2 - 1991-2000 - Yamaha - Jog - CY50 - Service - Manual

1991 - 2000
MOTORCYCLE
SERVICE MANUAL
Model : CY50B, CY50D, CY50E, CY50F,

CY50G, CY50H, CY50J, CY50M, SH50G
3SA281972000 *3SA281972000*
CY50B '91
SERVICE MANUAL
1990 by Yamaha Motor Co., Ltd.
1st Edition, August 1990
AIJ rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
NOTICE
This manual was written bythe Yamaha Motor Company primarily for use by Yamaha dealers and their
qualified mechanics. lt is not possible to put an entire mechanic's education into one manual, so it is
assumed that persons using this book to perform maintenance and repairs on Yamaha scooter have a
basic understanding of the mechanical concepts and procedures inherent in scooter repair technology.
Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or
unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will befo rwarded to all Authorized
Yamaha dealers and will, where applicable, appear in future editions ofthis manual.
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE GROUP
Y AMA HA MOTOR CO., LTD.
PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.
The Safety Alert Symbol means ATTENTION! BECO ME ALERT! YOUR SAFETY
IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death

to the scooter operator, a bystander, ora person inspecting or repairing the
scooter.
A CAUTION indecates special precautions that must be taken to avoid damage

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

HOW TO USE THIS MANUAL
CONSTRACTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See "lllustrated symbols")
1st title CD : This is a chapter with its symbol on the upper right of each page.
2nd title : This title appears on the upper of each page on the left of the chapter
symbol. (For the chapter "Periodic inspection and adjustment" the 3rd
title appears.)
3rd title : This is a final title.
MANUALFORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The infor-
mation has been compiled to provide the mechanic with an easy to read, handy reference that
contains comprehensive explanations of all disassembly, repair, assembly, and 'inspections.
A set of particularly important procedure is placed between a line of asterisks .. *.. with each
procedure preceded by " G ".
IMPORTANTFEATURES
Data anda special tool are framed in a box preceded by a relevant symbol .
An encircled numeral
indicates a part name, and an encircled alphabetical letter data oran
alignment mark (]), the others being indicated by an alphabeticalletter in a box@ .
A condition of a faulty component will precede an arrow symbol and the course of action re-
quired the symbol .
EXPLODED DIAGRAM
Each chapter provides exploded diagrams befare each disassembly section for ease in identif-
ying correct disassembly and assembly procedures.
FRONT FORK !CHAS r/i:J0j

------------------------
Crenooheh _j
Untt>e-cncuesepara!rngtool J
1!1 cr; ;;o.,.tlng 1001
9
iN.SPEcTION ANO REPAIR
Uutroomdedocrapet
NOTE------
Ta-tCI<!IOavorCiedamegrr.gthesparkplug
U'Uea<U Oo no1 un sf'1aro '"lltumnt
WarroaD-O -uramenl and raaurlaca

-"'"'-"
Atue"''"'"' ' :i an<lafhoc ne --=--;-- -....._...,
4)---H ;::o;;;:: ;;::::;;w .::.:.:::: ,;.:::.:::: """'
lf!l"'twarp-rtoutolopecofrcatooll.lt (: 0)
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P ca o - 600 Qt!l wet aa....:loa >&r an
-
theourhceploote.e.....,reeurbcethe"e..:l
"
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l'loUUH>ah8edaevarallo.....,IIOevood<t
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CD ILLUSTRATED SYMBOLS
I EF I I lsPEcl J

(Refer to the illustration)
lllustrated symbols(Dto are designed as thumb

tabsto indicatethe chapter's number and content.
CD General information
I JII fiil 1 ENG l'-1

(V Specifications
Periodic inspection and adjustment
Engine
Carburetion
Chassis
lcARBifl icHAsl ej (J) Electrical

@ Troubleshooting
(J)
IELEcl el l n l? 1 lllustrated symbols to @ are used to identify

@
the specifications appearing in the text.
Filling fluid
@ Lubricant
@ Spccial tool
(jJ) @ @ Tightening
@ Wear limit, clearance
@ Engine speed
@D.,V,A
@ @
@ @ lllustrated symbols @ to @ in the exploded

diagram indicate grade of lubricant and location
of lubrication point.
l l l
@ Apply engine oil
@ m m @
(j]) Apply gear oil
@ Apply molybdenum disulfide oil
@ Apply wheel bearing grease
@ Apply lightweight lithium-soap base grease
@ Apply molybdenum disulfid'e grease
@ Apply locking agent (LOCTITE)
'
''
@
INDEX
GENERAL INFORMATION GEN
INFO
SPECIFICATIONS
PERIODIC INSPECTION
ANO ADJUSTMENT
ENGINE OVERHAUL
CARBURETION CARB
CHASSIS CHA S
ELECTRICAL ELE C
TROUBLESHOOTING
--------- --' ' ' CHAPT ER
GENERAL INFORMATION
1.
SCOOTER IDENTIFICATION ................................................................................... A-8

VEHICLE IDENTIFICATION NUMBER ................................................................ A-8
ENGINE SERIAL NUMBER ................................................................................. A-8
IMPORTANT INFORMATION ................................................................................. A-8

PREPARATION FOR REMOVAL AND DISASSEMBLY ..................................... A-8
ALL REPLACEMENT PARTS .............................................................................. A-8
GASKETS, OIL SEALS, ANO 0-RINGS ............................................................. A-8
LOCK WASHERS/PLATES ANO COTTER PINS ................................................ A-9
BEARINGS ANO OIL SEALS .............................................................................. A-9
CIRCLIPS ............................................................................................................. A-9
SPECIAL TOOLS ...................................................................................................... A-9

FOR TUNE-UP ..................................................................................................... A-9
FOR ENGINE SERVICE ....................................................................................... A-9
FOR CHASSIS SERVICE ................................................................................... A-10
FOR ELECTRICAL COMPONENTS ................................................................... A-10
----------------------
l lj: l l
SCOOTER IDENTIFICATION 1 1:-"b 1 1
GENERAL INFORMATION
..----------------. SCOOTER IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number CD is stamped
into the frame.
NOTE=----------------------------
The vehicle identification numberis used to iden-
tify your scooter and may be used to register your
scooter with the licensing authority in your state.
Starting serial number:

JYA3SANO * MA000101
ENGINE SERIAL NUMBER

The engine serial number CD is stamped into the
crankcase.
Starting serial number:

3SA-000101
NOTE:
The first three digits of these numbers are for
model identifications; the remaining digits are
the unit production number.
Designs and specifications are subject to
change without notice.
1-1
IMPORTANT INFORMATION [ EF"tiMI
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL ANO
DISASSEMBL Y
1. Remove all dirt, mud, dust and foreign mate-
rial befare removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to "SPECIAL TOOL".
3. When disassembling the scooter, keep mated

parts together. This includes gears, cylinders,
pistons and other mated parts that have been
"mated" through normal wear. Mated parts
must be reused asan assembly or replaced.
4. Du ring the scooter disassembly, e lean all parts

and place them in trays in the arder of disas-
sembly. Thiswill speed up assemblytime and
help assure that all parts are correctly rein-
stalled.
5. Keep away from fire.
ALL REPLACEMENT PARTS

1. Use only genuine Yamaha parts for all
replacements. Use oil and/or grease recom-
mended by Yamaha for assembly and adjust-
ment. Other brands may be similar in function
and appearan"ce, but inferior in quality.
GASKETS, OIL SEALS, AND 0-RINGS

1. All gaskets, seals, and 0-rings should be re-
placed when an engine is overhauled. All
gasket surfaces, oil seallips, and 0-rings must
be cleaned.
2. Properly oil all mating parts and bearings dur-
ing reassembly. Apply grease to the oil seal
lips.
1-2
IMPORTANT INFORMATION 1 1 1
LOCK WASHERS/PLATES AND COTTER
PINS
1.Alllock washers/platesQ)and cotter pins must
be replaced when they are removed. Lock
tab(s) should be bent along the bolt or nut
flat(s) after the bolt or nut has been properly
tightened.
BEARINGS AND OIL SEALS

1.1nstall the bearing(s) and oil seal(s) with their
manufacturer's marks or numbers facing out-
ward. (In other words, the stamped letters
must be on the side exposed to view.) When
installing oil seal(s), apply a light coating of
light-weight lithiu m base grease to the seallip
(s). Oil the bearings liberally when installing.
Q) Oil seal
CAUl"IQt\k ---------
Do not use compressed air to spin the bearings
dry. This causes damage to the bearing surfaces.
Q) Bearing
CIRCLIPS
1. All circlips should be inspected carefully be-
fare reassembly. Always replace pistan pin
clips after one use. Replace distorted circlips.
When installing a circlipQ), makesurethatthe
sharp edged corn r W is positioned opposite
to the thrust it receives. See the sectional
view.
300 001 @ Shaft
1-3
SPECIAL TOOLS I EF I I
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
ca used bythe use of im propertools or improvised
techniques.
FOR TUNE UP
1.1nductive Tachometer
P/N. YU-08036-A
This tool is needed for detecting engine rpm.
2. Compression Gauge
P/N. YU-33223
This gauge is used to mea su re engine compres-

sion.
3. Fuel leve[ gauge

P/N. YM-01312-A
This gauge is used tome asure the fuellevel in the

float chamber.
FOR ENGINE SERVICE

1. Flywheel Holding Tool
P/N. YU-01235
This tool is used to the hold the flywheel magneto

and clutch assemblywhen removing or installing
the securing nut.
1-4
SPECIAL TOOLS
2. Flywheel Magneto Puller
1 1'"1EF
P/N. YM-01189
This tool is used to remove the flywheel.
3. Crankcase Separating Tool

P/N. YU-01135
This tool is used to remove the crankshaft or

separate the crankcase.
4. Crankshaft lnstalling Set

/ P/N. YU-90050- CD
Adapter (M10)
P/N. YM-90062- Cl)
:_)
/
'
This tools are used to install the crankshaft.
'
'
'
'
5. Sheave Holder
P/N. YS-01880
This tool is used when holding the clutch hub.
6. Clutch Spring Holder

P/N. YS-28891
This tool is used to disassembly and assem bly the

secondary sheave.
1-5
s_P_E_c_IA_L_T_o_o_L_si EF
7. Ouick Gasket
P/N. ACC-11001-01
YAMAHA Bond No. 1215
This sealant (Bond) is used for crankcase mating

surfaces, etc.
FOR CHASSIS SERVICE

1. Ring Nut Wrench
P/N. YU-33975
This too! is used to loasen and tighten the

steering ring nut.
FOR ELECTRICAL COMPONENTS

1. Pocket Tester
P/N. YU-03112
This instrument is invaluable for electrical system

inspection and adjustment.
2. Dynamic spark tester

P/N. YM-34487
This instrument is necessary for checking the

ignition system components.
1-6
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS .................................................................................. A-14
MAINTENANCE SPECIFICATIONS ....................................................................... A-15

ENGINE ............................................................................................................. A-15
CHASSIS ............................................................................................................. B-1
ELECTRICAL ........................................................................................................ B-2
GENERAL TOROUE SPECIFICATIONS ................................................................... B-3
DEFINITION OF UNITS ............................................................................................. B-3
LUBRICATION POINTS AND LUBRICANT TYPE ................................................... B-3

ENGINE ............................................................................................................... B-3
CHASSIS ............................................................................................................. B-4
CABLE ROUTING ...................................................................................................... B-4

isPEci JJ I
---------
G_E_N_ER_A_L_S_P_E_ct_FI_c_M_I_O_Ns_ISPEP'I -
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model CY50B
Model Code Number 3SA
Vehicle ldentification Number JYA3SANO *MA000101
Engine Starting Number 3SA-0001 01
Dimensions:
Overall Length 1,645 mm (64.8 in)
Overall Width 630 mm (24.8 in)
Overall Height 980 mm (38.6 in)
Seat Height 710 mm (28.0 in)
Wheelbase 1,115 mm (43.9 in)
Minimum Ground Clearance 80 mm (3.1 in)
Basic Weight:
With Oil and Full Fuel Tank 65 kg (1431b)
Minimum Turning Radius: 1,600 mm (63 in)
Engine:
Engine Type Air cooled 2-stroke, gasoline
Cylinder Arrangement Single cylinder, Vertical
Displacement 49 cm 3
Bore x Stroke 40.0 x 39.2 mm (1.575 x 1.543 in)
Compression Ratio 6.9: 1
Starting System Electric and kick starter
Lubrication System Separate lubrication (Yamaha Autolube)
Oil Type or Grade:
Engine Oil Yamalube2 or equivalent air-cooled, 2-stroke
engine oil
Transmission Oil SAE 10W30 type SE motor oil
Oil Capacity:
Oil Tank (engine oil) 0.8 L (0.7 lmp qt, 0.84 US qt)
Transmission Oil:
Periodic Oil Change 1.10 L (0.09 lmp qt, 0.11 US qt)
Total Amount 1.11 L (0.10 lmp qt, 0.12 US qt)
Air Filter Wet type element
Fuel:
Type Regular gasoline
Tank Capacity 3.5 L (0.77 lmp gal, 0.92 US gal)
2-1
GENERAL SPECIFICATIONS
Model CY50B
Carburetor:
Type/Man ufacturer Y14P/TEIKEI KIKAKI
Spark Plug:
Type/Manufacturer BPR7HS/NGK or W22FPR-U/ND
Gap 0.6- 0.7 mm (0.024- 0.028 in)
Clutch Type Dry, Centrifuga! automatic
Transmission:
Primary Reduction System Helical gear
Primary Reduction Ratio 48/13 (3.692)
Secondary Reduction System Spur gear
Secondary Red uction Ratio 38/11 (3.455)
Transmission Type V-belt
Operation Automatic
Chassis:
Frame Type Steel tube underbone
Caster Angle 26.5
Trail 72 mm (2.83 in)
Tire: Front Rear
Type Tubuless Tubeless
MB38/C-922 MB38/C-922
Size 80/90-1 o 34J 80/90-1 o 34J
Manufacture INOUE/CHENGSHIN INOUE/CHENGSHIN
Tire pressure (cold tire) 125 kPa 200 kPa
(1.25 kg/cm 2 , 18 psi) (2.00 kg/cm 2 , 29 psi)
Brake:
Front Brake Type Drum brake
Operation Right hand operation
Rear Brake Type Drum brake
Operation Left hand operation
Suspension:
Front Suspension Telescopic fork
Rear Suspension Unit swing
Shock Absorber:
Front Coil spring
Rear Coil spring/Oil damper
Wheel Travel:
Front Wheel Travel 42 mm (1.65 in)
Rear Wheel Travel 42 mm (1.65 in)
2-
10
GENERAL SPECIFICATIONS ISPECI .>U I lA-
Model CY50B
Electrical:
lgnition System CDI
Generator System Flywheel magneto
Battery Type or Model YT 4L-BS/GT 4L-BS
Battery Capacity 12V 4AH
Headlight type: Bulb type
Bulb Wattege x Ouantity:
Headlight 12V 25W/25W X 1
Taii/Brake light 12V 5W/21W X 1
Flasher light 12V 10W X 4
Meter light 12W 3.4W X 1
lndicator Light Wattage x Ouantity:
"TURN" 12V 1.7W X 1
"HIGH BEAM" 12V 1.7W X 1
"OIL" 12V 3.4W X 1
MAINTENANCE sPECIFicAnoNs jsPEcl P l
MAINTENANCE SPECIFICATIONS
ENGINE
Madel CY50B
Cylinder Head:
Warp Limit * 0.02 mm (0.00079 in)
*Unes indicate straightedge measurement
Cylinder:
Bare Size 39.993- 40.012 mm (1,575 in)
<Limit> <40.1 mm (1.579 in)>
Taper Limit 0.05 mm (0.002 in)
Out af Raund Limit 0.01 mm (0.0004 in)
Pistan:
Pistan Size 39.952- 39.972 mm (1.573- 1.57 4 in)
Measu ri ng Paint * 5 mm (0.2 in)
Pistan Clearance 0.034- 0.047 mm (0.0013- 0.0018 in)

<Limit> <0.1 mm (0.004 in)>
Oversize: 1st 40.25 mm (1.585 in)
2nd 40.50 mm (1.594 in)
Pistan Pin Bare Size 10.004- 10.015 mm (0.3939- 0.3943 in)
Pistan Pin:
Outside Diameter 9.996- 10.000 mm (0.3935- 0.3937 in)
Pistan Pin Clearance 0.004- 0.019 mm (0.0007- 0.0008 in)
<Limit> <0.07 mm (0.0028 in)>
Pistan Ring:
Sectianal Sketch (8 x T)JType
Tap Ring 1.5 x 1.8 mm (0.059 x 0.071 in)/Keystane
2nd Ring
End Gap (installed):
C]Js 1.5 x 1.8 mm (0.059 x 0.071 in)/Keystane
Tap Ring .. ,. 0.15-0.35 mm (0.006- 0.014 in)

T
2nd Ring 0.15-0.35 mm (0.006- 0.014 in)
Side Clearance (installed):
Tap Ring 0.03-0.05 mm (0.0012- 0.0020 in)
2nd Ring 0.03- 0.05 mm (0.0012- 0.0020 in)
Crankshaft:
-
F
Crank Width "A" 37.90- 37.95 mm (1.492- 1.494 in)

Run Out Limit "C" 0.03 mm (0.0012 in)
Connecting Rod Big End Side
Clearance"D" 0.2 - 0.5 mm (0.008- 0.020 in)
Small End Free Play "F" 0.4- 0.8 mm (0.015- 0.031 in)
2-4
MAINTENANcE sPECIFICATioNs lsPEcl P l lA- 1
Model CY50B
Automatic Centrifuga! Clutch:
Shoe Thickness 2.5 mm (0.1 O in)
<Wear Limit> <2.0 mm (0.08 in)>
Clutch Shoe Spring Free Length 26.2 mm (1.03 in)
Clutch Spring Free Length 95.4 mm (3.76 in)
<Limit> <92.4 mm (3.64 in)>
Clutch Housing lnside Diameter 105.0 mm (4.13 in)
<Wear Limit> <105.4 mm (4.15 in)>
Clutch-ln Revolution 3100- 3500 r/min
Clutch-Sta 11 Revol utia n 6050- 6550 r/min
V-Belt:
Width 16.6 mm (0.65 in)
Transmission:
Main Axle Runout Limit 0.08 mm (0.003 in)
Orive Axle Runout Limit 0.08 mm (0.003 in)
Kick Starter:
Type Ratchet type
Kick Clip Tension 150 - 250 g (5.3 - 8.8 oz)
Carburetor:
I.D. Mark 3KJ10
Main Jet (M.J.) #76
Jet Needle-clip Position (J.N.) 3ROO 3/5
Main Air Jet (M.A.J.) 02.0
Cutaway (C.A.) 2.5
Pilot Jet (P.J.) #42
Pilot Air Screw (A.S.) 1 and 5/8 turns out
Valve Seat Size (V.S.) 01.8
Starter Jet (P.J.) #48
Float Height 15.0- 17.0 mm (0.59- 0.67 in)
Engine ldling speed 1,800 r/min
Reed Valve:
Valve Stopper Height 6.0- 6.4 mm (0.24- 0.25 in)
Reed Valve Clearance Less than 0.2 mm (0.008 in)
Lubrication System:
Autolube Pump Stroke 0.5 mm (0.020 in)
2-5
-M_A_I_N_T_E_N_A_N_C_E_S_P_E_C_IF_IC_A_T_I_O_N_s_ISPECI fl
Tightening Torque
Part Tightening torque
Parts to be tightened !Thread size O'ty Remarks
na me Nm m-kg ftlb
Spark Plug - M14 x 1.25 1 20 2.0 14
Cylinder Head Nut M7 X 1.0 4 14 1.4 10
Stud Bolt - M7 X 1.0 4 17 1.7 12
Stator Assembly Screw M6 X 1.0 2 8 0.8 5.8
C.D.I. Magneto Nut M10 x 1.25 1 38 3.8 27
Air Shroud Screw M6 X 1.0 2 7 0.7 5.1
Fan Screw M6 X 1.0 3 7 0.7 5.1
Autolube Pump Screw M5 X 0.8 2 4 0.4 2.9
Reed Valve (carburetor joint) Bolt M6 X 1.0 4 9 0.9 6.5
Air Cleaner Case Screw M6 X 1.0 2 9 0.9 6.5
Exhaust Pipe Screw M6 X 1.0 2 9 0.9 6.5
Muffler Bolt M8 X 1.25 2 26 2.6 19
Muffler Protector Screw M6 X 1.0 2 9 0.9 6.5
Crankcase cover 1 Screw M6 X 1.0 11 9 0.9 6.5
Cover3 Screw M6 X 1.0 2 7 0.7 5.1
Transmission Oil Drain Bolt - M8 X 1.25 1 18 1.8 13
Kick Crank Bolt M6 X 1.0 1 9 0.9 6.5
Clutch Housing Nut M10x1.0 1 40 4.0 29
Clutch Carrier Nut M28 X 1.0 1 50 5.0 36
Primary Sheeve Nut M10x1.25 1 33 3.3 24
ldle Gear Plate Screw M6 X 1.0 2 8 0.8 5.8
Starter Motor Bolt M6 X 1.0 2 13 1.3 9.4
2-6
MAINTENANcE sPECIFicATioNs lsPEcl fJ I 1 B-
CHASSIS
Mo del CY50B
Steering System:
Steering Bearing Type Ball bearing
No./Size of Steel Balls
Upper 5/32 in 26 pes.
Lower 5/32 in 26 pes.
Front Suspension:
Front Fork Travel 47.8 mm (1.68 in)
Fork spring Free Length 91.5 mm (3.60 in)
<Limit> <87 mm (3.42 in)>
Spring Rate 5.64 N/mm (0.564/mm, 31.6 lb/in)
Stroke Zero- 47.8 mm (Zero- 1.88 in)
Optional Spring No.
Rear Suspension:
Shock absorber Travel 45 mm (1.77 in)
Spring Free Length 176.5 mm (6.95 in)
Spring Fitting Length 166.5 mm (6.56 in)
Spring Rate: (K1) 25.0 N/mm (2.5 kg/mm, 140.0 lb/in)
(K2) 37.0 N/mm (3.7 kg/mm, 207.2 lb/in)
(K3) 53.0 N/mm (5.3 kg/mm, 296.8 lb/in)
Stroke: (K1) Zero- 20 mm (Zero- 0.79 in)
(K2) 20- 35 mm (0.79- 1.38 in)
(K3) 35- 45 mm (1.38- 1.77 in)
Optional Spring No.
Wheel:
Front Wheel Type Panel wheel
Rear Wheel Type Panel wheel
Front Rim Size/Material MT 2.15 x 10/ Steel
Rear Rim Size/Material MT 2.15 x 10/ Steel
Rim Runout Limit:
Vertical 2.0 mm (0.08 in)
Lateral 2.0 mm (0.08 in)
Front Drum Brake:
Type Leading, Trailing
Drum lnside Diameter 95.0 mm (3.7 4 in)
Lining Thickness 4.0 mm (0.16 in)
Rear Drum Brake:
Type Leading, Trailing
Drum lnside Diameter 110.0 mm (4.33 in)
<Wear Limit> <111.0 mm (4.37 in)>
Lining Thickness 4.0 mm (0.16 in)
<Wear Limit> <2.0 mm (0.08 in)
2-7
MAINTENANCE SPECIFICATIONS ISPECI
Tightening Torque
Part Tghtenng torque
Parts to be tightened !Thread size O'ty Remarks
na me Nm mkg ftlb
Frame and Engne Bracket Nut M10 x 1.25 2 46 4.6 33
Engine Bracket and Engine Bolt M12 X 1.25 1 84 8.4 61
Rear Suspenson (upper) Nut M10 X 1.25 1 32 3.2 23
(lower) Bolt M8 X 1.25 1 18 1.8 13
Handlebar and Steering Column Bolt M10 X 1.25 1 60 6.0 43
Rng nut (steerng column) - M25 x 1.0 1 30 3.0 22
Front Wheel Axle Nut M10 x 1.25 1 47 4.7 34
Front Brake Cam Lever Bolt M5 X 0.8 1 4 0.4 2.9
Rear Brake Cam Lever Bolt M6 X 1.0 1 8 0.8 5.8
Rear Wheel Axle Nut M14 x 1.5 1 104 10.4 75.4
FueiSender Bolt M5 X 0.8 4 3 0.3 2.2
Carrier Nut M6 X 1.0 2 10 1.0 7.2
Carrier Bolt M8 X 1.25 1 16 1.6 11
Bridge Plate M8 X 1.25 4 26 2.6 19
Fuelcock Bolt M6 X 1.0 2 5 0.5 3.6
Fuel tank (upperl Nut M6 X 1.0 2 7 0.7 5.1
Fuel tank (lower) Bolt M6 X 1.0 2 7 0.7 5.1
Seat lock Bolt M6 X 1.0 2 7 0.7 5.1
Box (front) Bolt M6 X 1.0 2 8 0.8 5.8
Plastic Part (M6) - M6 X 1.0 - 6 0.6 4.3
(M5l - M5 X 1.0 - 1 0.1 0.7
2-8
MAINTENANcE sPEcrFrcATroNs jsPecjJ j 1 B-
ELECTRICAL
Mo del CY50B
Voltage: 12V
lgnition System:
lgnition Timing (B.T.D.C.) 14 at 5,000 r/min
Advancer Type Electrical
25
-u
-o
---
20
e
a:l
15
.,...
O>
E
-
f-- 10
e
o
-
.....
e 5
- O>
o 1 2 3 4 5 6 7 8 9
3
Engine Speed (x 10 r/min)
C.D. l.:
Magneto Modei/Manufacturer 3KJ/YAMAHA
Pickup Coil Resistance (color) 400 - 600Q at 2oc (68.F) (White/Red- Black)
Source Coil Resistance (color) 640 - 960Q at 2oc (68.F) (Biack/Red- Black)
C.D.I. Unit-Modei/Manufacturer 3KJ/YAMAHA
lgnition Coil:
Modei/Manufacturer 3KJ/YAMAHA
Primary Coil Resistance 0.56- o.84Q at 2oc (68.F)
Secondary Coil Resistance 5.68- 8.52kQ at 2oc (68.F)
Spark plug cap:
Resistance 4 - 6kQ at 2oc (68.F)
Charging System(Type: Flywheel magneto
C.D.I. Magneto:
Mo de 1/Manufactu rer 3KJ/YAMAHA
Charging Coil Resistance (color) 0.48- 0.72n at 2oc (68.F) (White- Black)
Charging Current 0.4 A at 3000 r/min- 1.0A at 8000 r/min
Lighting Coil Resistance (color) 0.45- 0.55 at 2oc (68.F) (Yellow/Red- Black)
Lighting Voltage 12V at 3000r/min- 15V at 8000 r/min
Voltage Regulator/Rectifier:
Type Semi conductor short circuit type
Mo de 1/Manufactu re r EHU-01TR27/MATSUSHITA or
No Load Regulated Voltage SH580-1 2/SHINDENGEN
13.5-14.5V
Capacity 5A
Withstand Voltage 240V
2-9
MAINTENANCE SPECIFICATIONS ISPECI t l
Mo del CY50B
Battery:
Capacity 12V, 4AH
Specific Gravity 1.32
Starter Motor:
Model DA5AN 3KJ
Manufacturer NIPPON DENSO YAMAHA
Output 0.15 kW 0.14 kW
Armature Coil Resistance 0.08- 0.100. 0.06- 0.080.
at 2oc (68.F) at 20"C (68"F)
Brush Length 4.5 mm (0.18 in) 3.9 mm (0.15 in)
<Wear Limit> <2.5 mm (0.10 in)> <0.9 mm (0.035 in)>
Brush Spring Pressure 250 - 450 gf (8.8 - 15.9 oz) 560- 840 gf (19.8- 29.7 oz)
Commutator Diameter 15.5 mm (0.61 in) 15.8 mm (0.62 in)
<Wear Limit> <14.5 mm (0.57 in)> <14.8 mm (0.58 in)>
Mica Undercut 0.9- 1.2 mm 1.15 mm (0.045 in)
(0.035 - 0.047 in)
Starter Relay:
Modei/Manufacturer 27V!TATEISHI 27V/MATSUSHITA
Amperage Rating 20A 26A
Coil Resistance 54- 660. at 20"C (68"F) 72 - 880. at 20"C (68"F)
Horn:
Ty pe/Ouantity Plain type/1 pe
Modei/Manufacturer GF-12/N IKKO
Maximum Amperage 1.5A
Flasher Relay:
Type Condenser type
Mo de 1/Man ufacture r FZ222SD/NIPPON DENSO
Self Cancelling Device No
Flasher Frequency 60- 120 cycle/min
Wattage 10Wx2+3.4W
Oil Leve! Gauge:
Modei/Manufacture r 3KJ/NIPPON BINYLON, 53UTAIHEIYOU ASTI
Circuit Breaker:
Type Fuse
Amperage for Individual Circuit x Ouantity:
Ma in 7A x 1
Fuel Sender Unit:
Model/Manufacturer YA-750-01-NO-FU/NIPPON SEIKI
Resistan ce (full) 4- 100. at 20"C (68"F)
(empty) 90- 1000. at 20"C (68"F)
2-1 o
--------G-E_N_E_R_A_L_T_O_R_Q_U_E_S_P_E_C_I_Fl_C_A_T_IO_N_S_/_ISPECI O
DEFINITION OF UNITS _ _ T 1_
1 s;
-
GENERAL TOROUE General torque
A B
SPECIFICATIONS (Nut) (Bolt)
specifications
This chart specifies torque for standard fasteners Nm m-kg ftlb

with standard I.S.O. pitch threads. Torque specifi- 10 mm 6mm 6 0.6 4.3
cations for special components or assemblies are 12 mm 8mm 15 1.5 11
included in the applicable sections of this book. 14 mm 10 mm 30 3.0 22
To avoid warpage, tighten multi-fastener assem- 17 mm 12 mm 55 5.5 40
blies in a crisscross fashio n, in prog ressive stages,
19 mm 14 mm 85 8.5 6.1
until full torque is reached. Unless otherwise
22 mm 16 mm 130 13.0 94
specified, torque specifications call for clean, dry
threads. Components should be at room
temperature.
A: Distance across flats

B: Outside thread diameter
DEFINITION OF UNITS
Unit Read Definition Measure
mm millimeter 10 -J meter Length
cm centimeter 1O 2 meter Length
kg kilogram 10 3 gram Weight
N Newton 1kg x m/sec 2 Force
Nm Newton meter Nxm Torque
m.kg Meter kilogram m xkg Torque
Pa Pascal N/m 2 Pressu re
N/mm Newton per millimeter N/mm Spring rate
L Liter
- Volume or Capacity
cm3 Cubic centimeter
r/min Revolution per minute - Engine Speed
2-11
lUBRICATION POINTS ANO lUBRICANT TYPE ISPECI :;
LUBRICATION POINTS ANO LUBRICANT TYPE
ENGINE
Lubrication Points {part name) Lubricant Type
Oil seal lips {all)
0-rings (all)
Bearing retainer
Crankshaft bearings
Needle bearings (connecting rod)
Main axle bearings
Orive axle bearings
Secondary sheave axle bearing -G
Pistan rings, pistan pins and pistons -G
Kick pinion gear
Kick shaft
Starter idle gear -G

Starter clutch pin -G
Oil pump driven gear and drive gear
Secondary sliding sheave cam groove BEL-RAY assembly lube
Secondary fixed sheave in-side dia. BEL-RAY assembly lube
Crankcase mating surfaces Yamaha bond No. 1215
2-12
LUBRICATION POINTS AND LUBRICANT TYPE jsPECI r l lB-
CHASSIS
Lubrication Points (part name) Lubricant Type
Ball bearing (steering shaft)
Throttle grip inner surface
Lever pivots and cable end
Oil seallip (front wheel)
Bearing (front wheel)
Speedometer gear
Center stand pivot
2-13
cABLE RouriNG jsPEci P l
CABLE ROUTING
CD Rectifier/regulator @ Fuse
@ Throttle cable 1 @ Ground terminal
@ Rear brake cable @ Oil hose
@ Speedometer cable [Al Clamp the cable and wireharness.
Front brake cable [ffi Clamp the wireharness, throttle cable 2 and rear brake cable.
Wireharness Pass the wireharness and throttle cable on the footrest bracket 2 .
(j) Throttle cable 2 [QJ Clamp the wireharness to the frame.
Oillevel gauge Cl.'J Mate the fuse box mating surface and lead.
Starter motor Jead And then insert it in the groove of box.
@ Starter relay [[) Pass the fuel overflow hose through the taillight ass'y guide.
(jJ) Fue! sender [ill lnsertthe cable tu be end in the holder and then insta!! the boots to the cable tu be end.
@ Taillight ass'y [8] Clamp the rear brake cable.
@ Fuel overflow hose ITJ lnstall the oil hose until stop it.
@ Banery lead (-) [JJ Do not twist the speedometer cable and front brake cable.
Banery lead (+) !].J Pass the speedometer cable and front brake cable through the hole of inner fender
1 and 2.
2-14
cABLE RouTING lsPEcl tJ I 1 B-
CD Horn [Al Clamp the C.O.I. unit lead.
Main switch llil Pass the fuel hose and vacuum hose through to thc carburetor via right side of
C.D.!. unit engine stay and between the oil tank and stay.
@) Fuel hose Pass the vacuum hose over the fuel hose.
Vacuum hose g Clip the fuel hose.
Fuelcock [QJ Pass the fuel hose under the seat bracket.
(J) Fuel overflow hose Clamp the fuel sender, taillight and battery lead H.
lgnition coil [[) Tighten the ignition coil together with ground lead.
Taillight lead [li] Pass the starter motor lead under the engine mounting bolt.
@ Fuel sender lead [8] Pass thc starter motor lead connector on the trame.
(jJ) Battery lead (-)
@ Auto choke unit lead
m Clamp the wireharness and startcr motor lead.
DJ Pass the auto choke unit lcad over the carburetor top and then connect /clamp.
@ High tension lead [K] Clamp thc wireharness at white tape aria.
@ Rectifier/regulator [] To engine.
@ C.D.I. magneto lead
@ Engine mounting bolt
2-15
-cA_B_L_E_Ro_u_T_IN_G_ISPEciPfl
CD Lever holder (right) [Al After installing, check the throttle operation.
Front brake cable ffil Clamp the front /rear brake cable, throttle cable and speedometer cable.
Flashier relay [g Tighten the handlebar install bolt and then clamp it.
ffi Rear brake cable [Q] Hook the lead to bracket of left handlebar.
Lever holder (left) [E] Clamp the wireharness only under the handlebar stem pin (6o).
Speedometer cable [E] Connect the flasherlight lead and then install it at flasherlight connector
(J) Throttle cable 1 holder.
Horn
Main switch
@ Rectifier/regulator
2-16
I J>Jlw41
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION ....................................................................................................... B-9
PERIODIC MAINTENANCE/LUBRICATION ............................................................ B-9
TAIL COVER ANO FOOTREST BOARD ................................................................... B-9

REMOVAL ........................................................................................................... B-9
INSTALLATION ................................................................................................. B-10
FRONT FENDER ANO FRONT PANEL .................................................................. B-10

RE MOVAL ......................................................................................................... B-10
INSTALLATION ................................................................................................. B-11
HANDLEBAR COVERS ........................................................................................... B-11

REMOVAL ......................................................................................................... B-11
INSTALLATION ................................................................................................. B-11
ENGINE ................................................................................................................... B-11

ENGINE IDLE SI?EED ADJUSTMENT .............................................................. B-11
THROTTLE CABLE FREE PLAY ADJUSTMENT .............................................. B-12
AUTOLUBE PUMP AIR BLEEDING .................................................................. B-12
SPARK PLUG INSPECTION .............................................................................. B-13
COMPRESSION PRESSURE MEASUREMENT ............................................... B-13
ENGINE OIL LEVEL INSPECTION .................................................................... B-14
TRANSMISSION OIL REPLACEMENT ............................................................. B-15
AIR CLEANER ELEMENT CLEANING .............................................................. B-15
FUEL COCK CLEANING .................................................................................... B-16
FUEL UNE INSPECTION ..................................................................................... C-1
CARBURETOR JOINT INSPECTION .................................................................. C-1
EXHAUST SYSTEM INSPECTION ..................................................................... C-1
CHASSIS .................................................................................................................... C-1

FRONT BRAKE LEVER FREE PLAY CHECK ....................................................... C-1
REAR BRAKE LEVER FREE PLAY CHECK ......................................................... C-2
BRAKE SHOE INSPECTION ............................................................................... C-2
-STEERING ADJUSTMENT ................................................................................. C-2
TIRE INSPECTION ............................................................................................... C-2
WHEEL INSPECTION .......................................................................................... C-3
CABLE INSPECTION ........................................................................................... C-3
LUBRICATION ..................................................................................................... C-3
FRONTFORK INSPECTION ................................................................................. C-4
REAR SHOCK ABSORBER INSPECTION ........................................................... C-4
ELECTRICAL .............................................................................................................. C-4

BATTERY INSPECTION ...................................................................................... C-4
FUSE INSPECTION ............................................................................................. C-7
HEADLIGHT BEAM ADJUSTMENT ................................................................... C-7
HEADLIGHT BULB RE PLACE ME NT ................................................................... C-8
INTRODUCTION/PERIODIC MAINTENANCE/ 11NS p 1 1
LUBRICATION ADJ ppi
----------------------------------------------------------
PERIODIC INSPECTION ANO ADJUSTMENT
INTRODUCTION
This chapter includes all information necessaryto perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable ve hiele operation and
a longer service life. The need for costly overhaul work will be greatly reduced. This information applies
to vehicles already in service as well as new vehicles that are being prepared for sale. All service techni-
cians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION
Unit: km (miles)
EVERY
BREAK-IN 3,000 6,000
ITEM REMARKS
500 (300) (2,000) or (4,000) or
6 months 12 months
Spark pi ug(s) Check condition. Clean or replace if necessary. o o o
Air filter Clean. Replace if necessary. o o
Check idle speed/starter operation.
Carburetor*
Adjust if necessary. o o
Check fuel hose and vacuum pipe for cracks or
Fuelline* damage. Replace if necessary. o o
Check oilleakage. Correct if necessary.
Transmission oil* Replace every 12,000 (8,000) or 24 months. REPLACE o o
(warm engine befare draining.)
Autolube pump* Check operation. Correct if necessary. Air bleeding. o o
Brake Check operation. Adjust if necessary. o o
Wheels* Check damage/runout. Repair if necessary. o o
Check bearings assembly for looseness/damage.
Wheel bearings* Re place if damaged. o o
Check bearings assembly for looseness.
Correct if necessary.
Steering bearing* Moderately repack every 12,000 (8,000) or 24 o o o
months.**
Rear shock absorber* Check operation/oil leakage. Replace if necessary. o o
V-belt* Check damage and wear. Replace if necessary. o
Check all chassis fittings and fasterners.
Fittings/Fasteners* Correcit if necessary. o o o
Centerstand* Check operation. Repair if necessary. o o o
* : lt is recommended that these items be serviced by a Yamaha dealer.
**: Medium weight wheel bearing grease.
3-1
TAIL COVER ANO FOOTREST BOARD 1 Ji.rlMiiil
TAIL COVER AND FOOTREST BOARD
REMOVAL
1. Open the seat lock.
2. Remove:
a Seat ()
3. Remove:
Cover ()
4. Disconnect:
e Rear flasher light leads
o Tail light leads
5. Remove:
Rear carrier Q)
o Fuel tank cap
NOTE=----------------------------
After removing the tail cover, immediately install
the tank cap on the tuel tank.
6. Remove:
Side covers CD (right and left)
NOTE=-----------------------------
When removing the side cover, unhook it at the
front and slide it backward.
3-2
TAIL COVER AND FOOTREST BOARD lNSJP 1 '""?k? 1
1 0
A
----------------------------------------------------------
7. Remove:
e Tail cover
8. Remove:
e Footrest board CD
INSTALLATION
When installing the footrest board and tail cover,
reverse the "REMOVAL" procedure.
Note the following points.
1. lnsert:
lnner damper stay CD
(in the box hale@)
\
2. lnstall:
Side covers CD
NOTE=----------------------------
Match the stayand hale, and then slide the
side cover forward.
Hook the front stay [Al .
3-3
FRONT FENDER, ANO FRONT PANEL
-------------------------------------------------------------
3.lnstall:
1 1 +el
AlNDSJP
Rear carrier
Bolt:
16 Nm (1.6 m kg, 12ft lb)
Nut:
10 Nm (1.0 m kg, 7.2 ft lb)
FRONT FENDER, ANO FRONT PANEL

REMOVAL
1. Remove:
Cap Q)
Front fender 0
NOTE:----------------------------
Before removing the fender, make sure that all
hooks are free.
2. Remove:
Main switch cap
Turn the cap counterclockwise.
3. Remove:
Front panel Q)
4. Remove:
e Footrest board bolts Q)
3-4
H_A_N_D_L_E_B_A_R_c_o_v_E_Rs_I J'Iiiil IB-
INSTALLATION
Reverse the "REMOVAL"procedure.
1.1nstall:
Front fender CD
NOTE: ----------------------------
After installing the front fender, make su re that all
hooks are securely fitted.
HANDLEBAR COVERS
REMOVAL
1. Remove:
Rear view mirror
Handlebar cover (front) CD
2. Disconnect:
Headlight leads
Flasher leads
3. Disconnect:
Speedometer cable
Meter leads
Flasher relay leads
4. Remove:
Handle cover (rear)
INSTALLATION
Reverse the "REMOVAL" procedure.
1. Connect:
Speedometer cable CD
Meter leads
Flasher relay leads @
3-5
ENGINE IDLE SPEED ADJUSTMENT lNDSJP 1
1A
o?ht? 1
----------------------------------------------------------
2. lnstall:
Handle cover (rear}
3. Connect:
Headlight leads
.. Flasher light leads
4.1nstall:
Handle cover (front)
NOTE=------------------------------
0 On the leftside, install the flasher light having a
chocolate color lead. Next, install the other
flasher light with a dark greencolor lead on the
right side.
o The leads of identcal colors should be con-
nected.
After installing the handlebar cover, make su re
that all hooks are securely fitted.
ENGINE
ENGINE IDLE SPEED ADJUSTMENT
1. Remove:
Cover
2. Tighten:
Pilota ir screw CD
Turn the pilota ir screw in untillightly seated.
3. Loasen:
Pilot air screw
Back it out from its lightly seated position.
Pilot Air Screw Turns Out:

1-5/8
3-6
THROTTLE CABLE FREE PLAY ADJUSTMENT 1 Jij1 @!liiil
4. Start the engine and let it warm up.
rrWb1;J n a _
Befare starting the engine, be sure to use the
centerstand for safety.
5. Attach:
., lnductive tachometer
To the spark plug lead
lnductlve Tachomete"
YU-08036-A
6. Check:
o Engine idle speed
Out of specification ---7 Adjust.
Engine ldle Speed:

1,800 r/min
7. Adjust:
Engine idle speed
*************************************
Adjustment steps:
O Turn the throttle, stop screw CD in or out until
specified idle speed is obtained.
Turn in ldle speed becomes higher.

Turn out ldle speed becomes lower.
*************************************
THROTTLE CABLE FREE PLAY
ADJUSTMENT
1. Check:
oThrottle cable free play
Out of specification ---7 Adjust.
Free play:
1.5-3.5 mm (0.06- 0.14 in}
*************************************
Throttle cable free play adjustment steps;
NOTE:-----------------------------
Before adjusting the throttle cable free play, the
engine idle speed should be adjusted.
First step:
e Loasen the locknut CD on the throttle cable.
e Turn the adjuster in or out until the specified
free play is obtained.
3-7
AUTOLUBE PUMP AIR BLEEDING 1 J.fl+5il
Turning in Free play is increased.
Turning out Free play is decreased.
e Tighten the locknuts.
NOTE:----------------------------
If the free play cannot be adjusted here, adjust it
at the carburetor side of the cable. (second step)
Second step:
e Remove the cover.
Loosenthe locknut(D.
Turn the adjuster(i)in or out until the specified
Turning in Free play is increased.

Tu rning out Free play is decreased.
e Tighten the locknut.

8 lnstall the cover
rrf@;NII Cfl _
After adjusting, turn the handlebar to right and
left and make sur e that the engine idling do es not
run faster.
*************************************
AUTOLUBE PUMP AIR BLEEDING

NOTE:----------------------------
The Autolube pump and delivery lines must be
bled on the following occasions:
Setting up a new scooter out of the crate.
Whenever the oil tan k has run dry.
o Whenever any portian of the engine oil system
is disconnected.
1. Remove:
Cover
Side cover (left and right)
Footrest board
Refer to "TAIL COVER AND FOOTREST
BOARD" section.
2. Remove:
o Fan cover CD
3-8
3. Air bleed:
*************************************
Air bleeding steps:
e Remove the bleed screw CD .
e Keepthe oil running out until air bubbles disap-
pear.
e When air bubbles are expelled completely,
tighten the bleed screw.
NOTE: -----------------------------
Check the bleed screw gasket, and if damaged,
replace with a new one.
lnstall the bleed screw.
NOTE: -----------------------------
Wipe off any oil on the crankcase.
*************************************
4.1nstall:
e Fan cover
Footrest board
Cover
Refer to "TAIL COVER ANO FOOTREST
BOARD" section.
SPARK PLUG INSPECTION

1. Remove:
Cover
Footrest board
Spark plug
2.1nspect:
Spark plug type lncorrect--
+ Re place.
Standard spark plug:

BPR 7HS (N.G.K.l
W22FPR-U (N.Q.)
3-9
- COMPRESSION PRESSURE MEASUREMENT _ IANosJPI I
1
_ _
3.1nspect:
Electrode CD
Wear/Damage -7 Replace.
o lnsulator
Abnormal color -7 Replace.
Normal color is a medium-to-lighttan color.
4. Clean the spear plug with a spark plug cleaner
or wire brush.
377-000 5. Measure:
Piug gap
Use a Wire Gauge or Feeler Gauge.
Out of specification -7 Regap.
Spark plug gap:

0,6 - 0.7 mm (0.024- 0.028 in)
6. Tighten:
Spark plug(s)
'-P> 1 Spark plug:
20 Nm (2.0 m kg, 14ft lb)

1
NOTE=----------------------------
Befare installing a spark plug, clean the gasket
surface and plug surface.
o lf a torque wrench is not available when yo u are
installing a spark plug, a good estmate of the
correcttorque is 1/4to 1/2 turns partfingertight.
Have the spark plug torqued to the correct val ve
as soon as possible with a torque wrench.
7.1nstall:
Footrest board
o Side cover (left and right)
e Cover
COMPRESSION PRESSURE MEASURE-

MENT
NOTE:
lnsufficient compression pressure will result in
performance loss.
1.Warm up the engine.

2. Remove:
Cover
Footrest board
3-10
Spark plug
3-11
- COMPRESSION PRESSURE MEASUREMENT. I1ANosJPI I .
3. Measure:
0!1 Compression pressure
*************************************
Measrement steps:
O lnstall the compression gauge CD using an
adapter.
O Crank over the engine with the electric starter
(be sure the battery is fully charged) with the
throttle wide open until the compression read-
ing on the gauge stabilizes.
e Check readings with specified levels (see chart)
Compresson gauge:
YU-33223
Compression pressure (at sea levell:

Standard:
800 kPa (8.0 kg/cm2, 114 psi)
Mnimum:
600 kPa (6.0 kg/cm2 , 85 psi)
Ft1!!@;J II t1 _
When cranking the engine, ground spark plug
lead to prevent sparking.
Compression test steps (below mnimum levels):

O Squirt a few drops of oil into cylinder.
o Measure compression again.
Reading Diagnosis
Higher than Worn cylinder, pistan
without oil and pistan rings
Defective pistan,
Same as ring (s), valve (s) and
without oil cylinder head gasket
Compression test steps (above standard levelsl:

O Check cylinder head or pistan crown for carbon
deposits.
e Remove the compression gauge with an
adapte r.
*************************************
3-10
- ENGINE OIL LEVEL INSPECTION _ I1ANosJPI I_ _
4.1nstall:
'p,
Spark plug
1 Spark plug:
20 Nm (2.0 m kg, 14ft lb)
' Refer to the "SPARK PLUG INSPECTION"

section.
Footrest board
Side cover (left and rightl
Cover
ENGINE OIL LEVEL INSPECTION
1. Place the scooter on the level place.
NOTE:--------------------------
Be sure the scooter is positioned stratight up and
on both wheels when inspecting the oil level.
2.1nspect:
Engine oil level
Oil level low Add sufficient oil by the
following inspection steps.
CD "OIL" indicator light
Engine oil level visual inspection steps:
Turn main switch to " *"

position.
1
+
"OIL" indicator light "OIL" indicator light
does not come on. comes on.
Turn main switch to

"ON" position.

"OIL" indicator light
does not come on.
.....
+
"OIL" indicator light
comes on.
lnspect faulty electrical

circuit, light bulbs etc.

Engine oillevel and elec-
trical circuit are OK.
l +
Supply engine oil.l
3-12
TRANSMISSION OIL REPLACEMENT 1 JiJI+el
Recommended Oil:
Yamalube 2 or equivalent air cooled
2 stroke engine oil.
Total:
0.8 L (0.7 lmp qt, 0.84 US qt)
NOTE: ------------------------------
lnstall the oil tank filler cap CD and push it fully into
the filler.
CAUTION:

...
Always use the same type of engine oil; mixing
; oils may result in a harmful chemical reaction and
lead to poor performance .
....> ; 1:
. .ollr Q /...
TRANSMISSION OIL REPLACEMENT

1.Warm up the engine at idle speed, then stop it.
2. Place the oil pan under the drain hale.
3. Remove:
Drain bolt CD
Drain the transmission oil.
Oil filler plug
4.1nspect:
Gasket (drain bolt)
0-ring@ (oil filler plug)
Damage--; Replace.
3-13
,_ AINDSJP.IP-1
- AIR CLEANER ELEMENT CLEANING
5.1nstall:
o Gasket
Drain bolt
l)iJ Drain Bolt:

18 Nm (1.8 m kg, 13ft lb)
6. Fill:
o Transmission case
Transmission Oil:
SAE 10W30 Type SE Motor Oil or GL
gear oil
Capacity:
0.1 L (0.09 lmp qt, 0.11 US qt)
NOTE: --------------------------..._
Wipe off any oil split on the crankcase, tire or
wheel.
7. lnstall:
e Oil filler plug
AIR CLEANER ELEMENT CLEANING

1. Remove:
Cover
o S ide cover ( left)
Refer to uTAIL COVER ANO FOOTREST
BOARDN section.
2. Remove:
o Air cleaner case Assembly CD
3-14
AIR CLEANER ELEMENT CLEANING I_ AINDS_ JPI++
-
3. Remove:
Air cleaner case CD
Air cleaner element @
CAUTION:
Never operate the engine with the air cleaner
element removed. This will allow unfiltered airto
enter, causing rapid wear and possible engine
damage. Additionally, operation without the
cleaner element will affect carburetorjetting with
subsequent poor performance and possible
engine overheating.
Be careful not to have rags orthe like blocking the
intake area of the air cleaner.
4.1nspect:
Eiement
Damage --7 Replace.
5.Ciean:
Air cleaner element
*************************************
Air cleaner element cleaning steps:
O Wash the element gently, but thoroughly in
solvent.
F!\W1J II tij _
Never use low flash point solvents such as
gasoline to clean the element. Such solvent may
lead to a fire or explosion.
e Squeeze the excess solvent out of the element

and let dry.
CAUTION;
Do not twist the element when squeezing the
element.
e Apply the Foam-air-filter oil or Yamalube 2 or

equivalent air cooled 2 storoke engine oil.
e Squeeze out the excess oil.
NOTE:------------------------------
The element should be wet but not dripping.
*************************************
3-15
FUEL COCK CLEANING INDSJPI&e_l
1 A
----------------------------------------------------------
6.1nstall:
o Air cleaner element
o Air cleaner case cover
o Air cleaner case assembly
e cover
e Side cover (left)
BOARD" section.
FUEL COCK CLEANING

1. Remove:
o Side cover (right)
BOARD" section.
2.Drain:
Fuel
rrwt.f.13N ' @1 _
FUEL IS HIGHLY FLAMMBLE:
o Always turn off the engine when draining.
e Ta ke ca re not to spill any fuel on the engine or
exhaust pipe/muffler when draining.
Never drain fu el while smoking or in the vicinity
of an open flame.
3. Remove:
Cap CD
Filter
e 0-ring
4. Clean:
Filter
Cap
Wash the filter and cap gently using solvent.
3-16
FUEL UNE INSPECTION/CARBURETOR JOINT INSPECTION
5.1nspect:
I JIIiwl rc.
_ _ - ---- _
Filter
0-ring
Damage Replace.
6. lnstall:
0-ring
Filter
Cap
Side cover
BOARD" section.
FUEL UNE INSPECTION

1. Remove:
Cover
Side cover (right)
BOARD" section.
2.1nspect:
Fuel pipe CD
Cracks/Damage Replace.
3.1nstall:
Cover
Side cover (right)
BOARD" section.
CARBURETOR JOINT INSPECTION

1. Remove:
Seat/Rear carrier
Tail cover/Side cover (left and right)
Footrestboard
Refer to the "TAIL COVER AND FOOTREST
BOARD" section.
Oil tan k CD
2. Disconnect
Oil leve! gauge lead
3.1nspect:
Carburetor joints CD
Refer to the "CARBURETOR" and "REED
VALVE - REMOVAL" section in the
CHAPTER 5.
3-17
EXHAUST SYSTEM INSPECTION/
FRONT BRAKE LEVER FREE PLAY CHECK
1 Jijlpl
_ _ .........._.... _
4.1nstall:
Oil tank
e Footrest board
e Tail cover/Side cover (left and right)
Seat/Carrier
BOARDH section.
EXHAUST SVSTEM INSPECTION

1. lnspect:
e Muffler assembly
e Gaskets G)
Exhaust gas leaks Replace.
*************************************
Replacement steps:
e Remove the muffler assembly.
e lnstall a new muffler assembly.
Bolt (exhaust pipe) :

9 Nm (0.9 m kg, 6.5 ft lb)
Bolt (muffler)@ : @
26 Nm (2,6 m kg, 19ft lb)
*************************************
CHASSIS
FRONT BRAKE LEVER FREE PLAY CHECK
,.---- -:.,.- t 1. Check:
e Front brake lever free play
---:::::=._
.. )
Out of specification Adjust.
10- 20 mm 10.4- 0.8 ;n)
*************************************
Front brake lever free play adjustment steps:
e Turn the adjuster CD in or out until the correct
*************************************
3-18
REAR BRAKE LEVER FREE PLAY CHECK/BRAKE SHOE [ INSPI 1
INSPECTION/STEERING ADJUSTMENT ADJ *%f
REAR BRAKE lEVER FREE PlAY CHECK
1. Check:
oRear brake lever free play
Out of specification ----" Adjust.
10 - 20 mm 10.4- 0.8 inl
*************************************
Xjt o:
Rear brake lever free play adjustment steps;
O Turn the adjuster Q) in or out until the correct
! J) *************************************
o Q
BRAKE SHOE INSPECTION

1. Actvate the brake lever.
2.1nspect:
e Wear indicator Q)
lndicator at wear limit line ----" Replace
brake shoes.
STEERING ADJUSTMENT
1. Place the scooter on its centerstand, then ele-
vate the front wheel.
2. Check:
Steering assembly bearings
Graspthe bottom ofthe forks and gently rack
the fork assembly back and forth.
Looseness----" Adjust.
3-19
TIRE INSPECTION
*************************************
JI*'+I
Steering head adjustment step;
e Remove the front fender and front panel.
Refer to "FRONT FENDER, ANO FRONT PANEL
section.
H
e Tighten the ring nutCDto specificaton using the

Ring Nut Wrench (YU-33975).
30 Nm (3.0 m kg, 22ft lbl
NOTE:----------------------------
Set the torque wrench to the ring nut wrench so
that they form a rig ht ang le.
e Move the handlebar up and down, and/or back

and forth. lf handlebar play is excess, tighten
the bolt to specification.
60 Nm (6.0 m kg. 43 ft lbl
e lnstall the front panel and front fender.

*************************************
TIRE INSPCTION
F!V.;JNigCfl _
Do not attempt to use tubeless tires on a wheel
designed for tube type tires only. Tire failure
and personal injury may result from sudden
deflation.
Wheel Tire
3..!0 007
Tubetype Tube type only
Tube type or
Tubeless type
tubeless type
Be sure to install the correct tube when using

tube type tires.
[8] Tire Tube!ess tire

lliJ Wheel [Q] Tube typ tire
C]) Air valve
Wheel (tubeless type)
@ Tube
@ Wheel (tube type)
3-20
T_I_R_E_IN_s_P_E_c_TI_O NI JPii+iil 1 C-
Front and Rear: r!w!!tti;J ,, t#l _
Manufacture Size Type
e After extensive tests, the tires mentioned have
INOUE 80/90-1 o, 34J MB38 * been approved by Yamaha motor Ca. Ltd. for
CHENGSHIN 80/90-10,34J C-922 * this model. NO guarantee for handling
(*Tubulcss tire) characteristics can be given iftire combinations
other than what is approved are used on this
scooter.
The front and rear tires should be of the same
manufacture and design.
1. Measure:
Air pressure
Out of specification Adjust.
Cold tire pressure

Front 125 kPa (1.25 kg/cm2 , 18 psi)
Rear 200 kPa (2.00 kg/cm2 , 29 psi)
341-003
Fr\fffi1J IIgCJI _
1. Proper loading ofyour scooter is important for
the handling, braking, and other performance
and safety characteristics of your scooter.
NEVER OVERLOAD YOUR SCOOTER. Make
sure the total weight of the cargo, rider, and
accessories (fairing, saddlebags, etc. if
approved for this model) does not exceed the
maximum load of the scooter. Operation of an
overloaded scooter could cause tire damage,
an accident, or even injury.
2. lmproper tire pressures greatly affect tire life
and handling. Check tire pressures prior to
each trip and adjust properly if necessary.lftire
pressures are too high, shocks from the road
will not be damped and will be carried to the
frame and handlebars, thus adversely affecting
riding comfort. In addition, scooter stability
will be peor when making a turn. lf tire
pressures are too low, tires will be deformed
greatly. thus shortening tire life. When braking
the wheels, tires could slip over wheel rims and
tire tubes could be broken. When turning the
cerner or the curve. the scooter could easily
turn over.
3-21
WHEEL INSPECTION/CABLE INSPECTION/LUBRICATION
2.1nspect:
I JJ ihl
_ _ ........ _
e Ti re surfaces
Wear/Damage ---) Replace.
Minimum tire tread depth

(front and rear):
0.8 mm (0.03 in)
341004
CD Tread depth
Side wall
Wear indicator
WHEEL INSPECTION
1 .lnspect:
Wheels
Damage/Bends---) Replace.
rp\f+@;J II @ -------------
Never attempt even small repairs to the wheel.
CABLE INSPECTION
1.1nspect:
eThrottle cable
oFront and rear brake cable
o Speedometer cable
Check for damage to the cable insulation
Corrosion/Damage---) Replace.
Obstruction Reroute.
Unsmoothness Lubricate.
LUBRICATION
Cable Lubrication
*************************************
Cable lubrication steps:
e Hold the cable in a vertical position.
O Apply lubrican! to the uppermost end of the
cable.
G Maintain its vertical position until the oil flows
to the bottom.
O Allow excess oil to drain, then reinstall the
cable.
*************************************
SAE 10W30 Type SE Moto' 011
3-22
FRONTFORK INSPECTION/ 11 NS p 1 1
REAR SHOCK ABSORBER INSPECTION :ADJ :i!lllii
Lever Lubrication
Lubricate pivoting part of each lever
SAE 1OW30 Type SE Moto Oil
Centerstand Lubrication
Lubricate the pivoting part.
SAE 10W30 Type SE Moto Oil 1
FRONTFORK INSPECTION
1.lnspect:
Front fork
Bends/Damage lnner tube comp, Fork
Ass'y- Re place.
Grease leakage lnner tube comp, Fork
Ass'y- Re place.
Unsmooth operation Fork Ass'y- Replace.
REAR SHOCK ABSORBER INSPECTION

1. lnspect:
Rear shock absorber
Oil leaks/Damage Replace.
2. Check
Tightening torque
32 Nm
1 Upper (nut)
Lower (bolt)
(3.2 m kg, 23 ft lb)
18 Nm
(1.8 m kg, 13ft lb)
3-23
I.ANosJPI I
1
-
_ _
BATTERY INSPECTION
ELECTRICAL
BATTERY INSPECTION
NOTE:----------------------------
Since the MF battery is of a sealed-type construc-
tion, it is impossible to measure the specific grav-
ity of the electrolyte in arder to check the state of
charge in the battery. Therefore, to check the state
of charge in the battery, voltage must be meas-
ured at the battery terminals.
CAUTION:
CHARGING METHOD
This battery is sealed type. Never remove
sealing caps even when charging. With the
sealing cap removed, this balancing will not be
maintained, and battery performance will
lower gradually.
e Never add water. lf distilled water is added,
chemical reaction in the battery will not
proceed in the normal way, thus making it
impossible for the battery to opera te regularly.
The charging time, charging current and
charging voltage for the MF battery is different
than general type batteries.
The MF batteryshould be charged as instructed
in the "Charging method". Should the battery
be overcharged, the electrolyte level willlower
extremely. Therefore, use special care when
charging the battery.
Avoid using any electrolyte other than
specified. The specific gravity of the M F battery
electrolyte is 1.32 at 20"C (68"F). (The specific
gravity ofthe general type battery electrolyte is
1.28.) lf the electrolyte whose specific gravity is
less than 1.32, the sulfuric acid will decrease
and thus low battery performance will result.
Should any electrolyte, whose specific gravity
is 1.32 or more, be used, the battery plates will
corrode and battery life will shorten.
rrwij;J II tCJ _
Battery electrolyte is dangerous; it contains
sulfuric acid and therefore is poisonous and
highly caustic.
Always follow these preventive mea sures:
Avoid bodily contact with elecrolyte as it can
cause severe burns or permanent eye injury.
Wear protective eye gear when handling or
367 009
working near batteries.
3-24
I.ANosJPI I
1
-
. _
BATTERY INSPECTION
Antidote (EXTERNAL):
e SKIN-Fiush with water.
s EYES-Fiush with water for 15 minutes and get
immediate medica! attention.
Antidote (INTERNAL):
Drink large quantities of water or milk follow
with milk of magnesia, beaten egg, or
vegetable oil. Getimmediate medica! attention.
Batteries also generate explosive hydrogen
gas, therefore you should always follow these
preventive measures:
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks, or open
flames (e.g., welding equipment, lighted
cigarettes, etc.)
DO NOT SMOKE When charging or handling
batteries.
KEEP BATTERIES ANO ELECTROLYTE OUT OF
REACH OF CHILDREN.
1. Remove:
' Side cover CD (leftl
BOARD" section.
2. Disconnect:
Battery leads
CA;UTlON:
Disconnect the negative lead first and then
disconnect the positive lead.
3. Remove:
Battery
4. Check:
Volt meter Battery condition
*************************************
Battery condition checking steps:
e Connect the pocket tester to the battery termi-
nals.
Tester (+) lead --t Battery (+)terminal.
Tester (-) lead --t Battery (-) terminal.
3-25
BATTERY INSPECTION 1 J"Jiwwl
,,, Relationship between open-circuit NOTE=----------------------------
voltage and charging time The state of a discharged MF battery can be
"'
Ol
i'l checked by measuring open circuit voltage (the

o>
voltage measured with the positive terminals
being disconnected).
Open-circuit voltage Charging time

T 12.8 V or higher No charging is necessary
Charging time
Thls varies dependlng on the temperature-, the state of eharge

12.7 V- 11.5 V 5 10 hours
In battery pi.ates and the e ectrolyte level.
Less than 11.5 V 15-20 hours
e Battery condition chart shown.

************************************
5. Charging method of MF battery
CAUTlON:
Condition of charge in battery( 0 o)
lf it is impossible to set the standard charging
current, be careful not to overcharge.
When charging the battery, be sure to remove
itfrom the machine. (lf charging has to be done
with the battery mounted on the machine for
sorne reason, be su reto disconnect the wire at
the negative terminal)
Never remove the sealing plug from the MF
battery.
Use special care so that charging clips are in a
Charging Ambient temperatura
full contact with the terminal and that they are
2sc
;;
not shorted. (A corroded clip ofthe charger may
"' 16
cause the battery to generate heat at the
o contact area. A weak clip spring may cause
> "
\.
'
'
14
13
..........
sparks.)
Befare removing the clips from the battery
"c'. ' -
o terminals, be sureto turn off the power switch
'
o
, .O Tme!Monu1osl
of the charger.
4 Check the Open-circuit voltage
Change in the open-circuit voltage of the MF
battery after being charged is shown below. As
shown in the figure, the open-circuit voltage is
stabilized 30 minutes after charging has been
completed.
Therefore, to checkthe condition ofthe battery,
measure the open-circuit voltage 30 minutes
after charging has been completed.
3-26
IANosJPI I
1
- BATTERY INSPECTION
. _ _
Charging method using a variable-current (voltage) type charger
Charger
AMP meter Measure the o pen-ci reuit NOTE:
voltage prior to charging.
EJ EJ 11
Voltage should be measured 30 minutes
aher the machine is stopped.
ro o, o
"'A"' Connect a ' charger
AMP meter to the battery
and
NOTE:
Set the changing voltage at 1617 v. (lf
the setting is lower, charging will be in-
-,, ' ""'

/ and start charging. sufficient. lf too high, the battery will be
over-charged.)
"--
VES '
Make sure the current is
higher than the standard
charging currentwritten on
NO
' the battery.
By turning the charging voltage

-adjust dial, setthe charging volt-' r--
age at 20 - 25 v.
v
Adjust the voltage so that cur- Monitor the amperage for 3-5
rent is at standard charging minutes to check if the standard
leve l. charging current is reached.
1A or more y
1A or less NO
lfthe current is morethan 1 amp,
adjustthe voltage to 16- 17 v and
continue charging.
Set the timer according to the After 5 minutes, ad- lf current do es not
charging time suitable for the just the voltage to 16- exceed standard
open-circuit voltage. 17 V, and continue charging current
charging. after 5 minutes,
re place the bat-
tery.
t
In case that charging requires more than 5 hours, it is advisable to
check the charging current after a lapse of 5 hours. lf there is any
change in the amperage, readjust the voltage to obtain the standard
charging current.
t
Measure the battery open-circuit voltage after having left the battery
unused for more than 30 minutes.
12.8 v or more--- Charging is complete.
12.7 v or less --- Recharging is required.
Under 12.0 v --- Replace the battery.
3-27
BATTERY INSPECTION 1 JiJii!?iil
Charging method using a constant-voltage type charger
NOTE; _
Measure the open-circuit
Voltage should be meas ured 30 minutes
voltage prior to charging. after the machine is stopped.
Connect a charger and

AMP meter to the battery,
and start charging.
Make sure the current is

YES higher than the standard NO
.--------------- r-------------,
charging current written on
the battery.
Charge the battery until the battery's This type of battery charger can not
charging voltage is 16 volts or more charge the MF battery. A variable volt-
age charger or a constant current
NOTE:------------------- charger is recommended.
Set the charging time at 20 hours
(maximum).
Charger
Check the open-circuit voltage after

having leftthe batteryfor30 minutes Volt meter
after charging.
12.8 v or more --- Charging is com-
plete.
12.7 v or less --- Recharging is neces-
sary.
Under 12 v --- Replace the battery.
3-28
BATTERV INSPECTION 1
Charging method using a constant current type charger (Exclusive for MF battery)
;.r 15*1
Measure the open-circuit NOTE:-----------------------
Voltage should be measured 30
voltage prior to charging. minutes after the machine is stopped.
Connect a charger and

AMP meter to the battery,
and start charging.
After one hour of charging,

VES NO
r-------------
make su re the rated charg- ------------
ing current of the charge is
flowing by checking AMP
meter.
Since the charging current is constant lf rated current is not flowing, replace
the charging time vares depending on the battery.
the battery capacity.
Set the charging time according to the
instructions specified for the charger.
Charger
AMP meter
o o
Measure the battery open-circuit volt-

age after having leftthe battery unused
for more than 30 minutes.
12.8 v or more--- Charging is complete.
12.7 v or less --- Recharging is required
Under 12.0 v --- Replace the battery.
3-29
FUSE INSPECTION
1. Remove:
e S ide cover CD (left)
2.1nspect:
e Fuse (j)
Detective -t Replace.
*************************************
Blown fuse procedure steps:
e Turn off ignition and the circuit.
e lnstall a new fuse of proper amperage.
G Turn on switches to verify operation of electri-
cal device.
e lffuse blows immediately again, check circuit in
question.
*************************************
F!\!A@;J II ijl -------------

oa not use fuses of higher amperage rating than
recommended. Extensive electrical system
damage and fire could result from substitution of
a fuse of improper amperage:
Description Amperage Ouantity

Main 7A 1
HEADLIGHT BEAM ADJUSTMENT
1. Adjust:
Headlight (vertically)
Vertical adjustment
Higher Loase!) the adjusters (j)
Lower Tighten the adjusters CD
Headlight (horizontal)
Horizontal adjustment
Right Tighten the adjuster @
Left Loasen the adjusters
3-30
HEADLIGHT BULB REPLACEMENT 1 J.r 1 . . 1 (.
HEADLIGHT BULB REPLACEMENT
1. Remove:
Handlebar cover (front) CD
2. Disconnect:
Headlight leads
Flasher light leads
3. Remove:
Headlight bulb cover
Headlight bulb
4. lnstall:
When installing the handlebarcover, reverse
the UREMOVAL" procedure.
3-31
----------- JitNI
CHAPTER 4.
ENGI'-1
ENGINE OVERHAUL
ENGINE REMOVAL ................................................................................................ C-12

TAIL COVER AND FOOTREST BOARD ............................................................ C-12
CARBURETOR TOP COVER ............................................................................. C-12
MUFFLER ASSEMBLY ...................................................................................... C-12
CABLES, LEADS AND PIPES ............................................................................ C-12
ENGINE REMOVAL ........................................................................................... C-13
ENGINE DISASSEMBLY ......................................................................................... C-13

CARBURETOR ................................................................................................... C-13
REAR WHEEL .................................................................................................... C-13
CENTER STAND ................................................................................................ C-13
CYLINDER HEAD AND CYLINDER ................................................................... C-13
PISTON PIN AND PISTON ............................................................................... C-14
KICK STARTER .................................................................................................. C-14
PRIMARY SHEAVE ........................................................................................... C-14
SECONDARY SHEAVE ..................................................................................... C-15
STARTER SYSTEM ........................................................................................... C-15
TRANSMISSION ............................................................................................... C-16
C.D.I. MAGNETO ............................................................................................... C-16
AUTOLUBE PUMP .............................................................................................. D-1
CRANKCASE AND CRANKSHAFT ..................................................................... D-1
INSPECTION ANO REPAIR ...................................................................................... D-2

CYLINDER HEAD ................................................................................................ D-2
CYLINDER AND PISTO N .................................................................................... D-2
PISTON RINGS ................................................................................................... D-3
PISTON PIN AND PISTO N PIN BEARING ......................................................... D-3
KICK STARTER .................................................................................................... D-4
TRANSMISSION ................................................................................................. D-4
AUTOLUBE PUMP .............................................................................................. D-4
CRANKSHAFT ..................................................................................................... D-4
PRIMARY SHEAVE ............................................................................................. D-5
SECONDARY SHEAVE ....................................................................................... D-5
V-BELT ................................................................................................................. D-6
STARTER CLUTCH AND GEARS ....................................................................... D-6
ENGINE ASSEMBLY AND ADJUSTMENT ............................................................ D-7

CRANKSHAFT AND CRANKCASE ..................................................................... D-7
AUTOLUBE PUMP .............................................................................................. D-9
C.D. l. MAGNETO ................................................................................................ D-9
TRANSMISSION ............................................................................................... D-10
STARTER SYSTEM ........................................................................................... D-11
SECONDARY SHEAVE ..................................................................................... D-13
PRIMARY SHEAVE ........................................................................................... D-13
KICK STARTER .................................................................................................. D-14
PISTON PIN AND PISTO N ............................................................................... D-16
CYLINDER AND CYLINDER HEAD ................................................................... D-16
REMOUNTING ENGINE ..................................................................................... E-1
ENG
ENGINE REMOVAL ENG
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE: ----------------------------
lt is not necessaryto remo ve the engine in orderto
remove the following components.
Cylinder head
Cylinder
Pistan
C.D.I. magneto
Starter motor
Primary and secondary sheave
Transmission
TAIL COVER ANO FOOTREST BOARD

1. Remove:
Seat
Rear carrier
S ide covers (left and right)
Tail cover
Footrest board
Refer to "CHAPTER 3. - TAIL COVER AND
FOOTREST BOARD" section.
CARBURETORTOPCOVER
1. Remove:
Air cleaner case assembly CD
2. Remove:
Carburetor top cover CD
NOTE: ----------------------------
Cover the carburetor with a clean rag to prevent
dirt or foreign matter into the carburetor.
Fuel hose@
Vacuum hose
4-1
ENGINE REMOVAL ENG
MUFFLER ASSEMBLY
1. Remove:
o Muffler assembly CD
e Fan cover
2. Loasen:
Rear wheel axle nut CD
NOTE=--------------------------
When loosethe rearwheel axle nut, applythe rear
brake.
CABLES, LEADS AND PIPES

1. Remove:
e Oil hose CD at oil pump side.
NOTE=----------------------------
Piug the oil hose so the oil will not drain out of it.
2. Remove:
Battery negative lead CD
Earth lead
3. Disconnect:
Starter moter lead @
4. Remove:
Spark plug cap
5. Disconnect:
CDI magneto lead CD
Auto choke unit lead
4-2
ENGINE REMOVAL/ENGINE DISASSEMBLY ENG ..
6. Remove:
e Rear brake cable G)
ENGINE REMOVAL
1. Remove:
Rear shock absorber bolt CD (lower)
e Engine mounting bolt
2. Remove:
e Engine
Lift up the frame and remove the engine.
3. Place the frame on a suitable stand.
ENGINE DISASSEMBLY
CARBURETOR
2 1. Remove:
Oil delivery hose G)
Carburetor
4-3
ENGINE DISASSEMBLY 1
REAR WHEEL
ENG 1 "-l
1. Remove:
Rear wheel
o Brake shoes Q)
o Plane washer 0
CENTER STAND
1. Remove:
Spring Q)
Clip 0
o Rubber washer
e Shaft CD
Clamp@
o Center stand
CYLINDER HEAD AND CYLINDER

NOTE=---------------------------
With the engine mounted, the cylinder head, cyl-
inder, and pistan can be maintained by removing
the following parts.
Cover and sidecover (left and right)
Footrest board
Fan cover and air shroud
Muffler assembly and cylinder stud bolt
1. Remove:
o Air should
e Cylinder head Q)
Cylinder head gasket
NOTE=---------------------------
e Befare loosening the cylinder head, loasen the
spark plug 0.
The cylinder head holding nuts should be loos-
ened 1/2 turn each time, and remove.
2. Remove:
Cylinder Q)
Cylinder gasket
4-4
ENGINE DISASSEMBLY ENG
PISTON PIN ANO PISTON
1. Remave:
Pistan pin clip CD
NOTE: -----------------------------
Befare removing the pistan pin clip, cover the
crankc-ase with a e lean rag so yo u will not acciden-
tally drap the clip into the crankcase.
2. Remave:
Pistan pin CD
Pistan
Pistan pin bearing
Do not use a hammer to drive the pistan pin out.
KICK STARTER
NOTE: -----------------------------
With the engine maunted, the kick starter can be
maintained by removing the fallawing parts.
Air cleaner case assembly
1. Remove:
Kick crank CD
Cover
2. Remove:
Crankcase caver CD (left)
4-5
ENGINE DISASSEMBLY 1 ENG l'\.1
3. Remove
o Kick pinion gear cD
NOTE=----------------------------
When remove the kick pinion gear, operate the
kick axle.
4. Unhook
Return spring (V
5. Remove:
o Circlip CD
Plain washer (V
e Kick shaft
PRIMARY SHEAVE
NOTE=----------------------------
With the engine mounted, the primary and secon-
dary sheave can be maintained by removing the
following parts.
Cover and side cover (left and right)
Footrest board
Fan cover
Crankcase cover (left)
1. Remove:
s Fan CD
2. Remove:
Nut CD (primary sheave)
NOTE=----------------------------
When loosening the nut (primary sheave), hold
the C.D.I. magneto using Flywheel Holding Tool
.
Flywheel Holding Tool: VU-
01235
4-6
ENGINE DISASSEMBLV ENG
3. Remove:
Conical spring washer CD
One-way clutch
Washer
o Primary fixed sheave @
Shim
V-Belt
4. Remove:
Collar CD
Primary sheave assembly
SECONDARY SHEAVE
1. Remove:
0-ring CD
Nut (secondary sheave)
NOTE:---------------------------
Hold the secondary sheave using Sheave Holder
.
Sheave Holder: YS-
01880
2. Remove:
Clutch housing CD
Secondary sheave assembly
Crankcase cover gasket
Dowel pins
3. Attach:
Sheave Holder CD
Socket Wrench (41MM)
Sheave Holde"
YS-01880
4. Loasen:
Clutch securing nut
CAUTIOf\!: ....
Do not remove the clutch securing nut yet.
4-7
ENGINE DISASSEMBLY ENG ,....
5. Attach: '
Clutch Spring Holder CD
NOTE:------------------------------
Compress the secondary sheave by Clutch
Spring Holder CD .
Clutch Sp,;ng Holde"

1
- - YS-28891
6. Remove:
Clutch securing nut
7. Remove:
Clutch assembly CD
o Clutch spring
Spring seat @)
8. Remove:
e Guide pins CD
Secondary sliding sheave
STARTER SYSTEM
NOTE:----------------------------
With the engine mounted, the starter system can
be maintained by removing the following parts.
Footrest board and Fan cover
Muffler assembly and Rear wheel
Crankcase cover (left)
Primary sheave
1. Remove:
Plate CD (id le gear)
ldle gear
Starter clutch assembly
Washer
Starter wheel gear
4-8
2. Remove:
Collar CD
Bearing
eWasher
3. Remove:
Starter motor CD
TRANSMISSION
NOTE:----------------------------
With the engine mounted, thetransmission can be
maintained by removing the following parts.
Air cleaner case assembly
Muffler assembly
o Rear wheel
Crank case cover (left)
V-belt and Secondary sheave
1. Remove:
Transmission case cover CD
Gasket
Dowel pins @
2. Remove:
Main axle CD
Orive axle
Plain washer @
Conical spring washer CD
4-9
3. Remove:
e Oil seal CD
e Circlip (V
Secondary sheave axle
C.D.I. MAGNETO
NOTE:-----------------------------
With the engine mounted, the C.D.I. magneto can
Seat and rear carrier
Tail cover and footrest board
Fan cover
Fan
1. Remove:
Nut CD (rotor)
Plain washer
NOTE:----------------------------
Hold the rotor to loasen the nut by the Flywheel
Holding Tool 0.
Flywheel Holding Tool: YU-

01235
2. Remove:
Rotor CD
Woodruff key
Use the Flywheel Magneto Puller (V.
Flywheel Magneto Puller: YM-

01189
3. Remove:
Stator assembly CD
4-10
4. Remove:
o Gasket CD
AUTOLUBE PUMP
NOTE:------------------------------
With the engine mounted, the autolube pump can
Cover and side cover
e Footrest board
Fan cover
C.D.I. magneto
1. Remove:
Autolube pump CD
2. Remove:
o Circlip CD
o Pump drive gear
Pin
Circlip 0
3. Remove:
Carburetor joint CD
o Reed valve
Reed valve gasket
4-11
ENG
ENGINE DISASSEMBLV
1_
"'-1 _
CRANKCASE ANO CRANKSHAFT

1. Remove:
Oil seal stopper CD
e Screws (crankcase)
NOTE=---------------------------
Loosen each screw 1/4 turn, and remove them
after all are loosened.
2. Attach:
Crankcase Separating Tool CD
Crankcase Separating Tool:
YU-01135
NOTE:----------------------------
Fully tighten the tool holding bolts, but make sure
the tool body is parallel with the case.lf necessary,
one screw may be backed out slightly to level tool
body.
3. Remove:
& Crankcase (right)
As pressure is applied, alternatelytap on the
engine mounting bosses.
CAUTION:
Use soft hammer to tap on the case half. Tap only
on reinforced portions of case. Do not tap on
gasket mating surface. Work slowly and carefully.
Make su re the case halves separate evenly. lf one
end "'hangs upH, take pressure offthepush screw,
realign, and start over. lf the cases do not
separate, check for a remaining case screw or
fitting. Do not force.
4. Attach:
Crankcase Separating Tool CD
Crankcase Separating Tool:

YU-01135
5. Remove:
Crankshaft @
4-12
INSPECTION AND REPAIR
INSPECTION ANO REPAIR
ENGI'-1 [[
CYLINDER HEAD
1. Eliminate:
Carbon deposits
Use a rounded scraper CD.
NOTE=----------------------------
Take care to avoid damaging the spark plug
threads. Do not use a sharp instrument. Avoid
scratching the aluminum.
2.1nspect:
1111 Cylinder head warpage
Out of specification Re-surface.
*************************************
Warpage measurement and re-surfacement
steps:
e Attach a straight edge(D anda thickness gauge
on the cylinder head.
e Measure the warpage limit.
rAl Warpage Limit:

o.o2 mm w.oooa in)
e lfthe warpage is out of specification, reface the
cylinder head.
O Place a 400 - 600 grit wet sandpaper on the
surface plate, and re-surface the head using a
figure-eight sanding pattern.
NOTE:-----------------------------
Rotate the head severa! times to avoid removing
too much material from one side.
*************************************
CYLINDER ANO PISTON

1. Eliminate:
Carbon deposits
Use a rounded scraper CD.
2.lnspect:
1111 Cylinder wall
Wear/Scratches Rebore or replace.
4-13
INSPECTION AND REPAIR
3. Eliminate:
1 1 '\.l ENG
o Carbon deposits
From th,e pistan crown and ring grooves.
4. Remove:
Score markes and lacquer deposits
From the sides of pisten.
Use a 600- 800 grit wet sandpaper.
NOTE=-----------------------------
Sand in a crisscross pattern. Do not sand exces-
sively.
5.1nspect:
o Pistan wall
Wear/Scratches/Damage ---+ Replace.
6. Measure:
o Piston-to cylinder clearance
*************************************
Piston-to cylinder clearance measurement steps:
First step:
O Measure the cylinder bore "'Cw with a Cylinder
Bore Gauge.
NOTE=----------------------------
Measure the cylinder bore "'C" in parallel to and at
right angles to the crankshaft. Then, find the aver-
age of the measurements.
Standard Wear Limit
Cylinder Bore 39.99 - 40.01 mm 40.10 mm

"C'' (1.574- 1.575 in) (1.579 in)
0.05 mm
TaperuT" - (0.0019 in)
Out of Round 0.01 mm
"R"
- (0.0004 in)
C= Maximum D
T = (Maximum D 1 or D 2 )-
(Maximum D 5 or D 6 )
R = (Maximum D,, D 3 or D5 )-
(Mnimum D 2 , D 4 or D 6 )
4-14
INSPECTION ANO REPAIR 1 l"\alENG
e lf out of specification, rebore or replace cylin-
der, and replace pistan and pistan rings as a set.
2nd step:
e Measure the pistan skirt diameter "P" with a
micro meter.
5.0 mm (0.20 in) from the pistan bottom edge
Pistan Size P
307-000
Standard 39.95 - 39.97 mm

(1.573- 1.574 in)
Oversize 1 40.25 mm (1.585 in)
Oversize 2 40.50 mm (1.594 in)
e lf out of specification, rep lace pistan and pistan

rings as a set.
3rd step:
O Calculate the piston-to-cylinder clearance with
following formula:
Piston-to cylinder Clearance =

Cylinder Bore "C""-
Pistan Skirt Diameter "P"
lf out of specification, rebore or replace cylin-

der, and re place pistan and pistan rings as a set.
Piston-to-cylinder Clearance:
0.034 - 0.047 mm
(0.0013 - 0.0018 in)
Limit:0.1 mm (0.004 in)
*************************************
PISTON RINGS
1. Measure:
S ide clearance
Out of specification ---7 Re place pistan and/or
rings.
Use a Feeler Gauge CD .
Standard Limit
307-005
0.03- 0.05 mm 0.10 mm

Top ring
(0.0012- 0.0020 in) (0.004 in)
2nd ring 0.03- 0.05 mm 0.10 mm

(0.0012- 0.0020 in) (0.004 in)
2.1nstall:
Pistan ring
lnto the cylinder
Push the ring with the pistan crown.
4-15
INSPECTION AND REPAIR ENG
3. Measure:
End gap
Out of specification Re place rings as a set.
Use a Feeler Gauge CD .
Standard Limit
Top ring 0.15-0.35 mm 0.70 mm

307 027 (0.006- 0.014 in) (0.028 in)
2nd ring 0.15- 0.35 mm 0.70 mm

(0.006- 0.014 in) (0.028 in)
Measuring Point 20 mm (0.8 in)

4. Oversize pistan ring size:
Ring size is stamped on top of the ring.
Oversize pistan ring

Oversize 1 25
Oversize 2 50
PISTON PIN AND PISTON PIN BEARING

1. lnspect:
Pistan pin
Blue discoloration/Groove Replace, then
inspect lubrication system.
2. Measure:
Outside diameter (pistan pin)
Out of specification Re place.
Out side diameter (pistan pin):

9.996- 10.000 mfll
(0.3935 - 0.3937 in)
3. Measure:
307-018
Pistan pin-to-pistan clearance
Out of specification Replace pistan.
Pistan pin-to-pistan clearance =

Bore size (pistan pin) -
Outside diameter (pistan pin)
Pisten pin-to-pisten clearance:

0.004- 0.0019 mm
(0.0002- 0.0008 in)
<Limit: 0.07 mm (0.028 in)>
4-16
INSPECTION ANO REPAIR ENG
4.1nspect:
Bearing (piston pin)
Pitting/Damage -----? Replace.
KICK STARTER
1.1nspect:
Kick gear teeth Q)
Kick pinion gear teeth @
Burrs/Chips/RoughnessJ\/Vear-----? Replace.
2.1nspect:
o Mating dogs (kick pinion gear and one-way
clutch)
Rounded edges/Damage-----? Replace.
3. Measure:
Clip tension (kick pinion gear)
Out of spedification-----? Re place.
Use a spring balance.
Standard Tension:
100-300 g (3.53- 10.6 oz)
4-17
TRANSMISSION
1. lnspect:
e Orive axle Q)
o Ma in axle CV
o Secondary sheave axle
Burrs/Chips/Roughness/Wear Replace.
CD
2.1nspect:
Secondary sheave axle bearing Q)
Main axle bearing @
Orive axle bearing
Spin the bearing inner race.
Excessive play/Roughness Replace.
Pitting/Oamage Replace.
AUTOLUBE PUMP
Wear oran interna! malfunction may cause pump
output to very from the factory setting. This situ-
ation is, however, extremely rare. lf improper
output is suspected, inspect the following:
1. lnspect:
Oelivery line
Obstructions Blow out.
0-ring
Wear/Oamage Replace.
2.1nspect:
Autolube pump drive gear teeth CD
eAutolube pump driven gear teeth @
Pitting/Wear/Oamage Replace
CRANKSHAFT
1. Measure:
Runout limit uC"
Connecting rod big end side clearance UD"
Small end free play limit UF"
Use V-Biocks, Dial Gauge and thickness
gauge.
4-18
INSPECTION ANO REPAIR ENG @11
Runout Limit MC":
0.03 mm (0.0012 in)
Connecting Rod Big End Side
Clearance UD":
0.2 - 0.5 mm (0.008 - 0.02 in)
Small End Free Play UF":
0.4- 0.8 mm (0.015- 0.031 in)
2.1nspect:
Bearings (crankshaftl
Spin the bearing inner race.
Excessive play/Roughness 4 Replace.
Pitting/Damage Replace.
PRIMARY SHEAVE
l.lnspect:
e Primary sliding sheave CD
e Primary fixed sheave
Wear/Cracks/Scratch/Damage----) Replace.
2. Check:
o Free movement
lnsert the collar into the primary sliding
sheave, and check for free movement.
Stick or excessive play 4 Replace the sheave
or collar.
3. Measure:
Out side diameter CD (weight)
Out of specification 4 Replace.
Out side liameter (weight)

1.50 mm (0.59 in)
<Limit 14.5 mm (0.57 in)>
4-19
/
I_N_s_P_E_c_T_Io_N_A_N_D_R_E_P_A_IR_,ENG
SECONDARY SHEAVE
1. lnspect:
e Secondary fixed sheave CD
e Secondary sliding sheave@
Scratch/Crack/Damage Replace as a set.
Oil seal
Damage Replace.
2. lnspect:
Torque cam groove CD
Guide pin@
Wear/Damage Replace as a set.
0-rings
Damage Replace.
3. Measure:
Clutch spring free length
Clutch Spring Free Length:

109.6 mm (4.31 in)
<Limit>:
94.0 mm (3.70 in)
4.1nspect:
Clutch housing inner surface
Use a rag soaked in lacquer

Oil
thinner or solvent.
Use an emery cloth
Scratches (lightly and evenly polishing).
Oil/Scratches
Remove.
5. Measure:
e Clutch housing inside diameter @
Out of specification Replace.
Clutch Housing lnside Diameter:

105.0 mm (4.13 in)
<Wear Limit>:
105.4 mm (4.15 in)
4-20
6. lnspect:
e Clutch shoes
Glazed parts ) Sand with coarse sandpaper.
NOTE=-----------------------------
After using the sand paper, clean ofthe polished
particles with cloth.
7. Mea su re:
Clutch shoe thickness @
Clutch Shoe Thickness:

2.5 mm (0.10 in)
<Wear Limit>:
2.0 mm (0.08 in)
V-BELT
1.1nspect:
V-belt
Crack;Wear-* Re place.
NOTE=-----------------------------
Replace the V-belt smeared with a lot of oil or
grease.
2. Measure:
V-belt width
Out of specification -* Re place.
V-Belt Width:
16.6 mm (0.65 in)
<Wear Limit>:
15.2 mm (0.60 in)
STARTER CLUTCH AND GEARS

1.1nspect:
Starter clutch
Push the dowel pinto arrow direction.
Unsmooth operation -* Replace starter
clutch assembly.
4-21
2. lnspect:
Starter wheel gear teeth CD
ldle gear teeth
Burrs/Chips/Roughness,.Wear --7 Replace.
Bearing (starter wheel gear)
Pitting/Damage --7 Replace.
4-22
ENGINE ASSEMBLY ANO ADJUSTMENT 1 ENG l'\.1
ENGINE ASSEMBLY AND ADJUSTMENT
CRANKSHAFT ANO CRANKCASE
Q) Oil seal Crank pin
(2) Oil seal stopper Connecting rod
@ Crankcase (right) @ Crank {left)
Dowel pin (jJ) Bearing
Bearing @ Engine mount spacer
Crank (right) @ Crankcase (leh)
(j) Bearing @ Oil seal
B CRANKSHAFT:
A: 37.90 - 37.95 mm

{1.492- 1.494 in)
9 N m {0.9 m kg, 6.5 ft lb) C: 0.03 mm {0.0012 in)
D: 0.2 - 0.5 mm
{0.08- 0.020 in)
F: <Limit> 1.0 mm {0.04 in)
0.4-0.8 mm
{0.016- 0.031 in)
11
1 6204 1
4-23
ENGINE ASSEMBLY ANO ADJUSTMENT 1 ENG
CRANKSHAFTANDCRANKCASE
CAUTION:
To protect the crankshaft against scratches orto
facilitate the operation of the installation, apply
the grease to the oil seallips, and applythe engine
oil to each bearing.
1. Attach:
Crankshaft lnstallation set
Crankshaft lnstallation Set:

Q) : YU-90050
(V: YM-90062
2.1nstall:
Crankshaft
{to left crankcase}
NOTE:
Hold the connecting rod at top dead center with
one hand while turning the nut of the lnstalling
Too! with the other. Operate the lnstalling Tool
until the crankshaft bottoms against the bearing.
3.1nstall:
Dowel pins CD
S pacer CV
4. Apply:
Y ama ha Bond No.1215
To the mating surfaces of both case helves.
Yamaha bond No.1215:

P/N. ACC-11001-01
4-24
ENGINE ASSEMBLY ANO ADJUSTMENT 1 ENG l'\.1 1 D
5. Attach:
Crankshaft lnstallation Set
Crankshaft lnstallation Set:

CJ); YU-90050
<1): YU-90062
6.1nstall:
Right crankcase
7. Tighten:
Crankcase holding screws
NOTE=-----------------------------
Tighten the crankcase holding screws in stage,
using a crisscross pattern.
9 Nm (0.9 m kg. 6.5 ft lbl
8. Check:
Crankshaft operation
Unsmooth operation Repair.
9.1nstall:
Oil seal stopper plate CD
Screw (oil seal stopper plate)
9 Nm (0.9 m kg, 6.5 ft lb)
4-25
ENGINE ASSEMBLY ANO ADJUSTMENT
AUTOLUBE PUMP AND C.D.I. MAGNETO
(j) Fan @ Oil delivery hose
ENG
-
C2) Plain washer (jJ) Oi 1 hose
@ Rotor assembly @Clip
G) Charge coil @ Autolube pump
W Lighting coil @ 0-ring
Pickup coil @ Circlip
(J) Stater assembly @ Oil pump drive gear
Oil seal @ Pin
Gasket
17Nm(0.7mkg,5.1ftlb)
i@@ 1 38 Nm (3.8 m kg, 27ft lb) 1

1
SOS-19-25-5 NS
9
1 A 1 USE NEW ONE 1
''>
1 AIUSENEWONE
.---4 _N_m_(_0_.4_m_ -kg-.-2-.9-ft__l_b )--4

1
1
1
o
)
CLtr=A:....., ,-U-SE-N E_W_O_N_E--,1
4-26
ENGINE ASSEMBLY ANO ADJUSTMENT ENG
AUTOLUBE PUMP
1.lnstall:
Circlip Q)
Pin C1)
C9 Pump drive gear
Circlip 0
2.Apply:
C9 Lithium soap base grease
(to O ring C1))
3.lnstall:
C9 Autolube pump Q)
Screw (autolube pump):

4 Nm (0.4 m kg, 2.9 ft lb)
4.Apply:
C9 Lithium soap base grease
(to autolube pump gear CD, )
15 ce (0.92 cu ;n)
C.D.I. MAGNETO
1.1nstall:
Gasket Q)
2.Apply:
Lithium soap base grease
(to oil seal Q) )
4 27
ENGINE ASSEMBLY AND ADJUSTMENT ENG
--
3. Pass the C.D.I. magneto lead through the
crankcase hale.
4. lnstall:
Stator assembly Q)
Screw (stator assembly):

8 Nm (0.8 mkg, 5.8 ftlbl
5. lnstall:
Woodruff key
C.D. l. magneto
Plain washer
Nut
NOTE:-----------------------------
When installing the C.D. l. magneto, make surethe
woodruff key is properly seated in the key way of
the crankshaft. Apply a light coating of lithium
soap base grease to the tapered portian of the
crankshaft end.
6. Tighten:
Nut (C.D.!. magneto)
Use Flywheel Holding Tool Q).
1)5J Flywheel holding tool:

YU-01235
38 Nm (3.8 m kg, 27ft lb)
4-28
ENGINE ASSEMBLY ANO ADJUSTMENT 1 ENG '"-' ID-'
TRANSMISSION
CD Circlip Secondary shcavc axle
(]) Bearing @ Bearing
@ Oil sea! @ Dowel pin
Orive axle @ Gasket
Bearing @ Transmission case cover
Main axle @ Circlip
(J) Conical spring washer @ Oil seal
Plain washer
A USE NEW ONE
1 6203DU 1
1 SDS-22-32-6 1
1 1 A 1 USE NEW ONE 1
,--------{ 1o 13
1 MHSA-17-28-SSXLTU-A \
A USE NEW ONE
9 N m (0.9 m kg, 6.5 ft lb)
4-29
ENGINE ASSEMBLY AND ADJUSTMENT _
---------------------------------------------
TRANSMISSION
I .-...1 _
ENGI
1. Apply:
_
10W30 Type SE Motor oil
(to transmission case cover bearing)
2. lnstall:
Secondary sheave axle CD
(to transmission case cover)
3.1nstall:
Circlip@
Oil seal CID
NOTE:----------------------------
Apply lithium soap base grease onto the oil sea!
lips.
4. Check:
e Secondary sheave axle operation
Unsmooth operation -t Repair.
5.Apply:
10W30 type SE Motor oil
(to main axle bearing and drive axle bearing)
6.1nstall:
Orive axle Q)
Main axle
o Conical spring washer CID
Plain washer 0
7. lnstall:
Gasket Q)
Dowel pins
Transmission case cover
Screw (case cover):
9 '1\lm (0.9 m kg, 6.5 ft lb)
4-30
STARTER SYSTEM
G) Collar
(2) Plain washer
ENGINE ASSEMBLY ANO ADJUSTMENT
(J) Shaft
Plain washcr
ENG " --
Bearing ldle gear
Starter wheel gear @ 0-ring
@ Starter clutch @ Starter motor
Plate
1
f>
13 Nm (1.3 m kg, 9.4 ft lb)
4-31
STARTER SYSTEM
1. lnstall:
Collar CD
Plain washer CV
Bearing
& Starter wheel gear @
Starter clutch
NOTE:
Apply lithium soap base grease to the baring
.
Apply molybdenum disulfide oil to the pin
(starter clutch) .
2.lnstall:
Plain washer CD
ldle gear
Plain washer CD
Plate (id le gear)
Screw (idle gear platel:

8 Nm (0.8 m kg, 5.8 ft lb)
NOTE:--------------------------
Apply engine oil to the idle gear CV.
3. lnstall:
Starter motor CD
13 Nm (1.3 m kg, 9.4ft lb]
NOTE=--------------------------
Apply lithium soap base g reasetothe 0-ring ofthe
starter motor.
4-32
PRIMARY ANO SECONDARY SHEAVE
ENGINE ASSEMBLY AND ADJUSTMENT 1 ENG 1 1 ID-
CD 0-ring Secondary sliding sheave
@Shim
Clutch housing @ V-belt
@Collar
Clutch carrier (j] Guide pin
@ Primary sliding sheave
@) Weight spring @ Secondary fixed sheave
Clutch spring @ Conical spring washer Clutch weight
@ Slider
Spring seat @ One-way clutch
@Cam
(J) Oil seal @ Washer
0-ring @ Primary fixed sheave
*: Apply BEL-RAY Assembly lube
B CLUTCH SPRING FREE LENGTH LIMIT:

95.4 mm (3.76 in)
C CLUTCH HOUSING WEAR LIMIT:
105.4 mm (4.15 in)
D CLUTCH SHOE WEAR LIMIT:
2.0 mm (0.079 in)
E V-BELT WEAR LIMIT:
15.2 mm (0.60 in) 40 Nm (4.0 m kg, 29ft lb)
---- --------------
F CL.UTCH WEIGHT LIMIT:
14.5 mm (0.57 in)
1 A 1 USE NEW ONE
16
4-33
ENGINE ASSEMBLV ANO ADJUSTMENT ENG
KICK STARTER
CD Kick shaft
@ Return spring
Collar
@ Plain washer
@ Circlip
Kick crank
(]) Clip
@ Kick pinion gear
1 9 N m (0.9 m kg, 6.5 ft lb)
1 A 1 USE NEW ONE 1 5
B
100- 300 g (3.53- 10.60 z)
4-34
SECONDARY SHEAVE
When assemblying the secondary sheave, re-
verse the disassembly procedure. Note the fol-
lowing points.
1. Apply:
o BEL-RAY Assembly Lube
(to the inside of the sliding/fixed sheave)
2.1nstall:
Sliding sheave CD
NOTE:-----------------------------
Be careful so that the oil seal lips are not turned
over when installing the sheave.
3. Apply:
BEL-RAY Assembly Lube
(to the torque cam grooves and 0-rings)
4. Check:
Sliding sheave
5.1nstall:
Clutch securing nut
Use Clutch Spring Holder CD
Clutch Spring Holder:
YS-28891
6. Tighten:
Clutch securing nut
Use Sheave Holder CD
Wrench (41MM).
Sheave holder:
YS-01880
1
4-35
50 Nm (5.0 m kg, 36ft lb)
ENGINE ASSEMBLY AND ADJUSTMENT
7 .lnstall:
ENGI I
Dowel pin CD
o Crankcase cover gasket
8.1nstall:
Secondary sheave assembly CD
Clutch housing
9. Tighten:
Nut CD (secondary sheave)
Use Sheave Holder
Sheave Holde"
YS-01880
40 N m (4.0 m kg, 29ft lb!
10.lnstall:
0-ring
PRIMARY SHEAVE
1. Clean:
Primary sliding sheave face CD
Primary fixed sheave face @
Collar
Weight
Primary sliding sheave ca m surface
2. lnstall:
Weight CD
Cam
Siider
Collar@
3. Check:
Ca m operation
Not smooth -4 Repair.
4-36
ENGINE ASSEMBLY ANO ADJUSTMENT ENG -
4.1nstall:
e Primary sheave assembly CD
e Collar
5.1nstall:
V-belt
Place the V-belt around the secondary
sheave, and compress the secondary sheave
spring hard so that the V-belt moves toward
the clutch hub.
NOTE:----------------------------
The V-belt must be installed with the arrow
frontward.
6.1nstall:
e Shim (i)
1 Primary fixed sheave

Washer@
One-way clutch @
Conical spring washer
Nut
7. Tighten:
Nut (i) (primary sheave)
ISI33 13.3 Nm m kg. 24ft lb]
NOTE:--------------------------
When tightening the nut (primary sheave), hold
the C.D.I. magneto using Flywheel Holding Tool
.
Flywheel Holding Tool:

YU-01235
4-37
8. Adjust:
e V-belt
Tense the V-belt by turning the primary sheave

severa! times.
9.lnstall:
o Fan CD
= Screw (fan):
7 Nm (0.7 m kg, 5.1 ft lb)
. 1/t; KICK STARTER

1. lnstall:
e
Return spring Q)
e Kick shaft @
t Collar
o Plain washer
,11, 1
Circlip
(
:r \
2. Hook:
Return spring Q)
(to the kick gear 0 and boss )
3.1nstall:
e Kick pinion gear Q)
4-38
ENGINE ASSEMBLY AND ADJUSTMENT ENG ..
r-------------------------- 4.1nstall:
e Crankcase cover CD
Screw (crankcase cover)
9 N m (0.9 m kg, 6.5 ft o lb)
5.1nstall:
e Cover CD
e Kick crank
Screw (cover)
7 Nm (0.7 m o kg, 5.1 ft o lb)
, .:;.a Kick crank
9 Nm (0.9 m kg, 6.5 ft lb)
4-39
PISTON, CYLINDER AND CYLINDER HEAD
CD Carburetar jaint (j) Cylinder gasket
Reed valve Pistan ring
(3) Gasket Pistan
@ Cylinder head @ Pistan pin
@ Cylinder head gasket (jJ) Pistan pin el ip
Cylinder @ Bearing
PISTON TO CYLINDER CLEARANCE: SPARK PLUG:

A 0.034- 0.047 mm (0.0013- 0.00181 in) MAN UFACTURER!TYPE:
Limit : 0.1 mm (0.004 in) E NGKJBPR7HS, ND/VV22FPR-U
END GAP (INSTALLED): PLUG GAP
Tap ring 0.6 - 0.7 mm (0.024 - 0.028 in)
0.15- 0.35 mm (0.006- 0.014 in)
Limit 1 9 N m (0.9 m kg, 6.5 ft lb)
e <0.07 mm (0.028 in)>
2nd ring
0.15- 0.35 mm (0.006- 0.014 in)
Limit
<0.07 mm (0.028 in)>
CD
SIDE CLEARANCE: o ,;y :-:;::
Top ring
0.03- 0.05 mm (0.0012- 0.0020 in)
O Limit < 0.10 mm (0.004 in)>
""E "'
2nd ring
0.03- 0.05 mm (0.0012- 0.0020 in)
\ )U
Limit < 0.10 mm (0.004 in)> o
o
1 Al USE NEW ONE IW
1 Al usE NEWONE 1
A USE NEW ONE
111 A 1 USE NEW ONE 1
aJ
6 'Jj
o(

20 Nm (2.0 m kg, 14ft lb) J (!} 11

1
....,.--------,
Al USE NEWONE 1
4-40
PISTON PIN AND PISTON
1.Apply:
Engine ail
(ta the crankshaft bearing, cannecting rad
big end bearing. small end bearing, pistan
pin, pistan ring graaves and pistan skirt
areas.)
2.1nstall:
o Reed valve gasket
o Reed val ve (j)
e Carburetar jaint
Carburetor joint
9 Nm (0.9 m kg, 6.5 ft lb)
3.1nstall:
S mal! end bearing
o Pistan CD
o Pistan pin
Pistan pin clip 0
NOTE:--------------------------
The arraw 0 an the pistan must paint ta the
exhaust side.
Befare installing the pistan pin clip, caver the
crankcase with a clean towel or rag so you will
nat accidentally drop the pin clip and material
inta the crankcase.
Always use a new pistan pin clip.
CYLINDER AND CYLINDER HEAD

1.lnstall:
Cylinder gasket (new gasket)
2. Check:
e Pistan rings
NOTE=--------------------------
Make sure the ring ends CD are praperly fitted
around the ring locating pins in the pistan
graaves.
4-41
Be sure to check the manufacturer's marks or
numbers stamped on the rings are on the top
side of the rings.
3. lnstall:
Cylinder CD
NOTE:--------------------------
Install the cylinderwith one hand while compress-
ing the pistan rings with the other hand.
4. lnstall:
Cylinder head gasket (new gasket)
5. lnstall:
e Cylinder head CD
Spark plug (V
NOTE:----------------------------
The arrow "EXH on the head cylinder must
point to the exhaust side.
Tighten the cylinder head holding nuts in stage,
using a crisscross pattern.
Cylinder Head Holding Nuts:

14 Nm (1.4 m kg, 10ft lb)
a---....-. Spark Plug:
20 Nm (2.0 m kg, 14ft lb)
6.1nstall:
Centerstand CD
Shaft
Cramp
Rubber washer C1)
Clip@
Spring
4-42
7. lnstall:
o Brake shoe plate Q)
0 Plain washer 0
Rear wheel
8. Insta!!:
o Reed valve ass'y Q)
0 Gasket 0
2
e Carbretor
Oil delivery hose @)
o Air cleaner case assembly
NOTE:--------------------------
Alignthe projectionwiththe projections .
o Befare installing theoil delivery hose, fill the en-
gine oil in it.
9.1nstall:
CD
o Air shroud
Oil hose 0
Oil delivery hose
NOTE:----------------------------
Pass the oil delivery hose and oil hose as shown.
10. Air bleeding:

o Autolube pump
Refer to "CHAPTER 3- AUTOLUBE PUMP
AIR BLEEDING" section.
REMOUNTING ENGINE
When remounting the engine, reverse the re-
moval procedure.
1.lnstall:
Engine mounting bolt CD
Rear shock absorber bolt 0 (lower)
These bolts should be temporarily secured.
2. Tighten:
Engine mounting bolt
Rear shock absorber bolt (lower)
4-43
ENGINE ASSEMBLY AND ADJUSTMENT ENGI I
Engine mounting bolt:
84 Nm (8.4 m kg, 61 ft lb)
Rear shock absorber bolt (lower):
32 Nm (3.2 m kg, 23ft lb)
3.1nstall:
e Carburetortop togetherwith throttle valve CD
Fuel hose /Vacuum pipe
Brake cable/plug cap
NOTE:----------------------------
When installing the throttle val ve into the carbure-
ter, align the groove ofthe throttle valve with the
projection of the carburetor.
4. Connect:
eAuto choke unit leads
e Starter motor lead
C.D.I. magneto lead
Earthlead
5. Tighten:
e Rear wheel axle nut CD
NOTE:-----------------------------
When tighten the rear wheel axle nut, apply the
rear brake.
'' Rear wheel axle nut:

' 95 Nm (9.5 m kg, 68ft lb)
6.1nstall:
Muffler CD
o Fa n cover CV
Bolt (muffler):
26 Nm (2.6 m kg, 19ft lb)
Bolt (exhaust pipe):
9 Nm (0.9 m kg, 6.5 ft lb)
7. Apply:
Transmission oil
Refer to CHAPTER 3- TRANSMISSION OIL
REPLACEMENT" section.
8. Adjust:
o Brake lever free play
Refer to "CHAPTER 3- FRONT/REAR BRAKE
LEVER FREE PLAY ADJUSTMENT" section.
Throttle cable free play
Refer to "THROTTLE CABLE FREE PLAY
ADJUSTMENT" section.
4-44
CHAPTER 5.
CARBURETION
AUTO CHOKE SYSTEM ............................................................................................ E-5

CONSTITUENTS ................................................................................................. E-5
WIRING SCHEMATIC .......................................................................................... E-5
OPERATION ......................................................................................................... E-5
CARBU RETOR ........................................................................................................... E-6

SECTION VIEW .................................................................................................... E-7
REMOVAL ............................................................................................................ E-7
DISASSEMBLY .................................................................................................... E-7
INSPECTION ........................................................................................................ E-8
ASSEMBLY .......................................................................................................... E-9
INSTALLATION ................................................................................................... E-9
AUTO CHOKE UNIT CHECK ............................................................................... E-9
FUEL COCK ............................................................................................................. E-10

INSPECTION ...................................................................................................... E-10
REED VALVE ........................................................................................................... E-10

REMOVAL .......................................................................................................... E-10
INSPECTION ...................................................................................................... E-11
INSTALLATION ................................................................................................. E-11
lcARBifl
----------l...-----'------=' --------------- 11
A_u_T_o_c_H_o_K_E_sv_s_T_E_M AR f 1 1 E-
CARBURETION
AUTO CHOKE SYSTEM
CO NSTITUENTS
The electric auto-choke consists of the Positive
Temperature Coefficient (P.T.C.) thermistor, wax
element and starter plunger.
CD P.T.C. thermistor
0 Wax element
@ 0-ring
@ Starter plunger
1 P.T.C. thermistor 1
When electric current flows in this thermistor, it

begins to be heated up toa specified temperature.
This specified temperature is then retained.
1 Wax element 1
The wax element changes its vol u me according to

a varying temperature ofthe thermistor, thereby
causing the starter plunger to operate.
1 Starter plunger 1
The starter plunger opens or clases the starter

passage according to changes in the vol ume ofthe
wax element.
WIRING SCHEMATIC
Power source is provided by the C.D.I. magneto
lighting coil.
CD C.D.I. magneto
0Rectifier/Regulator
@ Auto choke unit
5-1
AuTo cHoKE svsTEM lcARBI f 1
OPERATION
1 Cold engine
On the cold engine the wax element changes

(reduces) its volume according to the ambient
temperature.
In this state the starter plunger is at the top,
thereby opening the starter plunger.
:Air
....:Fue!
Running engine
When the engine is started, the heated P.T.C.

thermistor expands the wax element, gradually
pushing the starter plunger and controlling the
opening ofthe starter passage. The further heated
thermistor expands the wax element to a com-
plete extent, thereby fully closing the starter pas-
sage.
This in turn causes the engine r.p.m. to change (be
reduced) with time, finally coming to specified
idling.
The wax element expands during the ride as well
by means of the P.T.C. thermistor, thereby keep-
ing the starter passage fully closed.
<==:J: Air
,...: Fuel
5-2
A_u_T_o_c_H_o_K_E_s_v_s_T_E_M AR fl 1 E-
l Restarting after engine warm-up 1
1. Restarting right after ride:

The wax element is fully expanded, so the
starter passage is fully closed by the starter
plunger.
2. Restarting after leavi ng engine for a particular

time:
The wax element begins to reduce its volume
according to the ambient temperature,
permitting the starter plunger to open the
passage to meet the engine requirement.
5-3
c_A_R_B_U_R_E_T_O_R AR
CARBURETOR
CD Carburetor top cover @ Pilot jet @ Float chamber
@ Gasket Main nozzle @ Drain screw
@ Spring @ Main jet @ Auto choke unit assembly
G) Needle set (jJ) Needle valvc @ 0-ring
@ Throttle valve @ Float
Pilot air screw @ Float pin
(J) Throttle stop screw @ Gasket
A 1 SPECIFICATIONS
MAIN JET #76
JET NEEDLE 3R00-3/5
MAlN AIR JET (2)2.0
PILOT JET #42
STARTER JET #48
PILOT AIR SCREW 1 and 5/8 turns out
VALVE SEAT (2)1.8
FLOAT HEIGHT 15- 17 mm
(0.59 - 0.67 in)
ENGINE IDLE SPEED 1800 r/min
5-4
SECTION VIEW
G) Jet nc: edle (j) Starter plunger [Al Main metering system
C1) Throttle valve Starter jet needle [ID Slow metering system
@ Main nozzle Starter needle jet [Q Starter metering system
G) Main jet @ Starter jet [Q] Fuel metering system
Pilot jet (jJ) Needle valve [E] Air
@ Auto choke unit @ Float [[] Mixture
[ill Fuel
5-5
CARBURETOR
REMOVAL
1. Remove:
Refer to "CHAPTER 3-TAIL COVER AND
2. Disconnect:
Fuel pipe CD
Vacuum pipe
Oil detivery pipe
Auto choke unit lead
3. Remove:
Carburetor top 0
Carburetor
4. Remove:
Throttle valve CD
Throttle valve spring
Carburetor top cover@
DISASSEMBLY
1. Remove:
Float chamber CD
2. Remove:
Gasket CD
Float pin stop screw
Float pin@
Fioat
Needle valve @
5-6
c_A_R_B_u_R_ET_o_R_,CARBI 1
3. Remove:
oMain jet CD
e Main nozzle
Pilot jet
4. Remove:
Throttle stop screw CD
Pilotair screw 0
5. Remove:
Auto choke unit CD
0-ring
INSPECTION
1. lnspect:
Carburetor body CD
Float chamber
Contamination -7 Clean.
NOTE=-----------------------------
Use a petroleum based solvent for cleaning. Blow
out all passages and jets with compressed air.
2.lnspect:
Float (j)
Damage -7 Replace.
Gasket
Damage -7 Replace.
Needle valve
Wear/Contamination -7 Replace.
5-7
CARBURETORAR
3.1nspect:
o Throttle valve CD
Wear/Damage---+ Replace.
4. Check:
Free movement
Stick---+ Replace.
2 1nsert the throttle valve (D into the carburetor
body and check for free movement.
5.1nspect:
o Main jet CD
Main nozzle el)
o Pilot jet
Contamination---+ Replace.
6.1nspect:
e Throttle stop screw CD
o Pilotair screw
Jet needle Bends/Wear---
+ Replace.
7.Inspect:
Starter plunger CD
58
CARBURETOR
s: Measure:
e Float height
Out of specification--+ lnspect needle valve,
float a nd va lve seat.
Float Height:
15.0- 16.0 mm (0.63 0.04 in)
*************************************
Float height measurement steps:
8 lnstall the needle valve, float and float pinto the
carburetor body.
e Hold the carburetor in an upside down position.
e Measure the distance between the mating sur-
tace ofthe float chamber (gasket removed) and
top of the float using a gauge.
NOTE:
The float arm should be resting on the needle
valve, but not compressing the needle valve.
O lf the float height is not within specification,

inspect the needle valve, float and valve seat.
O lf it is worn, replace it.
*************************************
NOTE:-----------------------------
The float height is properly adjusted at the
Yamaha factory. Never attempt to adjust it.
ASSEMBLY
To assemble the carburetor, reverse the disas-
sembly procedures. Note the following points.
Befare reassembling, wash all parts in clean

gasoline.
Always use a new gasket.
1.1nstall:
Throttle valve CD
Jet needle @
Clip@
Spring seat @
Jet Needle Clip Position:

3/5
5-9
c_A_R_s_u_R_E_T_o_R AR
2.1nstall:
e Throttle val ve (J)
NOTE:-----------------------------
Aiign the groove (]) of the throttle valve with the
projection of the carburetor body.
3.1nstall:
Carburetor assembly
NOTE:----------------------------
.
Aiign the projection (J) with the projections
INSTALLATION
1.1nstall:
Carburetor assembly
Reserve the removal procedure.
AUTO CHOKE UNIT CHECK

1. Remove:
e Auto choke unit
2. Measure:
Starter plunger height
Plunger height will not change with the
temperature change --7 Replace.
5-1o
FUEL cocK lcARBI f 1 1 E-
FUEL COCK
INSPECTION
1. Stop the engine.
2. Remove:
Side cover {right)
Refer to "CHAPTER 3. - TAIL COVER AND
3.1nspect:
Fue! cock
*************************************
Fuel cock inspection steps:
e Disconnect the fu el hose CD.
8 Place the receptacle under the fuel hose end.
e lf fuel stops flowing out in a few seconds,
the fuel cock is in good condition.lf not, e lean or
replace the fuel cock.
e Disconnect the vacuum hose and breathe
in the vacuum hose with the mouth etc. for
vacuum.
e lffuel flows out ofthe fuel hose undervacuum
and stops under non-vacuum, the fuel cock is in
good condition.
lf not, clean or replace the vacuum hose, fuel
hose and fuel cock.
*************************************
REED VALVE
REMOVAL
1. Remove:
Refer to "CHAPTER 3-TAIL COVER AND
2. Remove:
Carburetor
Refer to "CARBURETOR- REMOVAL" sec-
tion.
3. Disconnect:
Oil level gauge lead CD
Oil hose@
4. Remove:
Oil tan k
5-11
FUEL COCK/REED VALVE ICARBI 1
5. Remove:
41 Carburetor joint CD
o Reed valve assembly
INSPECTION
1.1nspect:
Carburetor joint
Damage/ Cracks -7 Replace.
41 Reed va !ve
Fatigue/Cracks -7 Replace.
*************************************
lnspection steps:
e Visually inspect the reed valve.
NOTE:
Correct reed valve should fit flush or nearly flush
against valve seat.
O lf in doubt asto sealing ability, apply suction to

carburetor side of assembly.
e Leakage should be slight to moderate.
*************************************
2. Measure:
Valve stopper height CD:
Out of specification -7 Adjust stopper/Re-
place valve stopper.
Val ve Stopper Height CD:

6.0 - 6.4 mm (0.24 - 0.25 in)
3. Measure:
Reed valve clearance CD
Out of specification -7 Replace reed valve.
Reed Valve Clearance Q):

Less than 0.2 mm (0.008 in)
5-12
R_E_E_o_v_A_Lv EICARBI ]
INSTALLATION
When instal!ing the reed va!ve assembly, reverse
the removal procedure. Note the followng points.
1. 1 nstall:
o Gasket (new)
2. Tighten:
e Reed valve securng bolts
9 Nm {0.9 m o kg. 6.5 ft o lbl
NOTE:-----------------------------
Tighten each bolt gradually to avoid warping.
5-13
ITI REEo vALvE lcARBI f
5-14
CHAPTER 6.
CHASSIS
FRONTWHEEL ....................................................................................................... E-15

REMOVAL .......................................................................................................... E-15
INSPECTION ...................................................................................................... E-15
ASSEMBLY ........................................................................................................ E-16
INSTALLATION ................................................................................................... F-1
REAR WHEEL ............................................................................................................ F-2

REMOVAL ............................................................................................................ F-2
INSPECTION ........................................................................................................ F-2
ASSEMBLY .......................................................................................................... F-3
INSTALLATION ................................................................................................... F-3
HANDLEBAR. STEERING AND FRONT FORK ........................................................ F-4

REMOVAL ............................................................................................................ F-5
DISA.SSEMBLY .................................................................................................... F-6
INSPECTION ........................................................................................................ F-6
ASSEMBLY ANO INSTALLATION ...................................................................... F-7
REAR SHOCK ABSORBER ....................................................................................... F-8

RE MOVAL ............................................................................................................ F-9
INSPECTION ........................................................................................................ F-9
INSTALLATION ................................................................................................... F-9
G]
----------
lcHAs!I
F_R_o_N_T_w_H_E_E_L HA
CHASSIS
FRONT WHEEL
CD Wheel axle Return spring @ Wear indicator
Collar @ Brake shoe @ Camshaft lever
@ Oil seal ([j) Bearing @ Speedomcter driven gear
@ Bearing @ Oil seal @ Plain washer
Spacer @ Speedometer drive gear @Stop ring
Collar @ Camshaft
(]) Valve @ Brake shoe plate
@ Ring @ Camshaft seal
TIRE SIZE:
A
80/90-10, 34J
RIM RUNOUT LIMIT:
B Vertical: 2.0 mm (0.08 in)
LATERAL: 2.0 mm (0.08 in)
BRAKE DRUM WEAR LIMIT:
e 95.0 mm (3.74 in)
BRAKE LINING WEAR LIMIT:
D
2.0 mm (0.08 in)
WHEEL AXLE RUNOUT LIMIT:
E
0.25 mm (0.01 in)
Replace:
Brake shoe and return
spring as a set.
6-1
F_R_o_N_T_w_HE_E_LICHA
REMOVAL
1. Place the scooter on its centerstand and place
a suitable stand under the engine.
F!1T!@;NII t#J _
Securelysupportthescootersothere isno danger
of it falling over.
2. Remove:
Brake cable CD
Speedometer cable CV
Axle nut
3. Remove:
o Brake shoe CD
Return spring (V
Oil seal
Speedometer drive gear
Stop ring
Plain washer
o Speedometer driven gear (J)
INSPECTION
1. Measure:
Wheel axle runout
Out of specification -t Replace.
Wheel Axle Runout Limit:

0.25 mm (0.01 in)
r!W}!1;NII Cfl ------------

oo not attempt to straighten a bent axle.
2. Measure:
Wheel runout
Out of specification -t Replace.
Runout Limit:
Vertical2.0 mm (0.08 in)
Lateral 2.0 mm (0.08 in)
6-2
F_R_o_NT_w_H_E_EL_IcH
3.1nspect:
Wheel
Cracks/Bends/Warpage Replace.
4.1nspect:
o Wheel bea rings
Bearings allow play in the wheel hub or
wheel turns roughly Replace.
*************************************
Wheel bearing replacement steps:
O Clean the out side of the wheel hub.
e Remove the bearing using a general bearing
puller CD.
e lnstall the new bearing.
NOTE=-----------------------------
Use a socket that matches the outside diameter
of the race of the bearing.
Do not strike the inner race of balls ofthe bearing.

Contact should be made only with the outer race.
2
*************************************
5.1nspect:
Brake shoes
Glazed parts Sand with coarse sandpaper.
NOTE:----------------------------
After using the sand paper, clean ofthe polished
particles with cloth.
6. Measure:
Brake shoe thickness
Brake lining Thickness:

4.0 mm (0.16 in)
Limit: 2.0 mm (0.08 in)
6-3
F_R_o_NT_w_H_E_EL_IcH I l
7. lnspect:
e Brake drum inner surface
Oii/Scratches ---7 Remove.
Use a rag soaked in lacquer

Oil
thinner or solvent.
Use an emery cloth
Scratches (lightly and evenly polishing).
8. Measure:
Brake drum inside diameter
Out of specification ---7 Replace.
Brake Drum Wear Limit:

96.0 mm (3.78 in)
9.1nspect:
e Speedometer drive gear CD
111 Speedometer driven gear 0
2
Wear/Damage ---7 Replace.
ASSEMBLY
When assembling the brake shoe plate, reverse
the removal procedure.
1.Apply:
Lithium-soap base grease
To speedometer driven gear CD and oil seal
C2).
2.Apply:
To speedometer drive gear CD, dust seal
and brake cam shaft .
6-4
F_R_o_N_T_W_H_E_E_L HA
3. lnstall:
o Dust seal (new)
NOTE:----------------------------
Install the dust seal with their manufacturer's
marks or numbers facing outward.
4.1nstall:
o Brake cam shaft Q)
NOTE:----------------------------
Apply the lithiu m soa p base g reas.e onto the brake
cam shaft and pin.
After installing the brake ca m shaft, wipe off the

excess grease.
5.1nstall:
Wear indicator 0
NOTE:----------------------------
Aiign the wear indicator projection with A n line
N
as shown.
6.1nstall:
Ca m shaft lever Q)
NOTE=----------------------------
Aiign the camshaft mark with the lever mark0as
shown.
Bolt (cam shaft lever):

4 Nm (0.4 m kg, 2.9 ft lb)
7 .lnstall:
Brake shoe Q)
Return spring 0
When installing the brake shoe, take care not to

apply grease to the brake shoe.
6-5
F_R_o_N_T_w_H_E_E_LHA
INSTALLATION
When installing the front wheel, reverse the re-
moval procedure.
l.lnstall:
e Brake shoe plate.
NOTE=--------------------------
Make sure the projections CD inside the gear unit
are meshed with the flats 0 in the wheel hub.
2.1nstall:
e Front wheel
NOTE=----------------------------
Be sure the boss 0 on the front fork correctly
engages with the locating slotQ)on the brake shoe
plate assembly.
3.1nstall:
Front brake cable CD
., ."V; ,, Speedometer cable
' Axle nut@
Axlenut:
47 Nm (4.7 m kg, 34ft lbl
4. Adjust
Front brake lever free play
Referto "CHAPTER3-FRONTBRAKE LEVER
FREE PLAY CHECK" section.
Front brake lever free play:

10-20 mm {0.4- 0.8 in)
6-6
R : in ": a h:;; L----------- R E!:_A R W"!_ H!:EE L jcHASI
Valve Brake shoe
@ Ring (j) Brake camshaft
Plain washer Torsionspring
Return spring Wear indicator
& Camshaft lever
A TIRE SIZE:
80/90-1O, 34J
95 Nm (9'5 m kg , 68 f t. lb)
B BR1Ao
11 KE DRUM WEAR LIMIT
mm (4.37 in)
C BRAKE LINING WEAR LIM
2.1 mm (0.08 in) IT:
WHEEL RUNOUT LIMIT
VERTICAL 2 o
LATERAL . mm (0.08 in)
. 2.0 mm (0.08 in)
6-7
R_E_A_R_w_H_E_E_L H
REMOVAL
1. Remove:
o Muffler assembly
2. Loasen:
/(IIIJil//f Rear axle nut CD

NOTE=----------------------------
When loosening axle nut, apply the rear brake.
3. Remove:
Rear wheel
4. Remove:
Rear brake cable (j)
Brake shoe (g)
Plain washer @
INSPECTION
1.1nspect:
Wheel
Refer to "FRONT WHEEL - INSPECTION"
section.
2. Measure:
Wheel runout
Refer to "FRONT WHEEL- INSPECTION"
section.
Rim Runout Limits:

Vertical: 2.0 mm (0.08 in)
Lateral: 2.0 mm (0.08 in)
6-8
R_E_A_R_w_H_E_E_LicHASI I
3. Check:
Wheel bearings
section.
4.1nspect:
e Brake lining surface
section.
5. Measure:
e Brake lining thickness
section.
Brake Lining Thickness:

4.0 mm (0.16 in)
1----Jo..ll Wear Limit:
2.0 mm (0.08 in)
6.1nspect:
Brake drum inner surface
section.
7. Measure:
o Brake drum inside diameter
section.
Brake Drum Wear Limit:

111.0 mm (4.37 in)
ASSEMBLY
When assembling the brake shoe plate, reverse
the removal procedure.
1.1nstall:
Brake camshaft CD
NOTE=--------------------------
Applythe lithium soap base grease onto the brake
camshaft CD and pin@.
CAU1JON:
After installing the brake ca m shaft, take off the
excess grease.
6-9
2.1nstall:
Brake shoe (j)
o Return spring
NOTE:
lnstall with the punched mark outside.
CAUTION:.
When installing the spring and brake shoe, ake
care not to damage the spring.
3.1nstall:
Torsion spring (j)
Wear indicator
Ca m shaft lever
> --+---A NOTE:---------------

Align the wear indicator projection with "A"
lineas shown.
Align the punch marks @).
Bolt (cam shaft lever):

8 Nm (0.8 m kg, 5.8 ft lb)
4.1nstall:
Plain washer Q)
Brake cable
INSTALLATION
When installing the rear wheel, reverse the re-
moval procedure.
1. Clean:
Rear wheel axle (j)
2.lnstall:
Rear wheel
Plain washer Q)
Nut
NOTE=-------------------------
Make su re the splines on the wheel hub fit the rear
drive axle.
6-10
R_E_AR w_H_E_E_LICHAS 0
Nut (rear wheel axle):
104 Nm (10.4 m kg, 75.4 ft lb)
3.1nstall:
Muffler
Bolt (exhaust pipe side):

9 Nm (0.9 m kg, 6.5 ft lb)
Bolt (muffler side):
26 Nm (2.6 m kg, 19ft lb)
4.Adjust:
Rear brake lever free play
Referto "CHAPTER 3- REAR BRAKE LEVER
FREE PLAY CHECK" section.
6-11
HANDLEBAR, STEERING ANO FRONT FORK ICHASI bel
HANDLEBAR, STEERING ANO FRONT FORK
CD Trottle grip guide @ Cover @ Lower bearing race (lower}
CV Handlebar Rear brake cable @ Steering column
Throttle cable @ Ring nut @ Fork spring
G) Boot C[D Upper bearing race {upper} @ Rubber
@ Connector @ Bearing @ Spring seat
Throttle cable @ Upper bearing race (lower) lnner tube assembly (right)
(j) Front brake cable @ Lower bearing race {upper} @ lnner tube assembly {left}
BEARING SIZE:
A UPPER: 5/32 in
LOWER: 5/32 in
FORK SPRING FREE LENGTH:
B S.T.D.: 91.5 mm {3.60 in}
LIMIT: 87 mm (3.42 in}

; ---------- ----
1 60 Nm {6.0 m kg, 43ft lb} 1
6-12
HANDLEBAR, STEERING ANO FRONT FORK ICHASI 0
REMOVAL
1. Place the scooter on the centerstand and place
a suitable stand under the engine.
Fr\W.i1;NII CI _
Securely support the scooter so there is no
danger of it falling over.
2. Remove:
Front wheel
Refer to UFRONT WHEEL- RE MOVAL sec- H
tion.
3. Remove:
Front fender
o Front panel
Referto "CHAPTER 3-FRONT FENDER AND
FRONT PANEL" section.
4. Remove:
Handlebar cover
Rear view mirror
Refer to "CHAPTER 3 - HANDLEBAR
COVER" section.
5. Remove:
o Front brake cable CD
Rear brake cable
6. Disconnect:
Handlebar switch lead (D(Ieft and right)
Front brake switch lead
Rear brake switch lead
6-13
HANDLEBAR, STEERING ANO FRONT FORK ICHASI bel
7. Remove:
e Lever holder Q) (right)
o Handlebar switch <1) (right)
eThrottle grip (])
8. Remove:
e Handlebar switch CD (left)
9. Unhook:
Wire harness strap CD
10. Remove:
e Band
11. Remove:
Handlebar
6-14
HANDLEBAR, STEERING AND FRONT FORK JcHASI b0J
12. Remove:
e Ring nut CD
Use the Ring Nut Wrench
Ring nut wrench:
YU-33975
------<2
13.Remove:
Upper bearing race CD
NOTE:--------------------------
Supportthe steering column so that it may not fall
down.
Steering column
Bearings
DISASSEMBLY
1. Remove:
Boots CD
e Circlip
eQil seal
2. Remove:
lnner tu be CD
Spring seat
Rubber
Front fork spring
INSPECTION
1.lnspect:
e Handlebar CD
Bend/Damage/Crack Replace.
6-15
HANDLEBAR STEERING ANO FRONT FORK ICHASI 0
2. Wash the bearings in solvent.
3.1nspect:
e Bearing race CD
Bearings
NOTE:----------------------------
Aiways replace the bearing and race as a set.
Bearing Size:
Upper 5/32 in
Lower 5/32 in
Bearing Ouantity:
Upper 26 pes.
Lower 26 pes.
*************************************
Bearing race replacement steps:
e Remove the bearing race by hitting it on severa!
points.
e Set the bearing race.
e Orive in the bearing race evenly by hitting it on
several points.
CAUTION:
Unless the ball raee is installed evenly, it will
damage the frame or steering column.
Do not hit the fa ce of the ball race.
*************************************
4.1nspect:
Steering column
lnner fork tu be
Bends/Damage Replace.
rrwm;J II ttl _
Do not attempt to straighten a bent fork tube.
6-16
5. Measure:
Fork spring free length
Fork Spring Free Length:

91.5 mm (3.60 in)
Limit: 87 mm (3.42 in)
ASSEMBL Y ANO INSTALLTION

Reverse the disassembly and removal steps. Note
the following points.
iiWARNING
Proper cable and read routing is essential to issue
safe scooter operation. Refer to "CHAPTER 2 -
CABLE ROUTING".
1. Apply:
Molybdenum disulfide grease
2. Check:
Front fork operation
3. Apply:
Wheel bearing grease
(to upper bearings and lower bearings.)
6-17
HANDLEBAR, STEERING ANO FRONT FORK jcHASI
4.1nstall:
Steering column
Upper ball race
Ring nut
CAUTtON:
Hold the steering column until it is secured.
Upper ball race (nut):

4 Nm (0.4 m kg, 2.9 ft lb)
5. Tighten:
Ring nut CD
NOTE:-----------------------------
Set the torque wrench to the ring nutwrenchso
that they forma right angle.
IFj R;ng nut wcench'

YU-33975
l:i5J 30 Nm 13.0 m kg. 22ft lb)
6. lnstall:
Handlebar CD
2
Bolt
Nut
NOTE:-----------------------------
Match the bolt onto the steering column dent
.
CAUTION:
Befare installing the handlebar, wipe the oil off
the insertion portian using thinner, etc.
Bolt CD (handlebar)
60 Nm (6.0 m kg, 43ft lb)
7. Hook:
Wire harness strap CD
8.1nstall:
Band
NOTE:--------------------------
Clamp the wireharness.
6-18
9. Clamp
1 Throttle cable CD
Speedometer cable 0
Rear brake cable
Front brake cable 0
(to handlebar with the band .)
10. Apply:
(to throttle cable end and handlebar right
end.)
11. Adjust:
Front brake lever free play
Rear brake lever free play
Throttle cable free play
Front Brake Lever Free Play:

10- 20 mm (0.4- 0.8 in)
r--- Rear Brake Lever Free Play:
10- 20 mm (0.4- 0.8 in)
Throttle Cable Free Play:
1.5-3.5 mm (0.06- 0.14 in)
Referto "CHAPTER 3-FRONT BRAKE LEVER

FREE PLAY CHECK, REAR BRAKE LEVER
FREE PLAY CHECK and THROTTLE CABLE
PLAY ADJUSTMENT" section.
6-19
REAR SHOCK ABSORBER ICHASI 0
REAR SHOCK ABSORBER
CD Rear shock absorber
32 N m (3.2 m kg, 23ft lb)
\18Nm(1.8mkg,13ftlb) \
6-20
REAR sHocK ABsoRBER lcHAsl 0l
REMOVAL
1. Place the scooter on its centerstand.
2. Remove:
oRear shock absorber
INSPECTION
1.1nspect:
Rear shock absorber
Oil leaks/Damage Replace.
INSTALLATION
When installing the rear shock absorber, reverse
the remo val procedure. Note the following points.
l.lnstall:
Rear shock absorber
Upper:
32 Nm (3.2 m kg, 23 ft lb)
Lower:
18 Nm (1.8 m kg, 13ft lb)
6-21
=-9 1
----------
lcHAsl 01
CHAPTER 7.
ELECTRICAL
CY50B CIRCUIT DIAGRAM .................................................................................... F-13
ELECTRICAL COMPONENTS .................................................................................. F-14
CHECKING OF CONNECTIONS .............................................................................. F-15
CHECKING OF SWITCHES ...................................................................................... F-15

SWITCH CONNECTION AS SHOWN IN MANUAL ......................................... F-15
CHECKING SWITCH FOR TERMINAL CONNECTION ..................................... F-15
CHECKING OF BULBS .............................................................................................. G-1

KINDS OF BU LBS ............................................................................................... G-1
CHECKING BULB CONDITION .......................................................................... G-1
IGNITION AND STARTING SYSTEM ...................................................................... G-2

CIRCUIT DIAGRAM ............................................................................................ G-2
OUICK REFERENCE STARTING SYSTEM ........................................................ G-3
IGNITION AND STARTING CIRCUIT SYSTEM ................................................. G-4
INSPECTION PARTS .......................................................................................... G-4
ELECTRICAL STARTING SYSTEM ......................................................................... G-8

STARTER MOTOR CHECK ................................................................................. G-9
CHARGING SYSTEM .............................................................................................. G-11

CIRCUIT DIAGRAM .......................................................................................... G-11
TROUBLESHOOTING ....................................................................................... G-12
LIGHTING SYSTEM ............................................................................................... G-14

TROUBLESHOOTING ....................................................................................... G-15
SIGNAL SYSTEM ................................................................................................... G-16

TROUBLESHOOTING ......................................................................................... H-1
SIGNAL SYSTEM CHECK ................................................................................... H-2
METER ASSEMBLY .................................................................................................. H-7
AUTO CHOKE ........................................................................................................... H-8

CIRCUIT DIAGRAM ............................................................................................. H-8
TROUBLESHOOTING ......................................................................................... H-9
CV50B CIRCUIT DIAGRAM 1 ELECI i!iiiii l 1 F-1
ELECTRICAL
CY50B CIRCUIT DIAGRAM
0 o
@
CD
r B/W ..l.
WIR 8/W B/W---- j
BIR
B
..L
y:
$ Y/R
B
-b

-------R------ -
1
B B R
.J...
+
L
L
B
Gy
4-
G y
B ..B... ..B...
Br
:A rCh
@
B B B B B
.J..
...l..
- -
7-1
c_v_5_o_s_c_IR_c_u_I_T_D_IA_G R_A_M_IELECI
CD Spark plug @ Fuel meter
lgnition coil @ Fuel sender
@ C.D.I. magneto @ Flasher relay
GD C.D.I. unit @ "TURN" switch
@ Rectifier/Regulator @ Left flasher light (front)
Auto choke unit @ Left flnshcr light (rear)
(J) Main switch @ "TURN" indicator light
@Fuse @ Right flasher light (front)
@ Battery @ Right flasher light (rear)
(j]) Starter switch @ Horn
CJ) Starter relay @) "HORN" switch
@ Starter motor @ Front brake switch
@ "LIGHTS" (dimmer) switch Rear brake switch
(j] Headli ght @ Oil leve! gauge
(jj) "HlGH BEAM" indicator light @ "Oll" indicator light
@ Meter light @ Engine "stop" switch
@ Tail/Brake light
COLOR CODE
R Red p Pink
B Black L Blue
w White Y/R Yellow/Red

y Yellow LJW Blue/White
Br Brown G/Y Green/Yellow
Gy Gray B/W Black/White
o Orange B/R Black/Red
Ch Chocolate W/R White/Red
Dg Dark green Br/W Brown/White
G Green
7-2
ELECTRICAL COMPONENTS 1 ELECI E 1 1 F- ,
ELECTRICAL COMPONENTS
CV lgnition coil BATTERY
G) C.D.I. unit A CAPACITY: 12V, 4AH
@Fuse SPECIFIC GRAVITY: 1.32
Battery IGNITION COIL RESISTANCE
(jJ) Starter relay
B PRIMARY: 0.56- 0.84!.1 at 20"C (68.F)
@ Oillevel gauge
SECONDARY: 5.68 - 8.52 kn at 20"C (68.F)
7-3
ELECTRICAL COMPONENTS 1 ELECI iii 1
(5) Rectifier/Regulator
(]) Main switch
@ Flasher relay
@ Horn
7-4
c_HE_C_K_I_N_G_o_F c_o_N_N_E_c_T_IO_N siElECI
CHECKING OF CONNECTIONS
Dealing with stains, rust. moisture, etc. on the
connector.
1. Disconnect:
o Connector
2. Dry each terminal by an air blower.
3. Connect and disconnect the connector two or

three times.
4. Pull the lead to check that it will not come off.
5.1f the terminal comes off, bend up the pin CD
and reinsert the terminal into connector.
6. Connect:
Connector
7. Check for continuity by a tester.
NOTE:----------------------------
lfthere is no continuity, clean the terminals.
Be sure to perform the above steps 1 to 7 when
checking the wire harness.
e When replacing the C.D.l. unit, be su reto check
its con necto r.
For a fe Id remedy, use a contact revitalizer avai 1-
able on the market.
e Use the tester on the connector as shown.
7-5
CHECKING OF SWITCHES 1 ELECI E1
CHECKING OF SWITCHES
Check the switch es for the contin uity between the
terminal to determine correct connection.
Read the following for switch inspection.
SWITCH CONNECTION AS SHOWN IN

MANUAL
The manual contains a connection chartas shown
left showing the terminal connections of the
switches (e.g., main switch, handlebar switch,
bracket switch, lighting switch etc.)
The extreme left column indicates the switch

positions and the top line indicates the colors of
leads connected with the terminals in the switch
component.
" 0--D " indicates the terminals between which

there is a continuity of electricity; i.e., a closed
circuit at the respective switch positions.
In this chart:
"R and Br" and "LN.J and L/R" are continuous with
the "ON" switch position.
"B and BNV" is continuous with the "OFF" switch

position.
"B and BNV" is continuous with the ULOCK"

switch position.
"B and BNV" and "R and LJR" are continuouswith

the "P" switch position.
CHECKING SWITCH FOR TERMINAL

CONNECTION
Befare checking the switch, referto the connection
chart as shown above and check for the correct
terminal connection (closed circuit) by the color
combination.
To explain how to check the switch, the main

switch taken for example in the foltowing.
7-6
CHECKING OF SWITCHES 1 ELECI iiiiii 1 1 f ..'
1. Disconnect the main switch coupler from the
wireharness.
CA.UTION:
Never disconnect the main switch coupler by
pulling the leads. Otherwise, leads may be pulled
off the terminals inside the coupler.
2.1nspect whether any lead is off the terminal

inside the coupler. lf it is, repair it.
NOTE=----------------------------
If the coupler is clogged with mud or dust, blow it
off by compressed air.
3. Use the connection chart to check the color

combination for continuity (a closed circuit).ln
B B/W R Br L/W L/R this example, the continuity is as follows.
ON oL() o--o
OFF o-o "R and Br" and LNV and L/R" are continuous
LOCK o-o
with the "ON" switch position.
p o-o o :0 "B and BNV" is continuous with the UOFF"
1
L switch position.
"B and B/W" is continuous with the ULOCK"

switch position.
:1 :m "B and BNV" and "R and L!R" are continuous

with the "P" switch position.
Please
note that there is no continuity
(an open circuit) at all for the color combina-

tions other than the above.
4. Check the switch component for the

continuity between "R and Br".
*************************************
Checking steps:
e Turn the switch key to the "ON", "OFF",
"LOCK", and "P" severa! times.
O Set the pocket tester selector to the ".O x 1".
e Connect the tester (+) lead to the "R" lead
terminal in the coupler and the (-) lead to the
7-7 "Br" lead terminal.
c_H_E_c_K_IN_G o_F_s_w_IT_c_H_E s JELECI EiJ
NOTE:-----------------------------
Use thin pro bes for checking the contin uity Other-
wise, the probes may contact other terminals
inside the coupler.
O Check the continuity between "R" and "Br" at

the respective switch position of "ON" CD ,
"OFF" (V ,"LOCK"@, and "P" 0. There must
be continuity (the tester indicating "O") at the
"ON" switch position, and there must be no
continuity (the tester indicating 'oo") at "OFF",
"LOCK", or "P". There is something wrong
between "R" and "Br" ifthere is no continuity at
the "ON" position or ifthere is some continuity
either at the "OFF" or "LOCK" or "P".
NOTE=----------------------------
Check the switch for continuity severa! times.
*************************************
5. Next go on to checking of the continuity

2 CD between "B and BNJ", "LNJ and UR", and "R
and L/R" at the respective switch positions, as
in the same manner mentioned above.
6. lfthere is something wrong with anyone ofthe

combinations, replace the switch component.
7-8
c_H_Ec_K_I_N_G_o_F_s_u_L_Bs_IELECJ J IG
CHECKING OF BULBS
(FOR HEADLIGHT, TAIL/BRAKE
LIGHT, FLASHER LIGHT, METER
LIGHT, ETC.)
Check the bulb terminal continuity for the condi-
tion fo the bu lb.
KINDS OF BULBS
The bulbs used in the motorcycle are classified as
shown left by the shape of the bulb socket.
and@ are mainly used for the headlight.
is mainly used for the flasher light and tail/

brake light.
@ and are mainly used forthe meter light and

other indicator lights.
CHECKING BULB CONDITION

1. Remove the bulb.
NOTE:
Bulbs of the and@ type uses? bulb holder.
Remove the bulb holder befare removing the
bulb itself. Most ofthe bulb holders forthis type
can be removed by turning them counterclock-
wise.
Most of the bulbs and @ type can be
removed from the bulb sockets by pushing and
turning them counterclockwise.
Bulbs of the type can be removed from the
bulb sockets by simply pulling them out.
Be sureto hold the socket firmly when removing

the bulb. Never pull the lead. Otherwise, the lead
may be pulled off the terminal in the coupler.
HWARNING
Keep flammable products and your hands away
from the headlightbulbwhile itis on.ltwill be hot.
Do not touch the bulb until it cools down.
7-9
cHECKING oF suLss 1 ELEcl E1
2. Check the bulb terminals for continuity.
*************************************
Checking steps:
O Set the pocket tester selector to the "Q x 1 ".
O Connect the tester leads to the respective bulb
terminals. Take for example a 3-terminal bulb
as shown left. First check the continuity be-
tween theQ)and@terminals by connecting the
tester (+) lead to the CD terminal and the tester
(-) lead to the CV terminal. Then check the
continuity between the CD and terminals by
connecting the tester (+) lead still to the CD
terminal andthetester (-) lead totheterminal.
lf the tester shows ''oo" in either case, replace
the bulb.
*************************************
3. Check the bulb socket by installing a proven

bu lb to it. As in the checking of bulbs, connect
the pocket tester leads to the respective leads
of the socket and check for continuity in the
same manner as mentioned above.
7-10
- '
JG_N_J_TJ_O_N_A_N_o_s_T_A_R_T_JN_G_s_v_s_T_E_M_IELEcl 1 (;.
IGNITION AND STARTING SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows ignition and starter circuit.
Bffl ON
,----W/R----t @ BML--..:_8/W--------'
.----8/R ---L...,.._J
,_..........._
B
+
y:=il R
B
$B
Y/A1 1 1
B R
+ +
L
L
B Gy
B
Br
G
@1 R Gy
/\ r" @
B B
*
B B
- -
B
. 7-11
IGNITION ANO STARTIN SYSTEM 1 ELECI iiiiii 1
NOTE:--------------------------------------------------------------
For the color cedes see page 7-2.
CD Spark plug Battery

lgnition coil Starter switch
@ C.D.I. magneto <J) Starter relay
@ C.D.I. unit @ Starter motor
(J) Main switch Front brake switch
Fuse Rear brake switch
@ Engine "stop" switch
7-12
,_G_N_IT_I_o_N_A_N_o_s_m_R_T_I_N_G_s_v_s_T_E_M_IELECI I IG
1
QUICK REFERENCE CHART
Trouble mode
Enooeoooo /
operation of
starter motor
Malfunction during opcration
i
1
...
,,,. <o'
2e::' e::
g,..... ... ,..-_Qq, "' ..e?
..g 2 e::' b' "
q,
-2
. $"
o
.o b q, .... $
... ..E. : ce.::: e::
()
cz,
cz,
-2 !?> e:: -<:- cz,

o .o
.:::; - 'l1
b'
e::' _:;,.X o e: {!>
"' ,"'
......2 'l1
...E: 0 ::; <."' -2Q ..-.<..:- cz,
.&
cz, t:'lJ e::' -Q e, "'
o .;: .e:: q, "'
e::
"" "' <".'
2"' o"' .
.'::: ::?
..g -<:- .[J ..:::: ... (;
'lJ e:: ... ;:: .e:: .o .:!>
..'2 -5 e?
... ... e:: ' "'
()
.'::: "" .....
e:: -o
"" .9 "' "' *'

-2
-2 -2 "' "' OQ f' <".' ..:!' ,fJ
o * o
o .:;:
'l1
o "'l1 'l1
"'o
E: E: E: (; E: e, C;; e:: ..g -<:-:
t::Q ...
;f() .S
E:
..&.... g 'lJ
,' -QJ 'lJ
.<::: ,'
-<:-:
.:;:'lJ ..s-
.()
lnspection parts
c:? .if .:J ff o, o o, o, ()
ff
0 0 S S S S l..tJ
[Al BATIERY 1 1 1
1
llil FUSE 2
g STARTER MOTOR 3 2 2
[5] STARTER RELAY 4 3
[EJ MAIN SWITCH 5 6 6 1
[[] BRAKE SWITCH 6
STARTER SWITCH 7 1
[8] SPARK PLUG 1 1 1 1 1 2
[TI SPARK PLUG CAP 2 2 2 2 2 1 1
DJ IGNITION COIL 3 3 3 3 3 2 3
[K] SOURCE COIL 4 4 4 4
[[] PICKUP COIL 5 5 5 5
[MJ "ENGINE STOP" SWITCH 6 6
cm WIRE HARNESS 7 7 7 7 3 1 2
[Q] CDI UNIT 8 8 8 8 4
NOTE:--------------------------------------------------------------
[8] -
[M] & [Q] indicates the locatfon ofthe parts-connectors for checking.
7-13
Use the following special tools in this troubleshooting.
L - -P1-o_c_YkU-e-t03T_1e_1st2_e_r_= l
_
Dynamic Spark Tester:
YM-34487
HOW TO USE CHART:

Step 1. Look for an approprial trouble mode from the scooter phenomenon.
Step 2. Proceed to checking in the ascending arder of the numbers.
Step 3. Look for location by reference to the "LOCATION OF PARTS-CONNECTORS". (P. 7-14)
Step 4. Go to further details of checking. (P. 7-3- 7-28).
7-14
IGNITION ANO STARTING SYSTEM 1 ELECI E1
LOCATION OF PARTS CONNECTORS
7-15
,_G_N_IT_Io_N_A_N_o_s_ _R_T_I_N_G_s_v_s_T_E_M_IELEcl l IG-
IGNITION AND STARTING CIRCUIT SYSTEM
CD Spark plug @ Starter switch @] Source coi!
lgnition coi! @ Starter relay [] Pickup coi!
@ CDI unit @ Starter motor [9 Wave-shap shaping circuit
(J) Main switch @ Front brake switch [ill Condenser
Fuse @ Rear brake switch ffiJ Diode
Battery @ Engine "stop" switch W SCR
ID] To oillevel switch
.
Qill Q ffiJ
m 1'---- [ID pg]
<>l
[9 ... W/
<> <==
t 8
!
1
11 r
- o---s;w-
@
B/W
(J) 1
G/W B R Br Gy
--L--O---C---K-- o-
OFF o-0
CHECK o-K .;- ro
ON )D
... ..
__ t

J..
t
1
ti
: Currebt flow in ignition control circuit

... : Current flow in starter motor control circuit
7-16
IGNITION AND STARTING SYSTEM 1 ELECI E1
INSPECTION PARTS
C8J Battery lnspection
1. lnspect:
"'Battery terminal
Battery voltage
Tester Tester
lead lead Battery
Range
(Red) (Black) voltage
Positive Negative 12- 14V DC20V
Out of specificatio n--+ Recharge battery or repla ce

the battery.
Refer to the "BATTERY INSPECTION" section in
the CHAPTER 3.
[ID Fuse lnspection

1. lnspect:
Fuse for continuity
Fuse holder
Tester Tester
lead lead Conti- Range
nuity
[j (Red)
Fuse
(Black)
Fuse
Conti- nx1
370 001
holder
lead Q) lead m nuous
holder
Non-continuous --+ Replace fuse or fuse

holder.
Loase terminal --+ Rep lace fuse or fuse holder.
Amperage for Individual:

7A
Refer to the "FUSE INSPECTION" section in

the CHAPTER 3.
[Q Starter Motor lnspection

1. Con nect 12V battery to the starter motorterm i-
nals as shown.
NOTE:-----------------------------
Use full charged battery .
.cAU.l:tON:
Do not run the starter motor for more than a few
seconds.
Starter motor does not run --+ Go on to

steps 2 to 6.
7-17
IGNITION ANO STARTING SYSTEM 1 ElECI iii 1 1 G-
2. Measure:
o Brush length (each)
Mnimum Brush Length:
0.9 mm (0.035 in)/YAMAHA,
1.25 mm (0.10 inl/NIPPON DENSO
Out of specification Replace starter motor

assembly.
.\ Damaged surface of contact with commuta-
tor Repair.
3.1nspect:
Commutator condition
Damaged, worn, and bruned surface of
commutator Replace starter motor as-
o
sembly.
4. lnspect:
Armature coil for continuity.
Tester Tester
(Red) (Biack) nuity
Commu- Commu- Conti- D.x1

tator tator nuous
Commu- Non-
tator
!ron core conti- n x 1k
nuous
Bad condition Replace starter motor

assembly.
5. Measure:
Commutator diameter
Outside Diameter Wear Limit:
14.8 mm (0.58 in)/YAMAHA
14.5 mm (0.57 in)/NIPPON DENSO
Out of specification Re place starter motor

assembly.
6. Measure:
Mica undercut :
Out of specification Scrape mica using a
hacksaw blade.
Mica Undercut :
1.15 mm (0.045 in)/YAMAHA
0.9 - 1.2 mm (0.035 - 0.047 in)/
NIPPON DENSO
NOTE:------------------------------
The mica insulation of the commutator must be
undercut toen su re proper operation of the com-
mutator.
7-177-18
------------------
IGNITION ANO STARTING SYSTEM 1 ElECiiii 1
[QJ Starter Relay lnspection
1.1nspect:
Starter relay CD
Use the jumper leads@.
Starter motor does not run --t Go on to steps
2 and 3.
Battery Positive Terminal -4

Green/Yellow.
Battery Negative Terminal -4
Blue/White Terminal.
2. Disconnect:
Starter relay leads and connector
3.1nspect:
Starter relay for continuity.
Voltage
Range: Copuller Voltage not
nx1 Terminals applied applied
366016 Tester
lead R1
(Red) No
Continuity continuity
Tester
lead R2
(Black)
lrJ Main Switch lnspection

1.1nspect:
Flasher operation
Flasher does not move --t Go on to steps 2
and 3.
2. Disconnect:
Main switch coupler
3.1nspect:
Main switch for continuity.
Tester Tester
(Red) (Black) nuity
Terminal Terminal Conti-
(Red CD) (8rown0l nuous nx1
Terminal Terminal Conti-

(Biack/ (Biack @l nuous nx 1
Whitc@l
Referto the "CHECKING OF SWITCHES" sec-

tion.
Bad condition -4 Replace main switch.
7-18
IGNITION AND STARTING svsTEM 1 ELEci e1 1 G-
[IJ Brake Switch lnspection
1. Disconnect:
qf Brake switch connector

2.1nspection:
Brake switch for continuity.
Jl
G/Y Br
Tester Tester
{Red) {Biack) nuity
Terminal Terminal
{Brown Conbi- nx 1
(Green/
Q)) Yellow) nuous
Refer to the UCHECKING OF SWITCHES"

section.
Bad condition 4 Replace brake switch.
[GJ Starter Switch lnspection

1. Disconnect:
Starter switch connector
2 .lnspection:
Starter switch for continuity.
Tester Tester
(Red) (Biack) nuity
Terminal
Terminal Conti-
(Biue/
nuous
nx 1
White Q)) {Biackl
Refertothe "CHECKING OF SWITCH ES" sec-

tion.
Bad condition 4 Replace handlebar switch
(right)
[8] Spark Plug lnspection

1.1nspect:
Electro de CD
Wear/Damage 4 Replace spark plug.
lnsulator
Abnormal color Re place spark plug.
2. Measure:
Plug gap
377000 Use a Wire Gauge or Feeler Gauge.
7-19
IGNITION ANo sTARTING svsTEM 1 ELE el E1
Spark Plug Gap:
0.6- 0.7 mm (0.024- 0.028 in)
Out of specification Re place spark plug.

Refer to the "SPARK PLUG INSPECTION"
section in the CHAPTER 3.
3. Measure:
Spark gap
Use a Dynamic Spark Tester G).
M;n;mum Spa'k Gap'

[6] 6 mm (0.24 in)
Meets specification Replace spark plug.
Dynam;c Spa,k Te;te"

YM-34487
Meets specification Replace spark plug.
(I] Spark Plug Cap lnspection

1.1nspect:
Spark plug cap resistance
fE] Spark Plug Cap Resistance:

4 - 6Q at 20'C (68'F)
Out of specification Replace spark plug

cap.
NOTE:
Check the spark plug lead for anyfaultwhen fitting
the spark p lug capto it. lf a ny fault is fou nd, cut the
spark plug lead 5 mm (0.197 in) as its tip.
7-20
IGNITION ANo srARTING svsrEM 1 ELEcl& 1 1 G-
[JJ lgnition Coil lnspection
1. Disconnect:
$ Primary coil connector
2.1nspect:
Primary coil resistance
Tester Tester
lcad lead Specificated Range
(Red) (Biack) resistance
373 007 Terminal Termina'! 0.56- 0.84D. D.x1
(Orange) (Biack) at 2oc (68.Fl
Out of specification Replace ignition coil.
3.1nspect:
Secondary'coil resistance
Tester Tester
lead lead Specificated Range
(Red) (Biack) resistance
Spark Terminal 5.68- 8.52D. n x lk
plug lead (Biack) at 20c (68.F}
Out of specification Replace ignition coil.

373 008
[E] Source Coil Resistance lnspection

1. Disconnect:
So urce coil connector
2.1nspect:
So urce coil resistance
Tester Tester
lead lead Specificated Range
resistance
5?] (Red)
Terminal
(Biack/
(Biack}
Terminal 640-960 n n x 100
<Biack l at 20c (68.Fl
Red CD)
Out of specification Re place source coil.
7-21
IG_N_IT_I_o_N_A_N_o_s_T_A_R_T_IN_G_s_v_s_T_EM_IELECI I
[[] Pickup Coi! Resistance lnspection
1. Disconnect:
e Pickup .coi! connector
2.1nspect:
Pickup coi!
Tester Tester
lead lead S pecificated Tester
(Red) (Biack) resistance selection
Terminal Terminal 400- soo n nx 100

(White/ (Biack l at 2oc (68.F)
Red CD)
Out of specification-? Replace pickup coi!.
[MJ "ENGINE STOP" Switch lnspection

1. Disconnect:
,. "ENGINE STOP" switch connector
2. Check the "ENGINE STOP" switch component
forthe continuity between "Biack/WhiteCDand
Black ".
Refer to the "CHECKING OF SWITCH ES" sec-
tion.
Bad condition -? Replace hadlebar switch
(Right)
[N] Wire harness lnspection
1. lnspect:
Con nection
Damage
Repair/Replace
Refer to the wire harness inspection, see
page 7-23.
[QJ COI Unit Replacement

1. lnspect:
Connection
2. Replace:
e CDI unit CD
7-22
IGNITION AND STARTING SVSTEM 1 ELECI E1
Wireharness lnspection <1) lgnition coil @ Starter switch
@ CDI magneto @ Starter relay
lgnition System Check: [Al lliJ [El [Q] [I='J @) CDI unit @ Starter motor
(j) Main switch @ Front brake switch
Starter System Check: [[][m [8] [J] DJ [E][] @ Fu se Rear brake switch
Battery @) Engine "stop" switch
.1 ....
<:;:::::J'" ....
Q

"'- .... W/
<>l <> <>

11 T
- o--s;w
[fJ
l
B
.1.
- 1
33
B/W
B/W B R Br Gy (j)
------ o-1'..
LOCK
---OFF 0-IC
o--K ve-RJ
@
CHECK
ON )fO 1
... C8J
+-_it

..L. t L -
tr
L/W
1
-=
1
r [E]
B
NOTE:--------------------------
Check the continuity with the connector con-
nected, as shown.
For the connector shape, refer to the color wir-
ing diagram.
7-23
ELECTRICAL sTARTING svsTEM 1 ELEc! E1
ELECTRICAL STARTING SYSTEM NOTE=----------------------------
The starter motor for this scooter cqmes in two
STARTER MOTOR
types:
G) 0-ring DA5AN (NIPPON DENSO)
W Rubber Sea! 3KJ (YAMAHA)
@ Armature
@) Brush holder assembly
COMMUTATOR UNDER CUT:

A DA5AN: 0.9- 1.2 mm (0.035- 0.047 in)
3KJ: 1.15 mm (0.045 in)
COMMUTATOR DIAMETER WEAR LIMIT:
B DA5AN: 14.5 mm (0.57 in)
3KJ: 14.8 mm (0.58 in)
-
BRUSH WEAR LIMIT:
DA5AN: 2.5 mm (0.10 in)
3KJ: 0.9 mm (0.035 in)
7-24
ELECTRICAL STARTING SYSTEM 1 ELECII 1 G-'
STARTER MOTOR CHECK
Removal
1. Remove:
e Side cover (right)
e Muffler assembly
e Rear wheel
Starter motor
2. Remove:
Yoke assembly
3. Remove:
e Armature
Assembly
Reverse the removal procedure.
1. 1 nsta 11:
Brush holder assembly
7-25
ELECTRICAL STARTING svsTEM 1 ELE el e 1
2.1nstall:
e Armature coi! assembly
3. lnstall:
Rubber sea! Q)
4. lnstall:
Starter motor cover
'
:' .. .
. .
'
5.1nstall:

Bolts Q)
6. lnstall:
0-ring Q) (new)
NOTE=----------------------------
Apply a grease lightly.
7-26
ELECTRICAL STARTING SYSTEM 1 ELECI iiii 1 IG-1
lnstallation
1.lnstall:
Starter motor
1" 13 Nm (1.3 m kg, 9.4 ft. (bJ
7-27
ELECTRICAL STARTING SYSTEM 1 ELECI ilii!i 1
7-28
- ;
cH A R G I N;G s v;s T;E;M ----- c H A R G IN G s! !T E M IaEcl l IG-1

CIRCUIT DIAGRAM - -
Below circuit d.lag ram shows e hargm
. g circuit.
-- y-
1
1
1
B
+
L
l/W .:...
B :
B
-b
11 ' Gy
yB
G
t r-l L
@
.
G/Y
B B B B
'!!!!-
Br
Br Br
Br Br Br Br Br

"@
G
t t JI
p
Gy
G!Y
1
'
@)
Dg
'
B B 8 B
7-29
'*"
*
CHARGING SVSTEM 1 ElECiiiiiii 1
NOTE:-------------------------------------------------------
For the color codes, see page 7-2.
C.D.I. magneto
@ Rectifier/Regulator
@ Fuse
Battery
5 8 9
7-30
c_H_A_R_G_IN_G_s_vs_T_E_M_IELECI I IG-'
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED.
Procedure
Check;
1.Fuse 4. Charging coi! resistance
2. Battery 5. Wiring connection
3. Charge voltage (Entire charging system)
NOTE=------------------------------------------------------------------
Remove the following parts befare troubleshooting.
1)Cove SeaVRearcijrrier
2) Tail cover/Side cover (l, R)
Use the following special tools in this troubleshooting.
Pocket Tester: YU-

03112
NO CONTINUITY
1. Fuse
Remove the fuse.
Con nect the Pocket Tester (Q x 1) to the fu se.
Check the fuse for continuity. 1 Replace fuse.
l
CONTINUITY
INCORRECT
2. Battery
Check the battery condition.
Refer to the "BATTERY INSPECTION" se e-
Clean battery termi nals.
tion in the chapter 3. Recharge or replace battery
CORRECT
7-31
CHARGING SVSTEM 1 ELECI iiiEi 1
*
3. Charge voltage
Connect the Engine Tachometer to spark
plug lead.
Connect the Pocket Tester (DC20V) to the
battery.
Tester (+) Lead Battery (+)terminal

Tester (-) Lead Battery (-)terminal
Start the engine and accelerate to about

5,000 r/min. MEETS SPECIFICATION
Check charging voltage.
Charging Voltage:
14 - 15 at 5,000 r/min Replace battery.
OUTOF
SPECIFICATION
4. Charging coil resistance

Disconnect the C.D. l. magneto coupler from
the wire harness.
Con nect the Pocket Tester (Q x 1) to the
charging coil coupler.
C.D.I. magneto
Tester (+) Lead White CD Terminal

Tester (-) Lead Black 0 Terminal
7-32
CHARGING SYSTEM 1 ELECI E1
e Check the charging coi! for specificatcd OUT OF SPECIFICATION
resistance.
Charging Coil Resistance:

White- Black
0.48 - 0.720. at 20'C (68'F)
l
1 Replace charging coil.
1
MEETS
SPECIFICATION
POOR CONNECTION
5. Wiring connection
Check the entire charging system for
connections.
Refer to the "WIRING DIAGRAM" section. 1 Correct.
l
CORRECT
Replace rectifier/regulator.
7-33
CHARGING SVSTEM 1 ElECI 1
7-34
LIGHTING SVSTEM 1 ELECI Ei 1
LIGHTING SYSTEM
CJRCUIT DIAGRAM
Below circuit. d"Jagram shows light.1 9 c1
. rcuit.
8
l. q
1
B
+
L
." '.
8
@ IL
L
@
G/Y
8 8
..8....
Br B
Br r
1
G
7-35
-----------------------------------------
LIGHTING SYSTEM IELECI Ei 1
NOTE:------------------------------------------------------------
For color codes, see page 7-2.
COl magneto
Rectifier/Regulator
@ "LIGHTS" (dimmer} switch
@ Headlight
@ "HIGH BEAM" indicator light
@ Meter light
7-36
L_IG_H_T_IN_G_s_vs_T_E_M_IELEC IG-
TROUBLESHOOTING
HEADLIGHT "HIGH BEAM" INDICATOR LIGHT

AND/OR METER LIGHT DO NOT COME ON
Procedure
Check;
1. Bulb and bulb socket (HEADLIGHT) 4. Wiring connection
2. Lighting coil resistance (entire lighting system)
3. "LIGHT" (dimmer) switch
NOTE=----------------------------------------------------------------
1) Cover, Seat, Rear carrier, Tail cover, Side cover
2) Front fender
3) Handlebar cover (front)
Use the following special tool in this troubleshooting.
Pocket Tester:
YU-03112
NO CONTINUITY
1. Bulb and bulb socket (HEAQLIGHT)
Check the bu lb and bu lb socket for
continuity.
Refertothe "CHECKING OF BULBS" section.
l
Replace bulb and/or bulb socket .
.,JJr CONTINUITY
2. Lighting coil resistance

Disconnect the C.D.!. magneto coupler from
the wire harness.
Connect the Pocket Tester (Q x 1) to the
lighting coil coupler.
C.D.I. magneto
Tester (+) Lead -7 Yellow/Red Q) Terminal

Tester (-) Lead -7 Black Terminal
7-37
LIGHTING SYSTEM 1 ELECI iE!i 1
Check the lighting coil for specificated
resista nce.
OUT OF SPECIFICATION
(]) lighting coil
Lighting Coil Resistance:

Yellow/Red- Black
0.45 - 0.55Q at 20"C (68"F) Replace lighting coil.
1
MEETS
SPECIFICATION
3. "LIGHT" (dimmer) switch
<> Disconnect the handlebar switch (leh)
coupler from the wire harness.
Check the switch component for the
continuity between "Blue CD and Green "
and "Biue CD and Yellow (]) ".
Refer to the "CHECKING OF SWITCHES"
section.
INCORRECT
l
Re place handlebar switch (leh).
..JJ,.. CORRECT
POOR CONNECTION
Check the entire lighting system for
connections.
Refer to the "WIRING DIAGRAM" section. 1 Correct.
l
Replace rectifier/regulator.
7-38
c S I RGc N A;L}s v s T EM -------------- S IG N A LS YS T E M ElECI iiil -
UIT DIAGRAM - _
Below c1 rcuJ- t dJ.agram sh ow
. s S-Jgnal circuit.
r;: 1-.....
W/R
B/R
8
,ll
Y/:=11 ---R-----
8
@$ 8
Y/A
@
1
8
1
R
+ +
L
L
Gy
t IL L
@
G/Y
G/Y
B 8 8
Br Br
Br
7-39
si_G_N_A_L_s_v_s_T_E M IELEcl iiil
NOTE=------------------------------------------------------------------
Forthe color codes, see page 7-2.
0 Main switch @ "TURN" indicator light

@Fuse @ Front flasher light (right)
Battery @ Rear flasher light (right)
@ Taii/Brake light Horn
@ Fuel meter @ Horn switch
@ Fuel sender Front brake switch
Flasher relay Rear brake switch
@ "TURN" switch @ Oil level gauge
@ Front flasher light (left) @ Oil indicator light
@ Rear flasher light (left)
7-40
s_IG_N_A_L_s_v_s_TE_M_IE C IH-
TROUBLESHOOTING
FLASHER LIGHT, TAIL/BRAKE LIGHT, "OIL" INDICATOR LIGHT ANO "TURN" INDICATOR
LIGHT DO NOT COME ON.
HORN DOES NOT SOUND.
FUEL METER DOES NOT OPERATE.
Procedure
Check;
1. Fuse
2. Battery
3. Main switch
4. Wiring connection (signal system)
NOTE=----------------------------------------------------------------
1) Cover, Seat, Rear carrier, Side cover, Tail cover
2) Front fender
3) Handlebar cover (front)
Pocket Tester:
YU-03112
NO CONTINUITY
1.Fuse
Remove the fuse.
Connect the Pocket Tester (Q x 1) to the fu se.
Check the fuse for continuity . j Replace fuse.
l
.JJ, CONTINUITY
INCORRECT
2. Battery
Check the battery condition.
Refer to the "BATTERY INSPECTION" see-
tion in the CHAPTER 3.
.JJ, CORRECT
Clean battery termi nals.
Recharge or replace battery .
7-41
SIGNAL SYSTEM 1 ELECI E!! 1
Main switch
3.
Disconnect the main switch coupler from the
wire harness.
continuity between "Red(Dand Gray" and
"Red CD and Brown ".
section.
INCORRECT
J Replace main
l
switch.
CORRECT
4. Wiring connection POOR CONNECTION
Check the entire signal fpr connections.

Refer to the "WIRING DIAGRAM" section. l
Correct.
--------------
Check condition of each circuit for signa]

system.
Referto "SIGNAL SYSTEM CHECK" section.
7-42
s_tG_N_A_L_s_v_sT_E_M_IELEcl l IH
SIGNAL SYSTEM CHECK
1. Horn does not sound.
1. "HORN" switch
Disconnect the handlebar switch coupler
from the wi re harness.
continuity between "Pink Q) and Black ".
section.
INCORRECT
l
Replace "HORN" switch .
..JJ,.. CORRECT
2. Voltage
horn lead.
Tester (+) Lead ---7 Brown Q) Lead

Tester (-) Lead ---7 Frame Ground
CJ
-+ OUT OF SPECIFICATION
Turn the main switch to "ON".

Check for voltage {12V) on the " Brown" lead Check the
l
entire signa! system for
at the horn terminal. continuity.
MEETS SPECIFICATION
( 12V)
7-43
s1GNAL svsTEM 1 ELEcJiiiil
3. Horn
" Disconnect the "Pink" lead at the horn
terminal.
Connect a jumper leadCDto the horn terminal
and ground the jumper lead.
HORN IS SOUNDED
Turn the main switch to "ON". Horn is good.
HORN IS NOT
SOUNDED
4. Voltage
o Connect the Pocket Tester (DC20V) to the
horn at the Pink terminal.
Tester (+) Lead --7 Pink CD Lead

Tester (-) Lead --7 Frame Ground

Check for voltage (12Vl on the "Pink" lead at
the horn terminal. Replace horn.
l
MEETS SPECIFICATION
(12V)
(!djust or replace horn.
7-44
s_tG_NA_L_sv s T E M IELECI I IH
2. Taillight does not come on.
1. Bulb and bulb socket NO CONTINUITY
c. Checkthe bu lb and bulb socketforcontinuity.

Referto the "CHECKING OF BULBS" section.
1
l
Replace bulb and/or -b-u-lb_s_o_c_k-et-.----.
...J1. CONTINUITY
2. Voltage

bulb socket connector.
Tester (+) Lead ----:) Blue 1 Terminal

Tester (-) Lead----:) Black 2 Terminal
1
1
1
miQGN
l :rf[
G/
l \1---- L
B \
02
-+
Turn the main switch to "ON". OUT OF SPECIFICATION
Start the engine.
Checkforvoltage(12V)onthe "Biue" leadat
the bulb socket connector.
MEETS Check the entire signal system for
SPECIFICATION (12V) connections.
Refer to the "WIRING DIAGRAM"
1 This circuit is good.
section.
7-45
s_,G_N_A_L_s_v_s_T_E_MIELEcl l
3. Brake light does not come on.
o Checkthe bulb and bulb socketforcontinuity.

Referto the "CHECKING OF BULBS" section. 1 t
Rep1 ac e bu1 b a nd/or b_u_l_b_s_o_c_k_e_t_. ----.
CONTINUITY
2. Brake switch
Disconnectthe brake switch couplerfrom the
wire harness.
e Check the switch component for the
continuity between "Brown" Q) and Green/
Yellow CV ".
section.
INCORRECT
Replace brake switch.

l
CORRECT
3. Voltage
bu lb socket connector.
Tester (+) Lead ---7 Green/Yellow CD Terminal

Tester (-) Lead ---7 Black 0Terminal
7-46
s_IG_N_A_L_s_v_s_TE_M_IELECI 1 -
Turn the ma in switch to "ON".

l
The front brake lever and rear brake lever are Check the entire signa! system for
pulled. connections.
Check forvoltage (12V) on the Green/Yellow Refer to the "WIRING DIAGRAM"
lead at the bulb socket connector. section.
MEETS
SPECIFICATION (12V)
1 This circuit is good.
4. Flasher light and/or "TURN" indicator light do not blink.
Check the bulb and bulb socket for

continuity. Refer to the "CHECKING OF
BULBS" section.
l
Replace bulb and/or bulb socket .
..JJ,.. CONTINUITY
2. "TURN" switch
Disconnect the handleba r switch coupler
from the wire harness.
Check the switch com ponent for the
continuity between "Brow n/White CD and
Chocolate (V" and "Brown/White(j)and Dark
green (3) ". Refer to the "CHECKING OF
SWITCHES" section.
NO CONTINUITY
l
Re place handlebar switch (left).
CORRECT
7-47
SIGNAL SVSTEM 1 ELECI iiii 1
3. Voltage
Con nect the Pocket Tester (DC20V) to the
flasher relay.
Tester (+) Lead ---7 Brown CD Lead

D
r $, OUT OF SPECIFICATION

Check for voltage (12V) on the "Brown" lead Check the entire signa! system for
at the flasher relay terminal. connections.
MEETS
SPECIFICATION (12V)
4. Voltage
Con nect the Pocket Tester !DC20V) to the
flasher relay.
Tester (+) Lead ---7 Brown/White CD Lead

.Ir-
D
e<$
1
u OUT OF SPECIFICATION
-

Check for voltage (12V) on the "Brown/
White" lead at the flasher relay terminal.
1 Replace
l
flasher relay.
1
MEETS
SPECIFICATION (12V)
7-48
5. Voltage
o Connect the Pocket Tester (DC20V) to the
bu lb socket connector.
At Flasher Light (left):

Tester (+) Lead Chocolate Q) lead
Tester (-) Lead Frame Ground
At Flasher light (right):

Tester (+) lead Dark green @ lead
g g
Ch Dg
o Turn the ma in switch to "ON". OUT OF SPECIFICATION

Turn the "TURN" switch to "L" or uR''.
Check for voltage (12V) on the "Chocolate"
lead or "Dark green" lead atthe bulb socket
connector. 6. Wiring connection
Check the entire signa! system for
MEETS connections.
SPECIFICATION (12V) Refer to the "WIRING DIAGRAM"
section.
This circuit is good.
7-49
SIGNAL SVSTEM 1 ELECI E1
5. "OIL" indicator light does not come on.
NO CONTINUITY
1. Bulb and bulb socket
Check the bulb arid bulb socket for
continuity. Refer to the "CHECKING OF
BULBS" section.
1
l
Replace bulb and/or bulb socket.
CONTINUITY
2. Oil leve! switch

Remove the oil leve! switch from the oil
tank.
Connect the Pocket Tester (Q x 1) to the
oil leve! switch.
Tester (+) Lead --7 Terminal CD

Tester (-) Lead --7 Terminal
[A]---;
ffil
w JE_
'
--
1
2
CJ
ICi>@ t
1
Check the oillevel gauge for continuity.
Good
Switch position Bad condition
condition BAD CONDITION
o o
l
A Upright position X X
Upside down o o
B X X
position
0: Continuity X: Nocontinuity
1 Replace oil leve! switch. 1
GOOD CONDITION
7-50
s_JG_N_A_L_s_v_s_TE_M_,ELEC lli-
3. Voltage
bulb socket connector.
Tester (+) Lead Gray Q) Lead

l
Turn the main switch to u* u connections.
Check for voltage (12V) on the UGrayu lead Refer to the UWIRING DIAGRAMu
at bulb socket connector. section.
MEETS
SPECIFICATION (12V)
This circuit is good.
7-51
SIGNAL SYSTEM 1 ELECI E1
6. Fuel meter does not operate
1. Fuel sender
o Remove the fuel sender from the fuel tank.
Connect the Pocket Teste r (Q x 10) to the fu el
sender coupler.
Tester (+) Lead Green CD Terminal

Tester (-) lead Black 0 Terminal
Check the fuel sender for specificated

resistance.
Fuel Sender Resistance (Up ):
4 - 1OQ at 2oc (68"F)
Fuel Sender Resistan ce (Down @ ):
90- 1000 at 20"C (68.F) 1 Replace fuel sender.
BOTH MEET
SPECIFICATION
2. Voltage
fuel meter coupler.
Tester Lead Brown CD Terminal

Tester Lead Black 0 Terminal

Check for voltage (12V) on the "Brown" lead Check the entire signal system for
at the fuel meter coupler. connections.
MEETS
SPECIFICATION (12V)
*
7-52
SIGNAL SYSTEM 1 ELECI E1
3. Fuel meter
Movethefloatto "UPCD" or"DOWN CV".

Check the fuel meter needle moves
NOTE=----------------------------
Before reading the meter, stay put the float
"F" CD or "E" CV.
for more than three minutes respectively at
"Up" or "Down".
DOES NOT MOVE
l
Replace fuel meter.
MOVES
connections.
Refer to the "WIRING DIAGRAM" section.
7-53
METER ASSEMBLY 1 ELECI EEi 1
METER ASSEMBLY
Remo val
1. Remove:
e Handlebar cover (front and rear)
Refer to "CHAPTER 3- COVERS" secton.
2. Remove:
Meter lights
Leads
lndicator lights
. CAUTION:.
Do not remo ve the indicator bulbs by pulling the
leads.
lnstallation
Reverse the "REMOVAL" steps by noting the fol-
lowing points.
1.1nstall the meter lights and leads as shown.
CD "OIL" indicator light leads
(Gray and Black lead)
CV "TURN" indicator light lead
(Dark green and chocolate lead)
@ "HIGH BEAM" indicator light lead
(Yellow and Black lead)
<1) Meter light lead
(Biue and Black lead)
Fuel meter lead (Green)
Fuel meter lead (Brown)
(J) Fuel meter lead (Biack)
7-54
AUTO CHOKE
CIRCUIT DIAGRAM
Below circuit diagram shows aut choke circuit.
y:=Jl
B
$ B
YIR

1
8
1
..J...
+
.B.
...
Gy
G/Y
Br
: 7-55 :_ - - -- - -
AUTO CHOKE
NOTE:-------------------------------------------------
Forthe color codes, see page 7-2.
C.D.I. magneto
Auto choke unit assembly
7-56
A_u_T_o_c_H_o_K_EIELEC'' 1
TROUBLE SHOOTING
AUTO CHOKE DOES NOT OPERA TE.
Procedure
Check;
1. P.T.C. thermistor resistance
3. Voltage
NOTE=------------------------------------------------------------------
1) Cover, Seat, Rea r ca rrier
2) Side cover (left and right) Tail cover.
Pocket tester:
YU-03112
1. P.T.C. thermistor resistance

Disconnectthe auto choke unit couplerfrom
the wire harness.
Connect the pocket tester (Q x 1) to the auto
choke unit lead.
Tester (+) lead --7 Black CD

Tester (-) Iead --7 Black
P.T.C. thermist or resistance

2 - 6 Q at 20' C (68'F) Replace the auto choke unit.
MEETS SPECIFICATION
7-57
A_UT_o c_H_O_KE_,ELECI

" Disconnect the C.D. l. magneto coupler from
wire harness
" Connect the pocket tester (Q x 1) to the
lighting coil lead.
Tester (+) lead Yello w/Red CD terminal

Tester (-) lead Black terminal
Lighting coil r esistance:

0.4 - 0.6Q at 2oc
l
Replace the lighting coil.
.J.},. MEETS SPECIFICATION
3. Voltage
" Con nect th e pockettester (AC20V) to the auto
choke lead.
Tester (+) lead Yellow/Red CD terminal

Tester (-) lead Black terminal
Check the entire auto choke unit for
con nection.
Refer to the "WIRIN G DIAGRAM"
section.
e Turn the main switch to "ON".

Start the engine and accelerate to about
3,000r/min.
Check the voltage.
7-58
AUTO CHOKE 1 ELe el a 1
l
11 !JI Voltage:
.....!
MEETS SPECIFICATION
1 Auto choke unit.

------- :s g o o d ----=========- 1
7-59
------------ CHAPTER 8.
al ? 1
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ............................................................... H-14

FUEL SYSTEM .................................................................................................. H-14
ELECTRICAL SYSTEM ...................................................................................... H-14
COMPRESSION SYSTEM ................................................................................ H-15
POOR IDLE SPEED PERFORMANCE ..................................................................... H-15

POOR IDLE SPEED PERFORMANCE ............................................................... H-15
POOR MEDIUM ANO HIGH SPEED PERFORMANCE .......................................... H-15

FUEL SYSTEM .................................................................................................. H-15
ELECTRICAL SYSTEM ...................................................................................... H-15
COMPRESSION SYSTEM ................................................................................ H-16
FAULTY AUTOMATIC (V-BELT TYPE) .................................................................. H-16

SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERAT!NG ..................... H-16
CLUTCH-OUT FAILURE .................................................................................... H-16
POOR STANDING START (LOW CLIMBING ABILITY) ................................... H-16
POOR ACCELERATION (POOR HIGH SPEED) ................................................ H-16
IMPROPER KICKING ................................................................................................................ 1-1

SLIPPING .............................................................................................................................. 1-1
HARD KICKING ..................................................................................................... I-1
KICK CRANK NOT RETURNING ...................................................................................... 1-1
FAULTY BRAKE ........................................................................................................................ 1-1

POOR BRAKING EFFECT................................................................................................... 1-1
MALFUNCTION ................................................................................................................... 1-1
INSTABLE HANDING .............................................................................................................. 1-2

INSTABLE HANDING .......................................................................................................... 1-2
FAULTY SIGNAL AND LIGHTING SYSTEM ...................................................................... 1-2

HEADLIGHT DARK ............................................................................................................. 1-2
BULB BURNT OUT ............................................................................................................. 1-2
FLASHER DOES NOT LIGHT ........................................................................................... 1-2
FLASHER KEEPS ON.......................................................................................................... 1-2
FLASHER WINKS SLOWER .............................................................................................. 1-3
FLASHER WINKS OUICKER ............................................................................................. 1-3
HORN IS INOPERATIVE .................................................................................................... 1-3
OVERHEATING ........................................................................................................................... 1-3

OVERHEATING..................................................................................................................... 1-3
CY50B WIRING DIAGRAM

- STARTING FAILURE/HARD STARTING _ G LI _ ?. _
1
TROUBLESHOOTING
NOTE:--------------------------------------------------------------
The following troubleshooting does not cover all the possible causes of trouble. lt should be helpful,
however, as a guide to troubleshooting. Referto the relative procedure in this manual for inspection, ad-
justment and replacement of parts.
STARTING FAILURE/HARD STARTING
FUEL SYSTEM PROBABLE CAUSE

Fu el tank ------------,r-- Empty
L
Ciogged fuel filter
Deteriorated fuel or fuel containing water or
foreign material
Ciogged fuel tank cap
Fuel cock---------------,---
L
cloggedfuel hose
Ciogged Vacuum hose
Faulty diaphram
Carburetor-------------,--- Deteriorated fuel, fuel containing water of

foreign material
Ciogged pilot jet
Ciogged pilota ir passage
Sucked-in air
Groove-worn needle valve
lmproperly sealed valve seat
lmproperly adjusted fuel level
lmproperly set pilot jet
Ciogged starter jet
Starter plunger malfunction
lmproperly adjusted pilot air screw
Air cleaner------------ Ciogged a ir filter
8-1
STARTING FAILURE/HARD STARTING
ELECTRICAL SYSTEM PROBABLE CAUSE
Spark plug------------,.- lmproper plug gap
L
Worn electrodes
Wre between terminals broken
lmproper heat range
eFaulty spark plug cap
lgnition coii----------TL- Broken or shorted primary/secondary

Faulty spark plug lead
Broken body
L
CDI unt system---------. .- Faulty C.D.I. unit
Faulty source coi!
Faulty pick-up col
Switches and wiring -------..-- Faulty main switch

Broken or shorted wiring
Faulty Brake switch (front and rearl
Faulty starter switch
Faulty Engine "stop" switch
Starter motor-----------rL- Faulty starter motor

Faulty starter relay
Auto choke unt --------..,Lr-- Broken or shorted wiring

Faulty auto choke unit
8-2
STARTING FAILURE/HARD STARTING/ ITRBLI ? 1

L
POOR IDLE SPEED PERFORMANCE SHTG
Cylinder and cylinder head

COMPRESSION SYSTEM PROBABLE CAUSE
Loase spark plug
Loase cylinder head
Broken cylinder head gasket
Broken cylinder gasket
Pistan and pistan rings L Worn, damaged or seized cylinder
lmproperly installed pistan ring

Worn, fatigued or broken pistan ring
Seized pistan ring
Crankcase and crankshaft

L Seized or damaged pistan
lmproperly seated crankcase

lmproperly sealed crankcase (damaged oil
seal)
Seized crankshaft
Reed valve ----------.,..L- Deformed reed valve stopper

lmproperly seated read valve
Loase intake manifold
Broken gasket
Broken reed valve
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE PROBABLE CAUSE
L Carburetor -----------y-- lmproperly returned starter plunger
Ciogged or loase pilot jet
Ciogged pilot air passage
lmproperly adjusted id le speed
(throttle stop screw)
lmproper throttle/carburetor cable play
Fiooded carburetor
8-3
-
POOR MEDIUM AND HIGH SPEED PERFORMANCE l_ sTHRTBGll_ ?... 1_
POOR MEDIUM AND HIGH SPEED PERFORMANCE
FUEL SYSTEM PROBABLE CAUSE
,-- Ciogged fuel filter
Fuel tan k-----------...
L
Deteriorated fuel or fuel containing water or
foreign material
Ciogged fuel tank cap
Fuel cock -----------T'- Ciogged fuel hose
L
Ciogged vacuum hose
Faulty diaphram
Carburetor------------- Deteriorated fuel, fuel containing water or

foreign material
Sucked-in air
Groove-worn needle valve
lmproperly sealed valve seat
lmproperly set clip position of jet needle
lmproperly adjusted fuel leve!
Ciogged or loase main jet
Ciogged or loase main nozzle
Ciogged main air passage
Air cleaner ------------ Ciogged air filter
ELECTRICAL SYSTEM PROBABLE CAUSE

Spark plug -----------....-- lmproper plug gap
L
Worn electrodes
Wire between terminals broken
lmproper heat range
Faulty spark plug cap
CDI unit system --------r- Faulty C.D.L unit

1 Faulty source coil
- Faulty pickup coil
Auto choke unit --------rL- Broken or shorted wiring

Faulty auto choke unit
8-4
POOR MEDIUM AND HIGH SPEED PERFORMANCE IJn ?

COMPRESSION SYSTEM PROBABLE CAUSE
Cylinder and cylinder head Loase spark plug
Broken cylinder head gasket
o Broken cylinder gasket
Loase cylinder head
Worn, damaged or seized cylinder
Pistan and pistan ring -----..,Lr--- olmproperly installed pistan ring

Worn, fatigued or broken pistan ring
Seized pistan ring
Crankcase and crankshaft

L Seized or damaged pistan

lmproperly sealed crankcase
(damaged oil seal)
Seized crankshaft
Reed valve ----------.,.--Deformed reed valve stopper

elmproperly adjusted reed valve stopper height
lmproperly seated reed valve
Loase intake manifold
eBroken gasket
e Broken reed valve
8-5
FAULTY AUTOMATIC
?
FAULTV AUTOMATIC (V-BELT TVPE)
SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING
PROBABLE CAUSE
V-belt -------------- Worn, damaged or slipped V-belt
Primary sheave --------....-Worn or damaged ca m plate
-------,-L-
Secondary sheave
L Worn or damaged slider bushing
Broken compression spring
Pealed lining from clutch shoe
Worn spline of clutch housing
t
CLUTCH-OUT FAILURE PROBABLE CAUSE
Pcimacy 'heave---------- Seized primary sliding sheave and collar
Secondary sheave --------- Broken or fatigued clutch shoe spring
POOR STANDING START (LOW CLIMBING ABILITY)

PROBABLE CAUSE
V-belt -------------- Worn or slipped V-belt
Primary sheave ---------- Worn or improper operation of weight
Secondary sheave -------- Fatigued compression spring

L lmproper operation of secondary sliding
sheave
POOR ACCELERATION (POOR HIGH SPEED) PROBABLE CAUSE
t V-belt Worn or greasy V-belt
Secondary sheave -------.,.- Worn or greasy clutch shoe

L lmproper operation of secondary sliding
sheave
8-6
- S
IMPROPER KICKING G . LI. ?. 1_
IMPROPER KICKING
SLIPPING PROBABLE CAUSE
Kick axle assembly--------r--Low tension of kick clip
Worn kick axle
Worn or damaged kick gear
Damaged kick clip
Kick clip coming off
Damaged kick clip stopper
Transmission oil --------r-L- lmproper quality (low viscosity)

Deterioration
HARD KICKING PROBABLE CAUSE

Kick axle assembly -------TL- High tension of kick clip
Seized kick gear
Cylinder, pistan and pitan ring L Damaged or seized cylinder

Damaged or seized pistan
Crankcase and crankshaft L Damaged or seized pistan ring

lmproperly seated crankshaft
Damaged or seized crankshaft
Damaged or seized crankshaft bearing
KICK CRANK NOT RETURNING PROBABLE CAUSE

L Kick axle assembly -------T- Damaged kick return spring
L Kick return spring coming off

Kick clip coming off
Damaged kick return spring stopper
8-7
FAULTY BRAKE
?

FAULTY BRAKE
POOR BRAKING EFFECT PROBABLE CAUSE
L Drum brake ----------,..-- Worn brake shoe
Worn or rusty brake drum
lmproperly adjusted brake free play
lmproper brake cam lever position
lmproper brake shoe position
Fatigue/Damaged return spring
Oily or greasy brake shoe
Oily or greasy brake drum

Broken brake cable
1 Bent, deformed or damaged suspention arm
L
MALFUNCTION PROBABLE CAUSE
Bent or deformed suspention pivots

Damaged damper spring
Worn or damaged collar
Suspention oilleakage
8-8
-
INSTABLE HANDLING l_sTHRTBGLI_ ?. 1_
INSTABLE
INSTABLE HANDLING
Steering ------------rl-
HANDLING
PROBABLE CAUSE
Handlebar ------------- lmproperly installed or bent
lmproperly installed steering column

(improperly tightened ringnut)
Bent steering column
Damaged ball bearing or bearing race
Front forks -----------r- Broken damper spring

LBent or deformed suspention arm and pivots
Tires --------------rl- Uneven tire pressures on both sides
lncorrect tire pressure
Unevenly worn tires
Wheels -------------r- Damaged bearing

L Bent or loase wheel axle
Excessive wheel run-out
Fra me --------------.-- Twisted

L
Damaged head pipe
lmproperly installed bearing race
Engine bracket ----------- Bent or damaged
Rear shock absorber ------..,Lr--- Fatigued spring

Oil leakage
8-9
FAULTY SIGNAL ANO LIGHTING SYSTEM _ T HRTBGLI_
IS ?_ 1_
-----------------------------------------------------------------
FAULTY SIGNAL ANO LIGHTING SYSTEM
HEADLIGHT DARK PROBABLE CAUSE
L--------------- - lmproper bulb
Too many electric accessories
Hard charging (broken charging coil)
lncorrect connection
lmproperly grounded
Poor contacts (main or light switch)
Bulb life expires
BULB BURNT OUT PROBABLE CAUSE

1 lmproper bulb
L lmproperly grounded
Faulty mam and/or l1ght sw1tch
Bulb life expires
FLASHER DOES NOT LIGHT PROBABLE CAUSE

. ---y_ 1mprope rly gro unded
Discharged battery
Faulty "TURN" switch
Faulty flasher relay
Broken wireharness
Loas el y connected coupler
Bulb brunt out
Faulty fuse
FLASHER KEEPS ON PROBABLE CAUSE

1
1----------------....- Faulty flasher relay
L lnsufficient battery capacity

(nearly discharged)
Bulb burnt out
8-1 o
FAULTY SIGNAL ANO UGHTING SYSTEM/
OVERHEATING
FLASHER WINKS SLOWER PROBABLE CAUSE
1
------------------r- Faulty flasher relay
L
lnsufficient battery capacity
(nearly discharged)
lmproper bulb
Faulty main and/or flasher switch
FLASHER WINKS QUICKER PROBABLE CAUSE

1
Llmproper bulb
Faulty flasher relay
HORN IS INOPERATIVE PROBABLE CAUSE

....._---------------.,- Faulty battery
Faulty fuse
Faulty main and/or horn switch
lmproperly adjusted horn
Faulty horn
Broken wireharness
OVERHEATING
OVERHEATING
lgnition system --------.-L- PROBABLE CAUSE
lmproper spark plug gap
lmproper spark plug heat rang
lmproper ignition timing
Faulty system ---------....-lmproper carburetor main jet
L(improper setting)
Ciogged air cleaner element
Lean mixture (faulty autolube pump settings)
Compression system -------- Heavy carbon build-up
Cooling fan -----------,L.....-- Damaged cooling fan

Damaged a ir shrouds
Brake -------------- Dragging brake
8-11
1 1-4 1
CYSOB ('91) WIRING DIAGRAM
CD
(V
CD

ra
--{>iL @
GIY
BIWI B LIWI B
OFF OFF ( 0-
ON CHECK
ON 1 1 IQJ:<:
J CD Handlebar switch (Right)
@
CP= = =M=
Dq
B B
Dg Dg
O
sD----+-
L
B/W
(V "ENGINE
@ "START" switch
STOP" switch
(GREEN) Dg--c:J<:)--- ,-r{'\ Front brake switch

,--s @ M a in switch
lgnition coil
()t= --h 0 Spark plug
Auto choke
i
flr-- @ Rectifier/Regulator
@\.._)J-Gv @Fu el sender
@ Oil level switch
@Re m flasher light (Right)
@ Tail/brake light
@ Rear flasher light (Left)
(J:t=
@Fu se
@
@o QJ=:::::t-- "" J rt:

'---- R----,
Starter motor
@ Starter relay
m@
@ Battery
rt \o\ -t-t-11 --nlJ @ CDI unit

@
CDI magneto
--
-
"' Horn
OJ= :W -'' --r--r--
1
G p
@ Rem brake switch
@ Handlebar switch (Left)
@ "TURN" switch
@ "HORN" switch
"LIGHTS" (Dimmerl switch
(BROWN) Flasher relay
Ch IBr/WI Og @ Front flasher light (Left)
!:..,[_! @ Headlight
J "HIGH BEAM" indicator light
o o,W Br- j
@ @ @
@
Q)
@]) Meter light
@Fuel meter
@) "OIL" warning indicator light
"TURN" indicator light
@ Front flashcr light (Rig htl.

@
COLOR CODE
B ................ Black Y ................ Yellow O ............... Orenge
L ................ Blue R ................ Red
G ............... Grccn Pink
Br ............. Brown L(W ........... Bluc(Whitc
Gy ............ Gray G/Y ............
Ch ............ Chocolate Green/Yellow
Dg ............ Dark green Y/R ............ Yellow/Red
W ..............White Br(W ..........
B/R ........... Block/Red BrownfWhite
8(0/ ......... Black(White W/R ........... White/Red
CY508 ('91) WIRING DIAGRAM
o
@
C
D

Br
!

1 xac,
o?:l
O== Oq
Dg Og (V
. OFF /WB
G/Y
E9
---{>IL
-{>t- Br Gy
ON
/W B G
D -
s--+ - "'" B
W R
1
Y/R 1 W
B B 8
'(GREEN)
(GREEN) Dg--D<:}-Dg--r-{)
:ffi; :: ,Af)
r---B B @
oi\ fl-t-og- B /W
1
'e.Y \._)-J--Ch-
,_ n @
1" :=e()@
Br 1 1 1 1 1 1 T 1 1 1 1 f 1 1 T 1 1 1 1 1 1 1 1 1 1 1
rl---G/Y-0
()::t= 8
11 r 11 1r 1111 1 1 11'
l 1 ; 111 1 i 11
A----,
rt
()J==; --f: Y-
'---
1@
@
O _jGj
0 Rj
;
G
-+-t-----r-1
1 y
Br
"' . 11 w '1""
@
o BIBWr----_j g Lb;-Jig/Y Br : @ @
o
OFF
ON
@
@

Yamaha Motor Canada Ltd.
480 Gordon Baker Road
Toronto, ON M2H 3B4

2 - 1991-2000 - Yamaha - Jog - CY50 - Service - Manual

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2 - 1991-2000 - Yamaha - Jog - CY50 - Service - Manual

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Copyright:

Verfügbare Formate

1991 - 2000

Model : CY50B, CY50D, CY50E, CY50F,

PARTICULARLY IMPORTANT INFORMATION

Failure to follow WARNING instructions could result in severe injury or death

A CAUTION indecates special precautions that must be taken to avoid damage

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

3rd title : This is a final title.

FRONT FORK !CHAS r/i:J0j

1!1 cr; ;;o.,.tlng 1001

WarroaD-O -uramenl and raaurlaca

lllustrated symbols(Dto are designed as thumb

I JII fiil 1 ENG l'-1

lcARBifl icHAsl ej (J) Electrical

IELEcl el l n l? 1 lllustrated symbols to @ are used to identify

@ @ lllustrated symbols @ to @ in the exploded

SCOOTER IDENTIFICATION ................................................................................... A-8

IMPORTANT INFORMATION ................................................................................. A-8

SPECIAL TOOLS ...................................................................................................... A-9

Starting serial number:

ENGINE SERIAL NUMBER

Starting serial number:

3. When disassembling the scooter, keep mated

4. Du ring the scooter disassembly, e lean all parts

ALL REPLACEMENT PARTS

GASKETS, OIL SEALS, AND 0-RINGS

BEARINGS AND OIL SEALS

This tool is needed for detecting engine rpm.

This gauge is used to mea su re engine compres-

3. Fuel leve[ gauge

This gauge is used tome asure the fuellevel in the

FOR ENGINE SERVICE

This tool is used to the hold the flywheel magneto

This tool is used to remove the flywheel.

3. Crankcase Separating Tool

This tool is used to remove the crankshaft or

4. Crankshaft lnstalling Set

This tool is used when holding the clutch hub.

6. Clutch Spring Holder

This tool is used to disassembly and assem bly the

This sealant (Bond) is used for crankcase mating

FOR CHASSIS SERVICE

This too! is used to loasen and tighten the

FOR ELECTRICAL COMPONENTS

This instrument is invaluable for electrical system

2. Dynamic spark tester

This instrument is necessary for checking the

GENERAL SPECIFICATIONS .................................................................................. A-14

MAINTENANCE SPECIFICATIONS ....................................................................... A-15

GENERAL TOROUE SPECIFICATIONS ................................................................... B-3

DEFINITION OF UNITS ............................................................................................. B-3

LUBRICATION POINTS AND LUBRICANT TYPE ................................................... B-3

CABLE ROUTING ...................................................................................................... B-4

Pistan Clearance 0.034- 0.047 mm (0.0013- 0.0018 in)

Tap Ring .. ,. 0.15-0.35 mm (0.006- 0.014 in)

Crank Width "A" 37.90- 37.95 mm (1.492- 1.494 in)

This chart specifies torque for standard fasteners Nm m-kg ftlb

A: Distance across flats

Lubrication Points {part name) Lubricant Type

Oil seal lips {all)

Starter idle gear -G

Secondary sliding sheave cam groove BEL-RAY assembly lube

Secondary fixed sheave in-side dia. BEL-RAY assembly lube

Crankcase mating surfaces Yamaha bond No. 1215