Yamaha XF50W Wartungshandbuch

©YAMAHA XF50W SERVICE MANUAL LIT-11616-20-58 3B3-F8197-10

FEATURES EAS00897 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure t

CHECKING THE TIRES EAS00163 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification -&

CHECKING THE TIRES 2. Check: • tire surfaces Damage/wear -» Replace the tire. Minimum tire tread depth 0.8mm(0.03in) 1 Tire tread depth 2 Sidewall 3 W

CHECKING THE TIRES CHK ADJ <& w New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approxi

CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES CHK ADJ <& EAS00168 CHECKING THE WHEELS The following procedure applies to both of the

LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE CENTERSTAND CHK ADJ <& EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting poi

CHECKING AND CHARGING THE BATTERY BATTERY INSTRUCTION This is a sealed lype 12 volt battery. No liquid level inspection is ever needed and no refillin

CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea-suring the s

CHECKING AND CHARGING THE BATTERY CHK ADJ <& 13.0 12.5 12.0 11.5 11.5 j-Relationship between the open-circuit voltage and the charging time at

CHECKING AND CHARGING THE BATTERY CHK ADJ <& Make sure the battery charger lead clips are in full contact with the battery termi-nal and that t

CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger Ammeter Measure the open-circuit voltage prior to

IMPORTANT INFORMATION EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISAS-SEMBLY 1. Before removal and disassembly, remove all dirt, mud,

CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. Connect a charg

CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSE CHK ADJ <& 6. 7. Install: 8battery Connect: 8battery leads (to the battery terminals) cC F

CHECKING THE FUSE 2. Check: 8fuse ••••••••••••••••••••••• a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket test

REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: 8headlight unit 2. 3. Disconnect: 8headlight lead coupler Remove: 8dust

ADJUSTING THE HEADLIGHT BEAM CHK ADJ <& EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: headlight beam (vertically) ••••••••••••••••••••••• a.

CHAS (3^3^) CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE 4-1 FRONT WHEEL 4-2 FRONT BRAKE SHOE PLATE 4-3 REMOVING THE FRONT WHEEL 4-4 DISASSEMBLING THE BRAK

CHAS (3^3^) REAR SHOCK ABSORBER ASSEMBLY 4-37 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-38 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-38 INSTALLING

FRONT WHEEL AND BRAKE CHAS (3^3^) EAS00517 FRONT WHEEL AND BRAKE CHASSIS Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the p

EAS00518 FRONT WHEEL FRONT WHEEL AND BRAKE CHAS (3^3^) Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order liste

FRONT WHEEL AND BRAKE CHAS (3^3^) FRONT BRAKE SHOE PLATE Order Job/Part Q’ty Remarks Disassembling the front brake shoe plate Remove the parts in the

IMPORTANT INFORMATION ®-^> ^ //////K /////©// //////// ////// EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers

FRONT WHEEL AND BRAKE CHAS (3^3^) EAS00520 REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface. w Securely support the scooter so that th

FRONT WHEEL AND BRAKE EAS00525 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends -» Replace. Do not attempt

FRONT WHEEL AND BRAKE CHAS (3^3^) ••••••••••••••••••••••• a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screw

FRONT WHEEL AND BRAKE CHAS (3^3^) (If yj' ^ •—Q7\__ •B" ' w • • 12270603 EAS00536 CHECKING THE BRAKE The following procedure applies to

FRONT WHEEL AND BRAKE 4. Check: • brake drum inner surface Oil deposits -»Clean. Remove the oil with a rag soaked in lac-quer thinner or solvent. Scra

FRONT WHEEL AND BRAKE CHAS (3^5^) 3. Install: 8 camshaft lever (T) XI 8Nm(0.8m • kg, 5.8ft • lb) ••••••••••••••••••••••• a. Align the camshaft punch m

FRONT WHEEL AND BRAKE CHAS (3^3^) EAS00540 INSTALLING THE FRONT WHEEL 1. Lubricate: 8wheel axle 8wheel bearings 8oil seal lips 8speedometer drive gear

FRONT WHEEL AND BRAKE EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: 8 After replacing the tire, wheel or both, the front wheel static balanc

FRONT WHEEL AND BRAKE CHAS (3^% 3. Adjust: 8front wheel static balance ••••••••••••••••••••••• a. Install a balancing weight 1 onto the rim exactly op

REAR WHEEL AND BRAKE CHAS (3^3^) EAS00555 REAR WHEEL AND BRAKE Order Job/Part Q’ty Remarks Removing the rear wheel and brake Muffler 1 Self lock nut

IMPORTANT INFORMATION GEN INFO #^ (^E <D Vo. ;** EAS00021 EQUIPMENT PREPARATION Push Rivet (Push type) Assembly status of the push rivet(push type)

REAR WHEEL AND BRAKE CHAS (3^3^) EAS00564 REMOVING THE REAR WHEEL 1. Stand the scooter on a level surface. w Securely support the scooter so that ther

REAR WHEEL AND BRAKE CHAS (3^3^) EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: • rear wheel drive hub Cracks/damage -» Replace. (If /)> ^v-~

REAR WHEEL AND BRAKE CHAS (3^3^) 3. Measure: • brake drum inside diameter b Out of specification -» Replace the wheel. Brake drum inside diameter limi

REAR WHEEL AND BRAKE CHAS (3^3^) 3. Install: 8brake shoe kit1 8tension springs cC Do not put lubricating oil on the brake lining. Change the tension s

REAR WHEEL AND BRAKE CHAS (3^3^) EAS00574 INSTALLING THE REAR WHEEL 1. Lubricate: 8wheel axle Recommended lubricant Lithium-soap-based grease 2. Insta

FRONT FORK CHAS (3^3^) EAS00646 FRONT FORK S& 45Nm(4.5m • kg, 32.5 ft • lb) gR 30Nm(3.0m • kg, 21.7 ft • lb) Order Job/Part Q’ty Remarks 1 2 3 4

EAS00648 FRONT FORK CHAS (3^3^) (D 3R 23Nm(2.3m • kg, 16.6 ft < lb) Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the part

FRONT FORK CHAS (3^3^) EAS00651 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the scooter on a

FRONT FORK 2. Drain: 8fork oil 3. Remove: 8damper rod assembly bolt1 NOTE: While holding the damper rod with the damper rod holder 2 and T-handle3, lo

FRONT FORK CHAS (3^% 6. Remove: 8oil seal1 cC Never reuse the oil seal. 8Rag2 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to

CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8

FRONT FORK ® <? y \J$^ (gfm; ^® \ ^ EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. NOTE: 8

FRONT FORK CHAS (3^3^) 4. Install: 8oil seal 1New (with the fork seal driver weight 2 and adapter 3) ^ Fork seal driver weight 90890-01367(YM-A9409-7)

FRONT FORK CHAS (3^3^) NOTE: 8 While filling the front fork leg, keep it up-right. 8 After filling, slowly pump the front fork leg up and down to dist

HANDLEBAR CHAS (3^3^) EAS00664 HANDLEBAR -10^ Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Front fork up

HANDLEBAR CHAS (3^3^) -10^ Order Job/Part Q’ty Remarks 14 15 16 17 18 19 20 Front turn signal light(left) Front turn signal light bracket(left) Handl

HANDLEBAR CHAS (3^3^) EAS00666 REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no dang

HANDLEBAR EAS00673 INSTALLING THE HANDLEBAR 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it f

HANDLEBAR 5. Install: 8 throttle grip assembly1 8 right handlebar switch2 8 throttle cables 3 NOTE: 8 Align the projectiona on the right handlebar swi

STEERING HEAD CHAS (3^3^) EAS00675 STEERING HEAD HANDLEBAR BRACKET AND HEADLIGHT STAY BRACKET ®~. S^>48Nm(4.8m • kg, 34.7 ft • lb) S^60Nm(6.0m • kg

LOWER BRACKET LOWER BRACKET rV 30Nm(3.0m • kg, 21.7 ft • lb)f Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 Removing the lower bracket Front fork upp

SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriat

STEERING HEAD CHAS (3^3^) EAS00678 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. w Securely support the scooter so that there is

STEERING HEAD CHAS (3^3^) EAS00682 CHECKING THE STEERING HEAD 1. Wash: 8bearing balls 8bearing races Recommended cleaning solvent Kerosene 2. Check: 8

STEERING HEAD CHAS (3^3^) EAS00684 INSTALLING THE STEERING HEAD 1. Lubricate: 8bearing balls 1 8bearing races Recommended lubricant Lithium-soap-based

REAR SHOCK ABSORBER ASSEMBLY CHAS (3^3^) EAS00685 REAR SHOCK ABSORBER ASSEMBLY Order Job/Part Q’ty Remarks 1 2 3 4 Removing the rear shock absorber a

REAR SHOCK ABSORBER ASSEMBLY EAS00692 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the scooter on a level surface. w Securely support the scoote

REAR SHOCK ABSORBER ASSEMBLY CHAS (3^3^) EAS00698 INSTALLING THE REAR SHOCK AB-SORBER ASSEMBLY 1. Install: • rear shock absorber assembly 2. Tighten:

ENG % m CHAPTER 5 ENGINE ENGINE REMOVAL 5-1 LEADS, HOSES AND MUFFLER 5-1 ENGINE 5-3 INSTALLING THE ENGINE 5-4 CYLINDER HEAD 5-5 REMOVING THE CYLINDER

ENG % m REMOVING THE SECONDARY SHEAVE AND V-BELT 5-44 DISASSEMBLING THE SECONDARY SHEAVE 5-45 CHECKING THE CLUTCH SHOES 5-45 CHECKING THE V-BELT 5-46

ENGINE REMOVAL ENG %m EAS00188 ENGINE REMOVAL LEADS, HOSES AND MUFFLER ENGINE rV 10Nm(1.0m • kg, 7.2 ft* lb) rV 10Nm(1.0m • kg, 7.2 ft* lb) Order Job

ENGINE REMOVAL ENG %m r^10Nm(1.0m • kg, 7.2 ft* lb) 1* 10Nm(1.0m • kg, 7.2 ft • lb) Order Job/Part Q’ty Remarks 3 4 5 6 7 8 Crankshaft position senso

SPECIAL TOOLS Tool NO. Tool name / Function Illustration 90890-01384 YM-33299 90890-01403 YU-A9472 90890-01444 YM-A9409-7 90890-01468 YU-33270-B 9089

ENGINE REMOVAL ENG %m EAS00191 ENGINE Order Job/Part Q’ty Remarks 1 2 3 4 5 Removing the engine Rear shock absorber assembly lower bolt Engine mounti

ENGINE REMOVAL ENG % m EAS00192 INSTALLING THE ENGINE 1. Install: 8engine1 8engine mounting bolt2 8engine mounting nut3 NOTE: 8 Apply lithium-soap-bas

CYLINDER HEAD ENG %m EAS00221 CYLINDER HEAD P^9Nm(0.9m • kg, 6.5 ft • lb) P|^j8Nm(0.8m • kg, 5.8 ft • lb) n^10Nm(1.0m« kg, 7.2 ft* lb) I 4. i^\ 7 «13N

CYLINDER HEAD ENG % m P^9Nm(0.9m • kg, 6.5 ft • lb) «13Nm(1.3m • kg, 9.4 ft • lb) Order Job/Part Q’ty Remarks 10 Timing chain tensioner gasket 1 11

CYLINDER HEAD ENG %m EAS00225 REMOVING THE CYLINDER HEAD 1. Remove : 8V-belt case cover 8Refer to “BELT DRIVE”. 8cylinder head cover 2. Align: 8“I” ma

CYLINDER HEAD ENG %m 4. Remove: 8timing chain tensioner (along with the gasket) 8camshaft sprocket 1 8timing chain 2 NOTE: 8 To prevent the timing cha

CYLINDER HEAD ENG %m EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: 8combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a

CYLINDER HEAD ENG %m EAS00231 INSTALLING THE CYLINDER HEAD 1. Install: • gasket New • dowel pins 2. Install: • cylinder head 3. Tighten: • cylinder he

CYLINDER HEAD ENG %m cC Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. e. While holding the camshaf

CYLINDER HEAD ENG % m 7. Turn: 8crankshaft (several turns counterclockwise) 8. Check: 8“I” mark a Align the “I” mark on the AC magneto ro-tor with the

SPECIAL TOOLS Tool NO. Tool name / Function Illustration 90890-03141 YU-03141 90890-03182 YU-03182 90890-04101 90890-04058 YM-04058 90890-04145 90890

THE ROCKER ARMS AND CAMSHAFT ENG THE ROCKER ARMS AND CAMSHAFT % m Order Job/Part Q’ty Remarks 1 2 3 4 5 6 Removing the rocker arms and cam-shaft Cyli

THE ROCKER ARMS AND CAMSHAFT ENG % m EAS00202 REMOVING THE ROCKER ARMS AND CAM-SHAFT 1. Remove: 8intake rocker arm shaft 8exhaust rocker arm shaft 8in

THE ROCKER ARMS AND CAMSHAFT ENG ® m§> X \ m§> rgrxn^ 11151001 EAS00205 CHECKING THE CAMSHAFT 1. Check: •camshaft bushings Damage/wear -» Replac

THE ROCKER ARMS AND CAMSHAFT EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and roc

THE ROCKER ARMS AND CAMSHAFT 5. Measure: • rocker arm shaft outside diameter a Out of specification -» Replace. Rocker arm shaft outside diameter 9.98

THE ROCKER ARMS AND CAMSHAFT EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage -» Replace. 2. Check: • one

THE ROCKER ARMS AND CAMSHAFT EAS00220 ENG %m INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: 8camshaft 1 Recommended lubricant Camshaft Molybden

VALVES AND VALVE SPRINGS ENG % m EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve springs Remove the parts

VALVES AND VALVE SPRINGS ENG % m Order Job/Part Q’ty Remarks For installation, reverse the removal pro-cedure. 5-21

VALVES AND VALVE SPRINGS ENG %m EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before

Tool NO. SPECIAL TOOLS GEN INFO #^ Tool name / Function Illustration 90890-01326 YM-01326 90890-01294 YM-01300-1 90890-03153 YU-03153 90890-03181 908

VALVES AND VALVE SPRINGS y-Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attach-ment 90890-04148 YM-04148 4 . Remove: 8valve sp

VALVES AND VALVE SPRINGS ENG EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. M

VALVES AND VALVE SPRINGS ENG % m 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face Pitting/wear -* Grind the

VALVES AND VALVE SPRINGS EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: • carbo

VALVES AND VALVE SPRINGS X"7 V N\ a ^ ••••••••••••••••••••••• a. Apply a coarse lapping compound a to the valve face. cC Do not let the lapping c

VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • valve spring f

VALVES AND VALVE SPRINGS ENG % m EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr

VALVES AND VALVE SPRINGS ENG % m Valve spring compressor 90890-04019(YM-04019) Valve spring compressor attach-ment 90890-04148(YM-04148) 5. To secure

CYLINDER AND PISTON ENG % m EAS00251 CYLINDER AND PISTON Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the cylinder and piston Cylinder head T

CYLINDER AND PISTON ENG % m EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: 8piston pin clip 1 8piston pin 2 8piston 3 cC Do not use a hammer to

SPEC 0* CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2-1 ENGINE SPECIFICATIONS 2-2 CHASSIS SPECIFICATIONS 2-12 ELECTRICAL SPECIFICATIONS 2-15 CONVE

CYLINDER AND PISTON ENG EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: • piston wall • cylinder wall Vertical scratches -* Rebore or replace the

CYLINDER AND PISTON ENG % m e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C”

CYLINDER AND PISTON EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification -» Replace the pis-ton and piston

CYLINDER AND PISTON ENG % m EAS00265 CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration/grooves -* Replace the piston pin and then chec

CYLINDER AND PISTON ENG % m CHECKING THE TIMING CHAIN GUIDE 1. Check: 8 timing chain guide (exhaust side) Damage/wear -» Replace EAS00267 INSTALLING T

CYLINDER AND PISTON ENG % m 3. Install: 8gasket New 8dowel pins 4. Lubricate: 8piston 8piston rings 8cylinder (with the recommended lubricant) Recomme

BELT DRIVE ENG %m EAS00316 BELT DRIVE V-BELT CASE COVER %. 10Nm(1.0m • kg, 7.2 ft • lb) P|« 12Nm(1.2m • kg, 8.7 ft* lb) Order Job/Part Q’ty Remarks 1

BELT DRIVE ENG % m EAS00338 KICKSTARTER Order Job/Part Q’ty Remarks Disassembling the kickstarter Remove the parts in the order listed. V-belt case

BELT DRIVE ENG %m EAS00340 INSTALLING THE KICKSTARTER 1. Install: 8solid bush1 8kick shaft assembly2 8torsion spring3 2. Hook: 8torsion spring NOTE: H

BELT DRIVE ENG %m V-BELT AND PRIMARY/SECONDARY SHEAVE 40Nm (4.0 m«kg, 28.9 fHb) 30Nm (3.0 m«kg, 21.7 fHb) Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8

EAS00000 XF50W 2006 SERVICE MANUAL ©2006 by Yamaha Motor Taiwan Co., Ltd. First edition, September 2006 All rights reserved. Any reproduction or unaut

GENERAL SPECIFICATIONS SPEC 0* SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 3B32(USA) 3B33(CAN) … … Dimensions Overall length

BELT DRIVE ENG %m SECONDARY SHEAVE Order Job/Part Q’ty Remarks Disassembling the secondary sheave Disassemble the parts in the order listed. 1 Clutc

BELT DRIVE ENG %m EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: 8primary sheave nut 1 8plate washer 8oneway clutch 8primary fixed sheave 2 NOTE: Whi

BELT DRIVE ENG % m %-© 1 // / /Py*—\ 1 3. Remove: 8secondary sheave 1 8V-belt 2 NOTE: Remove the V-belt and secondary sheave from the primary sheave

BELT DRIVE Clutch shoe thickness 3.7mm(0.146in) <Limit>:2.0mm(0.079in) NOTE: 8 Inspect clutch shoesa. 8 After removing the clutch shoe spring, d

BELT DRIVE ENG EAS00321 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri-mary sheave weights. 1. Check: • primary

BELT DRIVE ENG %m EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights

BELT DRIVE ENG # 1 1&m\ EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: 8secondary fixed sheave’s inner surface 1 8secondary sliding sheave

BELT DRIVE ENG % m ® © If'/ /F^r~\\ 5. Install: 8secondary sheave 1 8spring 8clutch carrier 2 NOTE: Attach the clutch spring holder 3 and clutch

BELT DRIVE ENG %m Rotor holding tool 90890-01235 YU-01235 Socket wrench(39mm) 90890-01493 3. Install: • clutch housing (T) • secondary sheave nut® XI

BELT DRIVE ENG %m 5. Position: 8V-belt 1 NOTE: Position the V-belt in the primary sheave 2 (when the pulley is at its widest position) and in the seco

ENGINE SPECIFICATIONS SPEC 0* ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, SOHC … Displacement 0.049L(49c

STARTER CLUTCH AND AC MAGNETO ENG % m EAS00341 STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY Order Job/Part Q’ty Remarks 1 2 3 4 5 Removing the

STARTER CLUTCH AND AC MAGNETO ENG % m Order Job/Part Q’ty Remarks 6 7 8 Lock plate Crankshaft position sensor Stator coil assembly 1 1 1 For installa

STARTER CLUTCH AND AC MAGNETO ENG %m EAS00342 STARTER CLUTCH Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the starter clutch Engine oil AC ma

STARTER CLUTCH AND AC MAGNETO ENG % m EAS00347 REMOVING THE AC MAGNETO 1. Remove: 8AC magneto rotor nut1 8washer NOTE: 8 While holding the AC magneto

STARTER CLUTCH AND AC MAGNETO ENG % m EAS00344 REMOVING THE STARTER CLUTCH 1. Remove: 8crankcase cover (right)1 NOTE: Loosen each bolt 1/4 of a turn a

STARTER CLUTCH AND AC MAGNETO ENG %m EAS00351 CHECKING THE STARTER CLUTCH 1. Check: •starter clutch roller Damage/wear -» Replace. 2. Check: •starter

STARTER CLUTCH AND AC MAGNETO ENG %m EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: • idle gear • starter clutch • collar • roller • starter wheel

STARTER CLUTCH AND AC MAGNETO ENG % m 2. Tighten: •AC magneto rotor nut (T) XI 43 Nm (4.3 m * kg, 31.1 ft * lb) NOTE: • While holding the AC magneto r

EAS00360 OIL PUMP OIL PUMP ENG %m 4Nm (0.4 m«kg, 2.9 fHb) 3 Order Job/Part Q’ty Remarks Removing the oil pump Remove the parts in the order listed.

OIL PUMP 11710404 EAS00364 CHECKING THE OIL PUMP 1. Check: • oil pump drive gear • oil pump driven gear© • oil pump housing • oil pump housing cover C

ENGINE SPECIFICATIONS SPEC 0* Item Standard Limit Oil pump Oil pump type Trochoid … Inner rotor to outer rotor tip clearance 0.15mm(0.006in) or less

OIL PUMP ENG %m EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: 8inner rotor 8outer rotor 8oil pump shaft (with the recommended lubricant) Recommended

TRANSMISSION ENG % m EAS00419 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Transmission

TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Measure: • main axle runout (with a centering device and dial gauge ) Out of specification -» Repla

CRANKSHAFT ENG %m EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY 1* 7Nm (0.7 m»kg, 5.1 fHb) 5 7Nm (0.7 m»kg, 5.1 fHb) Order Job/Part Q’ty Remarks Removing t

CRANKSHAFT ENG %m fV 7Nm (0.7 m»kg, 5.1 fHb) 5 7Nm (0.7 m»kg, 5.1 fHb) Order Job/Part Q’ty Remarks 5 Hook 1 6 Drain plug 1 7 Oil strainer 1 8

CRANKSHAFT ENG %m EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 8centerstand assembly 2. Remove: 8crankcase bolts1 NOTE: Loosen each bolt 1/4 of a t

CRANKSHAFT ENG % m EAS00389 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: 8crankshaft assembly1 8timing chain2 8timing chain guide(intake side) NOTE: 8

CRANKSHAFT ENG % m 3. Measure: • crankshaft width Out of specification -»Replace the crank-shaft. Crankshaft width 42.45~42.50mm(1.671~1.673in) ^^^ //

CRANKSHAFT ENG EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE(INTAKE SIDE) 1. Check: • timing chain Damage/stiffness -> Replace the timi

CRANKSHAFT EAS00408 INSTALLING THE CRANKSHAFT 1. Install: 8timing chain guide (intake side) 8timing chain1 8crankshaft assembly2 NOTE: Install the tim

ENGINE SPECIFICATIONS SPEC 0* Item Standard Limit Camshaft Drive system Intake camshaft lobe dimensions B Measurement A Measurement B Exhaust camshaft

CRANKSHAFT ENG %m 3. Install: 8dowel pins 8spacer 8right crankcase1 NOTE: Tap lightly on the right crankcase with a soft-face hammer. 4. Tighten: •cra

COOL JC CHAPTER 6 COOLING SYSTEM RADIATOR 6-1 CHECKING THE RADIATOR 6-2 INSTALLING THE RADIATOR 6-3 THERMOSTAT 6-4 CHECKING THE THERMOSTAT 6-5 INSTALL

RADIATOR COOL JC EAS00454 RADIATOR COOLING SYSTEM Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 Removing the radiator Front cover Side cover(left and rig

RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction -» Clean. Apply compressed air to the rear of the radiator. Damage -» Re

RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: 8cooling system (with the specified amount of the recom-mended coolant) Refer to “CHANGING THE COOL

THERMOSTAT COOL JC EAS00460 THERMOSTAT 10Nm (1.0 m«kg, 7.2 fHb) 10Nm (1.0 m«kg, 7.2 fHb) 4 Order Job/Part Q’ty Remarks 1 2 3 4 5 6 Removing the therm

THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat (T) Does not open at 85 ~100°C (185 ~212°F) -» Replace. ••••••••••••••••••••••• a.

THERMOSTAT COOL JC EAS00466 INSTALLING THE THERMOSTAT 1. Install: • thermostat© • thermostat cover X| 10Nm(1.0m * kg, 7.2ft * lb) NOTE: Align the brea

WATER PUMP COOL JC EAS00468 WATER PUMP lyJ2|10 4i ,/ dr^ ® 10Nm(1.0m« kg, 7.2 ft* lb) Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 Removing the wate

WATER PUMP COOL JC 6 ®^^ ® 10Nm(1.0m • kg, 7.2 ft* lb) Order Job/Part Q’ty Remarks 10 11 12 Oil seal Bearing Gasket 1 1 1 For installation, reverse t

ENGINE SPECIFICATIONS SPEC 0* Item Standard Limit Timing chain Model/number of links Morse 92RH2005/82 … Tensioning system Automatic … Valve, valv

WATER PUMP COOL JC EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: 8water pump housing cover1 8dowel pin 8gasket 2. Remove: 8plate 2 8impeller shaft

WATER PUMP COOL JC EAS00475 ASSEMBLING THE WATER PUMP 1. Install: 8bearing1 NOTE: 8 Before installing the oil seal, apply tap wa-ter or coolant onto i

\ \Ji—-M§ Iae \ \Ji—-b// ^ WATER PUMP COOL JC 5. Install: 8gasket New 8water pump housing cover1 EAS00478 INSTALLING THE WATER PUMP 1. Install: • wate

FI ifl CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 7-1 WIRING DIAGRAM 7-2 ECU’S SELF-DIAGNOSTIC FUNCTION 7-4 CHECKING FOR A DEFECTIVE ENGINE

FUEL INJECTION SYSTEM FI ifl EAS00894 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 ECU q Air filter case 2 Engine trouble warning light w Catalytic

WIRING DIAGRAM FUEL INJECTION SYSTEM FI ifl BSD 5: © © Y L © < P/W x © Br/W B/L © © © Br/W B/L © < P/W x © Y © (BETWEEN MAIN 8 SUB -Hi,® "O

FUEL INJECTION SYSTEM FI ifl 1 AC magneto 3 Main fuse 4 Battery 8 Engine stop switch 9 ECU 0 Main switch q Intake air pressure sensor w Intake air tem

FUEL INJECTION SYSTEM FI ifl ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine con

FUEL INJECTION SYSTEM FI ifl EAS00901 CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB The engine trouble warning light comes on for 2 secon

FUEL INJECTION SYSTEM Fault code No. Item Symptom Engine startability Vehicle driveability 39 Fuel injector Fuel injector open or short circuit is

ENGINE SPECIFICATIONS SPEC 0* Item Standard Limit Valve stem to valve guide clearance Intake Exhaust Valve stem runout ^ w?. % ///////////////////// V

FUEL INJECTION SYSTEM FI ifl EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. *Engine trouble

FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators with con-necting

FUEL INJECTION SYSTEM FI ifl OPOWER OWARNING Fl Diagnostic Tool ©YAMAHA D03: 101 JP MODE DOWN o o o Setting the diagnostic mode 1. Turn the main switc

FUEL INJECTION SYSTEM Fault code table Fault codeNo. Symptom Probable cause of malfunction Diagnostic code 12 No normal signals are received from th

FUEL INJECTION SYSTEM EAS00907 Diagnostic mode table NOTE: 8 Check the intake air temperature and coolant temprature as close as possible to the intak

FUEL INJECTION SYSTEM Communication error with the FI diagnostic tool LCD Display Sympton Probable cause of malfunction Waiting for connec-tion... N

FUEL INJECTION SYSTEM FI ifl Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No. --

FUEL INJECTION SYSTEM FI ifl Fault code No. 13 Symptom Intake air pressure sensor-open or short circuit detected. Used diagnostic code No. D03 (intake

FUEL INJECTION SYSTEM FI ifl Intake air pressure sensor-hose system malfunction Fault code No. 14 Symptom (clogged or detached hose). tached hose). Us

FUEL INJECTION SYSTEM FI ifl Fault code No. 16 Symptom Stuck throttle position sensor detected. Used diagnostic code No. D01 (throttle position sensor

ENGINE SPECIFICATIONS SPEC 0* Item Standard Limit Valve springs Free length Intake 39.35mm(1.5492in) 37.38mm (1.4717in) Exhaust 41.57mm(1.6366in)

FUEL INJECTION SYSTEM FI ifl Fault code No. 21 Symptom Coolant temperature sensor open or short circuit is detected. Used diagnostic code No. D06 (coo

FUEL INJECTION SYSTEM FI ifl Fault code No. 22 Symptom Intake temperature sensor open or short circuit is detected. Used diagnostic code No. D05 (inta

FUEL INJECTION SYSTEM FI ifl Fault code No. 30 Symptom The vehicle has overturned. Used diagnostic code No. D08 (lean angle cut-off switch) Order Insp

FUEL INJECTION SYSTEM FI ifl Fault codeNo. 33 Symptom Open circuit detected in the primary lead of the ignition coil. Used diagnostic code No. D30 Ord

FUEL INJECTION SYSTEM FI ifl Fault code No. 39 Symptom Fuel injector open or short circuit is detected. Used diagnostic code No. D36 (fuel injector) O

FUEL INJECTION SYSTEM FI ifl Fault code No. 42 Symptom No normal signals are received from the speed sensor. Used diagnostic code No. D07 (speed senso

FUEL INJECTION SYSTEM FI ifl Power supply to the fuel injector, fuel pump and ignistion coil are not Fault code No. 43 Symptom normal. Used diagnostic

FUEL INJECTION SYSTEM FI ifl Fault code No. 46 Symptom Power supply to FI system is not normal. (red lead) Used diagnostic code No. --Order Inspection

FUEL INJECTION SYSTEM FI ifl Fault code No. 61 Symptom ISC (idle speed control) valve open or short circuit is detected. Used diagnostic code No. --Or

THROTTLE BODY AND FUEL INJECTOR EAS00909 THROTTLE BODY AND FUEL INJECTOR THROTTLE BODY FI ifl Order Job/Part Q’ty Remarks 1 2 3 4 5 6 Removing the th

ENGINE SPECIFICATIONS SPEC 0* Item Standard Limit Piston Piston-to-cylinder clearance Diameter D -D— Height H Piston pin bore(in the piston) Diameter

THROTTLE BODYAND FUEL INJECTOR FI ifl FUEL INJECTOR AND FUEL HOSE Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the fuel injector and fuel hos

THROTTLE BODYAND FUEL INJECTOR FI ifl FUEL TANK «& 4Nm(0.4m • kg, 2.9 ft • lb) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the par

THROTTLE BODY AND FUEL INJECTOR REMOVING THE FUEL HOSE 1. Extract the fuel in the fuel tank through the fuel tank filler hole with a pump. 2. Remove:

THROTTLE BODY AND FUEL INJECTOR FI ifl EAS00912 CHECKING THE FUEL INJECTOR 1. Check: 8 fuel injector Damage -» Replace. EAS00913 CHECKING THE THROTTLE

THROTTLE BODY AND FUEL INJECTOR FI ifl INSTALLING THE FUEL PUMP 1. Install: 8 fuel pump X| 4Nm(0.4m»kg, 2.9ft*Ib) NOTE: 8 Do not damage the installati

THROTTLE BODY AND FUEL INJECTOR EAS00915 CHECKING THE FUEL PUMP AND PRES-SURE REGULATOR OPERATION 1. Check: 8 pressure regulator operation •••••••••••

THROTTLE BODY AND FUEL INJECTOR FI ifl Positive tester probe -> blue terminal ® Negative tester probe -» black/blue terminal (2) f* Digital circuit

THROTTLE BODY AND FUEL INJECTOR EAS00916 FI ifl CHECKING THE ISC (IDLE SPEED CON-TROL) VALVE NOTE: Do not remove the ISC (idle speed control) valve un

AIR INDUCTION SYSTEM FI ifl EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned ex-haust gases by injecting fresh air

AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air induction system hose 2 Air filter case 3 Air induction system hose (air filter case

ENGINE SPECIFICATIONS SPEC 0* Item Standard Limit Oil ring i 1 B 1 i i T , Dimensions(B×T) 1.5×1.6mm (0.0591×0.0630in) … End gap(installed) 0.2~0.7mm

AIR INDUCTION SYSTEM FI ifl AIR CUT-OFF VALVE AND AIR FILTER CASE PV 7Nm(0.7m • kg, 5.1 ft • lb) 3R 7Nm(0.7m • kg, 5.1 ft • lb) Order Job/Part Q’ty R

AIR INDUCTION SYSTEM EAS00918 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection -» Connect properly. Cracks/damage -» Replace. 2. C

ELEC -+ CHAPTER 8 ELECTORICAL ELECTRICAL COMPONENTS 8-1 WIRING DIAGRAM 8-2 CHECKING SWITCH CONTINUITY 8-4 CHECKING THE SWITCHES 8-5 CHECKING THE BULBS

ELECTRICAL COMPONENTS ELEC +i EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 0 Spark plug cap 2 Front brake light switch q Fuel pump 3 Rect

WIRING DIAGRAM WIRING DIAGRAM ELEC +i P/W Y x Br/W R/B x x B/L B/W Lg W/R L/Y W B/R X f\ B/Y L/B G/Y Sb P B B x ^ rHi' 4= <— go nrn T ^ h &a

WIRING DIAGRAM 1 AC magneto COLOR CODE 2 Rectifier/regulator B Black 3 Main fuse Br Brown 4 Battery Ch Chocolate 5 Starter relay Dg Dark green 6

CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is i

CHECKING THE SWITCHES ELEC + 1 EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity betwee

CHECKING THE BULBS AND BULB SOCKETS EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connection

CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 8bulb w Since

ENGINE SPECIFICATIONS SPEC 0* Item Standard Limit Rocker arm/rocker arm shaft Rocker arm inside diameter Rocker arm shaft outside diameter Arm-to-shaf

CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: •

IGNITION SYSTEM ELEC +i EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM -•-1,® 8-9

IGNITION SYSTEM EAS00736 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Check: 1. main fuse 2. battery 3. spar

IGNITION SYSTEM EAS00742 4. Ignition spark gap Disconnect the spark plug cap from the spark plug. Connect the ignition checker 1 as shown. 2Spark plug

IGNITION SYSTEM • Measure the primary coil resistance. a Primary coil resistance 2.16 ~ 2.64 at 20°C(68°F) • Connect the pocket tester (£1 x1k) to the

IGNITION SYSTEM ELEC +i EAS00750 • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? YES

ELECTRIC STARTING SYSTEM ELEC +i EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main fuse Battery Starter relay Starter motor Start switch Engine s

ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OP-ERATION If the engine stop switch is set to “#” and the main switch is set to “ON

ELECTRIC STARTING SYSTEM EAS00757 TROUBLESHOOTING The starter motor fails to turn. Check: 1. main fuse 2. battery 3. starter motor 4. starting circuit

ELECTRIC STARTING SYSTEM ELEC EAS00758 w 8 A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery le

EAS00002 NOTICE This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. I

ENGINE SPECIFICATIONS SPEC 0* Item Standard Limit Clutch Clutch type Clutch shoe thickness Clutch shoe spring free length Clutch housing inside diamet

ELECTRIC STARTING SYSTEM ELEC +i EAS00761 5. Starter relay • Remove the starter relay . • Connect the pocket tester (Q x1) and bat-tery (12 V) to the

ELECTRIC STARTING SYSTEM EAS00766 11. Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wirin

ELECTRIC STARTING SYSTEM ELEC EAS00767 STARTER MOTOR +i ® MM ® Order Job/Part Q’ty Remarks 1 2 Removing the starter motor Front cover Single seat/Tru

ELECTRIC STARTING SYSTEM ELEC + 1 EAS00769 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt -» Clean with 600-grit sandpaper. 2. Measure: • comm

ELECTRIC STARTING SYSTEM ELEC +i b. If any resistance is out of specification, re-place the starter motor. ••••••••••••••••••••••• 5. Measure: • brush

ELECTRIC STARTING SYSTEM ELEC +i EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: 8brush seat 1 2. Install: 8washer1 8armature coil 2 8o-ing New 3 8s

CHARGING SYSTEM ELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM +i Y X R/B x x B/L l-l Lg R L/Y W B/R x B/Y LB G/Y Sb P Gy B B x Or X -vJHHL/-'

CHARGING SYSTEM ELEC +i EAS00774 TROUBLESHOOTING The battery is not being charged. Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil r

CHARGING SYSTEM ELEC +i NOTE: Make sure the battery is fully charged. • Is the charging voltage within specification? * NO YES lz The charging circui

LIGHTING SYSTEM ELEC +i EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM © © Y L © x © Br/W B/L © © © B/L © < x © v © I ! -H • 8-27

CHASSIS SPECIFICATIONS SPEC 0* CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Caster angle Trail Steel tube backbone 26° 84mm(3.31in) … …

LIGHTING SYSTEM EAS00781 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light or m

LIGHTING SYSTEM EAS00787 5. Wiring • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properl

LIGHTING SYSTEM ELEC +i EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 1. Headlight bulb an

LIGHTING SYSTEM ELEC +i YES V * NO This circuit is OK. The wiring circuit from the main switch to the headlight coupler or meter assembly coupler is f

LIGHTING SYSTEM ELEC +i 3. Voltage • Connect the pocket tester (DC 20 V) to the ECU coupler (wire harness side) as shown. Positive tester probe ->

LIGHTING SYSTEM EAS00792 4. The license plate light fails to come on. 1. License plate light bulb and socket • Check the license plate light bulb and

SIGNALING SYSTEM ELEC +i EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM ^<^ ^^ L/B © (D (3D © © © © © © © © © © © © (BETWEEN MAIN 8 SUB -H" Main fu

SIGNALING SYSTEM EAS00794 TROUBLESHOOTING • Any of the following fail to light: turn sig-nal light, brake light or an indicator light. • The horn fail

SIGNALING SYSTEM ELEC +i EAS00796 CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. 1. Horn switch • Check the horn switch for continuity. Ref

SIGNALING SYSTEM ELEC +i EAS00798 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and

CHASSIS SPECIFICATIONS SPEC 0* Item Standard Limit Rear tire Tire type Size Model(manufacturer) Tire pressure(cold) 0~175kg(0~386lb) Minimum tire trea

SIGNALING SYSTEM ELEC +i EAS00799 3. The turn signal light, turn signal indicator light or both fail to blink. 1. Turn signal indicator light bulb and

SIGNALING SYSTEM 5. Voltage • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. Positive tester probe

SIGNALING SYSTEM ELEC +i EAS00804 4. The fuel level meter fails to operate. 1. Fuel sender • Remove the fuel pump from the fuel tank. • Connect the po

SIGNALING SYSTEM ELEC +i 3. Fuel level meter • Set the main switch to “ON”. • Move the float up® or down (2). • Check that the fuel level meter needle

COOLING SYSTEM ELEC +i EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM © © Y L © X © Br/W B/L © © © B/L © < x © Y © I ! -H • 8-42

COOLING SYSTEM ELEC +i EAS00808 TROUBLESHOOTING • The coolant temperature indicator light fails to indicate. • The coolant temperature indicator light

COOLING SYSTEM ELEC EAS00812 4. Coolant temperature sensor Remove the coolant temperature sensor from the cylinder head. Connect the pocket tester ( ×

COOLING SYSTEM CHECKING THE COOLING SYSTEM 1. The coolant temperature indicator light fails to come on. 1. Coolant temperature indicator light bulb an

COOLING SYSTEM ELEC +i 4. Coolant temperature indicator light • Disconnect the coolant temperature sensor coupler at the coolant temperature sensor. •

TRBL Q SHTGl • CHAPTER 9 TROUBLE SHOOTING STARTING FAILURE/HARD STARTING 9-1 ENGINE 9-1 FUEL SYSTEM 9-1 ELECTRICAL SYSTEMS 9-1 STARTING FAILURES/HARD

CHASSIS SPECIFICATIONS SPEC 0* Item Standard Limit Steering system Steering bearing type Angular bearing … Lock-to-lock angle(left) 46° … Lock-to-lo

TRBL Q SHTGl • TURN SIGNAL DOES NOT COME ON 9-6 TURN SIGNAL BLINKS SLOWLY 9-6 TURN SIGNAL REMAINS LIT 9-6 TURN SIGNAL BLINKS QUICKLY 9-6 HORN DOES NOT

TRBL Q SHTGl • STARTING FAILURE/HARD STARTING EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible c

STARTING FAILURES/HARD STARTING/ INCORRECT ENGINE IDLING SPEED TRBL Q SHTGl • Starting system 8Faulty starter motor 8Faulty starter relay 8Faulty star

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY CLUTCH TRBL Q SHTGl • EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURE/HARD S

FAULTY CLUTCH/OVERHEATING/OVERCOOLING TRBL Q SHTGl • POOR SPEED PERFORMANCE Hose(s) and pipe(s) V-belt 8Damaged hose 8Worn V-belt 8Improperly conne

POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING EAS00859 TRBL Q SHTGl • POOR BRAKING PERFORMANCE Drum brake 8Worn brake shoe 8Worn o

TRBL Q SHTGl • FAULTY LIGHTING OR SIGNALING SYSTEM EAS00866 TURN SIGNAL REMAINS LIT FAULTY LIGHTING OR SIGNALING 8Faulty turn signal relay SYSTEM 8Bur

©YAMAHA YAMAHA MOTOR TAIWAN CO., LTD

XF50W WIRING DIAGRAM •q= »• r 0 r o , © X —^ • XK • c • X e 4, Oft • » MARK EXPLANATION R, Br, BrW... COLOR CODE 4 CONNECTING WITH GRD. WIRE ^L GR

ELECTRICAL SPECIFICATIONS SPEC 0* ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12V … Ignition system Ignition system type Transist

ELECTRICAL SPECIFICATIONS SPEC 0* Item Standard Limit Bulbs(voltage/wattage×quantity) Headlight Tail/brake light Front turn signal light Rear turn sig

ELECTRICAL SPECIFICATIONS SPEC 0* Item Standard Limit Fuse(amperage×quantity) Main fuse 15A×1 … Fuel gauge Model(manufacturer) Sender unit resistance

CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and

TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE Part to be tightened Part name Thread size Q’ty Tightening torque Remarks Part to be tightened Part

TIGHTENING TORQUES SPEC 0* Part to be tightened Part name Thread size Q’ty Tightening torque Remarks Part to be tightened Part name Thread size Q’ty

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 in

TIGHTENING TORQUES CHASSIS Part to be tightened Thread size Tightening torque Remarks Part to be tightened Thread size Nm m»kg ft»lb Remarks Frame an

TIGHTENING TORQUES SPEC 0* NOTE : 1. First,tighten the upper bearing inner race approximately 7Nm(0.7m»kg, 5.1ft»lb) by using the torque wrench and ch

LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE SPEC 0* Lubrication Point Lubricant Oil seal lips ^^TLS

LUBRICATION POINTS AND LUBRICANT TYPES SPEC 0* Lubrication Point Lubricant Drive axle taper rollor bearing —HI^GJ Transmission bearings ^HICGJ Second

LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Lubricant Front wheel oil seal lips ^^LSp^L Steering bearing and bearing ra

COOLING SYSTEM DIAGRAMS SPEC 0* EAS00033 A Insert until contacting with the latch of ra-COOLING SYSTEM DIAGRAMS diator tank. 1 Raidator cap B Install

COOLING SYSTEM DIAGRAMS SPEC 0* 1 Radiator 2 Radiator inlet hose 3 Radiator outlet hose 4 Thermostat 5 Water pump outlet hose A Install clip for the t

COOLING SYSTEM DIAGRAMS SPEC 0* 1 Thermostat assembly inlet breather hose 2 Breather hose 3 Water pump outlet hose 4 Radiator outlet hose 5 Water pump

CABLE ROUTING SPEC 0* EAS00035 CABLE ROUTING 1 Hose3 2 ECU 3 Ignition coil 4 Sidestand switch lead 5 Main switch 6 Hose 7 Coolant temperature sen-sor

CABLE ROUTING SPEC 0* 1 Speedometer A 2 Rectifier/Regulator 3 Turn signal relay B 4 Throttle cable Ass’y C 5 Holder 6 Cable holder 7 Rear brake cable

12 34 CHK igl ADJ I ^<\ 56 ENG % m 78 FI Ifl TRBL f} SHTGl • *Q SPEC CHAS (3^3^) COOL jK ELEC +i 90 qw © /•; ® H\ t y u m I o I p I ^4J ^Gj ^Mj B

CABLE ROUTING SPEC 0* 1 Fuel pump i Rear fender E Put the idle speed control 2 FI diagnostic tool connec- o Fuel injector lead lead and wire sub le

CABLE ROUTING SPEC 0* 1 Speedometer A Penetrate the rear brake D Penetrate the main switch 2 Rectifier/Regulator cable and throttle cable Comp.

G Let the left and right flasher lights, meter, and right lead wire of handle bar switch to face upward, let the main switch, front and rear brake swi

CABLE ROUTING SPEC 0* 1 Turn signal light lead(right) 2 Handlebar switch lead(right) 3 Front brake light switch lead 4 Turn signal light lead(left) 5

CHK ADJ <& CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 3-1 PERIODIC MAINTENANCE AND MINOR REPAIR 3-2 PERIODIC MAINTENANCE CHART FOR

CHK ADJ <& CHECKING THE WHEELS 3-48 CHECKING AND LUBRICATING THE CABLES 3-48 LUBRICATING THE LEVERS AND PEDALS 3-49 LUBRICATING THE CENTERSTAND

INTRODUCTION CHK ADJ <& EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recomm

PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM NO. ITEM ROUTI

PERIODIC MAINTENANCE AND MINOR REPAIR CHK ADJ GENERAL MAINTENANCE AND LUBRICATION CHART <& NO. ITEM ROUTINE INITIAL 600 mi (1,000 km) or 1 mon

PERIODIC MAINTENANCE AND MINOR REPAIR CHK ADJ <& * Since these items require special tools, data and technical skills, have a Yamaha dealer per

EAS00010 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS 0» SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS #% CHASSIS CHAS 4

COVER AND PANEL CHK ADJ <& EAS00038 COVER AND PANEL SIDE COVERS AND TAIL/BRAKE LIGHT Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the

COVER AND PANEL CHK ADJ <& Order Job/Part Q’ty Remarks control system. For installation, reverse the removal pro-cedure. 3-6

COVER AND PANEL CHK ADJ <& SINGLE SEAT AND TRUNK \y10Nm(1.0m • kg, 7.2 ft • lb) [s& 7Nm(0.7m• kg, 5.1 ft• lb) \l 12Nm(1.2m« kg, 8.7 ft* lb)

LEG SHIELD1,2 COVER AND PANEL CHK ADJ <& Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the leg shield1,2 Front fork upper cover Reflect

COVER AND PANEL CHK ADJ <& FOOTREST BOARD AND INNER FENDER Order Job/Part Q’ty Remarks 1 2 3 4 5 6 7 Removing the footrest board and in-ner fe

ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve cleara

ADJUSTING THE VALVE CLEARANCE CHK ADJ <& ••••••••••••••••••••••• a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the c

ADJUSTING THE VALVE CLEARANCE CHK ADJ <& Last digit 0 or 2 5 8 Rounded value 0 5 10 EXAMPLE: Original valve pad number =148(thickness =1.48mm(0

ADJUSTING THE VALVE CLEARANCE CHK ADJ <& n. Install the timing chain tensioner spring and cap bolt . XI 8Nm(0.8m * kg, 5.8ft * lb) o. Measure t

ADJUSTING THE VALVE CLEARANCE INTAKE MEASURED CLEARANCE ORIGINAL VALVE PAD NUMBER • MEASURED CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175

GEN jy* INFO \<^® CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION 1-1 VEHICLE IDENTIFICATION NUMBER 1-1 MODEL LABEL 1-1 FEATURES 1-2 OUTLINE O

ADJUSTING THE VALVE CLEARANCE CHK ADJ <& 8. Install: 8all removed parts NOTE: For installation, reverse the removal procedure. 9. Fill: 8coolin

CHECKING THE ENGINE IDLING SPEED CHK ADJ <& EAS00054 CHECKING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air

ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engi

CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1. Remove: 8 panel Refer to”FOOTREST BOARD AND IN-NER FENDER”. 2. Disconnect: 8 spark plug ca

CHECKING THE SPARK PLUG CHK ADJ <& 8. Install: • spark plug XI 13Nm(1.3m * kg, 9.4ft * lb) NOTE: Before installing the spark plug, clean the sp

CHECKING THE IGNITION TIMING CHK ADJ <& EAS00062 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring con

CHECKING THE IGNITION TIMING CHK ADJ <& 5. Check: 8ignition timing ••••••••••••••••••••••• a. Start the engine, warm it up for several min-utes

MEASURING THE COMPRESSION PRESSURE CHK ADJ <& EAS00067 MEASURING THE COMPRESSION PRES-SURE NOTE: Insufficient compression pressure will result

MEASURING THE COMPRESSION PRESSURE ••••••••••••••••••••••• a. Set the main switch to “ON”. b. With the throttle wide open, crank the en-gine until the

CHECKING THE ENGINE OIL LEVEL -T- V ~///^(S) \ ^ ^\ <\l. }yyf(M' ^ ib !a EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the scooter on a leve

SCOOTER IDENTIFICATION GEN INFO #^ EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identificati

CHANGING THE ENGINE OIL CHK ADJ <& EAS00076 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min-utes, and then turn it off.

CHANGING THE ENGINE OIL 8. 9. Install: 8engine oil filler cap Start the engine, warm it up for several min-utes, and then turn it off. 10.Check: 8engi

CHANGING THE TRANSMISSION OIL CHK ADJ <& CHANGING THE TRANSMISSION OIL 1. Stand the scooter on a level surface. NOTE: • Stand the scooter on a

MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: 8 engine oil level Below the minimum level mark -»Add the recom

MEASURING THE ENGINE OIL PRESSURE CHK ADJ <& 6. Install: 8oil gallery bolt XI 7Nm(0.7m * kg, 5.1ft * lb) 7. Install: • panel Refer to”FOOTREST

REPLACING THE AIR FILTER ELEMENT EAS00086 REPLACING THE AIR FILTER ELEMENT 1. Remove: 8front cover 8side cover(left) Refer to”SIDE COVERS AND TAIL/ BR

REPLACING THE AIR FILTER ELEMENT CHK ADJ <& 5. Install: 8side cover(left) 8front cover Refer to”SIDE COVERS AND TAIL/ BRAKE LIGHT”. 3-31

CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD/CHECKING THE FUEL HOSE EAS00094 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD 1. Remove: 8

CHECKING THE BREATHER HOSES CHK ADJ <& EAS00098 CHECKING THE BREATHER HOSES 1. Remove: 8front cover 8side cover(left and right) 8single seat/tr

CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler assembly and gasket. 1. Remove:

FEATURES EAS00896 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti

CHECKING THE COOLANT LEVEL EAS00103 CHECKING THE COOLANT LEVEL 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand.

CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: 8front cover 8side cover(left and right) 8battery /battery cover 8single s

CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: 8front cover 8side cover(right) 8coolant reservoir cap cover Refer to”COVER AND PANEL”.

CHANGING THE COOLANT 7. Fill: 8cooling system (with the specified amount of the recom-mended coolant) «0 Recommended antifreeze High-quality ethylene

CHANGING THE COOLANT CHK ADJ <& 9. Fill: 8coolant reservoir (with the recommended coolant to the maximum level mark 1) 10.Install: 8coolant res

ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE CHK ADJ <& EAS00109 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: 8 brake lever free play a O

CHECKING THE FRONT AND REAR BRAKE SHOES CHK ADJ <& EAS00127 CHECKING THE FRONT AND REAR BRAKE SHOES 1. 2. Operate the brake. Check: • wear indi

CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ <& EAS00148 CHECKING AND ADJUSTING THE STEER-ING HEAD 1. Stand the scooter on a level surface.

CHECKING AND ADJUSTING THE STEERING HEAD b. Loosen the upper bearing inner race2 com-pletely and then tighten it to specification with a steering nut

CHECKING THE FRONT FORK CHK ADJ <& EAS00151 CHECKING THE FRONT FORK 1. Stand the scooter on a level surface. w Securely support the scooter so