YAMAHA YQ50 AEROX 1997 User Manual [ru]

'97

YQ50

SERVICE

5BS-AE2

MANUAL

YQ50

SERVICE MANUAL

2st Edition, November 1997

reprinting or unauthorized use

without the written

permission of MBK INDUSTRIE

is expressly prohibited.

NOTICE

This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK 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 and MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe.

MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and MBK dealers and will, where applicable, appear in future editions of this manual.

DOCUMENTATION TECHNIQUE

MBK INDUSTRIE

PARTICULARY IMPORTANT INFORMATION

This material is distinguished by the following notation :

WARNING

CAUTION:

NOTE:

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander, or a person inspecting or repairing the scooter.

A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.

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

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL

This manual consists of chapters for the main categories of subjects. (See «illustrated symbols). 1st title 1 This is a chapter with its symbol on the upper right of each page. 2nd title 2 This title appears on the upper of each page on the left of the chapter symbol. (For

the chapter «Periodic inspection and adjustment» the 3rd title appears.)

3rd title 3 This is a final title.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. A set of particulary important procedure 4 is placed between a line of asterisks " preceded by "

IMPORTANT FEATURES

• Data and a special tools are framed in a box preceded by a relevant symbol 5.

• An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data for an alignement mark 7, the others being indicated by an alphabetical letter in a box 8.

• A condition of a faulty component will precede an arrow symbol and the course of action required the symbol 9.

•

" with each step

EXPLODED DIAGRAM

Each chapter provides exploded diagrams are before each disassembly section for ease in identifying correct disassembly and assembly procedures.

GEN

INFO

INSP

SPEC

ENG

ADJ

CARB

ELEC

CHAS

TRBL SHTG

ILLUSTRATED SYMBOLS

(REFER TO THE ILLUSTRATION)

Illustrated symbols Q to W are designed as thumb tabs to indicate the chapter’s number and content.

Q General information W Specifications E Periodic inspection and adjustment R Engine T Carburetion Y Chassis U Electrical I Troubleshooting

{

}

T.R

Illustrated symbols O to e are used to identify the specifications appearing in the text.

O Filling fluid P Lubricant { Special tool } Tightening q Wear limit, clearance w Engine speed e Ω, V, A

Illustrated symbols r to [ in the exploded diagram indicate grade of lubricant and location of lubrication point.

r Apply engine oil t Apply gear oil y Apply molybdenum disulfide oil u Apply wheel bearing grease i Apply lightweight lithium-soap base

grease

o Apply molybdenum disulfide grease p Apply locking agent (THREADLOCK ®) [ Use new one

[

INDEX

GENERAL INFORMATION

SPECIFICATIONS PERIODIC INSPECTION

AND ADJUSTMENT ENGINE OVERHAUL

COOLING SYSTEM

GEN

INFO

SPEC

INSP

ADJ

ENG

2 3

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

CARB

CHAS

ELEC

TRBL

SHTG

GEN

INFO

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

SCOOTER IDENTIFICATION ........................................................................1-1

VEHICLE IDENTIFICATION NUMBER....................................................1-1

ENGINE SERIAL NUMBER .....................................................................1-1

IMPORTANT INFORMATION ....................................................................... 1-2

ALL REPLACEMENT PARTS ................................................................. 1-2

GASKETS, OIL SEALS, AND O-RINGS .................................................. 1-2

LOCK WASHERS/PLATES AND COTTER PINS.................................... 1-2

BEARINGS AND OIL SEALS................................................................... 1-2

CIRCLIPS................................................................................................. 1-3

SPECIAL TOOLS ...........................................................................................1-4

GEN

햲

SCOOTER IDENTIFICATION

GENERAL INFORMATION

SCOOTER IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number Q 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 authority in your state.

INFO

햲

ENGINE SERIAL NUMBER

The engine serial number Q 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.

NOTE:

Designs and specifications are subject to change without notice.

1-1

GEN

IMPORTANT INFORMATION

ALL REPLACEMENT PARTS

1.Use only genuine parts for all replacements. Use oil and/or grease recommended by MBK/ YAMAHA for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality.

GASKETS, OIL SEALS, AND O-RINGS

1.All gaskets, seals and O-rings should be replaced when an engine is overhauled. All gaskets surfaces, oil seal lips and O-rings must be cleaned.

2.Properly oil all mating parts and bearing during reassembly. Apply grease to the oil seal lips.

INFO

LOCK WASHERS/PLATES AND COTTER PINS

1.All lock washers/plates Q and cotter pins 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 properly tightened.

BEARINGS AND OIL SEALS

1.Install the bearing(s) Q and oil seal(s) W with their manufacturer’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

CAUTION :

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

1-2

GEN

IMPORTANT INFORMATION

CIRCLIPS

1.All circlips should be inspected carefully before reassembly. Always replace piston pin clips once they have been removed. Replace bent circlips. When installing a circlip Q make sure that the sharp edge W is positioned opposite to the thrust E it receives. See the sectional view.

R Shaft

INFO

1-3

GEN

SPECIAL TOOLS

EB102000

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.

Tool N° Tool name/usage Illustration

90890-01135

90890-01189

90890-01235

Crankcase separating tool

This tool is used to separate the crankcase and remove the crankshaft.

Flywheel puller

This tool is used to remove the flywheel magneto.

Rotor holding tool

INFO

90890-01274 90890-01275 90890-01277 90890-01411

90890-01348

90890-01701

90890-01337

This tool is used to remove the flywheel magneto.

Crankshaft installer set.

These tools are used to install the crankshaft.

Locknut wrench

This tool is used when removing or installing the secondary sheave nut.

Sheave holder

This tool is used to hold the secondary sheave when removing or installing the nut.

Clutch spring holder.

This tool is used for compressing the spring of the secondary sheave when removing the nut.

1-4

GEN

SPECIAL TOOLS

Tool N° Tool name/usage Illustration

9079Q-02218

90890-01326

90890-1294

90890-01184 90890-01186

90890-03112

Ring nut wrench.

This tool is used to loosen and tighten the steering ring nut.

T-handle Damper rod holder

These tools are used for holding the damper rod holder when removing or installing the damper rod holder.

Fork seal driver weight. Fork seal driver attachment (ø27)

These tools are used wheninstalling the fork seals.

Pocket Tester

INFO

90890-03113

90890-06754

This instrument is invaluable for checking the electrical system.

Engine tachometer.

This tool is needed for detecting the engine rpm.

Ignition checker.

This instrument is necessary for checking the ignition system components.

1-5

SPEC

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS .......................................................................2-1

MAINTENANCE SPECIFICATIONS ..............................................................2-4

ENGINE ...................................................................................................2-4

CHASSIS .................................................................................................2-6

ELECTRICAL ...........................................................................................2-7

CABLE ROUTING ..........................................................................................2-8

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model YQ50

Dimensions:

Overall length 1.743 mm Overall width 690 mm Overall height 1.170mm Seat height 828 mm Wheelbase 1.256 mm Minimum ground clearance 185 mm

Basic weight:

With oil and full fuel tank 97 kg Minimum turning radius : 1.800 mm Engine:

Type

Cylinder arrangement Single cylinder, horizontal

Displacement 49 cm

Bore x stroke 40 x 39.2 mm

Compression ratio 7.9 : 1 (F)(B)(P)(E)(I)

Starting system Electric and kick starter Lubrication system: Separate lubrication (Yamaha Autolube ) Oil type or grade:

Engine oil: Semi-synthetic, in accordance with the

Transmission oil SAE 10W30 type SE motor oil Oil capacity:

Transmission oil:

Periodic oil change 0.11 L Total amount 0.13 L

Radiator capacity

Total amount (Including all routes) 1.2 L Air filter: Wet type element Fuel:

Type Regular unleaded gasoline with a research octane

Tank capacity 7.0 L

Liquid-cooled 2-stroke, gasoline torque induction.

8 : 1 (D)(NL)(CHE)

API TC TSC 3 Standard.

number of 91 or higher.

2-1

GENERAL SPECIFICATIONS

Model YQ50

Carburetor:

Type/Manufacturer PHBN12HS / DELL'ORTO Spark plug:

Type/Manufacturer BR8HS/NGK

Gap 0.5 ~ 0.7 mm Clutch type: Dry, centrifugal automatic Transmission:

Primary reduction system Helical gear

Primary reduction ratio 52/13 (4.000)

Secondary reduction system Spur gear

Secondary reduction ratio 43/14 (3.071)

Transmission V-belt

Operation Automatic Chassis:

Frame type Steel tube underbone

Caster angle 27°

Trail 90 mm Tire:

Type Tubeless

Size Front 130/60-13

Rear 140/60-13

Manufacturer/type Front PIRELLI / SL36

MICHELIN / BOPPER

Rear PIRELLI / SL36

MICHELIN / BOPPER

Tire pressure (cold tire) Front 150 kPa (1.50 kg/cm

Rear 150 kPa (1.50 kg/cm

Brake:

Front brake type Disc brake

Operation Right hand operation

Rear brake type Disk brake

Operation Left hand operation Suspension:

Front Telescopic fork

Rear Unit swing Shock absorber:

Front Coil spring/Oil damper

Rear Coil spring/Oil damper Wheel travel:

Front wheel travel 80 mm

Rear wheel travel 72 mm

)

SPEC

2-2

GENERAL SPECIFICATIONS

Model YQ50

Electrical:

Ignition system CDI

Charging system Flywheel magneto

Battery type/model GM4-3B, YB4L-B, FB4L-B

Battery capacity 12V 4AH Headlight type: Bulb Bulb wattage / quantity:

Headlight 12V 35W/35W x 1

Auxiliary light 12V 5W x 1

Taillight/brake light 12V 5W/21W x 1

Flasher light Front 12V 21W x 2

Rear 12V 10W x 2

Meter light 12V 1.2W x 3 Warning lights wattage / quantity:

“OIL” 12V 1.2W x 1

“HIGH BEAM” 12V 1.2W x 1

“TURN” 12V 1.2W x 1

“Cooling warning light“ 12V 1.2W x 1

SPEC

2-3

MAINTENANCE SPECIFICATIONS

ENGINE

Model YQ50

Cylinder head:

Warp limit 0.02 mm

Lines indicate straight edge measurements.

Cylinder:

Bore size 39.993 ~ 40.012 mm

Taper limit 0.05 mm Piston:

Piston size 39.957 ~ 39.977 mm

Measuring point

5 mm

SPEC

Piston clearance 0.029 ~ 0.042 mm

Piston pin bore size 10.004 ~ 10.019 mm Piston pin:

Outside diameter 9.996 ~ 10.000 mm Piston ring:

Sectional sketch (BxT)/Type:

Top ring 1.5 ~ 1.8 mm 2nd ring 1.5 ~ 1.8 mm

End gap (installed):

Top ring 0.15 ~ 0.35 mm 2nd ring 0.15 ~ 0.35 mm

Side clearance (installed):

Top ring 0.03 ~ 0.05 mm 2nd ring 0.03 ~ 0.05 mm

Crankshaft:

Crank width “A” 37.90 ~ 37.95 mm

Runout limit “C” 0.03 mm

Connecting rod big end side clearance “D” 0.2 ~ 0.5 mm

Big end radial clearance “E“ 0.004 ~ 0.017 mm

2-4

MAINTENANCE SPECIFICATIONS

Model YQ50

Automatic centrifugal clutch:

Clutch shoe thickness 2.0 mm

Clutch shoe spring free length 29.9 mm

Clutch housing inside diameter 107.0 mm

<Wear limit> 107.4 mm

Clutch-in revolution 3.950 ~ 4.450 r.p.m.

Clutch-stall revolution 6.900 ~ 7.700 r.p.m. V-belt:

Width 16.5 mm

<Wear limit> <15.7 mm> Transmission:

Main axle runout limit 0.08 mm

Drive axle runout limit 0.08 mm Kick starter:

Type Ratchet type

Kick clip tension 0.15 ~ 0.25 kg Carburetor:

I.D mark DELLORTO PHBN 12 HS

Main jet (M.J) #86 (F)(B)(P)(I)(E)

#85 (CHE)

#74 (NL) Main air jet (M.A.J) ø1.5 Jet needle (J.N) A21 - 2/5 (F)(B)(P)(I)(E)

A12 - 3/5 (D)(CHE)

A20 - 3/5 (NL) Needle jet (N.J) 210 GA (F)(B)(P)(I)(E)(D)

209 GA (CHE)

208 GA (NL) Cutaway (C.A) 3.0

4.0 (CHE)

Pilot jet (P.J) #36

#34 (CHE) Bypass 1 (B.P.1) 0.8 Air screw (A.S) 1 3/8 ± 1/8 (F)(B)(P)(I)(E)

1 3/4 ± 1/8 (D)

1 5/8 ± 1/8 (NL)

2 ± 1/8 (CHE) Valve seat size (V.S) 1.2 Starter jet (G.S.1) #45 Engine idle speed 1600 ~ 2000 rpm

Reed valve:

Valve stopper height 6.0 ~ 6.4 mm Reed valve clearance Less than 0.2 mm

Lubrication system: Autolube pump

Stroke 2.62 mm (F)(B)(P)(I)(E)

2.5 mm (D)(NL)(CHE)

Bore 0.5 mm

2-5

SPEC

MAINTENANCE SPECIFICATIONS

CHASSIS

Model YQ50

Steering system:

Steering bearing type Ball bearing No/Size of steel balls:

Upper 15 pcs (4.75 mm) Lower 15 pcs (4.75 mm)

Front suspension:

Front fork travel 80 mm Spring rate (K1) 5.7 N/mm Stroke (K1) 0 ~ 80 mm Optional spring No

Rear suspension:

Shock absorber travel 60 mm Spring free length 234 mm Spring fitting length 199.5 mm Spring rate (K1) 28 N/mm

(K2) 35 mm

Stroke (K1) 0 ~ 92 mm

(K2) 92 ~ 115 mm

Optional spring No

Wheels:

Front wheel type Cast wheel Rear wheel type Cast wheel Front wheel size/Material MT 3.00 x13 / Aluminium Front wheel size/Material MT 3.50 x13 / Aluminium

Rim runout limit:

Front 1.0 mm Rear 1.0 mm

Front disc brake:

Type Single disc Diameter and thickness 190 x 3.5 mm Pad thickness 4.5 mm <Wear limit> <2.0 mm> Master cylinder inside diameter 11 mm Caliper cylinder inside diameter 30 mm Brake fluid type DOT# 3 or DOT#4

Rear disk brake:

Front brake lever freeplay: 10 ~ 20 mm Rear brake lever freeplay: 10 ~ 20 mm

SPEC

2-6

MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL

Model YQ50

Voltage: 12 V Ignition system:

Ignition timing (B.T.D.C.) 14° at 5.000 r/min

CDI:

Pickup coil resistance (color) 400 ~ 600 Ω at 20°C (68°F) (White/Red-Black) Source coil resistance (color) 640 ~ 960 Ω at 20°C (68°F) (Black/Red-Black)

Ignition coil:

Minimum spark length 6 mm Primary coil resistance 0.56 ~ 0.84 Ω at 20°C (68°F) Secondary coil resistance 5.68 ~ 8.52 Ωk at 20°C (68°F)

Spark plug cap:

Resistance 5 kΩ at 20°C (68°F)

CDI Magneto:

Lighting coil resistance 0.32 ~ 0.48 Ω at 20°C (68°F)(Yellow/Red-Black) Lighting coil resistance 0.48 ~ 0.72 Ω at 20°C (68°F)(White-Black)

Voltage regulator/Rectifier:

Type Semi-conductor, short-circuit type No load regulated voltage 13 ~ 14 V Capacity 8 A Withstand voltage 600 V

Battery:

Specific gravity 1.280

Starter motor:

Out put 0.14 kW Armature coil resistance 0.06 ~ 0.08 Ω at 20°C (68°F) Brush overall lenght 3.9 mm <Wear limit> 0.9 mm Brush spring pressure 563 ~ 844 g Commutator diameter 15.8 mm <Wear limit> 14.8 mm Mica undercut (depth) 1.15 mm

Starter relay:

Amperage rating 20 A Coil winding resistance 54 ~ 66 Ω at 20°C (68°F)

Horn:

Maximum amperage 2.5 A

Flasher relay:

Type Condenser type Self canceling device No Flasher frequency 80 ~ 160 cycle/min

Fuel gauge:

Sender unit resistance (full) 1.5 ~ 7.5 Ω

(empty) 90 ~ 100 Ω

Contact braker:

Main fuse 7,5 A x 1

2-7

CABLE ROUTING

SPEC

CABLE ROUTING

Q Handlebar end grip W Right handlebar switch E Left handlebar switch R Handlebar T Flasher harness Y Right handlebar grip U Wireharness I Wireharness cord O Starter (choke) cable P Front handlebar cover { Speedometer case } Speedometer cable q Front brake hose w Rear brake hose

햲

햷

햳

A Push the end grip againt the handlebar and tighten to 0.6 ~ 0.8 m.kg. B Tighten the front screw first. C Apply the left switch handle against the handlebar. D Hole for the front flasher harness. E Install the right handlebar grip in regard to the right handlebar switch. F Group the connexions here. G Attach the wiring harness cord on the handlebar bracket. H Pass the starter (choke) through the handle cover.

I Glue the left handlebar grip.

J Cut the band at 5 mm of his end. K Clip the front handlebar cover on the speedometer case. L Front steering assembly:

• Tighten the ring nut in order to eliminate all play.

• Take care of installing the special washer on the steering ball race: teeth against teeth.

햵

햴

햲

10°

1.0 ~ 3.0 mm

햽

햶

햹

햶

햸

햺

햻

햾

햸

헀 햿

햺

햳

2-8

CABLE ROUTING

SPEC

CABLE ROUTING

Q Fuel sender W Fuel tank E Fuel overflow pipe R Fuel cock T Pipe bracket Y Frame U Trunk I Carburetor drain hose O Fuel pipe P Suction pipe { Bands

A Insert the fuel sender completly. B Turn the fuel sender so that the cable points toward. C Pass the fuel lines above the rear brake hose. D Pass the fuel overflow pipe in the trunk slot. E Push the fuel cock (without turning it) completly in the tank and screw

the collar. F Install the hoses facing to the inside of the frame. G Pass the fuel tank pipe overflow and carburetor drain pipes in the

bracket. H Attach the fuel and suction pipes in the bands.

I Pass the fuel overflow pipe inside the frame.

J Install the fuel pipes without lubricating them.

햲

햳

햷

햳

햸

햽

햴

햸

햻

햺

햳

H J

햵

햹

햶

5 ~ 10 mm MAX

2-9

CABLE ROUTING

SPEC

Q Seat lock W Starter motor E Ignition coil R Battery T Starter relay Y Fuse housing U Rear brake hose I Fuel sender O CDI unit P Oil lever gauge { Main switch } Rectifier/regulator q Head light w Water hose e Water temperature sender r Seat lock cable adjuster

햲

햳

A Set the seat lock adjuster so that there is a gap betwween 8 ~ 9 mm

at the seat lock aperture. B Install the starter relay on the footrest board. C Group the connections here. D Turn the connectors towards. E Puch the wiring inside. F Pass the wiring harness through the footrest board. G Turn the ground lead one turn around the starter motor leads. H The water temperature sender lead must go straight to the wiring

harness.

I Put one drop of Loctite 542 on the tread before installing the water

temperature sender.

J Install the head light protector correctly.

K Pass the main switch lead between the rectifier/regulator and the

steering head pipe.

햸

햵

햶

햹

햷

햴

D E

햺

햽

햿

햾

헂

햻

헀

헁

2-10

CABLE ROUTING

SPEC

Q Wiring harness W Resistor E Horn R Front brake hose T Speedometer cable Y Radiator U Water tank I Clamps P Frame

A Install the wiring harness in the middle of the frame. B Set the resistor at 45°0/+30’ on the frame bracket. C Clip the front brake hose on the front fork bracket. D Install the 8 clamps just beside the marks at the end side of the hoses.

햸

햷

햸

햷

햸

햷

햹

햲

햺

햷

햴

햳

햶

햵

2-11

CABLE ROUTING

SPEC

Q Rear brake hose W Seat lock cable E Wire harness R Throttle cable T Starter (choke) cable Y Speedometer cable U Frame I Oil hose (tank/oil pump) O Oil hose (oil pump/carburetor) P Water hoses

A Install the rear brake hose in the clip. B Install the oil delivery hose (from oil pump to carburator) under the

water hose. C Pass the rear brake hose under the frame reinforcement tube. D Align the mark on the water hose in front of the mark in the water pump

housing. E Pass the speedometer cable through the slot of the front fender. F Install the 8 clamps just beside the marks at the end side of the hoses.

햸

햲

27°±10°

햲

햳

햲

햸

햴

햲

햵

햶

햸

햺

햻

햸

햷

햹

햻

2-12

CHK

ADJ

CHK

ADJ

CHAPTER 3.

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION............................................................................................3-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............................ 3-1

COVERS ........................................................................................................3-3

REMOVAL................................................................................................ 3-3

HANDLEBAR COVERS .................................................................................3-7

REMOVAL................................................................................................ 3-7

ENGINE ....................................................................................................... 3-11

ENGINE IDLE SPEED ADJUSTMENT ..................................................3-11

THROTTLE CABLE FREE PLAY ADJUSTMENT .................................3-12

SPARK PLUG INSPECTION .................................................................3-13

AUTOLUBE PUMP AIR BLEEDING ......................................................3-14

ENGINE OIL LEVEL INSPECTION .......................................................3-15

TRANSMISSION OIL REPLACEMENT .................................................3-16

COOLANT LEVEL INSPECTION........................................................... 3-17

COOLANT REPLACEMENT ..................................................................3-17

AIR CLEANER ELEMENT CLEANING .................................................. 3-19

EXHAUST PIPE ASSEMBLY AND ADJUSTMENT ............................... 3-20

CHASSIS ..................................................................................................... 3-21

FRONT BRAKE LEVER FREE PLAY ADJUSTMENT ........................... 3-21

REAR BRAKE LEVER FREE PLAY ADJUSTMENT ............................. 3-21

BRAKE PAD INSPECTION.................................................................... 3-21

BRAKE FLUID LEVEL INSPECTION ....................................................3-22

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ................................. 3-23

STEERING HEAD ADJUSTMENT ......................................................... 3-23

TIRE INSPECTION ................................................................................3-24

WHEEL INSPECTION ...........................................................................3-25

CABLE INSPECTION AND LUBRICATION........................................... 3-25

LEVER LUBRICATION ..........................................................................3-26

CENTERSTAND LUBRICATION ...........................................................3-26

FRONT FORK INSPECTION .................................................................3-26

REAR SHOCK ABSORBER ..................................................................3-26

ELECTRICAL ...............................................................................................3-27

BATTERY INSPECTION........................................................................ 3-27

FUSE INSPECTION............................................................................... 3-28

HEADLIGHT BEAM ADJUSTMENT ......................................................3-29

HEADLIGHT LENS REPLACEMENT ....................................................3-29

HEADLIGHT BULB REPLACEMENT ....................................................3-29

INTRODUCTION/PERIODIC MAINTENANCE/

LUBRICATION INTERVALS

INSP

ADJ

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION

This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive 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 applies 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(miles)

EVERY

ITEM

1 Spark plug

2 Air filter

3 * Carburetor

4 * Fuel line

5 * Transmission oil

6 * Autolube pump

7 * Brakes (front and rear)

8 * Cooling system

9 * Wheels

10 * Wheel bearings

11 * Steering bearing

12 * Rear shock absorber

13 * V-belt

14 * Fitting/Fasteners

15 * Centerstand

16 * Battery

ROUTINE

• Check condition.

• Clean or replace if necessary.

• Clean.

• Replace if necessary.

• Check idle speed/choke operation.

• Adjust if necessary.

• Check fuel hose and vacuum pipe for cracks or damage.

• Replace if necessary.

• Check for oil leakage.

• Correct if necessary.

• Replace every 12,000 (8,000) or 24 months. (Warm engine before draining.)

• Check operation.

• Correct if necessary.

• Bleed the air.

• Check operation/fluid leakage/See NOTE.

• Correct if necessary.

• Check hoose condition.

• Replace if necessary.

• Replace coolant every 12.000 (8,000) or 24 months.

• Check damage/runout/Tightening torque.

• Replace/tighten if necessary.

• Check bearing assembly for looseness/damage.

• Replace if damaged.

• Check bearing assembly for looseness.

• Correct if necessary.

• Moderately repack every 12,000 (8,000) or 24 months.**

• Check operation/oil leakage.

• Replace if necessary.

• Check damage and wear.

• Replace if necessary.

• Check all chassis fittings and fasteners.

• Tighten if necessary.

• Check operation.

• Repair if necessary.

• Check specific gravity.

• Check breather pipe for proper operation.

• Correct if necessary.

BREAK-IN 1,000(600)

REPLACE

3,000

(2,000)or

6 months

6,000

(4,000)or

12 months

Items marked with an asterisk (*) require special tools, data and technical skills for servicing. Take the scooter to a Yamaha or MBK Dealer when servicing these items. ** : Medium weight wheel bearing grease.

3-1

+ 162 hidden pages