EAS00002 NOTICE This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
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EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Carburetor 8 Electrical system...
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CARBURETOR CARB...
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INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL LABEL .................. 1-1 IMPORTANT INFORMATION ..............1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ....1-2 REPLACEMENT PARTS ..............1-2 GASKETS, OIL SEALS AND O-RINGS ..........1-2 LOCK WASHERS/PLATES AND COTTER PINS ......
SCOOTER IDENTIFICATION INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL LABEL The model label 1 is affixed to the seat. This information will be needed to order spare parts.
5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but infe- rior in quality.
IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the...
CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8 lead 8 coupler 8 connector 2. Check: 8 lead 8 coupler 8 connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times.
SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
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90890-06754 Ignition checker YM-34487 This tool is used to check the ignition sys- tem components. 90890-85505 Yamaha bond NO.1215 ACC-11001-05-01 Sealant (Quick Gasket ®) This sealant (bond) is used on crankcase mating surfaces (e.g., crankcase mating surfaces). 90890-01348...
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SPECIAL TOOLS INFO Tool NO. Tool name / Function Illustration 90890-01312 Fuel level gauge YM-01312-A This gauge is used to measure the fuel le- ver in the float chamber.
SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Standard Limit Item System voltage … Ignition system Ignition system type C.D.I. … Ignition timing 14° BTDC at 5000r/min … Advancer type Fixed … Pick coil resistance/color 400 ~ 600Ωat 20°C (68°F)/ … black - white/red C.D.I.
CONVERTION TABLE / GENERAL TIGHTENING SPEC TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE Tightening Thread Part to be tightened Part name ’ torque Remarks size Nm m•kg ft•lb Spark plug — M 14 Cylinder head and cylinder Cylinder Stud bolt Air shroud 1 Screw Air shroud 1× 2 Screw Screw Autolube pump...
SPEC TIGHTENING TORQUES CHASSIS Tightening Thread Part to be tightened torque Remarks size m•kg ft•lb Frame and engine bracket M 12 Engine bracket, compression rod and engine M 10 Rear carrier Rear shock absorber and frame M 10 Rear shock absorber and engine Steering ring nut M 25 See “NOTE”...
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SPEC TIGHTENING TORQUES NOTE : 1. First, tighten the ring nut(lower) approximately 38Nm(3.8m•kg, 27.5ft•lb) by using the torque wrench, then loosen the ring nut 1/4 turn. 2. Second, tighten the ring nut(lower) approximately 12Nm(1.2m•kg, 8.7ft•lb) by using the torque wrench. 3.
SPEC CABLE ROUTING t Wire harness F Align the clip with the white EAS00035 CABLE ROUTING A Pass the speedometer cable brand. G Clamp the wire harness. through the right hole of front 1 Horn H Insert the seat cable through fender, then through the 2 Rectifier regulator guide.
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SPEC CABLE ROUTING 1 Brake cable A Pass the brake hose through 2 Speedometer cable the holder. 3 Fuel tank overflow hose B Insert the fuel overflowhose 4 Brake cable holder bottom. 5 Brake hose C Pass the fuel overflowhose 6 Brake hose holder through the rear fender hole.
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SPEC CABLE ROUTING 1 Brake hose A Tighting torque:3.5 ~ 5.5Nm. 2 Front fender B Assemble the brake hose 3 Front fork assembly holder 3 hang hook must cer- 4 Nut tainty hook the brake hose 5 Plate washer holder. 6 Brake hose holder 1 C Tighting torque:8.5 ~ 14Nm.
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SPEC CABLE ROUTING 1 Ignition coil e Battery - lead F Clamp autochoke leads and 2 Spark plug lead r Battery + lead autolube hose on to carbu- 3 Starter relay leads A Pass battery leads through retor throttle cable. 4 Auto choke leads G Pass the batter y leads the slot of footrestboard.
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SPEC CABLE ROUTING 1 Grip assembly C Route the front turn signal F Route the speedometer 2 Handlebar switch(right) light lead through the slot of cable through between the 3 Front brake light switch handlebar bracket and frame and the brake hose to 4 Speedometer through the backward of rear right side.
CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..................3-1 PERIODIC MAINTENANCE AND MINOR REPAIR ........ 3-1 Periodic maintenance chart for the emission control system ... 3-1 General maintenance and lubrication chart........3-2 COVER AND PANEL ................3-4 SEAT AND SIDE COVERS..............3-4 LOWER COWLING, UPPER COVER AND LEG SHIELD 1 ....
EAS00037 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17570 Periodic maintenance chart for the emission control system * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. INITIAL ODOMETER READING 1,000 km...
• Check operation. switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 19000 km (12000 mi) or 36 months, repeat the maintenance intervals starting from 7000 km...
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PERIODIC MAINTENANCE AND MINOR REPAIR EAU17620 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake system ● • When disassembling the master cylinder or caliper cylinder, always replace the brake fluid.
COVER AND PANEL EAS00038 COVER AND PANEL SEAT AND SIDE COVERS 13Nm (1.3 m•kg, 9.4 ft•lb) Order Job/Part Q’ty Remarks Removing the seat and side covers Remove the parts in the order listed. Battery box cover NOTE: Seat Insert the (-) screwdriver into the slot of Seat hanger battery box cover and pickup then re- Rear carrier...
COVER AND PANEL LOWER COWLING, UPPER COVER AND LEG SHIELD 1 Order Job/Part Q’ty Remarks Removing the lower cowling, upper Remove the parts in the order listed. cover, and leg shield 1 Lower cowling Head light lead coupler(low) Disconnect. Head light lead coupler(high) Disconnect.
COVER AND PANEL LEG SHIELD 2 AND FOOTREST BOARD 7Nm (0.7 m•kg, 5.1 ft•lb) Order Job/Part Q’ty Remarks Removing the leg shield 2 and foot- Remove the parts in the order listed. rest board Leg shield 1 Refer to “LOWER COWLING, UPPER COVER AND LEG SHIELD 1”.
COVER AND PANEL HANDLEBAR COVER(FRONT AND REAR) Order Job/Part Q’ty Remarks Removing the handlebar cover(front Remove the parts in the order listed. and rear) Handlebar cover(front) Speedometer cable Disconnect. Handlebar cover(rear) For installation, reverse the removal pro- cedure.
ADJUSTING THE ENGINE IDLING SPEED EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for sev- eral minutes.
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ADJUSTING THE ENGINE IDLING SPEED 5. Adjust: 8engine idling speed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained. Direction a Engine idling speed is increased. Direction b Engine idling speed is decreased.
CARB CHAPTER 4 CARBURETOR AIR INDUCTION SYSTEM ............... 4-1 AIR FILTER CASE ASSEMBLY ............4-1 CHECKING THE AIR INDUCTION SYSTEM ........4-3...
CARB AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM AIR FILTER CASE ASSEMBLY Order Job/Part Q’ty Remarks Removing the air filter case assem- Remove the parts in the order listed. Hose(to air filter) Disconnect. Disconnect. Pipe(to exhaust pipe) Air filter case assembly For installation, reverse the removal pro- cedure.
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CARB AIR INDUCTION SYSTEM Order Job/Part Q’ty Remarks Remove the parts in the order listed. Disassembling the air filter case as- sembly Damper Air filter case cap Reed valve Reed valve stopper Reed valve seat Reed valve assembly Element Plate O-ring Air filter case body For assembly, reverse the disassembly...
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CARB AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: 8 hoses Loose connection Connect properly. Cracks/damage Replace. 8 pipes Cracks/damage Replace. 2. Check: 8 reed valve 1 8 reed valve stopper 8 reed valve seat Cracks/damage Replace the reed valve assembly.
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1 Main switch YW50X WIRING DIAGRAM 2 Main fuse 3 Battery 4 Starter relay 5 Starter motor 6 Rectifier/regulator 7 Auto choke 8 C.D.I. magneto 9 C.D.I. Unit 0 Ignition coil LOCK q Spark plug OPEN w Front brake light switch CHECK e Rear brake light switch r Tail/brake light...