Yamaha T-50 Instrukcja Obsługi

SERVICEMANUALYQ505BS-AE2'97

GENINFO1-2IMPORTANT INFORMATIONIMPORTANT INFORMATIONALL REPLACEMENT PARTS1.Use only genuine parts for all replacements.Use oil and/or grease recommend

ENG4-393220328. Install :• Oil hose• Oil delivery hoseENGINE ASSEMBLY AND ADJUSTEMENTENGINE REMOUNTINGReverse the removal procedure.Note the following

ENG4-40ENGINE ASSEMBLY AND ADJUSTEMENT10. Install :• Muffler assemblyBolt (muffler) :26 Nm (2.6 m.kg)Bolt (exhaust pipe) :9 Nm (0.9 m.kg)T.RT.RCOOLING

5COOL

COOLCHAPTER 5.COOLING SYSTEMRADIATOR...5-1REMOVAL...

COOL5-116 Nm (1.6 m.kg)햲햳햴햵햵햶햷햸햹햺햻햽LTLT7 Nm (0.7 m.kg)RADIATORQ Coolant tank capW Coolant tankE RadiatorR HoseT Water pumpY O-RingU Impeller O-RingI C

COOL5-2COOLING SYSTEMCOOLING SYSTEMRADIATOR REMOVAL1.Remove:• Air filter• Carburetor assemblyRefer to chepter 6 "CABURETOR"2.Drain:• Radiato

COOL5-3COOLING SYSTEM햲햳햴햵햶햷햸햹햺햻햽햾햿7 Nm (0.7 m.kg)6.5 Nm (0.65 m.kg)6.5 Nm (0.65 m.kg)LSWATER PUMPQ Water pump housingW O-RingE ImpellerR SealT CoverY

COOL5-4COOLING SYSTEMWATER PUMP REMOVAL1.Remove:• Side coverRefer to chapter 3 "COVER"2.Drain:• Radiator• HosesRefer to chapter 3 "COOL

COOL5-5COOLING SYSTEMTHERMOSTATIC VALVEQ Thermostatic switchW Cylinder headE Thermostatic valveR Cylinder16 Nm (1.6 m.kg)햳햵햴햲LTLT

COOL5-6COOLING SYSTEMTHERMOSTATIC VALVE REMOVAL1.Drain:• CoolantRefer to the chapter 3 "COOLANT REMPLA-CEMENT"2.Remove:• Cylinder head• Ther

GENINFO1-3IMPORTANT INFORMATIONCIRCLIPS1.All circlips should be inspected carefully beforereassembly. Always replace piston pin clipsonce they have be

6CARB

CARBCHAPTER 6.CARBURETIONCARBURETOR ...6-1DELL'ORTO CA

CARB6-1CARBURETOR햲햳햴햵햶햷햸햹햺햻햽햾햿헀헁헂헃헄322034DELL'ORTO CARBURETORQ Carburetor topW GasketE Throttle valve springR Needle setT Throttle valveY Starter

CARB6-2CARBURETORREMOVAL1. Remove :• Side covers and footrest boardRefer to the section “SIDE COVERS ANDFOOTREST BOARD” in Chapter 3.• Air filter case

CARB6-3322006햲322028햲햳CARBURETOR3. Remove :• Pilot jet Q• Main jet W• Main nozzle E• Starter jet R4. Remove :• Throttle stop screw Q• Spring (throttle

CARB6-4CARBURETOR3. Check :• Needle valve QWear/Contamination ➞ Replace.• Float WDamage ➞ Replace.• GasketDamage ➞ Replace.4. Check :• Throttle valve

CARB6-5CARBURETOR322018햲햳햳햴햴햵******************************************************Float height measurement steps :• Install the needle valve, float a

CARB6-6CARBURETOR2. Install :• Throttle valve Q• Starter plungerNOTE:Align the groove W of the throttle valve with theprojection E of the carburetor b

CARB6-7FUEL COCKINSPECTION1. Stop the engine.2. Remove :• Side coversRefer to the section “SIDE COVERS ANDFOOTREST BOARD” in Chapter 3.3. Check :• Fue

CARB6-8REED VALVE3. Remove :• Carburetor joint• Reed valve assemblyINSPECTION1. Check :• Carburetor jointDamage/Cracks ➞ Replace.• Reed valveWear/Crac

GENINFO1-4EB102000SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly.Use only the appropriate speci

CARB6-9INSTALLATIONTo install the reed valve reverse the “REM-OVAL” procedure. Note the following points.1. Install :• Gasket (new)2. Tighten :• Reed

7CHAS

CHASCHAPTER 7.CHASSISFRONT WHEEL ...7-1REMOVAL...

CHAS7-1FRONT WHEELFRONT WHEELQ AxleW Speedometer gearE BearingR CollarT Front rimCHASSISY TireU ValveI CollarO SpacerP NutTIRE SIZE:130/60 - 13RIM RUN

CHAS7-2340008340006FRONT WHEELREMOVAL1. Remove :• Front caliper fixing bolts• Front caliper• Speedometer cable Q• Axle W• Front wheelNOTE:Never depres

CHAS7-3346005FRONT WHEELINSTALLATIONReverse the “Removal” procedure.Note the following points.1.Lubricate :• Front wheel axle• Bearings• Oil seal (lip

CHAS7-4FRONT BRAKEFRONT BRAKEQ DiskW BoltE CaliperR PistonT Piston sealsY Air bleed screwNOTE:Be sure to install the pads correctly.U Pad springI Pad

CHAS7-5FRONT BRAKENOTE:Drain completely before removingthe master cylinder.FRONT MASTER CYLINDERQ Master cylinderW Master cylinder piston ass'yE

CHAS7-6346005FRONT BRAKE• Disc brake components rarely requiredisassembly. Do not disassemblecomponents unless absolutely necessary.If any hydraulic c

CHAS7-7346005FRONT BRAKE4. Install :• Brake pads• Pad spring• Axle• PinNOTE :Be careful to install the brake pads correctly.5.Lubricate :• Mounting bo

GENINFO1-5SPECIAL TOOLSRing nut wrench.This tool is used to loosen and tighten thesteering ring nut.Pocket TesterThis instrument is invaluable for che

CHAS7-8FRONT BRAKE*******************************************************Removal steps :● Blow compressed air into the hose joint openingto force out

CHAS7-9FRONT BRAKE4. Remove :• Master cylinder dust boot Q• Master cylinder kit WINSPECTION AND REPAIRRecommended brake component replacementschedule

CHAS7-10347002347001FRONT BRAKE3. Check :• Brake hose QCracks/Wear/Damage ➞ Replace.4. Measure :• Brake disc deflectionOut of specification ➞ Inspect

CHAS7-11346005FRONT BRAKE2. Install :• Brake caliperApply LOCTITELOCTITE ®Bolt (brake caliper) :23 Nm (2.3 m.kg)3. Install :• Caliper body Q4. Install

CHAS7-121. Install :• Master cylinder Q• Install the master cylinder holder with thearrow mark pointing upwards.• Tighten the upper bolt first, then t

CHAS7-13REAR WHEELREAR WHEELQ Cover plugW NutE WasherR BoltT Rear wheel tireY ValveU Rear rimI Distance collarO Rear brake disk23 Nm (2.3 m.kg)120 Nm

CHAS7-14REAR WHEEL23 Nm (2.3 m.kg)23 Nm (2.3 m.kg)1.5 Nm (0.15 m.kg)14 Nm (1.4 m.kg)햲햳햴햵햶햷햷햸햹햺햻햽11 Nm (1.1 m.kg)REAR MASTER CYLINDERQ Master cylinderW

CHAS7-15REAR WHEELREMOVAL1. Remove:• Muffler assembly• Rear wheel fixing bolts• Rear wheelINSPECTION1. Check :• Rear wheelRefer to the section “FRONT

CHAS7-16REAR WHEEL3. Check :• Wheel bearingsRefer to the section “FRONT WHEELINSPECTION”.REAR BRAKEFor removal, inspection and assembly refer tothe se

CHAS7-17 FRONT FORKFRONT FORKQ Steering bracketW BoltE CirclipR Rubber capT CirclipY Spring seatU O-RingI SpringO PistonP Spring{ Spacer} Plungerq Dus

2SPEC

CHAS7-18342001354003 FRONT FORKREMOVALSecurely support the scooter with a standunder the engine.1. Place the scooter on an even surface.2. Disconnect

CHAS7-19 FRONT FORKDISASSEMBLY1. Remove :• Rubber plug Q• Circlip W• Spring seat E• Spring R2. Remove :• Bolt Q• Copper washerNOTE:To remove the drain

CHAS7-20 FRONT FORKINSPECTION1. Check :• Inner fork tube and fork components• Outer fork tubeWear/Scratches/Damage ➞ Replace.Never attempt to straight

CHAS7-21342001 FRONT FORK3. Install :• Copper washer• BoltNOTE:Tighten the drain bolt Q while holding the pistonwith the T-handle W and holder E.T-han

CHAS7-22STEERING HEAD AND HANDLEBARSTEERING HEAD AND HANDLEBARQ HandlebarW NutE BoltR Trottle gripT Throttle cableY Starter cable (Choke)60 Nm (6.0 m.

CHAS7-23354001STEERING HEAD AND HANDLEBARSTEERING HEAD ANDHANDLEBARREMOVALSecurely support the scooter so there is nodanger of it falling over.1. Plac

CHAS7-2411. Remove :• Upper bearing race QRing nut wrench :9079Q-02218• Steering shaft• Bearing ballsINSPECTION1. Check :• Handlebar QBends/Cracks/Dam

CHAS7-25354003STEERING HEAD AND HANDLEBAR• Unless installed correctly, the bearing raceswill damage the frame.• Never hit the bearing races on the bal

CHAS7-26354002STEERING HEAD AND HANDLEBARHold the steering shaft until it is securelyattached.4. Install :• Washer Q• Steering shaft lock nut WNOTE:Ti

8ELEC

SPECCHAPTER 2.SPECIFICATIONSGENERAL SPECIFICATIONS ...2-1MAINTENANCE SPECIFICATION

ELECCHAPTER 8.ELECTRICAL COMPONENTSELECTRICAL COMPONENTS ...8-1CIRCUIT DIAGRAM ...

ELEC8-1ELECTRICAL SYSTEM햲햳햵햴햸햶햷햹ELECTRICAL COMPONENTSQ Wire harnessW Fuel senderE Starter relayR Ignition coilT CDI unitY Oil senderU BatteryI Resista

ELEC8-2ELECTRICAL SYSTEM햲햳햴햵ELECTRICAL COMPONENTSQ Main switchW Flasher relayE HornR Rectifier/Regulator

ELEC8-3CIRCUIT DIAGRAMRBBWLOCKLOCK ON ONCHECKCHECK OFF OFFBr GyOFFOFF P0 P0YRYR ON ONYBYBLRLLGBGBHIHILOWLOWYLChBr/WBr/WDgNRBBBBB BBBB BBBBBBBBBBBBBBBB

ELEC8-4CIRCUIT DIAGRAMCOLOR CODERBWYBrGyOChDgGPLY/RL/WG/YB/WB/RW/RBr/WY/BG/WRedBlackWhiteYellowBrownGrayOrangeChocolateDark greenGreenPinkBlueYellow/R

ELEC8-5RBBWBWLOCKLOCK ON ONCHECKCHECK OFF OFFBrBrGyGyOFFOFF P0 P0YRYR ON ONYBYBLRLRLLGBHIHILOWLOWYLChBr/WBr/WDgNRBBBBB BBBB BBBBBBBBBBBBBBBBBBBBBBBBB

ELEC8-6: Current flow in ignition control circuit: Current flow in starter motor control circuitIGNITION AND STARTING SYSTEMIGNITION AND STARTING SYST

ELEC8-7OUT OFSPECIFICATIONOR NO SPARKTROUBLESHOOTINGTHE STARTING SYSTEM DOES NOT WORK (NO SPARK OR IRREGULAR SPARKS).NOTE :• Remove the following part

ELEC8-83.Spark plug cap resistance• Disconnect the spark plug cap.• Connect the pocket tester (Ω x 1 k) to thespark plug cap.• Check the resistance of

ELEC8-95.Pickup coil resistance• Disconnect the pickup coil coupler.• Connect the pocket tester (Ω x 100) to thepickup coil.Pocket tester (+) lead Q ➞

SPEC2-1SPECIFICATIONSGENERAL SPECIFICATIONSGENERAL SPECIFICATIONSDimensions:Overall length 1.743 mmOverall width 690 mmOverall height 1.170mmSeat heig

ELEC8-101.Fuse• Remove the fuse.• Connect the pocket tester (Ω x 1) to the fuse.• Check the fuse for continuity.CONTINUITY2.Battery• Check the conditi

ELEC8-114. Starter relay• Disconnect the Blue/White lead from thewire harness.• Connect the (-) Q terminal of the battery tothe Blue/White lead.• Chec

ELEC8-12IGNITION AND STARTING SYSTEMMEETSSPECIFICATION7.ConnectionsCheck all connections in the starter system.Refer to “WIRING DIAGRAM”.DOES NOT MEE

ELEC8-13RBBWBWLOCK ONCHECK OFFBrBrGyGyOFF P0YR ONYBLRLLGBGBHILOWLOWYLChBr/WBr/WDgNRBBBBB BBBB BBBBBBBBBBBBBBBBBBBBBBBBB BBMOOW/RB/RB/WL/WG/YRRRRWBr Gy

ELEC8-14TROUBLESHOOTINGTHE BATTERY IS NOT CHARGEDNOTE :• Remove the following parts before proceeding with the troubleshooting :1) Side covers (left a

ELEC8-154.Charging coil resistance• Disconnect the CDI magneto coupler fromthe wire harness.• Connect the pocket tester (Ω x 1) to thecharging coil.•

ELEC8-16RBBWLOCK ONCHECK OFFBr GyOFF P0YR ONYBLRLLGBGBHILOWYLChChBr/WDgDgNRBBBBB BBBB BBBBBBBBBBBBBBBBBBBBBBBBB BBMOOW/RB/RB/WL/WG/YRRRRWBr GyGyGyLR L

ELEC8-17TROUBLESHOOTINGTHE AUXILIARY LIGHT, HEADLIGHT, HEADLIGHT INDICATOR, TAIL LIGHT OR METERLIGHT DO NOT WORKNOTE :Remove the following parts befor

ELEC8-18MEETSSPECIFICATION3. Lighting coil resistance• Disconnect the lighting coil coupler from thewire harness.• Connect the pocket tester (Ω x 1) t

ELEC8-19MEETSSPECIFICATIONLIGHTING SYSTEM2. The meter light does not work.Circuit is in good condition.LIGHTING SYSTEM INSPECTION1. Headlight and head

SPEC2-2GENERAL SPECIFICATIONSModel YQ50Carburetor:Type/Manufacturer PHBN12HS / DELL'ORTOSpark plug:Type/Manufacturer BR8HS/NGKGap 0.5 ~ 0.7 mmClu

ELEC8-203. The tail light does not work.1. Bulb and socket• Check the bulb and socket for continuity.LIGHTING SYSTEM2. Voltage• Connect the pocket tes

ELEC8-21RBBWLOCKLOCK ON ONCHECKCHECK OFF OFFBrBrGyGyOFFOFF P0 P0YRYR ON ONYBYBLRLRLLGBGBHIHILOWLOWYLChBr/WDgNRBBBBB BBBB BBBBBBBBBBBBBBBBBBBBBBBBB BBM

ELEC8-22MEETSSPECIFICATIONMEETSSPECIFICATIONPocket tester :90890-03112Fuse defect ➞ Replace.2. Battery• Check the condition of the battery.Refer to “B

ELEC8-232. Voltage• Connect the pocket tester (DC20V) to thehorn lead.Pocket tester (+) lead ➞ Brown QPocket tester (-) lead ➞ Ground W• Turn the main

ELEC8-24HORN DOESNOT SOUNDMEETSSPECIFICATIONDefect in the wire harness between the mainswitch and the horn ➞ Repair.DOES NOT MEET SPECIFICATION3. Horn

ELEC8-25SIGNAL SYSTEM2. The tail light does not work.1. Bulb and socket• Check the bulb and socket for continuity.2. Brake switch• Disconnect the brak

ELEC8-26--Br/WBr햲햲햳햴LChBrWDgNRPBrWBrWL-Ch DgGBY3. Flasher does not work1. Bulb and socket• Check the bulb and socket for continuity.2. “TURN” switch•

ELEC8-27--Br/WBr햲MEETSSPECIFICATION4. Voltage• Connect the pocket tester (DC20V) to theflasher relay.Pocket tester (+) lead ➞ Brown / White QPocket te

ELEC8-28SIGNAL SYSTEMThis circuit is in good condition.2. Oil level switch• Disconnect the oil level switch from the oiltank.• Connect the pocket test

ELEC8-29SIGNAL SYSTEM3. Voltage• Connect the pocket tester (DC20V) to thebulb socket connector.Pocket tester (+) lead ➞ Grey QPocket tester (-) lead ➞

SPEC2-3GENERAL SPECIFICATIONSElectrical:Ignition system CDICharging system Flywheel magnetoBattery type/model GM4-3B, YB4L-B, FB4L-BBattery capacity 1

ELEC8-30COOLING SYSTEMCOOLING SYSTEMWIRING DIAGRAMRBBWBWLOCKLOCK ON ONCHECKCHECK OFF OFFBrBrGyGyOFFOFF P0 P0YRYR ON ONYBYBLRLRLLGBHIHILOWLOWYLChBr/WBr

ELEC8-31COOLING SYSTEMMEETSSPECIFICATIONMEETSSPECIFICATIONPocket tester :90890-03112Fuse defect ➞ Replace.2. Battery• Check the condition of the batte

ELEC8-32COOLING SYSTEM4. Thermo unit• Remove the thermo unit from the headcylinder.• Connect the pocket tester (Ω x100) then(Ω x 10) to the thermo uni

9TRBLSHTG

TRBLSHTGCHAPTER 9.TROUBLESHOOTINGSTARTING FAILURE/ HARD STARTING ...9-1FUEL SYSTEM ...

TRBLSHTG9-1STARTING FAILURE/HARD STARTINGTROUBLESHOOTINGNOTE:The following troubleshooting does not cover all the possible causes of trouble. It shoul

TRBLSHTG9-2STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCECOMPRESSION SYSTEMCylinder and cylinder head Crankcase and crankshaft• Loose spar

TRBLSHTG9-3POOR MEDIUM AND HIGH SPEED PERFORMANCE/FAULTY AUTOMATICPOOR MEDIUM AND HIGH SPEED PERFORMANCEFUEL SYSTEMFuel tank Carburetor• Clogged fuel

TRBLSHTG9-4FAULTY AUTOMATIC/OVER HEATING OR OVER-COOLINGOVER HEATING OR OVER-COOLINGOVER HEATING OVER-COOLINGIgnition system Cooling system• Improper

TRBLSHTG9-5IMPROPER KICKING/FAULTY BRAKEIMPROPER KICKINGSLIPPINGKick axle assembly Transmission oil• Low tension of kick clip • Improper quality (low

SPEC2-4Cylinder head:Warp limit 0.02 mm* Lines indicate straight edge measurements.Cylinder:Bore size 39.993 ~ 40.012 mm<Limit> <40.1 mm>T

TRBLSHTG9-6FRONT FORK OIL LEAKAGE AND FRONT FORKMALFUNCTION/INSTABLE HANDLINGINSTABLE HANDLINGINSTABLE HANDLINGHandlebar Wheels• Improperly installed

TRBLSHTG9-7FAULTY SIGNAL AND LIGHTING SYSTEMFlasher winks slower Horn is inoperative• Faulty flasher relay • Faulty battery• Insufficient battery capa

YQ50 WIRING DIAGRAMOFF ONLWB+-BOrRBBWBWOrBRGyBBr BWLOCK ONCHECK OFF OFFBRWYRBRBr GyRYWYRBrOFFPBONOFFLChBrWDgLGBGBHILOWNR P0YRBRRBRRGYGYLWRRBWGYBR WRWR

YQ50SERVICE MANUAL© 1997 by MBK INDUSTRIE2st Edition, November 1997All rights reserved. Anyreprinting or unauthorized usewithout the writtenpermission

SPEC2-5MAINTENANCE SPECIFICATIONSAutomatic centrifugal clutch:Clutch shoe thickness 2.0 mm<Wear limit> <1.0 mm>Clutch shoe spring free len

SPEC2-6CHASSISMAINTENANCE SPECIFICATIONSSteering system:Steering bearing type Ball bearingNo/Size of steel balls:Upper 15 pcs (4.75 mm)Lower 15 pcs (4

SPEC2-7ELECTRICALMAINTENANCE SPECIFICATIONSVoltage: 12 VIgnition system:Ignition timing (B.T.D.C.) 14° at 5.000 r/minCDI:Pickup coil resistance (color

SPEC2-8CABLE ROUTINGQ Handlebar end gripW Right handlebar switchE Left handlebar switchR HandlebarT Flasher harnessY Right handlebar gripU Wireharness

SPEC2-9CABLE ROUTING햲햳햳햴햵햶햸햹햺햻햽BCEH JDG햷I햲햳A햸햳F5 ~ 10 mm MAXCABLE ROUTINGQ Fuel senderW Fuel tankE Fuel overflow pipeR Fuel cockT Pipe bracketY FrameU

SPEC2-10Q Seat lockW Starter motorE Ignition coilR BatteryT Starter relayY Fuse housingU Rear brake hoseI Fuel senderO CDI unitP Oil lever gauge{ Main

SPEC2-11Q Wiring harnessW ResistorE HornR Front brake hoseT Speedometer cableY RadiatorU Water tankI ClampsP FrameCABLE ROUTING햲햳햴햵햶햷햸햹E햸햷햷햸햷햺A Instal

SPEC2-12햲햲햸햷햺ABCDEF햻햻햸햹햸햸햴햳햵햶햲햲27°±10°Q Rear brake hoseW Seat lock cableE Wire harnessR Throttle cableT Starter (choke) cableY Speedometer cableU Fram

3CHKADJ

CHKADJCHAPTER 3.PERIODIC INSPECTION AND ADJUSTMENTINTRODUCTION...

CAUTION:WARNING NOTICEThis manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealersand their qualified mechanics. It is not

INSPADJ3-1INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALSPERIODIC INSPECTION AND ADJUSTMENTINTRODUCTIONThis chapter includes all information n

INSPADJ3-2PERIODIC MAINTENANCE/LUBRICATION INTERVALSNOTE:Brake fluid replacement:1.When disassembling the master cylinder or caliper cylinder, replace

INSPADJ3-3125 344T.R2 Nm (0,2 m.kg) T.R3 Nm (0,3 m.kg) T.R8 Nm (0,8 m.kg) T.R8 Nm (0,8 m.kg) MarkName of the intervention/of the partQtyObservat

INSPADJ3-4453312 T.R2,5 Nm (0,25 m.kg) T.R6 Nm (0,6 m.kg) T.R3 Nm (0,3 m.kg) T.R8 Nm (0,8 m.kg) MarkName of the intervention/of the partQtyObservat

INSPADJ3-52143T.R6,5 Nm (0,65 m.kg) T.R13 Nm (1,3 m.kg) T.R3 Nm (0,3 m.kg) T.R2 Nm (0,2 m.kg) T.R6,5 Nm (0,65 m.kg) MarkName of the intervention/of th

INSPADJ3-6MarkName of the intervention/of the partQtyObservationCOVERSREMOVAL12342T.R2 Nm (0,2 m.kg) T.R3 Nm (0,3 m.kg) T.R3 Nm (0,3 m.kg) T.R3 Nm (0,

INSPADJ3-7MarkName of the intervention/of the partQtyObservationCOVERSHANDLEBAR COVERS1 Handlebar cover (front) 12 Handlebar cover (rear) 13 Meter 14

INSPADJ3-8MarkName of the intervention/of the partQtyObservationCOVERSREMOVALT.R3 Nm (0,3 m.kg) T.R3 Nm (0,3 m.kg) 121 Battery cover 12 Lower cover 1W

INSPADJ3-9MarkName of the intervention/of the partQtyObservationCOVERSREMOVAL1 Inner panel 1 Main switch ring. Turn the ringanticlockwise to remove it

INSPADJ3-10NOTE:Correct routing of cables and wires is essential for a safe operation of this scooter. Refer to the section“CABLE ROUTING” in Chapter

HOW TO USE THIS MANUALCONSTRUCTION OF THIS MANUALThis manual consists of chapters for the main categories of subjects. (See «illustrated symbols).1st

INSPADJ3-11ENGINE IDLE SPEED ADJUSTMENTENGINEENGINE IDLE SPEED ADJUSTMENT1. Tighten :• Pilot air screwTurn the pilot air screw in until lightly seated

INSPADJ3-126. Adjust :• Engine idle speed********************************************************Adjustment steps :• Turn the throttle stop screw in o

INSPADJ3-13SPARK PLUG INSPECTIONSPARK PLUG INSPECTION1. Remove :• Spark plug2. Inspect :• Electrode QWear/Damage ➞ Replace.• Insulator WAbnormal color

INSPADJ3-14AUTOLUBE PUMP AIR BLEEDINGAUTOLUBE PUMP AIR BLEEDING1. Bleed :• Pump housing and oil hose**************************************************

INSPADJ3-15ENGINE OIL LEVEL INSPECTION1. Inspect :• Oil levelOil level low ➞ Add oil to proper level asfollows.Q “OIL” indicator lightOIL LEVEL AND GA

INSPADJ3-16TRANSMISSION OIL REPLACEMENT1. Remove :• Drain plug Q• Oil filler plug WDrain the transmission oil.2. Check :• Gasket (drain plug)• O-ring

INSPADJ3-17COOLANT LEVEL INSPECTION/COOLANT REPLACEMENTCOOLANT LEVEL INSPECTIONNOTE:Install the scooter straight up when inspectingthe coolant level.

INSPADJ3-18COOLANT REPLACEMENTtoward the detent. This allows any residualpressure to escape. When the hissing sooundhas stopped, press down on the cap

INSPADJ3-19AIR CLEANER ELEMENT CLEANINGAIR CLEANER ELEMENT CLEANING1. Remove :• Air cleaner case cover Q2. Remove :• Air filter elementNever operate t

INSPADJ3-20EXHAUST PIPE ASSEMBLY AND ADJUSTMENT29 Nm (2.9 m.kg)7 Nm (0.7 m.kg)4.5 Nm (0.45 m.kg)MUFFLERQ Exhaust pipeW CylinderE CrankcaseR Bolt

ILLUSTRATED SYMBOLS(REFER TO THE ILLUSTRATION)Illustrated symbols Q to W are designed asthumb tabs to indicate the chapter’s number andcontent.Q Gener

INSPADJ3-21FRONT BRAKE LEVER FREE PLAY ADJUSTEMENT/REAR BRAKE LEVER FREE PLAY ADJUSTEMENT/BRAKE PAD INSPECTIONCHASSISFRONT BRAKE LEVER FREE PLAYADJUST

INSPADJ3-22BRAKE FLUID LEVEL INSPECTIONBRAKE FLUID LEVEL INSPECTIONNOTE:Position the scooter straight up when inspectingthe fluid level, and make sure

INSPADJ3-23354002346002AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/STEERING HEAD ADJUSTEMENTSTEERING HEAD ADJUSTMENT1 Check :• Steering assembly bearingsGra

INSPADJ3-24 Securing nut :23 Nm (2.3 m.kg)NOTE :Install the torque wrench on the ring nut wrenchso that it makes a 90° angle with it.● Move the handle

INSPADJ3-25TIRE INSPECTION/WHEEL INSPECTION/CABLE INSPECTION AND LUBRICATION2 Inspect :• Tire surfaceWear/Damage/Cracks/Road hazards ➞Replace.• Alumin

INSPADJ3-262. Check :• Cable movementStickiness ➞ Lubricate.Recommended lubricant :Engine oil SAE 10W30NOTE:Hold the cable end up and pour a few drops

INSPADJ3-27+UPPERLOWERELECTRICALBATTERY INSPECTION1. Inspect :• Battery fluid levelFluid level low ➞ Add to proper level.Fluid level should be betwe

INSPADJ3-28Always charge a new battery before usingit to ensure maximum performance.Battery electrolyte is dangerous. It containssulfuric acid which i

INSPADJ3-29FUSE INSPECTION/HEADLIGHT BEAM ADJUSTEMENTHEADLIGHT LENS REPLACEMENT******************************************************Fuse replacement

INSPADJ3-30HEADLIGHT LENS REPLACEMENT1. Remove :• Front cover Q2. Remove :• Headlight lens(Pull out the pins)3. Remove :• Gasket4. Install :Reverse th

12346789INDEXSPECIFICATIONSENGINE OVERHAULCARBURETIONCHASSISELECTRICALTROUBLESHOOTINGGENERAL INFORMATIONPERIODIC INSPECTIONAND ADJUSTMENTSPECENGCARBCH

4ENG

ENGCHAPTER 4.ENGINE OVERHAULENGINE REMOVAL ...4-1COVER REMOVAL ...

ENG4-1ENGINE OVERHAULENGINE REMOVALCOVER REMOVAL1. Remove :• CoversSee “CHAPTER 3 - SIDE COVERS ANDFOOTREST BOARD - HANDLEBAR COVER”.ENGINE REMOVALCAR

ENG4-2CABLES, LEADS AND HOSES1. Remove :• Oil hose on the oil pump sideNOTE:Plug the hose to prevent oil spillage.2. Disconnect :• CDI unit lead pump

ENG4-3ENGINE REMOVAL1. Place a suitable stand under the frame.2. Remove :• Rear shock absorber bolt (lower) Q• Engine mounting bolt W3. Remove :• Engi

ENG4-4ENGINE DISASSEMBLYREAR WHEEL1. Remove :• Rear wheel Refer to chapter 7 "REAR WHEEL"ENGINE DISASSEMBLYCENTERSTAND1. Remove :• Spring •

ENG4-5ENGINE DISASSEMBLY2. Remove :• Piston pin Q• Piston W• Piston pin bearing EDo not use a hammer to drive out thepiston pin.KICKSTARTER1. Remove :

ENG4-6PRIMARY SHEAVE1. Remove :• Oil pump housing2. Remove :• Nut (primary sheave)NOTE:To loosen the primary sheave nut hold the CDImagneto with a fl

ENG4-72. Remove :• Clutch housing Q• Secondary sheave W• Crankcase cover gasket• Dowel pins3. Attach :• Sheave holder Q• Nut wrench (41 mm)Sheave hold

ENG4-83190373190363170042. Remove :• Spacer Q• Bearing W• Washer E• Starter motorENGINE DISASSEMBLYTRANSMISSION1. Remove :• Transmission case Q• Gaske

1GENINFO

ENG4-93210052. Remove :• Rotor Q• Woodruff keyUse the flywheel puller WFlywheel puller :90890-01189• Stator assembly• GasketAUTOLUBE OIL PUMP1. Remove

ENG4-10ENGINE DISASSEMBLYloosen one screw as much as required to levelthe tool body.3. Remove :• Crankcase (right)As pressure is applied, keep tapping

ENG4-11307003301002INSPECTION AND REPAIRINSPECTION AND REPAIRCYLINDER HEAD1. Eliminate :• Carbon depositsUse a rounded scraper QNOTE:Take care to

ENG4-123070065. Inspect :• Piston wallWear/Scratches/Damage ➞ Replace.INSPECTION AND REPAIR6. Measure :• Piston to cylinder clearance*****************

ENG4-13307008a307007● If out of specification, replace piston and pistonrings as a set.3rd step :● Calculate the piston-to-cylinder clearance withfo

ENG4-14INSPECTION AND REPAIRStandard LimitTop 0.15 ~ 0.30 mm 0.70 mmring(0.005 ~ 0.011 in)(0.028 in)2nd 0.15 ~ 0.30 mm 0.70 mmring(0.005 ~ 0.011 i

ENG4-15319038INSPECTION AND REPAIRKICK STARTER1. Inspect :• Kick gear teeth Q• Kick pinion gear teeth WBurrs/Chips/Roughness/Wear ➞ Replace.2. Inspect

ENG4-16AUTOLUBE PUMPWear or an internal malfunction may cause thepump output to vary from the factory setting.This situation is, however, extremely ra

ENG4-173190082. Check :• Free movementInsert the collar W into the primary sliding sheaveQ, and check for free movement.Stick or excessive play ➞ Re

ENG4-18INSPECTION AND REPAIR4. Inspect :• Clutch housing inner surfaceOil/Scratches ➞ Remove.Use a rag soaked in lacquerthinner or solvent.Use an emer

GENINFOCHAPTER 1.GENERAL INFORMATIONSCOOTER IDENTIFICATION ...1-1VEHICLE IDENTIFI

ENG4-19INSPECTION AND REPAIR2. Measure :• V-belt width @Out of specification ➞ Replace.V-Belt width :16,5 mm (0.65 in)<Wear Limit> :15,7 mm (0.6

ENG4-20EELSE8 Nm (0.8 m.kg)13 Nm (1.3 m.kg)17,5 Nm (1.75 m.kg)LSCRANKSHAFT AND CRANKCASEQ Oil sealW Oil seal holderE Crankcase (right)R

ENG4-211. Attach :• Crankshaft installation tool Q, W, E, RCrankshaft installation tool :Q : 90890-01274W : 90890-01275E : 90890-01277R : 90890-014112

ENG4-227. Tighten :• Crankcase holding screwsNOTE:Tighten the crankcase holding screws in stages,using a crisscross pattern.Crankcase holding screw :1

ENG4-23AUTOLUBE PUMP AND CDI MAGNETOQ NutW Plain washerE Rotor assemblyR Lighting coilT Charge coilY Pick up coilU Stator assemblyI Oil sealO GasketP

ENG4-24314004AUTOLUBE PUMP1. Install :• Circlip Q• Pin W• Pump drive gear E• Circlip R2. Apply :• Lithium soap base grease(to O-ring )3. Install :• Au

ENG4-255. Install :• Woodruff key Q• Magneto rotor W• Plain washer E• Nut RNOTE:When installing the magneto rotor, make surethe woodruff key is proper

ENG4-26TRANSMISSIONQ CirclipW BearingE Oil sealR Drive axleT BearingY Main axleU Conical spring washerI Plain washerO Secondary sheave axleP Bearing{

ENG4-27TRANSMISSION1. Apply :• 10W30 Type SE Motor oil(to transmission case cover bearing)2. Install :• Bearing Q3. Install :• Oil seal W• Secondary

ENG4-28STARTER SYSTEMQ CollarW Starter wheel gearE BearingR Starter clutchT PlateY ShaftU WasherI Idle gearO O-RingP Starter motorENGINE ASSEMBLY AND

GENINFO1-1GENERAL INFORMATIONSCOOTER IDENTIFICATIONVEHICLE IDENTIFICATION NUMBERThe vehicle identification number Q is stampedinto the frame.NOTE:The

ENG4-29317010STARTER SYSTEM1. Install :• Collar Q• Washer W• Bearing E• Starter wheel gear R• Starter clutch TNOTE:• Apply lithium soap base grease to

ENG4-302221LS*30 Nm (3.0 m.kg)33 Nm (3.3 m.kg)50 Nm (5.0 m.kg)PRIMARY AND SECONDARY SHEAVEQ NutW Clutch housingE ClutchR Clutch

ENG4-31KICK STARTERQ Kick shaftW Return springE CollarR GasketT Transmission caseY WasherU CirclipsI Kick crankO Kick clipP RachetENGINE ASSEMBLY AND

ENG4-32SECONDARY SHEAVEWhen assembling the secondary sheave, reversethe disassembly procedure. Note the followingpoints.1. Apply :• BEL-RAY Assembly L

ENG4-333190268. Install :• Dowel pin• Gasket• Secondary sheave assembly Q• Clutch housing W9. Tighten :• Nut Q (secondary sheave)Use sheave holder W

ENG4-343190275. Install :• V-beltPlace the V-belt around the secondary sheave,and compress the secondary sheave springhard so that the V-belt

ENG4-353170153170144. Install :• Transmission case QScrew (Transmission case) :12 Nm (1.2 m.kg)5. Install :• Kick crank QBolt (kick crank) :10 Nm (1.0

ENG4-3620 Nm (2.0 m.kg)14 Nm (1.4 m.kg)11 Nm (1.1 m.kg)16 Nm (1.6 m.kg)4 Nm (0.4 m.kg)LTPISTON, CYLINDER AND CYLINDER HEADQ Carburetor joi

ENG4-37307013ENGINE ASSEMBLY AND ADJUSTEMENTPISTON PIN AND PISTON1. Apply :• Engine oil(to crankshaft bearing, connecting rod big endbearing, small e

ENG4-383. Install :• CylinderNOTE:Install the cylinder with one hand, whilecompressing the piston rings with the otherhand.ENGINE ASSEMBLY AND ADJUSTE