Yamaha 2SCT Manuals

Manuals and User Guides for Yamaha 2SCT. We have 1 Yamaha 2SCT manual available for free PDF download: Service Manual

Yamaha 2SCT Service Manual

Yamaha 2SCT Service Manual (574 pages)

Brand: Yamaha | Category: Motorcycle | Size: 39.8 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  5
- Symbols
  6
- General Information
  9
  - Identification
    10
  - Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    YCC-T (Yamaha Chip Controlled Throttle)
    11
    
    OUTLINE of the TCS (Traction Control System)
    13
    
    Instrument Functions
    17
    
    D-Mode (Drive Mode)
    25
  - Important Information
    26
    
    Preparation for Removal and Disassembly
    26
    
    Replacement Parts
    26
    
    Gaskets, Oil Seals and O-Rings
    26
    
    Lock Washers/Plates and Cotter Pins
    26
    
    Bearings and Oil Seals
    26
    
    Circlips
    27
    
    Rubber Parts
    27
  - Basic Service Information
    28
    
    Quick Fasteners
    28
    
    Electrical System
    29
  - Special Tools
    33
Specifications

41
- General Specifications
  42
- Engine Specifications
  43
- Chassis Specifications
  48
- Electrical Specifications
  51
- Tightening Torques
  53
- Lubrication Points and Lubricant Types
  56
  - Engine
    56
  - Chassis
    57
- Lubrication System Chart and Diagrams
  60
  - Engine Oil Lubrication Chart
    60
  - Lubrication Diagrams
    62
- Cooling System Diagrams
  72
- Cable Routing
  76
Periodic Checks and Adjustments

109
- General Maintenance and Lubrication Chart
  111
- Introduction
  111
- Periodic Maintenance
  111
- Periodic Maintenance Chart for the Emission Control System
  111
- Checking the Fuel Line
  114
- Checking the Vehicle Using the Yamaha Diagnostic Tool
  114
- Adjusting the Valve Clearance
  115
- Checking the Spark Plugs
  115
- Checking the Engine Idling Speed
  118
- Synchronizing the Throttle Bodies
  119
- Checking the Canister
  120
- Checking the Throttle Body Joints
  120
- Adjusting the Exhaust Gas Volume
  121
- Checking the Air Induction System
  121
- Checking the Cylinder Head Breather Hose
  121
- Replacing the Air Filter Element
  121
- Adjusting the Clutch Lever Free Play
  122
- Adjusting the Front Disc Brake
  123
- Checking the Brake Fluid Level
  123
- Checking the Brake Operation
  123
- Adjusting the Rear Disc Brake
  124
- Checking the Front Brake Pads
  124
- Bleeding the Hydraulic Brake System (Abs)
  125
- Checking the Front Brake Hoses
  125
- Checking the Rear Brake Hose
  125
- Checking the Rear Brake Pads
  125
- Checking the Tires
  126
- Checking the Wheels
  126
- Checking the Swingarm Operation
  128
- Checking the Wheel Bearings
  128
- Drive Chain Slack
  128
- Lubricating the Swingarm Pivot
  128
- Checking and Adjusting the Steering Head
  129
- Lubricating the Drive Chain
  129
- Adjusting the Shift Pedal
  130
- Checking the Chassis Fasteners
  130
- Lubricating the Brake Lever
  130
- Lubricating the Clutch Lever
  130
- Lubricating the Pedal
  130
- Lubricating the Steering Head
  130
- Adjusting the Front Fork Legs
  131
- Checking the Centerstand
  131
- Checking the Front Fork
  131
- Checking the Sidestand
  131
- Checking the Sidestand Switch
  131
- Lubricating the Centerstand
  131
- Lubricating the Sidestand
  131
- Adjusting the Rear Shock Absorber Assembly
  133
- Checking the Rear Shock Absorber Assembly
  133
- Changing the Engine Oil
  134
- Checking the Connecting Arm and Relay Arm
  134
- Checking the Engine Oil Level
  134
- Engine
  135
  - Measuring the Engine Oil Pressure
    135
  - Checking the Coolant Level
    136
  - Checking the Cooling System
    136
  - Changing the Coolant
    137
- Cooling System
  138
  - Checking the Front Brake Light Switch
    138
  - Adjusting the Rear Brake Light Switch
    139
  - Checking and Lubricating the Cables
    139
  - Checking the Throttle Grip
    139
  - Checking and Charging the Battery
    140
  - Checking the Fuses
    140
  - Adjusting the Headlight Beams
    140
Chassis

141
- General Chassis (1)
  
  147
  - Installing the Seats
    147
- General Chassis (2)
  
  148
  - Removing the Fuel Tank Front Cover
    153
  - Installing the Fuel Tank
    153
  - Removing the Front Side Cowlings
    153
  - Installing the Front Side Cowlings
    154
  - Adjusting the Windshield Height
    155
- General Chassis (3)
  
  156
  - Removing the Fuel Tank Covers
    160
  - Installing the Fuel Tank Covers
    160
- Front Wheel
  
  164
  - Removing the Front Wheel
    164
  - Disassembling the Front Wheel
    164
  - Checking the Front Wheel
    164
  - Assembling the Front Wheel
    165
  - Maintenance of the Front Wheel Sensor and Sensor Rotor
    166
  - Adjusting the Front Wheel Static Balance
    167
  - Installing the Front Wheel (Disc Brake)
    168
  - Rear Wheel
    173
  - Removing the Rear Wheel
    173
  - Disassembling the Rear Wheel
    173
  - Checking the Rear Wheel
    174
  - Checking the Rear Wheel Drive Hub
    174
  - Checking and Replacing the Rear Wheel Sprocket
    174
  - Assembling the Rear Wheel
    174
  - Maintenance of the Rear Wheel Sensor and Sensor Rotor
    175
  - Adjusting the Rear Wheel Static Balance
    175
  - Installing the Rear Wheel (Disc Brake)
    175
- Front Brake
  
  178
- Rear Brake
  
  191
  - Introduction
    197
  - Checking the Rear Brake Disc
    197
  - Replacing the Rear Brake Pads
    197
  - Removing the Rear Brake Caliper
    198
  - Disassembling the Rear Brake Caliper
    199
  - Checking the Rear Brake Caliper
    199
  - Assembling the Rear Brake Caliper
    200
  - Installing the Rear Brake Caliper
    200
  - Removing the Rear Brake Master Cylinder
    201
  - Checking the Rear Brake Master Cylinder
    201
  - Assembling the Rear Brake Master Cylinder
    202
  - Installing the Rear Brake Master Cylinder
    202
- Abs (Anti-Lock Brake System)
  
  203
  - Abs Components Chart
    205
  - Removing the Hydraulic Unit Assembly
    206
  - Checking the Hydraulic Unit Assembly
    206
  - Installing the Hydraulic Unit Assembly
    206
  - Hydraulic Unit Operation Tests
    208
  - Checking the Abs Warning Light
    211
- Handlebar
  
  212
  - Adjusting the Handlebar Position
    214
  - Removing the Handlebar
    215
  - Checking the Handlebar
    215
  - Installing the Handlebar
    215
  - Installing the Rearview Mirrors and Handguards
    217
- Front Fork
  
  219
  - Removing the Front Fork Legs
    222
  - Disassembling the Front Fork Legs
    222
  - Checking the Front Fork Legs
    223
  - Assembling the Front Fork Legs
    224
  - Installing the Front Fork Legs
    229
- Steering Head
  
  230
  - Removing the Lower Bracket
    232
  - Checking the Steering Head
    232
  - Installing the Steering Head
    233
- Rear Shock Absorber Assembly
  
  235
- Swingarm
  
  238
  - Removing the Swingarm
    239
  - Checking the Swingarm
    239
  - Installing the Swingarm
    240
- Chain Drive
  
  241
  - Removing the Drive Chain
    242
  - Checking the Drive Chain
    242
  - Checking the Drive Sprocket
    243
  - Checking the Rear Wheel Sprocket
    243
  - Checking the Rear Wheel Drive Hub
    243
  - Installing the Drive Chain
    244
Engine

247
- Engine Inspection
  
  250
  - Measure the Compression Pressure
    250
- Engine Removal
  
  252
  - Removing the Engine
    256
  - Installing the Engine
    256
- Camshafts
  
  258
  - Removing the Camshafts
    260
  - Checking the Camshafts
    261
  - Checking the Timing Chain and Camshaft Sprocket
    262
  - Checking the Timing Chain Guides
    262
  - Checking the Timing Chain Tensioner
    262
  - Installing the Camshafts
    263
- Cylinder Head
  
  268
- Valves and Valve Springs
  
  272
  - Removing the Valves
    272
  - Checking the Valves and Valve Guides
    272
  - Checking the Valve Seats
    274
  - Checking the Valve Springs
    275
  - Checking the Valve Lifters
    276
  - Installing the Valves
    276
- Generator and Starter Clutch
  
  280
  - Removing the Generator
    280
  - Removing the Starter Clutch
    280
  - Checking the Starter Clutch
    280
  - Installing the Starter Clutch
    281
  - Installing the Generator
    281
- Electric Starter
  
  283
  - Checking the Starter Motor
    285
  - Assembling the Starter Motor
    286
  - Installing the Starter Motor
    286
  - Clutch
    287
  - Removing the Clutch
    291
  - Checking the Friction Plates
    292
  - Checking the Clutch Plates
    292
  - Checking the Clutch Springs
    293
  - Checking the Clutch Housing
    293
  - Checking the Clutch Boss
    294
  - Checking the Pressure Plate
    294
  - Checking the Primary Drive Gear
    294
  - Checking the Primary Driven Gear
    294
  - Checking the Pull Lever Shaft and Pull Rod
    294
  - Installing the Clutch
    295
- Shift Shaft
  
  298
  - Checking the Shift Shaft
    299
  - Checking the Stopper Lever
    299
  - Installing the Shift Shaft
    299
- Oil Pump
  
  300
  - Checking the Sprocket and Chain
    302
  - Checking the Oil Pump
    302
  - Checking the Relief Valve
    302
  - Assembling the Oil Pump
    303
  - Installing the Oil Pump
    303
- Oil Pan
  
  304
  - Removing the Oil Pan
    305
  - Checking the Oil Strainer
    305
  - Installing the Oil Pan
    305
- Crankcase
  
  306
  - Disassembling the Crankcase
    307
  - Checking the Crankcase
    307
  - Assembling the Crankcase
    307
- Connecting Rods and Pistons
  
  311
  - Removing the Connecting Rods and Pistons
    311
  - Checking the Cylinder and Piston
    311
  - Checking the Piston Rings
    312
  - Checking the Piston Pin
    313
  - Checking the Connecting Rods
    313
  - Installing the Connecting Rod and Piston
    316
- Crankshaft and Balancer Shaft
  
  321
  - Removing the Crankshaft and Balancer Shaft
    321
  - Checking the Oil Nozzles
    321
  - Checking the Crankshaft
    321
  - Checking the Balancer Shaft
    323
  - Installing the Crankshaft
    324
  - Installing the Balancer Assembly
    325
- Transmission
  
  326
  - Removing the Transmission
    330
  - Checking the Shift Forks
    330
Cooling System

335
- Radiator
  
  336
  - Checking the Radiator
    337
  - Installing the Radiator
    337
- Oil Cooler
  
  339
  - Checking the Oil Cooler
    340
  - Installing the Oil Cooler
    340
- Thermostat
  
  341
  - Checking the Thermostat
    342
  - Installing the Thermostat Assembly
    342
- Water Pump
  
  343
  - Disassembling the Water Pump
    345
  - Checking the Water Pump
    345
  - Assembling the Water Pump
    345
  - Fuel System
    347
    
    Fuel Tank
    350
    
    Air Induction System
    362
  - Electrical System
    369
  - General Information
    369
    
    Electric Starting System
    378
  - Specifications
    427
    
    Troubleshooting Details
    503
  - Troubleshooting
    547
    
    Troubleshooting
    548
    
    Wiring Diagram
    569

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