BWS_NG_1998

CW50RS5FX-AE1

'98

SERVICEMANUAL

CW50RSSERVICE MANUAL

© 1998 by MBK INDUSTRIE1st Edition, July 1998

All rights reserved. Anyreprinting or unauthorized use

without the writtenpermission of MBK INDUSTRIE

is expressly prohibited.

CAUTION:

WARNING

NOTICE

This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealersand their qualified mechanics. It 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 andMBK scooters have a basic understanding of the mechanical concepts and procedures inherent inscooter repair technology. Without such knowledge, attempted repairs or service to this model mayrender it unfit to use and/or unsafe.

MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications andsignificant changes in specifications or procedures will be forwarded to all Authorized YAMAHA andMBK dealers and will, where applicable, appear in future editions of this manual.

DOCUMENTATION TECHNIQUEMBK INDUSTRIE

PARTICULARY IMPORTANT INFORMATIONThis material is distinguished by the following notation :

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury ordeath to the scooter operator, a bystander, or a person inspecting orrepairing the scooter.

A CAUTION indicates special precautions that must be taken to avoiddamage to the scooter.

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

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUALThis manual consists of chapters for the main categories of subjects. (See «illustrated symbols).1st title 1 This is a chapter with its symbol on the upper right of each page.2nd title 2 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 3 This is a final title.

MANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informa-tion has been compiled to provide the mechanic with an easy to read, handy reference that containscomprehensive explanations of all disassembly, repair, assembly, and inspections.A set of particulary important procedure 4 is placed between a line of asterisks " * " with each steppreceded by " • ".

IMPORTANT FEATURES• Data and a special tools are framed in a box preceded by a relevant symbol 5.• An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data for analignement mark 7, the others being indicated by an alphabetical letter in a box 8.• A condition of a faulty component will precede an arrow symbol and the course of action requiredthe symbol 9.

EXPLODED DIAGRAMEach chapter provides exploded diagrams are before each disassembly section for ease in identifyingcorrect disassembly and assembly procedures.

ILLUSTRATED SYMBOLS(REFER TO THE ILLUSTRATION)

Illustrated symbols Q to W are designed asthumb tabs to indicate the chapter’s number andcontent.

Q General informationW SpecificationsE Periodic inspection and adjustmentR EngineT CarburetionY ChassisU ElectricalI Troubleshooting

Illustrated symbols O to e are used to identifythe specifications appearing in the text.

O Filling fluidP Lubricant Special tool Tighteningq Wear limit, clearancew Engine speede Ω, V, A

Illustrated symbols r to [ in the explodeddiagram indicate grade of lubricant and locationof lubrication point.

r Apply engine oilt Apply gear oily Apply molybdenum disulfide oilu Apply wheel bearing greasei Apply lightweight lithium-soap base

greaseo Apply molybdenum disulfide greasep Apply locking agent (THREADLOCK ®)[ Use new one

INSPADJ

TRBLSHTG

GENINFO

ENG

CHASCARB

ELEC

SPEC

T.R

Q W

RE

T Y

U I

O P

q w

e

r

u

p [

t y

i o

1

2

3

4

5

6

7

8

INDEX

SPECIFICATIONS

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GENERAL INFORMATION

PERIODIC INSPECTIONAND ADJUSTMENT

SPEC

ENG

CARB

CHAS

ELEC

TRBLSHTG

GENINFO

INSPADJ

1GENINFO

GENINFO

CHAPTER 1.GENERAL INFORMATION

SCOOTER IDENTIFICATION ........................................................................1-1VEHICLE IDENTIFICATION NUMBER....................................................1-1ENGINE SERIAL NUMBER .....................................................................1-1

IMPORTANT INFORMATION ....................................................................... 1-2ALL REPLACEMENT PARTS ................................................................. 1-2GASKETS, OIL SEALS, AND O-RINGS ..................................................1-2LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-2BEARINGS AND OIL SEALS ...................................................................1-2CIRCLIPS .................................................................................................1-3

SPECIAL TOOLS ...........................................................................................1-3FOR TUNE UP .........................................................................................1-3FOR ENGINE SERVICE ..........................................................................1-4FOR CHASSIS SERVICE ........................................................................1-5FOR ELECTRICAL COMPONENTS ........................................................1-5

GENINFO

1-1

SCOOTER IDENTIFICATION

GENERALINFORMATION

SCOOTER IDENTIFICATIONVEHICLE IDENTIFICATION NUMBERThe vehicle identification number Q is stampedinto the frame.

NOTE:The vehicle identification number is used toidentify your scooter and may be used to registeryour scooter with the licensing authority in yourstate.

ENGINE SERIAL NUMBERThe engine serial number Q is stamped into thecrankcase.

NOTE:Designs and specifications are subject to changewithout notice.

GENINFO

1-2

IMPORTANT INFORMATION

IMPORTANT INFORMATIONALL REPLACEMENT PARTS1.Use only genuine parts for all replacements.

Use oil and/or grease recommended by MBK/YAMAHA for assembly and adjustment. Otherbrands may be similar in function andappearance, but inferior in quality.

GASKETS, OIL SEALS, AND O-RINGS1.All gaskets, seals and O-rings should be

replaced when an engine is overhauled. Allgaskets surfaces, oil seal lips and O-ringsmust be cleaned.

2.Properly oil all mating parts and bearing duringreassembly. Apply grease to the oil seal lips.

LOCK WASHERS/PLATES AND COTTERPINS1.All lock washers/plates Q and cotter pins

must be replaced when they are removed.Lock tab(s) should be bent along the bolt or nutflat(s) after the bolt or nut has been properlytightened.

BEARINGS AND OIL SEALS1.Install the bearing(s) Q and oil seal(s) W with

their manufacturer’s marks or numbers facingoutward. (In other words, the stamped lettersmust be on the side exposed to view.) Wheninstalling oil seal(s), apply a light coating oflightweight lithium base grease to the seallip(s). Oil the bearings liberally when installing.

CAUTION:

Do not use compressed air to spin thebearings dry. This causes damage to thebearing surfaces.

GENINFO

1-3

IMPORTANT INFORMATION/SPECIAL TOOLS

CIRCLIPS1.All circlips should be inspected carefully before

reassembly. Always replace piston pin clipsonce they have been removed. Replace bentcirclips. When installing a circlip Q make surethat the sharp edge W is positioned oppositeto the thrust E it receives. See the sectionalview.

R Shaft

SPECIAL TOOLSThe proper special tools are necessary forcomplete and accurate tune-up and assembly.Using the correct special tool will help preventdamage caused by the use of improper tools orimprovised techniques.

FOR TUNE UP

Inductive tachometer 90890-03113

Ignition checker 90890-06754

GENINFO

1-4

Crankshaft installing tool set90890-01274 Q90890-01275 W90890-01277 E90890-01411 R

FOR ENGINE SERVICE

Flywheel magneto puller 90890-01189

Flywheel holding tool 90890-01235

SPECIAL TOOLS

Crankcase separating tool90890-01135

Sheave holder90890-01701

Clutch serving nut wrench90890-01348

Clutch spring holder90890-01337 Q90890-01016 W

GENINFO

1-5

SPECIAL TOOLS

FOR CHASSIS SERVICE

Oil seal guide adapter90890-01400

Damper rod holder90890-01294

Steering Head wrench9079Q-02218

T-HANDLE90890-01326

Pocket Tester90890-03112

FOR ELECTRICALCOMPONENT

Oil seal guide90890-01367

30

2SPEC

SPEC

CHAPTER 2.SPECIFICATIONS

GENERAL SPECIFICATIONS .......................................................................2-1

MAINTENANCE SPECIFICATIONS ..............................................................2-4ENGINE ...................................................................................................2-4CHASSIS .................................................................................................2-7ELECTRICAL ...........................................................................................2-8

CABLE ROUTING ........................................................................................2-10

SPEC

2-1

GENERAL SPECIFICATIONS

SPECIFICATIONSGENERAL SPECIFICATIONS

Dimensions:Overall length 1.746 mm (0.07 in)Overall width 675 mm (26.5 in)Overall height 1.120 mm (0.04in)Seat height 803 mm (31.61 in)Wheelbase 1.206 mm (0.05 in)Minimum ground clearance 153 mm (6.02 in)

Basic weight:With oil and full fuel tank 83 kg (183 lbs)

Minimum turning radius : 1.800 mm (0.07 in)

Engine:Type Air-cooled 2-stroke, gasoline torque induction.Cylinder arrangement Single cylinder, VerticalDisplacement 49,2 cm3

Bore x stroke 40 x 39.2 mm (1.57 x 1.54 in)Compression ratio 7.22 : 1Starting system Electric and kick starter

Lubrication system: Separate lubrication (Yamaha Autolube )

Oil type or grade:Engine oil: SEMI-SYNTHETIC, in accordance with

API TC TSC 3 STANDARD.Transmission oil SAE 10W30 type SE motor oil

Oil capacity:Transmission oil:Periodic oil change 0.11 L (0.10 Imp qt, 0.12 US qt)Total amount 0.13 L (0.11 Imp qt, 0.13 US qt)

Air filter: Wet type element

Fuel:Type Regular unleaded gasoline with a reserch octane

number of 91 or higher.Tank capacity 6.5 L (1.42 Imp gal, 1.71 US gal)

Model CW50RS

SPEC

2-2


Model CW50RS

Carburetor:Type/Manufacturer 5FX / TEIKEI

PHBN12 HS / DELL'ORTO

Spark plug:Type/Manufacturer BR8HS/NGKGap 0.5 ~ 0.7 mm (0.19 ~ 0.27 in)

Clutch type: Dry, centrifugal automatic

Transmission:Primary reduction system Helical gearPrimary reduction ratio 52/13 (4.000)Secondary reduction system Spur gearSecondary reduction ratio 42/13 (3.323)Transmission V-beltOperation Automatic

Chassis:Frame type Steel tube underboneCaster angle 27°Trail 90 mm (3.54 in)

Tire:Type Front Tubeless

Rear TubelessSize Front 120/90-10

Rear 130/90-10Manufacturer Front MICHELIN (REGGAE)

Rear MICHELIN (REGGAE)

Tire pressure (cold tire):Up to 90 kg Front 150 kPa (1.50 kg/cm2, 21.3 psi)

Rear 150 kPa (1.50 kg/cm2, 21.3 psi)90 kg ~ maximum load Front 150 kPa (1.50 kg/cm2, 21.3 psi)

Rear 160 kPa (1.60 kg/cm2, 22.7 psi)

Brake:Front brake type Disc brakeOperation Right hand operationRear brake type Drum brakeOperation Left hand operation

Suspension:Front Telescopic forkRear Unit swing

Shock absorber:Front Coil spring/Oil damperRear Coil spring/Oil damper

Wheel travel:Front wheel travel 80 mm (3.14 in)Rear wheel travel 60 mm (2.36 in)

SPEC

2-3

Electrical:Ignition system CDICharging system Flywheel magnetoBattery type/model GM4-3B, YB4L-B, FB4L-BBattery capacity 12V 4AH

Headlight type Bulb

Bulb wattage / quantity:Headlight 12V 35W/35W x 1Auxiliary light 12V 5W x 1Taillight/brake light 12V 5W/21W x 1Flasher light Front 12V 10W x 2

Rear 12V 10W x 2Meter light 12V 1.2W x 2

Warning lights wattage / quantity:“OIL” 12V 1.2W x 1“HIGH BEAM” 12V 1.2W x 1“TURN” 12V 1.2W x 1


Model CW50RS

SPEC

2-4

Cylinder head:Warp limit 0,02 mm (0.0008 in)

* Lines indicate straight edge measurements.

Cylinder:Bore size 39.993 ~ 40.012 mm (1.576 ~ 1.575 in)Taper limit 0.05 mm (0,0002 in)

Piston:Piston size 39.952 ~ 39.972 mm (1.576 ~ 1.574 in)Measuring point * 5 mm (0.19 in)

Piston clearance 0.034 ~ 0.047 mm (0.001 ~ 0.002 in)<Limit> <0.1 mm (0.004 in)>Oversize 1st 40.25 (1.58 in)Oversize 2nd 40.50 (1.59 in)Piston pin bore size 10.004 ~ 10.019 mm (0.394 ~ 0.395 in)

Piston pin:Outside diameter 9.996 ~ 10.000 mm (0.393 ~ 0.394 in)

Piston ring:Sectional sketch (BxT)/Type:Top ring 1.2 ∼ 1.8 mm (0.05 ~ 0.07 in)2nd ring 1.2 ∼ 1.8 mm (0.05 ~ 0.07 in)

End gap (installed):Top ring 0.15 ~ 0.30 mm (0.006 ~ 0.012 in)2nd ring 0.15 ~ 0.30 mm (0.006 ~ 0.012 in)

Side clearance (installed):Top ring 0.03 ~ 0.05 mm (0.001 ~ 0.002 in)2nd ring 0.03 ~ 0.05 mm (0.001 ~ 0.002 in)

MAINTENANCE SPECIFICATIONSENGINE

MAINTENANCE SPECIFICATIONS

Model CW50RS

SPEC

2-5


Crankshaft:

Crank width “A” 37.90 ~ 37.95 mm (1.492 ~ 1.494 in)Runout limit “C” 0.03 mm (0.001 in)Connecting rod big end 0.2 ~ 0.5 mm (0.007 ~ 0.019 in)side clearance “D”

Automatic centrifugal clutch:Shoe thickness 2.0 mm (0.08 in)<Wear limit> <1.0 mm (0.039 in)>Clutch shoe spring free length 29.9 mm (1.177 in)Clutch-in revolution 3.250 ~ 3.750 r.p.m.Clutch-stall revolution 6.100 ~ 6.900 r.p.m.

V-belt:Width 16.5 mm (0.64 in)<Wear limit> <15.7 mm (0.61 in)>

Transmission:Main axle runout limit 0.08 mm (0.003 in)Drive axle runout limit 0.08 mm (0.003 in)

Kick starter:Type Ratchet typeKick clip tension 0.15 ~ 0.25 kg (0.33 ~ 0.55 lbs)

Reed valve:Valve stopper height 4.0 ~ 4.4 mm (0.15 ~ 0.17 in)Reed valve clearance 0.2 mm (0.007 in)

Lubrication system: Autolube pumpStroke 2.62 mm (0.103 in)Bore 0.5 mm (0.019 in)

Model CW50RS

SPEC

2-6


Carburetor: DELL’ORTO TEIKEI

I.D. mark PHBN12 HS 5FX

Main jet (M.J.) #90 #88

Main air jet (M.A.J.) 1.5 2.0

Jet needle (J.N.) 211 GA 3/5 3S12-3/5

Needle jet (N.J.) 2.110 GA 2,085

Cutaway (C.A.) 4.0 3.0

Pilot jet (P.J.) #36 #50

Bypass (B.P.1) 0.80 0.80

Pilot air screw (A.S.) 1+3/8 ±1/8 out 1+1/2 ±1/4 out

Valve seat size (V.S.) 1 1.2

Starter jet (G.S.1) #40 #46

Engine idle speed 2000 ± 200 rpm 2000 ± 200 rpm

SPEC

2-7


Steering system:Steering bearing type Ball bearingNo/Size of steel balls:Upper 15 pcs (4.77 mm)Lower 15 pcs (4.77 mm)

Front suspension:Front fork travel 80 mm (3.14 in)Spring rate (K1) 5.7 Nmm (0.57 kg/mm, 31.92 lb/in)Stroke (K1) 0 ~ 80 mm (0 ~ 3.14 in)Optional spring No

Rear suspension:Shock absorber travel 70 mm (2.75 in)Spring free length 165 mm (6.49 in)Spring fitting length 151.5 mm (5.96 in)Spring rate (K1) 26 Nmm (2.6 kg/mm, 145.61 lb/in)Stroke (K1) 0 ~ 40 mm (0 ~ 1.57 in)Spring rate (K2) 36 Nmm (3.6 kg/mm, 201.62 lb/in)Stroke (K2) 40 ~ 70 mm (1.57 ~ 2.75 in)Optional spring No

Wheels:Front wheel type Cast wheelRear wheel type Cast wheelFront wheel size/Material MT 3.00 x10 / AluminiumRear wheel size/Material MT 3.50 x10 / Aluminium

Rim runout limit:Radial 1.0 mm (0.039 in)Lateral 1.0 mm (0.039 in)

Front disc brake:Type Single discDiameter and thickness 190 x 3.5 mm (7.48 x 3.5 in)Pad thickness 3.75 mm (0.15 in)<Wear limit> <0.5 mm (0.0019 in)>Master cylinder inside diameter 11 mm (0.43 in)Caliper cylinder inside diameter 30 mm (1.18 in)Brake fluid type DOT# 3 or DOT# 4

Rear drum brake:Type Leading, trailingDrum inside diameter 110 mm (4.33 in)<Wear limit> <110.5 mm (4.35 in)>Lining thickness 4.0 mm (0.15 in)<Wear limit> <2.0 mm (0.07 in)>Spring free length 54 mm (2.12 in)

Front brake lever freeplay: 10 ~ 20 mm (0.39 ~ 0.78 in)Rear brake lever freeplay: 10 ~ 20 mm (0.39 ~ 0.78 in)

CHASSIS

Model CW50RS

SPEC

2-8


Voltage: 12 V

Ignition system:Ignition timing (B.T.D.C.) 14° at 5.000 r/min

CDI:Pickup coil resistance (color) 400 ~ 600 Ω at 20°C (68°F) (White/Red-Black)Source coil resistance (color) 640 ~ 960 Ω at 20°C (68°F) (Black/Red-Black)

Ignition coil:Minimum spark length 6 mm (0.23 in)Primary coil resistance 0.32 ~ 0.48 Ω at 20°C (68°F)Secondary coil resistance 5.68 ~ 8.52 Ωk at 20°C (68°F)

Spark plug cap:Resistance 5 kΩ at 20°C (68°F)

CDI Magneto:Lighting coil resistance 0.32 ~ 0.48 Ω at 20°C (68°F)(Yellow/Red-Black)Charging coil resistance 0.48 ~ 0.72 Ω at 20°C (68°F)(White-Black)

Voltage regulator/Rectifier:Type Semi-conductor, short-circuit typeNo load regulated voltage 13 ~ 14 VCapacity 8 A

ELECTRICAL

Model CW50RS

SPEC

2-9

Battery:Capacity 12V, 4 AhSpecific gravity 1.280

Starter motor:Output 0.14 kWArmature coil resistance 0.06 ~ 0 08 Ω a 20°C (68°F)Brush length 3.9 mm (0.15 in)<Wear limit> <0.9 mm (0.035 in)>Brush spring pressure 563 ~ 844 gr (19.85 ~ 29.76 oz)Commutator diameter 15.8 mm (0.62 in)<Wear limit> <14.8 mm (0.58 in)>Mica undercut 1.15 mm (0.045 in)

Starter relay:Amperage rating 20 ACoil resistance 54 ~ 66 Ω at 20°C (68°F)

Horn:Type/Quantity Plain type/1 pc.Model/Manufacturer TR9/TRANSVALMaximum amperage 2.5 A

Flasher relay:Type Condenser typeSelf cancelling device NoFlasher frequency 65 - 95 cycle/minWattage 2x(10+3)W

Circuit breaker:Type Fuse

Amperage for individual circuit x Quantity:Main 7 A x 1

Fuel sender unit:Resistance (full) 7.4 ~ 9.0 Ω at 20°C (68°F) (empty) 82 ~ 98 Ω at 20°C (68°F)

Model CW50RS


SPEC

2-10

CABLE ROUTING

CABLE ROUTINGQ Rectifier/regulatorW BatteryE Fuse holderR Oil tankT Fuel level senderY Brake hose guideU Head lightI Speedometer cable

A Pass the wire harness under the frame.B Attach on the mole fender (only on the left Side).C Attach the wire harness with a plastic band.D Attach all the wire.E Cut the end of each plastic clip only after the

tightening.F Attach all the wires and the mud guard.G Pass the wire under the frame dropout.H Clamp the throttle cables and the starter cable all

together.I The oil level switch connector must be slightly

inclined (0° to 30°).

O Ignition coilP Oil level gauge Mudguard Starter motorq CDI magnetow Brake wiree Under cover

6

6

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1

111

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11111

1111

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000

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0 00

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9

B

G

I

E

H

FC

D

A

10 0+5

30–10

SPEC

2-11

CABLE ROUTING

Q Grip assembly (right)W Handle switch (right)E Front stop switchR Front master cylinderT Plain washerY Union boltU Flasher relayI Handle switch (left)O Grip assembly (left)P Rear brake lever Starter cable

6

6

6

RIGHT

FRONT

LEFT

1 MINI

5–1

A

B

C

D

F

E

2

3

1 2 3 4 56 7 8 9

0

q

w

e

r

t

y

u

i

o

p [ ]

]

A

A S

D

8

4

Brake hoseq Handle coverw Speedometer assemblye Handle coverr Speedometer cablet Wire harnessy Plastic clipu Nut flangei Bolt flangeo Fitting nutp Washer

[ Upper race ball] Steering ballsA Lower race ballS FrameD Front fork assembly

SPEC

2-12

CABLE ROUTING

6

6

6

RIGHT

FRONT

LEFT

1 MINI

5–1

A

B

C

D

F

E

2

3

1 2 3 4 56 7 8 9

0

q

w

e

r

t

y

u

i

o

p [ ]

]

A

A S

D

8

4

A Install the handlebar switch before the master cylinder.B Install all connectors under the handlebar and the speedometer assembly.C Attach the wire harness holder on the frame dropout.D Do not clamp the speedometer cable and the brake wire.E Apply grease.F Install in the correct position.

SPEC

2-13

CABLE ROUTING

Q Rear brake cableW Rear stop switchE Handlebar switch (left)R Handlebar switch (right)T Throttle cableY Grip 5FXU Master cylinder

A Install the cable end stop on the brake leverholder.

B Adjust the grip mark with the seal surface.C Install the boot after the adjustment.D Apply grease on the throttle cable end and on

the cable holder.E Install the front brake wire as shown.

I Front brake hoseO Starter cableP Throttle cable Rear brake cable Wire harnnessq Speedometer cable

6

1.5 ~ 3 mm

90¡–

5¡

10¡

FRONT

5 mm

A

C

D

E

B

3CHKADJ

CHKADJ

CHAPTER 3.PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION ............................................................................................3-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............................3-1

COVERS ........................................................................................................3-3REMOVAL ................................................................................................3-3INSTALLATION ........................................................................................3-6

HANDLEBAR COVERS .................................................................................3-7REMOVAL ................................................................................................3-7INSTALLATION ........................................................................................3-7

ENGINE .........................................................................................................3-9ENGINE IDLE SPEED ADJUSTMENT ....................................................3-9THROTTLE CABLE FREE PLAY ADJUSTMENT .................................3-10SPARK PLUG INSPECTION .................................................................3-11AUTOLUBE PUMP AIR BLEEDING ......................................................3-12ENGINE OIL LEVEL INSPECTION .......................................................3-13TRANSMISSION OIL REPLACEMENT .................................................3-14AIR CLEANER ELEMENT CLEANING ..................................................3-15

CHASSIS .....................................................................................................3-16FRONT BRAKE LEVER FREE PLAY ADJUSTMENT ...........................3-16REAR BRAKE LEVER FREE PLAY ADJUSTMENT .............................3-16BRAKE PADS INSPECTION .................................................................3-16BRAKE SHOE INSPECTION .................................................................3-17BRAKE FLUID LEVEL INSPECTION ....................................................3-17AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)- ................................3-18STEERING HEAD ADJUSTMENT .........................................................3-18TIRE INSPECTION ................................................................................3-19WHEEL INSPECTION ...........................................................................3-20CABLE INSPECTION AND LUBRICATION ...........................................3-20LEVER LUBRICATION ..........................................................................3-21CENTERSTAND LUBRICATION ...........................................................3-21FRONT FORK INSPECTION .................................................................3-21REAR SHOCK ABSORBER ..................................................................3-22

ELECTRICAL ...............................................................................................3-23BATTERY INSPECTION........................................................................3-23FUSE INSPECTION ...............................................................................3-24HEADLIGHT BEAM ADJUSTMENT ......................................................3-25HEADLIGHT LENS REPLACEMENT ....................................................3-26HEADLIGHT BULB REPLACEMENT ....................................................3-26

INSPADJ

3-1

Spark plug*

Air filter

Carburetor*

Fuel line*

Transmission oil*

Autolube pump *

Front brake*

Rear brake*

Wheels*

Wheel bearings*

Steering bearings*

Rear shock absorber*

V-belt*

Fittings/Fasteners*

Centerstand*

Battery *

ITEM REMARKS

BREAK-IN

1,000

(600)

EVERY

3,000(2,000)or

6 Months

6,000(4,000)or

12 Months

PERIODIC INSPECTION AND ADJUSTMENTINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicleoperation and a longer service life. The need for costly overhaul work will be greatly reduced. Thisinformation applies to vehicles already in service as well as new vehicles that are being prepared forsale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

RE-PLACE

Check condition. Clean or replace if necessary.

Clean. Replace if necessary.

Check idle speed/starter operation. Adjust if neces-sary.

Check fuel hose and vacuum hose for cracks ordamage. Replace if necessary.

Check oil leakage. Correct if necessary.Replace every 12,000 (8,000) or 24 months (warmengine before draining).

Check operation.

See NOTE. Correct if necessary. Air bleeding.Check operation/fluid leakage. Correct if necessary.

Check operation. Adjust if necessary.

Check balance/runout. Repair if necessary.

Check bearing assembly for looseness /damage.Replace if damaged.

Check bearing assembly for looseness. Correct ifnecessary. Moderately repack every 12,000 (8,000)or 24 months.**

Check operation/oil leakage. Repair if necessary.

Check damage and wear. Replace if necessary.

Check all chassis fittings and fasteners.

Correct if necessary. Check operation. Repair ifnecessary.

Check specific gravity. Check breather hose forproper operation. Correct if necessary.

*: It is recommended that these items be serviced by a MBK or a Yamaha dealer.

**: Medium weight wheel bearing grease.

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Km(miles)

INSPADJ

3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

NOTE:Brake fluid replacement:1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check

the brake fluid level and add fluid as required.2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.3.Replace the brake hoses every four years, or when cracked or damaged.

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3-3

353001

COVERS

REMOVAL1. Remove:• Seat Q

2. Remove:• Rear cover Q

3. Remove:• Side cover (left and right) Q

4. Remove:• Battery cover Q

When removing the cover, be careful not todamage the mounting clips.

5. Remove:• Seat cover Q

COVERS

CAUTION:

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3-4

367001

6. Disconnect:• Battery terminals Q

7. Remove:• Battery W

8. Remove:• Footrest board Q

9. Remove:• Front cover Q


10. Remove:• Headlight socket QTurn the headlight socket clockwise, thenremove it.

11 . Remove:• Main switch ring QTurn the ring clockwise to remove it.

COVERS

CAUTION:

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3-5

13. Remove:• Lower cover Q

14. Remove:• Front wheel QRefer to the section “ FRONT WHEEL - RE-MOVAL” in Chapter 6.

12. Remove:• Inner panel Q

15. Disconnect:• Flasher light couplers (left and right) Q

16. Remove:• Front fender Q

COVERS

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3-6

INSTALLATION:Reverse the “REMOVAL” procedure. Note thefollowing points.

NOTE:Correct routing of cables and wires is essentialfor a safe operation of this scooter. Refer to thesection “CABLE ROUTING” in Chapter 2.

NOTE:Be careful not to pinch any wires with the covers.

NOTE:When installing the covers, be careful not todamage the mounting clips.

COVERS

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3-7

HANDLEBAR COVERSREMOVAL1. Remove:• Handlebar cover (front) Q


HANDLEBAR COVERS

2. Remove:• Auxiliary light socket Q

3. Remove:• Rear handlebar cover screws• Rear handlebar cover Q

4. Remove:• Meter coupler Q• Speedometer cable W

INSTALLATIONReverse the “REMOVAL” procedure. Note thefollowing points:

1. Connect:• Speedometer cable• Meter connector

CAUTION:

INSPADJ

3-8

2. Install:• Rear handlebar cover• Rear handlebar cover screws• Auxiliary light socket

3. Install:• Front brake hose(into the slot in the front fender)

4. Install:• Front handlebar cover

5. Install:• Front handlebar cover screws

NOTE:When installing the handlebar covers, be carefulnot to damage any cables. Refer to the section“CABLE ROUTING” in Chapter 2 for properrouting of wires.

HANDLEBAR COVERS

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3-9

322025

ENGINE IDLE SPEED ADJUSTMENT

ENGINEENGINE IDLE SPEED ADJUSTMENT1. Tighten:• Pilot air screw QTurn the pilot air screw in until lightly seated.

2. Loosen:• Pilot air screwBack out from the lightly seated position.

Pilot air screw position:DELL'ORTO1+3/8 turns out ± 1/8TEIKEI1+1/2 turns out ± 1/4

4. Attach:• Inductive tachometer Q(to the spark plug lead)

Inductive tachometer:90890-03113

3. Start the engine and let it warm up for severalminutes.

For safety reasons, place the scooter on thecenter stand before starting the engine.

WARNING

5. Check:• Engine idle speed

Out of specification Adjust.

Engine idle speed:2000 ± 200 r/min

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3-10

322025

6. Adjust:• Engine idle speed********************************************************Adjustment steps:• Turn the throttle stop screw Q in or out until

specified idling speed is obtained.

*******************************************************THROTTLE CABLE FREE PLAYADJUSTMENT1 Check:• Throttle cable free play


Free play:1.5 ~ 3 mm (0.06 ~ 0,12 in)

*******************************************************Throttle cable free play adjustment steps:

NOTE:Before adjusting the throttle cable free play, theengine idle speed should be adjusted.

First step:• Loosen the locknut on the throttle cable.• Turn the adjuster in or out until the specified

free play is obtained.

• Tighten the locknuts.

After adjusting, turn the handlebar to theright and left, making sure that the engineidling speed does not change.

*******************************************************

Turning left Idling speed increased.

Turning right Idling speed decreased.

Turning left Idling speed increased.

Turning right Idling speed decreased.

ENGINE IDLE SPEED ADJUSTMENT/THROTTLE CABLE FREE PLAY ADJUSTEMENT

WARNING

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3-11

SPARK PLUG INSPECTION

SPARK PLUG INSPECTION1. Remove:• Spark plug2. Inspect:• Electrode Q

Wear/Damage Replace.• Insulator W

Abnormal color Replace.

Standard spark plug:BR8HS (NGK)

3. Measure:• Plug gap @

Out of specification Adjust.Use a wire gauge or feeler gauge.

Spark plug gap @:0,5 ~ 0,7 mm (0.020 ~ 0.028 in)

4. Tighten:• Spark plugBefore installing the spark plug, clean the gasketsurface and plug surface.

NOTE:First tighten by hand, then torque to specifica-tion.

Spark plug:20 Nm (2.0 m • kg, 14ft • lb)

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3-12

AUTOLUBE PUMP AIR BLEEDING1. Remove:• Fan cover Q

AUTOLUBE PUMP AIR BLEEDING

2. Bleed:• Pump housing and oil hose*******************************************************Pump bleeding steps: Place a rag under the pump. Remove the bleed screw Q. Let oil run until there are no more air bubblesin it. When there are no more bubbles, tighten thebleed screw.

NOTE:Check the condition of the bleed screw gasket.If it is damaged, replace it with a new one.

Start the engine. Let the engine run two or three minutes at 2000rpm. This will force out any air in the hose.*******************************************************

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3-13

ENGINE OIL LEVEL INSPECTION1. Inspect:• Oil level

Oil level low Add oil to proper level asfollows.

Q “OIL” indicator light

OIL LEVEL AND GAUGE CHECK

ENGINE OIL LEVEL INSPECTION

Turn main switchto "*'

"OIL" indicatordoesn't light.

Inspect Faultyelectrical circuit,Light bulb etc.

Engine oil leveland electric circuit

are OK.

"OIL" indicator goes

"OIL" indicatorstays on.

Add oil.

"OIL" indicatorstays on.

Turn main switchto "ON".

"OIL" indicatorlight.

Recommended oil:Semi-synthetic oil in accordancewith APITC TSC3 STANDARD.Capacity:Total:1.3 L (1.14 Imp qt, 1.37 US qt)

NOTE:Install the oil tank filler cap Q and push it fullyinto the filler.

CAUTION:Always use the same type of engine oil;mixing oils may result in a harmful chemicalreaction and lead to poor performance.

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3-14

TRANSMISSION OIL REPLACEMENT1. Remove:• Drain plug Q• Oil filler plug WDrain the transmission oil.

2. Check:• Gasket (drain plug)• O-ring (oil filler plug)

Damaged Replace.

3. Install:• Gasket• Drain plug

Drain plug:18 Nm (1.8 m • kg, 13 ft • lb)

4. Fill:• Transmission case

Transmission oil:SAE 10W30 type SE motor oil.

Capacity:Periodic replacement

0.11 L(0.096 Imp qt, 0.116 US qt)

Total amount0.13 L(0.114 Imp qt, 0.137 US qt)

NOTE:Wipe off any oil spilt on the crankcase, tire orwheel.

5 Install:• Oil filler plug

TRANSMISSION OIL REPLACEMENT

T.R

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3-15

AIR CLEANER ELEMENT CLEANING

AIR CLEANER ELEMENT CLEANING1. Remove:• Air cleaner case cover Q2. Remove:• Air filter element

Never operate the engine with the air cleanerelement removed. Unfiltered air will causerapid wear of engine parts and possibleengine damage.

3.Inspect:• Element Q• Damage replace.4.Clean:• Air filter element

*******************************************************Cleaning steps:• Wash the element gently but thoroughly insolvent.

Never use low flashpoint solvents such asgasoline to clean the element. Such solventsmay lead to fire or explosion.

• Squeeze excess solvent out of the element andlet dry.

Do not twist the element.

• Apply foam air filter oil or SAE 10W30 typ SEoil on the element.• Sqeeze out the excess oil.

*******************************************************

NOTE:The element should be wet but not dripping.

CAUTION:

WARNING

CAUTION:

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3-16

a

FRONT BRAKE LEVER FREE PLAY ADJUSTEMENT/REAR BRAKE LEVER FREE PLAY ADJUSTEMENT/

BRAKE PADS INSPECTION

CHASSISFRONT BRAKE LEVER FREE PLAYADJUSTMENT1. Check:• Front brake lever free play @


Free play:10 ~ 20 mm (0.40 ~ 0.80 in)

A soft or spongy feeling in the brake lever canindicate the presence of air in the brakesystem. This air must be removed by bleedingthe brake system before the scooter isoperated. Air in the system will reduce brakeperformance and can result in loss of controland an accident. Inspect and bleed the systemif necessary.

REAR BRAKE LEVER FREE PLAYADJUSTMENT1. Check:• Rear brake lever free play @


Free play:10 ~ 20 mm (0.40 ~ 0.80 in)

*******************************************************Adjustment steps:• Turn the adjuster Q in W or out E until thespecified free play is obtained.********************************************************

347003

BRAKE PADS INSPECTION

1.Measure:• Brake pads

Out of specification Replace.NOTE:Replace the brake pad and spring as a set whenreplacing the brake pads.

Wear limit @:0.5 mm (0.02 in)

WARNING

a

INSPADJ

3-17

BRAKE SHOE INSPECTION1. Apply the rear brake lever.

2. Inspect:• Wear indicator Q

Indicator reaches the wear limit line W

Replace brake shoes.

BRAKE SHOE INSPECTION/BRAKE FLUID LEVEL INSPECTION

BRAKE FLUID LEVEL INSPECTION

NOTE:Position the scooter straight up when inspectingthe fluid level, and make sure be turning thehandlebar that the top of the master cylinder ishorizontal.

1. Inspect:• Brake fluid level

Brake fluid level is under “LOWER” level line Q Fill to proper level.

Recommended brake fluid:DOT # 3 or DOT # 4

The brake fluid may corrode painted surfacesor plastic parts. Always clean up spilled fluidimmediately.

• Use only the designated quality fluid.Otherwise, the rubber seals may deterioratecausing leakage and poor brakeperformance.

• Refill with the same type of fluid. Mixingfluids may result in a harmful chemical re-action leading to poor brake performance.

• Be careful that water does no enter themaster cylinder when refilling. Water willsignificantly lower the boiling point of thefluid and may result in vapor lock.

CAUTION:

WARNING

INSPADJ

3-18

354002

346002

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/STEERING HEAD ADJUSTEMENT

AIR BLEEDING(HYDRAULIC BRAKE SYSTEM)1. Bleed:• Brake fluid.*******************************************************Air bleeding steps:a. Add proper brake fluid into the reservoir.b. Install the diaphragm. Be careful not to spill

any fluid or allow the reservoir to overflow.c. Connect a clear plastic tube Q tightly to the

caliper bleed screw.d. Place the other end of the tube into a con-

tainer.e. Slowly apply the brake lever several times.f. Pull the lever as far as possible and hold it

there.g. Loosen the bleed screw and pull the lever all

the way.h. When the lever is completely pulled, tighten

the bleed screw, then release the lever.i. Repeat steps (e) to (h) until all air bubbles have

been removed from the system.j. Add brake fluid to proper level.

Check the operation of the brake afterbleeding the brake system.

*******************************************************

STEERING HEAD ADJUSTMENT1 Check:• Steering assembly bearingsGrasp the bottom of the forks and gently rock thefork assembly back and forth.

Looseness Adjust steering head.

*******************************************************Steering head adjustment steps: Remove the front fender and the front panels.Refer to “COVERS REMOVAL”. Unscrew the securing nut Q Tighten the nut W

Stearing head wrench:9079Q - 02218

Do not overtighten.

WARNING

WARNING

INSPADJ

3-19

Stearing head wrench:9079Q - 02218

Security nut:27.5Nm (2.75 m.kg, 19.89 ft.lb)

Move the handlebar up and down and fromfront to rear. If steering play is too important,tighten the nut to the specified torque.

Stearing head nut:60 Nm (6.0 m • kg, 43.3 ft • lb)

*******************************************************

STEERING HEAD ADJUSTEMENT/TIRE INSPECTION

Tire pressure (cold) Front RearUp to 90 kg 150 kPa 150 kPa

(1.50 kgf/cm2) (1.50 kgf/cm2)90 kg ~ maximum 150 kPa 160 kPaload * (1.50 kgf/cm2) (1.60 kgf/cm2)Maximum load: 182 kg

* Maximum load is the total weight of rider, passenger,accessories and luggage.

TIRE INSPECTION1. Measure:• Air pressure


354001

WARNING

Check the steering head by turning it lock tolock. If it binds, remove the steering stemassembly and inspect the steering bearings.

Install the steering shaft lock nut and tighten itto the specified torque.

NOTE:Tighten the steering shaft lock nut while holdingthe ring nut with the ring nut wrench.

Proper loading of your scooter is importantfor the handling, braking, and other perform-ance and safety characteristics of yourscooter. Do not carry loosely packed itemsthat can shift.Securely pack your heaviest items close tothe center of the scooter, and distribute theweight evenly from side to side. And checkthe condition and pressure of your tires.NEVER OVERLOAD YOUR SCOOTER.

Make sure the total weight of the cargo, rider,passenger, and accessories (fairing,saddlebags, etc. if approved for this model)does not exceed the maximum load of thescooter. Operation of an overloaded scootercould cause tire damage, an accident, oreven injury.

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3-20

TIRE INSPECTION/WHEEL INSPECTION/CABLE INSPECTION AND LUBRICATION

2 Inspect:• Tire surface

Wear/Damage/Cracks/Road hazards Re-place.

• Aluminum wheelsDamage/Bends Replace.

Never attempt even small repairs to the wheel.

Ride conservatively after installing a tire toallow it to seat itself properly on the rim.

• If the tire is removed with a tire lever, use asuitable protection to prevent damaging the rim.• When installing the tire, make sure the arrowpoints to the front.3.Measure:• Tire tread depth

Out of specification Replace.

Minimum tire tread depth(front and rear):0,8mm (0.03 in)

Q Tread depthW Side wallE Wear indicator

WHEEL INSPECTION1.Inspect:• Wheels

Damage/Bends Replace.

Never attempt even small repairs to the wheel.

CABLE INSPECTION AND LUBRICATION

A damaged cable sheath will rapidly corrode.As a result, the cable cannot move smoothlyinside the sheath. Since this situation isdangerous, replace a damaged cableimmediately.

1. Check:• Cable sheath• Cable end

Damage Replace.

WARNING

WARNING

WARNING

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3-21

CABLE INSPECTION AND LUBRICATION/CENTERSTAND LUBRICATION/

FRONT FORK INSPECTION

2. Check:• Cable movement

Stickiness Lubricate.

Recommended lubricant:Engine oil SAE 10W30

NOTE:Hold the cable end up and pour a few drops of oilinto the sheath.

3. Lubricate the throttle cable end and the cableguide notch on the throttle grip with grease Q.

Recommanded lubricant:Lithium soap based grease

LEVER LUBRICATION1. Lubricate rotating parts of the levers


CENTERSTAND LUBRICATION1. Lubricate rotating parts


FRONT FORK INSPECTION1.Check:• Front fork

Bend/Damage Replace fork assembly as aset.Excessive oil leakage Replace fork assem-bly as a set.Unsmooth operation Replace fork assem-bly.

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3-22

REAR SHOCK ABSORBER1.Check:• Rear shock absorber Q

Oil leaks/Damage Replace.2.Check:• Tightening torque

Upper bolt:31 Nm (3.1 m • kg, 22.4 ft • lb)

Lower bolt:17 Nm (1.7 m • kg, 12.2 ft • lb)

REAR SHOCK ABSORBER

T.R

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3-23

+UPPERLOWER

ELECTRICALBATTERY INSPECTION1. Inspect:• Battery fluid level

Fluid level low Add to proper level.Fluid level should be between upper and lowerlevel marks.Q Upper levelW Lower level

Refill with distilled water only. Tap watercontains minerals which are harmful to abattery.

BATTERY INSPECTION

2. Inspect:• Breather hose

Obstruction Remove.3. Inspect:• Battery

*******************************************************Replace the battery if: Battery voltage will not rise to a specific valueor bubbles fail to rise during charging. Sulfation of one or more cells occurs. (Asindicated by the plates turning white, or anaccumulation of material in the bottom of thesell.) Specific gravity readings after a long, slowcharge indicate that one cell is lower than therest. Warpage or buckling of plates or insulators isevident.*********************************************************

4. Measure:• Specific gravity

Less than 1.280 Recharge battery.

Charging Current:0.4 amps/10 hrs

Specific Gravity:1.280 at 20°C (68° F)

CAUTION:

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3-24

Always charge a new battery before usingit to ensure maximum performance.

Battery electrolyte is dangerous. It containssulfuric acid which is poisonous and highlycaustic.Always follow these preventive measures:• Avoid bodily contact with electrolyte as it

can cause severe burns and permanenteye injury.

• Wear protective eye gear when handling orworking near batteries.

Antidote (EXTERNAL):• SKIN – Flush with water.• EYES – Flush with water for 15 minutes and

get immediate medical attention.Antidote (INTERNAL):• Drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg,or vegetable oil. Get immediate medicalattention.

Batteries generate explosive hydrogen gas.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 han-dling batteries.

KEEP BATTERIES AND ELECTROLYTE OUTOF REACH OF CHILDREN.

FUSE INSPECTION1. Remove the battery cover.2. Inspect:• Fuse

Blown Replace.

BATTERY INSPECTION/FUSE INSPECTION

CAUTION:

WARNING

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3-25

FUSE

FUSE INSPECTION/HEADLIGHT BEAM ADJUSTEMENT

******************************************************Fuse replacement steps: Turn off the ignition. Install a new fuse of the right amperage. Turn on the switches to verify the operation ofthe electric circuit. If the fuse immediately blows again, check theelectric circuit.*******************************************************

Never use a fuse with a rating higher thanspecified. An improper fuse may causedamage to the electrical circuit, and possiblycause a fire.

Fuse:Main circuit: 7A

3 Install:• Battery cover

When installing the battery cover, pay par-ticular attention to the following points:• No cable or wire should cross the area

marked “NO”.• The (+) terminal cover should be properly

installed.• Cables and wires should be routed as

shown in the illustration, within the appro-priate area.

Q. “NO” zoneW. “+”-terminalE. WiringR. Battery vent

HEADLIGHT BEAM ADJUSTMENT1. Adjust:• Headlight beam

Higher Turn out screw Q

Lower Turn in screw Q

WARNING

CAUTION:

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3-26

HEADLIGHT LENS REPLACEMENT

1. Remove:• Front cover Q

2. Remove:• Headlight lens(Pull out the cotter pins)

3. Remove:• Gasket

4. Install:Reverse the “REMOVAL” procedure.

HEADLIGHT BULB REPLACEMENT1. Remove:• Front cover

2. Remove:• Headlight bulb socket Q(Turn one quart of a turn).

3. Remove:• Headlight bulb

4. Install:Reverse the “REMOVAL” procedure.

HEADLIGHT LENS REPLACEMENTHEADLIGHT BULB REPLACEMENT

4ENG

ENG

CHAPTER 4.ENGINE OVERHAUL

ENGINE REMOVAL .......................................................................................4-1COVER REMOVAL ..................................................................................4-1CARBURETOR ........................................................................................4-1CABLES, LEADS AND HOSES ...............................................................4-2ENGINE REMOVAL .................................................................................4-3

ENGINE DISASSEMBLY ...............................................................................4-4REAR WHEEL .........................................................................................4-4CENTER STAND .....................................................................................4-4CYLINDER HEAD AND CYLINDER ........................................................4-4PISTON PIN AND PISTON ......................................................................4-4KICK STARTER .......................................................................................4-5PRIMARY SHEAVE .................................................................................4-6SECONDARY SHEAVE ...........................................................................4-6STARTER SYSTEM .................................................................................4-7TRANSMISSION ......................................................................................4-8CDI MAGNETO ........................................................................................4-8AUTOLUBE OIL PUMP............................................................................4-9CRANKCASE AND CRANKSHAFT .........................................................4-9

INSPECTION AND REPAIR ........................................................................4-11CYLINDER HEAD ..................................................................................4-11CYLINDER AND PISTON ......................................................................4-11PISTON RINGS .....................................................................................4-13PISTON PIN AND PISTON PIN BEARING............................................4-14KICK STARTER .....................................................................................4-15TRANSMISSION ....................................................................................4-15AUTOLUBE PUMP ................................................................................4-16CRANKSHAFT .......................................................................................4-16PRIMARY SHEAVE ...............................................................................4-16SECONDARY SHEAVE .........................................................................4-17V-BELT ...................................................................................................4-18STARTER CLUTCH AND GEARS .........................................................4-19

ENGINE ASSEMBLY AND ADJUSTMENT .................................................4-20CRANKSHAFT AND CRANKCASE .......................................................4-21AUTOLUBE PUMP ................................................................................4-23CDI MAGNETO ......................................................................................4-24TRANSMISSION ....................................................................................4-26STARTER SYSTEM ...............................................................................4-28PRIMARY SHEAVE ...............................................................................4-30SECONDARY SHEAVE .........................................................................4-31KICK STARTER .....................................................................................4-35PISTON PIN AND PISTON ....................................................................4-36CYLINDER AND CYLINDER HEAD ......................................................4-37ENGINE REMOUNTING ........................................................................4-39

ENG

4-1

320000

322032

ENGINE OVERHAULENGINE REMOVALCOVER REMOVAL1. Remove:• CoversSee “CHAPTER 3 - COVERS AND HANDLE-BAR COVER”.

ENGINE REMOVAL

CARBURETOR1. Remove:• Air cleaner case assembly Q

2. Disconnect:• Carburetor cover• Hoses• Carburetor top

3.Remove:• Carburetor Q

4. Remove:• Air shroud Q• Muffler assembly W

5. Loosen:• Rear axle nut Q

NOTE:Apply the rear brake while loosening the rearaxle nut.

340002

ENG

4-2

385000

324000

321000

CABLES, LEADS AND HOSES1. Remove:• Oil hose Q on the oil pump side

NOTE:Plug the hose to prevent oil spillage.

2. Disconnect:• CDI unit lead pump side• Spark plug cap• Starter motor lead

3. Remove:• Rear brake cable Q

ENGINE REMOVAL

ENG

4-3

320001(a)

ENGINE REMOVAL1. Place a suitable stand under the frame.

2. Remove:• Rear shock absorber bolt (lower) Q• Engine mounting bolt W

3. Remove:• Engine

NOTE:Lift up the frame and remove the engine.

4. Place the frame on a suitable stand.

ENGINE REMOVAL

ENG

4-4

304002

301005

ENGINE DISASSEMBLYREAR WHEEL1. Remove:• Rear wheel• Brake shoes Q• Plate washer W

ENGINE DISASSEMBLY

CENTERSTAND1. Remove:• Spring Q• Clip W• Rubber washer E• Axle R• Clamp T• Center stand Y

CYLINDER HEAD AND CYLINDER1. Remove:• Air shroud• Cylinder head Q• Cylinder head gasket

NOTE:• Before loosening the cylinder head nuts, loosen

the spark plug.• Loosen the cylinder head nuts crosswise 1/4 of

a turn each before removing them.

2. Remove:Cylinder QCylinder gasket W

PISTON PIN AND PISTON1. Remove:• Piston pin clip Q

NOTE:Before removing the piston pin clip, cover thecrankcase with a clean rag, so that the clipcannot accidentally fall into the crankcase.

307001

346001

358001

ENG

4-5

ENGINE DISASSEMBLY

2. Remove:• Piston pin Q• Piston W• Piston pin bearing E

Do not use a hammer to drive out thepiston pin.

KICKSTARTER1. Remove:• Transmission cover Q (left)

2. Remove:• Kick pinion gear Q

NOTE:To remove the kick pinion gear, push down thekick crank.

3 Unhook:• Kick return spring W

4. Remove:• Kick crank• Circlips Q• Plate washer W• Kick shaft E

307002

313001

317001

317002

CAUTION:

ENG

4-6

319035

PRIMARY SHEAVE1. Remove:• Fan2. Remove:• Nut Q (primary sheave)

NOTE:To loosen the primary sheave nut hold the CDImagneto with a flywheel holder W.

Flywheel holder:90890-01235

ENGINE DISASSEMBLY

3. Remove:• Washer Q• Ratchet W• Washer E• Fixed primary sheave R• Washer T• V-belt

4. Remove:• Spacer Q• Primary sliding sheave W

SECONDARY SHEAVE1. Remove:• Nut Q (secondary sheave)

NOTE:Hold the secondary sheave with a sheave holderW to loosen the nut.

Sheave holder:90890-01701

319001

319002

319003

ENG

4-7

2. Remove:• Clutch housing Q• Secondary sheave W• Crankcase cover gasket• Dowel pins

3. Attach:• Sheave holder Q• Nut wrench (39 mm)


4. Loosen:• Clutch securing nut

Loosen the nut but do not remove it yet.

ENGINE DISASSEMBLY

5. Attach:• Clutch spring holder Q

NOTE:Compress the secondary sheave using the clutchspring holder Q.

Clutch spring holder:90890-01337

6. Remove:• Clutch securing nut

7. Remove:• Clutch assembly Q• Clutch spring W• Spring seat E• Guide pin R• Secondary sliding sheave T• Secondary fixed sheave Y

STARTER SYSTEM1. Remove:• Starter clutch assembly Q• Plate W (idle gear)• Idle gear E• Starter wheel gear R• Spacer T• Bearing Y• Washer U

311001

311002

317003

319004

319031

WARNING

ENG

4-8

319037

319036

317004

2. Remove:• Spacer Q• Bearing W• Washer E• Starter motor

ENGINE DISASSEMBLY

TRANSMISSION1. Remove:• Transmission case Q• Gasket• Dowel pins

2. Remove:• Drive shaft Q• Main shaft W• Plate washer E• Conical spring washer R

3. Remove:• Oil seal Q• Secondary sheave axle W

CDI MAGNETO1. Remove:• Nut Q (rotor)• Plate washer

NOTE:Hold the rotor using a flywheel holder W toloosen the nut.

Flywheel holder:90890-01235

319032

321004

ENG

4-9

313009

321005

2. Remove:• Rotor Q• Woodruff keyUse the flywheel puller W

Flywheel puller:90890-01189

• Stator assembly• Gasket

AUTOLUBE OIL PUMP1. Remove:• Autolube oil pump Q

2. Remove:• Circlips Q• Pump drive gear W• Pin E• Circlip R

CRANKCASE AND CRANKSHAFT1. Remove:• Oil seal stopper Q• Screws (crankcase)

NOTE:Loosen each screw one quart of a turn beforebeginning to remove them.

2. Attach:• Crankcase separating tool Q

Crankcase separating tool:90890-01135

NOTE:Fully tighten the tool holding bolts. Insure thatthe tool body is parallel with the case. If necessary,

ENGINE DISASSEMBLY

313002

314001

314002

ENG

4-10

ENGINE DISASSEMBLY

loosen one screw as much as required to levelthe tool body.

3. Remove:• Crankcase (right)As pressure is applied, keep tapping carefully onthe engine mounting bosses.

Use a soft hammer to tap on the case. Taponly on reinforced spots of the case. Nevertap on the gasket mating surfaces. Workslowly and carefully. Make sure the casesseparate evenly. If one end “hangs up” takethe pressure off the push screw, realign thecases and the tool and start again. If thecases do not separate at all, check for aremaining case screw or fitting. Do not force.

4. Attach:• Crankcase separating tool Q

Crankcase separating tool:90890-01135

5. Remove:• Crankshaft W

313004

CAUTION:

ENG

4-11

307003

301002

INSPECTION AND REPAIR

INSPECTION AND REPAIRCYLINDER HEAD1. Eliminate:• Carbon depositsUse a rounded scraper Q

NOTE:Take care to avoid damaging the spark plugthreads. Do not use a sharp instrument. Avoidscratching the aluminum.

2. Inspect:• Cylinder head warpage

Out of specification Re-surface.*******************************************************Warpage measurement and re-surfacementsteps : Attach a straight edge Q and a thickness

gauge W to the cylinder head. Measure the warpage limit.

Warpage limit:0.02 mm (0.001 in)

If the warpage is out of specification, re-surfacethe cylinder head.

NOTE:Rotate the head several times to avoid removingtoo much material from one side.

*******************************************************CYLINDER AND PISTON1. Eliminate:• Carbon depositsUse a rounded scraper Q2. Inspect:• Cylinder wall

Wear/Scratches Replace.

3. Eliminate:• Carbon depositsFrom the piston crown Q and ring grooves W.4. Remove:• Score marks and lacquer depositsFrom the sides of piston.

301001

301003

304001

ENG

4-12

307006

@

5. Inspect:• Piston wall

Wear/Scratches/Damage Replace.


6. Measure:• Piston to cylinder clearance********************************************************Piston to cylinder clearance measurementsteps :First step : Measure the cylinder bore “C” with a cylinderbore gauge.

NOTE:Measure the cylinder bore “C” in parallel to andat right angles to the crankshaft. Then, calculatethe average of the measurements.

Standard Wear limit

Cylinder 39.99 ~ 40.01mm 40.10 mmBore “C” (1.574 ~ 1.575 in) (1.579 in)

Taper _ 0,05mm"T" (0.002 in)

C = Maximum DT = (Maximum D1,D3 or D5) -

(Maximum D2,D4 or D6 )

2nd step: Measure the piston skirt diameter “P” with amicrometer.@ 5 mm (0.20 in) from the piston bottom edge.

Piston Size:Standard:

39.952 ~ 39.972 mm(1.57 ~ 1.57 in)

If out of specification, replace cylinder, pistonand piston rings as a set.

307004

D1D2

D3D4

D5D6

307005

NOTE:Sand in a crisscross pattern. Do not sandexcessively.

ENG

4-13

307008

a

307007

If out of specification, replace piston and pistonrings as a set.

3rd step: Calculate the piston-to-cylinder clearance withfollowing formula:

Piston-to cylinder clearance =Cylinder Bore “C” –Piston Skirt Diameter “P”

If out of specification, replace cylinder, pistonand piston rings as a set.

Piston-to-cylinder clearance:0.034 ~ 0.047 mm(0.0013 ~ 0.0018 in)

<Wear limit : 0.1 mm (0.004 in)>

*******************************************************


PISTON RINGS1. Measure:• Side clearance Out of specification Replace piston and/or

rings. Use a Feeler Gauge Q

Standard Limit

Top 0.03 ~ 0.05 mm 0.10 mmring (0.0012 ~ 0.0020 in) (0.004 in)

2nd 0.03 ~ 0.05 mm 0.10 mmring (0.0012 ~ 0.0020 in) (0.004 in)

2. Install:• Piston ring• Into the cylinderPush the ring with the piston crown.

3. Measure:• End gap

Out of specification Replace rings as a set.Use a Feeler Gauge Q

ENG

4-14


Standard Limit

Top 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 in) (0.028 in)

@ Measuring Point 20 mm (0.8 in)

PISTON PIN AND PISTON PIN BEARING1. Inspect:• Piston pin

Blue discoloration/Groove Replace, theninspect lubrication system.

2. Measure:• Outside diameter (piston pin)


Outside diameter (piston pin):9.996 ~ 10.000 mm(0.3935 ~ 0.3937 in)

3. Measure:• Piston pin-to-piston clearance

Out of specification Replace piston.

Piston pin-to-piston clearance =Bore (piston pin) b -Outside diameter (piston pin) a

Piston pin-to-piston clearance:0.004 ~ 0.023 mm(0.0002 ~ 0.0009 in)<Limit : 0.07 mm (0.028 in)>

4. Inspect:• Bearing (piston pin)

Pitting/Damage Replace

307009

a

307010

b

307011

ENG

4-15

319038


KICK STARTER1. Inspect:• Kick gear teeth Q• Kick pinion gear teeth W

Burrs/Chips/Roughness/Wear Replace.

2. Inspect:• Mating dogs (kick pinion gear and one-wayclutch)

Rounded edges/Damage Replace.

3. Measure:• Clip tension (kick pinion gear) Q

Out of specification Replace.Use a spring balance W.

Standard tension:150 ~ 250 g (5.3 ~ 8.8 oz.)

TRANSMISSION1. Inspect:• Drive axle Q• Main axle W• Secondary sheave axle E

Burrs/Chips/Roughness/Wear Replace.

2. Inspect:• Secondary sheave axle bearing Q• Main axle bearing W• Drive axle bearing ESpin the bearing inner race.

Excessive play/Roughness Replace.Pitting/Damage Replace.

317005

317006

317007

319005

ENG

4-16

AUTOLUBE PUMPWear or an internal malfunction may cause thepump output to vary from the factory setting.This situation is, however, extremely rare. Ifimproper output is suspected, inspect thefollowing:

1. Inspect:• Delivery line

Obstructions Blow out.• O-ring

Wear/Damage Replace.

2. Inspect:• Autolube pump drive gear teeth Q• Autolube pump driven gear teeth W

Pitting/Wear/Damage Replace.


CRANKSHAFT1. Measure:• Crankshaft width "A"• Runout limit “C”• Connecting rod big end side clearance “D” Use V-blocks, dial gauge and thickness gauge.

Crankshaft width "A":37.90 ~ 37.95 mm(1.492 ~ 1.494 in)

Runout limit “C”:0.03 mm (0.0012 in)

Connecting rod big end sideclearance “D”:

0.2 ~ 0.5 mm (0.008 ~ 0.02 in)

PRIMARY SHEAVE

1. Inspect:• Primary sliding sheave Q• Primary fixed sheave W

Wear/Cracks/Scratch/Damage Replace.

308001

314003

319006

ENG

4-17

319008

2. Check:• Free movementInsert the collar W into the primary sliding sheaveQ, and check for free movement.

Stick or excessive play Replace the sheaveand/or collar.

3. Measure:• Outside diameter Q (weight)


Outside diameter (weight):15.0 mm (0.59 in)<Limit 14.5 mm (0.57 in)>

SECONDARY SHEAVE

1. Inspect:• Secondary fixed sheave Q• Secondary sliding sheave W

Scratch/Crack/Damage Replace as a set.• Oil seal E

Damage Replace.


2. Inspect:• Torque cam groove Q• Guide pin W

Wear/Damage Replace as a set.• O-rings E

Damage Replace.

3. Measure:• Clutch spring free length


Clutch spring free length:121.7 mm

<Limit>106.7 mm

319007

319009

319010

319011

ENG

4-18


4. Inspect:• Clutch housing inner surface

Oil/Scratches Remove.

Use a rag soaked in lacquerthinner or solvent.

Use an emery cloth (lightlyand evenly polishing).

5. Measure:• Clutch housing inside diameter @


Clutch housing inside diameter:107.0 mm ( 4.21 in)

<Wear Limit>:107.4 mm ( 4.22 in)

6. Inspect:• Clutch shoes

Glazed parts Sand with coarse sandpaper.

NOTE:After using the sand paper, clean off the polishedparticles with a cloth.

Oil

Scratches

7. Measure:• Clutch shoe thickness @


Clutch shoe thickness:2.0 mm (0.08 in)

<Wear Limit> :1 mm (0.039 in)

V-BELT1. Inspect:• V-belt

Crack/Wear Replace.

NOTE:Replace the V-belt if it is greasy or oily.

319012

@

319013

@

319030

ENG

4-19


2. Measure:• V-belt width @Out of specification Replace.

V-Belt width:16,5 mm (0.65 in)

<Wear Limit>:15,7 mm (0.62 in)

STARTER CLUTCH AND GEARS1. Inspect:• Starter clutchPush the dowel pin in arrow direction.

Unsmooth operation Replace starter clutchassembly.

2. Inspect:• Starter wheel gear teeth Q• Idle gear teeth W

Burrs/Chips/Roughness/Wear Replace.• Bearing E (starter wheel gear)

Pitting/Damage Replace.

317008

317009

312001

ENG

4-20

313008

9 Nm (0.9 m.kg, 6.5 ft.lb) 13 Nm (1.3 m.kg, 9.4 ft.lb)

ENGINE ASSEMBLY AND ADJUSTMENT


Q Oil sealW Oil seal holderE Crankcase (right)R Dowel pinT BearingY Crankshaft (right)U Bearing

A CRANKSHAFT:Crank width:37,90 ~ 37,95 mm(1.49 ~ 1.50 in)Runout limit:< 0,03 mm>< 0,002 in>Big end side clearance:0,2 ~ 0,5 mm(0,008 ~ 0,020 in)

I Crankshaft pinO Connecting rodP Crankshaft (left) Bearing Engine mount shaftq Crankcase (left)w Oil seal

ENG

4-21

1. Attach:• Crankshaft installation tool Q, W, E, R

Crankshaft installation tool:Q : 90890-01274W : 90890-01275E : 90890-01277R : 90890-01411

2. Install:• Crankshaft(to left crankcase)

NOTE:Hold the connecting rod at top dead center withone hand while tightening the nut of theinstallation tool with the other. Tighten theinstallation tool until the crankshaft bottomsagainst the bearing.

CRANKSHAFT AND CRANKCASE

To protect the crankshaft against scratchesand to facilitate the engine assembly andinstallation, apply grease to oil seal lips, andengine oil to bearings.


3. Install:• Dowel pins Q• Spacer W

4. Apply:• HEATPROOF or Yamaha Bond No.1215To the mating surfaces of both case halves.

HEATPROOF or Yamaha BondNo.1215

313005

313006

CAUTION:

ENG

4-22

313009

313009

7. Tighten:• Crankcase holding screws

NOTE:Tighten the crankcase holding screws in stages,using a crisscross pattern.

Crankcase holding screw:9 Nm (0.9 m • kg,( 6.5 ft • lb)

8. Check:• Crankshaft operation

Unsmooth operation Repair.

Never hit on the crankshaft.

9. Install:• Oil seal stopper plate Q

Screw (oil seal stopper plate):9 Nm (0.9 m • kg,( 6.5 ft • lb)

5. Attach:• Crankshaft installation tool Q, W, E, R

Crankshaft installation tool:Q : 90890-01274W : 90890-01275E : 90890-01277R : 90890-01411

NOTE:Hold the connecting rod at top dead center withone hand while tightening the nut of the installa-tion tool with the other. Tighten the installationtool until the crankcase halves close with oneanother.

6. Install:• Right crankcase


308003

T.R

T.R

CAUTION:

ENG

4-23


AUTOLUBE PUMP AND CDI MAGNETOQ FanW Plain washerE Rotor assemblyR Lighting coilT Charge coilY Pick up coilU Stator assemblyI Oil seal

O GasketP Oil hose Oil delivery hose Clipq Autolube pumpw O-ringe Circlipr Oil pump drive gear

314007

6.5 Nm (0.65 m.kg, 4.7 ft.lb)

4 Nm (0.4 m.kg, 2.9 ft.lb)

37.5 Nm (3.75 m.kg, 27.1 ft.lb)

8 Nm (0.8 m.kg, 5.8 ft.lb)

ENG

4-24

314004

AUTOLUBE PUMP1. Install:• Circlip Q• Pin W• Pump drive gear E• Circlip R

2. Apply:• Lithium soap base grease(to O-ring Q)

3. Instal:• Autolube pump W

Screw (autolube pump):4 Nm (0.4 m • kg, 2.9 ft • lb)


4. Apply:• Lithium soap base grease(to autolube pump gear Q, W)

Lithium soap base grease:15 cc (0.92 cu • in)

CDI MAGNETO1. Install:• Gasket

2. Apply:• Lithium soap base grease(to oil seal Q)

3. Pass the CDI magneto lead through thecrankcase hole.

4. Install:• Stator assembly

Screw (stator assembly):8 Nm (0.8 m • kg, 5.8 ft • lb)

314005

314006

321001

T.R

T.R

ENG

4-25

5. Install:• Woodruff key Q• Magneto rotor W• Plain washer E• Nut R

NOTE:When installing the magneto rotor, make surethe woodruff key is properly seated in the keyway of the crankshaft. Apply a light coating oflithium soap base grease to the tapered portionof the crankshaft end.


6. Tighten:• Nut Q (magneto rotor)Use the flywheel holding tool W.

Flywheel holding tool:90890-01235

Nut (Flywheel magneto):37.5 Nm (3.75 m • kg, 27.1 ft • lb)

321002

321004

T.R

ENG

4-26

TRANSMISSIONQ CirclipW BearingE Oil sealR Drive axleT BearingY Main axleU Conical spring washerI Plain washer

O BearingP Secondary sheave axle Bearing Dowel pinq Gasketw Transmission case covere Oil seal


319033

12 Nm (1.2 m.kg, 8.7 ft.lb)

ENG

4-27

TRANSMISSION1. Apply:• 10W30 Type SE Motor oil(to transmission case cover bearing)

2. Install:• Bearing Q

3. Install:• Oil seal W• Secondary sheave axle E

NOTE:Apply lithium soap base grease onto the oil seallips.

4. Check:• Secondary sheave axle operation


5. Apply:• 10W30 type SE Motor oil(to main axle bearing and drive axle bearing)

6. Install:• Main axle Q• Drive axle W• Conical spring washer E• Plain washer R

NOTE:• Apply lithium soap base grease onto the oil seallips.• Always use a new gasket.

7. Install:• Gasket • Dowel pins • Transmission case cover

Screw (case cover):9 Nm (0.9 m • kg, 6.5 ft • lb)


319014

319016

319017

T.R

ENG

4-28


STARTER SYSTEM

Q CollarW WasherE BearingR Starter wheel gearT CollarY Starter clutch

U PlateI ShaftO Plain washerP Idle gear O-ring Starter motor

317017

13 Nm (1.3 m.kg, 9.4 ft.lb)

8 Nm (0.8 m.kg, 5.8 ft.lb)

ENG

4-29

317010

STARTER SYSTEM1. Install:• Collar Q• Washer W• Bearing E• Starter wheel gear R• Starter clutch T

NOTE:• Apply lithium soap base grease to the bearing.• Apply molybdenum disulfide oil to the shaft(starter clutch).


2. Install:• Plain washer Q• Idle gear W• Plain washer E• Plate R (idle gear)

Screw (idle gear plate):8 Nm (0.8 m • kg, 5.8 ft • lb)

NOTE:Apply engine oil to the idle gear W.

3. Install:• Starter motor Q

Screw (starter motor):13 Nm (1.3 m • kg, 9.4 ft • lb)

NOTE:Apply lithium soap base grease to the O-ring ofthe starter motor.

317011

317012

317013

T.R

T.R

ENG

4-30

50 Nm (5.0 m.kg, 36.2 ft.lb)

40 Nm (4.0 m.kg, 28.9 ft.lb)

319034

30 Nm (3.0 m.kg, 21.7 ft.lb)


PRIMARY AND SECONDARY SHEAVEQ Clutch housingW ClutchE Clutch shoe springR Clutch springT Spring seatY GasketU O-ringsI Secondary sliding sheaveO V-beltP Guide pin Secondary fixed sheave

A Spring (secondary sheave)free lenght limit: 106.7 mm(4.20 in)

B Clutch housing weare limit:107.4 mm (4.22 in)

C Clutch shoes wear limit:1 mm (0.039 in)

D V-belt wear limit:15.7 mm (0.62 mm)

E Weight outside diameterlimit : 14.5 mm (0.57 in)

Conical spring washerq One-way clutchw Washere Primary fixed sheaver Plate washert Spacery Primary sliding sheaveu Clutch weightsi Slidero Cam

*Apply BEL-RAY Assembly Lube ®

ENG

4-31

A KICK CLIP FRICTION FORCE : 0,15 ~ 0,25kg


KICK STARTER

Q Kick shaftW Return springE CollarR Plain washerT CirclipY Gasket

U Dowel pinI Transmission caseO Kick crankP Kick pinion gear Kick pinion gear clip

317018(a)

12 Nm (1,2 m.kg, 8.7 ft.lb)

10 Nm (1,0 m.kg, 7.2 ft.lb)

150 ~ 250 g

ENG

4-32

SECONDARY SHEAVEWhen assembling the secondary sheave, reversethe disassembly procedure. Note the followingpoints.1. Apply:• BEL-RAY Assembly Lube ®(to the sliding parts of the sheave)

2. Install:• Sliding sheave Q

NOTE:Wind adhesive tape around the end of the sheaveto avoid turning over the oil seal lips wheninstalling the sheave.


3. Install:• Pin Q

4. Apply:• BEL-RAY Assembly Lube ®(to the torque cam grooves and O-rings)

5. Check:• Sliding sheaveUnsmooth operation Repair.

Remove excessive grease.

6. Install:• Clutch securing nutUse the clutch spring holder Q

Clutch spring holder:90890-01337

7. Tighten:• Clutch securing nutUse sheave holder Q (39 mm).


Clutch securing nut:50 Nm (5.0 m • kg, 36 ft • lb)

319018

319019

319020

319021

319031

T.R

CAUTION:

ENG

4-33

319026

8. Install:• Dowel pin• Gasket• Secondary sheave assembly Q• Clutch housing W

9. Tighten:• Nut Q (secondary sheave)

Use sheave holder W

Sheave holder:P/N. 90890-01701

Nut (secondary sheave):40 Nm (4.0 m • kg, 29 ft • lb)

PRIMARY SHEAVE1. Clean:• Primary sliding sheave face Q• Primary fixed sheave face W• Collar E• Weight R• Primary sliding sheave cam surface T

2. Install:• Weight Q• Cam W• Slider E• Collar R

3.Check:• Cam operation


4. Install:• Primary sheave assembly Q• Collar W


319022

319023

319024

319025

T.R

ENG

4-34

319035

319027

5. Install:• V-beltPlace the V-belt around the secondary sheave,and compress the secondary sheave springhard so that the V-belt moves toward the clutchhub.

NOTE:• The arrow on the V-belt must point to the front.• Make sure the V-belt is not stained with oil orgrease.

6. Install:• Shim Q• Primary fixed sheave W• Washer E• One-way clutch R• Washer T• Nut Y


7. Tighten:Nut Q (primary sheave)

Nut (primary sheave):30 Nm (3.0 m • kg, 21.7 ft • lb)

NOTE:When tightening the nut (primary sheave), holdthe magneto rotor using the flywheel holding toolW.

Flywheel holding tool:90890-01235

8. Adjust:• V-beltTense the V-belt by turning the primary sheaveseveral times.

319028

T.R

ENG

4-35

320000

317015

317014

4. Install:• Transmission case Q

Screw (Transmission case):9 Nm (0.9 m • kg, 6.5 ft • lb)

5. Install:• Kick crank Q

Bolt (kick crank):9 Nm (0.9 m • kg, 6.5 ft • lb)

9. Install:• Fan Q

Screw (fan):7 Nm (0.7 m • kg, 5.1 ft • lb)


KICK STARTER1. Install:• Return spring Q• Kick shaft W• Collar E• Washer R• Circlip T

2. Hook:• Return spring(to the kick gear and boss)

3. Install:• Kick pinion gear Q

NOTE:Install the clamp as shown.

319029

T.R

T.R

T.R

317016(a)

ENG

4-36

304003

20 Nm (2.0 m.kg, 14.0 ft.lb) 10 Nm (1.0 m.kg, 7.2 ft.lb)


PISTON, CYLINDER AND CYLINDER HEAD

Q Carburetor jointW Reed valveE GasketR Cylinder headT Cylinder head gasketY Cylinder

U Cylinder gasketI Piston ringO PistonP Piston pin Piston pin clip Bearing

A Piston clearance :0.034 ~ 0.047 mm (0.0013 ~ 0.0017 in)

B Piston rings end gap :0.15 ~ 0.30 mm (0.006 ~ 0.012 in)

C Piston rings side clearance :0.03 ~ 0.05 mm (0.0012 ~ 0.0019 in)

D Spark plug :Type : BR8HSManufacturer : NGK

ENG

4-37

308004

307013


PISTON PIN AND PISTON1. Apply:• Engine oil Q(to crankshaft bearing, connecting rod big endbearing, small end bearing, piston pin, pistonring grooves and piston skirt .)

2. Install:• Small end bearing• Piston Q• Piston pin E• Piston pin clip R

NOTE:• The arrow W on the piston must point to the

exhaust side.• Before installing the piston pin clip, cover the

crankcase with a clean towel or rag so you willnot accidentally drop the pin clip and materialinto the crankcase.

• The ends of the piston pin clip must notcome together at the slot in the pistongroove.

• Always use a new piston pin clip.

CYLINDER AND CYLINDER HEAD1. Install:• Cylinder gasket (new gasket)2. Check:• Piston rings

NOTE:• Make sure the ring ends Q are properly fittedaround the ring locating pins in the piston grooves.• Be sure to check the manufacturer’s marks ornumbers stamped on the rings are on the topside of the rings.

307012

WARNING

ENG

4-38

304002

301004

3. Install:• Cylinder Q

NOTE:Install the cylinder with one hand, while com-pressing the piston rings with the other hand.


7. Install:• Brake shoe plate Q• Plain washer W• Rear wheel

4. Install:• Cylinder head gasket (new gasket)

5. Install:• Cylinder head Q• Spark plug W

NOTE:• Tighten the cylinder head holding nuts in stages,

and crisscross sequence.• The arrow E on the cylinder head must point to

the front.

Nut (cylinder head):10 Nm (1.0 m • kg, 7.2 ft • lb)

Spark plug:20 Nm (2.0 m • kg, 14 ft • lb)

6. Install:• Center stand Q• Shaft W• Clamp E• Rubber washer R• Clip T• Spring Y

346001

358002

T.R

ENG

4-39

385000

322032

320001

8. Install:• Air shroud• Oil hose• Oil delivery hose


9. Air bleeding:• Autolube pumpRefer to the section “CHAPTER 3 – AUTOLUBEPUMP AIR BLEEDING”.

ENGINE REMOUNTINGReverse the removal procedure.Note the following points.1. Install:• Engine mounting bolt Q• Rear shock absorber bolt W (lower)These bolts should be temporarily secured.2. Tighten:• Engine mounting bolt• Rear shock absorber bolt (lower)

Engine mounting bolt:84 Nm (8.4 m • kg, 61 ft • lb)

Rear shock absorber bolt (lower):16 Nm (1.6 m • kg, 12 ft • lb)

3. Install:• Carburetor top together with throttle valve Q• Fuel hose W/Vacuum hose E• Brake cable/plug cap

NOTE:When installing the throttle valve into thecarburetor, align the groove of the throttle valvewith the projection of the carburetor.

4. Connect:• Starter motor• CDI magneto lead• Earth

T.R

ENG

4-40

320000


5. Tighten:• Rear wheel axle nut Q

NOTE:When tightening the rear wheel axle nut, applythe rear brake.

Rear wheel axle nut:105 Nm (10,5 m • kg, 76 ft • lb)

6. Install:• Muffler assembly Q• Fan cover W.

Bolt (muffler):26 Nm (2.6 m • kg, 19 ft • lb)

Bolt (exhaust pipe):9 Nm (0.9 m • kg, 6.5 ft • lb)

7. Fill:• Transmission oilRefer to “CHAPTER 3 – TRANSMISSION OILREPLACEMENT” section.8. Adjust:• Brake lever free playRefer to “CHAPTER 3 – FRONT/REAR BRAKELEVER FREE PLAY ADJUSTMENT” section.• Engine idle speed• Throttle cable free playRefer to “THROTTLE CABLE FREE PLAYADJUSTMENT” and “ENGINE IDLE SPEEDADJUSTMENT”.

340002

T.R

T.R

5CARB

CARB

CHAPTER 5.CARBURETION

CARBURETOR ..............................................................................................5-1TEIKEI CARBURETOR............................................................................5-1DELL'ORTO CARBURETOR ...................................................................5-3REMOVAL ................................................................................................5-5DISASSEMBLY ........................................................................................5-5INSPECTION ...........................................................................................5-7ASSEMBLY ..............................................................................................5-9INSTALLATION ......................................................................................5-10

FUEL COCK .................................................................................................5-11INSPECTION .........................................................................................5-11FUEL FILTER CLEANING .....................................................................5-11

REED VALVE ...............................................................................................5-11REMOVAL ..............................................................................................5-11INSPECTION .........................................................................................5-12INSTALLATION ......................................................................................5-13

CARB

5-1

TEIKEI CARBURETORQ Carburetor topW GasketE Throttle valve springR Needle setT Throttle valveY Starter plunger springU Starter plungerI Air screwO Throttle stop screw

P Pilot jet Needle jet Needle valveq Main jetw Float pine Floatr Float chamber gaskett Float chambery Drain screw

CARBURETOR

322033

CARB

5-2

CARBURETOR



Main jet (M.J.) #90 #88


Jet needle (J.N.) 211 GA 3/5 3S12-3/5




Bypass (B.P.1) 0.80 0.80





CARB

5-3

CARBURETOR

322034

DELL'ORTO CARBURETORQ Carburetor topW GasketE Throttle valve springR Needle setT Throttle valveY Starter plunger springU Starter plungerI Air screwO Throttle stop screw

P Pilot jet Needle jet Needle valveq Main jetw Float pine Floatr Float chamber gaskett Float chambery Drain screw

CARB

5-4

CARBURETOR



Main jet (M.J.) #90 #88


Jet needle (J.N.) 211 GA 3/5 3S12-3/5




Bypass (B.P.1) 0.80 0.80





CARB

5-5

322030

CARBURETOR

REMOVAL1. Remove:• Side covers and footrest boardRefer to the section “SIDE COVERS ANDFOOTREST BOARD” in Chapter 3.• Air filter case assembly

2. Disconnect:• Fuel hose Q• Oil hose W

TEIKEI CARBURETOR3. Remove:• Carburetor top• Throttle valve• Starter plunger• Carburetor

DELL’ORTO CARBURETOR3. Remove:• Carburetor top• Throttle valve• Starter plunger top• Starter plunger• Carburetor

DISASSEMBLY (TEIKEI CARBURETOR)1. Remove:• Float chamber Q

2. Remove:• Float pin screw Q• Float pin W• Float E• Needle valve R• Gasket T

322001

322002

CARB

5-6

CARBURETOR

3. Remove:• Main jet Q• Needle jet W• Pilot jet E

4. Remove:• Throttle stop screw Q• Spring (throttle stop screw)• Air screw W• Spring (air screw)

5. Remove:• Needle clip Q• Jet needle W• Throttle valve E

DISASSEMBLY (DELL’ORTOCARBURETOR)

1. Remove:• Float chamber Q

2. Remove:• Float pin Q• Float W• Needle valve E

322003

322004

322005

322007

322026

CARB

5-7

322006

322028(a)

CARBURETOR

3. Remove:• Pilot jet Q• Main jet W• Needle jet E• Starter jet R

4. Remove:• Throttle stop screw Q• Spring (throttle stop screw)• Air screw W• Spring (air screw)

5. Remove:• Needle clip Q• Jet needle W• Throttle valve E

INSPECTION1. Check:• Carburetor body Q

Dirt Clean.

NOTE:Use a petroleum based solvent for cleaning.Blow out all passages and jets with compressedair.

2. Inspect:• Main jet Q• Needle jet W• Pilot jet E• Starter jet (DELL’ORTO)

Contamination Clean.

322027

322029

322012

CARB

5-8

CARBURETOR

3. Check:• Needle valve Q

Wear/Contamination Replace.• Float W

Damage Replace.• Gasket

Damage Replace.

4. Check:• Throttle valve Q


5. Check:• Throttle valve free movement

Unsmooth/stickiness Replace.Insert the throttle valve Q into the carburetorbody W and check for smooth movement.

6. Check:• Throttle stop screw Q• Air screw W• Needle E• Starter plunger R


7. Measure:• Needle valve• Valve seat

322013

322014

322015

322016

NOTE:The float height is factory-adjusted. Never try toadjust it yourself.

CARB

5-9

CARBURETOR

ASSEMBLYReverse the “DISASSEMBLY” procedures. Notethe following points.

• Before reassembling the carburetor washall its components in clean gasoline.

• Always use new gaskets.

1. Install:• Needle W• Clip E• Throttle valve Q• Spring seat R• Spring

Jet needle clip position:3/5

2. Install:• Throttle valve Q• Starter plunger

NOTE:Align the groove W of the throttle valve with theprojection E of the carburetor body.

3. Install:• Carburetor

NOTE:Align projection Q with projection W.

322019

322020

CAUTION:

322018

CARB

5-10

CARBURETOR

INSTALLATIONTo install the carburetor reverse the “REMOVAL”procedures. Note the following points.1. Install:• Carburetor cover Q• Air hose WPass the air hose through the hole E in thecarburetor cover.

2. Adjust:• Throttle cable free playRefer to the section “THROTTLE CABLE FREEPLAY ADJUSTMENT” in Chapter 3.

3. Install:• Air filter case

322021

CARB

5-11

352001

322031

FUEL COCKINSPECTION1. Stop the engine.

2. Remove:• Side coversRefer to the section “SIDE COVERS ANDFOOTREST BOARD” in Chapter 3.

3. Check:• Fuel cock

********************************************************Fuel cock inspection steps : Disconnect the fuel hose Q. Place a receptacle under the fuel hose end. If fuel stops flowing within a few seconds, thefuel cock is in good condition. If not clean orreplace the fuel cock. Disconnect the vacuum hose and breathe inthrough the hose to create a vacuum in the fuelcock.If fuel flows out of the fuel hose when vacuum isapplied and stops flowing when vacuum stops,the fuel cock is in good condition.If not, clean or replace the vacuum hose, the fuelhose and the fuel cock.********************************************************

FUEL COCK/REED VALVE

FUEL FILTER CLEANINGThe fuel filter Q is fitted inside the fuel tank. It isaccessible when the fuel hose (between the fueltank and the fuel cock) is disconnected.

REED VALVEREMOVAL1. Remove:• Side coversRefer to the section “SIDE COVERS ANDFOOTREST BOARD” in Chapter 3.

2. Remove:• CarburetorRefer to section “CARBURETOR REMOVAL”.

CARB

5-12

REED VALVE

3. Remove :• Carburetor joint• Reed valve assembly

INSPECTION1. Check :• Carburetor joint

Damage/Cracks Replace.• Reed valve

Wear/Cracks/Damage Replace.*********************************************************Reed valve inspection steps : Visually inspect the reed valve.

NOTE:A reed valve in good condition should be com-pletely or at least nearly flush with the valve seat.

If in doubt, apply suction to the carburetor sideof the assembly. Leakage should be minimal to moderate.*********************************************************

2. Measure:• Valve stopper height Q

Out of specification Replace valve stopper.

Valve stopper height:4.0 ~ 4.4 mm (0.157 ~ 0.173 in)

3. Measure:• Reed valve clearance Q

Out of specification Replace reed valve.

Reed valve clearance:Less than 0.2 mm (0.008 in)

322022

322023

322024

CARB

5-13

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

2. Tighten:• Reed valve assembly bolts

Reed valve assembly bolts:9 Nm (0.9 m.kg, 6.5 ft.lb)

NOTE:Tighten the screws crosswise in several steps toprevent warpage of the read valve assembly andthe carburetor joint.

REED VALVE

T.R

6CHAS

CHAS

CHAPTER 6.CHASSIS

FRONT WHEEL .............................................................................................6-1REMOVAL ................................................................................................6-2INSPECTION ...........................................................................................6-2INSTALLATION ....................................................................................... 6-3

FRONT BRAKE..............................................................................................6-4BRAKE PAD REPLACEMENT .................................................................6-6CALIPER DISASSEMBLY .......................................................................6-7MASTER CYLINDER DISASSEMBLY .....................................................6-8INSPECTION AND REPAIR ....................................................................6-9CALIPER ASSEMBLY ...........................................................................6-10MASTER CYLINDER ASSEMBLY .........................................................6-11

REAR WHEEL .............................................................................................6-13REMOVAL ..............................................................................................6-14INSPECTION .........................................................................................6-14ASSEMBLY ............................................................................................6-15INSTALLATION ......................................................................................6-16

FRONT FORK ..............................................................................................6-18REMOVAL ..............................................................................................6-19DISASSEMBLY ......................................................................................6-20INSPECTION .........................................................................................6-21ASSEMBLY ............................................................................................6-21INSTALLATION ......................................................................................6-22

STEERING HEAD AND HANDLEBAR ........................................................6-23REMOVAL ..............................................................................................6-24INSPECTION .........................................................................................6-25ASSEMBLY AND INSTALLATION .........................................................6-26

CHAS

6-1

FRONT WHEEL

Q AxleW Speedometer gearE BearingR CollarT Valve

CHASSIS

FRONT WHEEL

Y Oil sealU CollarI Axle nutO TireP Front wheel

TIRE SIZE:120/90-10

RIM RUNOUTLIMIT:VERTICAL:1,0 mm (0.040in)LATERAL:1,0 mm (0.040in)

B

A

340001(a)

LS

LS

CHAS

6-2

340008

340006

FRONT WHEEL

REMOVAL1. Remove:• Front caliper fixing bolts• Front caliper• Speedometer cable Q• Axle W• Front wheel

NOTE:Never depress the brake lever when the wheelis off the scooter. Otherwise the brake pads willbe forced shut.

INSPECTION1. Inspect:• Front axle runout


Axle runout limit:0.25 mm (0.01 in)

Do not attempt to straighten a bent axle.

2. Measure:• Wheel runout


Rim runout limit:Radial: 1.0 mm (0.040 in)Lateral: 1.0 mm (0.040 in)

3. Inspect:• Tire

Wear/Cracks/Warpage Replace.

4. Inspect:• Wheel bearings

Bearings allow play in the wheel hub orwheel turns roughly Replace.

5. Check:• Speedometer gear Q


340003

340007

340004

WARNING

CHAS

6-3

346005

FRONT WHEEL

INSTALLATIONReverse the “Removal” procedure.Note the following points.1.Lubricate:• Front wheel axle• Bearings• Oil seal (lips)• Drive/driven gear (speedometer)

Recommended lubricant:Lithium soap base grease

2. Install:• Speedometer gear unit Q

NOTE:Be sure that the two projections at the gear unitmesh with the two slots on the wheel hub.

3. Install:• Front wheel Q• Front caliper W

NOTE:Be sure that the slot (torque stopper) of the gearunit housing is positioned correctly.

4.Tighten:• Front wheel axle• Front caliper mounting bolts

Front wheel axle:35 Nm (3.5 m • kg, 25.3 ft • lb)

Front caliper mounting bolts:23 Nm (2.3 m • kg, 16.6 ft • lb)

Make sure that the brake hoses are routedproperly.

340004

T.R

WARNING

CHAS

6-4

FRONT BRAKE

FRONT BRAKE

Q Brake discW BoltE CaliperR PistonT Piston sealsY Air bleed screw

NOTE:Be sure to install the pads correctly.U Pad spring

I Pad retainerO Brake padsP O. ring Bolt Mounting bolt

A PAD WEAR LIMIT:B DISC WEAR LIMIT:

A 0,5 mm (0.02 in)B 3.2 mm (0.12 in)

6 Nm (0,6 m.kg; 4 ft.lb)

21,5 Nm (2,15 m.kg; 16 ft.lb)

23 Nm ( 2,3 m.kg; 17 ft.lb)

23 Nm ( 2,3 m.kg; 17 ft.lb)

LT

LT

347009(a)

CHAS

6-5

BRAKE FLUIDDOT# 3 or DOT# 4

A

23 Nm (2,3 m.kg; 17 ft.lb)

23 Nm (2,3 m.kg; 17 ft.lb)

10,8 Nm (1,08 m.kg; 8 ft.lb)

3 Nm ( 0,3 m.kg; 2,17 ft.lb)

NOTE:Drain completely before removing the mastercylinder.

MASTER CYLINDER DISASSEMBLY

Q Master cylinderW Master cylinder piston ass'yE DiaphragmR Master cylinder capT ScrewY Master cylinder bracket

FRONT BRAKE

U BoltI Brake hoseO BoltP Bolt Copper washer

347007

CHAS

6-6

346005

347003

FRONT BRAKE

• Disc brake components rarely requiredisassembly. Do not disassemblecomponents unless absolutely necessary.If any hydraulic connection is disconnected,the entire system must be disassembled,drained, cleaned, and then properly filledand bled after reassembly. Do not usesolvents on internal brake component.

• Solvents will cause seals to swell anddistort. Use only clean brake fluid forcleaning. Use care with brake fluid. Neverallow brake fluid to come in contact withthe eyes. Brake fluid can damage paintedsurfaces and plastic parts.

BRAKE PAD REPLACEMENTIt is not necessary to disassemble the brakecaliper and brake hose to replace the brakepads.1. Remove:• Pin Q• Axle W

2. Remove:• Pad spring E• Brake pads R

NOTE:Replace the brake pads as a set when either oneis worn to the limit.

3.Measure:• Brake pads


NOTE:Replace the brake pad and spring as a set whenreplacing the brake pads.

Wear limit @:0.5 mm (0.020 in)

WARNING

CHAS

6-7

346005

FRONT BRAKE

4. Install:• Brake pads• Pad spring• Axle• Pin

NOTE:Be careful to install the brake pads correctly.

5.Lubricate:• Mounting bolt (caliper body)

Recommended lubricant:Lithium soap base grease

6.Install:• Wheel axle• Mounting bolt

Wheel axle:35 Nm (3.5 m • kg, 25.3 ft • lb)

Mounting bolt:23 Nm (2.3 m • kg, 17 ft • lb)

LOCTITE ®

347004

T.R

CALIPER DISASSEMBLY

NOTE:Before disassembling the front brake caliper,drain all brake fluid from the brake hose, mastercylinder, brake caliper and tank.

1.Remove:• Union bolt Q• Copper washers W

NOTE:Place the open end of the drain hose into acontainer and pump out the remaining brakefluid carefully.

2.Remove:• Caliper body• Caliper bracket3. Remove:• Piston• Piston seals Q

CHAS

6-8

FRONT BRAKE

*******************************************************Removal steps : Blow compressed air into the hose joint opening

to force out the piston from the caliper body.

• Never try to pry out the piston.• Cover the piston with a rag. Use care sothat the piston does not cause injury as it isexpelled from the cylinder.

Remove the piston seals.

********************************************************

MASTER CYLINDER DISASSEMBLY

NOTE:Before disassembling the front brake mastercylinder, drain all brake fluid from the brakehose, master cylinder, brake caliper and reser-voir tank.

1. Remove:• Upper handlebar cover

2. Remove:• Brake switch• Brake lever• Union bolt

NOTE:Release the brake switch by pushing with ascrew driver into the hole on the lower side of thebrake lever and pull out the brake switch.

3. Remove:• Master cylinder holder• Master cylinder

346004

WARNING

CHAS

6-9

FRONT BRAKE

4. Remove:• Master cylinder dust boot Q• Master cylinder kit W

As required

Every two years

Every four years

Replace only whenbrakes are disassembled

Brake pads

Piston seal,Dust seal

Brake hoses

Brake fluid

347008

347005

347006

INSPECTION AND REPAIRRecommended brake component replacementschedule:

All internal parts should be cleaned in newbrake fluid only. Do not use solvents as theywill cause seals to swell and distort.

1. Inspect:• Caliper piston Q

Scratches/Rust/Wear Replace caliperassembly.

• Caliper body WWear/Scratches/Cracks/Damage Replacecaliper assembly.

Replace the piston seals whenever the caliperis disassembled.

2. Inspect:• Master cylinder

Wear/Scratches Replace the mastercylinder assembly.

• Master cylinder body/DiaphragmCracks/Damage Replace.

• Master cylinder kitScratches/Wear/Damage Replace as a set.

WARNING

WARNING

CHAS

6-10

347002

347001

FRONT BRAKE

3. Check:• Brake hose Q

Cracks/Wear/Damage Replace.

4. Measure:• Brake disc deflection

Out of specification Inspect wheel runout.If wheel runout is good, replace the brake disc(s).

Maximum deflection:0.25 mm (0.01 in)

• Brake disc thicknessOut of specification Replace.

Minimum thickness:3,2 mm (0.12 in)

Bolt (brake disc):23 Nm (2.3 m • kg, 17 ft • lb)LOCTITE®

CALIPER ASSEMBLY

• All internal parts should be cleaned in newbrake fluid only.

• Internal parts should be lubricated withclean brake fluid when installed.

Recommended brake fluid:DOT #3 or DOT #4

• Replace the piston seals whenever a caliperis disassembled.

1. Install:• Piston seals Q• Caliper piston W

Always use new piston seals.

346014

346015

T.R

WARNING

WARNING

CHAS

6-11

346005

FRONT BRAKE

2. Install:• Brake caliper

Bolt (brake caliper):23 Nm (2.3 m • kg, 17 ft • lb)

3. Install:• Caliper body Q

4. Install:• Brake hose W• Copper washers E• Union bolt R

Union bolt:23 Nm (2.3 m • kg, 17 ft • lb)

When installing the brake hose to the caliper,turn the brake pipe against the projection onthe caliper.

• Proper hose routing is essential to insuresafe operation. Refer to “CABLE ROUTING”.

• Always use new copper washers.

MASTER CYLINDER ASSEMBLY

• All internal parts should be cleaned in newbrake fluid only.

• Internal parts should be lubricated withclean brake fluid when installed.

Recommended brake fluid:DOT #3 or DOT #5

T.R

T.R

CAUTION:

WARNING

WARNING

CHAS

6-12

1. Install:• Master cylinder Q

• Tighten the upper bolt first, then the lowerbolt.

Bolt (master cylinder holder):9 Nm (0.9 m • kg, 6.5 ft • lb)

2. Install:• Brake lever 2

NOTE:Apply lithium soap base grease to the brakelever pivot.

3. Install:• Brake hose 3• Copper washers 4• Union bolts 5• Brake switch 6

Union bolt:23 Nm (2.3 m • kg, 17 ft • lb)

• Proper hose routing is essential to insuresafe operation. Refer to “CABLE ROUTING”in CHAPTER 2.

• Always use new copper washers.

FRONT BRAKE

4. Check that the brake hose does not touchother parts (throttle cable, wire harness, etc.)when the handlebar is turned to the left or right.Repair if necessary.

T.R

T.R

CAUTION:

WARNING

CHAS

6-13

340005(a)

LS

A TIRE SIZE: 130/90-10

B DRUM BRAKE WEAR LIMIT:110,5 mm (4.40 in)

C BRAKE LINING WEAR LIMIT:2 mm (0.08 in)

D RIM RUNOUT LIMIT:VERTICAL : 1,0 mm (0.04in)LATERAL : 1,0 mm (0.04in)

12 Nm (1,2 Kg.m ; 8.67 ft.lb)

13 Nm (1,3 Kg.m ; 9.4 ft.lb)

E REPLACE BRAKE LININGSAND SPRINGS AS A SET

REAR WHEEL

REAR WHEEL

Q Rear wheel ass’yW TireE ValveR AxleT NutY O-ring

U Brake shoeI SpringO Brake camshaftP Brake camshaft lever Wear indicator Bolt

q Washerw Nute Washer

105 Nm (10,5 Kg.m ; 76 ft.lb)

CHAS

6-14

REAR WHEEL

REMOVAL1. Remove:• Muffler ass’y

2. Loosen:• Rear axle nut

NOTE:Pull the rear brake to loosen the axle nut.

3. Remove:• Rear wheel

4. Remove:• Brake cable• Brake shoes Q• Plain washer W

INSPECTION1. Check:• Rear wheelRefer to the section “FRONT WHEELINSPECTION”.2.Measure :• Wheel runoutRefer to the section “FRONT WHEELINSPECTION”.

Rim runout limits:Radial : 1.0 mm (0.04 in)Lateral : 1.0 mm (0.04 in)

346006

340007

CHAS

6-15

346007

a

REAR WHEEL

3. Check:• Wheel bearingsRefer to the section “FRONT WHEELINSPECTION”.

4. Check:• Brake lining surface

Glazed spots Eliminate with sandpaper.

NOTE:After sanding the brake lining remove dust par-ticles from the brake shoe with a clean cloth.

5. Measure:• Brake lining thickness

Out of specification Replace

Brake lining thickness:4.0 mm (0.16 in)

Wear limit:2.0 mm (0.08 in)

6. Check:• Brake drum inner surface

Oil/Scratches Repair.

7. Measure:• Brake drum inside diameter @


Brake drum inside diameter:

110 mm ( 4.33 in)Wear limit:

110.5 mm (4.35 in)

ASSEMBLYReverse the “REMOVAL” procedure.Note the following points.

1. Install:• Brake camshaft Q

NOTE:Apply lithium soap base grease onto the brakecamshaft Q and pin W.

After installing the brake camshaft, removethe excess of grease.

346008

a

346009

CAUTION:

340008

CHAS

6-16

REAR WHEEL

2. Install:• Brake shoes Q• Return spring W

NOTE:The arrow mark E must point outwards.

When installing the springs and the brakeshoes, take care not to damage the springs

3. Install:• Wear indicator Q• Camshaft lever W

NOTE:• Align the wear indicator tip Q with the line “A”

as shown.• Align the punch marks E.

Bolt (camshaft lever):10 Nm (1.0 m • kg, 7.23 ft • lb)

4. Install:• Plain washer Q• Brake cable

INSTALLATIONReverse the REMOVAL procedure.Note the following points.

1. Clean:• Rear wheel axle

2. Install:• Rear wheel• Plain washer Q• Nut W

NOTE:Make sure the splines on the wheel hub fit ontothe rear drive axle.

346010

346011

A

346012

346013

T.R

CAUTION:

CHAS

6-17

REAR WHEEL

Nut (rear wheel axle):105 Nm (10.5 m • kg, 76 ft • lb)

3. Install:• Muffler

Bolt (exhaust pipe):9 Nm (0.9 m • kg, 6.5 ft • lb)

Bolt (muffler):26 Nm (2.6 m • kg, 19 ft • lb)

4. Adjust:• Rear brake lever free play.Refer to the section “REAR BRAKE LEVERFREE PLAY ADJUSTMENT” in CHAPTER 3.

T.R

T.R

CHAS

6-18

FRONT FORKQ Steering bracketW BoltE CirclipR Rubber capT CirclipY Spring seatU CirclipI Inner tubeO Spring

FRONT FORK

P Piston Spring Stopperq Washerw Bolte Dust bootr Circlipt Oil sealy Outer fork tube

A FRONT FORK TUBE CAPACITY: 75 cc ( 2.53 oz)

B FRONT FORK OIL GRADE:ISO 6743 / 4-LHV 46

342012(a)

T.R30 Nm (0.3 m.kg)

T.R22.5 Nm (2.25 m.kg)

T.R23 Nm (2,3 m.kg)

CHAS

6-19

342001

354003

FRONT FORK

REMOVAL

Securely support the scooter with a standunder the engine.

1. Place the scooter on an even surface.2. Disconnect:• Speedometer cable3. Remove:• Front wheelRefer to section “FRONT WHEEL” in Chapter 6.4. Remove:• Front fenderRefer to section “COVERS - REMOVAL ANDINSTALLATION” in Chapter 3.5. Remove:• Steering headRefer to section “STEERING HEAD ANDHANDLEBAR” in Chapter 6.6. Remove:• Nut Q• Washer W• Ring nut E

NOTE:• Loosen the ring nut with the ring nut wrench R.

Ring nut wrench:9079Q-02218

• Support the steering shaft to prevent it fromfalling.

7. Remove:• Front fork assembly• Bearing balls

8. Remove:• Circlips

9 Loosen• Bolt W

10. Remove:• Fork leg (complete)

T.R

WARNING

342000(a)

CHAS

6-20

FRONT FORK

DISASSEMBLY1. Remove:• Rubber plug Q• Circlip W• Spring seat E• Spring 4

2. Remove:• Bolt Q• Copper washer

NOTE:To remove the drain bolt Q, use the T-handle Wand the holder E.

T-handle for front fork:90890-01326

Holder:90890-01294

3. Remove:• Inner fork tube Q• Piston W• Spring E• Stopper 4

4. Remove:• Dust boot Q• Circlip W• Oil seal E

342010

342014

342015(a)

342016

CHAS

6-21

FRONT FORK

INSPECTION1. Check:• Inner fork tube and fork components• Outer fork tube

Wear/Scratches/Damage Replace.

Never attempt to straighten a bent fork tubeas this may dangerously weaken the tube.

ASSEMBLYReverse the “DISASSEMBLY” procedure.Note the following points.

NOTE:• When reassembling the front fork, make sure

you use following new parts:• Oil seals• Circlips and retainers

• Make sure that all components are clean be-fore reassembling.

1. Install:• Stopper• Inner fork tube• Spring• Piston

NOTE:Before installing the oil seal, apply lithium soapgrease onto the oil seal lips.

2. Install:• Oil seal• Circlip• Dust boot

WARNING

CHAS

6-22

FRONT FORK

3. Install:• Copper washer• Bolt

NOTE:Tighten the drain bolt Q while holding the pistonwith the T-handle W and holder E.

T-handle for front fork:90890-01326

Holder:90890-01294

4. Fill:• Fork oil

Fork oil type:ISO 6743/4-LHV 46

Amount (per fork tube):75 cc

5. Install:• Spring• Spring seat• Circlip• Rubber plug

INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Install:• Left and right fork tube into the steering crown.

2.Install:• Circlips 1

3. Install:• Pinch bolts 2

Pinch bolt:30 Nm (3.0 m • kg; 21.7 ft • lb)

342010

T.R

342001

CHAS

6-23

STEERING HEAD AND HANDLEBAR

STEERING HEAD AND HANDLEBARQ HandlebarW NutE BoltR GripT Throttle gripY Throttle cableU ScrewI Brake cableO Starter cable

354004(a)

CHAS

6-24


354001

STEERING HEAD ANDHANDLEBARREMOVAL

Securely support the scooter so there is nodanger of it falling over.

1. Place the scooter on an even surface.2. Remove:• Front fender• Inner panels• Upper handlebar coverRefer to section “REMOVAL AND INSTALLATI-ON OF COVERS” in Chapter 3.3. Drain:• Front brake systemRefer to section “FRONT BRAKE” in Chapter 6.4. Remove:• Front brake master cylinderRefer to section “FRONT BRAKE” in Chapter 6.5. Remove:• Front brake caliper mounting bolts6. Remove:• Front wheelRefer to section “FRONT BRAKE” in Chapter 6.7. Remove:• Rear brake cable• Throttle grip8. Disconnect:• Ground wire• All couplers• Wire harness band• Clamp9. Remove:• Nut Q• Bolt• Handlebar10. Remove:• Ring nut• Washer

WARNING

CHAS

6-25

11. Remove:• Upper bearing race Q

Steering head nut wrench:9079Q-02218

• Steering shaft• Bearing balls

INSPECTION1. Check:• Handlebar Q

Bends/Cracks/Damage Replace.

2. Wash the bearing balls in solvent.

3. Check:• Bearing races Q

Pitting/Damage Replace.• Bearing balls

Pitting/Damage Replace.

NOTE:Always replace the bearing balls and the upperand lower bearing races as a set.

Bearing race replacement steps : Drive out the bearing race from the steering

tube by hitting on it in several places. Remove the bearing race on the steering shaft

with a hammer and a chisel Q as shown. Drive in the new bearing races evenly by

hitting on them in several places.

*******************************************************


354005

354006

354007

CHAS

6-26


354003

• Unless installed correctly, the bearing raceswill damage the frame.

• Never hit the bearing races on the ballrace surface.

*********************************************************

4. Check:• Steering shaft

Bend/Damage Replace.

Never attempt to straighten a bent steeringshaft.

ASSEMBLY AND INSTALLATIONReverse the “REMOVAL” and “DISASSEMBLY”procedure.Note the following points.

Proper cable and hose routing is essential toinsure safe scooter operation. Refer to section“CABLE ROUTING” in Chapter 2.

1. Install:• Bearing balls

2. Apply:• Bearing grease (onto upper and lower bearingballs)

3. Install:• Steering shaft• Bearing race (upper) Q


354009

354010

354008

CAUTION:

WARNING

WARNING

CHAS

6-27

354002


Hold the steering shaft until it is securelyattached.

4. Install:• Washer Q• Steering shaft lock nut W

NOTE:Tighten the steering shaft lock nut with the Steer-ing head nut wrench. Set the torque wrench to thering nut wrench so that they form a right angle.


Steering shaft ring nut:27.5 Nm (2.75 m.kg, 19.9 ft.lb)

5. Install:• Handlebar Q• Bolt W (new)• Nut E (new)

NOTE:• Install the handlebar onto the steering shaft

notch.• Install the wire harness, the throttle cable, the

speedometer cable and the rear brake cable.

6. Install:• Throttle grip (complete)• Master cylinder• Brake hose (into the clip)

• Before installing the handlebar, wipe off anytrace of oil from the inserted section of theshaft with solvent.

• Insert the bolt from the left as shown.

Bolt (handlebar):60 Nm (6.0 m.kg, 43.3 ft.lb)

7. Install:• BandRefer to section “CABLE ROUTING” in Chapter 2.

354011

T.R

T.R

CAUTION:

CAUTION:

7ELEC

ELEC

CHAPTER 7.ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS ......................................................................7-1

CIRCUIT DIAGRAM .......................................................................................7-3

IGNITION AND STARTING SYSTEM ............................................................7-5CIRCUIT DIAGRAM .................................................................................7-5IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM ....................7-6TROUBLESHOOTING .............................................................................7-7

CHARGING SYSTEM ..................................................................................7-13CIRCUIT DIAGRAM ...............................................................................7-13TROUBLESHOOTING ...........................................................................7-14

LIGHTING SYSTEM ....................................................................................7-16CIRCUIT DIAGRAM ...............................................................................7-16TROUBLESHOOTING ...........................................................................7-17

SIGNAL SYSTEM ........................................................................................7-21WIRING DIAGRAM ................................................................................7-21TROUBLESHOOTING ...........................................................................7-22

ELEC

7-1

ELECTRICAL COMPONENTSELECTRICAL COMPONENTSQ Wire harnessW Fuel senderE Ignition coilR Starter relayT BatteryY CDI unitU Oil sender

BATTERY:SPECIFIC GRAVITY: 1.280IGNITION COILPrimary coil resistance:

0.32 ~ 0.48 Ω at 20°C (68°F)Secondary coil resistance:

5.68 ~ 8.52 Ω at 20°C (68°F)

ELECTRICAL COMPONENTS

383002

ELEC

7-2


Q Main switchW Rectifier / RegulatorE HornR Flasher relay

Starter motor coil resistance:0.06 - 0.08 Ω at 20°C (68°F)

Brush wear limit:0.9 mm (0.035 in)

Commutator diameter wear limit:14.8 mm (0.582 in)

Commutator mica undercut:1.15 mm (0.045 in)

383001

ELEC

7-3

CIRCUIT DIAGRAM

CIRCUIT DIAGRAM

O

B

B

B

B B B

B

NR

L

BB B B B B B B B

P Gy

Gy

Gy

B

Y

Y

G

GL

L L L

B

B

B

B

GY

Br

GG Y

Br

Dg

DgBrW

Ch

Ch

Br Br

B

B

RR

R

R

WR

BR

Br

W

YR

OFFLOWHI

YR

LW

BW

LOCKOFF

ONCHECK

BW

4

3

5

6

wqt

y

i

uo p [ ]

DH

G

F

SA

K

J

L

r

7

8

9

0 1

2

e

ELEC

7-4

CIRCUIT DIAGRAM

COLOR CODEBBrChDgGGyLOPRSbW

YB/RB/WBr/WBr/YG/BG/YL/WW/RY/BY/R

BlackBrownChocolateDark greenGreenGreyBlueOrangePinkRedSky blueWhite

YellowBlack/RedBlack/WhiteBrown/WhiteBrown/YellowGreen/BlackGreen/YellowBlue/WhiteWhite/RedYellow/BlackYellow/Red

Q Spark plugW Ignition coilE CDI magnetoR CDI unitT Rectifier/regulatorY Starter motorU Starter relayI BatteryO FuseP Main switch Starter switch "LIGHTS" switchq Meter lightw Meter lighte Headlightr Position lightt Tail/Stop light

y Flasher relayu Flasher indicatori "TURN" switcho Rear flasher light (left)p Front flasher light (left)[ Rear flasher light (right)] Front flasher light (right)A Front stop switchS Rear stop switchD HornF Horn switchG Oil level indicatorH Oil level gaugeJ Fuel meterK SenderL High beam indicator

ELEC

7-5

O

B

B

B

B B B

B

NR

L

BB B B B B B B B

P Gy

Gy

Gy

B

Y

Y

G

GL

L L L

B

B

B

B

GY

Br

GG Y

Br

Dg

DgBrW

Ch

Ch

Br Br

B

B

RR

R

R

WR

BR

Br

W

YR

OFFLOWHI

YR

LW

BW

LOCKOFF

ONCHECK

BW

4

3

5

6

wqt

y

i

uo p [ ]

DH

G

F

SA

K

J

L

r

7

8

9

0 1

2

e

IGNITION AND STARTING SYSTEM


Q Spark plugW Ignition coilE CDI Magneto

R CDI unitY Starter motorU Starter Relay

I BatteryO FuseP Main switch

Starter switchA Front brake switchS Rear brake switch

ELEC

7-6

RBBW

LOCKLOCK

ON ON

CHECKCHECK

OFF OFF

Br GyGy

BB

O

BB

BB

BB

M

L/W

G/Y

R

B

BB

BB

W/R

B/W

B/R

Br

R

374001

c

d

d

fe e

e

e

a

b

g

: Current flow in ignition control circuit: Current flow in starter motor control circuit


IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAMQ Spark plugW Ignition coilR CDI unitU Starter MotorI Starter relayO FuseP Battery Starter switch

Main switcht Front brake switchy Rear brake switch

Source coilPickup coilWave-shape shaping circuitCondenserDiodeSCRTo oil level switch

a

b

c

de

fg

ELEC

7-7

OUT OFSPECIFICATIONOR NO SPARK

372000

TROUBLESHOOTING

THE STARTING SYSTEM DOES NOT WORK (NO SPARK OR IRREGULAR SPARKS).

NOTE:• Remove the following parts before proceeding with the troubleshooting:

1) Side covers (left and right)• For accurate troubleshooting use the following special tools:

Ignition checker: Pocket tester:90890-06754 90890-03112

INCORRECT

The spark plug is defective. Replace it oradjust the spark plug gap.

MEETS SPECIFICATION

Ignition system in good condition.


1.Spark plug

• Check the spark plug type.• Check the condition of the spark plug.• Check the spark plug gap.

Refer to “SPARK PLUG INSPECTION” inChapter 3.


Spark plug gap:0.5 ~ 0.7 mm (0.019 ~ 0.028 in)

CORRECT

2.Spark check

• Remove the spark plug cap.• Connect the ignition checker Q.

WSpark plug capESpark

• Check the length of the spark gap.• Start the engine and increase the spark

length until the engine begins to misfire.

Minimum spark gap:6.0 mm (0.24 in)

ELEC

7-8

3.Spark plug cap resistance

• Disconnect the spark plug cap.• Connect the pocket tester (Ω x 1 k) to the

spark plug cap.• Check the resistance of the spark plug cap.

Spark plug cap resistance:5kΩ at 20°C (68°F)

MEETSSPECIFICATION

4.Ignition coil resistance

• Disconnect the ignition coil leads.• Connect the pocket tester (Ω x 1) to the

ignition coil.

Ignition coil :Pocket tester (+) lead OrangePocket tester (-) lead Ground

• Check the primary coil resistance.

Primary coil resistance:0.32 ~ 0.48 Ω at 20°C (68°F)

• Connect the pocket tester (Ω x 1k) to theignition coil.

Pocket tester (+) lead GroundPocket tester (-) lead Spark plug lead

• Check the secondary coil resistance.

Secondary coil resistance:5.68 ~ 8.52 Ω at 20°C (68°F)

MEETSSPECIFICATION

DOES NOT MEETSPECIFICATION

Replace the spark plug cap


Defect. Replace the ignition coil.


372001

372002

372003

ELEC

7-9

5.Pickup coil resistance

• Disconnect the pickup coil coupler.• Connect the pocket tester (Ω x 100) to the

pickup coil.

Pocket tester (+) lead Q White / RedPocket tester (-) lead W Ground

• Check the pickup coil resistance.

Pickup coil resistance:400 ~ 600 Ω at 20°C (68°F)

MEETSSPECIFICATION

6.Source coil resistance

• Disconnect the source coil coupler from thewire harness.

• Connect the pocket tester (Ω x 100) to thesource coil.

Pocket tester (+) lead Q Black / RedPocket tester (-) lead W Ground

• Check the source coil resistance.

Source coil resistance:640 ~ 960 Ω at 20°C (68°F)

MEETSSPECIFICATION

7.Connections

• Check all connections in the ignition sys-tem.Refer to “WIRING DIAGRAM”.

GOODCONNECTIONS

Replace the CDI unit.



Pickup coil defect Replace.


Source coil defect Replace.

POOR CONNECTIONS

Repair.

372004

Y/R wx W/R B/R

CDIMAGNETO

372005

Y/R wx W/R B/R

CDIMAGNETO

ELEC

7-10

1.Fuse

• Remove the fuse.• Connect the pocket tester (Ω x 1) to the fuse.• Check the fuse for continuity.

CONTINUITY

2.Battery

• Check the condition of the battery.Refer to “BATTERY INSPECTION” inCHAPTER 3.

Open circuit voltage:12.8 V or more at à 20°C (68°F)

MEETSSPECIFICATION

3.Starter motor

• Use a jumper lead E * to connect the (+) Qterminal of the battery to the starter motorterminal W.

• Check the starter motor operation.

DOES NOT WORK

Starter defect Repair or replace.

TROUBLESHOOTING

STARTER MOTOR DOES NOT WORK


1) Side covers (left and right)2) Footrest boards3) Front panel4) Handlebar cover

• For accurate troubleshooting use the following special tools:

Pocket tester:90890-03112


WORKS

NO CONTINUITY

Defect Replace fuse.


• Clean battery terminals.• Charge or replace the battery.

*

• If the gauge of the jumper lead is smallerthan that of the battery leads, the jumperlead might melt or burn.

• This test could cause sparks. Neverperform it near a gas source or nearflammable products.

372006

M + -

CAUTION:

ELEC

7-11

RBBWBW

LOCK

ON

CHECK

OFF

BGyGyBrBrR

BrBr GyGy

R B/WB/W

372008

4. Starter relay

• Disconnect the Blue/White lead from thewire harness.

• Connect the (-) Q terminal of the battery tothe Blue/White lead.


WORKS

5. Main switch

• Disconnect the main switch from the wireharness.

• Check for continuity between Red Q andBrown W.

MEETSSPECIFICATION

6.Starter switch

• Disconnect the right handlebar switch cou-pler from the wire harness.

• Check for continuity between Blue / WhiteQ and Black W.


DOES NOT WORK

Starter relay defect Replace.


Main switch defect Replace.

372007

M + -

L/W

ELEC

7-12

372009A


MEETSSPECIFICATION

7.Connections

Check all connections in the starter system.Refer to “WIRING DIAGRAM”.


Starter switch defect Replace right handle-bar switch.

POOR CONNECTIONS

Repair.

OFF

ON

LW B

B

LRYRLW

YB L

372009B

ELEC

7-13

O

B

B

B

B B B

B

NR

L

BB B B B B B B B

P Gy

Gy

Gy

B

Y

Y

G

GL

L L L

B

B

B

B

GY

Br

GG Y

Br

Dg

DgBrW

Ch

Ch

Br Br

B

B

RR

R

R

WR

BR

Br

W

YR

OFFLOWHI

YR

LW

BW

LOCKOFF

ONCHECK

BW

4

3

5

6

wqt

y

i

uo p [ ]

DH

G

F

SA

K

J

L

r

7

8

9

0 1

2

e

CHARGING SYSTEM

CHARGING SYSTEMWIRING DIAGRAM

E CDI magnetoT Rectifier / regulator

I BatteryO Fuse

ELEC

7-14

TROUBLESHOOTING

THE BATTERY IS NOT CHARGED


1) Side covers (left and right) and foot rest board.• For accurate troubleshooting use the following special tools:

Inductive tachometer: Pocket tester:90890-03113 90890-03112

367001

1.Fuse (Main)


CONTINUITY

2.Battery

• Check the condition of the battery. Refer to “BATTERY INSPECTION” in CHAPTER 3.

Open circuit voltage:12,8 V or more at 20°C (68°F)

3.Charging voltage

• Connect the engine tachometer to the sparkplug lead.

• Connect the pocket tester (DC20V) to thebattery terminals.

Pocket tester (+) lead Battery (+) terminalPocket tester (-) lead Battery (-) terminal

• Start the engine and accelerate to about5000 rpm.

• Check the charging voltage.

Charging voltage :14 ~ 15 V at 5.000 tr/mn

CHARGING SYSTEM

NO CONTINUITY

Fuse defect Replace.



MEETS SPECIFICATION

Charging circuit is OK.

372010

- +

NOTE:Use a fully charged battery.

OUT OFSPECIFICATION

ELEC

7-15

4.Charging coil resistance

• Disconnect the CDI magneto coupler fromthe wire harness.

• Connect the pocket tester (Ω x 1) to thecharging coil.

• Check the charging coil resistance

Tester (+) lead White QTester (–) lead Ground W

Charging coil resistance:0.48 ~ 0.72 Ω at 20°C (68°F)

MEETSSPECIFICATION

5.Connections

Check all connections in the charging system.Refer to “WIRING DIAGRAM”.

MEETSSPECIFICATION

Replace the rectifier/regulator.

CHARGING SYSTEM

OUT OF SPECIFICATION

Charging coil defect Replace.

POOR CONNECTIONS

Repair.

372015

Y/R wx W/R B/R

CDIMAGNETO

ELEC

7-16

O

B

B

B

B B B

B

NR

L

BB B B B B B B B

P Gy

Gy

Gy

B

Y

Y

G

GL

L L L

B

B

B

B

GY

Br

GG Y

Br

Dg

DgBrW

Ch

Ch

Br Br

B

B

RR

R

R

WR

BR

Br

W

YR

OFFLOWHI

YR

LW

BW

LOCKOFF

ONCHECK

BW

4

3

5

6

wqt

y

i

uo p [ ]

DH

G

F

SA

K

J

L

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7

8

9

0 1

2

e

LIGHTING SYSTEMCIRCUIT DIAGRAM

LIGHTING SYSTEM

E CDI magneto “LIGHTS” switch

q Meter lightw Meter light

e Headlightr Position light

t Tail/Stop lightL “HIGH BEAM“ indicator light

ELEC

7-17

372009A

TROUBLESHOOTING

THE AUXILIARY LIGHT, HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT, TAILLIGHT OR METER LIGHT DO NOT WORK

NOTE:Remove the following parts before proceeding with the troubleshooting:

• Side covers and footrest board• Handlebar covers

For accurate troubleshooting use the following special tools:


CONTINUITY

1. “LIGHTS” switch• Disconnect the right handlebar switch cou-

pler from the wire harness.• Set the switch to “ ” .• Check for continuity between

Yellow / Red Q and Blue W

Yellow / Red Q and Green 3

• Then set the switch to “ ”.• Check for continuity between:

Yellow / Red Q and Blue WYellow / Red Q and Yellow 4

NO CONTINUITY

"Light" switch defect Replace.

LIGHTING SYSTEM

372013(a)

OFFOFF

P0 P0

YRYR

ON ON

G

BYL

YRYR LWLW

L G Y

ELEC

7-18

MEETSSPECIFICATION

2. Lighting coil resistance

• Disconnect the lighting coil coupler from thewire harness.

• Connect the pocket tester (Ω x 1) to thelighting coil.

• Check the lighting coil resistance

Tester (+) lead Yellow / Red QTester (-) lead Ground W

Lighting coil resistance:0.32 ~ 0.48Ω at 20°C (68°F)

Lighting coil defect Replace.

POOR CONNECTIONS

Repair.

Circuit is in good condition.

LIGHTING SYSTEM

MEETSSPECIFICATION

3. Connections

• Check all connections in the lighting system.Refer to “WIRING DIAGRAM”.


372036

Y/R wx W/R B/R

CDIMAGNETO

ELEC

7-19

372017(a)

B BY Y

MEETSSPECIFICATION

LIGHTING SYSTEM

2. The meter light does not work.


LIGHTING SYSTEM INSPECTION1. Headlight and headlight indicator do not work.

1. Bulb and socket

• Check the bulb and socket for continuity.

CONTINUITY

2. Voltage

• Connect the pocket tester (AC20V) to theheadlight coupler.

Headlight:• “LO”:Pocket tester (+) lead Green QPocket tester (-) lead Black E• “HI”:Pocket tester (+) lead Yellow WPocket tester (-) lead Black E• Headlight indicator:Pocket tester (+) lead Yellow RPocket tester (-) lead Black T

• Set the main switch to “ON”.• Start the engine.• Switch from “HI” to “LO” and back.• Check the voltage (12V) between the head-

light coupler leads.

NO CONTINUITY

Replace bulb or socket.

1. Bulb and socket


CONTINUITY


There is a defect in the wire harness betweenthe main switch and the headlight couplerand/or between the main switch and theheadlight indicator coupler Repair.

NO CONTINUITY


ELEC

7-20

372037(a)

Br Br

Gy Gy

Dg Dg

Ch ChG G

L L

B BY Y

3. The taillight does not work.

1. Bulb and socket


LIGHTING SYSTEM

2. Voltage

• Connect the pocket tester (AC20V) to themeter light coupler.

Pocket tester (+) lead Blue QPocket tester (-) lead Black W

• Set the main switch to “ON”.• Start the engine.• Check the voltage (12V) between the head-

light coupler leads “Blue” and “Black”.

MEETSSPECIFICATION

2. Voltage

• Connect the pocket tester (AC20V) to thetaillight coupler.


• Set the main switch to “ON”.• Start the engine.• Check the voltage (12V) between the head-



There is a defect in the wire harness betweenthe main switch and the meter light coupler Repair.

NO CONTINUITY



There is a defect in the wire harness betweenthe main switch and the taillight coupler Repair.


CONTINUITY

MEETSSPECIFICATION


372019(a)

Dg

Dg

DgDg

B

B

B

B --

B

GYGY

Ch

Ch

L

LLL

B

GY GY

Ch Ch

110

11025

0

250

250

ELEC

7-21

O

B

B

B

B B B

B

NR

L

BB B B B B B B B

P Gy

Gy

Gy

B

Y

Y

G

GL

L L L

B

B

B

B

GY

Br

GG Y

Br

Dg

DgBrW

Ch

Ch

Br Br

B

B

RR

R

R

WR

BR

Br

W

YR

OFFLOWHI

YR

LW

BW

LOCKOFF

ONCHECK

BW

4

3

5

6

wqt

y

i

uo p [ ]

DH

G

F

SA

K

J

L

r

7

8

9

0 1

2

e

SIGNAL SYSTEMWIRING DIAGRAM

SIGNAL SYSTEM

I BatteryO Fuse0 Main switcht Tail / Stop lighty Flasher relay

u Flasher indicatori "TURN" switcho Rear flasher light (left)p Front flasher light (left)[ Rear flasher light (right)

] Front flasher light (right)A Front stop switchS Rear stop switchD HornF "HORN" switch

G Oil level indicatorH Oil level gaugeJ Fuel meterK Sender

ELEC

7-22

MEETSSPECIFICATION

MEETSSPECIFICATION

RBBW

LOCKLOCK

ON ON

CHECKCHECK

OFF OFF

BGyGyBrBrR

Br Gy

R B/W

372040



2. Battery


Battery voltage:12.8 V or more at 20°C (68°F)

SIGNAL SYSTEM

TROUBLESHOOTING

FLASHER LIGHTS, BRAKE LIGHT, “OIL” WARNING LIGHT DO NOT WORKHORN DOES NOT SOUND


• Side covers and footrest board• Handlebar cover


1. Fuse

• Remove the fuse.• Connect the pocket tester (Ω x 1) to the fuse.• Check the fuse for continuity.Refer to “FUSE INSPECTION” in Chapter 3.

CONTINUITY

3. Main switch


• Turn the main switch to “”.• Check for continuity between:

Red Q and Grey E

• Turn the main switch to “ON”.• Check for continuity between:

Red Q and Brown WDOES NOT MEET SPECIFICATION


DOES NOT MEET SPECIFICATION


NO CONTINUITY

ELEC

7-23

2. Voltage

• Connect the pocket tester (DC20V) to thehorn lead.

Pocket tester (+) lead Brown QPocket tester (-) lead Ground W

• Turn the main switch to ON.• Check for voltage (12V) between “Brown”

and the ground.

SIGNAL SYSTEM

4. Connections

• Check all connections in the signal system.Refer to “WIRING DIAGRAM”.

Check the condition of each circuit of thesignal system.

Refer to the section “SIGNAL SYSTEMCHECK”.

SIGNAL SYSTEM CHECK1. Horn does not sound

1. “HORN” switch

• Disconnect the handlebar switch (left) fromthe wire harness.

• Check for continuity between:

Black Q and Pink W.

NO CONTINUITY

Horn switch is defect Replace.

POOR CONNECTIONS

Repair.GOODCONNECTIONS

CONTINUITY

372029(a)

PB

ONON

OFFOFF

BrWDg

-B

Ch P

ELEC

7-24

HORN DOESNOT SOUND

MEETSSPECIFICATION

Defect in the wire harness between the mainswitch and the horn Repair.


3. Horn

• Disconnect the “Pink” lead at the horn terminal.• Ground the horn terminal Q with a jumper

lead.• Set the main switch to ON.

4. Voltage

• Connect the pocket tester (DC20V) to the“Pink” lead.

Pocket tester (+) lead Pink QPocket tester (-) lead Ground

• Turn the main switch to ON.• Press the “HORN” switch.• Check the voltage (12V) between “Pink” andground.

MEETSSPECIFICATION

Horn is defect Replace.


SIGNAL SYSTEM

HORN SOUNDS

Horn in good condition.

Adjust the horn.

372025

Br P

372026

Br

372027

Br P

ELEC

7-25

SIGNAL SYSTEM

2. The brake light does not work.

1. Bulb and socket


2. Brake switch

• Disconnect the brake switch leads from thewire harness.


Brown Q and Green / Yellow W

3. Voltage

• Connect the pocket tester (DC20V) to thesocket.

Pocket tester (+) lead Green / Yellow QPocket tester (-) lead Black W

• Turn the main switch to “ON”.• Pull the brake lever.• Check the voltage (12V) between “ Green /

Yellow” Q and “Black” W.

There is a defect in the wire harness betweenthe main switch and the brake light socket Repair.


CONTINUITY

CONTINUITY


MEETSSPECIFICATION

NO CONTINUITY


Brake switch is defect Replace.

NO CONTINUITY

Br G/YON (Pull in)OFF (Free)

Br G/Y

372030

372019(a)

Dg

Dg

DgDg

B

B

B

B --

B

GYGY

Ch

Ch

L

LLL

B

GY GY

Ch Ch

110

110

250

250

250

ELEC

7-26

3. Flasher does not work

1. Bulb and socket


2. “TURN” switch


• Check for continuity between :

Left side : Brown / White Q and Chocolate WRight side : Brown / White Q and Dark green E

3. Voltage

• Connect the pocket tester (DC20V) to theflasher relay.

Pocket tester (+) lead Brown QPocket tester (-) lead Ground

• Turn the main switch to ON.• Check the voltage (12V) between the “Brown”

lead and the ground.

SIGNAL SYSTEM

NO CONTINUITY

NO CONTINUITY


Left handlebar switch is defect Replace.

CONTINUITY

CONTINUITY

MEETSSPECIFICATION


Defect in the wire harness between the mainswitch and the flasher relay Repair.

-

-

Br/WBr/W

BrBr

372033

372032(a)

BrW Dg

LNR

Ch

BrWDg

-B

Ch P

ELEC

7-27MEETSSPECIFICATION

4. Voltage


Pocket tester (+) lead Brown / White QPocket tester (-) lead Ground

• Turn the main switch to “ON”.• Check the voltage (12V) between Brown /

White and the ground.

5. Voltage

• Connect the pocket tester (DC20V) to theflasher connector.

Left flasher bulb:Pocket tester (+) lead Chocolate QPocket tester (-) lead Ground

Right flasher bulb:Pocket tester (+) lead Dark green WPocket tester (-) lead Ground

• Turn the main switch to “ON”.• Set the “TURN” switch to “L”, then to “R”.• Check the voltage (12V) between “Choco-

late” and the ground, then “Dark green “ andthe ground.



SIGNAL SYSTEM

MEETSSPECIFICATION

Flasher relay defect Replace.

Defect in the wire harness between the mainswitch and the flasher bulb socket Re-pair.

-

-

Br/WBr/W

BrBr

372034

372038(a)

Dg

Dg

DgDg

B

B

B

B --

B

GYGY

Ch

Ch

L

LLL

B

GY GY

Ch Ch

110

110

250

250

250

ELEC

7-28

SIGNAL SYSTEM

This circuit is in good condition.

2. Oil level switch

• Disconnect the oil level switch from the oiltank.

• Connect the pocket tester (Ω x 1) to the oillevel switch.

Pocket tester (+) lead Terminal QPocket tester (-) lead Terminal Q

• Check the switch for continuity.

Float Good Badposition condition condition

HIGH X O X O

LOW O X X O

O : Continuity X : No continuity

NO CONTINUITY


Replace oil level switch is defect.


4. The “OIL” indicator light does not work.

1. Bulb and socket


CONTINUITY

MEETSSPECIFICATION

372035

A

B

ELEC

7-29

372039(a)

Br

Gy

Dg

ChG

L

SIGNAL SYSTEM

3. Voltage

• Connect the pocket tester (DC20V) to thebulb socket connector.

Pocket tester (+) lead Grey QPocket tester (-) lead Ground

• Turn the main switch to ON.• Check the voltage (12V) between “Grey” and

the ground.


MEETSPECIFICATION


4. Connections


8TRBLSHTG

TRBLSHTG

CHAPTER 8.TROUBLESHOOTING

STARTING FAILURE/ HARD STARTING .....................................................8-1FUEL SYSTEM ........................................................................................8-1ELECTRICAL SYSTEM ...........................................................................8-1COMPRESSION SYSTEM ......................................................................8-2

POOR IDLE SPEED PERFORMANCE .........................................................8-2POOR IDLE SPEED PERFORMANCE ...................................................8-2

POOR MEDIUM AND HIGH SPEED PERFORMANCE ................................8-3FUEL SYSTEM ........................................................................................8-3ELECTRICAL SYSTEM ...........................................................................8-3COMPRESSION SYSTEM ......................................................................8-3

FAULTY AUTOMATIC (V-BELT TYPE) .........................................................8-3MOTORCYCLE DOES NOT MOVE WHILE ENGINE IS OPERATING...8-3CLUTCH -OUT FAILURE .........................................................................8-4POOR STANDING START (LOW CLIMBING ABILITY) ..........................8-4POOR ACCELERATION (POOR HIGH SPEED) ....................................8-4

OVER HEATING ............................................................................................8-4OVER HEATING ......................................................................................8-4

IMPROPER KICKING ....................................................................................8-5SLIPPING .................................................................................................8-5HARD KICKING .......................................................................................8-5KICK CRANK NOT RETURNING ............................................................8-5

FAULTY BRAKE ............................................................................................8-5POOR BRAKING EFFECT ......................................................................8-5

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION ...........8-6OIL LEAKAGE ..........................................................................................8-6MALFUNCTION .......................................................................................8-6

INSTABLE HANDLING ..................................................................................8-6INSTABLE HANDLING ............................................................................8-6

FAULTY SIGNAL AND LIGHTING SYSTEM .................................................8-7

TRBLSHTG

8-1

STARTING FAILURE/HARD STARTING

TROUBLESHOOTING

NOTE:The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection,adjustment and replacement of parts.

STARTING FAILURE/HARD STARTINGFUEL SYSTEMFuel tank Carburetor• Empty • Deteriorated fuel, fuel containing water or• Clogged fuel filter foreign material• Deteriorated fuel or fuel containing water or • Clogged pilot jet

foreign material • Clogged pilot air passage• Clogged fuel tank cap • Sucked-in airFuel cock • Deformed float• Clogged fuel hose • Groove-worn needle valve• Clogged vacuum • Improperly sealed valve seat• Faulty diaphragm • Improperly adjusted fuel levelAir cleaner • Improperly set pilot jet• Clogged air filter • Clogged starter jet

• Starter plunger malfunction• Improperly adjusted pilot air screw

ELECTRICAL SYSTEMSpark plug CDI unit system• Improper plug gap • Faulty CDI unit• Worn electrodes • Faulty source coil• Wire between terminals broken • Faulty pick-up coil• Improper heat range Switches and wiring• Faulty spark plug cap • Faulty main switchIgnition coil • Broken or shorted wiring• Broken or shorted primary/secondary coil • Faulty brake switch (front or rear)• Faulty spark plug lead• Broken bodyStarter motor• Faulty starter motor• Faulty starter relay

TRBLSHTG

8-2

STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE

COMPRESSION SYSTEMCylinder and cylinder head Crankcase and crankshaft• Loose spark plug • Improperly seated crankcase• Loose cylinder head or cylinder • Improperly sealed crankcase• Broken cylinder head gasket (damaged oil seal)• Broken cylinder gasket • Seized crankshaft• Worn, damaged or seized cylinder Reed valvePiston and piston rings • Deformed reed valve stopper• Improperly installed piston ring • Improperly seated reed valve• Worn, fatigued or broken piston ring • Loose intake manifold• Seized piston ring • Broken gasket• Seized or damaged piston • Broken reed valve

POOR IDLE SPEED PERFORMANCEPOOR IDLE SPEED PERFORMANCECarburetor• Improperly returned starter plunger• Clogged or loose pilot jet• Clogged pilot air jet• Improperly adjusted idle speed ( throttle stop screw)• Improper throttle cable play• Flooded carburetor

TRBLSHTG

8-3

POOR MEDIUM AND HIGH SPEED PERFORMANCE/FAULTY AUTOMATIC

POOR MEDIUM AND HIGH SPEED PERFORMANCEFUEL SYSTEMFuel tank Carburetor• Clogged fuel filter • Deteriorated fuel, fuel containing water or• Deteriorated fuel or fuel containing water or foreign material

foreign material • Sucked-in air• Clogged fuel tank cap • Deformed floatFuel cock • Groove-worn needle valve• Clogged fuel hose • Improperly sealed valve seat• Clogged vacuum hose • Improperly set clip position of jet needle• Faulty diaphragm • Improperly adjusted fuel levelAir cleaner • Clogged or loose main jet• Clogged air cleaner • Clogged or loose main nozzle

• Clogged main air passageELECTRICAL SYSTEMSpark plug CDI unit system• Improper plug gap • Faulty CDI unit• Worn electrodes • Faulty source coil• Wire between terminals broken • Faulty pick-up coil• Improper heat range• Faulty spark plug cap

COMPRESSION SYSTEMCylinder and cylinder head Crankcase and crankshaft• Loose spark plug • Improperly seated crankcase• Loose cylinder head or cylinder • Improperly sealed crankcase• Broken cylinder head gasket (damaged oil seal)• Broken cylinder gasket • Seized crankshaft• Worn, damaged or seized cylinderPiston and piston rings Reed valve• Improperly installed piston ring • Deformed reed valve stopper• Worn, fatigued or broken piston ring • Improperly adjusted reed valve stopper height• Seized piston ring • Improperly sealing reed valve• Seized or damaged piston • Loose intake manifold

• Broken gasket• Broken reed valve

FAULTY AUTOMATIC (V-BELT TYPE)MOTORCYCLE DOES NOT MOVE WHILE ENGINE IS OPERATING.V-belt Secondary sheave• Worn, damaged or slippery v-belt • Broken compression springPrimary sheave • Pealed lining from clutch shoe• Worn or damaged cam plate • Worn spline of clutch housing• Worn or damaged slider bushing

TRBLSHTG

8-4

FAULTY AUTOMATIC/OVER HEATING

OVER HEATINGOVER HEATINGIgnition system Engine oil• Improper spark plug gap • Improper engine oil quality (high viscosity)• Improper spark plug heat range • Low engine oil quality• Faulty ignitor unit

BrakesFuel system • Dragging brake• Improper carburetor setting• Improper fuel level adjustment Cooling fan• Clogged air cleaner element • Damaged cooling fan• Lean mixture (Air in the autolube pump) • Damaged air shrouds

Compression system• Heavy carbon deposit build-up

CLUTCH-OUT FAILUREPrimary sheave Secondary sheave• Seized primary sliding sheave and collar • Broken or fatigued clutch shoe spring

POOR STANDING START (LOW CLIMBING ABILITY)V-belt Secondary sheave• Worn, damaged or slippery v-belt • Fatigued compression springPrimary sheave • Improper operation of secondary sliding sheave• Worn or improper operation of weight

POOR ACCELERATION (POOR HIGH SPEED)V-belt• Worn or greasy V-beltSecondary sheave• Worn or greasy clutch shoe• Improper operation of secondary sliding sheave

TRBLSHTG

8-5

IMPROPER KICKING/FAULTY BRAKE

IMPROPER KICKINGSLIPPINGKick axle assembly Transmission oil• Low tension of kick clip • Improper quality (low viscosity)• Worn kick axle • Deterioration• Worn or damaged kick gear• Damaged kick clip• Kick clip coming off• Damaged kick clip stopper

HARD KICKINGKick axle assembly Crankcase and crankshaft• High tension of kick clip • Improperly seated crankcase• Seized kick gear • Improperly seated crankshaft

• Damaged or seized crankshaftCylinder, piston and piston ring • Damaged or seized crankshaft bearing• Damaged or seized cylinder• Damaged or seized piston• Damaged or seized piston ring

KICK CRANK NOT RETURNINGKick axle assembly• Damaged kick return spring• Kick return spring coming off• Kick clip coming off• Damaged kick return spring stopper

FAULTY BRAKEPOOR BRAKING EFFECTFront disc brake Rear drum brake• Worn brake pads • Worn brake shoe• Worn disc • Worn or rusty brake drum• Air in brake fluid • Improperly adjuster brake play• Leaking brake fluid • Improper brake cam lever• Wrong brake fluid • Improper brake shoe position• Seized main cylinder piston • Fatigue/damaged return spring• Faulty caliper seal kit • Oily or greasy brake shoe• Loose union bolt • Oily or greasy brake drum• Broken brake hose • Broken brake cable• Oily or greasy disc/brake pads• Improper brake fluid level• Excessive free play (brake lever)

TRBLSHTG

8-6

FRONT FORK OIL LEAKAGE AND FRONT FORKMALFUNCTION/

INSTABLE HANDLING

INSTABLE HANDLINGINSTABLE HANDLINGHandlebar Wheels• Improperly installed or bent • Damaged bearing

• Bent or loose wheel axle• Excessive wheel run-out

Steering Frame• Improperly installed steering column • Twisted

(Improperly tightened ring nut) • Damaged head pipe• Bent steering column • Improperly installed bearing race• Damaged ball bearing or bearing race

Front forks Engine bracket• Broken damper spring • Bent or damaged• Bent or deformed suspension arm and pivots• Oil level

Tires Rear shock absorber• Incorrect tire pressure • Improper adjustment• Uneven tire pressures on both sides • Fatigued spring• Unevenly worn tires • Oil leakage

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTIONOIL LEAKAGE MALFUNCTION• Bent, damaged or rusty inner tube • Bent, deformed or damaged inner tube• Damaged or cracked outer tube • Bent or deformed outer tube• Damaged oil seal lip • Damaged fork spring• Improperly installed oil seal • Worn or damaged slide metal• Improper oil level (too much) • Bent or damaged damper rod• Loose damper rod holding bolt • Improper oil viscosity• Broken cap bolt O-ring • Improper oil level• Loose drain bolt or damaged drain bolt gasket

TRBLSHTG

8-7

FAULTY SIGNAL AND LIGHTING SYSTEM

Flasher winks slower Horn is inoperative• Faulty flasher relay • Faulty battery• Insufficient battery capacity (nearly discharged) • Faulty fuse• Improper bulb • Faulty main and/or horn switch• Faulty main and/or flasher switch • Improperly adjusted horn

• Faulty horn• Broken wire harness

Flasher winks quicker• Improper bulb• Faulty flasher relay

FAULTY SIGNAL AND LIGHTING SYSTEMHeadlight dark Flasher does not light• Improper bulb • Improperly grounded• Too many electric accessories • Discharged battery• Hard charging (broken charging coil) • Faulty flasher switch• Incorrect connection • Faulty flasher relay• Improperly grounded • Broken wire harness• Poor contacts (main or light switch) • Loosely connected coupler• Bulb life expired (high internal resistance) • Bulb burnt out

• Faulty fuse

Bulb burnt out Flasher keeps on• Improper bulb • Faulty flasher relay• Improperly grounded • Insufficient battery capacity• Faulty main and/or light switch (nearly discharged)• Bulb life expired

CW50RS WIRING DIAGRAM

COLORS CODEB Black L Blue Y Yellow G/Y Green/YellowBr Brown O Orange B/R Black/Red L/W Blue/WhiteCh Chocolate P Pink B/W Black/White W/R White/RedDg Dark green R red Br/W Brown/White Y/R Yellow/WhiteG Green Sb Sky blue Br/Y Brown/Yellow Y/R Yellow/RedGy Grey W White G/B Green/Black

Q Handlebar switch (right)W "START" switchE "LIGHT" switchR Main switchT Ignition coilY Spark plugU Rectifier / regulatorI Fuel lever senderO Oil level gaugeP Rear flasher light (right) Tail /Stop light Rear flasher light (left)q Starter motorw Starter switche Batteryr Fuset CDI unity CDI magnetou Horni Handle switch (left)o "TURN" switchp "HORN" switch[ Flasher relay] Front flasher light (left)A Head lightS Meter lightD Meter lightF Fuel meterG Flasher indicatorH Oil caution indicatorJ "HIGH BEAM" indicator lightK Position lightL Front flasher light (right): Rear stop switcha Front stop switch

Br

Br

BrBr

Br

Br BrW

BrW

Br

Br

GY

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Gy Gy

Dg Dg Dg

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Ch

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Ch

B B BB

B

BB

B

B

B

B

B

Y

B

Ch Ch Ch ChB B B

G

GG

B BY Y

Y

G

G

L

Y

L

Y

Y

Y

Y

G

G

G

G

B

B

B

B

B

B

B

B

B

B

Br GyDg

DgDgDg

B

B

B

B --

B

BB

BWOr

Or

Or

B

B

B

BR

BR

BR

WRWR

WR

YR

YR

YR

W

W

W

BrP

BrW

BrW

BrW

BrW

BrW

Dg

Dg

Dg

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Dg

B

B-

-B

B

B

ONLNR

OFF

Ch

Ch

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Ch

Ch

P

P

P

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P

BR

RR

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LW

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RR

GYGY

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LLL

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BGY GY GY

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B

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YR

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W

W

R

R

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Gy

Gy

Gy

Br

Br

Br

BrBW

BW

BW

Or B

B

OFFOFF

LOCK

CHECKON

LOWHI

OFFON

L

L

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LW

LW

LW

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YR

YR

LYR

L

L

L L

GY

GY

Br

*

*

(BLACK)

(GREEN)

187.8

110

110

250

250

250

12V 4AH

1

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56

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8 9

0

qwe

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]

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CW50RS5FX-ME2

'00

SUPPLEMENTARYSERVICE MANUAL

CW50RS ('00)SUPPLEMENTARYSERVICE MANUAL

© 1999 by MBK INDUSTRIE1st Edition, September 1999

All rights reserved. Anyreprinting or unauthorized use

without the writtenpermission of MBK INDUSTRIE

is expressly prohibited.

FOREWORD

This supplementary service manual has been prepared to introduce new service and data for theCW50RS ('00). For complete service information procedures it is necessary to use this supplementaryservice manual together with the following manual.

CW50RS ('99) SERVICE MANUAL : 5FX-ME1

CAUTION:

WARNING

NOTICE

This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealersand their qualified mechanics. It 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 andMBK scooters have a basic understanding of the mechanical concepts and procedures inherent inscooter repair technology. Without such knowledge, attempted repairs or service to this model mayrender it unfit to use and/or unsafe.

MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications andsignificant changes in specifications or procedures will be forwarded to all Authorized YAMAHA andMBK dealers and will, where applicable, appear in future editions of this manual.

DOCUMENTATION TECHNIQUEMBK INDUSTRIE

PARTICULARY IMPORTANT INFORMATIONThis material is distinguished by the following notation :

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury ordeath to the scooter operator, a bystander, or a person inspecting orrepairing the scooter.

A CAUTION indicates special precautions that must be taken to avoiddamage to the scooter.

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

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUALThis manual consists of chapters for the main categories of subjects. (See «illustrated symbols).1st title 1 This is a chapter with its symbol on the upper right of each page.2nd title 2 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 3 This is a final title.

MANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informa-tion has been compiled to provide the mechanic with an easy to read, handy reference that containscomprehensive explanations of all disassembly, repair, assembly, and inspections.A set of particulary important procedure 4 is placed between a line of asterisks " * " with each steppreceded by " • ".

IMPORTANT FEATURES• Data and a special tools are framed in a box preceded by a relevant symbol 5.• An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data for analignement mark 7, the others being indicated by an alphabetical letter in a box 8.• A condition of a faulty component will precede an arrow symbol and the course of action requiredthe symbol 9.

EXPLODED DIAGRAMEach chapter provides exploded diagrams are before each disassembly section for ease in identifyingcorrect disassembly and assembly procedures.

ILLUSTRATED SYMBOLS(REFER TO THE ILLUSTRATION)

Illustrated symbols Q to W are designed asthumb tabs to indicate the chapter’s number andcontent.

Q General informationW SpecificationsE Periodic inspection and adjustmentR EngineT CarburetionY ChassisU ElectricalI Troubleshooting

Illustrated symbols O to e are used to identifythe specifications appearing in the text.

O Filling fluidP Lubricant Special tool Tighteningq Wear limit, clearancew Engine speede Ω, V, A

Illustrated symbols r to [ in the explodeddiagram indicate grade of lubricant and locationof lubrication point.

r Apply engine oilt Apply gear oily Apply molybdenum disulfide oilu Apply wheel bearing greasei Apply lightweight lithium-soap base

greaseo Apply molybdenum disulfide greasep Apply locking agent (THREADLOCK ®)[ Use new one

INSPADJ

TRBLSHTG

GENINFO

ENG

CHASCARB

ELEC

SPEC

T.R

Q W

RE

T Y

U I

O P

q w

e

r

u

p [

t y

i o

CONTENTS

ELECTRICAL COMPONENTS ......................................................................... 1

CIRCUIT DIAGRAM .......................................................................................... 3

IGNITION AND STARTING SYSTEM............................................................... 5CIRCUIT DIAGRAM .................................................................................... 5IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM ....................... 6TROUBLESHOOTING ................................................................................ 7

CHARGING SYSTEM ..................................................................................... 13CIRCUIT DIAGRAM .................................................................................. 13TROUBLESHOOTING .............................................................................. 14

LIGHTING SYSTEM ....................................................................................... 16CIRCUIT DIAGRAM .................................................................................. 16TROUBLESHOOTING .............................................................................. 17

SIGNAL SYSTEM ........................................................................................... 21WIRING DIAGRAM ................................................................................... 21TROUBLESHOOTING .............................................................................. 22

ELEC

-1-

ELECTRICAL COMPONENTSELECTRICAL COMPONENTSQ Wire harnessW Fuel senderE Ignition coilR Starter relayT BatteryY CDI unitU Oil sender

BATTERY:SPECIFIC GRAVITY: 1.280IGNITION COILPrimary coil resistance:

0.32 ~ 0.48 Ω at 20°C (68°F)Secondary coil resistance:

5.68 ~ 8.52 Ω at 20°C (68°F)


383002

ELEC

-2-


Q Main switchW Rectifier / RegulatorE HornR Flasher relay

Starter motor coil resistance:0.06 - 0.08 Ω at 20°C (68°F)

Brush wear limit:0.9 mm (0.035 in)

Commutator diameter wear limit:14.8 mm (0.582 in)

Commutator mica undercut:1.15 mm (0.045 in)

383001

ELEC

-3-

CIRCUIT DIAGRAM

CIRCUIT DIAGRAM

--

M

LOCK

OFF

CHECK

ON

(BLACK)

(GREEN)

(GREEN)

(BLACK)

Br

Br

Br

Br

Gy

Gy

Gy

Gy

B

B

B

R

R

R

BW

BW

BW

Gy

Br

R

B

BW

BW

Or

Or

Or

B

B

B

B

BR BR

WR WR

W

W YR

YR -

-

W

YR

W

YR

YR

R W B YR

R

B

R

R

R

R

R

LW

LW

B

GY

GY

R A R

B A

B

LW

B

Br

BrW

Br

Br

B

B

G

GG

BG

Y

Ch

Dg

Y Y

GY

B B

Br

G GCh ChP P

BrW BrW

LRLRDg Dg

B

L GY

B

Br

LGy

R

B

R

B

A

MAIN HARNESS STARTER MOTOR

T

Q W E

R

Y

U

IO

P

B

q

t

y

u i

r

o

[

]

p12V10W

12V10W

12V21W / 5W

12V35W / 35W

OFF

YR LR

L LR

ON

OFF

LW B

ON

LL

L

BBLW

YR

LR/L

LW

YR

LR

OFF

B

B

P

P

ON

HI

LOW

LRG Y

Y

L

N

R

BrW

BrW

Ch

Ch

Dg

Dg

12V10W

B

e

Dg

Dg

B

12V10W

B

B

w

Ch

Ch

B

12V10W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

B

Y

Y

B

B

B

M

KL

N

F G H

C

A B

D E

J

L

Gy

G

Br

L Br

Ch

GyCh

Dg

GDg

L GY

Ch

B _

GY

Ch_

__

Dg

L

B

Dg

ELEC

-4-

CIRCUIT DIAGRAM

COLOR CODEBBrChDgGGyLOPRSbW

YB/RB/WBr/WBr/YG/BG/YL/RL/WW/RY/BY/R

BlackBrownChocolateDark greenGreenGreyBlueOrangePinkRedSky blueWhite

YellowBlack/RedBlack/WhiteBrown/WhiteBrown/YellowGreen/BlackGreen/YellowBlue/RedBlue/WhiteWhite/RedYellow/BlackYellow/Red

Q C.D.I. magnetoW C.D.I. unitE Ignition coilR Spark plugT Main switchY FuseU BatteryI Rectifier / regulatorO Starter relayP Starter motor Right handle switch

A Starter switchB Lighting switch

Left handle switchC "HORN" switchD "Hi / Lo" switchE Flasher switch

q Head lightw Left front flasher

e Right front flasherr Taillight assembly

F Left rear flasherG Right rear flasherH Tail / Stop light

t Horny Flasher relayu Front stop switchi Rear stop switcho Oil level gaugep Fuel sender[ Meter assembly

J Meter lightK Oil warning lightL Flasher indicator lightM High beam indicator lightN Fuel meter

] Position light

ELEC

-5-


IGNITION AND STARTING SYSTEMCIRCUIT DIAGRAM

--

M

LOCK

OFF

CHECK

ON

(BLACK)

(GREEN)

(GREEN)

(BLACK)

Br

Br

Br

Br

Gy

Gy

Gy

Gy

B

B

B

R

R

R

BW

BW

BW

Gy

Br

R

B

BW

BW

Or

Or

Or

B

B

B

B

BR BR

WR WR

W

W YR

YR -W

YR

W

YR

YR

R W B YR

R

B

R

R

R

R

R

LW

LW

B

GY

GY

R A R

B A

B

LW

B

Br

BrW

Br

Br

B

B

G

GG

BG

Y

Ch

Dg

Y Y

GY

B B

Br

G GCh ChP P

BrW BrW

LRLRDg Dg

B

L GY

B

Br

LGy

R

B

R

B

A


T

Q W E

R

Y

U

IO

P

B

q

t

y

u i

r

o

[

]

p12V10W

12V10W

12V21W / 5W

12V35W / 35W

OFF

YR LR

L LR

ON

OFF

LW B

ON

LL

L

BBLW

YR

LR/L

LW

YR

LR

OFF

B

B

P

P

ON

HI

LOW

LRG Y

Y

L

N

R

BrW

BrW

Ch

Ch

Dg

Dg

12V10W

B

e

Dg

Dg

B

12V10W

B

B

w

Ch

Ch

B

12V10W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

B

Y

Y

B

B

B

M

KL

N

F G H

C

A B

D E

J

L

Gy

G

Br

L Br

Ch

GyCh

Dg

GDg

L GY

Ch

B _

GY

Ch_

Dg

L

B

Dg

Q C.D.I. magnetoW C.D.I. unitE Ignition coilR Spark plugT Main switch

Y FuseU BatteryO Starter relayP Starter motor

Right handle switchA Starter switch

u Front stop switchi Rear stop switch

ELEC

-6-

RBBW

LOCKLOCK

ON ON

CHECKCHECK

OFF OFF

Br GyGy

BB

O

BB

BB

BB

M

L/W

G/Y

R

B

BB

BB

W/R

B/W

B/R

Br

R

374001

c

d

d

fe e

e

e

a

b

g

: Current flow in ignition control circuit: Current flow in starter motor control circuit


IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAMQ Spark plugW Ignition coilR CDI unitU Starter MotorI Starter relayO FuseP Battery Starter switch

Main switcht Front brake switchy Rear brake switch

Source coilPickup coilWave-shape shaping circuitCondenserDiodeSCRTo oil level switch

a

b

c

de

fg

ELEC

-7-

OUT OFSPECIFICATIONOR NO SPARK

372000

TROUBLESHOOTING

THE STARTING SYSTEM DOES NOT WORK (NO SPARK OR IRREGULAR SPARKS).


1) Side covers (left and right)• For accurate troubleshooting use the following special tools:

Ignition checker: Pocket tester:90890-06754 90890-03112

INCORRECT

The spark plug is defective. Replace it oradjust the spark plug gap.

MEETS SPECIFICATION

Ignition system in good condition.


1.Spark plug

• Check the spark plug type.• Check the condition of the spark plug.• Check the spark plug gap.

Refer to “SPARK PLUG INSPECTION” inChapter 3.


Spark plug gap:0.5 ~ 0.7 mm (0.019 ~ 0.028 in)

CORRECT

2.Spark check

• Remove the spark plug cap.• Connect the ignition checker Q.

WSpark plug capESpark

• Check the length of the spark gap.• Start the engine and increase the spark

length until the engine begins to misfire.

Minimum spark gap:6.0 mm (0.24 in)

ELEC

-8-

3.Spark plug cap resistance

• Disconnect the spark plug cap.• Connect the pocket tester (Ω x 1 k) to the

spark plug cap.• Check the resistance of the spark plug cap.

Spark plug cap resistance:5kΩ at 20°C (68°F)

MEETSSPECIFICATION

4.Ignition coil resistance

• Disconnect the ignition coil leads.• Connect the pocket tester (Ω x 1) to the

ignition coil.

Ignition coil :Pocket tester (+) lead OrangePocket tester (-) lead Ground

• Check the primary coil resistance.

Primary coil resistance:0.32 ~ 0.48 Ω at 20°C (68°F)

• Connect the pocket tester (Ω x 1k) to theignition coil.

Pocket tester (+) lead GroundPocket tester (-) lead Spark plug lead

• Check the secondary coil resistance.

Secondary coil resistance:5.68 ~ 8.52 Ω at 20°C (68°F)

MEETSSPECIFICATION


Replace the spark plug cap


Defect. Replace the ignition coil.


372001

372002

372003

ELEC

-9-

5.Pickup coil resistance

• Disconnect the pickup coil coupler.• Connect the pocket tester (Ω x 100) to the

pickup coil.

Pocket tester (+) lead Q White / RedPocket tester (-) lead W Ground

• Check the pickup coil resistance.

Pickup coil resistance:400 ~ 600 Ω at 20°C (68°F)

MEETSSPECIFICATION

6.Source coil resistance

• Disconnect the source coil coupler from thewire harness.

• Connect the pocket tester (Ω x 100) to thesource coil.

Pocket tester (+) lead Q Black / RedPocket tester (-) lead W Ground

• Check the source coil resistance.

Source coil resistance:640 ~ 960 Ω at 20°C (68°F)

MEETSSPECIFICATION

7.Connections

• Check all connections in the ignition sys-tem.Refer to “WIRING DIAGRAM”.

GOODCONNECTIONS

Replace the CDI unit.



Pickup coil defect Replace.


Source coil defect Replace.

POOR CONNECTIONS

Repair.

372004

Y/R wx W/R B/R

CDIMAGNETO

372005

Y/R wx W/R B/R

CDIMAGNETO

ELEC

-10-

1.Fuse


CONTINUITY

2.Battery


Open circuit voltage:12.8 V or more at à 20°C (68°F)

MEETSSPECIFICATION

3.Starter motor

• Use a jumper lead E * to connect the (+) Qterminal of the battery to the starter motorterminal W.


DOES NOT WORK

Starter defect Repair or replace.

TROUBLESHOOTING

STARTER MOTOR DOES NOT WORK


1) Side covers (left and right)2) Footrest board3) Front panel4) Handlebar cover

• For accurate troubleshooting use the following special tools:



WORKS

NO CONTINUITY

Defect Replace fuse.



*

• If the gauge of the jumper lead is smallerthan that of the battery leads, the jumperlead might melt or burn.

• This test could cause sparks. Neverperform it near a gas source or nearflammable products.

372006

M + -

CAUTION:

ELEC

-11-

RBBWBW

LOCK

ON

CHECK

OFF

BGyGyBrBrR

BrBr GyGy

R B/WB/W

372008

4. Starter relay

• Disconnect the Blue/White lead from thewire harness.

• Connect the (-) Q terminal of the battery tothe Blue/White lead.


WORKS

5. Main switch


• Check for continuity between Red Q andBrown W.

MEETSSPECIFICATION

6.Starter switch


• Check for continuity between Blue / WhiteQ and Black W.


DOES NOT WORK

Starter relay defect Replace.



372007

M + -

L/W

ELEC

-12-

372009A


MEETSSPECIFICATION

7.Connections

Check all connections in the starter system.Refer to “WIRING DIAGRAM”.


Starter switch defect Replace right handle-bar switch.

POOR CONNECTIONS

Repair.

OFF

ON

LW B

B

LRYRLW

YB L

372009B

ELEC

-13-

CHARGING SYSTEM

CHARGING SYSTEMCIRCUIT DIAGRAM

--

M

LOCK

OFF

CHECK

ON

(BLACK)

(GREEN)

(GREEN)

(BLACK)

Br

Br

Br

Br

Gy

Gy

Gy

Gy

B

B

B

R

R

R

BW

BW

BW

Gy

Br

R

B

BW

BW

Or

Or

Or

B

B

B

B

BR BR

WR WR

W

W YR

YR -W

YR

W

YR

YR

R W B YR

R

B

R

R

R

R

R

LW

LW

B

GY

GY

R A R

B A

B

LW

B

Br

BrW

Br

Br

B

B

G

GG

BG

Y

Ch

Dg

Y Y

GY

B B

Br

G GCh ChP P

BrW BrW

LRLRDg Dg

B

L GY

B

Br

LGy

R

B

R

B

A


T

Q W E

R

Y

U

IO

P

B

q

t

y

u i

r

o

[

]

p12V10W

12V10W

12V21W / 5W

12V35W / 35W

OFF

YR LR

L LR

ON

OFF

LW B

ON

LL

L

BBLW

YR

LR/L

LW

YR

LR

OFF

B

B

P

P

ON

HI

LOW

LRG Y

Y

L

N

R

BrW

BrW

Ch

Ch

Dg

Dg

12V10W

B

e

Dg

Dg

B

12V10W

B

B

w

Ch

Ch

B

12V10W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

B

Y

Y

B

B

B

M

KL

N

F G H

C

A B

D E

J

L

Gy

G

Br

L Br

Ch

GyCh

Dg

GDg

L GY

Ch

B _

GY

Ch_

Dg

L

B

Dg

Q C.D.I. magnetoY FuseU BatteryI Rectifier / regulator

ELEC

-14-

TROUBLESHOOTING

THE BATTERY IS NOT CHARGED


1) Side covers (left and right) and footrest board.• For accurate troubleshooting use the following special tools:

Inductive tachometer: Pocket tester:90890-03113 90890-03112

367001

1.Fuse (Main)


CONTINUITY

2.Battery

• Check the condition of the battery. Refer to “BATTERY INSPECTION” in CHAPTER 3.

Open circuit voltage:12,8 V or more at 20°C (68°F)

3.Charging voltage

• Connect the engine tachometer to the sparkplug lead.

• Connect the pocket tester (DC20V) to thebattery terminals.

Pocket tester (+) lead Battery (+) terminalPocket tester (-) lead Battery (-) terminal

• Start the engine and accelerate to about5000 rpm.

• Check the charging voltage.

Charging voltage :14 ~ 15 V at 5.000 tr/mn

CHARGING SYSTEM

NO CONTINUITY




MEETS SPECIFICATION

Charging circuit is OK.

372010

- +

NOTE:Use a fully charged battery.

OUT OFSPECIFICATION

ELEC

-15-

4.Charging coil resistance

• Disconnect the CDI magneto coupler fromthe wire harness.

• Connect the pocket tester (Ω x 1) to thecharging coil.

• Check the charging coil resistance

Tester (+) lead White QTester (–) lead Ground W

Charging coil resistance:0.48 ~ 0.72 Ω at 20°C (68°F)

MEETSSPECIFICATION

5.Connections

Check all connections in the charging system.Refer to “WIRING DIAGRAM”.

MEETSSPECIFICATION

Replace the rectifier/regulator.

CHARGING SYSTEM


Charging coil defect Replace.

POOR CONNECTIONS

Repair.

372015

Y/R wx W/R B/R

CDIMAGNETO

ELEC

-16-

LIGHTING SYSTEMCIRCUIT DIAGRAM

LIGHTING SYSTEM

--

M

LOCK

OFF

CHECK

ON

(BLACK)

(GREEN)

(GREEN)

(BLACK)

Br

Br

Br

Br

Gy

Gy

Gy

Gy

B

B

B

R

R

R

BW

BW

BW

Gy

Br

R

B

BW

BW

Or

Or

Or

B

B

B

B

BR BR

WR WR

W

W YR

YR -W

YR

W

YR

YR

R W B YR

R

B

R

R

R

R

R

LW

LW

B

GY

GY

R A R

B A

B

LW

B

Br

BrW

Br

Br

B

B

G

GG

BG

Y

Ch

Dg

Y Y

GY

B B

Br

G GCh ChP P

BrW BrW

LRLRDg Dg

B

L GY

B

Br

LGy

R

B

R

B

A


T

Q W E

R

Y

U

IO

P

B

q

t

y

u i

r

o

[

]

p12V10W

12V10W

12V21W / 5W

12V35W / 35W

OFF

YR LR

L LR

ON

OFF

LW B

ON

LL

L

BBLW

YR

LR/L

LW

YR

LR

OFF

B

B

P

P

ON

HI

LOW

LRG Y

Y

L

N

R

BrW

BrW

Ch

Ch

Dg

Dg

12V10W

B

e

Dg

Dg

B

12V10W

B

B

w

Ch

Ch

B

12V10W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

B

Y

Y

B

B

B

M

KL

N

F G H

C

A B

D E

J

L

Gy

G

Br

L Br

Ch

GyCh

Dg

GDg

L GY

Ch

B _

GY

Ch_

Dg

L

B

Dg

Q C.D.I. magneto Right handle switch

B Lighting switch Left handle switch

D "Hi / Lo" switchq Head light

r Taillight assemblyH Tail / Stop light

[ Meter assemblyJ Meter lightM High beam indicator light

] Position light

ELEC

-17-

372009A

TROUBLESHOOTING

THE AUXILIARY LIGHT, HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT, TAILLIGHT OR METER LIGHT DO NOT WORK


• Side covers and footrest board• Handlebar covers



CONTINUITY

1. “LIGHTS” switch


• Set the switch to “ ” .• Check for continuity between

Yellow / Red Q and Blue / Red W NO CONTINUITY

"Light" switch defect Replace.

LIGHTING SYSTEM

372009A

CONTINUITY

2. “HI / LO” switch• Disconnect the “HI / LO” switch coupler (left)

from the wire harness.• Set the switch to " ".• Check for continuity between

Blue / Red Q and Green W

• Then set the switch to “ ”.• Check for continuity between:

Blue / Red Q and Yellow E

NO CONTINUITY

"HI / LO" switch defect Replace.

OFF

YR LR

ON

L

B LW

YR

LR_

-Y

B

GChP

BrW

LR Dg

HI

LOW

LRG Y

ELEC

-18-

MEETSSPECIFICATION

2. Lighting coil resistance

• Disconnect the lighting coil coupler from thewire harness.

• Connect the pocket tester (Ω x 1) to thelighting coil.

• Check the lighting coil resistance

Tester (+) lead Yellow / Red QTester (-) lead Ground W

Lighting coil resistance:0.32 ~ 0.48Ω at 20°C (68°F)

Lighting coil defect Replace.

POOR CONNECTIONS

Repair.


LIGHTING SYSTEM

MEETSSPECIFICATION

3. Connections

• Check all connections in the lighting system.Refer to “WIRING DIAGRAM”.


372036

Y/R wx W/R B/R

CDIMAGNETO

ELEC

-19-

372017(a)

B BY Y

MEETSSPECIFICATION

LIGHTING SYSTEM

2. The meter light does not work.


LIGHTING SYSTEM INSPECTION1. Headlight and headlight indicator do not work.

1. Bulb and socket


CONTINUITY

2. Voltage

• Connect the pocket tester (AC20V) to theheadlight coupler.

Headlight:• “LO”:Pocket tester (+) lead Green QPocket tester (-) lead Black E• “HI”:Pocket tester (+) lead Yellow WPocket tester (-) lead Black E• Headlight indicator:Pocket tester (+) lead Yellow RPocket tester (-) lead Black T

• Set the main switch to "ON".• Start the engine.• Set the light switch to " ".• Switch from "HI" to "LO" and back.• Check the voltage (12V) between the head-

light coupler leads.

NO CONTINUITY


1. Bulb and socket


CONTINUITY


There is a defect in the wire harness betweenthe main switch and the headlight couplerand/or between the main switch and theheadlight indicator coupler Repair.

NO CONTINUITY


ELEC

-20-

372037(a)

Br Br

Gy Gy

Dg Dg

Ch ChG G

L L

B BY Y

3. The taillight does not work.

1. Bulb and socket


LIGHTING SYSTEM

2. Voltage

• Connect the pocket tester (AC20V) to themeter light coupler.


• Set the main switch to "ON".• Start the engine.• Set the light switch to " ".• Check the voltage (12V) between the head-


MEETSSPECIFICATION

2. Voltage

• Connect the pocket tester (AC20V) to thetaillight coupler.


• Set the main switch to “ON”.• Start the engine.• Set the light switch to " ".• Check the voltage (12V) between the head-



There is a defect in the wire harness betweenthe main switch and the meter light coupler Repair.

NO CONTINUITY



There is a defect in the wire harness betweenthe main switch and the taillight coupler Repair.


CONTINUITY

MEETSSPECIFICATION


B

L GY

12V10W12V21W / 5W12V10W

L GY

Ch

B _

GY

Ch_

Dg

L

B

Dg

ELEC

-21-

SIGNAL SYSTEMCIRCUIT DIAGRAM

SIGNAL SYSTEM

--

M

LOCK

OFF

CHECK

ON

(BLACK)

(GREEN)

(GREEN)

(BLACK)

Br

Br

Br

Br

Gy

Gy

Gy

Gy

B

B

B

R

R

R

BW

BW

BW

Gy

Br

R

B

BW

BW

Or

Or

Or

B

B

B

B

BR BR

WR WR

W

W YR

YR -W

YR

W

YR

YR

R W B YR

R

B

R

R

R

R

R

LW

LW

B

GY

GY

R A R

B A

B

LW

B

Br

BrW

Br

Br

B

B

G

GG

BG

Y

Ch

Dg

Y Y

GY

B B

Br

G GCh ChP P

BrW BrW

LRLRDg Dg

B

L GY

B

Br

LGy

R

B

R

B

A


T

Q W E

R

Y

U

IO

P

B

q

t

y

u i

r

o

[

]

p12V10W

12V10W

12V21W / 5W

12V35W / 35W

OFF

YR LR

L LR

ON

OFF

LW B

ON

LL

L

BBLW

YR

LR/L

LW

YR

LR

OFF

B

B

P

P

ON

HI

LOW

LRG Y

Y

L

N

R

BrW

BrW

Ch

Ch

Dg

Dg

12V10W

B

e

Dg

Dg

B

12V10W

B

B

w

Ch

Ch

B

12V10W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

B

Y

Y

B

B

B

M

KL

N

F G H

C

A B

D E

J

L

Gy

G

Br

L Br

Ch

GyCh

Dg

GDg

L GY

Ch

B _

GY

Ch_

Dg

L

B

Dg

T Main switchY FuseU Battery Left handle switch

C "HORN" switchE Flasher switch

w Left front flashere Right front flasher

r Taillight assemblyF Left rear flasherG Right rear flasherH Tail / Stop light

t Horny Flasher relayu Front stop switchi Rear stop switch

o Oil level gaugep Fuel sender[ Meter assembly

K Oil warning lightL Flasher indicator lightN Fuel meter

ELEC

-22-

MEETSSPECIFICATION

MEETSSPECIFICATION

RBBW

LOCKLOCK

ON ON

CHECKCHECK

OFF OFF

BGyGyBrBrR

Br Gy

R B/W

372040



2. Battery


Battery voltage:12.8 V or more at 20°C (68°F)

SIGNAL SYSTEM

TROUBLESHOOTING

FLASHER LIGHTS, BRAKE LIGHT, “OIL” WARNING LIGHT DO NOT WORKHORN DOES NOT SOUND


• Side covers and footrest board• Handlebar cover


1. Fuse

• Remove the fuse.• Connect the pocket tester (Ω x 1) to the fuse.• Check the fuse for continuity.Refer to “FUSE INSPECTION” in Chapter 3.

CONTINUITY

3. Main switch


• Turn the main switch to “”.• Check for continuity between:

Red Q and Grey E

• Turn the main switch to “ON”.• Check for continuity between:

Red Q and Brown WDOES NOT MEET SPECIFICATION




NO CONTINUITY

ELEC

-23-

2. Voltage

• Connect the pocket tester (DC20V) to thehorn lead.


• Turn the main switch to ON.• Check for voltage (12V) between “Brown”

and the ground.

SIGNAL SYSTEM

4. Connections


Check the condition of each circuit of thesignal system.

Refer to the section “SIGNAL SYSTEMCHECK”.

SIGNAL SYSTEM CHECK1. Horn does not sound

1. “HORN” switch



Black Q and Pink W.

NO CONTINUITY

Horn switch is defect Replace.

POOR CONNECTIONS

Repair.GOODCONNECTIONS

CONTINUITY

-Y

B

GChP

BrW

LR Dg

OFF

B P

ON

ELEC

-24-

HORN DOESNOT SOUND

MEETSSPECIFICATION

Defect in the wire harness between the mainswitch and the horn Repair.


3. Horn

• Disconnect the “Pink” lead at the horn terminal.• Ground the horn terminal Q with a jumper

lead.• Set the main switch to ON.

4. Voltage

• Connect the pocket tester (DC20V) to the“Pink” lead.

Pocket tester (+) lead Pink QPocket tester (-) lead Ground

• Turn the main switch to ON.• Press the “HORN” switch.• Check the voltage (12V) between “Pink” andground.

MEETSSPECIFICATION

Horn is defect Replace.


SIGNAL SYSTEM

HORN SOUNDS

Horn is in good condition.

Adjust the horn.

372025

Br P

372026

Br

372027

Br P

ELEC

-25-

SIGNAL SYSTEM

2. The brake light does not work.

1. Bulb and socket


2. Brake switch

• Disconnect the brake switch leads from thewire harness.


Brown Q and Green / Yellow W

3. Voltage

• Connect the pocket tester (DC20V) to thesocket.

Pocket tester (+) lead Green / Yellow QPocket tester (-) lead Black W

• Turn the main switch to “ON”.• Pull the brake lever.• Check the voltage (12V) between “ Green /

Yellow” Q and “Black” W.

There is a defect in the wire harness betweenthe main switch and the brake light socket Repair.


CONTINUITY

CONTINUITY


MEETSSPECIFICATION

NO CONTINUITY


Brake switch is defect Replace.

NO CONTINUITY

Br G/YON (Pull in)OFF (Free)

Br G/Y

372030

B

L GY

12V10W12V21W / 5W12V10W

L GY

Ch

B _

GY

Ch_

Dg

L

B

Dg

ELEC

-26-

3. Flasher does not work

1. Bulb and socket


2. “TURN” switch


• Check for continuity between :

Left side : Brown / White Q and Chocolate WRight side : Brown / White Q and Dark green E

3. Voltage



• Turn the main switch to ON.• Check the voltage (12V) between the “Brown”

lead and the ground.

SIGNAL SYSTEM

NO CONTINUITY

NO CONTINUITY


Left handlebar switch is defect Replace.

CONTINUITY

CONTINUITY

MEETSSPECIFICATION


Defect in the wire harness between the mainswitch and the flasher relay Repair.

-

-

Br/WBr/W

BrBr

372033

-Y

B

GChP

BrW

LR Dg

L

N

R

BrWCh Dg

ELEC

-27-MEETSSPECIFICATION

4. Voltage


Pocket tester (+) lead Brown / White QPocket tester (-) lead Ground

• Turn the main switch to “ON”.• Check the voltage (12V) between Brown /

White and the ground.

5. Voltage

• Connect the pocket tester (DC20V) to theflasher connector.

Left flasher bulb:Pocket tester (+) lead Chocolate QPocket tester (-) lead Black W

Right flasher bulb:Pocket tester (+) lead Dark green EPocket tester (-) lead Black R

• Turn the main switch to "ON".• Set the "TURN" switch to the left, then to the

right.• Check the voltage (12V) between "Choco-

late" and "Black", then "Dark green" and"Black".



SIGNAL SYSTEM

MEETSSPECIFICATION

Flasher relay defect Replace.

REAR: Defect in the wire harness betweenthe main switch and the flasher bulb socket Repair.FRONT: Defect in the wire harness be-tween the main switch and the flasher bulbcoupler Repair.

-

-

Br/WBr/W

BrBr

372034

B

L GY

12V10W12V21W / 5W12V10W

L GY

Ch

B _

GY

Ch

Ch

_Dg

L

B

Dg

Dg

B

Dg

DgDg

B

12V10W

B

B

Ch

ChCh

B

12V10W

B

FRONT:

REAR:

ELEC

-28-

SIGNAL SYSTEM


2. Oil level switch

• Disconnect the oil level switch from the oiltank.

• Connect the pocket tester (Ω x 1) to the oillevel switch.

Pocket tester (+) lead Terminal WPocket tester (-) lead Terminal Q

• Check the switch for continuity.

Float Good Badposition condition condition

HIGH X O X O

LOW O X X O

O : Continuity X : No continuity

NO CONTINUITY


Replace oil level switch is defect.


4. The “OIL” indicator light does not work.

1. Bulb and socket


CONTINUITY

MEETSSPECIFICATION

372035

A

B

ELEC

-29-

SIGNAL SYSTEM

3. Voltage

• Connect the pocket tester (DC20V) to thebulb socket connector.

Pocket tester (+) lead Grey QPocket tester (-) lead Black W

• Turn the main switch to "ON".• Check the voltage (12V) between "Grey"

and "Black".


MEETSPECIFICATION


4. Connections


YCh

Dg

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

B

LBrGy

(GREEN)

(BLACK)

Y

Y

B

B

L

Gy

G

Br

L Br

Ch

GyCh

Dg

GDg

CW50RS WIRING DIAGRAM Q C.D.I. magnetoW C.D.I. unitE Ignition coilR Spark plugT Main switchY FuseU BatteryI Rectifier / regulatorO Starter relayP Starter motor Right handle switch

A Starter switchB "Light" switch

Left handle switchC "HORN" switchD "Hi / Lo" switchE Flasher switch

q Head lightw Left front flashere Right front flasherr Taillight assembly

F Left rear flasherG Right rear flasherH Tail / Stop light

t Horny Flasher relayu Front stop switchi Rear stop switcho Oil level gaugep Fuel sender[ Meter assembly

J Meter lightK Oil warning lightL Flasher indicator lightM High beam indicator lightN Fuel meter

] Position light

COLOR CODEB BlackBr BrownCh ChocolateDg Dark greenG GreenGy GreyL BlueOr OrangeP PinkR RedW WhiteY YellowB/R Black/RedB/W Black/WhiteBr/W Brown/WhiteG/Y Green/YellowL/R Blue/RedL/W Blue/WhiteW/R White/RedY/R Yellow/Red

--

M

LOCK

OFF

CHECK

ON

(BLACK)

(GREEN)

(GREEN)

(BLACK)

Br

Br

Br

Br

Gy

Gy

Gy

Gy

B

B

B

R

R

R

BW

BW

BW

Gy

Br

R

B

BW

BW

Or

Or

Or

B

B

B

B

BR BR

WR WR

W

W YR

YR -

-

W

YR

W

YR

YR

R W B YR

R

B

R

R

R

R

R

LW

LW

B

GY

GY

R A R

B A

B

LW

B

Br

BrW

Br

Br

B

B

G

GG

BG

Y

Ch

Dg

Y Y

GY

B B

Br

G GCh ChP P

BrW BrW

LRLRDg Dg

BL G

Y

B

Br

LGy

R

B

R

B

A


T

Q W E

R

Y

U

IO

P

B

q

t

y

u i

r

o

[

]

p12V10W

12V10W

12V21W / 5W

12V35W / 35W

OFF

YR LR

L LR

ON

OFF

LW B

ON

LL

L

BBLW

YR

LR/L

LW

YR

LR

OFF

B

B

P

P

ON

HI

LOW

LRG Y

Y

L

N

R

BrW

BrW

Ch

Ch

Dg

Dg

12V10W

B

e

Dg

Dg

B

12V10W

B

B

w

Ch

Ch

B

12V10W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

12V

1.2

W

B

Y

Y

B

B

B

M

KL

N

F G H

C

A B

D E

J

L

Gy

G

Br

L Br

Ch

GyCh

Dg

GDg

L GY

Ch

B _

GY

Ch_

__

Dg

L

B

Dg

Documents

BWS_NG_1998