Yamaha YSR50T User Manual

YS R5OT

SERVICE MANUAL

01987 by Yamaha Motor Corporation, U.S.A. 1st Edition, March 1987

Printed in U.S.A.

PINO. LIT-Il616-O6-05

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 educationinto one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use andlor 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 Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

TECHNICAL PUBLlCATlONS

SERVICE DIVISION

MOTORCYCLE OPERATIONS

YAMAHA MOTOR CO., LTD.

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.

A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle.

A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle.

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 inspection operations.

In this revisedformat, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.,

Bearings

Pitting1Damage-, Replace.

EXPLODED DIAGRAM

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

	ILLUSTRATED SYMBOLS
	(Refer to the illustration)
	Illustrated symbols @ to @ are designed as
I ENG 1	thumb tabs to indicate the chapter'snumber and
	content.
	aGeneral information
	@ Specifications
	@ Periodic inspection and adjustment
	@ Engine
	@ Cooling system
	@ Carburetion
	aChassis
	@ Electrical
	@ Troubleshooting

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

@Filling fluid Lubricant

@Special tool

@Tightening

@Wear limit, clearance

@Engine speed

@9,v, A

Illustrated symbols 0to @ in the exploded diagram indicate grade of lubricant and location of lubrication point.

0 Apply engine oil @ Apply gear oil

8 Apply molybdenum disulfide oil

@Apply wheel bearing grease

Apply lightweight lithium-soap base grease

@Apply molybdenum disulfide grease

@Apply locking agent (LOCTITE@)

INDEX

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND ADJUSTMENT

ENGINE OVERHAUL

CHASSIS

ELECTRICAL

GEN

INFO

INSP

ADJ

+o,

ELEC

TROUBLESHOOTING

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1

ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1..1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12.
PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . . . . .	1.2
ALL REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
GASKETS, OIL SEALS. AND O.RINGS . . . . . . . . . . . . . . . . . . . . . . . . . .	1..3
LOCK WASHERSIPLATE AND COTTER PINS . . . . . . . . . . . . . . . . . . . .	1.3

BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1..3

ClRCLlPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.-4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.-4 FOR TUNE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.-4 FOR ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1..5 FOR CHASSIS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16. FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.

MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2..4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. -.4 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.-8 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211.

GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. .14

DEFINITION OF UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2..14

t N t i I N t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.-15 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.-15

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2..16

--	-
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . .	3-1
PERIODIC MAINTENANCE/LUBRlCATlON INTERVALS . . . . . . . . . . .		. 3.1
COWLINGS REMOVAL AND INSTALLATION . . . . . .	. . . . . . . . . . . . . . . .	3.3	INFO
COWLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . .	3-3	INFO
SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . .	3.4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . .	3.4
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . .	3.4
THROTTLE CABLE FREE PLAY ADJUSTMENT . . . .	. . . . . . . . . . . . . . .	. 3.5
AUTOLUBE PUMP CABLE ADJUSTMENT . . . . . . . .	. . . . . . . . . . . . . . .	. 3.5
AUTOLUBE PUMP STROKE ADJUSTMENT . . . . . . .	. . . . . . . . . . . . . . .	. 3.6
AUTOLUBE PUMP AIR BLEEDING ................................		3.8
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . .	3.9
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.10
ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.10
TRANSMISSION OIL LEVEL INSPECTION. . . . . . . . .	. . . . . . . . . . . . . . .	3.11
TRANSMISSION OIL REPLACEMENT . . . . . . . . . . . . .	. . . . . . . . . . . . . . .	3.12
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.13
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . .	3.14
CARBURETOR JOINT INSPECTOIN. . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.16
FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.17
Y.E.I.S. HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.17
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.17
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3-17
FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.17
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.18
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.18
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.19
BRAKE SHOE INSPECTION . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.19
BRAKE LIGHT SWITCH ADJUSTMENT . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.19
BRAKE HOSE INSPECTION .....................................		3.19
DRIVE CHAIN SLACK ADJUSTMENT . . . . . . . . . . . .	. . . . . . . . . . . . . . .	3.20
DRIVE CHAIN LUBRICATION . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.21
STEERING HEAD ADJUSTMENT . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . .	3.21
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.23
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.24
CABLE INSPECTION AND LUBRICATION . . . . . . . . . .	. . . . . . . . . . . . . .	3.24
LEVER AND PEDAL LUBRICATION . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.25
SIDESTAND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . .	3.25

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3..26 FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3..28 HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3..29 HEADLIGHT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

CHAPTER 4.

ENGINE OVERHAUL

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-1 TRANSMISSION OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-1 COWLING AND SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-1 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.-.2

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-2 AUTOLUBE PUMP CABLE AND HOSE . . . . . . . . . . . . . . . . . . . . . . . . . .4..2

LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. -.3

CLUTCH CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.

DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. .-3

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44.

ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.4..5
CYLINDER HEAD. CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . .	.4.5
CLUTCH AND PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . .	.4.6
KICK AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.4.-8
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.4.-9
CDI MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.4.-9
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4.-10
TRANSMISSION. SHIFTER AND CRANKSHAFT . . . . . . . . . . . . . . . . . .	4.11

INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4..13 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-13 CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4..13 PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-15 PISTON PIN AND BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4..16

rl I I T ~ U

4-17

... w . .w . . ....	L.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .".
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		4.-19
TRANSMISSION AND SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		4.-20
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		4.-21
CRANKCASE	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4. -.22
AUTOLUBE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		4.-22

ENGINE ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 4. .24 CRANKSHAFT. SHIFTER AND TRANSMISSION . . . . . . . . . . . . . . . . . 4..24 CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-25 CDI MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. -30 SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-32

KICK AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-32 CLUTCH AND PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . .4.34 CYLINDER HEAD. CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . .4.37

REMOUNTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.40

CHAPTER 5.

CARBURETION

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-.5-1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56.

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7

REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.-8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.-8 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. -8

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

5.9

	CHAPTER 6.
	CHASSIS
FRONT WHEEL . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.-1
REMOVAL . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
INSPECTION . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
INSTALLATION . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
REAR WHEEL . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
REMOVAL . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
INSPECTION . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
INSTALLATION . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
FRONT BRAKE . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10

BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6..11 CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6..13 MASTER CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14 INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-19
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.21
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6..21
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.6.23
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-26

STEERING HEAD AND HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-28
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-29
lNSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.30

REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . .6.33 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.-35 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. -35 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. -36 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-6-36

DRIVE CHAIN AND SPROCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 6 .38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 6 -38
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6 . .38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..	6 39

CHAPTER 7.

ELECTRICAL

YSR50T CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 COLOR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.-2

ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73.

IGNITION AND STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 IGNITION CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . .7.6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7..7

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7..16 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7..18

LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7..22

TROUBLESHOOTING (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.24

TROUBLESHOOTING (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.27

SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7..30 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.32

DISPLAY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.42 TROUBLESHOOTING (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.44 TROUBLESHOOTING (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.48 DISPLAY SYSTEM TEST AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . .7.50

CHAPTER 8.

TROUBLESHOOTING

STARTING FAILUREIHARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8..1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8..2 COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8..3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .812.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8..12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..11

POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3

POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3

POOR MEDIUM AND HIGH SPEED PERFORMANCE . . . . . . . . . . . . . .8.4 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..4 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..4 COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5

FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..6 HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.-6 CHANGE PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. -6 JUMP-OUT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.-6

CLUTCH SLIPPINGIDRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..7 CLUTCH SLIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87. CLUTCH DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.-7

IMPROPER KICKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.-8 SLIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.-8 HARD KICKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.-8 KICK CRANK NOT RETURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8..8

FAULTY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.-9 POOR BRAKING EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..9

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION . . .	.8.9
OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.8.-9
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8. .-9
INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8..10

INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .810.

FAULTY SIGNAL AND LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8..11 HEADLIGHT DARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.-11 BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..11 FLASHER DOES NOT LIGHT

FLASHER KEEPS ON FLASHER WINKS SLOWER FLASHER WINKS QUICKER HORN IS INOPERATIVE

OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..13 OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. -13

pqm

INFO

YSR5OT WIRING DIAGRAM

your state.

IAL N

The engine serial num left side sf the en

.	:	:	-
		cThe first three di	ts sf these numbers are for
		model identificat	ns; %heremainin
		duction number.
		specifications are su
		without notice.

IMPORTANT INFORMATION I

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1.Remove all dirt, mud, dust, and foreign material before removing and disassembling.

2.Use proper tools and cleaning equipment. Refer to "SPECIAL TOOL."

3.When disassembling the motorcycle, keep mated parts together. This includes gears, cylinders, pistons, and other mated parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced.

4.During the motorcycle disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

5. Keep away from fire.

IMPORTANT INFORMATION PI

ALL REPLACEMENT PARTS

1.We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

GASKETS, OIL SEALS, AND O-RINGS

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

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

LOCK WASHERSIPLATES AND COlTER

PINS

1.All lock washers1Plates @ 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(s1and oil seal(s)with their manufacturer's marksor 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 light-weight lithium base grease to the seal lip(s).Oil the bearings liberally when installing.

@Oil seal

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

@ Bearing

SPEClAL TOOLS 1 -

ClRCLlPS

1.All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip @, make sure that the sharp edged corner @ is positioned opposite to the thrust @ it receives. See the sectional view.

@IShaft

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.

FOR TUNE UP

1.Inductive Timing Light

PIN. YM-33277

This tool is necessaryfor adjusting ignition timing.

2.Fuel Level Gauge

P I N . YM-01312

This gauge is used to measure the fuel level in the float chamber.

1-4

3.Inductive Tachometer PIN. YU-08036

This tool is needed for detecting engine rpm.

FOR ENGINE SERVICE

1.Universal Clutch Holder PIN. YM-91042

This tool is used to hold the clutch when loosening or tightening the clutch boss locknut.

2.Universal Rotor Holder PIN. YU-01235

This tool is used when loosening or tightening the flywheel magneto securing bolt.

3.Flywheel Puller PIN. YM-01189

This tool is used for removing the flywheel.

4.Piston Pin Puller PIN. YU-01304

This tool is used to remove the piston pin.

SPECIAL TOOLS wl

5.Crankcase Separating Tool PIN. YU-01135

This tool is used to split the crankcases as well as remove the crankshaft from either case.

6. Crankshaft Installing Tool . . . . . . . . . . . . .0

PIN. YU-90050

Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . .0

PIN. YM-90063

These tools are used to install the crankshaft.

FOR CHASSIS SERVICE

1. Front Fork Seal Driver (Weight) . . . . .

PIN. YM-33963

Adapter . . . . . . . . . . . . . . . . . . . . . . . . . .

PIN. YM-33281

This tool is used when installing the fork seal.

2.Ring Nut Wrench PIN. YU-33975

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

1-6

SPECIAL TOOLS wlGEN

FOR ELECTRICAL COMPONENTS

1.Coil Tester PIN. YU-33261

This tester is necessary for checking the ignition system components.

2.Pocket Tester PIN. YU-03112

This tester is invaluable for checking the electrical system.

GENERAL SPECIFICATIONS

SPECIFICATIONS

ISPEC / pf I

GENERAL SPECIFICATIONS

Model
Model Code Number:
Vehicle Identification Number:
Engine Starting Number
Dimensions:
Overall Length	1,630 mm (64.2 in)
Overall Width	635 mm (25.0 in)
Overall Height	930 mm (36.6 in)
Seat Height	660 mm (26.0 in)
Wheelbase	1,055 mm (41.5 in)
Minimum Ground Clearance	120 mm (4.7 in)
Basic Weight:
With Oil and Full Fuel Tank
Minimum Turning Radius:	2,400 mm (94.5 in)
Engine:
Engine Type	Air cooled 2-stroke
Induction System	Reed valve
Cylinder Arrangement	Forward inclined single cylinder
Displacement	49.3 cm3
Bore x Stroke	40.0 x 39.2 mm (1.57x 1.54 in)
Compression Ratio	7.4 : 1
Starting System	Kick starter
Lubrication System:
TYpe	Separate lubrication (Yamaha Autolube)
Engine Oil Type	Yamalube " 2 or air cooled 2 stroke engine oil with
	"BIA certified for service TC-W"
Transmission Oil Type	Yamalube " 4 , SAE 10W30 type SE motor oil or
	"GL" gear oil
Oil Capacity:
Engine Oil (Oil Tank)	0.73 L (0.64 Imp qt, 0.77 US qt)
Transmission Oil:
Periodic Oil Change	0.60 L (0.53 Imp qt, 0.63 US qt)
Total Amount	0.65 L (0.57 Imp qt, 0.69 US qt)
Air Filter
Type	Wet type element

GENERAL SPECIFICATIONS ISPEC / pf I

Model

Fuel:

TYpe

Fuel Tank Capacit I

Full Amount

Reserve Amount

Carburetor:

Type/ Quantity

Manufacturer

Spark Plug:

TypeIQuantity

Manufacturer

Plug Gap

Clutch:

Type

Transmission:

TYpe

Primary Reduction System

Primary Reduction Ratio

Secondary Reduction System

Secondary Reduction Ratio

Operation

Gear Ratio

1st

2nd

3rd

4th

5th

Chassis:

Frame Type

Caster Angle

Trail

Tire:

TYpe

Size

Front

Rear

Tire Pressure (Cold Tire):

Basic Weight:

With Oil and Full Fuel Tank

Maximum Load*

Cold Tire Pressure:

Zero -Maximum Load*

Regular gasoline

8.0L (1.76 Imp gal, 2.11 US gal)

1.5L (0.33 Imp gal, 0.39 US gal)

VM16SH/1 pc.

MIKUNI

B7HS or B8HS NGK

0.5 -0.6 mm (0.020-0.024 in)

Wet, multiple disc

Constant mesh 5-speed Helical gear

68/19 (3.579) Chain drive 44/12 (3.667)

Left foot operation

Double cradle 25.3'

64 mm (2.52 in)

Tubeless

3.50-12 2PR

4.00-12 2PR

FRONT

* Load is total weight of cargo, rider, and accessories.

2-2

		GENERAL SPECIFICATIONS 1 -
	Model
Brake:
Front Brake Type		Single disc brake
Front Brake Operation		Right hand operation
Rear Brake Type		Drum brake
Rear Brake Operation		Right foot operation
Suspension:
Front Suspension Type		Telescopic fork
Rear Suspension Type		Swingarm (Monocross suspension)
Shock Absorber:
Front Shock Absorber		Coil springloil damper
Rear Shock Absorber		Coil springloil damper
Wheel Travel:
Front Wheel Travel		90 mm (3.5 in)
Rear Wheel Travel		75 mm (3.0 in)
Electrical:
Ignition System		CDI Magneto
Generator System		Flywheel magneto
Battery:
Type
Capacity
Headlight:
TYpe		Sealed beem
Bulb Wattage (Quantity):
Headlight
TailIBrake Light
Flasher Light
Licence Light
Meter Light
"NEUTRAL" lndicator Light
"HIGH	BEAM" lndicator Light
"TURN"	lndicator Light

"OIL" Warning lndicator Light (Light Emitting Diode)

MAINTENANCE SPECIFICATIONS ISPEC 1 p9 I

MAINTENANCE SPECIFICATIONS

ENGINE

	Model
Cylinder Head:	*
Warpage Limit	0.02 mm (0.001 in)
	"Lines indicate straightedge measurement.

Cylinder:
Bore Size	40.00-40.02		mm (1.575- 1.576 in)
Taper Limit	0.05	mm (0.002 in)
Out of Round Limit	0.01	mm (0.0004 in)
Piston:
Piston Size "D"	39.96-39.98		mm (1.573- 1.574 in)
Measuring Point "a"	5 mm (0.20 in)

Piston Off-Set		0.2 mm (0.008 in)
Piston-to-Cylinder Clearance		0.030 -0.035 mm (0.0012-0.0014 in)
< Limit >		<0.1 mm (0.004 in)>
Oversize 1st		40.25 mm (1.58 in)
Oversize 2nd		40.50 mm (1.59 in)
Piston Ring:
Sectional Sketch	Top Ring	Keystone type
		B = 1.2 mm (0.047 in)
		T = 1.6 mm (0.063 in)
		Plain type
		B = 1.2 mm (0.047 in)
OTg= 1.6 mm (0.063 in)
L	T	~
End Gap (Installed)	Top Ring	0.15 -0.35 mm (0.006-0.014 in)
	2nd Ring	0.15-0.35	mm (0.006-0.014	in)
Side Clearance	Top Ring	0.03-0.05	mm (0.001-0.002	in)
	2nd Ring	0.03-0.05	mm (0.001-0.002	in)

MAINTENANCE SPECIFICATIONS ISPEC 1 pp I

	Model
Crankshaft:
Crank Width "A"		37.90-37.95 mm (1.492- 1.494 in)
Runout Limit "B"		0.03 mm (0.0012 in)
Big End Side Clearance "C"		0.2- 0.7 mm (0.008-0.028 in)
<Limit >		<1.0 mm (0.04 in)>
Small End Free Play "D"		0.8- 1.0 mm (0.032-0.039 in)
<Limit >	-	<1.5 mm (0.06 in)>
	D

Clutch:
Friction Plate:
Thickness	3.5 mm (0.138 in)
Quantity	2 pcs.
Wear Limit	2.7 mm (0.106 in)
Clutch Plate:
Thickness	2.0 mm (0.079 in)
Quantity	1 PC.
Warpage Limit	0.05 mm (0.002 in)
Clutch Spring:
Free Length	28.2 mm (1.11 in)
Quantity	4 pcs.
Minimum Free Length	26.2 mm (1.03 in)
Clutch Release Method	Inner push, cam push
<Push Rod Bending Limit >	~ 0 . mm2 (0.008 in)>
Transmission:
Main Axle Runout Limit	0.08 mm (0.003 in)
Drive Axle Runout Limit	0.08 mm (0.003 in)
-

Shifter:

TYpe

Guide Bar Bending Limit

Kick Starter:

TYpe

Cam drum and guide bar 0.025 mm (0.001 in)

Kick and Mesh type

	MAINTENANCE SPECIFICATIONS 1 -
Model
Air Filter:
Oil Grade	Foam-Air-Filter oil or Yamalube "2"
Carburetor:
I.D. Mark	2AL 01
Main Jet	# 120
Air Jet	42.5
Jet Needle-Position	3621-4
Needle Jet	E-0
Cutaway	2.0
Pilot Outlet	40.9
Pilot Jet	# 17.5
Air Screw	1-118
Valve Seat Size	41.5
Starter Jet	# 20
Fuel Level	0- 1 mm (0- 0.04 in)
Float Height	21 -23 mm (0.83-0.91 in)
Idling Speed	1,300 - 1,400 rlmin
Reed Valve:
Valve Thickness	0.15 mm (0.006 in)
Valve Stopper Height	6.7-7.3 mm (0.26- 0.29 in)
Valve Bending Limit	0.3 mm (0.012 in)
Lubrication System:
Autolube Pump
Color Code	Green
Minimum Stroke	0.20 -0.25 mm (0.008-0.010 in)
Maximum Stroke	1.85-2.05	mm (0.073-0.081 in)
Minimum Output	0.50-0.63	cm3 per 200 strokes
Maximum Output	4.64 -5.15 cm3 per 200 strokes
Pulley Adjusting Mark	At idle

MAINTENANCE SPECIFICATIONS ISPEC / p9 I

TIGHTENING TORQUE
Part to be tightened	BoltINut	Tightening torque
Part to be tightened	size
	size
Spark plug
Cylinder head
Autolube pump
Intake manifold
Muffler (Front)
Muffler (Rear)
Crankcase
Crankcase cover
Transmission oil drain bolt
Autolube pump cover
Kick crank assembly
Primary drive gear
Clutch boss
Pressure plate
Stopper plate (Bearing)
Stopper plate (Shift cam)
Shift lever adjuster nut
Change pedal
Stator
CDI magneto
Neutral switch

MAINTENANCE SPECIFICATIONS pi+q

CHASSIS
	Model
Steering System:
Bearing Type		Ball Bearing
Bearing Size (Quantity)
Upper
Lower
Front Suspension:
Front Fork Travel		90 mm (3.54 in)
Fork Spring Free Length (Left side only)		374.2 mm (14.7 in)
< Limit >		<367 mm (14.4 in)>
Spring Rate	(K1)	8.2 Nlmm (0.83 kglmm, 46.6 Iblin)
Stroke	(KI)	0.0-90.0 mm (0.0 -3.5	in)
Optional Spring		No.
		LEFT		RIGHT
Oil Capacity		126 cm3 (4.44 Imp oz,		164 cm3 (5.77 Imp oz,
		4.26 US oz)		5.54 US oz)
Oil Level		146 mm (5.74 in)		51 mm (2.01 in)
		From top of inner tube		From top of inner tub(
		fully compressed without		compressed without
		spring.		spring.
Oil Grade		Yamaha fork oil 10WT or		t
		equivalent
3ear Suspension:
Shock Absorber Travel		18.0 mm (0.71 in)
Spring Free Length		86 mm (3.4 in)
Fitting Length		82 mm (3.2 in)
Spring Rate	(K1)	353 Nlmm (36 kglmm, 2,020 Iblin)
Stroke	(K1)	0.0- 18 mm (0.0-0.71	in)
Optional Spring		No.
Swingarm:
Free Play Limit (Swingarm end)		1.0 mm (0.039 in)
		Move swingarm end side to side
Front Wheel:
TYpe		Panel wheel
Rim Size		MT2.50 x 12
Rim Material		Steel
Rim Runout Limit
Vertical		2.0 mm (0.08 in)
Lateral		2.0 mm (0.08 in)

MAINTENANCE SPECIFICATIONS pqi$q

I	Model
Rear Wheel:
Type		Panel wheel
Rim Size		MT2.50 x 12
Rim Material		Steel
Rim Runout Limit
Vertical		2.0 mm (0.08 in)
Lateral		2.0 mm (0.08 in)
Drive Chain:
Type! Manufacturer		420M/ DAIDO
Number of Links		99 Links+joint
Chain Free Play		25-30 mm (1.0- 1.2 in)
Front Disc Brake:
TYpe		Single
Disc Outside Diameter		203 mm (8.00 in)
Disc Thickness		4.0 mm (0.16 in)
Pad Thickness		6.0 mm (0.24 in)
<Wear	Limit >	<0.5 mm (0.02 in)>
Master Cylinder lnside Diameter		11.O	mm (0.433 in)
Caliper Cylinder lnside Diameter		34.9 mm (1.37 in)
Brake Fluid Type		DOT No. 3
Rear Drum Brake:
TYpe		Leading, Trailing
Brake Drum lnside Diameter		110 mm (4.33 in)
< Limit >		<111 mm (4.37 in)>
Shoe Spring Free Length		50.5 mm (1.99 in)
Lining Thickness		4 mm (0.16 in)
<Limit >		<2 mm (0.08 in)>
Brake Lever and Brake Pedal:
Brake Lever Free Play		2-5	mm (0.08-0.20	in)
Brake Pedal Free Play		20-30 mm (0.8-1.2		in)
		Below top of footrest
Clutch Lever Free Play		2-3	mm (0.08-0.12	in)
Throttle Cable Free Play		3-7	mm (0.12-0.28	in)
		At grip flange

MAINTENANCE SPECIFICATIONS

TIGHTENING TORQUE

Tightening torque

Part to be tightened

BoltlNut size

ft-lb

Chassis:

Engine mounting;

Engine stay

Frame and engine

Pivot shaft and nut

Rear shock absorber and frame

Front fork cap bolt (Handlebar)

Under bracket and inner tube

Steering ring nut

Refer to NOTE

Steering stem bolt

Wheel hub and wheel rim

Front brake disc and wheel hub

Brake caliper and outer tube

Front wheel axle and nut

Brake cam lever and camshaft

Rear wheel sprocket and wheel hub

Tension bar and platelframe

Rear wheel axle and nut

Rear view mirror and stay

Brake hose union bolt

Footrest and frame

Cowling stay and frame

Windscreen and cowling

CDI unit and frame

Rectifier1Regulator

Down tube and frame

Engine bracket (Front) and frame

Engine bracket (Rear) and frame

NOTE:

1.First, tighten the ring nut approximately 30 Nm (3.0 m-kg, 22 ft-lb) by using the torque wrench, then loosen the ring nut one turn.

2.Retighten the ring nut to specification.

+ 202 hidden pages

Yamaha YSR50T User Manual

CONTENTS