Engine. Yamaha XF50W

ADJUSTING THE VALVE CLEARANCE

EAS00049

ENGINE


The following procedure applies to all of the valves.

NOTE:

• Valve clearance adjustment should be made on a cold engine, at room temperature.

• When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.

1. Remove:

• front cover

• side cover(left and right)

• battery /battery cover

• single seat/trunk

• footrest board

• Refer to”COVER AND PANEL”.

2. Drain:

• coolant

(completely from the radiator)

3. Remove:

• radiator cover ®

• radiator

• fan case ®

Refer to”RADIATOR”in chapter 6.

4. Remove:

• spark plug cap

• spark plug

• ignition coil

• cylinder head cover

5. Remove:

• water pump

Refer to”WATER PUMP”in chapter 6.

6. Measure:

• valve clearance

Out of specification -» Adjust.

Valve clearance (cold)

Intake valve

0.10 ~ 0.16mm(0.0039 ~ 0.0063in)

Exhaust valve

0.18 ~ 0.24mm(0.0071 ~ 0.0094in)

3-10


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• • • • • • • • • • • • • • • • • • • • • • • a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compression stroke, align the punch mark a in the camshaft sprocket with the stationary b on the plate. c. Align the TDC mark c on the AC magneto rotor with the stationary pointer d on the crankcase cover. d. Measure the valve clearance with a thickness gauge ® .

Out of specification -» Adjust.

• • • • • • • • • • • • • • • • • • • • • • •

3-11

7. Adjust: valve clearance

• • • • • • • • • • • • • • • • • • • • • • • a. Remove the timing chain tensioner and camshaft sprocket. b. Remove the head nuts, bolts and plate. c. Remove the rocker arm shaft, rocker arm and collar. d. Remove the valve p a d 2 with a magnetic b a r 1 .

NOTE:

8 Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.

8 Make a note of the position of each valve pad so that they can be installed in the correct place. e. Select the proper valve pad from the following table.

Valve pad thickness range Available valve pads

Nos.

120 ~ 240

1.20 (0.0472in)

~ 2.40 mm

(0.0945 in)

25 thicknesses in

0.05 mm (0.002 in) increments f. Round off the original valve pad number according to the following table.


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Last digit

0 or 2

5

8

Rounded value

0

5

10

EXAMPLE:

Original valve pad number =148(thickness

=1.48mm(0.0583in))

Rounded value =150 g. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.

NOTE:

The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. h. Install the new valve pad .

NOTE:

• Lubricate the valve pad with molybdenum disulfide oil.

• Install the valve pad in the correct place. i. Install the rocker arm, collar and rocker arm shaft. j. Install the plate and cylinder head nuts

X | 10Nm(1.0m

* kg, 7.2ft

* lb) k. Install the cylinder head bolts .

X | 10Nm(1.0m

* kg, 7.2ft

* lb) l. Install the camshaft sprocket.

X | 30Nm(3.0m

* kg, 21.7ft

* lb) m. Install the timing chain tensioner and gasket.

X | 9Nm(0.9m

* kg, 6.5ft

* lb)

3-12


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X I 8Nm(0.8m

* kg, 5.8ft

* lb) o. Measure the valve clearance again. p. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.

• • • • • • • • • • • • • • • • • • • • • • •

3-13


INTAKE

ORIGINAL VALVE PAD NUMBER •

0.00~0.04

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0.05~0.09

0.10~0.16

0.17~0.21 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.22~0.26 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.27~0.31 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.32~0.36 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.37~0.41 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.42~0.46 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.47~0.51 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.52~0.56 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.57~0.61 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.62~0.66 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.67~0.71 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.72~0.76 180 185 190 195 200 205 210 215 220 225 230 235 240

0.77~0.81 185 190 195 200 205 210 215 220 225 230 235 240

0.82~0.86 190 195 200 205 210 215 220 225 230 235 240

0.87~0.91 195 200 205 210 215 220 225 230 235 240

0.92~0.96 200 205 210 215 220 225 230 235 240

0.97~1.01 205 210 215 220 225 230 235 240

1.02~1.06 210 215 220 225 230 235 240

1.07~1.11 215 220 225 230 235 240

1.12~1.16 220 225 230 235 240

1.17~1.21 225 230 235 240

1.22~1.26 230 235 240

1.27~1.31 235 240

1.32~1.36 240

VALVE CLEARANCE(cold):

0.10~0.16mm(0.0039~0.0063in)

Example:175 pad is installed

Measured clearance is 0.24mm(0.0094in)

Replace pad 175 with pad 185

Pad number: (example)

Pad No.175=1.75mm(0.0689in)

Pad No.185=1.85mm(0.0728in)

EXHAUST

ORIGINAL VALVE PAD NUMBER X

0.00~0.02

0.03~0.07

0.08~0.12

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0.13~0.17

0.18~0.24

0.25~0.29 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.30~0.34 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.35~0.39 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.40~0.44 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.45~0.49 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.50~0.54 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.55~0.59 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.60~0.64 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.65~0.69 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.70~0.74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.75~0.79 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.80~0.84 180 185 190 195 200 205 210 215 220 225 230 235 240

0.85~0.89 185 190 195 200 205 210 215 220 225 230 235 240

0.90~0.94 190 195 200 205 210 215 220 225 230 235 240

0.95~0.99 195 200 205 210 215 220 225 230 235 240

1.00~1.04 200 205 210 215 220 225 230 235 240

1.05~1.09 205 210 215 220 225 230 235 240

1.10~1.14 210 215 220 225 230 235 240

1.15~1.19 215 220 225 230 235 240

1.20~1.24 220 225 230 235 240

1.25~1.29 225 230 235 240

1.30~1.34 230 235 240

1.35~1.39 235 240

1.40~1.44 240

VALVE CLEARANCE(cold):

3-14


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8. Install:

8all removed parts

NOTE:

For installation, reverse the removal procedure.

9. Fill:

8cooling system

(with the specified amount of the recommended coolant)

Refer to”CHANGING THE COOLANT”.

3-15

CHECKING THE ENGINE IDLING SPEED

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EAS00054

CHECKING THE ENGINE IDLING SPEED

NOTE:

Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression.

1. Start the engine and let it warm up for several minutes.

2. Remove:

8 panel

Refer to”FOOTREST BOARD AND IN-

NER FENDER”.

3. Connect:

8 digital circuit tester

(onto the spark plug lead of cylinder)

Digital circuit tester

90890-06760

4. Check:

• engine idling speed

Out of specification -» Replace the throttle body assembly.

A Engine idling speed

2000~2200r/min

5. Install:

8 panel


NER FENDER”.

3-16

ADJUSTING THE THROTTLE CABLE FREE PLAY

EAS00056

ADJUSTING THE THROTTLE CABLE FREE

PLAY

NOTE:

Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly.

1. Check:

• throttle cable free play a

Out of specification ^Adjust.

Throttle cable free play (at the flange of the throttle grip)

1.5~3.5mm (0.06~0.14in)

2. Adjust:

8throttle cable free play

• • • • • • • • • • • • • • • • • • • • • • •

Handlebar side a. Loosen the locknut 1 . b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained.

Direction a Throttle cable free play is increased.

Direction b Throttle cable free play is decreased. c. Tighten the locknut. w

After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.

• • • • • • • • • • • • • • • • • • • • • • •

3-17

CHECKING THE SPARK PLUG

EAS00060


1 . Remove:

8 panel


NER FENDER”.

2. Disconnect:

8 spark plug cap w

Remove the spark plug cap, the engine is extremely hot.

3. Remove:

8 spark plug c C

Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder.

4. Check:

8 spark plug type

Incorrect -* Change.

Spark plug type (manufacturer)

CR7E(NGK)

3-18

5. Check:

8 electrode ©

Damage/wear -* Replace the spark plug.

8 insulator ©

Abnormal color -* Replace the spark plug.

Normal color is medium-to-light tan.

6. Clean:

8 spark plug

(with a spark plug cleaner or wire brush)

7. Measure:

8 spark plug gap a

(with a wire Thickness gauge)

Out of specification -* Regap.

Spark plug gap

0.7 ~0.8mm(0.028 ~0.031in)


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8. Install:

• spark plug

X I 13Nm(1.3m

* kg, 9.4ft

* lb)

NOTE:

Before installing the spark plug, clean the spark plug and gasket surface.

9. Connect:

• spark plug cap

10. Install:

• panel


NER FENDER”.

3-19

CHECKING THE IGNITION TIMING

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EAS00062

CHECKING THE IGNITION TIMING wiring connections of the entire ignition system.

Make sure all connections are tight and free of corrosion.

1. Remove:

8front cover

8side cover(left and right)

8battery /battery cover

8single seat/trunk

Refer to”COVER AND PANEL”.

2. Drain:

8coolant

(completely from the radiator)

3. Remove:

8radiator cover

8radiator

8fan case


4. Attach:

8timing light 1

8digital circuit tester2

(onto the spark plug lead of cylinder)

Timing light

90890-03141

YU-03141

Digital circuit tester

90890-06760

3-20

CHECKING THE IGNITION TIMING

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5. Check:

8ignition timing

• • • • • • • • • • • • • • • • • • • • • • • a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed.

A Engine idling speed

2000 ~ 2200r/min b. Check that the mark a on the AC magneto rotor is within the firing range b on the right crankcase cover.

Incorrect firing range -» Check the ignition system.

• • • • • • • • • • • • • • • • • • • • • • •

NOTE:

The ignition timing is not adjustable.

6. Remove:

• timing light

• digital circuit tester

7. Install:

• fan case

• radiator

• radiator cover


8. Fill:

• cooling system


Refer to”CHANGING THE COOLANT”.

9. Install:




• front cover


3-21

MEASURING THE COMPRESSION PRESSURE

CHK

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EAS00067

MEASURING THE COMPRESSION PRES-

SURE

NOTE:

Insufficient compression pressure will result in a loss of performance.

1. Measure:

8 valve clearance

Out of specification -» Adjust

Refer to “ADJUSTING THE VALVE

CLEARANCE”.

2. Start the engine, warm it up for several minutes, and then turn it off.

3. Remove:

8 panel


NER FENDER”.

4. Disconnect:

8 spark plug cap w

Remove the spark plug cap, the engine is extremely hot.

5. Remove:

8spark plug c C

Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling into the cylinder.

6. Install:

8compression gauge 1

3-22

^

Compression gauge

90890-03081

YU-33223

7. Measure:

8 compression pressure

Out of specification -» Refer to steps (c) and (d).

Compression pressure (at sea level)

Minimum

1262kPa(12.62kg/cm

2

, 179.7psi)

Standard

1450kPa(14.5kg/cm

2

, 206.5psi)

Maximum

1624kPa(16.24kg/cm

2

, 231.3psi)

MEASURING THE COMPRESSION PRESSURE

• • • • • • • • • • • • • • • • • • • • • • • a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.

FflWUzWIgM

To prevent sparking, ground the spark plug lead before cranking the engine. c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits.

Carbon deposits -» Eliminate. d. If the compression pressure is below the minimum specification, pour a teaspoonful engine of oil into the spark plug bore and measure again.

Refer to the following table.

Compression pressure

(with oil applied into the cylinder)

Reading Diagnosis

Higher than without oil Piston ring(s) wear or damage -» Repair.

Same as without oil Piston ring(s), valves, cylinder head gasket or piston possibly defective -» Repair.

• • • • • • • • • • • • • • • • • • • • • • •

8. Remove:

• compression gauge

9. Install:

• spark plug

X I 13Nm(1.3m

* kg9.4ft

* lb)

10. Connect:

• spark plug cap

11. Install:

• panel


NER FENDER”.

3-23

CHECKING THE ENGINE OIL LEVEL

EAS00069

CHECKING THE ENGINE OIL LEVEL

1. Stand the scooter on a level surface.

NOTE:

8 Place the scooter on a suitable stand.

8 Make sure the scooter is upright.

- T - V ~//

/

^(S) \ ^ ^ \

<\l.

}yyf(M' ^


3. Check:

8 engine oil level

The engine oil level should be between the minimum level mark a and maximum level mark b .

Below the minimum level mark -» Add the recommended engine oil to the proper level.

i b

!

a

*0

Recommended engine oil type

YAMALUBE 4, SAE10W30 or

SAE20W40

Recommended engine oil grade

API service SG type or higher

JASO standard MA c C

Do not allow foreign materials to enter the crankcase.

NOTE:

Before checking the engine oil level, wait a few minutes until the oil has settled.


5. Check the engine oil level again.

NOTE:

Before checking the engine oil level, wait a few minutes until the oil has settled.

3-24

CHANGING THE ENGINE OIL

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EAS00076



2. Place a container under the engine oil drain bolt.

3. Remove:

8engine oil filler cap 1

8engine oil drain bolt 2

(along with the gasket)

4. Drain:

8engine oil

(completely from the crankcase)

5. If the oil filter element is also to be replaced or cleaned, perform the following procedure.

• • • • • • • • • • • • • • • • • • • • • • • a. Remove the oil strainer cover 1,spring3 and oil filter element 4 . b. Replace the O-ring New 2 c. Install the new or clean oil filter element and the oil strainer cover.

Oil strainer cover

32Nm(3.2m

• kg, 23.1ft

• lb)

• • • • • • • • • • • • • • • • • • • • • • •

6. Install:

• engine oil drain bolt


3-25

X | 23Nm(2.3m

* kg, 16.6ft

* lb)

7. Fill:

• crankcase

(with the specified amount of the recommended engine oil)

«0

Quantity

Total amount

0.8~0.9L(0.74~0.83 Imp qt, 0.87~0.98

US qt)

Periodic oil change

0.73~0.83L(0.67~0.76 Imp qt,

0.80~0.90 US qt)


8. Install:

8engine oil filler cap


10.Check:

8engine

(for engine oil leaks)

11.Check:

8engine oil level

Refer to “CHECKING THE ENGINE OIL

LEVEL”.

12.Check: engine oil pressure

• • • • • • • • • • • • • • • • • • • • • • • a. Slightly loosen the oil gallery bolt <RN.1>. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Refer to “OIL PUMP” in chapter 5. d. Start the engine after solving the problem(s) and check the engine oil pressure again. e. Tighten the oil gallery bolt to specification.

V

%

Oil gallery bolt

7Nm (0.7m

• kg, 5.1ft

• lb)

• • • • • • • • • • • • • • • • • • • • • • •

3-26

CHANGING THE TRANSMISSION OIL

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CHANGING THE TRANSMISSION OIL


NOTE:

• Stand the scooter on a suitable stand.

• Make sure that the scooter upright.


3. Place a container under the transmission oil drain bolt.

4 Remove:

• transmission oil fill bolt


• transmission oil drain bolt ©

5. Drain:

• transmission oil

(completely from the transmission case)

6. Install:

• transmission oil drain bolt

X I 13Nm(1.3m

* kg, 9.4ft

* lb)

7. Fill:

• transmission case

(with the specified amount of the recommended transmission oil)

K} Recommended oil

SAE10W30 hypoid gear oil

Total amount

0.11~0.13L(0.10~0.12 Imp qt,

0.12~0.14 US qt)

Periodic oil change

0.09~0.11L(0.08~0.10 Imp qt,

0.10~0.12 US qt)

8. Install:

• transmission oil fill bolt ©


X I 23Nm(2.3m

* kg, 16.6ft

* lb)

3-27

9. Start the engine for several minutes to warm it up and check for the oil leakage.

10.Check:

• transmission case

(for transmission oil leaks)

MEASURING THE ENGINE OIL PRESSURE

EAS00077


1. Check:

8 engine oil level

Below the minimum level mark -» Add the recommended engine oil to the proper level.

Refer to”CHECKING THE ENGINE OIL

LEVEL”.


C

When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine.

3. Remove:

8 panel


NER FENDER”.

4. Lossen:

8oil gallery bolt 1 w

The engine, muffler and engine oil are extremely hot.

5. Check:

8engine oil pressure

• • • • • • • • • • • • • • • • • • • • • • • a. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. b. Check the engine oil passages, the oil filter and oil pump for damage or leakage.Refer to”OIL PUMP” in chapter 5. c. Start the engine after solving the problem(s) and check the engine oil pressure again.

3-28

• • • • • • • • • • • • • • • • • • • • • • •


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6. Install:

8oil gallery bolt

X I 7Nm(0.7m

* kg, 5.1ft

* lb)

7. Install:

• panel


NER FENDER”.

3-29

REPLACING THE AIR FILTER ELEMENT

EAS00086


1. Remove:

8front cover

8side cover(left)

Refer to”SIDE COVERS AND TAIL/

BRAKE LIGHT”.

2. Remove:

8air filter case c o v e r 1

8air filter element

3-30

3. Check:

8 air filter element ©

Damage/dirty^ Replace.

NOTE:

8 Replace the air filter element every

4000km(2000mi) .

8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

4. Install:

8 air filter element

8 air filter case cover

X I 10Nm(1.0m

* kg, 7.2ft

* lb)

C

Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the throttle body tuning, leading to poor engine performance and possible overheating.

NOTE:

When installing the air filter element into the air filter case cover, make sure their sealing surfaces are aligned to prevent any air leaks.


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5. Install:

8side cover(left)

8front cover

Refer to”SIDE COVERS AND TAIL/

BRAKE LIGHT”.

3-31

CHECKING THE THROTTLE BODY JOINT AND

INTAKE MANIFOLD/CHECKING THE FUEL HOSE

EAS00094

CHECKING THE THROTTLE BODY JOINT

AND INTAKE MANIFOLD

1. Remove:

8front cover


8single seat/trunk


2. Check:

• throttle body joint (T)

• intake manifold (2)

Cracks/damage -» Replace.

Refer to “FUEL INJECTION SYSTEM” in chapter 7.

3. Install:



• front cover


EAS00096

CHECKING THE FUEL HOSE

The following procedure applies to all of the fuel hose.

1. Remove:

• front cover



• footrest board


3-32

2. Check:

• fuel hose (T)


Loose connection -» Connect properly.

3. Install:

• footrest board



• front cover


CHECKING THE BREATHER HOSES

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EAS00098

CHECKING THE BREATHER HOSES

1. Remove:

8front cover


8single seat/trunk

Refer to”COVER AND PANEL”. fer

\ \

X

\ ^ V v^ tx tU

1>f a i i l ^

Si M ^

> i

2. Check:

8 breather hose (T)

8 transmission case breather hose (2)


Loose connection -» Connect properly.

C

Make sure the breather hoses are routed correctly.

3. Install:

8single seat/trunk


8front cover


3-33

CHECKING THE EXHAUST SYSTEM

EAS00099

CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the muffler assembly and gasket.

1. Remove:

8muffler assembly

Refer to”ENGINE REMOVAL”in chapter

5.

2. Check:

• muffler assembly (T)

Crack/damage -» Replace.

• gasket (2)

Exhaust gas leak -» Replace.

3. Check:

• tightening torque

Exhaust pipe nut (3)

13Nm(1.3m

• kg, 9.4ft

• lb)

Muffler and rear arm bolt (4)

31Nm(3.1m

• kg, 22.4ft

• lb)

4. Install:

8muffler assembly

Refer to”ENGINE REMOVAL”in chapter

5.

3-34

CHECKING THE COOLANT LEVEL

EAS00103

CHECKING THE COOLANT LEVEL


NOTE:

8 Place the scooter on a suitable stand.

8 Make sure the scooter is upright.

2. Check:

8 coolant level

The coolant level should be between the maximum level mark a and minimum level mark b .

Below the minimum level mark -» Add the recommended coolant to the proper level.

C

8 Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant.

8 Use only distilled water. However, if distilled water is not available, soft water may be used.


4. Check:

8 coolant level

NOTE:

Before checking the coolant level, wait a few minutes until it settles.

3-35

CHECKING THE COOLING SYSTEM

EAS00104

CHECKING THE COOLING SYSTEM

1. Remove:

8front cover


8battery /battery cover

8single seat/trunk

8footrest board


8radiator cover


J l " iy,

\ / -/C-^y ^

<^Cl&

^^\^y^fe^^\^p—\

N^gf

/ ^ I \ X M T ^

^ ^ v

Vg

°V

X3

'•'•':\ 1 '

^7

/

*

s

o )

^~ ^ ^^sr^/^js,

2. Check:

• radiator ©

• radiator inlet hose (2)

• radiator outlet hose (3)


Refer to “COOLING SYSTEM” in chapter 6.

3. Install:

• radiator cover


• footrest board




• front cover


3-36

CHANGING THE COOLANT

EAS00105


1. Remove:

8front cover

8side cover(right)

8coolant reservoir cap cover


8radiator cover


2. Disconnect:

8coolant reservoir hose 1

3. Drain:

8coolant

(from the coolant reservoir)

8coolant

(from the radiator under drain bolt)

4. Remove:

8radiator cap

8coolant reservoir cap w

A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows:

Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.

5. Connect:

8coolant reservoir hose

6. Install:

8radiator under drain bolt

X I 1Nm(0.1m

* kg, 0.7ft

* l b )

3-37


7. Fill:

8cooling system


«0 Recommended antifreeze

High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines

Mixing ratio

4:6(antifreeze:water)

Quantity

Total amount

0.50L(0.46 Imp qt, 0.53 US qt)

Coolant reservoir capacity

0.26L(0.23 Imp qt, 0.28 US qt)

Up to the maximum level mark

3-38

NOTE:

The specified amount of coolant is a standard amount. Fill the cooling system with coolant until coolant comes out of the air bleed bolt hole.

Handling notes for coolant

Coolant is potentially harmful and should be handled with special care. w

If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.

If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.

If coolant is swallowed, induce vomiting and get immediate medical attention. c C

Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant.

Use only distilled water. However, if distilled water is not available, soft water may be used.

If coolant comes into contact with painted surfaces, immediately wash them with water.

Do not mix different types of antifreeze.

8. Install:

8radiator cap


CHK

ADJ

< &

9. Fill:

8coolant reservoir

(with the recommended coolant to the maximum level mark 1 )

10.Install:

8coolant reservoir cap

11.Start the engine, warm it up for several minutes, and then stop it.

12.Check:

8coolant level

Refer to “CHECKING THE COOLANT

LEVEL”.

NOTE:

Before checking the coolant level, wait a few minutes until the coolant has settled.

13.Install:

8radiator cover


8coolant reservoir cap cover

8side cover(right)

8front cover


3-39

Engine. Yamaha XF50W

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Engine. Yamaha XF50W

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