

.

 

 

 

 

 

 

 

A NOTE provides key information to make procedures easier or clearer.

 

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www

 

 

 

 

 

 

 

 

ACAUTIONindicatesspecialprocedutrhesatmustbefollowedtoavoid

 

 

 

 

damage to the scooter.

 

 

 

 

 

 

 

 

 

 

 

 

 

A WARNING

 

from

 

 

 

 

 

 

 

 

 

 

 

 

indicates special procedures that must be followed to avoid injury

 

 

 

 

to a scooter operator or person inspecting or repairing the scooter.

 

 

MANUAL

 

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FORMAT

 

 

 

 

 

 

 

 

 

 

 

All of the procedures

in this manual are organized in a sequential, step-by-step format.

The

informa-

tion

has been compiled to provide the mechanic with

an easy to read, 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

action required will

follow the symbol,

e.g.,

 

 

 

 

 

 

 

Bearings

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pitting/Damage_ Replace.

 

 

 

 

 

 

 

 

 

 

 

EXPLODED

DIAGRAM

 

 

 

 

 

 

 

 

 

 

 

Each chapter

provides exploded

diagrams before each disassembly section for ease in identifying cor-

rect disassembly and assembly

procedures.

 

 

 

 

 

 

 

 

(9

 

 

®

 

 

IGENINFO

 

 

 

(_

 

 

(_)

 

 

ENG %_JDI

IC OOL _i

(_

 

 

(_)

 

 

ICARB[

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1

_"AS1_I

 

®

 

 

®

 

 

®

 

 

®

_

 

 

6_

 

 

_

 

(_)

 

 

(_)

--

 

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_

 

=

 

 

_

 

_

 

@

 

(_

 

(_

 

_

_

_

 

_L_.._

iLLUSTRATED

SYMBOLS

(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

( )

Filling

fluid

 

 

.

specifications

appearing in the text.

the

(

 

Lubricant

 

 

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Tightening

 

 

(_)

 

 

WearEnginelimit,speedclearance

Illustrated

symbols

(_

to

(_ in

the

exploded

diagram

indicate grade

of

lubricant

and

location

of lubrication point.

 

 

 

 

 

®Apply engine o,1

®Apply gear oil

@(_Apply molybdenumwheel bearing disulfidegrease oil

_(_))Apply molybdenumlightweight lithiumdisulfide-soapgreasebase grease Apply locking agent (LOCTITE ®)

®

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i

INDEX

GENERAL,NFORMAT,ON

 

 

 

 

 

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ENGINE OVERHAUL

 

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.

 

CARBURETION

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CHASSIS

 

 

 

 

 

ELECTRICAL

'_'%_

ENG _

CARB_,

CHAS_

L..,-.-----J

ELEC_

APPENDICES

APPX_

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GEN

CHAPTER 1

GENERAL INFORMATNON

SCOOTER IDENTIFICATION

.......................................

 

 

VEHICLE IDENTIFICATION

NUMBER ..............................

 

ENGINE SERIAL NUMBER

.......................................

 

 

IMPORTANT INFORMATION

......................................

 

 

ALl. REPLACEMENT PARTS .....................................

 

 

GASKETS, OIL SEALS, AND O-RINGS

............................

LOCK WASHER/PLATES

AND COTTER PINS .....................

BEARINGS AND OIL SEALS .....................................

 

 

CIRCLIPS ......................................................

 

 

 

ScooterTime

SPECIAL TOOLS

 

 

 

 

 

 

.net

FOR TUNE-UP ..................................................

 

 

 

 

FOR ENGINE SERVICE

..........................................

 

 

 

FOR CHASSIS SERVICE .........................................

 

 

 

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:

ScooterTime

 

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

IMPORTANT INFORMATION
ALL REPLACEMENT PARTS

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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GASKETS, OIL SEALS, AND O-RINGS

1. All gaskets, seals,

 

and

O-rings should be

 

replaced when

an engine is overhauled. All

 

 

 

 

net

 

 

gasket surfaces, oil seal lips and O-rings must

 

be cleaned.

.

 

 

 

 

 

 

 

ScooterTime

 

 

 

2. Properly oil all mating parts and bearings dur-

 

ing reassembly. Apply grease to the oil seal

 

lips.

 

 

 

 

 

LOCK WASHERS/PLATES

AND

COTTER

PINS

 

 

 

 

 

.

 

 

 

 

 

www

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.

 

 

 

(_ and cotter pins

1. All lock washers/Plates

1-2

INFO

iMPORTANT

__)

_

iNFORMATiON

BEARINGS AND OIL SEALS

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_/_////_

/J

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Do not use compressed air to spin the bear-

ings dry. This causes damage

to the bearing

surfaces.

 

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(_ Bearing

 

 

CIRCLIPS

 

 

 

 

1. All circlips should be inspected carefully

.

ereasore reoaceO ton

www

 

 

 

clips after one use. Replace distorted circlips.

 

 

the sharp edged corner (_

is positioned op-

 

 

When

installing a cirelip (_,

make sure th at

 

 

posite

to the thrust (_) it receives. See the

sectional view.

(_) Shaft

1-3

3

I GEN

 

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.

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FOR TUNE-UP

 

1. Inductive Tachometer

 

P/N. YU-08036

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This tool is needed for detecting engine rpm.

.

ScooterTime

 

2. Compression Gauge

 

P/N. YU-33223

 

.

 

This gauge is used to measure engine compr-

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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

I GEN

SPECIAL TOOLS

P

i . . . . . . . . . . . . .

i r

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

 

secondary sheave.

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ScooterTime

 

 

5.

Thickness Gauge

.

P/N. YU-03001

 

 

 

www

 

 

 

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

l

SPECIAL TOOLS I ,.Fol

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.

@

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9.Sealant (Quick Gasket~) P/N. ACC-11001-05-01

 

This sealant (bond) is used for crankcase mating

 

surfaces.

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ScooterTime

 

 

 

FOR C H A S S I S SERVICE

 

 

1. Ring Nut Wrench

 

 

 

.

 

(~

 

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P/N. YU-01268

 

 

P/N. YU-33975 . . . . . . . . . . . . . . . . . . . . .

(~

 

 

 

This tool is used to loosen and tighten the steer-

from

ing ring nut.

 

 

 

 

 

 

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.

 

2. Electro Tester

 

P/N. YU-33260

!J

This instrument is necessary for ignition system

inspection.

1-6

INSP

CHAPTER 2

PERiODiC iNSPECTiONS AND ADJUSTMENTS

INTRODUCTION

.................................................

 

 

 

 

 

PERIODIC MAINTENANCE/LUBRICATION

INTERVALS ............

 

 

TAIL COVER .....................................................

 

 

 

 

 

 

REMOVAL

....................................................

 

 

 

 

 

INSTALLATION ................................................

 

 

 

 

 

FRONT FENDER, FRONT PANEL AND

FOOTREST B OARD

.........

net

REMOVAL

 

 

 

 

 

....................................................

 

 

 

.

INSTALLATION

 

 

 

 

 

 

 

 

THROTTLE CABLE FREE PLAY ADJUSTMENT.ScooterTime...................

 

HANDLEBAR

COVERS ...........................................

 

 

 

 

REMOVAL

.....................................................

 

 

 

 

 

INSTALLATION ................................................

 

 

 

 

 

ENGINE ..........................................................

 

 

 

 

 

 

ENGINE IDLE SPEED ADJUSTMENT

.............................

 

 

AUTOLUBE

PUMP CABLE ADJUSTMENT ........................

 

 

AUTOLUBE

PUMP AIR BLEEDING ...............................

 

 

 

 

 

 

from

 

 

 

AIR CLEANER ELEMENT CLEANINGwww.............................

 

 

FUEL COCK CLEANING

........................................

 

 

 

COMPRESSION

PRESSURE MEASUREMENT .....................

 

 

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ENGINE OIL LEVEL INSPECTION ................................

 

 

 

TRANSMISSION

OIL REPLACEMENT .... ........................

 

 

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

I INSPli

INTRODUCTION/PERIODIC

PERIODIC

INSPECTIONS

AND

ADJUSTMENTS

 

INTRODUCTION

 

 

 

 

 

 

 

 

This chapter includes all information

necessary

to perform recommended inspections and adjustments.

These preventiw, • maintenance procedures, if followed,

 

will ensure more reliable vehicle operation

and

a longer service life. The need for

costly overhaul work

will be greatly reduced.

This information

ap-

plies to vehicles already

in service

as well as new vehicles that

are being prepared

for sale. All service

technicians should be familiar with this entire

chapter.

 

 

 

 

PERIODIC

MAINTENANCE/LUBRICATION

INTERVALS

 

 

 

 

 

 

 

 

 

 

Unit: km (mi)

 

 

 

 

 

 

 

 

 

 

net

 

 

 

 

 

 

 

 

 

BREAK-IN

 

ITEM

 

 

REMARKS

 

500

 

 

 

 

 

 

 

 

 

.

 

 

 

 

 

 

 

 

ScooterTime

 

 

 

 

 

 

 

 

 

 

(300)

Spark plug

 

Check/Clean or replace.

 

 

 

O

Air

filter

 

Clean. Replace if necessary.

 

 

 

Carburetor

 

Check/Adjust/idle speed,

starter operation.

 

©

Fuel line

 

Check fuel

hose for

cracks or damage.

 

 

Transmission oil

Replace (Warm engine before draining).

Replace

 

 

 

 

 

 

 

.

 

 

 

 

 

Every 12,000 (8,000) or 24 months.

 

 

Autolube pump

 

 

 

www

 

 

O

Check/Adjust/Air bleeding.

 

 

Brake

 

Check operation. Adjust

if necessary.

 

 

Wheels*

 

Check balance/damage/runout.

 

 

 

 

 

 

 

 

from

 

 

 

 

 

Wheel bearings

Check bearings assembly for looseness/

 

 

damage. Replace if damaged.

 

 

 

 

 

Check bearings assembly for looseness.

 

 

 

 

DownloadedReplace if

necessary.

12,000 (8,000)

Check

Steering bearing

Moderately

repack

every

 

 

 

or 24 months.**

 

 

 

 

 

Rear shock

absorber

Check

operation.

 

 

 

 

 

Fittings/Fasteners

Check

all chassis fittings

and fasteners.

 

O

Battery

 

Check specific gravity. Check breather pipe

 

 

 

for proper

operation.

 

 

 

 

V-belt

 

Check damage and wear.

 

 

 

**:

Medium

weight wheel

bearing

grease.

 

 

 

 

 

EVERY

3,000 6,000

(2,000) or (4,000) or 6 months 12 months

©O

O

©

 

©

O

O

Check

Check

 

O

O

O

O

O

O

O

Check

Check

O

O

O

O

O

O

 

O

2-1

TAIL COVER ADJ

TAIL COVER
REMOVAL

1.Open the seat lock.

2.Remove:

=Seat

3. Remove:

-Cover (_

_

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ScooterTime

 

4. Remove:

 

 

,Grab

bar

 

.

 

 

www

, Rear carrier

 

(With

rear flasher lights and taillight)

 

5. Disconnect:

 

 

,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

 

INSTALLATION

When installing the tail cover, reverse the "REMOVAL" procedure.

Note the following points.

i_J_.

i__i

1.Install: ®Side covers

NOTE:

 

 

 

 

 

net

 

 

 

After installing the side covers, make sure that

 

 

 

all hooks are securely fitted.

 

 

 

 

.

 

 

 

ScooterTime

 

 

 

 

2. Connect:

 

 

 

.

eRear flasher light leads

 

 

www

NOTE:

 

 

 

The leads of identical colors should be connected.

 

 

 

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from

 

 

 

 

 

 

 

 

 

31 install: ®Rear carrier

7Nm (0.7 m,kg, 5.1 ft-lb)

4.Install: eSeat

 

 

m,kg,

!_

7 Nm (0.7

5.1 ft,lb)

2-3

-

I

FRONT FENDER, FRONT PANEL

INSP

 

AND FOOTREST BOARD

iADJ

FRONT FENDER, FRONT PANEL

AND FOOTREST BOARD

REMOVAL 1. Remove:

-Tail cover

Refer to "TAIL COVER" section.

 

2. Remove:

 

®Front fender

_,

NOTE:

@

i:Q::!i!_-::

_N %

- -_ -

_iiiii:iiii__"

 

i:iiii!i!ilii_i

 

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Before removing

 

net

 

the fender, make sure that all

 

hooks are free.

.

 

 

ScooterTime

 

 

 

3. Remove:

 

 

 

.

,Main switch

cap

 

 

 

 

 

 

www

 

Turn the cap counterclockwise.

 

 

 

from

 

 

 

 

 

4. Remove:

®Front panel

5.Remove:

, Footrest board

2-4

I INSP

FRONT FENDER, FRONT PANEL

E

 

A N D FOOTREST B O A R D / H A N D L E B A R COVERS

 

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.

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HANDLEBAR COVERS

.

 

www

R E M O V A L

 

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 (~)

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from

 

NOTE:

Position the cables as shown.

Front brake cable

(~)Throttle cable

(~)Rear brake cable

 

 

 

net

 

 

.

 

ScooterTime

 

 

3.

Connect:

 

.

eHeadlight lead and flasher ]~ght leads

Install:

 

www

4.

 

 

® Handlebar cover (Front)

 

 

®Rear view mirror(s)

ENGINE

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

 

THROTTLE CABLE FREE PLAY A D J U S T M E N T

 

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

 

 

 

Engine idle speed adjustment steps;

 

®Start the engine at idle speed.

 

 

eTurn the throttle stop screw (~ clockwise to

 

 

 

net

 

 

increase engine speed and counterclockwise

 

 

.

 

 

to decrease engine speed.

 

ScooterTime

 

 

5. Install:

 

.

eTail cover

 

Refer to "TAIL COVER" section.

www

 

 

 

 

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

 

=Loosen the Iocknut (_.

 

oTurn the adjuster (_

in or out until the cor-

!_:__......

rect free play is obtained.

 

=Tighten the Iocknut.

 

Downloaded

from

 

AUTOLUBE PUMP

CABLE ADJUSTMENT

NOTE:

 

net

 

 

 

 

Beforeadjustingthe pump cable, adjustthe throt-

tle cable free play.

.

 

 

 

ScooterTime

 

 

1. Remove:

 

 

.

=Tail cover

 

 

Refer to "TAIL

COVER" section.

www

 

 

* Front fender

 

 

 

 

 

 

=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

 

4. Close the throttle grip completely.

5. Check:

®Autolube pump pulley position (_

 

 

 

 

 

 

net

 

 

 

 

Out of position-*Adjust.

 

 

 

 

 

 

.

 

 

 

ScooterTime

 

 

 

 

 

 

®:

 

 

(0.0-0.04

in)

 

 

 

 

0.0-1.0

mm

_

 

 

Autolube

Pump

Pulley

Position

 

Autolube

pump pulley position

adjustment

.

 

 

 

 

 

 

 

steps:

 

 

 

 

 

www

 

 

 

 

 

 

 

 

oLoosen the Iocknut _.

 

 

 

®Turn the adjuster (_

in or out until the pump

 

 

plunger pin (_

is aligned with the mark _)

 

 

on the pump pully.

 

 

 

 

eTighten the Iocknut.

 

 

 

 

6.

Install:

 

 

 

 

 

 

 

 

oAutolube pump cover

 

 

 

 

oFootrest board

 

 

 

 

 

 

®Front

panel

 

 

 

 

 

 

 

• Front fender

 

 

 

 

 

 

 

eTail cover

 

 

 

 

 

 

 

Refer to "FRONT

FENDER, FRONT PANEL

 

 

 

AND

FOOTREST

BOARD"

and "TAIL

COVER" section.

AUTOLUBE PUMP AIR BLEEDING

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

 

 

 

net

 

 

.

 

ScooterTime

 

 

3. Remove:

 

 

 

• Bleed screw

@

 

 

.

 

 

 

NOTE:

 

 

 

www

 

 

from

Place a rag under the Autolube pump.

4. Start the engine at idle speed.

 

 

5. Air bleed:

 

 

 

Keep the oil

running out until air bubbles

 

disappear.

 

 

 

NOTE:

 

 

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

AiR CLEANER ELEMENT CLEANING

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:

 

eAutolube

pump cover

• Footrest

board

 

 

 

 

®Front

panel

 

net

 

 

 

 

Front fender

 

 

 

 

 

.

 

 

 

 

oTail cover

 

 

ScooterTime

 

 

 

 

 

Refer to "FRONT PANEL, FRONT FENDER

 

 

 

 

ANT

FOOTREST BOARD" and "TAIL

 

 

 

 

COVER" section.

 

 

AIR

CLEANER ELEMENT CLEANING

 

.

1. Remove:

 

 

 

 

®Side cover (Left)

 

www

 

 

 

NOTE:

 

 

 

 

 

 

 

 

 

 

When removing the side cover, unhook it at the

from

 

front and slide it forward.

 

 

 

 

 

 

 

 

 

 

2.

Remove:

 

 

 

 

 

 

®Air cleaner case cover (_

 

 

 

 

eAir cleaner element

i i : i_iii i:i i_i!i !_i!i i_ !

i

 

 

 

 

 

 

 

Never operate the engine with

the air cleaner

element

removed.

This will

allow

unfiltered

air to enter,

causing

rapid

wear

and possi-

ble engine

damage.

Additionally,

operation

without

the

cleaner

element will affect car-

buretor

jetting

with

subsequent

poor perfor-

mance

and

possible

engine overheating.

Be careful

not to

have rags

or the

like block-

ing the

intake

area

of the

air

cleaner.

2-11

;'='8 I

AiR CLEANER LEMENT CLEANHNG/

INSP

 

FUEL COCK CLEANING

ADJ

 

3. Clean:

 

 

 

oAir cleaner element

 

 

Air cleaner element cleaning steps:

 

oWash the element gently, but thoroughly in

 

solvent.

 

 

 

Never use low flash point

solvents such as

 

gasoline

to clean the element. Such sol-

 

vent may

lead to a fire

or explosion.

Downloaded

from

 

 

oSqueeze the excess solvent out of the element

 

 

and let dry.

 

net

 

 

 

 

 

 

 

 

:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

 

 

 

 

.

 

 

ScooterTime

 

when squeezing

 

 

Do not twist

the element

 

 

the element.

 

 

 

 

 

4. Inspect:

 

 

 

 

 

oElement

 

 

 

.

Damage-

Replace.

 

5. Apply:

 

 

 

www

 

 

 

 

 

oFoam-air-filter

oil or SAE 10W30 type SE

 

 

 

 

motor oil

 

 

 

 

 

Onto the element.

 

 

 

6. Squeeze out the excess

oil.

 

 

NOTE:

 

 

 

 

 

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

I,NsP

E

ADJ

FUEL COCK CLEANHNG

 

2.Drain: =Fuel

FUEL IS HIGHLY FLAMMABLE:

__

 

_k,_

 

 

==_£

'=_

{

"

(_

 

_,_/

(_)

_* '!_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

 

 

vicinity

of an open flame.

 

 

 

net

 

 

 

.

 

.ScooterTime®Filter (

 

 

3. Remove:

 

 

*Cap

(

from

www

4. Clean:

 

 

Filter

 

oCap

 

 

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

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