Yamaha NEO'S YN50 Service manual

YN50
2002
5RN-AE1
SERVICE MANUAL
YN50
SERVICE MANUAL
© 2002 Yamaha Motor España, S.A.
First Edition, September 2002
All rights reserved.
The reprinting or use of this material without
the written authorisation of Yamaha Motor
España, S.A is forbidden.
Printed in Spain.
WARNING
This Manual was written by Yamaha Motor España, S.A. principally for the use of Yamaha/MBK
agents and qualified mechanics. As it is not possible to give full mechanical instructions in a manual,
it is presumed that the persons using the book to carry out the maintenance and repair of
Yamaha/MBK motorcycles have a basic knowledge of the concepts and procedures inherent in the
technology of motorcycle repair. Without such knowledge any attempt to repair or service this
model may cause problems in its use and/or safety.
Yamaha Motor España, S.A., is continually trying to improve all models which it manufactures.
Authorised Yamaha/MBK agents will be notified of all significant modifications and changes in the
specifications or procedures and these will appear where applicable in future editions of this
manual.
PARTICULARLY IMPORTANT INFORMATION
This material used the following notation.
s
A danger symbol means ATTENTION, BE CAREFUL, YOUR
SAFETY IS IN DANGER!
WARNING
Non-compliance with a WANING may cause the serious injury or
death of the driver, a bystander or the person inspecting of
repairing the mortorcycle.
ATTENTION:
ATTENTION indicates the special precautions which should be
taken in order to avoid damage to the motorcycle.
NOTE:
NOTE provides key information to make the procedures easier
and clearer.
HOW TO USE THIS MANUAL
FORMAT OF THIS MANUAL
This manual is composed of chapters on the main subject categories (See “Illustrated Symbols”).
First heading : This is a chapter with a symbol at the top right-hand side of each page.
Second heading : This title appears at the top of each page to the left of the chapter symbol.
(For the “Inspection and periodic adjustments” chapter the third heading appears)
Third heading : This is a final heading.
MANUAL FORMAT
All procedures in this manual are organised sequentially, step by step. The information has been
compiled to make reading easy for the mechanic and to provide useful reference material which
contains ample explanations of all disassembly, repair, assembly and inspection procedures. A
particularly important procedure is placed between a lines of asterisks “**” with each procedure preceded by “•”.
IMPORTANT CHARACTERISTICS
• Data and special tools are put in a box preceded by a corresponding symbol .
• A number within a circle indicates the number of a part, and an alphabetical letter within a
circle indicates data or an alignment mark , everything else is indicated by a letter within a
box .
• The conditions of defective components will precede an arrow symbol and the course of action
to be followed will follow the symbol .
DETAILED DIAGRAM
Each chapter provides detailed diagrams before each disassembly section, for the easy identification of disassembly/assembly procedures.
ILLUSTRATED SYMBOLS
GEN
INFO
(See illustration)
Illustrated symbols to are designed as
tabs to be followed with the thumb to indicate
the chapter number and the index.
SPEC
INSP/
ADJ
ENG
CARB
CHAS
General information
Specifications
Periodic inspection and adjustment
General overhaul of the engine
Carburation
Chassis
Electrical system
Troubleshooting
TRBL/
SHTG
ELEC
10
11
12
13
14
Illustrated symbols to 15 will be used to
identify the specifications which appear in the
text.
Refill with fluid
10 Lubricant
11 Special tool
12 Tightening
13 Wear limit, clearance
14 Engine speed
15 Ω V, A
Illustrated symbols 16 to 23 of detailed diagrams, indicate the degree of lubricant and
the location of the lubrication point.
15
16
17
18
19
20
21
22
23
NEW
16 Apply engine oil
17 Apply gear oil
18 Apply molybdenum disulphide oil
19 Apply grease to wheel bearings
20 Apply grease with lightweight lithium soap
base
21 Apply molybdenum disulphide grease
22 Apply bonding agent (LOCTITE®)
23 Use a new part.
INDEX
GENERAL INFORMATION
GEN/
INFO
1
SPEC
2
PERIODIC INSPECTION
AND ADJUSTMENTS
INSP
ADJ
3
GENERAL OVERHAUL OF
ENGINE
ENG
4
CARB
5
CHAS
6
ELEC
7
TRBL
SHTG
8
SPECIFICATIONS
CARBURATION
CHASSIS
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN/
INFO
1
GEN/
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION OF THE SCOOTER…………………………………………1-1
SERIAL NUMBER OF THE FRAME …………………………………………1-1
ENGINE SERIAL NUMBER……………………………………………………1-1
IMPORTANT INFORMATION …………………………………………………1-2
CHANGE OF ALL PARTS ……………………………………………………1-2
OIL SEALS AND O-RINGS ……………………………………………………1-2
SEALING WASHERS/PLATE AND KEYS……………………………………1-2
BEARING AND OIL SEALS …………………………………………………1-2
CIRCLIPS ………………………………………………………………………1-3
SPECIAL TOOLS …………………………………………………………………1-3
FOR SERVICING THE ENGINE ………………………………………………1-3
FOR SERVICING THE CHASSIS ……………………………………………1-5
FOR ELECTRICAL COMPONENTS …………………………………………1-6
IDENTIFICATION OF THE SCOOTER
GEN/
INFO
GENERAL INFORMATION
SCOOTER IDENTIFICATION
FRAME SERIAL NUMBER
The serial number of the frame is stamped
on the steering head pipe.
Frame VTL5AD
according standard EU0
Frame VTLSA15
according standard EU1
Frame VTLSA19
according Mofa Version
ENGINE SERIAL NUMBER
The engine serial number is stamped on
the upper part of the rear left-hand section of
the gear box.
NOTE:
The first three digits of these numbers identify
the model, the remaining digits are the manufacturing number of the unit.
NOTE:
The designs and specification are subject to
change without prior notice.
1-1
IMPORTANT INFORMATION
GEN/
INFO
IMPORTANT INFORMATION
CHANGE OF ALL PARTS
1. We recommend that original Yamaha parts
are used as spare parts. Use the oil and/or
grease recommended by Yamaha for
assembly and adjustment.
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets and o-rings should be replaced
when the engine is overhauled and repaired.
All gasket surfaces, the lips of seals and orings should be cleaned.
2. Lubricate with grease all corresponding
parts and bearings during assembly. Apply
grease on the lips of seals.
SEALING WASHER/PLATES AND KEYS
1. All washers/plates and keys should be
replaced when they are removed. The locking tabs should be folded along the flat
parts of the bolts or nuts after correctly tightening them.
BEARINGS AND OIL SEALS
1. Install the bearings and oil seals with
their manufacturer’s marks or numbers
facing outwards (i.e. the printed letters
should on the side exposed to view). When
the oil seals are installed, apply a thin layer
of light lithium-based grease on the edges
of the seal. Put oil on the bearings when
they are installed.
ATTENTION:
Do not turn the bearings in compressed air
to dry them. This will damage the surface
of the bearings.
1-2
IMPORTANT INFORMATION /
SPECIAL TOOLS
GEN/
INFO
CIRCLIPS
1. All circlips should be carefully inspected
before assembly. Always replace circlips of
the piston drum after use. Replace deformed circlips. When installing a circlip ,
ensure that the corner with the sharp edge
is placed in the opposing direction to
the thrust it receives. See sectional
view. Axle
SPECIAL TOOLS
Appropriate special tools are needed to complete and perfect assembly with accuracy.
Using correct tools will help to avoid damage
caused by the use of incorrect tools or improvised techniques.
FOR SERVICING THE ENGINE
1. Engine wheel holding tool
(90890-01235)
2. Engine wheel removal tool
(90890-01362)
3. Crankcase separation tool
(90890-01135)
1-3
SPECIAL TOOLS
GEN/
INFO
4. Pulley wheel clamp
(90890-01701)
5. Clutch spring compressor
(90890-01337)
6. Crankshaft installer crucible... (90890-01274)
7. Crankshaft installer bolt... (90890-01275)
1-4
SPECIAL TOOLS
GEN/
INFO
8. Adaptor (M10)... (90890-01277)
9. Spacer... (90890-01411)
FOR SERVICING THE CHASSIS
1. T-shaped handle 2... (90890-01326)
Shock absorber rod support... (90890-01294-A)
2. Counterbalance for insertion of fork seals
(90890-01184)
3. Accessory for insertion of fork seals
(90890-01186)
1-5
SPECIAL TOOLS
GEN/
INFO
4. Steering nuts wrench
(90890-01403)
FOR ELECTRICAL COMPONENTS
1. Pocket tester
(90890-03112)
2. Ignition tester
(90890-06754)
1-6
SPEC
2
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS …………………………………………………2-1
MAINTENANCE SPECIFICATIONS ……………………………………………2-3
ENGINE …………………………………………………………………………2-3
CHASSIS ………………………………………………………………………2-5
ELECTRICAL SYSTEM ………………………………………………………2-6
CABLE ROUTING ……………………………………………………………2-7
GENERAL SPECIFICATIONS
Model
SPEC
YN50R
Engine:
Engine type
Arrangement of cylinders
Cylinder capacity
Diameter and stroke
Compression ratio
Starter system
Reed valve, petrol, 2-stroke, air-cooled
One cylinder inclined to the front
49.2 cc
40.0 x 39.2 mm
11.6:1 5AD 10.2:1 SA15 11:1 SA19
Electrical and pedal kickstart
Lubrication system:
Type or grade of oil:
Engine oil
Transmission oil
Yamaha autolubrication
2-stroke air-cooled engine oil
SE type 10W30 SAE engine oil
Oil capacity:
Oil sump (engine oil)
Transmission oil
Periodic change of oil
Total quantity
1.2 L
0.10 L
0.11 L
Air filter:
Fuel:
Type
Fuel tank capacity
Flue type
Unleaded petrol
6.5 L
Carburettor:
Type/Manufacturer
PHVA/DELLORTO/PY12,1/GURTNER
Spark plug:
Type/Manufacturer
Distance between electrodes
5AD y SA15
BR8HS/N.G.K.
0.6 ~ 0,7 mm
Clutch type:
Dry, automatic centrifugal
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Type of transmission
SA19
BPR4HS/NGK
0.6 ~ 0.7 mm
Helicoidal gearing
52/13 (4.00)
Straight gearing
42/13(3.230) 5AD-SA15 45/12(33.750) SA19
Automatic one speed
(Trapezoidal belt type)
Automatic centrifuge type
Action
Chassis:
Frame
Inclination angle of front axle
Trail
Steel underside of pipe
26,5°
92.5 mm
Tyres:
Size (FR)
Size (R)
120/70-12
130/70-12
Tyre pressures (cold):
(Front)
(Rear)
2-1
1.75 kg/cm2
2.00 kg/cm2
GENERAL SPECIFICATIONS
Model
SPEC
YN50R
Brakes:
Front brake type
Operation
Rear brake type
Operation
Disc brake
Right-hand operation
Drum brake
Left-hand operation
Suspension:
Front suspension
Rear suspension
Telescopic fork
Balancing unit
Shock absorber:
Front shock absorber
Rear shock absorber
Spring/oil shock absorber
Spring/oil shock absorber
Travel of wheels:
Travel of front wheel
Travel of rear wheel
70 mm
60 mm
Electrical system:
Ignition system
Generating system
Battery type or model
Battery capacity
DC-C.D.I.
Magnetic flywheel
YB4C-B
12V4AH
Type of headlight:
Bulb voltage/quantity:
Headlamp
Rear light/brake
Indicator
Metre light
Bulb type
25W/25Wx2
5/21W
10Wx4
1.2Wx2
Warning lights/quantity:
Oil
Fuel
Indicators
2Wx1
2Wx1
2Wx2
2-2
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Model
YN50R
Cylinder head:
Warping limit
0.02 mm
* The lines indicate the measurement
Cylinder:
Internal diameter
<Limit>
Taper limit
Eccentricity limit
39.993 ~ 40.012 mm
<40.1 mm>
0.05 mm
0.01 mm
Piston:
Piston size
Measurement point
Piston clearance
First clearance
39.952 ~ 39.972 mm
5 mm
0.034 ~ 0.047 mm
40.50 mm
Piston ring:
Cross section
BxT
Distance between ends
(installed)
<Limit>
Lateral clearance
1.5 x 1.8 mm
0.15 ~ 0.35 mm
<0.6 mm>
0.03 ~ 0.05 mm
Crank shaft:
Width of crank shaft “A”
Deflection limit “C”
Connecting rod big
end clearance “D”
Free play from small end “F”
Free play “E”
37.90 ~ 37.95 mm
0.03 mm
0.2 ~ 0.5 mm
0.4 ~ 0.8 mm
0.004 ~ 0.017 mm
2-3
MAINTENANCE SPECIFICATIONS
Model
SPEC
YN50R
Automatic centrifugal clutch:
Thickness of clutch shoe
<Limit>
Free length of clutch shoe
spring
Clutch revolutions
Clutch binding revolutions
3.600±250 rpm
5.600±400 rpm
Transmission:
Main axle deflection limit
Drive axle deflection limit
0.08 mm
0.08 mm
Choke handle:
Type
Pedal friction force
Ratchet type
150 ~ 250 g
2 mm
<1 mm>
29.9 mm
Air filter oil grade (oil filter):
Oil for foam air filter
2T oil for air-cooled engines
Carburettor:
Type/Manufacturer/Quantity
Main jet
(M.J.)
Retaining position of jet
needles
(J.N.)
Main air jet
(M.A.I.)
Pilot jet
(P.J.)
Pilot air screw
(P.A.S.)
Valve seat size
engine idling
PHVA/Dellorto/1
YP12/GURTNER/1
#78/5AD
#65//SA15 #74/5AD
#62/SA15 #60/SA19
A12-3/5
ø 1.5
#36/5AD
1 1/4 ± 1/4
A20-3/5
ø 1.5
#36/SA15
2 1/8 ± 1/8
1.2
1.800 r.p.m.
2-4
B10A-2/3
–
#38/5AD
1 1/8
B10A-2/3
–
#38/SA15
1 7/8
1.4
1.800 r.p.m
L3035H-1/3
–
#36/SA19
1 7/8
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Model
YN50R
Steering system:
Steering bearing type
Front suspension:
Travel of front shock absorber
Free length of shock absorber
spring
<Limit>
Spring/stroke ratio
Oil capacity
Oil grade
Rear suspension:
Shock absorber travel
Length of spring coupling
Spring/stroke ratio
Ball bearing
70 mm
226 mm
(K1)
(K2)
1.12 Kgf/mm
1.78 Kgf/mm
45 cm3±1
10 W shock absorber oil or equivalent
60 mm
221 mm
3.75 Kgf/mm
7,10 Kgf/mm
(K1)
(K2)
Wheels:
Type of front wheel
Type of rear wheel
Size/material of front wheel
Size/material of rear wheel
Rim run-out limit
Vertical
Lateral
Alloy rim
Alloy rim
12 x 3.5 aluminium
12 x 3.5 aluminium
1.0 mm
1.0 mm
Front disc brake
Type
External diameter and disc
thickness
Thickness of pads
<Limit>
Internal diameter of master cylinder
Internal diameter of calliper
Brake fluid type
190.0 x 3.5 mm
4 mm
<0.8 mm
11 mm
30.16 mm
DOT 4
Drum brake:
Type
Internal diameter of drum
<Limit>
Lining thickness
<Limit>
Shoes
110 mm
110.5 mm
4.0 mm
2.0 mm
Single
Brake levers
Free play of brake lever
(right)/position
Free play of brake lever
(left)/position
2 ~ 5 mm /at the end of the lever
5 ~ 10 mm /at the end of the lever
2-5
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL SYSTEM
Model
YN50R
Ignition system:
Type
Ignition distribution (A.P.M.S.)
DC-C.D.I.
14*/5.000 r/min
C.D.I.:
Harnessing coil resistance (colour)
400 ~ 600 Ω a 20 oC (68 oF)
(Black/Red-Black)
Ignition coil:
Spark plug electrodes gap
Primary coil resistance
Secondary coil resistance
6.0 mm
0.56 ~ 0.84 Ω at 20 °C
5,68 ~ 8,52 KΩ at 20 °C
Charging system:
Charging output
0.4 A or more/3.000 rpm/min
1 A or less/8.000 rpm/min
4.8 ~ 7.2 Ω a 20 °C (68 °F)
Charging coil resistance (colour)
(Black-White)
Lighting system:
Lighting output
12 V or more/3.000 rpm/min,
15 V or less/8.000 rpm/min
0.4 ~ 0.6 Ω a 20 °C (68 °F)
(Yellow/Red-Black)
Lighting coil resistance (colour)
Battery:
Type:
Capacity
Specific gravity
YB4L-B
12V4AH
1280/20 °C
Starter system:
Type:
Constant mesh type
Starter motor:
Output
Induction coil resistance
Brush length
<Limit>
0.14 kw
0.064 ~ 0.079 Ω at 20 °C
3.9 mm
<0.9 mm>
Circuit breaker:
Type:
Amperage/Quantity
Principal
Fuse
7A x 1
2-6
CABLE ROUTING
SPEC
CABLE ROUTING
A Insert the seat closing cable through the
Front brake pipe
Rear brake cable
Rear brake calliper
Rear mudguard
Rear warning light
Vacuum tube
Fuel pipe
Speedometer cable
Installation
10 Breather
11 Accelerator cable
12 Seat closing cable
13 Oil hose
14 choke wire
frame orifice
B Connect the oil tube to the carburettor
C Splice the fuel pipe to the cock
D Splice the fuel pipe to the carburettor
E Press the earth cable and the starter motor
together
F Splice all the cables except the brake hose,
without tightening
G Splice to the frame wire harness and throtle
H Pass the brake cable through the guide
2-7
CABLE ROUTING
SPEC
A Splice the electrical installation to the frame
B Splice the oil pipe to the tank
C Connect the oil pipe to the pump
D Splice the installation to the frame
E Tighten the earth cable and the ignition coil
Rectifier/Regulator
Main switch
Fuel level measurer
Horn
Ignition coil
Spark plug cable
Oil level sensor
Oil tank
C.D.I.
together
F Pass the speedometer cable through the
guide
G Fit the grommet in the small hole of the
underbracket
2-8
CABLE ROUTING
A Do not pinch the accelerator cable when
Front break switch
SPEC
assembling the handlebar covers
Electrical installation
Intermittent relay
Speedometer assembly
Accelerator cable
Rear brake cable
Choke cable
Front brake hose
B Accelerator cable tensioner. Cover after
adjusting
C Connect the brake switch cables in this area
D Do not pass the brake pipe through the flange
2-9
INSP
ADJ
3
INSP
ADJ
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS …3-1
REAR BODYWORK AND FOOTREST ………………………………………3-2
REMOVAL ………………………………………………………………………3-2
INSTALLATION …………………………………………………………………3-3
MUDGUARDS, LOWER COVER AND FRONT PANEL ……………………3-4
REMOVAL ………………………………………………………………………3-5
INSTALLATION …………………………………………………………………3-5
HANDLEBAR COVERS …………………………………………………………3-5
REMOVAL ………………………………………………………………………3-5
INSTALLATION …………………………………………………………………3-5
ENGINE ……………………………………………………………………………3-6
ADJUSTMENT OF ENGINE IDLING …………………………………………3-6
ADJUSTMENT OF FREE PLAY OF TROTTLE CABLE ……………………3-7
SPARK PLUG INSPECTION …………………………………………………3-8
INSPECTION OF ENGINE OIL LEVEL ………………………………………3-9
CHANGE OF TRANSMISSION OIL ………………………………………3-10
AUTOLUBE PUMP AIR BLEEDING ………………………………………3-10
CLEANING AIR FILTER………………………………………………………3-10
CHASSIS …………………………………………………………………………3-12
ADJUSTMENT OF FREE PLAY OF FRONT BRAKE LEVER ………………3-12
ADJUSTMENT OF FREE PLAY OF REAR BRAKE LEVER…………………3-12
INSPECTION OF BRAKE PADS ……………………………………………3-12
INSPECTION OF BRAKE SHOES …………………………………………3-13
INSPECTION OF BRAKE FLUID LEVEL …………………………………3-13
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) …………………………3-14
STEERING ADJUSTMENT …………………………………………………3-14
INSPECTION OF TYRES ……………………………………………………3-15
WHEEL INSPECTION ………………………………………………………3-16
INSPECTION OF REAR FORK ……………………………………………3-16
REAR SHOCK ABSORBER INSPECTION…………………………………3-16
ELECTRICAL SYSTEM…………………………………………………………3-17
INSPECTION OF BATTERY …………………………………………………3-17
INSPECTION OF FUSES ……………………………………………………3-19
ADJUSTMENT OF HEADLAMP BEAM ……………………………………3-20
REPLACEMENT OF HEADLAMP BULB …………………………………3-20
INTRODUCTION / PERIODIC MAINTENANCE /
LUBRICATION INTERVALS
INSP
ADJ
PERIOD INSPECTION AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to carry out inspections and adjustments recommended. These preventive maintenance procedures, if they are correctly followed, will ensure the
most reliable operation of the vehicle and a longer useful life. The need for overhauls and costly
repairs will be greatly reduced. This applies both to vehicles which are already in service and to
new vehicles which are ready for sale. All service technicians should familiarise themselves with
the entire chapter.
PERIODIC MAINTENANCE / LUBRICATION INTERVALS
ODOMETER READING
( x 1.000 km)
N.
1
*
2
INTEM
CHECK OR MAINTENANCE JOB
Fuel line
Spark Plug
1
6
12
• Check fuel hoses and vacuum hose
for cracks
√
√
• Check condition.
• Clean and regap.
√
• Replace.
3
Air filter element
• Clean.
*
Front brake
• Check operation, fluid level and vehicle for
fluid leakage.
√
*
Rear brake
*
Brake hose
• Check operation and adjust brake lever freeplay.
√
√
√
• Replace. (See NOTE on page 6-5)
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Every 4 years
7
*
Wheels
• Check runout and for damage.
√
√
√
√
8
*
Tires
•
•
•
•
√
√
√
√
√
√
√
√
√
√
√
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
*
Wheel
bearings
• Check bearing for looseness or damage.
10
*
Steering bearings
• Check bearing play and steering for roughness.
√
√
• Lubricate with lithium-soap-based grease.
11
*
12
√
Whenever worn to the limit
• Check for cracks or damage.
9
CHECK
Whenever worn to the limit
• Replace brake shoes.
6
√
√
√
√
24
√
√
• Replace brake pads.
5
√
√
• Replace.
4
ANNUAL
18
Every 24.000 km
Chassis fasteners
• Make sure that all nuts, bolts and screws are
properly tightened.
√
√
√
√
√
Centerstand
• Check operation.
√
√
√
√
√
• Lubricate.
13
*
Front fork
• Check operation and for oil leakage.
√
√
√
√
14
*
Rear shock absorber
assembly
• Check operation and shock absorber for oil
leakage.
√
√
√
√
15
*
Carburetor
• Check starter (choke) operation.
√
√
√
√
√
√
√
√
• Adjust engine idling speed.
16
*
Autolube pump
• Check operation.
√
• Bleed if necessary.
17
18
Final gear oil
*
19
20
*
21
• Check oil level and vehicle for oil leakage.
√
• Change.
√
V-belt
• Replace
Front and rear brake
switches
• Check operation.
Moving parts
• Lubricate.
and cables
Lights, signals
and switches
• Check operation.
• Adjust headlight beam.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
• Since these items require special tools, data and technical skills, have a Yamaha/MBK dealer perform the service.
NOTE:
•
•
••
••
••
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
3-1
REAR BODYWORK AND FOOTREST
INSP
ADJ
REAR BODYWORK AND FOOTREST
REMOVAL
1. Raise the seat
2. Remove:
• Seat 3. Remove:
• Battery cover
4. Remove:
• Rear cover
5. Remove:
• Side covers
NOTE:
When the side covers are being removed
unhook them from the catches and slide
them outwards.
3-2
REAR BODYWORK AND FOOTREST
INSP
ADJ
6. Remove:
• Footrest INSTALLATION
When the foot support panel and the rear
cover are being installed, reverse the removal
process.
Remember the following points.
1. Install:
• Side covers
NOTE:
• Match up the support and hole and then
apply pressure.
3-3
REAR BODYWORK, MUDGUARDS
INSP
ADJ
REAR BODYWORK, MUDGUARDS
REMOVAL
1. Remove:
• Main switch cover.
Turn the cover to the left and pull
upwards.
2. Remove:
• Upper screws in ignition key panel
• Rear fairing assembly and headlight
NOTE:
Disconnect the headlight cable and indicators.
3. Remove:
• Front lower fairing screws • Carrier hook bolt
• Footrest lower cover screws
4. Remove:
• Battery cover
• Battery, fuse and starter relay
• Bottom footrest cover
• Footrest
• Bottom rear fairing
NOTE:
Disconnect indicator cables.
• Mudguards
INSTALLATION
Reverse the removal process.
NOTE:
After installing all plastic parts, check that all
hooks are properly attached.
3-4
HANDLEBAR COVERS
INSP
ADJ
HANDLEBAR COVERS
REMOVAL
1. Remove:
• Front handlebar cover • Rear handlebar cover INSTALLATION
Reverse the removal procedure. Remember
the following points.
1. Install:
• Front handlebar cover • Rear handlebar cover NOTE:
When installing the rear cover, check that the
speedometer cables goes through its housing.
NOTE:
After installing the handlebar cover, ensure
that all the hooks are properly coupled.
3-5
ADJUSTMENT OF ENGINE IDLING
INSP
ADJ
ENGINE
ADJUSTMENT OF ENGINE IDLING
1. Tighten:
• Pilot air screw Turn the pilot air screw inwards until it
seats itself lightly.
2. Loosen:
• Pilot air screw.
Unscrew it from its lightly seated position.
OUTWARDS TURNS OF THE PILOT AIR SCREW:
DELLORTO
GURTNER
EU0
EU1
EU0
EU1
MOFA
1 1/2±14
2 1/8±1/8
1 1/8
1 7/8
1 7/8
3. Start the engine and let it warm up.
s WARNING
Before starting the engine, ensure that the
central safety stand is being used.
4. Join:
• Inductive tachometer On the spark plug cable
Inductive tachometer
90890-03113
5. Check:
• Engine idling.
Outside specified value
Adjust.
Engine idling
1.800 rpm
6. Adjust:
• Engine idling
Adjustment steps:
• Turn the accelerator stop screw outward
or inwards until the specified idling is obtained.
Turn inwards Increases idling.
Turn outwards Decreases idling.
3-6
AJUSTE DEL JUEGO LIBRE DEL
CABLE DEL ACELERADOR
INSP
ADJ
ADJUSTMENT OF FREE PLAY OF THROTTLE CABLE
1. Check:
• Free play of throttle cable a
Outside specified value Adjust.
Free play
2 ~ 5 mm
Steps for adjusting the free play of the
throttle cable:
NOTE:
Before adjusting the free play of the throttle,
engine idling should be adjusted.
First step:
• Loosen the lock nut of the throttle cable.
• Turn the adjuster inwards or outwards
until the specified free play is obtained.
Turn inwards Free play increases.
Turn outwards Free play decreases.
• Tighten the lock nuts.
NOTE:
If the free play cannot be adjusted, adjust the
cable on the side of the carburettor (second
step).
Second step:
• Remove the cover.
• Loosen the lock nut .
• Turn the adjuster inwards or outwards
until the specified free play is obtained.
Turn inwards Free play increases.
Turn outwards Free play decreases.
• Tighten the lock nut.
• Install the cover.
s WARNING
After adjustment, turn the handlebar to the
right and left and check that the idling does
not vary.
3-7
SPARK PLUG INSPECTION
INSP
ADJ
SPARK PLUG INSPECTION
1. Inspect:
• Incorrect type of spark plug
Replace
Standard spark plug (5AD y SA15)
BR8HS/N.G.K.
for SA19
BRP4HS/N.G.K.
2. Inspect:
• Electrode Worn/Damaged Replace
• Insulator Abnormal colour Replace
The normal colour is a light to medium
coffee colour.
3. Clean the spark plug with a spark plug cleaner or wire brush.
4. Measure:
• Distance between electrodes
Use a thickness gauge.
Outside the specified value Correct
Gap between electrodes
0.6 ~ 0.7 mm
5. Tighten:
• Spark plug
Spark plug
2.0 m • kg
3-8
INSPECTION OF ENGINE OIL LEVEL
INSP
ADJ
INSPECTION OF ENGINE OIL
LEVEL
1. Inspect:
• Engine oil level
Low oil level Add sufficient oil.
Oil indicator light “OIL CAUTION”
Visual inspection steps for engine oil level
Place main switch in
position (h)
The “OIL CAUTION”
indicator light is not lit.
The “OIL CAUTION”
indicator light is lit.
Place the main switch in
position “f”
Inspect for defective
electric circuit, bulbs,
etc.
The “OIL CAUTION”
indicator light is not lit.
The “OIL CAUTION”
indicator light is lit.
The engine oil level and
electric circuit are in
good condition.
Supply engine oil.
The “OIL CAUTION”
indicator light is not lit.
Recommended oil:
JASO grade FC 2 stroke
engine oil or equivalent
Total:
1.2 L
NOTE:
After filling the oil tank, replace the cap and
close the seat.
3-9
CHANGE OF TRANSMISSION OIL /
CLEANING AIR FILTER
INSP
ADJ
CHANGE OF TRANSMISSION OIL
1. Remove:
• Drainage bolt Drain the transmission oil.
• Oil refill cap 2. Inspect:
• Gasket (drainage screw)
• O-ring (refill cap)
Damaged Change
3. Install:
• Gasket
• Drainage screw
2
4
Drainage screw
18 Nm (1.8 m • kg)
4. Fill:
• Transmission Case
Transmission oil
SE engine oil type SAE 30 or GL
gear oil
Caacity:
0.11 L
CLEANING AIR FILTER
Carburettor side
1. Remove:
• Air filter box assembly 3-10
INSP
ADJ
CLEANING AIR FILTER
2. Remove:
• Air filter box • Air filter
ATTENTION:
Never start up the engine with the air filter
removed. This will allow the entry of unfiltered air, causing rapid wear and possible
damage to the engine. Also, using the engine without the filter will affect the carburettor jets resulting in poor performance and
the possible overheating of the engine.
Be careful not to block the inlet area of the
air filter with cloths or rags.
3. Inspect:
• Damaged element
4. Clean:
• Air filter
Change
Steps for cleaning air filter:
• Wash the filter carefully but completely with
solvent.
s WARNING
Never use solvents with a low flammability
point, such as petrol, to clean the filter.
Such solvents may cause fire or explosions.
• Clean off excess solvent from the filter and
leave it to dry.
ATTENTION:
Do not wring the filter when drying it.
• Apply oil for foam air filters or YAMAHA 2T
engine oil or equivalent oil for 2 stroke aircooled engines.
• Wipe off the excess oil.
NOTE:
The filter should be wet but not dripping.
3-11
ADJUSTMENT OF FREE PLAY OF FRONT BRAKE LEVER /
ADJUSTMENT OF FREE PLAY OF REAR BRAKE LEVER /
INSPECTION OF BRAKE PADS
INSP
ADJ
CHASSIS
ADJUSTMENT OF FREE PLAY OF FRONT
BRAKE LEVER
1. Check:
• Free play of the front brake lever.
2 ~ 5 mm
s WARNING
The soft or spongy feeling of the brake lever
may indicate the presence of air in the
brake system. This air should be extracted
by bleeding the brake system before using
the vehicle. Air in the system will reduce the
braking capacity and may cause loss of
control and accidents. Inspect and bleed
the system if it is necessary.
ADJUSTMENT OF FREE PLAY OF REAR
BRAKE LEVER
1. Check.
• Free play of rear brake lever a
Outside specified value Adjust
5 ~ 10 mm
Steps for adjusting the free play of the rear
brake lever:
• Turn the adjuster inwards or outwards
until the correct free play is obtained.
INSPECTION OF BRAKE PADS
1. Activate the front brake lever
2. Inspect:
• Brake pads.
Wear indicator almost contacts with
the brake disc Replace the set of
brake pads.
See “CHANGE OF BRAKE PADS” section in chapter 6.
3-12
INSPECTION OF BRAKE SHOES /
INSPECTION OF BRAKE FLUID LEVEL
INSP
ADJ
NSPECTION OF BRAKE SHOES
1. Activate the brake lever
2. Inspect:
• Wear indicator Indicator on wear limit line the brake shoes.
Change
INSPECTION OF BRAKE FLUID LEVEL
NOTE:
Place the scooter upright when inspecting the
fluid level.
1. Inspect:
• Fluid level.
The fluid level is below the minimum
level line Refill up to correct level.
Recommended fluid:
DOT 4
ATTENTION:
The fluid may corrode painted surfaces or
plastic parts. Always clean any spilt fluid
immediately.
s WARNING:
• Only use fluid of the designated quality.
Otherwise the rubber seals may deteriorate due to leakages and poor performance of the brakes.
• Refill with the same type of fluid. The mixture of fluids may cause a damaging chemical reaction which may cause the poor
performance of the brakes.
• Take care not to let water enter the pump
while it is being filled. The water will lower
the boiling point of the fluid significantly
and may cause a steam blockage.
3-13
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) /
STEERING ADJUSTMENT
INSP
ADJ
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
1. Bleed:
• Brake fluid
Steps for air bleeding:
a. Add the appropriate amount of brake fluid
to the sump.
b. Install the diaphragm. Take care not to spill
fluid or to let the sump overflow.
c. Connect the clean plastic tube .
d. Place the other end of the tube in a container.
e. Slowly apply the brake lever several times.
f. Pull the lever inwards. Keep it in this position.
g. Loosen the bleed screw and tighten the
lever as far as it will go.
h. Tighten the bleed screw when it has reached its limit, afterwards loosen the lever.
i. Repeat steps (e) to (h) until the air bubbles
in the system have been removed.
j. Add brake fluid to the correct level.
s WARNING
Check the brake operation after bleeding
the system.
STEERING ADJUSTMENT
1. Check:
• Steering assembly bearings Press down
the bottom of the fork and carefully
move the assembly forwards and backwards.
Loose Adjust
3-14
INSP
ADJ
INSPECTION OF TYRES
Steps for tightening the steering nut:
1. Tighten the lower ring to 3.8 m • kg.
2. Loosen the lower ring nut 1/2 of a turn
and tighten to 0.65 m • kg.
3. Check the steering for smooth operation.
4. Install rubber washer .
5. Install central ring nut and hand tighten
untill the lower and central ring nuts slots
allignet.
6. Install the lock washer .
7. Supporting the lower and central ring nuts,
install and thigten the upper ring nut to
7.5 m • kg.
INSPECTION OF TYRES
s WARNING
• Do not try to use tubeless tyres in a wheel
designed only for inner tube tyres. This
may cause damage to the tyre and personal injury due to a puncture.
Wheel
Tube type
tubeless type
Tyre
Only imer tube type
With or without tube
type
1. Measure:
• Air pressure
Outside specified value
Basic weight:
With oil sump and fuel
tank full
Maximum load*
Cold tyre
pressure
2. Inspect:
• Tyre surface
Worn/Damaged
Adjust
87 kg
155
front
1.75kg/cm2
Rear
2.00 kg/cm2
Change
Minimum depth of thread of tyres
0.8 mm
Thread depth
Side wall
Wear indicator
3-15
WHEEL INSPECTION / INSPECTION OF REAR FORK /
REAR SHOCK ABSORBER INSPECTION
INSP
ADJ
WHEEL INSPECTION
1. Inspect:
• Wheels damaged/warped
Replace.
s WARNING:
Never try to make even the smallest
repairs on wheels.
INSPECTION OF REAR FORK
1. Inspect:
• Rear fork
Bent/Damaged Fork bar Change
Oil leaks Seals Change
Rough operation Fork assembly Change
REAR SHOCK ABSORBER INSPECTION
1. Inspect:
• Rear shock absorber
Oil leaks/Damage Replace
2. Check
• Coupling torque
3-16
Upper
(nut)
3.2 m • kg
Lower
(bolt)
1.8 m • kg
BATTERY INSPECTION
INSP
ADJ
ELECTRICAL SYSTEM
BATTERY INSPECTION
1. Remove:
• Battery cover
See “REAR BODYWORK” section
2. Inspect:
The fluid level between the maximum and minimum marks.
Incorrect Refill
ATTENTION:
Add only distilled water; tap water contains
minerals which are damaging to the battery.
3. Inspect:
• Battery terminals
Dirty terminals Clean with a wire
brush
Bad connection Correct
NOTE:
Once the terminals are clean, apply a thin
cover of grease.
4. Check:
• The density of the electrolyte
Less than 1,280 Recharge the battery
Charge current:
0.3 Amps/10 Hrs
Electrolyte density:
1,280 at 20 °C (68 °F)
3-17
BATTERY INSPECTION
INSP
ADJ
Change the battery in the following cases:
• When the voltage does not reach the specified value and bubbles do not appear, even
after several hours of charging.
• When one or more of the trays become
sulphated, which can be seen when the
plates become white are material accumulates on the bottom.
• When the density readings after slow charging over a prolonged period, indicate that
one of the trays is lower than the other.
• When the warping or ondulation of one of
the plates or insulators is evident.
ATTENTION:
Always charge new batteries before
assembling them, in order to guarantee
maximum performance.
s WARNING
The electrolyse in the battery is dangerous;
it contains sulphuric acid and is consequently poisonous and very caustic.
Always follow the following preventive
measures:
• Avoid physical contact with the electrolyte which can cause serious burns or permanent damage to sight.
• Use protective glasses when handling
batteries or working near them. Antidote
(EXTERNAL):
• SKIN - Wash with water.
• EYES - Wash with water for 15 minutes
and consult a doctor immediately.
Antidote (INTERNAL):
• Drink large quantities of water or milk,
followed by milk of magnesia, beaten egg
of vegetable oil.
• See a doctor immediately.
Batteries also generate explosive hydrogen
gas, so that the following preventive measures should always be observed:
• Charge the batteries in a well ventilated
area.
• Maintain the batteries away from fire,
sparks or flames (for example, soldering
equipment, lit cigarettes, etc.).
• DO NOT SMOKE while batteries are being
charged or handled.
MAINTAIN BATTERIES AND THE ELECTROLYSE OUT OF THE REACH OF CHILDREN.
3-18
INSPECTION OF FUSES
INSP
ADJ
INSPECTION OF FUSES
1. Remove:
• The battery cover
See the “FRONT BODYWORK” section
2. Inspect:
• Fuse Defective
Replace
Steps to be taken for blown fuses:
• Disconnect the ignition and circuit.
• Install a new fuse of the correct amperage.
• Connect the switches to check the correct
operation of the electrical device.
• If the fuse blows immediately after, check
the circuit concerned.
s WARNING
Do not use fuses of a higher amperage than
that recommended. This can cause extensive damage to the electrical system and fire.
Description
Principal
3-19
Amperage
7A
Quantity
1
ADJUSTMENT OF HEADLAMP BEAM /
REPLACEMENT OF HEADLAMP BULB
INSP
ADJ
ADJUSTMENT OF HEADLAMP BEAM
1. Adjust:
• Headlamp (vertically)
To raise the beam Turn the screw inwards
To lower the beam Turn the screw outwards
REPLACEMENT OF HEADLAMP BULB
1. Remove:
• Front fairing
2. Disconnect
• Headlamp cables
3. Remove:
• Headlamp bulb cover
• Headlamp bulb
4. Install:
When the front fairing is installed, reverse
the removal process
3-20
ENG
4
ENG
CHAPTER 4
GENERAL OVERHAUL OF ENGINE
ENGINE REMOVAL ………………………………………………………………4-1
REAR COVER AND FOOTREST PANEL ……………………………………4-1
CARBURETTOR ………………………………………………………………4-1
SILENCER ASSEMBLY ………………………………………………………4-1
CABLES AND TUBES …………………………………………………………4-2
REMOVAL OF ENGINE ………………………………………………………4-3
DISASSEMBLY THE ENGINE …………………………………………………4-4
REAR WHEEL …………………………………………………………………4-4
CENTRAL SUPPORT …………………………………………………………4-4
CYLINDER HEAD AND CYLINDERS ………………………………………4-4
PISTON PINS AND PISTON …………………………………………………4-4
KICK STARTER…………………………………………………………………4-5
PRIMARY PULLEY WHEEL …………………………………………………4-6
SECONDARY PULLEY WHEEL ………………………………………………4-6
STARTER SYSTEM ……………………………………………………………4-7
TRANSMISSION ………………………………………………………………4-8
MAGNETIC FLYWHEEL ………………………………………………………4-8
AUTOLUBRICATION PUMP …………………………………………………4-9
CRANKCASE AND CRANKSHAFT …………………………………………4-9
INSPECTION AND REPAIR ……………………………………………………4-11
CYLINDER HEAD ……………………………………………………………4-11
CYLINDER AND PISTON ……………………………………………………4-11
PISTON RINGS ………………………………………………………………4-13
PISTON PIN AND PISTON PIN BEARING ………………………………4-14
KICK STARTER ………………………………………………………………4-15
TRANSMISSION………………………………………………………………4-16
AUTOLUBRICATION PUMP…………………………………………………4-16
CRANKSHAFT ………………………………………………………………4-16
PRIMARY PULLEY WHEEL …………………………………………………4-17
SECONDARY PULLEY WHEEL ……………………………………………4-18
TRAPEZOIDAL BELT …………………………………………………………4-19
GEARS AND STARTER CLUTCH …………………………………………4-19
ASSEMBLY AND ADJUSTMENT OF ENGINE ……………………………4-21
CRANKSHAFT AND CRANKCASE…………………………………………4-21
AUTOLUBRICATION PUMP…………………………………………………4-23
FLYWHEEL MAGNET ………………………………………………………4-24
TRANSMISSION………………………………………………………………4-25
STARTER MOTOR ……………………………………………………………4-27
SECONDARY PULLEY WHEEL ……………………………………………4-29
PRIMARY PULLEY WHEEL …………………………………………………4-29
STARTER PEDAL ……………………………………………………………4-30
PISTON AND PISTON PIN …………………………………………………4-35
CYLINDER AND HEAD ……………………………………………………4-36
ENGINE ASSEMBLY …………………………………………………………4-38
ENGINE REMOVAL
ENG
GENERAL OVERHAUL OF
THE ENGINE
REMOVAL OF ENGINE
REAR BODYWORK AND FOOTREST
1. Remove:
• Side covers (left and right)
• Rear cover
• Footrest panel See section in chapter 3
“REAR BODYWORK AND FOOTREST”
CARBURETTOR
1. Remove:
• Air filter box assembly 1
2. Disconnect:
• Autochoke wire • Trhottle cable
3. Remove:
• Oil discharge tube • Fuel supply tube
• Carburettor 1
SILENCER ASSEMBLY
1. Remove:
• Silencer assembly • Ventilator cover 2. Loosen:
• Rear axle nut NOTE:
When the rear wheel axle nut is loosened,
apply the rear brake.
1
4-1
ENGINE REMOVAL
ENG
CABLES AND PIPES
1. Remove:
• Oil pipe from side of oil pump.
NOTE:
Position oil pipe so that the oil does not spill
out.
2. Remove:
• Bolts (trunk)
• Overflow bowl rivets
NOTE:
To remove the overflow bowl, take off the fuel
and oil caps and replace them immediately
after removing the bowl.
3. Disconnect:
• Battery cable • Starter motor cable • Magnetic flywheel cable • Spark plug pipe
4. Remove:
• Rear brake cable 1
4-2
ENGINE REMOVAL
ENG
ENGINE REMOVAL
1. Remove:
• Rear shock absorber screw (lower)
2. Remove:
• Engine assembly screw • Engine Lift the frame and remove the
engine
3. Place the frame on a suitable support
4-3
DISASSEMBLY THE ENGINE
ENG
DISASSEMBLY ENGINE
REAR WHEEL
1. Remove:
• Rear wheel
• Brake shoes • Flat washer CENTRAL STAND
1. Remove:
• Clip • Rubber washer • Axle
• Clasp • Spring • Central stand CYLINDER HEAD AND CYLINDER
1. Remove:
• Cover
• Cylinder head • Cylinder head gasket
NOTE:
• Before loosening the cylinder head, loosen
the spark plug .
• The position nuts of the cylinder head
should be loosened by 1/2 a turn each time
and then removed.
2. Remove:
• Cylinder • Cylinder gasket PISTON PIN AND PISTON
1. Remove:
• Piston pin clip NOTE:
Before removing the piston pin clip, cover the
crankcase with a clean cloth so that it does
not accidentally fall into the crankcase.
4-4
DISASSEMBLY THE ENGINE
ENG
2. Remove:
• Piston pin • Piston • Piston pin bearing ATTENTION:
Do not use a hammer to take out the piston pin.
KICKSTART SYSTEM
1. Remove:
• Kickstart pedal
• Crankcase cover (left)
2. Remove:
• Guide(air filter)
• Air filter
3. Remove:
• Pedal gear NOTE:
When the pedal gear removed, move the
pedal axle.
4. Unhook:
• Return spring 5. Remove:
• Circlip • Flat washer • Pedal axle 4-5
DISASSEMBLY THE ENGINE
ENG
PRIMARY PULLEY WHEEL
1. Remove:
• Fan
2. Remove:
• Nut (primary pulley wheel)
NOTE:
When the nut is loosened (primary pulley
wheel), support the magnetic flywheel using
the engine wheel support tool Engine wheel holding tool:
90890-01235
3. Remove:
• Conical spring washer • One-way clutch • Washer • Fixed primary pulley wheel • Shim • Trapezoidal belt
4. Remove:
• Hub • Primary pulley wheel assembly SECONDARY PULLEY WHEEL
1. Remove:
• Nut (secondary pulley wheel)
NOTE:
Support the secondary pulley wheel using the
pulley wheel clamp .
Pulley wheel clamp:
90890-01701
2. Remove:
• Clutch drum • Secondary pulley wheel assembly • Crankcase cover gasket
• Centring devices
4-6
DISASSEMBLY THE ENGINE
ENG
3. Apply:
• Pulley wheel clamp • Nut spanner (41MM)
Pulley wheel clamp:
90890-01701
4. Loosen:
• Clutch positioning nut
ATTENTION:
Do not remove the clutch positioning nut
yet.
5. Apply:
• Clutch spring compressor Clutch spring compressor:
90890-01337
6. Remove:
• Clutch positioning nut 7. Remove:
• Clutch assembly • Clutch spring • Spring seat • Guide pins
• Secondary sliding pulley wheel
STARTER SYSTEM
1. Remove:
• Plate (intermediate gearing)
• Intermediate gearing • Starter clutch assembly • Washer
• Starter wheel gearing 2. Remove:
• Bushing • Bearing • Washer • Starter motor
4-7
DISASSEMBLY THE ENGINE
ENG
TRANSMISSION
1. Remove:
• Transmission box cover • Gasket • Centring devices NOTE:
Before proceeding to disassemble the transmission cap, empty the oil.
2. Remove:
• Main axle • Drive axle • Flat washer • Conical spring washer 3. Remove:
• Oil seal • Bearing • Secondary pulley wheel axle MAGNETIC FLYWHEEL
1. Remove:
• Nut (rotor)
• Flat washer
NOTE:
Support the rotor to loosen the nut with the
engine flywheel support tool .
Engine flywheel support tool
90890-01235
2. Remove:
• Rotor • Woodruff key
Use the magnetic flywheel extractor Magnetic flywheel extractor
90890-01362
• Stator assembly
• Gasket
4-8
DISASSEMBLY THE ENGINE
ENG
AUTOLUBRICATION PUMP
1. Remove:
• Autolubrication pump 2. Remove:
• Elastic circlip • Pump drive gearing • Pin • Elastic circlip 3. Remove:
• Carburettor gasket • Reed valve
• Reed valve gasket
CRANKCASE AND CRANKSHAFT
1. Remove:
• Oil seal catch • Screws (crankcase)
NOTE:
Loosen each screw 1/4 of a turn and remove
them after loosening them.
2. Apply:
• Crankcase separation tool Crankcase separation tool
90890-01135
NOTE:
Fully tighten the positioning nuts of the tool,
but ensure that the tool body is parallel with
the box. If necessary, slightly loosen one of
the screws to level the body of the tool.
4-9
DISASSEMBLY THE ENGINE
ENG
3. Remove:
• Crankcase (right)
While pressure is applied, strike alternatively on the engine assembly hubs.
4. Apply:
• Crankcase separation tool Crankcase separation tool
90890-01135
5. Remove:
• Crankshaft 4-10
INSPECTION AND REPAIR
ENG
INSPECTION AND REPAIR
CYLINDER HEAD
1. Eliminate:
• Carbon deposits Use a rounded scraper
2. Inspect:
• Cylinder head warping.
Outside specified value
Rectify
Steps for measuring warping and rectification:
• Join a straight edge and a thickness calibration on the cylinder head
• Measure the limit of the warping
Warping limit
0.02 mm
• If the warping is outside the specified value,
rectify the cylinder head
NOTE:
Turn the cylinder head several times to avoid
removing too much material from one side
CYLINDER AND PISTON
1. Eliminate:
• Carbon deposits Use a rounded file 2. Inspect:
• Cylinder wall Wear/striping Rectify or
change
3. Eliminate:
• Carbon deposits From the piston crown and ring grooves.
4-11
ENG
INSPECTION AND REPAIR
4. Remove:
• Cracking marks and carbon deposits on
piston sides.
5. Inspect:
• Piston wall
Wear/striping/damage Change
6. Measure:
• Cylinder piston clearance
Steps for measuring the clearance of the
cylinder piston
First step:
• Measure the lower diameter “C” with a dial
gauge.
NOTE:
Measure the inner diameter of cylinder “C” in
parallel and at right angles to the crankshaft.
Then find the mean of the measurements.
Standard
Wear
limit
40.0 mm
40.10 mm
Taper
“T”
–
0.05 mm
Eccentricity
“R”
–
0.01 mm
Inner diameter
of cylinder “C”
“C” = Maximum D
“T” = (Maximum D1 o D2) - (Maximum D5
or D6)
“R” = (Maximum D1 D3 o D5) (Maximum D2 D4 o D6)
• If this is outside the specified value, rectify
or
change the cylinder, change the piston and
the set of rings.
Second step:
• Measure the diameter of the piston skirt “P”
with a micrometer.
a 5.0 mm (0.20 in) from the inner edge of
the
piston
4-12
INSPECTION AND REPAIR
ENG
Size of the piston P
Standard
1st Clearance
2st Clearance
39.952 ~ 39.997 mm
40.25 mm
40.50 mm
• If this is outside the specified value change
the piston and the set of rings.
Third step:
• Calculate the clearance of the piston to the
cylinder using the following formula:
Clearance of piston to cylinder =
Inner diameter of cylinder “C” –
Diameter of piston skirt “P”
• If this is outside the specified value, rectify
or change the cylinder and change the piston and set of rings.
Cylinder-piston clearance
0.034 ~ 0.047 mm
Limit
0.1 mm
PISTON RINGS
1. Measurement:
• Lateral clearance Outside specified value
Change the piston and/or rings. Use
a thickness gauge .
Standard
Limit
Top ring
0.03~0.05 mm
0.10 mm
Second ring
0.03~0.05 mm
0.10 mm
2. Install:
• Piston rings on the cylinder
Press the ring and the piston crown
together.
4-13
INSPECTION AND REPAIR
ENG
3. Measure:
• Gap between ends
Outside specified value Change set
of rings.
Use a thickness gauge .
Standard
Limit
Top ring
0.15~0.35 mm
0.60 mm
Second ring
0.15~0.35 mm
0.60 mm
a Measurement point 20 mm (0.8 in)
4. Clearance of piston rings:
The size of the rings is not stamped on its
upper part.
Piston ring clearance
1st Clearance
40.25 mm
2st Clearance
40.50 mm
PISTON PIN AND PISTON PIN BEARING
1. Inspect:
Piston pin
Blue discolouring/Groove Change, then
inspect the lubrication system.
2. Measure:
• External diameter a (Piston pin clip)
Outside specified value Change
External diameter (piston pin clip)
9.996 ~ 10.00 mm
3. Measure:
• Clearance of piston pin to piston:
Outside specified value Change the
piston
Clearance of piston pin to piston=
Size of inner diameter (Piston pin) b External diameter (piston pin housing) a
Clearance of piston pin to piston
0.004 ~ 0.016 mm
Limit
0.07 mm
4-14
INSPECTION AND REPAIR
ENG
4. Inspect:
Bearing (piston pin)
Pitting/Damage Change
KICKSTART
1. Inspect:
• Pedal gear teeth • Pedal pinion gear teeth Burrs/Spalling/Non-uniformity/Wear
Change
2. Inspect:
• Locking bolt(pedal pinion gear and one
way clutch)
Rounded edges/Wear Change
3. Measure:
• Spring tension (pedal pinion gear)
Outside specified value Change
Use a dynamometer
Standard tension
150 ~ 250 gr
4-15
INSPECTION AND REPAIR
ENG
TRANSMISSION
1. Inspect:
• Drive axle • Main axle • Secondary pulley wheel axle Burrs/Spalling/Non-uniformity/Wear
Change
2. Inspect:
• Secondary pulley wheel axle bearing • Main axle bearing • Drive axle bearing Pivot the inner guide of the bearing.
Excessive play/Non-uniformity Change
Pitting/Damage Change
AUTOLUBRICATION PUMP
Internal wear or poor operation may cause
the pump to deviate from its factory adjustment. However, this is very uncommon. If
incorrect operation is suspected, inspect the
following:
1. Inspect:
• Supply line Obstruction Apply air
under
pressure
• O-ring Wear/Damage Change
2. Inspect:
• Drive gear teeth of the autolubrication
pump • Gear teeth driven by autolubrication
pump Pitting/Wear/Damage Change
CRANKSHAFT
1. Measurement:
• Deflection limit “C”
• Clearance on big end side “D”
• Limit of free play at small end of connecting rod “F”
Outside specified value Change.
Use V blocks, dial gauges and thickness
gauge.
4-16
INSPECTION AND REPAIR
ENG
Deflection limit “C”:
0.03 mm
Clearance on big end side “D”:
0.2 ~ 0.5 mm
Free play at small end “F”:
0.4 ~ 0.8 mm
2. Inspect:
• Bearings (crankshaft) Pivot the inner bearing guide.
Excessive
play/Non-uniformity
Change
Pitting/Damage Change
PRIMARY PULLEY WHEEL
1. Inspect:
• Primary sliding pulley wheel • Primary fixed pulley wheel Wear/Cracks/Striping/Damage Change
2. Check:
• Free movement Insert the bushing in the
primary sliding pulley wheel and check if
there is free movement.
If it catches or there is excessive play Change the pulley wheel or the bushing.
3. Measure:
• External diameter (roller)
Outside specified value Change.
External diameter (roller)
15.0 mm
Limit:
14,5 mm
4-17
INSPECTION AND REPAIR
ENG
SECONDARY PULLEY WHEEL
1. Inspect:
• Secondary fixed pulley wheel • Secondary sliding pulley wheel Striping/Cracks/Damage Change set.
• Oil seal Damage Change.
2. Inspect:
• Turning cam groove • Guide pin Wear/Damage Change set.
• O-ring Damaged Change.
3. Measure:
• Free length of variator spring.
Outside specified value Change
Free length of secondary pulley
wheel
109.6 mm
<Limit>
90.4 mm
4. Inspect:
• Inner surface of the clutch hub
Oil/Striping Clean
Oil
Striping
Use a cloth dampened with
dissolvent
Use sand paper (polish lightly
and uniformly)
5. Measure:
a
• Internal diameter of the clutch hub Outside specified value Change
Internal diameter of clutch hub
105.0 mm
<Wear limit>
105.4 mm
4-18
INSPECTION AND REPAIR
ENG
6. Inspect:
• Clutch shoes shiny parts
sand paper.
Polish with
NOTE:
After using sand paper, clean the polished
particles with a cloth.
7. Measure:
• Thickness of clutch shoe a
Outside specified value Change
Thickness of clutch shoe
2.0 mm
<Wear limit>
1.0 mm
TRAPEZOIDAL BELT
1. Inspect:
• Trapezoidal belt
Cracks/Wear Change
NOTE:
Replace the trapezoidal belt if it is dirty with
oil or grease.
2. Measure:
• Width of trapezoidal belt a
Outside specified value Change
Width of trapezoidal belt
16.5 mm
<Wear limit>
15.7 mm
STARTER CLUTCH AND GEARS
1. Inspect:
• Starter clutch Press the conical pin in the
direction of the arrow.
Rough operation Change the starter
clutch assembly
4-19
INSPECTION AND REPAIR
ENG
2. Inspect:
• Starter wheel gear teeth • Intermediate gear teeth Burrs/Spalling/Non-uniformity/Wear
Change
• Bearing (starter wheel gear)
Pitting/Damage Change
4-20
ASSEMBLY AND ADJUSTMENT OF ENGINE
ASSEMBLY AND ADJUSTMENT OF ENGINE
CRANKSHAFT AND CRAKCASE
Oil seal
Oil seal catch
Crankcase (right)
Centring device
Bearing
Crankcase (right)
Bearing
Crankshaft pin
Connecting rod
10 Crankcase (left)
11 Bearing
12 Engine mounting spacer
13 Crankcase (left)
14 Oil seal
CRANKSHAFT
A: 37.90 ~ 37.95 mm
C: 0.03 mm
D: 0.2 ~ 0.5 mm
F: <Limit> 1.0 mm
0.4 ~ 0.8 mm
4-21
ENG
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
CRANKSHAFT AND CRANKCASE
1. Place:
• Crankshaft installation tool
Crankshaft installation tool:
: 90890-01411
: 90890-01274
: 90890-01275
: 90890-01277
2. Install:
• Crankshaft
(in left crankcase)
3. Install:
• Centring device
• Engine mounting spacer
4. Apply:
• Yamaha N.º 1215 adhesive on the
corresponding surfaces of both halves of
the crankcase
Yamaha N. 1215 adhesive:
90890-85505
5. Place:
• Crankshaft installation tool
Crankshaft installation tool:
: 90890-01411
: 90890-01274
: 90890-01275
: 90890-01277
6. Install:
• Right crankcase
7. Tighten:
• Crankcase positioning screws
NOTE:
Tighten the crankcase positioning screws in
stages, using a crossed method for tightening.
Crankcase screws
0.9 m • kg
8. Check:
• Rotation of crankshaft
Rough turning Repair
9. Install:
• Oil seal catch plate Screw (oil seal catch plate)
0.9 m • kg
4-22
ASSEMBLY AND ADJUSTMENT OF ENGINE
AUTOLUBRICATION PUMP AND MAGNETIC FLYWHEEL
Fan
Flat washer
Rotor assembly
Charge coil
Lighting coil
Harnessing coil
Stator plate
Oil seal
Gasket
10 Oil outlet pipe
11 Oil pipe
12 Bushing
13 Autolubrication pump
14 O-ring
15 Elastic circlip
16 Oil pump drive gear
17 Pin
4-23
MOT
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
AUTOLUBRICATION PUMP
1. Install:
• Elastic circlip • Pin • Pump drive gear • Elastic circlip 2. Apply:
• Grease with lithium soap base
(on the o-ring )
3. Install:
• Autolubrication pump Screw (autolubrication pump)
0.4 m • kg
4. Apply:
• Grease with lithium soap base
(on the autolubrication pump gear , )
15 cc
FLYWHEEL MAGNETO
1. Install:
• Seal
2. Apply:
• Grease with lithium soap base
(on the oil reten )
3. Pass the wheel cable through the crankcase
orifice.
4. Install:
• Stator assembly
Screw (stator assembly)
0.8 m • kg
5. Install:
• Key
• Magnetic wheel
• Flat washer
• Nut
4-24
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
TRANSMISSION
Circlip
Bearing
Oil seal
Drive axle
Bearing
Main axle
Conical spring washer
Flat washer
Secondary pulley wheel axle
10 Bearing
11 Centring device
12 Seal
13 Transmission box cover
14 Bearing
15 Oil seal
4-25
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
6. Tighten:
• Nut (flywheel magneto)
Use the engine wheel support tool .
Engine wheel support tool
90890-01235
Flywheel nut
4.3 m • kg
TRANSMISSION
1. Apply:
• SE engine oil type 10W30
(on the transmission box cover bearing)
2. Install:
• Secondary pulley wheel axle (on transmission box cover)
3. Install:
• Circlip • Oil seal NOTE:
Apply grease with lithium soap based on the
oil seal lips.
4. Check:
• Rotation of secondary pulley wheel axle.
Rough rotation Repair.
5. Apply:
• SE type 10W30 engine oil
(on bearing of main axle and drive axle
bearing)
6. Install:
• Drive axle • Main axle
• Conical spring washer • Flat washer 7. Install:
• Gasket
• Conical pins
• Transmission box cover
Screw (box cover)
0.9 m • kg
4-26
ASSEMBLY AND ADJUSTMENT OF ENGINE
STARTER SYSTEM
Bushing
Bearing
Starter wheel gear
Starter clutch
Plate
Axle
Flat washer
Intermediate gear
O-ring
10 Starter engine
4-27
MOT
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
STARTER SYSTEM
1. Install:
• Bushing • Bearing • Starter wheel gear • Starter clutch NOTE:
• Apply grease with a lithium soap base on
the bearing .
• Apply molybdenum disulphide oil on the pin
(starter clutch) .
2. Install:
• Flat washer • Intermediate gear • Flat washer • Plate (intermediate gear)
Screw (intermediate gear plate)
0,8 m • kg
NOTE:
Apply engine oil on the intermediate gear .
3. Install:
• Starter motor Starter motor bolts
1,3 m • kg
NOTE:
Apply grease with a lithium soap base on the
o-ring of the starter motor.
4-28
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
SECONDARY AND PRIMARY PULLEY WHEEL
Nut
Clutch drum
Clutch plate
Shoe spring
Clutch spring
Spring seat
Oil seal
O-ring
Secondary sliding pulley
wheel
10 Trapezoidal belt
11 Guide pin
12 Secondary fixed pulley wheel
13 Conical washer
14 One-way clutch
15 Washer
16 Fixed primary pulley wheel
FREE LENGTH LIMIT OF VARIATOR:
83 mm
WASTE LIMIT OF CLUTCH HOUSING:
107.4 mm
WASTE LIMIT OF CLUTCH SHOES:
1.0 mm
TRAPEZOIDAL BELT WASTE LIMIT:
15.7 mm
VARIATOR ROLLER LIMIT:
14.5 mm
4-29
17 Shim
18 Hub
19 Sliding primary pulley wheel
20 Rollers
21 Runner
22 Cam
23 Washer
*: Apply assembly lube
ASSEMBLY AND ADJUSTMENT OF ENGINE
KICKSTART PEDAL
Pedal axle
Return spring
Bushing
Flat washer
Elastic retainer
Starter pedal
Spring
Pedal pinion gear
10 Nm (1.0 m • kg)
150 ~ 250 g
4-30
MOT
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
SECONDARY PULLEY WHEEL
When assembling the secondary pulley
wheel, reverse the disassembly procedure.
Remember the following points:
1. Apply:
• Assembly grease
(in the sliding/fixed pulley wheel)
2. Install:
• Sliding pulley wheel NOTE:
Take care that the lips of the oil seals do not
turn when the pulley wheel is installed.
3. Apply:
• Assembly grease
(on the torsion cam grooves and o-rings)
4. Check:
• Sliding pulley wheel.
Faulty operation Repair.
5. Install:
• Clutch positioning bolt
Use the clutch spring compressor Clutch spring compressor
90890-01337
6. Tighten:
• Clutch positioning nut
Use the pulley wheel clamp Spanner (41 MM).
Pulley wheel clamp
90890-01701
5.0 m • kg
4-31
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
7. Install:
• Conical pin
• Crankcase cover seal
• Secondary pulley wheel assembly • Clutch drum 8. Tighten:
• Nut (secondary pulley wheel)
Use the pulley wheel support Pulley wheel clamp
90890-01701
Clutch drum nut
4.0 m • kg
9. Install
• O-ring PRIMARY PULLEY WHEEL
1. Clean:
• Surface of primary sliding pulley wheel
• Surface of primary fixed pulley wheel • Hubs • Rollers • Roller races 2. Install:
• Counterbalance • Race • Runner • Hub 3. Check:
• Operation of race Rough operation Repair.
4. Install:
• Primary pulley wheel assembly • Hub 5. Install:
• Trapezoidal belt
NOTE:
The trapezoidal belt should be installed with
the arrow facing towards the front.
4-32
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
6. Install:
• Shim • Primary fixed pulley wheel • Washer • One-way clutch • Conical spring washer • Nut 7. Tighten:
• Nut (primary pulley wheel)
Primary pulley wheel nut
3,3 m • kg
NOTE:
When the nut is tightened (primary pulley
wheel), support the magnetic flywheel using
the engine wheel support tool Engine wheel support tool
90890-01235
8. Adjust:
• Trapezoidal belt
Tense the trapezoidal belt by turning the
primary pulley wheel several times
9. Install:
• Fan
Screw (fan)
0.7 m • kg
KICKSTART PEDAL
1. Install:
• Return spring • Pedal axle • Bushing • Flat washer • Elastic circlip 4-33
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
2. Hook on:
• Return spring
(on pedal gear and hub)
3. Install:
• Pedal pinion gear 4. Install:
• Crankcase cover Screw (crankcase cover)
7 Nm (0.7 m • kg)
5. Install:
• Kickstart pedal Kickstart pedal
0.9 m • kg
4-34
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
PISTON, CYLINDER AND CYLINDER HEAD
Carburettor gasket
Reed valve
Gasket
Cylinder head
Cylinder head gasket
Cylinder
Cylinder seal
Piston rings
Piston
10 Piston pin
11 Circlips
12 Bearing
SPARK PLUG
MANUFACTURER/TYPE:
NKG/BR7HS
GAP BETWEEN ELECTRODES
0.06 ~ 0.7 mm
CLEARANCE FROM PISTON TO
CYLINDER:
0.034 ~ 0.047 mm
Limit: 0.1 mm
BETWEEN ENDS (INSTALLED):
Top ring
0.15 ~ 0.35 mm
Limit:
0.60 mm
Second ring
0.15 ~ 0.35 mm
Limit:
0.60 mm
LATERAL CLEARANCE:
Top ring
0.03 ~ 0.05 mm
Limit
0.10 mm
Second ring
0.03 ~ 0.05 mm
Limit
0.10 mm
4-35
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
PISTON AND PISTON PIN
1. Apply:
• Engine oil
(in the crankshaft bearing, big end bearing, small end bearing, piston pin, piston
ring grooves and piston skirt areas.)
2. Install:
• Reed valve gasket
• Reed valve • Carburettor gasket Carburettor gasket
0.9 m • kg
3. Install:
• Small end bearing
• Piston • Piston pin • Piston circlips NOTE:
• The arrow of the piston should point to
the exhaust side.
• Before installing the piston circlip, cover the
crankcase with a towel or clean cloth so
that the circlip and other materials do not
accidentally fall into the crankcase.
• Always use new piston circlips.
CYLINDER AND CYLINDER HEAD
1. Install:
• Cylinder gasket (Use a new gasket)
2. Check:
• Piston rings
NOTE:
• Ensure that the ends of the rings are
correctly coupled around the centring devices on the piston grooves.
• Check that the manufacturers symbols or
numbers printed on the rings are on the
upper side of same.
4-36
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
3. Install:
• Cylinder NOTE:
Install the cylinder with one hand while compressing the piston rings with the other.
4. Install:
• Cylinder head gasket (new gasket)
5. Install:
• Cylinder head • Spark plug • Air protector
NOTE:
• The arrow “EX” from the cylinder head
should point to the exhaust side.
• Tighten the cylinder head positioning nuts
in several steps, using a cris-cross pattern
Cylinder head positioning screws
1.4 m • kg
spark plug
2.0 m • kg
6. Install:
• Central stand • Spring • Axle • Clasp • Rubber washer • Strap loop 7. Install:
• Brake shoes • Flat washer • Rear wheel
4-37
ASSEMBLY AND ADJUSTMENT OF ENGINE
ASSEMBLY OF ENGINE
When the engine is being assembled, reverse
the removal procedure
1. Install:
• Engine assembly bolt • Rear shock absorber bolt (lower)
MOT
Engine assembly bolt
8.4 m • kg
Rear shock absorber bolt (lower)
1.8 m • kg
2. Install:
• Carburettor
• Oil supply pipe
• Fuel pipes
• Air filter box assembly
NOTE:
• Align the projection of the carburettor with
the projections of the head
• Before installing the oil supply pipe, fill it
with oil.
3. Install:
• Oil pipe
• Oil supply pipe
NOTE:
Pass the oil supply pipe and the oil pipe
through as shown.
4. Bleed the air:
• Autolubrication pump
Consult chapter 3, section – “BLEEDING
OF AIR FROM THE AUTOLUBRICATION
PUMP”.
5. Tighten:
• Rear wheel axle nut 1
NOTE:
When the rear wheel axle nut is tightened,
apply the rear brake.
rear wheel axle bolt
12.5 m • kg
4-38
ASSEMBLY AND ADJUSTMENT OF ENGINE
MOT
6. Install:
• Silencer • Fan cover 2
Bolt (silencer)
2.6 m • kg
Bolt (exhaust pipe)
0.9 m • kg
1
7. Apply:
• Transmission oil.
See chapter 3 section - “CHANGING
TRANSMISSION OIL”.
8. Adjust:
• Free play of brake levers.
See chapter 3, section – “ADJUSTMENT
OF FREE PLAY OF FRONT/REAR
BRAKE LEVER”.
• Free play of accelerator cable See section “ADJUSTMENT OF FREE PLAY OF
ACCELERATOR CABLE”.
9. Install:
• Helmet carrier
• Overflow bowl
• Footrest
• Rear bodywork
• Rear cover
Follow the reverse process to the removal
procedure.
10. Install:
• Battery in its footrest housing
11. Connect:
• Battery cables
Positive cable + to positive terminal +
of battery
Negative cable – to negative terminal –
of battery
12. Place:
• Front cover
4-39
CARB
5
CARB
CHAPTER 5
CARBURETOR
CARBURETOR ……………………………………………………………………5-1
REMOVING THE CARBURETOR ……………………………………………5-2
DISASSEMBLING THE CARBURETOR ……………………………………5-2
CHECKING THE CARBURETOR ……………………………………………5-3
ASSEMBLING THE CARBURETOR …………………………………………5-5
CHECKING THE AUTOCHOKE UNIT ………………………………………5-6
INSTALLING THE CARBURETOR……………………………………………5-7
FUEL COCK ………………………………………………………………………5-7
CHECKING THE FUEL COCK ………………………………………………5-7
REED VALVE ………………………………………………………………………5-8
REMOVING THE REED VALVE ………………………………………………5-8
CHECKING THE REED VALVE ………………………………………………5-8
INSTALLING THE REED VALVE………………………………………………5-9
CARBURETOR
CARB
EAS00480
CARBURETOR
CARBURETOR
Pilot jet
Throttle valve spring
Spring catch
Throttle valve
Jet needle
Pilot air screw
Throttle stop screw
Needle jet
Main jet
10 Float
11 Float gasket
12 Drain screw
13 Needle valve
14 Float chamber
15 Autochoke unit
carburetor dell’orto
15
carburetor gurtner
15
13
13
10
10
11
11
14
14
12
5-1
CARBURETOR
REMOVING THE CARBURETOR
1. Remove:
• air filter box
• helmet box
Refer to “REAR BODYWORK, MUDGUARD” in chapter 3
2. Drain:
• fuel (from drain screw )
3. Disconnect:
• autochoke lead coupler • fuel hose • vacuum hose • oil delivery hose • throttle cable (with throttle valve) • clamp (fixing clip) CARB
4. Remove:
• carburetor
DISASSEMBLING THE CARBURETOR
1. Remove:
• float chamber 2. Remove:
• float pin • float • needle valve 3. Remove:
• pilot jet • main jet • needle jet 5-2
CARBURETOR
CARB
4. Remove:
• throttle stop screw (with spring,
washer and o-ring)
• pilot air screw (with spring)
5. Remove:
• spring seat • jet needle • throttle valve • throttle valve spring
EAS00485
CHECKING THE CARBURETOR
1. Check:
• carburetor body Dirty Clean
NOTE:
For cleaning, use a petrol based solvent. Clean
the pipes and jets with compressed air
2. Check:
• main jet • needle jet • pilot jet Dirty Clean
3. Check:
• needle valve Wear/Dirty Clean
• float Damage Change
• gasket Damage Change
5-3
CARBURETOR
CARB
4. Check:
• throttle valve Wear/Damage Change
5. Check:
• throttle valve displacement
Irregular movement/Catches Change
Insert the throttle valve in the body and check its displacement.
6. Check:
• throttle stop screw • pilot air screw • jet needle • starter plunger Wear/Damage Change
7. Measure:
• Float height a
Outside specifications
float and valve seat
Check valve,
Float height a
15.0 mm ~ 17.0 mm
Steps for measuring the height of the float:
• Assemble the valve, float and axle on the
carburettor body
• Turn the carburettor upside down
• Using a vernier caliper, measure the distance
between the plane of the bowl gasket (without the gasket) and the upper part of the
float.
5-4
CARBURETOR
CARB
NOTE:
The arm of the float should be supported on
the valve without compressing it.
• If the height of the float is not within the specified limits, inspect the valve and its seat.
• Substitute both parts if any part of them is
worn.
• If both are in good condition, replace the
float.
• Check the height of the float again.
NOTE:
The height of the float is adjusted in the factory. Do not try to modify it under any circumstances.
EAS00487
ASSEMBLING THE CARBURETOR
The assembly of the carburetor is carried out
following the reverse procedure to “DISASSEMBLY”. Bear in mind the following points:
CAUTION:
• Before assembling the carburetor, wash
all of the parts in a petroleum-based solvent.
• Always use new gaskets.
1. Install:
• jet needle • clip • throttle valve • spring seat
• spring
Jet needle clip position:
3/5 (Dell’orto)
2/3 (Gurtner)
1/3 (Mofa Version)
2. Install:
• throttle valve NOTE:
Align the groove with the carburetor projection .
5-5
CARB
CARBURETOR
EAS00503
CHECKING THE AUTOCHOKE UNIT
NOTE:
When checking the autochoke unit, the
ambient temperature must be lower than 45°C
(113°F).
1. Remove:
• carburetor
2. Check:
• autochoke unit
a. Connect a 3.3 mm hose to the starter air
passage and blow into the hose.
NOTE:
When the starter plunger is open, air should
come out of the other side of the starter air
passage.
Starter plunger
opens
Perform step (3)
Starter plunger
closes
Replace the autochoke unit.
3. Check:
• autochoke unit
a. Connect the autochoke unit leads to a
12.0 V battery for five minutes.
Positive batter lead yellow/red
Negtive battery lead black
b. Connect a 3.3 mm hose to the starter air
passage and blow into the hose.
Starter plunger
opens
Replace the autochoke unit.
Starter plunger
closes
Autochoke is OK.
5-6
CARBURETOR/ FUEL COCK
CARB
EAS00492
INSTALLING THE CARBURETOR
1. Adjust:
• engine idling speed
Engine idling speed
1.800 rpm
Refer to “ADJUSTING HE ENGINE IDLING
SPEED” in chapter 3.
2. Adjust:
• throttle cable free play
Throttle cable free play (at the
flange of the throttle grip)
2 ~ 5 mm
Refer to “ADJUSTING HE ENGINE IDLING
SPEED” in chapter 3.
EAS00505
FUEL COCK
CHECKING THE FUEL COCK
1. Stop the engine.
2. Remove:
• helmet box
Refer to chapter 3, “REAR BODYWORK,
MUDGUARD” section.
3. Inspect:
• fuel cock
Steps for inspecting fuel cock:
• Disconnect the fuel hose • Place a receptacle under the end of the fuel
hose.
• Disconnect the vacum hose and suction
to create a vacuum
• If the fuel comes out of the fuel hose as a
result of applying a vacuum and stops when
the vacuum is stopped, the cock is in good
condition. If not, clean or replace the vacuum
hose, the fuel hose and cock.
5-7
REED VALVE
CARB
REED VALVE
REMOVING THE REED VALVE
1. Remove:
• helmet box
Refer to “REAR BODYWORK, MUDGUARD” in chapter 3.
• air filter box assembly 2. Remove:
• carburetor
See section “REMOVING THE CARBURETOR”
3. Remove:
• carburetor joint • reed valve assembly
CHECKING THE REED VALVE
1. Inspect:
• carburetor joint
Damage/Cracks Change
• reed valve
Fatigue/Cracks Change
Inspection steps:
• Visually inspect the reed valve.
• If there is any doubt on how to seal, apply
suction on the carburettor side.
• Leaks should be light or moderate.
5-8
REED VALVE
CARB
2. Measure:
• valve stopper height Out of specification Adjust the stopper/Replace the valve stopper.
Height of valve stopper 6.0 ~ 6.4 mm
3. Measure:
• clearance of reed valve Out of specification Replace the reed
valve.
Clearance of reed valve Less than 0.2 mm
INSTALLING THE REED VALVE
When the reed valve assembly is installed,
reverse the removal procedure. Bear in mind
the following points.
1. Install:
• gasket New
2. Tighten:
• tighten the bolts for reed valve
Reed valve
11 Nm (1.1 m • kg)
NOTE:
Tighten each bolt gradually to avoid it being
deformed.
5-9
CHAS
6
CHAS
CHAPTER 6
CHASSIS
FRONT WHEEL …………………………………………………………………6-1
EXTRACTION …………………………………………………………………6-2
INSPECTION……………………………………………………………………6-2
INSTALLATION …………………………………………………………………6-3
REAR BRAKE ……………………………………………………………………6-4
CHANGE OF BRAKE BLOCKS ………………………………………………6-5
DISASSEMBLY OF CALLIPER ………………………………………………6-6
INSPECTION AND REPAIR …………………………………………………6-7
ASSEMBLY OF CALLIPER ……………………………………………………6-7
ASSEMBLY OF PUMP ………………………………………………………6-8
REAR WHEEL ……………………………………………………………………6-9
EXTRACTION …………………………………………………………………6-10
INSPECTION …………………………………………………………………6-10
ASSEMBLY ……………………………………………………………………6-11
INSTALLATION ………………………………………………………………6-12
REAR FORK ……………………………………………………………………6-13
EXTRACTION …………………………………………………………………6-14
DISASSEMBLY ………………………………………………………………6-14
INSPECTION …………………………………………………………………6-15
ASSEMBLY ……………………………………………………………………6-16
INSTALLATION ………………………………………………………………6-18
HANDLEBAR AND STEERING ………………………………………………6-19
REMOVAL ……………………………………………………………………6-20
INSPECTION …………………………………………………………………6-21
INSTALLATION ………………………………………………………………6-22
FRONT WHEEL
CHASSIS
FRONT WHEEL
Tyre
Oil seal
Spacer
10 Nut
11 Washer
Wheel axle
Speedometer gear unit
Bearing
Spacer
Hub
Rim assembly
TYRE SIZE:
120/70/12
RIM RUN-OUT LIMIT:
Vertical: 1.0 mm
Lateral: 1.0 mm
WHEEL AXLE BEND LIMIT:
0.25 mm
6-1
CHAS
FRONT WHEEL
CHAS
REMOVAL
1. Remove:
• brake caliper • Axle • Wheel
NOTE:
Do not press the brake lever when the wheel
is removed from the scooter, otherwise the
brake blocks will be closed under force.
INSPECTION
1. Measure:
• Bend of wheel axle
Outside specified value
Change
Bend limitof wheel axle
0.25 mm
s WARNING
Do not try to straighten a bent axle
2. Measure:
• Run out of wheel
Outside specified value
Change
Run-out limit:
Vertical: 1.0 mm
Lateral: 1.0 mm
3. Inspect:
• Wheel Cracks/Marked/Deformed Change
4. Inspect:
• Wheel bearings
Bearings allow play on the wheel hub or
the wheel turns abruptly Change
5. Inspect:
• Speedometer gear unit Wear/Damage Change
6-2
FRONT WHEEL
CHAS
INSTALLATION
Reverse the removal process. Bear in mind the
following points.
1. Lubricate:
• Front wheel axle
• Bearings
• Oil seal (edges)
• Drive gear (speedometer)
Recommended lubricant:
Grease with lithium soap base
2. Install:
• Speedometer gear unit NOTE:
Ensure that the two projections in the gear
unit are engaging with the flat surface of the
gear unit.
3. Install:
• Front wheel
NOTE:
Ensure that the projection (torsion stopper) of the casing of the gear unit is correctly
positioned.
4. Tighten:
• Front wheel axle:
Front wheel axle:
4.8 m • kg
s WARNING:
Ensure that the brake pipe is correctly
positioned.
6-3
FRONT BRAKE
FRONT BRAKE
Master cylinder cap
Retaining bolt
Bleed screw
Calliper assembly
Block spring
Pad set
Piston seal
Piston
Brake disc
10 Diaphragm
11 Hose
12 Brake pump assembly
13 Assembly plate
14 Copper washer
15 Assembly bolt
16 Brake light switch cable
TYPE OF BRAKE FLUID
DOT 3 or 4
WEAR LIMIT OF BRAKE PADS:
0.8 mm
WEAR LIMIT OF BRAKE DISC:
3.0 mm
6-4
CHAS
FRONT BRAKE
CHAS
EAS00583
REPLACING THE FRONT BRAKE PADS
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose or
disassemble the brake caliper.
1. Remove:
• brake pad cover • brake pad clip • brake pad pin • brake pad spring 2. Remove:
• brake pads (along with the brake pad shims )
3. Measure:
• brake pad wear limit a
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm
4. Install:
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
a
a. Connect a clear plastic hose tightly to
the bleed screw . Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 m• kg)
d. Install a new brake pad shim onto each
new brake pad .
a
6-5
FRONT BRAKE
CHAS
NOTE:
a on the brake pad shim
The triangle mark must point in the direction of disc rotation.
e. Install new brake pads and a new brake
pad spring .
b
NOTE:
b of the brake pad spring
The arrow mark must point in the direction of disc rotation.
5. Install:
• brake pad pins
• brake pad clips
• brake pad cover
6. Chek:
• brake fluid level
Below the minimum level mark Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
REMOVING THE BRAKE HOSE
NOTE:
Before replacing the brake hose, drain the
brake fluid from the entire brake system.
1. Remove:
• union bolt • copper washers • brake hose NOTE:
To collect any remaining brake fluid, place a
container under the end of the brake hose.
6-6
FRONT BRAKE
CHAS
CHECKING THE BRAKE HOSE
1. Check:
• brake hoses cracks/damage/wear Replace.
BRAKE HOSE ASSEMBLY
s WARNING
• All internal parts should be cleaned only
in new brake fluid.
• Internal parts should be lubricated with
brake fluid when installed.
Recommended brake fluid
DOT 4
2
3
1. Install:
• Brake hose • Copper washers • Assembly bolts • Brake switch 1
Assembly bolt:
2.3 m • kg
4
s WARNING
• The correct positioning of the hose is
essential to ensure the safe operation of
the scooter. See “CABLE ROUTING”.
• Always use new copper washers.
2. Ensure that the brake hose does not touch
other parts (accelerator cable, installation,
cables, etc.) by turning the handlebar to the
left and right. If it does touch, correct this.
6-7
FRONT BRAKE
CHAS
CHECKING THE BRAKE DISC
1. Measure:
• Deflection of brake disc
Outside specified value Inspect runout of wheel.
If the wheel is in good condition, change
the brake disc
Maximum deflection
0.5 mm
• Brake disc thickness
Outside specified value
Minimum thickness
3.0 mm
Bolt (brake disc)
2.0 m • kg
LOCTITE®
6-8
Change
REAR WHEEL
CHAS
REAR WHEEL
Flat washer
Valve
Nut
Flat washer
Return spring
Brake shoe
Brake cam
Shoe axle
Wear indicator
10 Brake lever
TYRE SIZE:
130/70-12
BRAKE DRUM WEAR LIMIT:
110.5 mm
BRAKE SHOE WEAR LIMIT:
2.0 mm
WHEEL RUN-OUT LIMIT:
Vertical: 1.0 mm
Lateral: 1.0 mm
Change:
Brake shoes and return
spring as a set
6-9
REAR WHEEL
CHAS
REMOVAL
1. Remove:
• Exhaust pipe assembly
2. Loosen:
• Rear axle nut NOTE:
When the axle nut is loosened, apply rear
brake.
3. Remove:
• Rear wheel
4. Remove:
• Rear brake cable • Brake shoes • Flat washer INSPECTION
1. Inspect:
• Wheel
See “INSPECTION OF REAR WHEEL”
section
2. Measure:
• Wheel run-out
See “INSPECTION OF REAR WHEEL”
section
Rim run-out limits:
Vertical: 1.0 mm
Lateral: 1.0 mm
3. Check:
• Wheel bearings Consult the “INSPECTION OF REAR WHEEL” section
4. Inspect:
• Brake shoes Crystallisation
with sand paper.
Polish
NOTE:
After using sand paper, clean the polished
particles with a cloth.
6-10
REAR WHEEL
CHAS
5. Measure:
• Thickness of brake shoes a
Outside specified value Change
Brake shoes thickness
4.0 mm
Limit: 2.0 mm
6. Inspect:
• Drum brake iner surface
Oil/Scratches Change
7. Measure
• Drum brake inner diameter a:
Out of specification Change
Wear limit of brake drum
110.5 mm
ASSEMBLY
When the brake shoe carrier plate is assembled, reverse the removal procedure.
Bear in mind the following points.
1. Install:
• Brake cam 2
NOTE:
Apply Grease with a lithium soap base on the
brake camand pin .
1
ATTENTION:
After installing the brake cam, remove
excess grease.
2. Install:
• Brake shoes • Return spring 1
3
NOTE:
Install with the mark outwards.
2
3. Install:
• Torsion spring • Wear indicator • Cam lever 1
NOTE:
2
3
• Align the projection of the wear indicator with the line as shown.
• Align the punch marks .
4
6-11
REAR WHEEL
CHAS
Bolt (cam lever):
0.7 m • kg
4. Install:
• Flat washer • Brake cable
INSTALLATION
When installing the rear wheel, reverse the
removal procedure.
The following points should be remembered.
1. Install:
• Rear wheel
• Flat washer • Nut Nut (Rear wheel axle):
12.5 m • kg
2. Install:
• Silencer
Bolt (exhaust pipe side):
0.9 m • kg
Bolt (silencer side):
2.6 m • kg
3. Adjust:
• Free play of rear brake lever
See section in chapter 3 “CHECKING
FREE PLAY OF REAR BRAKE LEVER”.
6-12
FRONT FORK
CHAS
FRONT FORK
Front fork assembly (left)
Rubber cap
Restraining ring
Restraining ring
Cap
O-ring
Dust guard
Retainer
Oil seal
10 Fork spring
11 Sliding metal
12 Shock absorber rod
13 Return spring
14 Bar
15 Oil lock piece
16 Outer tube
17 Front fork assembly (right)
FREE LENGTH OF FORK SPRING:
LIMIT:
LEFT 226 mm
RIGHT 226 mm
FORK OIL CAPACITY:
50 cc ± 1 cc
GRADE:
10 W oil fork or equivalent
6-13
FRONT FORK
CHAS
REMOVAL
1. Place the scooter on its central stand and
place an adequate support under the engine
2. Remove:
• Brake callipers
Consult “FRONT BRAKE REMOVAL” section
3. Remove:
• Front wheel
See “FRONT WHEEL REMOVAL SECTION”
4. Remove:
• Mudguard, front fairing
See chapter 3 “FRONT BODYWORK,
MUDGUARD”
1
5. Loosen:
• Positioning bolt (fork)
6. Remove:
• Restraining ring • FRONT FORK 2
3
DISASSEMBLY
1. Remove:
• Rubber cap
• Restraining ring • Cap
• Fork spring
2. Drain:
• Fork oil
3. Remove:
• Mudguard
• Retainer 6-14
CHAS
FRONT FORK
4. Remove:
• Bolt (shock absorber rod) • Copper washer
NOTE:
Remove the bolt (shock absorber rod) while
the shock absorber rod is held with the Thandle and a support T-handle:
90890-01326
Support:
90890-01294-A
5. Remove:
• Inner pipe
• Shock absorber rod
• Oil lock piece (left side)
• Oil seal
INSPECTION
1. Inspect:
• Fork bar
• Outer tube
• Shock absorber rod
Striping/Warping/Wear/Damage
Change
s WARNING
Do not try to straighten a fork bar or an
outer tube as this may dangerously weaken the tube.
2. Measure:
• Fork spring
Above specified limit
Change
Free length of fork spring (limit) :
Left 226 mm
Right 226 mm
3. Inspect:
• Oil lock piece
• O-ring (cover)
Wear/Damage Change
6-15
FRONT FORK
CHAS
ASSEMBLY
Reverse the disassembly procedure. Bear in
mind the following points.
NOTE:
• When assembling the fork, ensure that the
following new parts are used.
• Oil seal
• Mudguard
• Sliding metal
• Ensure that all components are clean before
assembly.
1. Install:
• Shock absorber rod
• Oil lock piece (left side)
• Bar • Copper washer (new)
• Bolt (shock absorber rod) Bolt (hydraulic rod):
23 Nm (2.3 m • kg, 17 • lb)
LOCTITE®
NOTE:
Tighten the bolt (hydraulic rod) while supporting the bar with the T-handle and the support .
T-handle:
90890-01326
Support:
90890-01294-A
2. Install:
• Oil seal Use a counterbalance for installing fork
seals and an adaptor .
Counterbalance for installing oil
seals:
90890-01184
Adaptor:
90890-01186
NOTE:
Before installing the oil seal, apply grease
with a lithium soap base on the edges of
same.
ATTENTION:
Ensure that the numbered side of the seal
is facing upwards.
6-16
FRONT FORK
CHAS
3. Install:
• Retainer • Dust guard
NOTE:
Couple the retainer correctly on the groove of
the outer tube .
4. Fill :
• Fork oil
Each fork:
50 cm3
10 W fork oil or equivalent after
filling, slowly pump the fork to
distribute the oil.
Oil level:
95 mm
From the upper part of the inner
fork tube totally compressed without the spring.
NOTE:
Place the fork in a vertical position.
5. Install:
• Fork spring
• Cover
• Restraining ring
• Rubber cap
NOTE:
• Before installing the cover, apply grease to
the o-ring.
• Couple the restraining ring correctly on the
inner tube groove.
6-17
FRONT FORK
CHAS
INSTALLATION
Reverse the removal procedure.
The following points should be remembered
1. Install:
• Front fork:
• Stopper ring
NOTE:
Attach the stopper ring correctly on the inner
tube groove.
2. Tighten:
• Positioning bolt (lower bracket)
Positioning bolt (inner lever arm)
30 Nm (3.0 m • kg, 22 ft • lb)
3. Install:
• Front wheel
• Brake calliper
• Clasp (brake hose)
• Speedometer cable
See “FRONT WHEEL” section
• Front mudguard
See chapter 3, section “FRONT BODYWORK MUDGUARD”
Wheel axle
48 Nm (4.8 m • kg, 35 ft • lb)
6-18
HANDLEBAR AND STEERING
CHAS
HANDLEBAR AND STEERING
11 Lock washer
12 Center ring nut
13 Rubber washer
14 Lower ring nut
15 Bearing cover
16 Upper bearing race
17 Bearing cage
18 Bearing race
19 Lower bracket
Handlebar
Grip cap
Throttle grip
Throttle grip guide
Grip
Nut
Bolt
Throttle cable
Brake cable
10 Upper ring nut
10
11
13
15
17
16
18
12
14
16
18
17
19
6-19
HANDLEBAR AND STEERING
CHAS
REMOVAL
1. Place the scooter on its central stand and
place a suitable support under the engine.
2. Remove:
• Front wheel
See section “REMOVAL OF FRONT
WHEEL”
3. Remove:
• Mudguard
• Front fairing
See chapter 3,“FRONT BODYWORK,
MUDGUARDS” section.
4. Remove:
• Handlebar covers See chapter 3 “HANDLEBAR COVER” section
NOTE:
Before completely removing the rear cover
with the speedometer, disconnect the speedometer cable and the signalling and lighting
system cables.
5. Remove:
• Front fork
See “REMOVAL OF FRONT FORK” section
6. Remove:
• Brake pump support
• Brake pump.
• Throttle grip
2
1
7. Remove:
• Flange (electrical installation)
1
6-20
HANDLEBAR AND STEERING
CHAS
8. Remove:
• Upper ring nut
Ring nut wrench for steering
90890-01403
s WARNING
Support the steering axle so that it does
not fall.
9. Remove:
• Lock washer
• Central ring nut
• Rubber washer
• Lower ring nut
• Bearing cover
• Lower bracket
INSPECTION
1. Wash the bearing and race with solvent.
2. Inspect:
• Bearings
• Bearing race
Pitted/Damage Change
Steps for replacing the bearing race:
• Remove steering bearing races using a long
rod and the hammer as shown.
• Remove the bearing race from the shaft
using a chisel and the hammer as
shown.
• Install the new mudguard and the guides.
6-21
HANDLEBAR AND STEERING
CHAS
NOTE:
• Always change the bearing and the races
together.
• Change the mudguard whenever the steering head is disassembled.
ATTENTION:
If the bearing race is not coupled correctly,
the steering tube may be damaged.
3. Inspect:
• Lower lever arm (with steering rod)
Cracks/Damage Change
4. Inspect:
• Handlebar Cracks/Damage
Change
s WARNING
Do not try to straighten a bent handlebar
since this can weaken it dangerously.
INSTALLATION
Reverse the steps for disassembly and removal. The following points should be remembered
1. Apply:
• Wheel bearing grease
(on upper bearings and lower bearings.)
2. Install:
• Lower bracket • Lower ring nut • Rubber washer • Central ring nut • Lock washer • Upper ring nut ATTENTION:
Support the steering column until it is in
position.
6-22
HANDLEBAR AND STEERING
CHAS
3. Tighten:
• Steering nut
Steps for tightening the steering nut:
1. Tighten the lower ring nut to 3.8 m•kg.
2. Loosen the lower ring nut 1/2 of a turn
and tighten to 0.65 m•kg.
3. Check the steering for smooth operation.
4. Install rubber washer .
5. Install central ring nut and hand tighten
untill the lower and central ring nuts slots
allignet.
6. Install the lock washer .
7. Supporting the lower and central ring nuts,
install and thigten the upper ring nut to 7.5
m•kg.
4. Install:
• Handlebar • Bolt • Nut
NOTE:
Match up the bolt on the tooth of the steering column .
Bolt (handlebar)
4.3 m • kg
5. Install:
• Flange
NOTE:
Support electrical installation
6. Apply:
• Grease with lithium soap base
(on the end of the accelerator cable and
right end of the handlebar.)
6-23
HANDLEBAR AND STEERING
CHAS
7. Install:
• Brake pump 1
NOTE:
First tighten the upper bolt, then the lower
bolt.
Bolt (brake pump)
0.9 m • kg
8. Install:
• Rear handlebar cover with speedometer
• Front handlebar cover
NOTE:
Connect the speedometer cables, signalling
and lighting systems.
ATTENTION:
Situate the speedometer cable through its
housing in the rear cover.
9. Install:
• Front fork
See “INSTALLATION OF FRONT FORK
SECTION”.
10. Install:
• Front wheel
See section “INSTALLATION OF FRONT
WHEEL”
6-24
ELEC
7
ELEC
CHAPTER 7
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS …………………………………………………7-1
IGNITION AND STARTER SYSTEM……………………………………………7-3
CIRCUIT DIAGRAM ……………………………………………………………7-3
IGNITION AND STARTER CIRCUIT SYSTEM ………………………………7-4
TROUBLESHOOTING …………………………………………………………7-5
CHARGING SYSTEM …………………………………………………………7-10
CIRCUIT DIAGRAM …………………………………………………………7-10
LOCATION AND REPAIR OF FAULTS ……………………………………7-11
LIGHTING SYSTEM ……………………………………………………………7-13
CIRCUIT DIAGRAM …………………………………………………………7-13
LOCATION AND REPAIR OF FAULTS ……………………………………7-14
CHECKING OF LIGHTING SYSTEM ………………………………………7-15
SIGNALLING SYSTEM …………………………………………………………7-17
CIRCUIT DIAGRAM …………………………………………………………7-17
LOCATION AND REPAIR OF BREAKDOWNS ……………………………7-18
CHECKING OF SIGNALLING SYSTEM ……………………………………7-19
ELECTRICAL COMPONENTS
ELEC
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
Wire harness
Starter motor
CDI unit
Engine oil level gauge
Starter relay
Fuel level gauge
Battery
Ignition coil
BATTERY
SPECIFIC GRAVITY: 1,280
IGNITION COIL:
PRIMARY COIL RESISTANCE:
0.56 ~ 0.84 Ω at 20 °C (68 °F)
SECONDARY COIL RESISTANCE:
5.7 ~ 8.5 Ω at 20 °C (68 °F)
7-1
ELECTRICAL COMPONENTS
Main switch/seat lock
Turn signal relay
Rectifier/regulator
Horn
7-2
ELEC
IGNITION AND STARTER SYSTEM
IGNITION AND STARTER SYSTEM
CIRCUIT DIAGRAM
. CDI magneto
. CDI
. Spark plug
. Main switch
. Fuse
. Battery
. Starter relay
10 .
11 .
24 .
25 .
34 .
7-3
Starter motor
“START” switch
Front brake switch
Rear brake switch
Ignition coil
ELEC
ELEC
IGNITION AND STARTER SYSTEM
SISTEMA DE ENCENDIDO Y ARRANQUE
11 Starter switch
12 Main switch
18 Front brake switch
19 Rear brake switch
B Pick-up coil
G To oil level switch
Spark plug
Ignition coil
CDI unit
Starter motor
Starter relay
Fuse
10 Battery
INDUCED COIL RESISTANCE:
0.05 ~ 0.06 _ at 20 °C (68 °F)
BRUSH WEAR LIMIT:
0.9 mm
COMMUTATOR WEAR LIMIT:
16.6 mm
MICA LOWER CUT-OFF:
1.35 mm
0
DC
W/L
CDI
B
UNIT
B
B
Br
B
LOCK
B/W
OPEN
OFF
CHECK
ON
B/W
G
B
R
Current which flows in the ignition control circuit
Current which flows in the starter motor control circuit
7-4
Br
IGNITION AND STARTER SYSTEM
ELEC
TROUBLESHOOTING
IF THE IGNITION SYSTEM IS NOT OPERATING
(NO SPARK OR INTERMITTENT SPARK)
NOTE:
• Remove the following parts before carrying out the repair of fault .
1) Side covers (right and left)
2) Rear cover
3) Footrest panel
• Use the following special tools to repair faults.
Ignition tester:
90890-06754
Pocket tester:
90890-03112
Standard spark plug
BR7HS (NGK)
1. Spark plug
• Check spark plug conditions.
• Check type of spark plug.
• Check distance between electrodes .
Consult chapter 3 “INSPECTION OF
SPARK PLUG”
Distance between electrodes
0.6 ~ 0.7 mm
INCORRECT
CORRECT
Defective spark plug, change or adjust the
distance between the electrodes
2. Gap of the ignition spark plug
• Disconnect the spark plug pipe from the
spark plug.
• Connect the ignition tester as shown.
Spark plug pipe
Spark gap
• Check spark gap
• Start the engine and increase the spark
jump until ignition fails.
Minimum spark gap:
6.0 mm
SATISFIES THE SPECIFIED VALUE
OUTSIDE
SPECIFIED
VALUE OR
NO SPARK
The ignition system is in good condition.
7-5
IGNITION AND STARTER SYSTEM
ELEC
3. Spark plug cap resistance
• Remove spark plug cap
• Connect the pocket tester (Ωx1k) on the
spark plug cap.
• Check if the spark plug pipe has the specified resistance
Resistance of spark plug:
5 kΩ at 20 °C (68 °F)
SATISFIES
THE
SPECIFIED
VALUE
OUTSIDE SPECIFIED VALUE
Replace the spark plug cap
4. Resistance of ignition coil
• Disconnect the ignition coil cables.
• Connect the pocket tester (Ωx1) on the
ignition coil .
Ignition coil:
Cable (+) of tester Terminal +
(orange)
Cable (–) of tester Terminal –
(ground)
• Check if the primary coil has the specified
resistance.
Primary coil resistance:
0.56 ~ 0.84 Ω at 20 °C (68 °F)
• Connect the pocket tester (Ωx1k) on the
ignition bobbin.
Cable (+) of tester Cable of spark
plug
Cable (–) of tester Ground
• Check if the secondary coil has the specified resistance.
Secondary coil resistance:
5.7 ~ 8.5 kΩ at 20 °C (68 °F)
(Spark plug cable - Coil cable)
OUTSIDE SPECIFIED VALUE
BOTH SATISFY
THE SPECIFIED
VALUE
The ignition coil is defective, replace it
7-6
IGNITION AND STARTER SYSTEM
ELEC
5. Pick up coil resistance
• Disconnect the Pick up coil coupler of the
installation
• Connect the pocket tester (Ωx100) on the
pick up coil terminal.
Cable (+) of tester White blue
Cable (–) of tester Black
• Check if the pick up coil has the specified
resistance.
OUTSIDE SPECIFIED VALUE
Resistance of harnessing coil
250 ~ 370 Ω at 20 °C (68 °F)
The pick up coil is defective, replace it
SATISFIES
THE SPECIFIED VALUE
6. Connections
Check the connections throughout the ignition system for connections.
Consult the “ELECTRICAL DIAGRAM”section
Correct
CORRECT
Replace the CDI unit.
7-7
IGNITION AND STARTER SYSTEM
ELEC
THE STARTER MOTOR DOES NOT FUNCTION
NOTE:
• Remove the following parts before repairing the faults.
1) Side covers (right and left)
2) Rear cover
3) Front mudguard
4) Handlebar cover (upper)
• Use the following special tool for these repairs.
Pocket tester:
90890-03112
1. Fuse
• Remove the fuse.
• Connect the pocket tester (Ωx1) on the
fuse.
• Check the fuse to see if there is continuity.
NO CONTINUITY
The fuse is defective
CONTINUITY
2. Battery
• Check the conditions of the battery.
Consult the “INSPECTION OF THE BATTERY” section in chapter 3.
INCORRECT
• Clean the battery terminals
• Recharge or change battery.
Open circuit voltage:
12.8 V or more at 20 °C (68 °F)
CORRECT
s WARNING:
• The bridge cable should have the same
capacity as the cable or more, otherwise
the cable may burn .
• This composition may cause sparks, as a
result, ensure that there are no gases or
inflammable liquids in the area.
3. Starter motor
• Connect the positive terminal of the battery
and the starter motor cable using a
bridge cable *
STARTER MOTOR DOESN’T TURN
• Check the operation of the starter motor.
STARTER MOTOR
TURNS
The starter motor is defective, repair or
change.
7-8
IGNITION AND STARTER SYSTEM
ELEC
4. Starter relay
• Disconnect the starter relay cable from the
installation.
• Connect the battery to the starter relay
cables as shown using the bridge cables
.
• Check the operation of the starter motor.
INCORRECT
The main switch is defective, change.
DOES MOVE
5. Main switch
• Disconnect the coupler of the main switch
from the installation.
• Check the switch component to see if
there is continuity between “Red and
Brown ”.
DOESN’T MOVE
The starter relay is defective, change
CORRECT
6. Starter switch
• Disconnect the coupler of the handlebar
switch (right) from the installation.
• Check the starter switch component to see
if there is continuity between “Blue/White
and Black ”
INCORRECT
The starter switch is defective, change the
handlebar switch (right).
CORRECT
7. Connections
BAD CONNECTION
• Check the connections throughout the ignition system.
See the “ELECTRICAL DIAGRAM”
Correct
7-9
CHARGING SYSTEM
CHARGING SYSTEM
CIRCUIT DIAGRAM
Flywheel Magneto
Fuse
Battery
Rectifier/Regulator
7-10
ELEC
CHARGING SYSTEM
ELEC
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED
NOTE:
• Remove the following parts before carrying out the repair of the fault.
1) Side covers (right and left)
2) Rear cover
• Use the following special tool for this repair.
Inductive tachometer:
90890-03113
Pocket tester:
90890-03112
1. Fuse (main)
• Remove the fuse.
• Connect the pocket tester (Ωx1) to the
fuse.
• Check the fuse to see if there is continuity
NO CONTINUITY
The fuse is defective, change.
CONTINUITY
2. Battery
INCORRECT
• Check the condition of the battery.
See chapter 3, section “INSPECTION OF
THE BATTERY”.
Open circuit voltage:
12.8 V or more at 20 °C (68 °F)
• Clean the battery terminals
• Recharge or change the battery.
CORRECT
3. Charging voltage
• Connect the inductive tachometer on the
spark plug cable
• Connect the pocket tester (20 V CC) on the
battery.
Cable (+) of the tester Terminal (+)
Cable (–) of the tester Terminal (–)
• Start the engine and accelerate to 5,000
rpm/min.
• Check charging voltage.
SATISFIES THE SPECIFIED VALUE
Charging voltage:
14 ~ 15 V at 5,000 rpm/min.
NOTE:
The charging circuit is in good condition.
Use a fully charged battery.
OUTSIDE SPECIFIED VALUE
7-11
CHARGING SYSTEM
ELEC
4. Charge coil resistance
• Disconnect the charge coil coupler from the
installation.
• Connect the pocket tester(Ωx1) on the
charge coils.
• Measure the resistances of the charge coil.
Cable (+) of the tester White cable Cable (–) of tester Yellow/Red Cable Charge coil resistance:
0,288 ~ 0.432 Ω at 20 °C (68 °F)
OUTSIDE SPECIFIED VALUE
SATISFIES THE
SPECIFIED VALUE
The charge coil is defective, change
5. Connections
Check the connections throughout the ignition system.
Consult the “ELECTRICAL DIAGRAM” section.
BAD CONNECTION
Correct.
GOOD
Change the rectifier/regulator
7-12
LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM
Flywheel
14 Light dinmer switch
16 Headlamp
21 Brake and rear light
27 Meter light
7-13
ELEC
LIGHTING SYSTEM
ELEC
TROUBLESHOOTING
HEADLAMP, “HIGH BEAM” LIGHT INDICATOR, REAR LIGHT
AND/OR METER LIGHT DO NOT LIGHT UP
NOTE:
• Remove the following parts before repairing the faults.
1) Side covers (right and left)
2) Rear cover
3) Handlebar cover (upper)
• Use the following special tool for these repairs.
Pocket tester:
90890-03112
1. Light switch “k j”
• Disconnect the coupler of the main switch
(left) from the installation.
• Place the switch “k j” in position “j”.
• Check the switch component to see if
there is continuity between “Blue/Yellow”
and “Blue/Green ”.
INCORRECT
correct
The “LIGHTS” switch (intensity control) is
defective, Change the handlebar switch
(left).
2. Resistance of the lighting coil
• Disconnect the lighting coil coupler from
the installation
• Connect the pocket tester (Ωx1) on the
lighting coils.
• Measure the resistances of the lighting coil.
Cable (+) of tester Yellow/Red Cable (–) of tester Ground OUTSIDE SPECIFIED VALUE
Lighting coil resistance:
0,176 ~ 0,264 Ω at 20 °C (68 °F)
The lighting coil is defective, change.
SATISFIES THE
SPECIFIED VALUE
7-14
LIGHTING SYSTEM
ELEC
3. Connections
Check the connections throughout the lighting system.
See “ELECTRICAL DIAGRAM” section
BAD CONNECTION
Correct
CORRECT
The circuit is in good condition
CHECKING LIGHTING SYSTEM
1. The headlight does not light
NO CONTINUITY
1. Bulb and bulb holder
• Check the bulb and bulb holder to see if
there is continuity.
Replace the bulb and/or bulb holder.
CONTINUITY
2. Voltage
• Connect the pocket tester (20 V AC) on the
headlight.
Headlamp light:
Cable (+) of Yellow or Green
Cable (–) of tester Black
A When the switch “k j”(intensity control)
is in position “k”.
B When the switch “k j” (intensity control)
is in position “j”.
• Place the main switch on “f”.
• Start the engine.
• Place the switch “k j” (dimmer switch) in
position “k” or “j”.
• Check if there is a voltage (12 V) in the
“Green” and “Yellow” cable in the connectors of the bulb holder.
OUTSIDE SPECIFIED VALUE
SATISFIES
THE SPECIFIED
VALUE (12 V)
The connection circuit of the main switch to
the bulb holder connector is defective, repair
it.
The circuit is in good condition.
7-15
LIGHTING SYSTEM
ELEC
2. The panel light does not light.
NO CONTINUITY
1. Bulb and bulb holder
• Check the bulb and bulb holder to see if
there is continuity.
Replace the bulb and/or bulb holder.
CONTINUITY
2. Voltage
• Connect the pocket tester (20 V AC) on the
bulb holder coupler.
Cable (+) of the tester Blue terminal Cable (–) of tester Black terminal • Place the main switch on “ON”
• Check if there is a voltage (12 V) in the
“Blue cable” of the connector of the bulb
holder.
OUTSIDE SPECIFIED VALUE
SATISFIES THE
SPECIFIED
VALUE(12 V)
The connection circuit of the main switch to
the bulb holder connector is defective, repair
it.
The circuit is in good condition
3. The rear light does not light.
1. Bulb and bulb holder.
• Check the bulb and bulb holder for continuity.
NO CONTINUITY
CONTINUITY
Replace the bulb and/or bulb holder.
2. Voltage
• Connect the pocket tester (20 V AC) in the
bulb holder connector .
Cable (+) of the tester Blue terminal Cable (–) of tester Black terminal • Place the main switch on “ON”.
• Start engine.
• Check if there is a voltage (12 V on the
“Blue” cable of the bulb holder connector).
OUTSIDE SPECIFIED VALUE
The connection circuit of the main switch to
the bulb holder connector is defective, repair
it.
SATISFIES THE
SPECIFIED VALUE
(12 V)
The circuit is in good condition.
7-16
SIGNALLING SYSTEM
SIGNALLING SYSTEM
CIRCUIT DIAGRAM
Speed sensor
Main switch
Fuse
Battery
13 Horn
13 “HORN” switch
15 “TURN” switch
17 Front indicator light (Left)
18 Front indicator light (Right)
19 Rear indicator light (Left)
20
21
22
23
24
25
26
27
28
7-17
Rear indicator light (Right)
Tail light
Horn
Indicator relay
Front brake switch
Rear brake switch
Oil level switch
Motor lights
Fuel sensor
ELEC
SIGNALLING SYSTEM
ELEC
TROUBLESHOOTING
• INDICATOR LIGHT, BRAKE LIGHT, AND/OR INDICATING LIGHTS DO NOT LIGHT.
• THE HORN DOES NOT SOUND
NOTE:
• Remove the following parts before repairing the faults .
1) Front cover .
4) Front lower fender
2) Inner cover
3) Rear panel (battery box)
• Use the following special tool for the repairs.
Pocket tester:
90890-03112
1. (Main) fuse
• Remove the fuses.
• Connect the pocket tester (Ωx1) on the
fuses.
• See “INSPECTION OF FUSES” in chapter
3.
NO CONTINUITY
The fuse is defective, change.
CORRECT
2. Battery
• Check the operation of the battery.
See section “INSPECTION OF THE BATTERY” in chapter 3.
INCORRECT
Open circuit voltage:
12.8 V or more at 20 °C (68 °F)
• Clean the battery terminals
• Charge or change the battery.
CORRECT
3. Main switch
• Disconnect the main switch coupler of the
installation
• Check the switch component for continuity
between “Red and Brown ” and “Red
and Gray ”.
INCORRECT
The main switch is defective, change
SATISFIES
THE SPECIFIED
VALUE
7-18
SIGNALLING SYSTEM
ELEC
4. Connections
• Check the connections throughout the signalling system.
• See the “ELECTRICAL DIAGRAM”section
BAD CONNECTION
Repair
CORRECT
Check the conditions for each signalling system circuit.
Consult the “CHECKING SIGNALLING SYSTEM” section.
CHECKING SIGNALLING SYSTEM
1. Horn does not operate
1.“HORN” switch.
• Disconnect the coupler of the handlebar
switch (left) from the installation and horn
cable.
• Check the switch component for continuity
between “Black and Red ”.
INCORRECT
The “HORN” switch is defective, change the
handlebar switch (left).
CORRECT
2. Voltage
• Connect the pocket tester (20 V DC) on the
horn cable.
Cable (+) of the tester Brown Cable (–) of tester Frame earth
• Place the main switch on “ON”
• Check if there is a voltage (12 V) in the
brown cable of the horn terminal.
OUTSIDE SPECIFIED VALUE
SATISFIES
THE SPECIFIED
VALUE (12 V)
The connection circuit from the main switch
to the horn terminal is defective, repair.
7-19
SIGNALLING SYSTEM
ELEC
3. Horn
• Disconnect the “Pink” cable from the horn
terminal.
• Connect a bridge cable on the horn terminal and earth the bridge cable.
• Place the main switch on “ON”.
THE HORN SOUNDS
The horn is in good condition.
THE HORN DOES
NOT SOUND.
4. Voltage
• Connect the pocket tester (20 V DC) on the
horn, on the “Pink” terminal.
Cable (+) of tester Pink Cable (–) of tester Earth of frame
• Place main switch on “ON”.
• Check if there is a voltage (12 V) in the
“Pink” cable on the horn terminal.
OUTSIDE SPECIFIED VALUE
SATISFIES
THE SPECIFIED
VALUE
The horn is defective.
Adjust the horn.
2.The brake lights do not light.
1.Bulb and bulb holder.
NO CONTINUITY
• Check the bulb and bulb holder for continuity
Change the bulb and/or bulb holder.
CONTINUITY
2.Brake switch
• Disconnect the brake switch cables from
the installation.
• Check the switch component for continuity
between “Brown and Green/Yellow ”.
7-20
SIGNALLING SYSTEM
ELEC
INCORRECT
The brake switch is defective, change.
CORRECTO
3.Voltage
• Connect the pocket tester (20 V DC) on the
bulb holder connector.
Cable (+) of tester Green/Yellow Cable (–) of tester Black • Place the main switch on “ON”.
• Activate the brake lever.
• Check if there is a voltage (12 V) on the
“Green/Yellow” cable of the bulb holder
connector.
OUTSIDE SPECIFIED VALUE
The connection circuit from the main switch
to the connector of the bulb holder is
defective, change.
SATISFIES THE
SPECIFIED VALUE
(12 V)
The circuit is in good condition.
3. The Master lights do not flash.
1. Bulb and bulb holder.
• Check the bulb and bulb holder for continuity.
NO CONTINUITY
Change the bulb and/or bulb holder.
CONTINUITY
2.Turning signal switch “b”
• Disconnect the handlebar switch coupler
(left) from the installation.
• Check the switch component for continuity
between “Brown/white” and “Chocolate
” and “Brown/White” and “Dark
green” CORRECT
7-21
SIGNALLING SYSTEM
ELEC
INCORRECT
The “TURN” is defective, change the handlebar switch (left).
3.Voltage
• Connect the pocket tester (20 V DC) on the
flasher relay .
Cable (+) of tester Brown
Cable (–) of tester Fame ground
• Place the main switch on “ON”.
• Check if there is a voltage (12 V) on the
“Brown” cable and “Frame ground” of the
flasher relay terminal.
OUTSIDE SPECIFIED VALUE
SATISFIES THE
SPECIFIED VALUE
(12 V)
The indicator relay is defective, change
4. Voltage
• Connect the pocket tester (20VDC) on the
flaster relay.
Cable (+) of tester White/Brown
Cable (-) of tester Frame ground
• Place the main switch on “ON”
• Chek it there is a vollàge (12V) on the
“Brown / White” cable and “Frame ground”
of the flasher relay terminal.
OUTSIDE SPECIFIED VALUE
SATISFIES THE
SPECIFIED VALUE
(12V)
The flasher relay is faulty, change
5. Voltage
• Connect the pocket tester (20 V DC) on the
bulb holder receptacle.
On the indicator light (left):
Cable (+) of the tester Chocolate Cable (–) of tester Frame ground
On the indicator light (right):
Cable (+) of tester Dark Green Cable (–) of tester Frame ground
7-22
SIGNALLING SYSTEM
• Place the main switch on “f”.
• Place the switch “b” on position “c” or
“d”.
• Check if there is a voltage (12 V) on the
“Chocolate” or “Dark Green” cable of the
bulb holder connector.
ELEC
OUTSIDE SPECIFIED VALUE
SATISFIES THE
SPECIFIED VALUE
(12 V)
The connection circuit from the “TURN”
switch to the bulb holder connector is
defective, review.
The circuit is in good condition.
4. The oil indicator light “OIL” does not light.
1. Bulb and bulb holder
NO CONTINUITY
• Check the bulb and bulb holder for continuity.
CONTINUITY
Change the bulb and/or bulb receptacle.
2.Oil level switch
• Remove the oil sump oil level switch.
• Connect the pocket tester (Ωx1) on the oil
level switch.
Cable (+) of tester Terminal Cable (–) of tester Terminal • Check the oil level measurer for continuity.
Switch
position
Good
condition
A Vertical
position
upwards
x
B Reverse
position
: Continuity
Bad
condition
x
POOR CONDITION
x
x
Change the oil level switch.
x: No continuity
GOOD CONDITION
3. Voltage
• Connect the pocket tester (20 V DC) on
the bulb holder connector .
Cable (+) of tester Gray Cable (–) of tester Frame ground
7-23
SIGNALLING SYSTEM
• Place main switch on “*”
• Check if there is a voltage (12 V) on the
“Gray” cable of the bulb holder connector
OUTSIDE SPECIFIED VALUE
SATISFIES THE
SPECIFIED VALUE
(12 V)
4. Connections
• Check the connections throughout the signalling system.
See the “ELECTRICAL DIAGRAM”
section.
The circuit is in good condition.
5. The speedometer fails to come on.
1. Voltage
• Connect the pocket tester (DC 20 V) to the
multi-function meter socket coupler (wire
harness side) as shown.
Positive tester probe red/yellow Negative tester probe black/yellow 3
R/
Y
B/
Y
L/
G
2
1
Gy Y GR
R
Br
L Ch Dg
B BY
Sb G RY LG
Dg Ch L
LG RY G Sb
GR Y Gy
BY B
Br
R
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of
red/yellow on the multi-function meter
coupler (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
ELEC
NO
Replace the speed
sensor.
7-24
SIGNALLING SYSTEM
2. Speed sensor
• Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness side)
as shown.
Positive tester probe blue/green Negative tester probe black/yellow L B R
L/ B/ R/
G Y Y
• Set the main switch to “ON”.
• Elevate the front wheel and slowly rotate it.
• Measure the voltage (DC 12 V) of
red/yellow and black/yellow. With each full
rotation of the front wheel, the voltage reading should cycle from 0 V to 5 ~ 11V to 0
V to 5 ~ 11V, etc.
• Does the voltage reading cycle correctly?
YES
The circuit is OK.
NO
Replace the speed
sensor.
7-25
ELEC
?
LOC
AVER
8
LOC
AVER
CHAPTER 8
LOCATION AND REPAIR OF BREAKDOWNS
LOCATION AND REPAIR OF ENGINE BREAKDOWNS ……………………8-1
ELECTRICAL SYSTEM ………………………………………………………8-1
COMPRESSION SYSTEM ……………………………………………………8-2
INLET AND EXHAUST SYSTEM ……………………………………………8-3
ELECTRICAL DIAGRAM YN50
TROUBLE SHOOTING
LOC
AVER
ELECTRICAL SYSTEM
IGNITION COIL
• The primary and secondary
coils are broken or defective.
• The high voltage cable is
defective.
• The spark plug cap is
defective.
* CHECK ALL CABLE CONNECTIONS
MAIN SWITCH
• The main switch is short
circuited.
SPARK PLUG
• Excessive carbon deposits.
• Damp electrodes.
• Incorrect gap.
• Broken.
SOURCE COIL
• The coils are broken.
PICK-UP COIL
• The coils are broken.
• Incorrect ignition distribution.
8-1
CDI UNIT
• CDI unit defective
TROUBLE SHOOTING
LOC
AVER
COMPRESSION SYSTEM
FATIGUE/CRACKS
DEFECTIVE SEALING
DAMAGE
DAMAGE/WEAR
DAMAGE/WEAR
WEAR/CRACKS/DAMAGE
DAMAGE
WEAR/STRIPING
INSUFFICIENT
TIGHTENING TORQUE
WEAR/CATCHING/BREAKS
CARBON DEPOSITS
DAMAGE
WARPING/CARBON DEPOSITS
8-2
TROUBLE SHOOTING
LOC
AVER
INLET AND EXHAUST SYSTEM
FUEL TANK CAP
• Obstructed
FUEL COCK
• Obstructed
DAMP TYPE
FUEL PIPE
• Obstructed
AIR FILTER ELEMENT
• Dirty or obstructed
CARBURETTOR JOINT
• Air leaks
MUFFLER
• Obstructed
EXHAUST PIPE
• Cracked or broken
• Carbon deposits
(CARBURETTOR)
NEEDLE
• Badly adjusted
(Average speed)
AIR SCREW
• Badly adjusted
(Idling and starting)
MAIN JET
• Incorrect size
• Obstructed (High speed)
ACCELERATOR STOPPING SCREW
• Badly adjusted
(Idling and starting)
FLOAT VALVE
• Worn
FLOAT
• Incorrect adjustment of fuel level
• Broken
PILOT JET
• Obstructed (Low range)
BOWL
• Accumulated dust and/or water
8-3
ELECTRICAL DIAGRAM YN50
COLOUR CODE
COMPONENTS
B ...............................BLACK
R ...............................RED
L................................BLUE
G...............................GREEN
O...............................ORANGE
Y ...............................YELLOW
P ...............................PINK
BR.............................BROWN
CH ............................CHOCOLATE
SB.............................SKY BLUE
DG ............................DARK GREEN
W ..............................WHITE
B/BR .........................BLACK/BROWN.
B/Y............................BLACK/YELLOW
B/R ...........................BLACK/RED
B/W...........................BLACK/WHITE
G/R ...........................GREEN/RED
G/Y ...........................GREEN/YELLOW
BR/W ........................BROWN/WHITE
W/R...........................WHITE/RED
W/B...........................WHITE/BLACK
W/G ..........................WHITE/GREEN
Y/L ............................YELLOW/BLUE
Y/R............................YELLOW/RED
L/B............................BLUE/BLACK
L/W ...........................BLUE/WHITE
L/Y ............................BLUE/YELLOW
R/Y............................RED/YELLOW
L/G............................BLEU/GREEN
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
31.
33.
34.
Flywheel magneto
CDI UNIT
SPEED SENSOR
Spark plug
Main switch
Fuse
Battery
Rectifier/regulator
Starter relay
Starter motor
Starter switch
Horn switch
Dimmer switch
Turn lights switch
Headlight
Front left turn light
Front right turn light
Rear left turn light
Rear right turn light
Tail light
Horn
Turn lights relay
Front stop switch
Rear stop switch
Oil level switch
Instrument panel
Fuel sender
License light (UK only)
Auto choke
Ignition coil