BWS NG 1998

CW50RS
SERVICE
MANUAL
'98
5FX-AE1
CW50RS
SERVICE MANUAL
1998 by MBK INDUSTRIE
1st Edition, July 1998
All rights reserved. Any
reprinting or unauthorized use
without the written
permission of MBK INDUSTRIE
is expressly prohibited.
NOTICE
This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealers
and their qualified mechanics. It is not possible to put an entire mechanics education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and
MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in
scooter repair technology. Without such knowledge, attempted repairs or service to this model may
render it unfit to use and/or unsafe.
MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and
significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and
MBK dealers and will, where applicable, appear in future editions of this manual.
DOCUMENTATION TECHNIQUE
MBK INDUSTRIE
PARTICULARY IMPORTANT INFORMATION

This material is distinguished by the following notation :
The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE :
Failure to follow WARNING instructions could result in severe injury or

death to the scooter operator, a bystander, or a person inspecting or
repairing the scooter.
A CAUTION indicates special precautions that must be taken to avoid

damage to the scooter.
A NOTE provides key information to make procedures easier or clearer.
HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This 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 FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particulary important procedure 4 is placed between a line of asterisks " * " with each step
preceded 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 an
alignement 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 required
the symbol 9.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams are before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
ILLUSTRATED SYMBOLS
GEN
INFO
(REFER TO THE ILLUSTRATION)
SPEC
Illustrated symbols Q to W are designed as

thumb tabs to indicate the chapters number and
content.
INSP
ADJ
ENG
Q General information
W Specifications
E Periodic inspection and adjustment
R Engine
T Carburetion
Y Chassis
U Electrical
I Troubleshooting
CARB
CHAS
TRBL
SHTG
ELEC
O
Illustrated symbols O to e are used to identify

the specifications appearing in the text.
T.
Illustrated symbols r to [ in the exploded

diagram indicate grade of lubricant and location
of lubrication point.
r
O Filling fluid
P Lubricant
{ Special tool
} Tightening
q Wear limit, clearance
w Engine speed
e , V, A
r Apply engine oil

t Apply gear oil
y Apply molybdenum disulfide oil
u Apply wheel bearing grease
i Apply lightweight lithium-soap base
grease
o Apply molybdenum disulfide grease
p Apply locking agent (THREADLOCK )
[ Use new one
INDEX
GENERAL INFORMATION
GEN
INFO
SPECIFICATIONS
SPEC
PERIODIC INSPECTION
AND ADJUSTMENT
INSP
ADJ
ENGINE OVERHAUL
ENG
CARBURETION
CARB
CHASSIS
CHAS
ELECTRICAL
ELEC
TRBL
SHTG
TROUBLESHOOTING
GEN
INFO
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
SCOOTER IDENTIFICATION ........................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER .................................................... 1-1
ENGINE SERIAL NUMBER ..................................................................... 1-1
IMPORTANT INFORMATION ....................................................................... 1-2
ALL REPLACEMENT PARTS ................................................................. 1-2
GASKETS, OIL SEALS, AND O-RINGS .................................................. 1-2
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-2
BEARINGS AND OIL SEALS ................................................................... 1-2
CIRCLIPS ................................................................................................. 1-3
SPECIAL TOOLS ........................................................................................... 1-3
FOR TUNE UP ......................................................................................... 1-3
FOR ENGINE SERVICE .......................................................................... 1-4
FOR CHASSIS SERVICE ........................................................................ 1-5
FOR ELECTRICAL COMPONENTS ........................................................ 1-5
SCOOTER IDENTIFICATION
GEN
INFO
GENERAL
INFORMATION
SCOOTER IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number Q is stamped
into the frame.
NOTE:
The vehicle identification number is used to
identify your scooter and may be used to register
your scooter with the licensing authority in your
state.
ENGINE SERIAL NUMBER

The engine serial number Q is stamped into the
crankcase.
NOTE:
Designs and specifications are subject to change
without notice.
1-1
IMPORTANT INFORMATION
GEN
INFO
IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1.Use only genuine parts for all replacements.
Use oil and/or grease recommended by MBK/
YAMAHA for assembly and adjustment. Other
brands may be similar in function and
appearance, but inferior in quality.
GASKETS, OIL SEALS, AND O-RINGS

1.All gaskets, seals and O-rings should be
replaced when an engine is overhauled. All
gaskets surfaces, oil seal lips and O-rings
must be cleaned.
2.Properly oil all mating parts and bearing during
reassembly. Apply grease to the oil seal lips.
LOCK WASHERS/PLATES AND COTTER

PINS
1.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 nut
flat(s) after the bolt or nut has been properly
tightened.
BEARINGS AND OIL SEALS

1.Install the bearing(s) Q and oil seal(s) W with
their manufacturers marks or numbers facing
outward. (In other words, the stamped letters
must be on the side exposed to view.) When
installing oil seal(s), apply a light coating of
lightweight lithium base grease to the seal
lip(s). Oil the bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the

bearings dry. This causes damage to the
bearing surfaces.
1-2
IMPORTANT INFORMATION/SPECIAL TOOLS
GEN
INFO
CIRCLIPS
1.All circlips should be inspected carefully before
reassembly. Always replace piston pin clips
once they have been removed. Replace bent
circlips. When installing a circlip Q make sure
that the sharp edge W is positioned opposite
to the thrust E it receives. See the sectional
view.
R Shaft
SPECIAL TOOLS
The proper special tools are necessary for
complete and accurate tune-up and assembly.
Using the correct special tool will help prevent
damage caused by the use of improper tools or
improvised techniques.
Inductive tachometer
90890-03113
FOR TUNE UP
Ignition checker
90890-06754
1-3
SPECIAL TOOLS
GEN
INFO
Flywheel magneto puller

90890-01189
FOR ENGINE SERVICE
Crankcase separating tool

90890-01135
Flywheel holding tool

90890-01235
Crankshaft installing tool set

90890-01274 Q
90890-01275 W
90890-01277 E
90890-01411 R
Clutch serving nut wrench

90890-01348
Sheave holder
90890-01701
Clutch spring holder

90890-01337 Q
90890-01016 W
1-4
SPECIAL TOOLS
GEN
INFO
Steering Head wrench

9079Q-02218
FOR CHASSIS SERVICE
T-HANDLE
90890-01326
Damper rod holder

90890-01294
Oil seal guide

90890-01367
Oil seal guide adapter

90890-01400
30
Pocket Tester
90890-03112
FOR ELECTRICAL
COMPONENT
1-5
SPEC
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
MAINTENANCE SPECIFICATIONS .............................................................. 2-4
ENGINE ................................................................................................... 2-4
CHASSIS ................................................................................................. 2-7
ELECTRICAL ........................................................................................... 2-8
CABLE ROUTING ........................................................................................ 2-10
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
Model
CW50RS
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
1.746 mm (0.07 in)

675 mm (26.5 in)
1.120 mm (0.04in)
803 mm (31.61 in)
1.206 mm (0.05 in)
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
Cylinder arrangement
Displacement
Bore x stroke
Compression ratio
Starting system
Air-cooled 2-stroke, gasoline torque induction.

Single cylinder, Vertical
49,2 cm3
40 x 39.2 mm (1.57 x 1.54 in)
7.22 : 1
Electric and kick starter
Lubrication system:
Separate lubrication (Yamaha Autolube )
Oil type or grade:

Engine oil:
Transmission oil
SEMI-SYNTHETIC, in accordance with

API TC TSC 3 STANDARD.
SAE 10W30 type SE motor oil
Oil capacity:
Transmission oil:
Periodic oil change
Total amount
0.11 L (0.10 Imp qt, 0.12 US qt)

0.13 L (0.11 Imp qt, 0.13 US qt)
Air filter:
Wet type element
Fuel:
Type
Tank capacity
Regular unleaded gasoline with a reserch octane

number of 91 or higher.
6.5 L (1.42 Imp gal, 1.71 US gal)
2-1
Model
SPEC
CW50RS
Carburetor:
Type/Manufacturer
5FX / TEIKEI
PHBN12 HS / DELL'ORTO
Spark plug:
Type/Manufacturer
Gap
BR8HS/NGK
0.5 ~ 0.7 mm (0.19 ~ 0.27 in)
Clutch type:
Dry, centrifugal automatic
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission
Operation
Helical gear
52/13 (4.000)
Spur gear
42/13 (3.323)
V-belt
Automatic
Chassis:
Frame type
Caster angle
Trail
Steel tube underbone

27
90 mm (3.54 in)
Tire:
Type
Size
Manufacturer
Tire pressure (cold tire):

Up to 90 kg
90 kg ~ maximum load
Front
Rear
Front
Rear
Front
Rear
Tubeless
Tubeless
120/90-10
130/90-10
MICHELIN (REGGAE)
MICHELIN (REGGAE)
Front
Rear
Front
Rear
150 kPa (1.50 kg/cm2, 21.3 psi)

150 kPa (1.50 kg/cm2, 21.3 psi)
150 kPa (1.50 kg/cm2, 21.3 psi)
160 kPa (1.60 kg/cm2, 22.7 psi)
Brake:
Front brake type
Operation
Rear brake type
Operation
Disc brake
Right hand operation
Drum brake
Left hand operation
Suspension:
Front
Rear
Telescopic fork
Unit swing
Shock absorber:
Front
Rear
Coil spring/Oil damper

Coil spring/Oil damper
Wheel travel:
Front wheel travel
Rear wheel travel
80 mm (3.14 in)
60 mm (2.36 in)
2-2
Model
CW50RS
Electrical:
Ignition system
Charging system
Battery type/model
Battery capacity
CDI
Flywheel magneto
GM4-3B, YB4L-B, FB4L-B
12V 4AH
Headlight type
Bulb
Bulb wattage / quantity:

Headlight
Auxiliary light
Taillight/brake light
Flasher light
SPEC
Front
Rear
Meter light
Warning lights wattage / quantity:
OIL
HIGH BEAM
TURN
12V 35W/35W x 1
12V 5W x 1
12V 5W/21W x 1
12V 10W x 2
12V 10W x 2
12V 1.2W x 2
12V 1.2W x 1
12V 1.2W x 1
12V 1.2W x 1
2-3
MAINTENANCE SPECIFICATIONS
SPEC
ENGINE
Model
Cylinder head:
Warp limit
CW50RS
0,02 mm (0.0008 in)
Lines indicate straight edge measurements.
Cylinder:
Bore size
Taper limit
39.993 ~ 40.012 mm (1.576 ~ 1.575 in)

0.05 mm (0,0002 in)
Piston:
Piston size
Measuring point
39.952 ~ 39.972 mm (1.576 ~ 1.574 in)

5 mm (0.19 in)
Piston clearance
<Limit>
Oversize 1st
Oversize 2nd
Piston pin bore size
Piston pin:
Outside diameter
Piston ring:
Sectional sketch (BxT)/Type:
Top ring
2nd ring
End gap (installed):
Top ring
2nd ring
Side clearance (installed):
Top ring
2nd ring
0.034 ~ 0.047 mm (0.001 ~ 0.002 in)

<0.1 mm (0.004 in)>
40.25 (1.58 in)
40.50 (1.59 in)
10.004 ~ 10.019 mm (0.394 ~ 0.395 in)
9.996 ~ 10.000 mm (0.393 ~ 0.394 in)
1.2 1.8 mm (0.05 ~ 0.07 in)

1.2 1.8 mm (0.05 ~ 0.07 in)
0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
0.03 ~ 0.05 mm (0.001 ~ 0.002 in)
0.03 ~ 0.05 mm (0.001 ~ 0.002 in)
2-4
Model
SPEC
CW50RS
Crankshaft:
Crank width A
Runout limit C
Connecting rod big end
side clearance D
37.90 ~ 37.95 mm (1.492 ~ 1.494 in)

0.03 mm (0.001 in)
0.2 ~ 0.5 mm (0.007 ~ 0.019 in)
Automatic centrifugal clutch:

Shoe thickness
<Wear limit>
Clutch shoe spring free length
Clutch-in revolution
Clutch-stall revolution
2.0 mm (0.08 in)

<1.0 mm (0.039 in)>
29.9 mm (1.177 in)
3.250 ~ 3.750 r.p.m.
6.100 ~ 6.900 r.p.m.
V-belt:
Width
<Wear limit>
16.5 mm (0.64 in)

<15.7 mm (0.61 in)>
Transmission:
Main axle runout limit
Drive axle runout limit
0.08 mm (0.003 in)

0.08 mm (0.003 in)
Kick starter:
Type
Kick clip tension
Ratchet type
0.15 ~ 0.25 kg (0.33 ~ 0.55 lbs)
Reed valve:
Valve stopper height
Reed valve clearance
4.0 ~ 4.4 mm (0.15 ~ 0.17 in)

0.2 mm (0.007 in)
Lubrication system:
Stroke
Bore
Autolube pump
2.62 mm (0.103 in)
0.5 mm (0.019 in)
2-5
SPEC
Carburetor:
DELLORTO
TEIKEI
I.D. mark
PHBN12 HS
5FX
#88
Main jet
(M.J.)
#90
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.)
1.2
#40
#46
2000 200 rpm
2000 200 rpm
Starter jet
Engine idle speed
(G.S.1)
2-6
SPEC
CHASSIS
Model
Steering system:
Steering bearing type
No/Size of steel balls:
Upper
Lower
CW50RS
Ball bearing
15 pcs (4.77 mm)
15 pcs (4.77 mm)
Front suspension:
Front fork travel
Spring rate (K1)
Stroke (K1)
Optional spring
80 mm (3.14 in)
5.7 Nmm (0.57 kg/mm, 31.92 lb/in)
0 ~ 80 mm (0 ~ 3.14 in)
No
Rear suspension:
Shock absorber travel
Spring free length
Spring fitting length
Spring rate (K1)
Stroke (K1)
Spring rate (K2)
Stroke (K2)
Optional spring
70 mm (2.75 in)
165 mm (6.49 in)
151.5 mm (5.96 in)
26 Nmm (2.6 kg/mm, 145.61 lb/in)
0 ~ 40 mm (0 ~ 1.57 in)
36 Nmm (3.6 kg/mm, 201.62 lb/in)
40 ~ 70 mm (1.57 ~ 2.75 in)
No
Wheels:
Front wheel type
Rear wheel type
Front wheel size/Material
Rear wheel size/Material
Cast wheel
Cast wheel
MT 3.00 x10 / Aluminium
MT 3.50 x10 / Aluminium
Rim runout limit:

Radial
Lateral
1.0 mm (0.039 in)

1.0 mm (0.039 in)
Front disc brake:

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

Type
Drum inside diameter
<Wear limit>
Lining thickness
<Wear limit>
Spring free length
Leading, trailing
110 mm (4.33 in)
<110.5 mm (4.35 in)>
4.0 mm (0.15 in)
<2.0 mm (0.07 in)>
54 mm (2.12 in)
Front brake lever freeplay:

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

10 ~ 20 mm (0.39 ~ 0.78 in)
2-7
SPEC
ELECTRICAL
Model
CW50RS
Voltage:
12 V
Ignition system:
Ignition timing (B.T.D.C.)
14 at 5.000 r/min
CDI:
Pickup coil resistance (color)
Source coil resistance (color)
400 ~ 600 at 20C (68F) (White/Red-Black)

640 ~ 960 at 20C (68F) (Black/Red-Black)
Ignition coil:
Minimum spark length
Primary coil resistance
Secondary coil resistance
6 mm (0.23 in)
0.32 ~ 0.48 at 20C (68F)
5.68 ~ 8.52 k at 20C (68F)
Spark plug cap:

Resistance
5 k at 20C (68F)
CDI Magneto:
Lighting coil resistance
Charging coil resistance
0.32 ~ 0.48 at 20C (68F)(Yellow/Red-Black)

0.48 ~ 0.72 at 20C (68F)(White-Black)
Voltage regulator/Rectifier:
Type
No load regulated voltage
Capacity
Semi-conductor, short-circuit type

13 ~ 14 V
8A
2-8
Model
SPEC
CW50RS
Battery:
Capacity
Specific gravity
12V, 4 Ah
1.280
Starter motor:
Output
Armature coil resistance
Brush length
<Wear limit>
Brush spring pressure
Commutator diameter
<Wear limit>
Mica undercut
0.14 kW
0.06 ~ 0 08 a 20C (68F)
3.9 mm (0.15 in)
<0.9 mm (0.035 in)>
563 ~ 844 gr (19.85 ~ 29.76 oz)
15.8 mm (0.62 in)
<14.8 mm (0.58 in)>
1.15 mm (0.045 in)
Starter relay:
Amperage rating
Coil resistance
20 A
54 ~ 66 at 20C (68F)
Horn:
Type/Quantity
Model/Manufacturer
Maximum amperage
Plain type/1 pc.

TR9/TRANSVAL
2.5 A
Flasher relay:
Type
Self cancelling device
Flasher frequency
Wattage
Condenser type
No
65 - 95 cycle/min
2x(10+3)W
Circuit breaker:
Type
Amperage for individual circuit x Quantity:
Main
Fuel sender unit:
Resistance
(full)
(empty)
Fuse
7Ax1
7.4 ~ 9.0 at 20C (68F)
82 ~ 98 at 20C (68F)
2-9
SPEC
CABLE ROUTING
CABLE ROUTING
Q Rectifier/regulator
W Battery
E Fuse holder
R Oil tank
T Fuel level sender
Y Brake hose guide
U Head light
I Speedometer cable
O
P
{
}
q
w
e
A
B
C
D
E
Pass the wire harness under the frame.

Attach on the mole fender (only on the left Side).
Attach the wire harness with a plastic band.
Attach all the wire.
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).
Ignition coil
Oil level gauge
Mudguard
Starter motor
CDI magneto
Brake wire
Under cover
6
6
6
6
6
6
2221
2221
6
6
6
6
2221
6
2221
2221
2221
22216
6
6
6
6
2221
6
2221
1 2
1
2
1
3
6
1
1
4
6
2
0
0
5
1
5
3
4
3
6
6
+5
10 0
5
5
5
5
5
5
5
5
6
0
2221
6
2
2221
2
1
6
5
2221
6
1
2221
02 1
2221
6
6
5
1
2221
6
6
6 2
1
0
6
2221
2
5
6
2221 6
2221
5
6
1
2
1
1
2221
2221
6
2
0
2
2221
6
2
2
1
5
6
6
2
1
2
6
6
2
3
4
3
4
1
2
2221
2221
5
3
3
3
6
1
6
5
1
1
2
5
4
3
1
2
5
6
1
1
6
5
5
5
3
5
5
5
5
5
5
5
5
H
3010
2-10
CABLE ROUTING
Q
W
E
R
T
Y
U
I
O
P
{
}
q
w
e
r
t
y
u
i
o
p
Grip assembly (right)

Handle switch (right)
Front stop switch
Front master cylinder
Plain washer
Union bolt
Flasher relay
Handle switch (left)
Grip assembly (left)
Rear brake lever
Starter cable
[
]
A
S
D
Brake hose
Handle cover
Speedometer assembly
Handle cover
Speedometer cable
Wire harness
Plastic clip
Nut flange
Bolt flange
Fitting nut
Washer
1 MINI
SPEC
Upper race ball

Steering balls
Lower race ball
Frame
Front fork assembly
2
51
3 4
3 4 56
B
6
t
E
o
p
[
]
A
S
A
]
D
F
y
r
RIGHT
FRONT
u
LEFT
2-11
CABLE ROUTING
A
B
C
D
E
F
SPEC
Install the handlebar switch before the master cylinder.

Install all connectors under the handlebar and the speedometer assembly.
Attach the wire harness holder on the frame dropout.
Do not clamp the speedometer cable and the brake wire.
Apply grease.
Install in the correct position.
1 MINI
2
51
3 4
3 4 56
B
6
t
E
o
p
[
]
A
S
A
]
D
F
y
r
RIGHT
FRONT
u
LEFT
2-12
SPEC
CABLE ROUTING
Rear brake cable
I
Rear stop switch
O
Handlebar switch (left) P
Handlebar switch (right) {
Throttle cable
}
Grip 5FX
q
Master cylinder
Front brake hose

Starter cable
Throttle cable
Rear brake cable
Wire harnness
Speedometer cable
A Install the cable end stop on the brake lever

holder.
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.

B

FRONT
1.5 ~ 3 mm
Q
W
E
R
T
Y
U
9 0
5 mm
10
2-13
CHK
ADJ
CHK
ADJ
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION ............................................................................................ 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............................ 3-1
COVERS ........................................................................................................ 3-3
REMOVAL ................................................................................................ 3-3
INSTALLATION ........................................................................................ 3-6
HANDLEBAR COVERS ................................................................................. 3-7
REMOVAL ................................................................................................ 3-7
INSTALLATION ........................................................................................ 3-7
ENGINE ......................................................................................................... 3-9
ENGINE IDLE SPEED ADJUSTMENT .................................................... 3-9
THROTTLE CABLE FREE PLAY ADJUSTMENT ................................. 3-10
SPARK PLUG INSPECTION ................................................................. 3-11
AUTOLUBE PUMP AIR BLEEDING ...................................................... 3-12
ENGINE OIL LEVEL INSPECTION ....................................................... 3-13
TRANSMISSION OIL REPLACEMENT ................................................. 3-14
AIR CLEANER ELEMENT CLEANING .................................................. 3-15
CHASSIS ..................................................................................................... 3-16
FRONT BRAKE LEVER FREE PLAY ADJUSTMENT ........................... 3-16
REAR BRAKE LEVER FREE PLAY ADJUSTMENT ............................. 3-16
BRAKE PADS INSPECTION ................................................................. 3-16
BRAKE SHOE INSPECTION ................................................................. 3-17
BRAKE FLUID LEVEL INSPECTION .................................................... 3-17
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)- ................................ 3-18
STEERING HEAD ADJUSTMENT ......................................................... 3-18
TIRE INSPECTION ................................................................................ 3-19
WHEEL INSPECTION ........................................................................... 3-20
CABLE INSPECTION AND LUBRICATION ........................................... 3-20
LEVER LUBRICATION .......................................................................... 3-21
CENTERSTAND LUBRICATION ........................................................... 3-21
FRONT FORK INSPECTION ................................................................. 3-21
REAR SHOCK ABSORBER .................................................................. 3-22
ELECTRICAL ............................................................................................... 3-23
BATTERY INSPECTION ........................................................................ 3-23
FUSE INSPECTION ............................................................................... 3-24
HEADLIGHT BEAM ADJUSTMENT ...................................................... 3-25
HEADLIGHT LENS REPLACEMENT .................................................... 3-26
HEADLIGHT BULB REPLACEMENT .................................................... 3-26
INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
INSP
ADJ
PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as new vehicles that are being prepared for
sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
ITEM
REMARKS
BREAK-IN
EVERY
1,000
3,000(2,000) 6,000(4,000)
or
or
6 Months
12 Months
(600)
Spark plug*
Check condition. Clean or replace if necessary.
Air filter
Clean. Replace if necessary.
Carburetor*
Check idle speed/starter operation. Adjust if necessary.
Fuel line*
Check fuel hose and vacuum hose for cracks or

damage. Replace if necessary.
Transmission oil*
Check oil leakage. Correct if necessary.

REReplace every 12,000 (8,000) or 24 months (warm PLACE
engine before draining).
Autolube pump *
Check operation.
Front brake*
See NOTE. Correct if necessary. Air bleeding.

Check operation/fluid leakage. Correct if necessary.
Rear brake*
Check operation. Adjust if necessary.
Wheels*
Check balance/runout. Repair if necessary.
Wheel bearings*
Check bearing assembly for looseness /damage.

Replace if damaged.
Steering bearings*
Check bearing assembly for looseness. Correct if

necessary. Moderately repack every 12,000 (8,000)
or 24 months.**
Rear shock absorber*
Check operation/oil leakage. Repair if necessary.
V-belt*
Check damage and wear. Replace if necessary.
Fittings/Fasteners*
Check all chassis fittings and fasteners.
Centerstand*
Correct if necessary. Check operation. Repair if

necessary.
Battery *
Check specific gravity. Check breather hose for

proper operation. Correct if necessary.
*: It is recommended that these items be serviced by a MBK or a Yamaha dealer.

**: Medium weight wheel bearing grease.
3-1
Km(miles)
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INSP
ADJ
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.
3-2
COVERS
INSP
ADJ
COVERS
REMOVAL
1. Remove:
Seat Q
353001
2. Remove:
Rear cover Q
3. Remove:
Side cover (left and right) Q
4. Remove:
Battery cover Q
CAUTION:
When removing the cover, be careful not to
damage the mounting clips.
5. Remove:
Seat cover Q
3-3
COVERS
INSP
ADJ
6. Disconnect:
Battery terminals Q
7. Remove:
Battery W
367001
8. Remove:
Footrest board Q
9. Remove:
Front cover Q
CAUTION:
10. Remove:
Headlight socket Q
Turn the headlight socket clockwise, then
remove it.
11 . Remove:
Main switch ring Q
Turn the ring clockwise to remove it.
3-4
COVERS
INSP
ADJ
12. Remove:
Inner panel Q
13. Remove:
Lower cover Q
14. Remove:
Front wheel Q
Refer to the section FRONT WHEEL - REMOVAL in Chapter 6.
15. Disconnect:
Flasher light couplers (left and right) Q
16. Remove:
Front fender Q
3-5
COVERS
INSP
ADJ
INSTALLATION:
Reverse the REMOVAL procedure. Note the
following points.
NOTE:
Correct routing of cables and wires is essential
for a safe operation of this scooter. Refer to the
section CABLE ROUTING in Chapter 2.
NOTE:
Be careful not to pinch any wires with the covers.
NOTE:
When installing the covers, be careful not to
3-6
HANDLEBAR COVERS
INSP
ADJ
HANDLEBAR COVERS
REMOVAL
1. Remove:
Handlebar cover (front) Q
CAUTION:
2. Remove:
Auxiliary light socket Q
3. Remove:
Rear handlebar cover screws
Rear handlebar cover Q
4. Remove:
Meter coupler Q
Speedometer cable W
INSTALLATION
Reverse the REMOVAL procedure. Note the
following points:
1. Connect:
Speedometer cable
Meter connector
3-7
HANDLEBAR COVERS
INSP
ADJ
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 careful
not to damage any cables. Refer to the section
CABLE ROUTING in Chapter 2 for proper
routing of wires.
3-8
ENGINE IDLE SPEED ADJUSTMENT
INSP
ADJ
ENGINE
ENGINE IDLE SPEED ADJUSTMENT
1. Tighten:
Pilot air screw Q
Turn the pilot air screw in until lightly seated.
2. Loosen:
Pilot air screw
Back out from the lightly seated position.
322025
Pilot air screw position:

DELL'ORTO
1+3/8 turns out 1/8
TEIKEI
1+1/2 turns out 1/4
3. Start the engine and let it warm up for several

minutes.
WARNING
For safety reasons, place the scooter on the
center stand before starting the engine.
4. Attach:
Inductive tachometer Q
(to the spark plug lead)
Inductive tachometer:
90890-03113
5. Check:
Engine idle speed
Out of specification Adjust.
Engine idle speed:
2000 200 r/min
3-9
ENGINE IDLE SPEED ADJUSTMENT/

THROTTLE CABLE FREE PLAY ADJUSTEMENT
INSP
ADJ
6. Adjust:
Engine idle speed
********************************************************
Adjustment steps:
Turn the throttle stop screw Q in or out until
specified idling speed is obtained.
322025
Turning left
Idling speed increased.
Turning right
Idling speed decreased.
*******************************************************
THROTTLE
CABLE
FREE
PLAY
ADJUSTMENT
1 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, the
engine 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.
Turning left
Idling speed increased.
Turning right
Idling speed decreased.
Tighten the locknuts.
WARNING
After adjusting, turn the handlebar to the
right and left, making sure that the engine
idling speed does not change.
*******************************************************
3-10
SPARK PLUG INSPECTION
INSP
ADJ
SPARK PLUG INSPECTION

1. Remove:
Spark plug
2. Inspect:
Electrode Q
Wear/Damage Replace.
Insulator W
Abnormal color Replace.
Standard spark plug:
BR8HS (NGK)
3. Measure:
Plug gap @
Use a wire gauge or feeler gauge.
Spark plug gap @:
0,5 ~ 0,7 mm (0.020 ~ 0.028 in)
4. Tighten:
Spark plug
Before installing the spark plug, clean the gasket
surface and plug surface.
NOTE:
First tighten by hand, then torque to specification.
Spark plug:
20 Nm (2.0 m kg, 14ft lb)
3-11
AUTOLUBE PUMP AIR BLEEDING
INSP
ADJ
AUTOLUBE PUMP AIR BLEEDING

1. Remove:
Fan cover Q
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 bubbles
in it.
When there are no more bubbles, tighten the
bleed 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 2000
rpm. This will force out any air in the hose.

*******************************************************
3-12
ENGINE OIL LEVEL INSPECTION
INSP
ADJ
ENGINE OIL LEVEL INSPECTION

1. Inspect:
Oil level
Oil level low Add oil to proper level as
follows.
Q OIL indicator light
OIL LEVEL AND GAUGE CHECK

Turn main switch
to "*'
"OIL" indicator
doesn't light.
"OIL" indicator
light.
Turn main switch

to "ON".
"OIL" indicator goes
Inspect Faulty
electrical circuit,
Light bulb etc.
Engine oil level

and electric circuit
are OK.
"OIL" indicator
stays on.
Add oil.
"OIL" indicator
stays on.
Recommended oil:
Semi-synthetic oil in accordance
with 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 fully
into the filler.
CAUTION:
Always use the same type of engine oil;
mixing oils may result in a harmful chemical
reaction and lead to poor performance.
3-13
TRANSMISSION OIL REPLACEMENT
INSP
ADJ
TRANSMISSION OIL REPLACEMENT

1. Remove:
Drain plug Q
Oil filler plug W
Drain the transmission oil.
2. Check:
Gasket (drain plug)
O-ring (oil filler plug)
Damaged Replace.
3. Install:
Gasket
Drain plug
T.
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 amount
0.13 L
(0.114 Imp qt, 0.137 US qt)
NOTE:
Wipe off any oil spilt on the crankcase, tire or
wheel.
5 Install:
Oil filler plug
3-14
AIR CLEANER ELEMENT CLEANING
INSP
ADJ
AIR CLEANER ELEMENT CLEANING

1. Remove:
Air cleaner case cover Q
2. Remove:
Air filter element
CAUTION:
Never operate the engine with the air cleaner
element removed. Unfiltered air will cause
rapid wear of engine parts and possible
engine damage.
3.Inspect:
Element Q
Damage replace.
4.Clean:
Air filter element
*******************************************************
Cleaning steps:
Wash the element gently but thoroughly in
solvent.
WARNING
Never use low flashpoint solvents such as
gasoline to clean the element. Such solvents
may lead to fire or explosion.
Squeeze excess solvent out of the element and
let dry.
CAUTION:
Do not twist the element.
Apply foam air filter oil or SAE 10W30 typ SE

oil on the element.
Sqeeze out the excess oil.
*******************************************************
NOTE:
The element should be wet but not dripping.
3-15
FRONT BRAKE LEVER FREE PLAY ADJUSTEMENT/

REAR BRAKE LEVER FREE PLAY ADJUSTEMENT/
BRAKE PADS INSPECTION
INSP
ADJ
CHASSIS
a
FRONT BRAKE LEVER FREE PLAY

ADJUSTMENT
1. Check:
Front brake lever free play @
Free play:
10 ~ 20 mm (0.40 ~ 0.80 in)
WARNING
A soft or spongy feeling in the brake lever can
indicate the presence of air in the brake
system. This air must be removed by bleeding
the brake system before the scooter is
operated. Air in the system will reduce brake
performance and can result in loss of control
and an accident. Inspect and bleed the system
if necessary.
REAR BRAKE LEVER FREE PLAY
ADJUSTMENT
1. 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 the
specified free play is obtained.
********************************************************
BRAKE PADS INSPECTION

1.Measure:
Brake pads
Out of specification Replace.
NOTE:
Replace the brake pad and spring as a set when
replacing the brake pads.
Wear limit @:
0.5 mm (0.02 in)
347003
3-16
BRAKE SHOE INSPECTION/

BRAKE FLUID LEVEL INSPECTION
INSP
ADJ
BRAKE SHOE INSPECTION

1. Apply the rear brake lever.
2. Inspect:
Wear indicator Q
Indicator reaches the wear limit line W
Replace brake shoes.
BRAKE FLUID LEVEL INSPECTION

NOTE:
Position the scooter straight up when inspecting
the fluid level, and make sure be turning the
handlebar that the top of the master cylinder is
horizontal.
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
CAUTION:
The brake fluid may corrode painted surfaces

or plastic parts. Always clean up spilled fluid
immediately.
WARNING
Use only the designated quality fluid.
Otherwise, the rubber seals may deteriorate
causing leakage and poor brake
performance.
Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical reaction leading to poor brake performance.
Be careful that water does no enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
3-17
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/

STEERING HEAD ADJUSTEMENT
346002
INSP
ADJ
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 container.
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.
WARNING
Check the operation of the brake after
bleeding the brake system.
*******************************************************
STEERING HEAD ADJUSTMENT

1 Check:
Steering assembly bearings
Grasp the bottom of the forks and gently rock the
fork 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
WARNING
354002
Do not overtighten.
3-18
STEERING HEAD ADJUSTEMENT/

TIRE INSPECTION
INSP
ADJ
Check the steering head by turning it lock to

lock. If it binds, remove the steering stem
assembly and inspect the steering bearings.
Install the steering shaft lock nut and tighten it
to the specified torque.
NOTE:
Tighten the steering shaft lock nut while holding
the ring nut with the ring nut wrench.
Stearing head wrench:
9079Q - 02218
Security nut:
27.5Nm (2.75 m.kg, 19.89 ft.lb)
354001
Move the handlebar up and down and from

front 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)
*******************************************************
TIRE INSPECTION
1. Measure:
Air pressure
Tire pressure (cold)
Up to 90 kg
90 kg ~ maximum
load *
Maximum load:
WARNING
Front
Rear
150 kPa
150 kPa
(1.50 kgf/cm2) (1.50 kgf/cm2)
150 kPa
160 kPa
(1.50 kgf/cm2) (1.60 kgf/cm2)
182 kg
* Maximum load is the total weight of rider, passenger,
accessories and luggage.
Proper loading of your scooter is important

for the handling, braking, and other performance and safety characteristics of your
scooter. Do not carry loosely packed items
that can shift.
Securely pack your heaviest items close to
the center of the scooter, and distribute the
weight evenly from side to side. And check
the 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 the
scooter. Operation of an overloaded scooter
could cause tire damage, an accident, or
even injury.
3-19
TIRE INSPECTION/WHEEL INSPECTION/

CABLE INSPECTION AND LUBRICATION
INSP
ADJ
2 Inspect:
Tire surface
Wear/Damage/Cracks/Road hazards Replace.
Aluminum wheels
Damage/Bends Replace.
Never attempt even small repairs to the wheel.
WARNING
Ride conservatively after installing a tire to

allow it to seat itself properly on the rim.
If the tire is removed with a tire lever, use a
suitable protection to prevent damaging the rim.
When installing the tire, make sure the arrow
points to the front.
3.Measure:
Tire tread depth
Minimum tire tread depth
(front and rear):
0,8mm (0.03 in)
Q Tread depth
W Side wall
E Wear indicator
WHEEL INSPECTION
1.Inspect:
Wheels
Damage/Bends Replace.
WARNING
Never attempt even small repairs to the wheel.
CABLE INSPECTION AND LUBRICATION
WARNING
A damaged cable sheath will rapidly corrode.
As a result, the cable cannot move smoothly
inside the sheath. Since this situation is
dangerous, replace a damaged cable
immediately.
1. Check:
Cable sheath
Cable end
Damage Replace.
3-20
CABLE INSPECTION AND LUBRICATION/

CENTERSTAND LUBRICATION/
FRONT FORK INSPECTION
INSP
ADJ
2. Check:
Cable movement
Stickiness Lubricate.
Recommended lubricant:
Engine oil SAE 10W30
NOTE:
Hold the cable end up and pour a few drops of oil
into the sheath.
3. Lubricate the throttle cable end and the cable
guide notch on the throttle grip with grease Q.
Recommanded lubricant:
Lithium soap based grease
LEVER LUBRICATION
1. Lubricate rotating parts of the levers
CENTERSTAND LUBRICATION
1. Lubricate rotating parts
FRONT FORK INSPECTION

1.Check:
Front fork
Bend/Damage Replace fork assembly as a
set.
Excessive oil leakage Replace fork assembly as a set.
Unsmooth operation Replace fork assembly.
3-21
REAR SHOCK ABSORBER
INSP
ADJ
REAR SHOCK ABSORBER

1.Check:
Rear shock absorber Q
Oil leaks/Damage Replace.
2.Check:
Tightening torque
T.
3-22
Upper bolt:
31 Nm (3.1 m kg, 22.4 ft lb)
Lower bolt:
17 Nm (1.7 m kg, 12.2 ft lb)
BATTERY INSPECTION
INSP
ADJ
ELECTRICAL
UPPER
LOWER
BATTERY INSPECTION
1. Inspect:
Battery fluid level
Fluid level low Add to proper level.
Fluid level should be between upper and lower
level marks.
Q Upper level
W Lower level
CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.
2. Inspect:
Breather hose
Obstruction Remove.
3. Inspect:
Battery
*******************************************************
Replace the battery if:
Battery voltage will not rise to a specific value
or bubbles fail to rise during charging.
Sulfation of one or more cells occurs. (As
indicated by the plates turning white, or an
accumulation of material in the bottom of the
sell.)
Specific gravity readings after a long, slow
charge indicate that one cell is lower than the
rest.
Warpage or buckling of plates or insulators is
evident.
*********************************************************
4. Measure:
Specific gravity
Less than 1.280 Recharge battery.
Charging Current:
0.4 amps/10 hrs
Specific Gravity:
1.280 at 20C (68 F)
3-23
BATTERY INSPECTION/
FUSE INSPECTION
INSP
ADJ
CAUTION:
Always charge a new battery before using
it to ensure maximum performance.
WARNING
Battery electrolyte is dangerous. It contains
sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive measures:
Avoid bodily contact with electrolyte as it
can cause severe burns and permanent
eye injury.
Wear protective eye gear when handling or
working 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 medical
attention.
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 handling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
FUSE INSPECTION
1. Remove the battery cover.
2. Inspect:
Fuse
Blown Replace.
3-24
FUSE INSPECTION/
HEADLIGHT BEAM ADJUSTEMENT
INSP
ADJ
******************************************************
Fuse replacement steps:
Turn off the ignition.
Install a new fuse of the right amperage.
Turn on the switches to verify the operation of
the electric circuit.
If the fuse immediately blows again, check the
electric circuit.
*******************************************************
WARNING
Never use a fuse with a rating higher than
specified. An improper fuse may cause
damage to the electrical circuit, and possibly
cause a fire.
Fuse:
Main circuit: 7A
3 Install:
Battery cover
FUSE
CAUTION:
When installing the battery cover, pay particular 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 appropriate area.
Q. NO zone
W. +-terminal
E. Wiring
R. Battery vent
HEADLIGHT BEAM ADJUSTMENT

1. Adjust:
Headlight beam
3-25
Higher
Turn out screw Q
Lower
Turn in screw Q
HEADLIGHT LENS REPLACEMENT

HEADLIGHT BULB REPLACEMENT
INSP
ADJ
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 REPLACEMENT

1. Remove:
Front cover
2. Remove:
Headlight bulb socket Q
(Turn one quart of a turn).
3. Remove:
Headlight bulb
4. Install:
3-26
ENG
ENG
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL ....................................................................................... 4-1
COVER REMOVAL .................................................................................. 4-1
CARBURETOR ........................................................................................ 4-1
CABLES, LEADS AND HOSES ............................................................... 4-2
ENGINE REMOVAL ................................................................................. 4-3
ENGINE DISASSEMBLY ............................................................................... 4-4
REAR WHEEL ......................................................................................... 4-4
CENTER STAND ..................................................................................... 4-4
CYLINDER HEAD AND CYLINDER ........................................................ 4-4
PISTON PIN AND PISTON ...................................................................... 4-4
KICK STARTER ....................................................................................... 4-5
PRIMARY SHEAVE ................................................................................. 4-6
SECONDARY SHEAVE ........................................................................... 4-6
STARTER SYSTEM ................................................................................. 4-7
TRANSMISSION ...................................................................................... 4-8
CDI MAGNETO ........................................................................................ 4-8
AUTOLUBE OIL PUMP ............................................................................ 4-9
CRANKCASE AND CRANKSHAFT ......................................................... 4-9
INSPECTION AND REPAIR ........................................................................ 4-11
CYLINDER HEAD .................................................................................. 4-11
CYLINDER AND PISTON ...................................................................... 4-11
PISTON RINGS ..................................................................................... 4-13
PISTON PIN AND PISTON PIN BEARING ............................................ 4-14
KICK STARTER ..................................................................................... 4-15
TRANSMISSION .................................................................................... 4-15
AUTOLUBE PUMP ................................................................................ 4-16
CRANKSHAFT ....................................................................................... 4-16
PRIMARY SHEAVE ............................................................................... 4-16
SECONDARY SHEAVE ......................................................................... 4-17
V-BELT ................................................................................................... 4-18
STARTER CLUTCH AND GEARS ......................................................... 4-19
ENGINE ASSEMBLY AND ADJUSTMENT ................................................. 4-20
CRANKSHAFT AND CRANKCASE ....................................................... 4-21
AUTOLUBE PUMP ................................................................................ 4-23
CDI MAGNETO ...................................................................................... 4-24
TRANSMISSION .................................................................................... 4-26
STARTER SYSTEM ............................................................................... 4-28
PRIMARY SHEAVE ............................................................................... 4-30
SECONDARY SHEAVE ......................................................................... 4-31
KICK STARTER ..................................................................................... 4-35
PISTON PIN AND PISTON .................................................................... 4-36
CYLINDER AND CYLINDER HEAD ...................................................... 4-37
ENGINE REMOUNTING ........................................................................ 4-39
ENGINE REMOVAL
ENG
ENGINE OVERHAUL
ENGINE REMOVAL
COVER REMOVAL
1. Remove:
Covers
See CHAPTER 3 - COVERS AND HANDLEBAR COVER.
CARBURETOR
1. Remove:
Air cleaner case assembly Q
2. Disconnect:
Carburetor cover
Hoses
Carburetor top
3.Remove:
Carburetor Q
322032
4. Remove:
Air shroud Q
Muffler assembly W
320000
5. Loosen:
Rear axle nut Q
NOTE:
Apply the rear brake while loosening the rear
axle nut.
340002
4-1
ENGINE REMOVAL
ENG
CABLES, LEADS AND HOSES

1. Remove:
Oil hose Q on the oil pump side
NOTE:
Plug the hose to prevent oil spillage.
321000
2. Disconnect:
CDI unit lead pump side
Spark plug cap
Starter motor lead
385000
3. Remove:
Rear brake cable Q
324000
4-2
ENGINE REMOVAL
ENG
ENGINE REMOVAL
1. Place a suitable stand under the frame.
2. Remove:
Rear shock absorber bolt (lower) Q
Engine mounting bolt W
320001(a)
3. Remove:
Engine
NOTE:
Lift up the frame and remove the engine.
4. Place the frame on a suitable stand.
4-3
ENGINE DISASSEMBLY
ENG
ENGINE DISASSEMBLY
REAR WHEEL
1. Remove:
Rear wheel
Brake shoes Q
Plate washer W
346001
CENTERSTAND
1. Remove:
Spring Q
Clip W
Rubber washer E
Axle R
Clamp T
Center stand Y
358001
CYLINDER HEAD AND CYLINDER

1. 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.
301005
2. Remove:
Cylinder Q
Cylinder gasket W
304002
PISTON PIN AND PISTON

1. Remove:
Piston pin clip Q
NOTE:
Before removing the piston pin clip, cover the
crankcase with a clean rag, so that the clip
cannot accidentally fall into the crankcase.
307001
4-4
ENGINE DISASSEMBLY
ENG
2. Remove:
Piston pin Q
Piston W
Piston pin bearing E
CAUTION:
Do not use a hammer to drive out the
piston pin.
307002
KICKSTARTER
1. Remove:
Transmission cover Q (left)
313001
2. Remove:
Kick pinion gear Q
NOTE:
To remove the kick pinion gear, push down the
kick crank.
3 Unhook:
Kick return spring W
317001
4. Remove:
Kick crank
Circlips Q
Plate washer W
Kick shaft E
317002
4-5
ENGINE DISASSEMBLY
ENG
PRIMARY SHEAVE
1. Remove:
Fan
2. Remove:
Nut Q (primary sheave)
NOTE:
To loosen the primary sheave nut hold the CDI
magneto with a flywheel holder W.
319035
Flywheel holder:
90890-01235
3. Remove:
Washer Q
Ratchet W
Washer E
Fixed primary sheave R
Washer T
V-belt
319001
4. Remove:
Spacer Q
Primary sliding sheave W
319002
SECONDARY SHEAVE
1. Remove:
Nut Q (secondary sheave)
NOTE:
Hold the secondary sheave with a sheave holder
W to loosen the nut.
Sheave holder:
90890-01701
319003
4-6
ENGINE DISASSEMBLY
ENG
2. Remove:
Clutch housing Q
Secondary sheave W
Crankcase cover gasket
Dowel pins
3. Attach:
Sheave holder Q
Nut wrench (39 mm)
319004
Sheave holder:
90890-01701
4. Loosen:
Clutch securing nut
WARNING
Loosen the nut but do not remove it yet.
319031
5. Attach:
Clutch spring holder Q
NOTE:
Compress the secondary sheave using the clutch
spring holder Q.
Clutch spring holder:
90890-01337
311001
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
311002
STARTER SYSTEM
1. Remove:
Starter clutch assembly Q
Plate W (idle gear)
Idle gear E
Starter wheel gear R
Spacer T
Bearing Y
Washer U
317003
4-7
ENGINE DISASSEMBLY
ENG
2. Remove:
Spacer Q
Bearing W
Washer E
Starter motor
317004
TRANSMISSION
1. Remove:
Transmission case Q
Gasket
Dowel pins
319036
2. Remove:
Drive shaft Q
Main shaft W
Plate washer E
Conical spring washer R
319037
3. Remove:
Oil seal Q
Secondary sheave axle W
319032
CDI MAGNETO
1. Remove:
Nut Q (rotor)
Plate washer
NOTE:
Hold the rotor using a flywheel holder W to
loosen the nut.
Flywheel holder:
90890-01235
321004
4-8
ENGINE DISASSEMBLY
ENG
2. Remove:
Rotor Q
Woodruff key
Use the flywheel puller W
Flywheel puller:
90890-01189
Stator assembly
Gasket
321005
AUTOLUBE OIL PUMP

1. Remove:
Autolube oil pump Q
314001
2. Remove:
Circlips Q
Pump drive gear W
Pin E
Circlip R
314002
CRANKCASE AND CRANKSHAFT

1. Remove:
Oil seal stopper Q
Screws (crankcase)
NOTE:
Loosen each screw one quart of a turn before
beginning to remove them.
313009
2. Attach:
Crankcase separating tool Q
Crankcase separating tool:
90890-01135
NOTE:
Fully tighten the tool holding bolts. Insure that
the tool body is parallel with the case. If necessary,
313002
4-9
ENGINE DISASSEMBLY
ENG
loosen one screw as much as required to level

the tool body.
3. Remove:
Crankcase (right)
As pressure is applied, keep tapping carefully on
the engine mounting bosses.
CAUTION:
Use a soft hammer to tap on the case. Tap
only on reinforced spots of the case. Never
tap on the gasket mating surfaces. Work
slowly and carefully. Make sure the cases
separate evenly. If one end hangs up take
the pressure off the push screw, realign the
cases and the tool and start again. If the
cases do not separate at all, check for a
remaining case screw or fitting. Do not force.
4. Attach:
Crankcase separating tool Q
Crankcase separating tool:
90890-01135
5. Remove:
Crankshaft W
313004
4-10
INSPECTION AND REPAIR
ENG

CYLINDER HEAD
1. Eliminate:
Carbon deposits
Use a rounded scraper Q
301001
301002
NOTE:
Take care to avoid damaging the spark plug
threads. Do not use a sharp instrument. Avoid
scratching the aluminum.
2. Inspect:
Cylinder head warpage
Out of specification Re-surface.
*******************************************************
Warpage measurement and re-surfacement
steps :
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-surface

the cylinder head.
301003
NOTE:
Rotate the head several times to avoid removing
too much material from one side.
*******************************************************
CYLINDER AND PISTON
1. Eliminate:
Carbon deposits
Use a rounded scraper Q
2. Inspect:
Cylinder wall
Wear/Scratches Replace.
304001
3. Eliminate:
Carbon deposits
From the piston crown Q and ring grooves W.
4. Remove:
Score marks and lacquer deposits
From the sides of piston.
307003
4-11
ENG
NOTE:
Sand in a crisscross pattern. Do not sand
excessively.
5. Inspect:
Piston wall
Wear/Scratches/Damage Replace.
307004
6. Measure:
Piston to cylinder clearance
********************************************************
Piston to cylinder clearance measurement
steps :
First step :
Measure the cylinder bore C with a cylinder
bore gauge.
D1
D2
D3
D5
NOTE:
Measure the cylinder bore C in parallel to and
at right angles to the crankshaft. Then, calculate
the average of the measurements.
D4
D6
Standard
Cylinder
Bore C
307005
Taper
"T"
Wear limit
39.99 ~ 40.01mm 40.10 mm

(1.574 ~ 1.575 in) (1.579 in)
_
0,05mm
(0.002 in)
C = Maximum D
T = (Maximum D1,D3 or D5) (Maximum D2,D4 or D6 )
If out of specification, replace cylinder, piston

and piston rings as a set.
2nd step:
Measure the piston skirt diameter P with a
micrometer.
@ 5 mm (0.20 in) from the piston bottom edge.
@
Piston Size:
Standard:
39.952 ~ 39.972 mm
(1.57 ~ 1.57 in)
307006
4-12
ENG
If out of specification, replace piston and piston

rings as a set.
3rd step:
Calculate the piston-to-cylinder clearance with
following formula:
Piston-to cylinder clearance =
Cylinder Bore C
Piston Skirt Diameter P
If out of specification, replace cylinder, piston
and 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 RINGS
1. Measure:
Side clearance
Out of specification Replace piston and/or
rings.
Use a Feeler Gauge Q
Standard
Limit
307007
Top
ring
0.03 ~ 0.05 mm
(0.0012 ~ 0.0020 in)
0.10 mm
(0.004 in)
2nd
ring
0.03 ~ 0.05 mm
(0.0012 ~ 0.0020 in)
0.10 mm
(0.004 in)
2. Install:
Piston ring
Into the cylinder
Push the ring with the piston crown.
307008
3. Measure:
End gap
Out of specification Replace rings as a set.
Use a Feeler Gauge Q
4-13
ENG
Standard
Limit
Top
ring
0.15 ~ 0.30 mm
(0.005 ~ 0.011 in)
0.70 mm
(0.028 in)
2nd
ring
0.15 ~ 0.30 mm
(0.005 ~ 0.011 in)
0.70 mm
(0.028 in)
@ Measuring Point 20 mm (0.8 in)

PISTON PIN AND PISTON PIN BEARING
1. Inspect:
Piston pin
Blue discoloration/Groove Replace, then
inspect lubrication system.
2. Measure:
Outside diameter (piston pin)
Outside diameter (piston pin):

9.996 ~ 10.000 mm
(0.3935 ~ 0.3937 in)
307009
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
307010
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
307011
4-14
ENG
KICK STARTER
1. Inspect:
Kick gear teeth Q
Kick pinion gear teeth W
Burrs/Chips/Roughness/Wear Replace.
317005
2. Inspect:
Mating dogs (kick pinion gear and one-way
clutch)
Rounded edges/Damage Replace.
317006
3. Measure:
Clip tension (kick pinion gear) Q
Use a spring balance W.
Standard tension:
150 ~ 250 g (5.3 ~ 8.8 oz.)
317007
TRANSMISSION
1. Inspect:
Drive axle Q
Main axle W
Secondary sheave axle E
319005
2. Inspect:
Secondary sheave axle bearing Q
Main axle bearing W
Drive axle bearing E
Spin the bearing inner race.
Excessive play/Roughness Replace.
Pitting/Damage Replace.
319038
4-15
ENG
AUTOLUBE PUMP
Wear or an internal malfunction may cause the
pump output to vary from the factory setting.
This situation is, however, extremely rare. If
improper output is suspected, inspect the
following:
1. Inspect:
Delivery line
Obstructions Blow out.
O-ring
2. Inspect:
Autolube pump drive gear teeth Q
Autolube pump driven gear teeth W
Pitting/Wear/Damage Replace.
314003
CRANKSHAFT
1. 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 side
clearance D:
0.2 ~ 0.5 mm (0.008 ~ 0.02 in)
308001
PRIMARY SHEAVE
1. Inspect:
Primary sliding sheave Q
Primary fixed sheave W
Wear/Cracks/Scratch/Damage Replace.
319006
4-16
ENG
2. Check:
Free movement
Insert the collar W into the primary sliding sheave
Q, and check for free movement.
Stick or excessive play Replace the sheave
and/or collar.
319007
3. Measure:
Outside diameter Q (weight)
Outside diameter (weight):
15.0 mm (0.59 in)
<Limit 14.5 mm (0.57 in)>
319008
SECONDARY SHEAVE
1. Inspect:
Secondary fixed sheave Q
Secondary sliding sheave W
Scratch/Crack/Damage Replace as a set.
Oil seal E
Damage Replace.
319009
2. Inspect:
Torque cam groove Q
Guide pin W
Wear/Damage Replace as a set.
O-rings E
Damage Replace.
319010
3. Measure:
Clutch spring free length
Clutch spring free length:
121.7 mm
<Limit>
106.7 mm
319011
4-17
ENG
4. Inspect:
Clutch housing inner surface
Oil/Scratches Remove.
Oil
Use a rag soaked in lacquer

thinner or solvent.
Scratches
Use an emery cloth (lightly

and evenly polishing).
319030
5. Measure:
Clutch housing inside diameter @
Clutch housing inside diameter:
107.0 mm ( 4.21 in)
<Wear Limit>:
107.4 mm ( 4.22 in)
319012
6. Inspect:
Clutch shoes
Glazed parts Sand with coarse sandpaper.
NOTE:
After using the sand paper, clean off the polished
particles with a cloth.
7. Measure:
Clutch shoe thickness @
Clutch shoe thickness:

2.0 mm (0.08 in)
<Wear Limit> :
1 mm (0.039 in)
319013
V-BELT
1. Inspect:
V-belt
Crack/Wear Replace.
NOTE:
Replace the V-belt if it is greasy or oily.
4-18
ENG
2. Measure:
V-belt width @
V-Belt width:
16,5 mm (0.65 in)
<Wear Limit>:
15,7 mm (0.62 in)
312001
STARTER CLUTCH AND GEARS

1. Inspect:
Starter clutch
Push the dowel pin in arrow direction.
Unsmooth operation Replace starter clutch
assembly.
317008
2. Inspect:
Starter wheel gear teeth Q
Idle gear teeth W
Bearing E (starter wheel gear)
317009
4-19
ENGINE ASSEMBLY AND ADJUSTMENT
ENG

Q
W
E
R
T
Y
U
I
O
P
{
}
q
w
Oil seal
Oil seal holder
Crankcase (right)
Dowel pin
Bearing
Crankshaft (right)
Bearing
9 Nm (0.9 m.kg, 6.5 ft.lb)
Crankshaft pin
Connecting rod
Crankshaft (left)
Bearing
Engine mount shaft
Crankcase (left)
Oil seal
13 Nm (1.3 m.kg, 9.4 ft.lb)
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)
313008
4-20
ENG
CRANKSHAFT AND CRANKCASE

CAUTION:
To protect the crankshaft against scratches
and to facilitate the engine assembly and
installation, apply grease to oil seal lips, and
engine oil to bearings.
1. Attach:
Crankshaft installation tool Q, W, E, R
Crankshaft installation tool:

Q : 90890-01274
W : 90890-01275
E : 90890-01277
R : 90890-01411
2. Install:
Crankshaft
(to left crankcase)
NOTE:
Hold the connecting rod at top dead center with
one hand while tightening the nut of the
installation tool with the other. Tighten the
installation tool until the crankshaft bottoms
against the bearing.
3. Install:
Dowel pins Q
Spacer W
313005
4. Apply:
HEATPROOF or Yamaha Bond No.1215
To the mating surfaces of both case halves.
HEATPROOF or Yamaha Bond
No.1215
313006
4-21
ENG
5. Attach:
Crankshaft installation tool Q, W, E, R
Crankshaft installation tool:

Q : 90890-01274
W : 90890-01275
E : 90890-01277
R : 90890-01411
NOTE:
Hold the connecting rod at top dead center with
one hand while tightening the nut of the installation tool with the other. Tighten the installation
tool until the crankcase halves close with one
another.
6. Install:
Right crankcase
7. Tighten:
Crankcase holding screws
NOTE:
Tighten the crankcase holding screws in stages,
using a crisscross pattern.
T.
Crankcase holding screw:

9 Nm (0.9 m kg,( 6.5 ft lb)
313009
8. Check:
Crankshaft operation
Unsmooth operation Repair.
CAUTION:
Never hit on the crankshaft.
308003
9. Install:
Oil seal stopper plate Q
T.
313009
4-22
Screw (oil seal stopper plate):

9 Nm (0.9 m kg,( 6.5 ft lb)
ENG
AUTOLUBE PUMP AND CDI MAGNETO

O Gasket
Q Fan
P Oil hose
W Plain washer
{ Oil delivery hose
E Rotor assembly
} Clip
R Lighting coil
q Autolube pump
T Charge coil
w O-ring
Y Pick up coil
e Circlip
U Stator assembly
r Oil pump drive gear
I Oil seal
4 Nm (0.4 m.kg, 2.9 ft.lb)
6.5 Nm (0.65 m.kg, 4.7 ft.lb)
37.5 Nm (3.75 m.kg, 27.1 ft.lb)
8 Nm (0.8 m.kg, 5.8 ft.lb)
314007
4-23
ENG
AUTOLUBE PUMP
1. Install:
Circlip Q
Pin W
Pump drive gear E
Circlip R
314004
2. Apply:
Lithium soap base grease
(to O-ring Q)
3. Instal:
Autolube pump W
T.
R
314005
Screw (autolube pump):

4 Nm (0.4 m kg, 2.9 ft lb)
4. Apply:
(to autolube pump gear Q, W)
Lithium soap base grease:
15 cc (0.92 cu in)
314006
CDI MAGNETO
1. Install:
Gasket
2. Apply:
(to oil seal Q)
321001
3. Pass the CDI magneto lead through the

crankcase hole.
4. Install:
Stator assembly
T.
R
4-24
Screw (stator assembly):

8 Nm (0.8 m kg, 5.8 ft lb)
5. Install:
Woodruff key Q
Magneto rotor W
Plain washer E
Nut R
321002
ENG
NOTE:
When installing the magneto rotor, make sure
the woodruff key is properly seated in the key
way of the crankshaft. Apply a light coating of
lithium soap base grease to the tapered portion
of the crankshaft end.
6. Tighten:
Nut Q (magneto rotor)
Use the flywheel holding tool W.
Flywheel holding tool:

90890-01235
T.
R
321004
4-25
Nut (Flywheel magneto):

37.5 Nm (3.75 m kg, 27.1 ft lb)

TRANSMISSION
Q Circlip
W Bearing
E Oil seal
R Drive axle
T Bearing
Y Main axle
U Conical spring washer
I Plain washer
ENG
O Bearing
P Secondary sheave axle
{ Bearing
} Dowel pin
q Gasket
w Transmission case cover
e Oil seal
12 Nm (1.2 m.kg, 8.7 ft.lb)
319033
4-26
ENG
TRANSMISSION
1. 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 seal
lips.
319014
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
319016
NOTE:
Apply lithium soap base grease onto the oil seal
lips.
Always use a new gasket.
7. Install:
Gasket
Dowel pins
Transmission case cover
T.
319017
4-27
Screw (case cover):

9 Nm (0.9 m kg, 6.5 ft lb)
ENG

STARTER SYSTEM
Q Collar
W Washer
E Bearing
R Starter wheel gear
T Collar
Y Starter clutch
U Plate
I Shaft
O Plain washer
P Idle gear
{ O-ring
} Starter motor
13 Nm (1.3 m.kg, 9.4 ft.lb)
8 Nm (0.8 m.kg, 5.8 ft.lb)
317017
4-28
ENG
STARTER SYSTEM
1. Install:
Collar Q
Washer W
Bearing E
Starter wheel gear R
Starter clutch T
317010
NOTE:
Apply lithium soap base grease to the bearing.
Apply molybdenum disulfide oil to the shaft
(starter clutch).
317011
2. Install:
Plain washer Q
Idle gear W
Plain washer E
Plate R (idle gear)
T.
Screw (idle gear plate):

8 Nm (0.8 m kg, 5.8 ft lb)
317012
NOTE:
Apply engine oil to the idle gear W.
3. Install:
Starter motor Q
T.
317013
Screw (starter motor):

13 Nm (1.3 m kg, 9.4 ft lb)
NOTE:
Apply lithium soap base grease to the O-ring of
the starter motor.
4-29

PRIMARY AND SECONDARY SHEAVE
Q Clutch housing
} Conical spring washer
W Clutch
q One-way clutch
E Clutch shoe spring
w Washer
R Clutch spring
e Primary fixed sheave
T Spring seat
r Plate washer
Y Gasket
t Spacer
U O-rings
y Primary sliding sheave
I Secondary sliding sheave u Clutch weights
O V-belt
i Slider
P Guide pin
o Cam
{ Secondary fixed sheave
ENG
*Apply BEL-RAY Assembly Lube
50 Nm (5.0 m.kg, 36.2 ft.lb)
40 Nm (4.0 m.kg, 28.9 ft.lb)
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 diameter
limit : 14.5 mm (0.57 in)
30 Nm (3.0 m.kg, 21.7 ft.lb)
319034
4-30
ENG
KICK STARTER
Q Kick shaft
W Return spring
E Collar
R Plain washer
T Circlip
Y Gasket
U Dowel pin
I Transmission case
O Kick crank
P Kick pinion gear
{ Kick pinion gear clip
A KICK CLIP FRICTION FORCE : 0,15 ~ 0,25

kg
150 ~ 250 g
12 Nm (1,2 m.kg, 8.7 ft.lb)
10 Nm (1,0 m.kg, 7.2 ft.lb)
317018(a)
4-31
ENG
SECONDARY SHEAVE
When assembling the secondary sheave, reverse
the disassembly procedure. Note the following
points.
1. Apply:
BEL-RAY Assembly Lube
(to the sliding parts of the sheave)
319018
2. Install:
Sliding sheave Q
NOTE:
Wind adhesive tape around the end of the sheave
to avoid turning over the oil seal lips when
installing the sheave.
319019
3. Install:
Pin Q
4. Apply:
BEL-RAY Assembly Lube
(to the torque cam grooves and O-rings)
319020
5. Check:
Sliding sheave
CAUTION:
Remove excessive grease.
6. Install:
Clutch securing nut
Use the clutch spring holder Q
Clutch spring holder:
90890-01337
319021
7. Tighten:
Clutch securing nut
Use sheave holder Q (39 mm).
Sheave holder:
90890-01701
T.
319031
4-32
Clutch securing nut:

50 Nm (5.0 m kg, 36 ft lb)
ENG
8. Install:
Dowel pin
Gasket
Secondary sheave assembly Q
Clutch housing W
319022
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 SHEAVE
1. Clean:
Primary sliding sheave face Q
Primary fixed sheave face W
Collar E
Weight R
Primary sliding sheave cam surface T
T.
319023
319024
319025
2. Install:
Weight Q
Cam W
Slider E
Collar R
3.Check:
Cam operation
4. Install:
Primary sheave assembly Q
Collar W
319026
4-33
ENG
5. Install:
V-belt
Place the V-belt around the secondary sheave,
and compress the secondary sheave spring
hard so that the V-belt moves toward the clutch
hub.
NOTE:
The arrow on the V-belt must point to the front.
Make sure the V-belt is not stained with oil or
grease.
6. Install:
Shim Q
Primary fixed sheave W
Washer E
One-way clutch R
Washer T
Nut Y
319027
7. Tighten:
Nut Q (primary sheave)
T.
319035
Nut (primary sheave):

30 Nm (3.0 m kg, 21.7 ft lb)
NOTE:
When tightening the nut (primary sheave), hold
the magneto rotor using the flywheel holding tool
W.
Flywheel holding tool:
90890-01235
8. Adjust:
V-belt
Tense the V-belt by turning the primary sheave
several times.
319028
4-34
ENG
9. Install:
Fan Q
T.
Screw (fan):
7 Nm (0.7 m kg, 5.1 ft lb)
320000
KICK STARTER
1. Install:
Return spring Q
Kick shaft W
Collar E
Washer R
Circlip T
317014
2. Hook:
Return spring
(to the kick gear and boss)
3. Install:
Kick pinion gear Q
NOTE:
Install the clamp as shown.
317015
4. Install:
Transmission case Q
T.
Screw (Transmission case):

9 Nm (0.9 m kg, 6.5 ft lb)
319029
5. Install:
Kick crank Q
T.
317016(a)
4-35
Bolt (kick crank):

9 Nm (0.9 m kg, 6.5 ft lb)
ENG
PISTON, CYLINDER AND CYLINDER HEAD

Q Carburetor joint
W Reed valve
E Gasket
R Cylinder head
T Cylinder head gasket
Y Cylinder
U Cylinder gasket
I Piston ring
O Piston
P Piston pin
{ Piston pin clip
} Bearing
20 Nm (2.0 m.kg, 14.0 ft.lb)
10 Nm (1.0 m.kg, 7.2 ft.lb)
B
C
Piston clearance :
0.034 ~ 0.047 mm (0.0013 ~ 0.0017 in)
Piston rings end gap :
0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
Piston rings side clearance :
0.03 ~ 0.05 mm (0.0012 ~ 0.0019 in)
Spark plug :
Type : BR8HS
Manufacturer : NGK
304003
4-36
ENG
PISTON PIN AND PISTON

1. Apply:
Engine oil Q
(to crankshaft bearing, connecting rod big end
bearing, small end bearing, piston pin, piston
ring grooves and piston skirt .)
308004
2. Install:
Small end bearing
Piston Q
Piston pin E
Piston pin clip R
307012
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 will
not accidentally drop the pin clip and material
into the crankcase.
WARNING
The ends of the piston pin clip must not
come together at the slot in the piston
groove.
Always use a new piston pin clip.
CYLINDER AND CYLINDER HEAD

1. Install:
Cylinder gasket (new gasket)
2. Check:
Piston rings
307013
NOTE:
Make sure the ring ends Q are properly fitted
around the ring locating pins in the piston grooves.
Be sure to check the manufacturers marks or
numbers stamped on the rings are on the top
side of the rings.
4-37
ENG
3. Install:
Cylinder Q
NOTE:
Install the cylinder with one hand, while compressing the piston rings with the other hand.
304002
4. Install:
Cylinder head gasket (new gasket)
5. Install:
Cylinder head Q
Spark plug W
301004
NOTE:
Tighten the cylinder head holding nuts in stages,
and crisscross sequence.
The arrow E on the cylinder head must point to
the front.
T.
6. Install:
Center stand Q
Shaft W
Clamp E
Rubber washer R
Clip T
Spring Y
Nut (cylinder head):

10 Nm (1.0 m kg, 7.2 ft lb)
Spark plug:
20 Nm (2.0 m kg, 14 ft lb)
358002
7. Install:
Brake shoe plate Q
Plain washer W
Rear wheel
346001
4-38
ENG
8. Install:
Air shroud
Oil hose
Oil delivery hose
9. Air bleeding:
Autolube pump
Refer to the section CHAPTER 3 AUTOLUBE
PUMP AIR BLEEDING.
320001
ENGINE REMOUNTING
Reverse 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)
T.
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
322032
NOTE:
When installing the throttle valve into the
carburetor, align the groove of the throttle valve
with the projection of the carburetor.
4. Connect:
Starter motor
CDI magneto lead
Earth
385000
4-39
ENG
5. Tighten:
Rear wheel axle nut Q
NOTE:
When tightening the rear wheel axle nut, apply
the rear brake.
T.
R
Rear wheel axle nut:

105 Nm (10,5 m kg, 76 ft lb)
340002
6. Install:
Muffler assembly Q
Fan cover W.
T.
R
320000
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 oil
Refer to CHAPTER 3 TRANSMISSION OIL
REPLACEMENT section.
8. Adjust:
Brake lever free play
Refer to CHAPTER 3 FRONT/REAR BRAKE
LEVER FREE PLAY ADJUSTMENT section.
Engine idle speed
Refer to THROTTLE CABLE FREE PLAY
ADJUSTMENT and ENGINE IDLE SPEED
ADJUSTMENT.
4-40
CARB
CARB
CHAPTER 5.
CARBURETION
CARBURETOR .............................................................................................. 5-1
TEIKEI CARBURETOR ............................................................................ 5-1
DELL'ORTO CARBURETOR ................................................................... 5-3
REMOVAL ................................................................................................ 5-5
DISASSEMBLY ........................................................................................ 5-5
INSPECTION ........................................................................................... 5-7
ASSEMBLY .............................................................................................. 5-9
INSTALLATION ...................................................................................... 5-10
FUEL COCK ................................................................................................. 5-11
INSPECTION .........................................................................................5-11
FUEL FILTER CLEANING ..................................................................... 5-11
REED VALVE ............................................................................................... 5-11
REMOVAL .............................................................................................. 5-11
INSPECTION .........................................................................................5-12
INSTALLATION ...................................................................................... 5-13
CARBURETOR
TEIKEI CARBURETOR
Q Carburetor top
W Gasket
E Throttle valve spring
R Needle set
T Throttle valve
Y Starter plunger spring
U Starter plunger
I Air screw
O Throttle stop screw
CARB
P Pilot jet
{ Needle jet
} Needle valve
q Main jet
w Float pin
e Float
r Float chamber gasket
t Float chamber
y Drain screw
322033
5-1
CARBURETOR
CARB
Carburetor:
DELLORTO
TEIKEI
I.D. mark
PHBN12 HS
5FX
#88
Main jet
(M.J.)
#90
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.)
1.2
#40
#46
2000 200 rpm
2000 200 rpm
Starter jet
Engine idle speed
(G.S.1)
5-2
CARBURETOR
DELL'ORTO CARBURETOR
Q Carburetor top
W Gasket
E Throttle valve spring
R Needle set
T Throttle valve
Y Starter plunger spring
U Starter plunger
I Air screw
O Throttle stop screw
CARB
P Pilot jet
{ Needle jet
} Needle valve
q Main jet
w Float pin
e Float
r Float chamber gasket
t Float chamber
y Drain screw
322034
5-3
CARBURETOR
CARB
Carburetor:
DELLORTO
TEIKEI
I.D. mark
PHBN12 HS
5FX
#88
Main jet
(M.J.)
#90
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.)
1.2
#40
#46
2000 200 rpm
2000 200 rpm
Starter jet
Engine idle speed
(G.S.1)
5-4
CARBURETOR
CARB
REMOVAL
1. Remove:
Side covers and footrest board
Refer to the section SIDE COVERS AND
FOOTREST BOARD in Chapter 3.
Air filter case assembly
2. Disconnect:
Fuel hose Q
Oil hose W
TEIKEI CARBURETOR
3. Remove:
Carburetor top
Throttle valve
Starter plunger
Carburetor
322030
DELLORTO CARBURETOR
3. Remove:
Carburetor top
Throttle valve
Starter plunger top
Starter plunger
Carburetor
DISASSEMBLY (TEIKEI CARBURETOR)

1. Remove:
Float chamber Q
322001
2. Remove:
Float pin screw Q
Float pin W
Float E
Needle valve R
Gasket T
322002
5-5
CARBURETOR
CARB
3. Remove:
Main jet Q
Needle jet W
Pilot jet E
322003
4. Remove:
Throttle stop screw Q
Spring (throttle stop screw)
Air screw W
Spring (air screw)
322004
5. Remove:
Needle clip Q
Jet needle W
Throttle valve E
322005
DISASSEMBLY (DELLORTO
CARBURETOR)
1. Remove:
Float chamber Q
322007
2. Remove:
Float pin Q
Float W
Needle valve E
322026
5-6
CARBURETOR
3. Remove:
Pilot jet Q
Main jet W
Needle jet E
Starter jet R
CARB
322027
4. Remove:
Spring (throttle stop screw)
Air screw W
Spring (air screw)
322028(a)
5. Remove:
Needle clip Q
Jet needle W
Throttle valve E
322029
INSPECTION
1. Check:
Carburetor body Q
Dirt Clean.
NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with compressed
air.
322006
2. Inspect:
Main jet Q
Needle jet W
Pilot jet E
Starter jet (DELLORTO)
Contamination Clean.
322012
5-7
CARBURETOR
3. Check:
Needle valve Q
Wear/Contamination Replace.
Float W
Damage Replace.
Gasket
Damage Replace.
CARB
322013
4. Check:
Throttle valve Q
322014
5. Check:
Throttle valve free movement
Unsmooth/stickiness Replace.
Insert the throttle valve Q into the carburetor
body W and check for smooth movement.
322015
6. Check:
Air screw W
Needle E
Starter plunger R
322016
7. Measure:
Needle valve
Valve seat
NOTE:
The float height is factory-adjusted. Never try to
adjust it yourself.
5-8
CARBURETOR
CARB
ASSEMBLY
Reverse the DISASSEMBLY procedures. Note
the following points.
CAUTION:
Before reassembling the carburetor wash
all 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
322018
2. Install:
Throttle valve Q
Starter plunger
NOTE:
Align the groove W of the throttle valve with the
projection E of the carburetor body.
322019
3. Install:
Carburetor
NOTE:
Align projection Q with projection W.
322020
5-9
CARBURETOR
INSTALLATION
To install the carburetor reverse the REMOVAL
procedures. Note the following points.
1. Install:
Carburetor cover Q
Air hose W
Pass the air hose through the hole E in the
carburetor cover.
CARB
322021
2. Adjust:
Refer to the section THROTTLE CABLE FREE
PLAY ADJUSTMENT in Chapter 3.
3. Install:
Air filter case
5-10
FUEL COCK/
REED VALVE
CARB
FUEL COCK
INSPECTION
1. Stop the engine.
2. Remove:
Side covers
3. Check:
Fuel cock
322031
********************************************************
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, the
fuel cock is in good condition. If not clean or
replace the fuel cock.
Disconnect the vacuum hose and breathe in
through the hose to create a vacuum in the fuel
cock.
If fuel flows out of the fuel hose when vacuum is
applied and stops flowing when vacuum stops,
the fuel cock is in good condition.
If not, clean or replace the vacuum hose, the fuel
hose and the fuel cock.
********************************************************
FUEL FILTER CLEANING

The fuel filter Q is fitted inside the fuel tank. It is
accessible when the fuel hose (between the fuel
tank and the fuel cock) is disconnected.
352001
REED VALVE
REMOVAL
1. Remove:
Side covers
2. Remove:
Carburetor
Refer to section CARBURETOR REMOVAL.
5-11
REED VALVE
CARB
3. Remove :
Carburetor joint
Reed valve assembly
322022
INSPECTION
1. 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 completely or at least nearly flush with the valve seat.
If in doubt, apply suction to the carburetor side
of 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)
322023
3. Measure:
Reed valve clearance Q
Out of specification Replace reed valve.
Reed valve clearance:
Less than 0.2 mm (0.008 in)
322024
5-12
REED VALVE
CARB
INSTALLATION
To install the reed valve reverse the REMOVAL procedure. Note the following points.
1. Install:
Gasket (new)
2. Tighten:
Reed valve assembly bolts
T.
R
Reed valve assembly bolts:

9 Nm (0.9 m.kg, 6.5 ft.lb)
NOTE:
Tighten the screws crosswise in several steps to
prevent warpage of the read valve assembly and
the carburetor joint.
5-13
CHAS
CHAS
CHAPTER 6.
CHASSIS
FRONT WHEEL ............................................................................................. 6-1
REMOVAL ................................................................................................ 6-2
INSPECTION ........................................................................................... 6-2
INSTALLATION ....................................................................................... 6-3
FRONT BRAKE .............................................................................................. 6-4
BRAKE PAD REPLACEMENT ................................................................. 6-6
CALIPER DISASSEMBLY ....................................................................... 6-7
MASTER CYLINDER DISASSEMBLY ..................................................... 6-8
INSPECTION AND REPAIR .................................................................... 6-9
CALIPER ASSEMBLY ........................................................................... 6-10
MASTER CYLINDER ASSEMBLY ......................................................... 6-11
REAR WHEEL ............................................................................................. 6-13
REMOVAL .............................................................................................. 6-14
INSPECTION .........................................................................................6-14
ASSEMBLY ............................................................................................ 6-15
INSTALLATION ...................................................................................... 6-16
FRONT FORK .............................................................................................. 6-18
REMOVAL .............................................................................................. 6-19
DISASSEMBLY ...................................................................................... 6-20
INSPECTION .........................................................................................6-21
ASSEMBLY ............................................................................................ 6-21
INSTALLATION ...................................................................................... 6-22
STEERING HEAD AND HANDLEBAR ........................................................ 6-23
REMOVAL .............................................................................................. 6-24
INSPECTION .........................................................................................6-25
ASSEMBLY AND INSTALLATION ......................................................... 6-26
FRONT WHEEL
CHAS
CHASSIS
FRONT WHEEL
Q Axle
W Speedometer gear
E Bearing
R Collar
T Valve
Y Oil seal
U Collar
I Axle nut
O Tire
P Front wheel
TIRE SIZE:
120/90-10
RIM RUNOUT
LIMIT:
VERTICAL:
1,0 mm (0.040in)
LATERAL:
1,0 mm (0.040in)

LS
LS
340001(a)
6-1
FRONT WHEEL
CHAS
REMOVAL
1. Remove:
Front caliper fixing bolts
Front caliper
Speedometer cable Q
Axle W
Front wheel
NOTE:
Never depress the brake lever when the wheel
is off the scooter. Otherwise the brake pads will
be forced shut.
340003
INSPECTION
1. Inspect:
Front axle runout
Axle runout limit:
0.25 mm (0.01 in)
340006
WARNING
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)
340007
3. Inspect:
Tire
Wear/Cracks/Warpage Replace.
4. Inspect:
Wheel bearings
Bearings allow play in the wheel hub or
wheel turns roughly Replace.
340008
5. Check:
Speedometer gear Q
340004
6-2
FRONT WHEEL
CHAS
INSTALLATION
Reverse the Removal procedure.
1.Lubricate:
Front wheel axle
Bearings
Oil seal (lips)
Drive/driven gear (speedometer)
2. Install:
Speedometer gear unit Q
NOTE:
Be sure that the two projections at the gear unit
mesh with the two slots on the wheel hub.
340004
3. Install:
Front wheel Q
Front caliper W
NOTE:
Be sure that the slot (torque stopper) of the gear
unit housing is positioned correctly.
346005
4.Tighten:
Front wheel axle
Front caliper mounting bolts
T.
R
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)
WARNING
Make sure that the brake hoses are routed

properly.
6-3
CHAS
FRONT BRAKE
FRONT BRAKE
Q
W
E
R
T
Y
Brake disc
Bolt
Caliper
Piston
Piston seals
Air bleed screw
U
I
O
P
{
}
NOTE:
Be sure to install the pads correctly.
Pad spring
Pad retainer
Brake pads
O. ring
Bolt
Mounting bolt
A
B
PAD WEAR LIMIT:

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)

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

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

LT
347009(a)
6-4
FRONT BRAKE
CHAS
MASTER CYLINDER DISASSEMBLY

Q Master cylinder
W Master cylinder piston ass'y
E Diaphragm
R Master cylinder cap
T Screw
Y Master cylinder bracket
NOTE:
U Bolt
Drain completely before removing the master
I Brake hose
cylinder.
O Bolt
P Bolt
{ Copper washer
3 Nm ( 0,3 m.kg; 2,17 ft.lb)

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

BRAKE FLUID
DOT# 3 or DOT# 4
23 Nm (2,3 m.kg; 17 ft.lb)

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

347007
6-5
FRONT BRAKE
CHAS
WARNING
Disc brake components rarely require
disassembly. Do not disassemble
components unless absolutely necessary.
If any hydraulic connection is disconnected,
the entire system must be disassembled,
drained, cleaned, and then properly filled
and bled after reassembly. Do not use
solvents on internal brake component.
Solvents will cause seals to swell and
distort. Use only clean brake fluid for
cleaning. Use care with brake fluid. Never
allow brake fluid to come in contact with
the eyes. Brake fluid can damage painted
surfaces and plastic parts.
BRAKE PAD REPLACEMENT

It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1. Remove:
Pin Q
Axle W

2. Remove:
Pad spring E
Brake pads R
346005
NOTE:
Replace the brake pads as a set when either one
is worn to the limit.
3.Measure:
Brake pads
NOTE:
Replace the brake pad and spring as a set when
replacing the brake pads.
Wear limit @:
0.5 mm (0.020 in)
347003
6-6
FRONT BRAKE
CHAS
4. Install:
Brake pads
Pad spring
Axle
Pin
NOTE:
Be careful to install the brake pads correctly.
5.Lubricate:
Mounting bolt (caliper body)
6.Install:
Wheel axle
Mounting bolt
T.
Wheel axle:
35 Nm (3.5 m kg, 25.3 ft lb)
Mounting bolt:
23 Nm (2.3 m kg, 17 ft lb)
LOCTITE
CALIPER DISASSEMBLY
NOTE:
Before disassembling the front brake caliper,
drain all brake fluid from the brake hose, master
cylinder, brake caliper and tank.
1.Remove:
Union bolt Q
Copper washers W

346005
NOTE:
Place the open end of the drain hose into a
container and pump out the remaining brake
fluid carefully.
2.Remove:
Caliper body
Caliper bracket
3. Remove:
Piston
Piston seals Q
347004
6-7
FRONT BRAKE
CHAS
*******************************************************
Removal steps :
Blow compressed air into the hose joint opening
to force out the piston from the caliper body.
WARNING
Never try to pry out the piston.
Cover the piston with a rag. Use care so
that the piston does not cause injury as it is
expelled from the cylinder.
346004
Remove the piston seals.
********************************************************
MASTER CYLINDER DISASSEMBLY

NOTE:
Before disassembling the front brake master
cylinder, drain all brake fluid from the brake
hose, master cylinder, brake caliper and reservoir tank.
1. Remove:
Upper handlebar cover
2. Remove:
Brake switch
Brake lever
Union bolt
NOTE:
Release the brake switch by pushing with a
screw driver into the hole on the lower side of the
brake lever and pull out the brake switch.
3. Remove:
Master cylinder holder
Master cylinder
6-8
FRONT BRAKE
CHAS
4. Remove:
Master cylinder dust boot Q
Master cylinder kit W

347008

Recommended brake component replacement
schedule:
Brake pads
As required
Piston seal,
Dust seal
Every two years
Brake hoses
Every four years
Brake fluid
Replace only when

brakes are disassembled
WARNING
All internal parts should be cleaned in new
brake fluid only. Do not use solvents as they
will cause seals to swell and distort.
1. Inspect:
Caliper piston Q
Scratches/Rust/Wear Replace caliper
assembly.
Caliper body W
Wear/Scratches/Cracks/Damage Replace
caliper assembly.
WARNING
Replace the piston seals whenever the caliper

is disassembled.
347005
2. Inspect:
Master cylinder
Wear/Scratches Replace the master
cylinder assembly.
Master cylinder body/Diaphragm
Cracks/Damage Replace.
Master cylinder kit
Scratches/Wear/Damage Replace as a set.
347006
6-9
FRONT BRAKE
CHAS
3. Check:
Brake hose Q
Cracks/Wear/Damage Replace.

346014
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)
347001
Brake disc thickness

Minimum thickness:
3,2 mm (0.12 in)
T.
R
Bolt (brake disc):

23 Nm (2.3 m kg, 17 ft lb)
LOCTITE
347002
CALIPER ASSEMBLY
WARNING
brake fluid only.
Internal parts should be lubricated with
clean brake fluid when installed.

DOT #3 or DOT #4
Replace the piston seals whenever a caliper

is disassembled.
1. Install:
Piston seals Q
Caliper piston W
WARNING
346015
Always use new piston seals.
6-10
FRONT BRAKE
CHAS
2. Install:
Brake caliper
T.
R
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

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

346005
CAUTION:
When installing the brake hose to the caliper,
turn the brake pipe against the projection on
the caliper.
WARNING
Proper hose routing is essential to insure
safe operation. Refer to CABLE ROUTING.
Always use new copper washers.
MASTER CYLINDER ASSEMBLY
WARNING
brake fluid only.
Internal parts should be lubricated with
clean brake fluid when installed.

DOT #3 or DOT #5
6-11
FRONT BRAKE
CHAS
1. Install:
Master cylinder Q

CAUTION:
Tighten the upper bolt first, then the lower
bolt.
T.
R

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 brake
lever pivot.

3. Install:
Brake hose 3
Copper washers 4
Union bolts 5
Brake switch 6
T.
Union bolt:
23 Nm (2.3 m kg, 17 ft lb)
WARNING
Proper hose routing is essential to insure
safe operation. Refer to CABLE ROUTING
in CHAPTER 2.
Always use new copper washers.
4. Check that the brake hose does not touch

other parts (throttle cable, wire harness, etc.)
when the handlebar is turned to the left or right.
Repair if necessary.
6-12
REAR WHEEL
CHAS
REAR WHEEL
Rear wheel assy
Tire
Valve
Axle
Nut
O-ring
U
I
O
P
{
}
q Washer
w Nut
e Washer
Brake shoe
Spring
Brake camshaft
Brake camshaft lever
Wear indicator
Bolt
TIRE SIZE:
130/90-10
DRUM BRAKE WEAR LIMIT:

110,5 mm (4.40 in)
105 Nm (10,5 Kg.m ; 76 ft.lb)

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)
REPLACE BRAKE LININGS

AND SPRINGS AS A SET
LS
Q
W
E
R
T
Y
13 Nm (1,3 Kg.m ; 9.4 ft.lb)

12 Nm (1,2 Kg.m ; 8.67 ft.lb)
340005(a)
6-13
REAR WHEEL
CHAS
REMOVAL
1. Remove:
Muffler assy
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
346006
INSPECTION
1. Check:
Rear wheel
Refer to the section FRONT WHEEL
INSPECTION.
2.Measure :
Wheel runout
INSPECTION.
Rim runout limits:
Radial : 1.0 mm (0.04 in)
Lateral : 1.0 mm (0.04 in)
340007
6-14
REAR WHEEL
CHAS
3. Check:
Wheel bearings
INSPECTION.
4. Check:
Brake lining surface
Glazed spots Eliminate with sandpaper.
340008
NOTE:
After sanding the brake lining remove dust particles 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)
346007
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:
346008
110.5 mm (4.35 in)
ASSEMBLY
1. Install:
Brake camshaft Q
346009
NOTE:
Apply lithium soap base grease onto the brake
camshaft Q and pin W.
CAUTION:
After installing the brake camshaft, remove
the excess of grease.
6-15
REAR WHEEL
CHAS
2. Install:
Brake shoes Q
Return spring W
NOTE:
The arrow mark E must point outwards.
346010
CAUTION:
When installing the springs and the brake
shoes, take care not to damage the springs
3. Install:
Wear indicator Q
Camshaft lever W

A
NOTE:
Align the wear indicator tip Q with the line A
as shown.
Align the punch marks E.
346011
T.
R
Bolt (camshaft lever):

10 Nm (1.0 m kg, 7.23 ft lb)
4. Install:
Plain washer Q
Brake cable

346012
INSTALLATION
1. Clean:
Rear wheel axle
2. Install:
Rear wheel
Plain washer Q
Nut W
NOTE:
Make sure the splines on the wheel hub fit onto
the rear drive axle.
346013
6-16
REAR WHEEL
T.
R
CHAS
Nut (rear wheel axle):

105 Nm (10.5 m kg, 76 ft lb)
3. Install:
Muffler
T.
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 LEVER
FREE PLAY ADJUSTMENT in CHAPTER 3.
6-17
CHAS
FRONT FORK
FRONT FORK
Q Steering bracket
W Bolt
E Circlip
R Rubber cap
T Circlip
Y Spring seat
U Circlip
I Inner tube
O Spring
P Piston
{ Spring
} Stopper
q Washer
w Bolt
e Dust boot
r Circlip
t Oil seal
y Outer fork tube
FRONT FORK TUBE CAPACITY:

75 cc ( 2.53 oz)
FRONT FORK OIL GRADE:

ISO 6743 / 4-LHV 46
22.5 Nm (2.25 m.kg)
T.R
T.R
30 Nm (0.3 m.kg)

T.R
23 Nm (2,3 m.kg)

342012(a)
6-18
FRONT FORK
CHAS
REMOVAL
WARNING
Securely support the scooter with a stand
under the engine.
1. Place the scooter on an even surface.
2. Disconnect:
Speedometer cable
3. Remove:
Front wheel
Refer to section FRONT WHEEL in Chapter 6.
4. Remove:
Front fender
Refer to section COVERS - REMOVAL AND
INSTALLATION in Chapter 3.
5. Remove:
Steering head
Refer to section STEERING HEAD AND
HANDLEBAR in Chapter 6.
6. Remove:
Nut Q
Washer W
Ring nut E

NOTE:
Loosen the ring nut with the ring nut wrench R.
T.
354003
Ring nut wrench:

9079Q-02218
Support the steering shaft to prevent it from

falling.
7. Remove:
Front fork assembly
Bearing balls
342000(a)
8. Remove:
Circlips
9 Loosen
Bolt W
342001
10. Remove:
Fork leg (complete)
6-19
FRONT FORK
CHAS
DISASSEMBLY
1. Remove:
Rubber plug Q
Circlip W
Spring seat E
Spring 4

342014
2. Remove:
Bolt Q
Copper washer
NOTE:
To remove the drain bolt Q, use the T-handle W
and the holder E.
T-handle for front fork:

90890-01326
Holder:
90890-01294
342010
3. Remove:
Inner fork tube Q
Piston W
Spring E
Stopper 4

342015(a)
4. Remove:
Dust boot Q
Circlip W
Oil seal E

342016
6-20
FRONT FORK
CHAS
INSPECTION
1. Check:
Inner fork tube and fork components
Outer fork tube
Wear/Scratches/Damage Replace.
WARNING
Never attempt to straighten a bent fork tube

as this may dangerously weaken the tube.
ASSEMBLY
Reverse the DISASSEMBLY procedure.
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 before reassembling.
1. Install:
Stopper
Inner fork tube
Spring
Piston
NOTE:
Before installing the oil seal, apply lithium soap
grease onto the oil seal lips.
2. Install:
Oil seal
Circlip
Dust boot
6-21
FRONT FORK
3. Install:
Copper washer
Bolt
NOTE:
Tighten the drain bolt Q while holding the piston
with the T-handle W and holder E.
CHAS
T-handle for front fork:

90890-01326
Holder:
90890-01294
342010
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
INSTALLATION
1. Install:
Left and right fork tube into the steering crown.
2.Install:
Circlips 1
3. Install:
Pinch bolts 2
T.
342001
6-22
Pinch bolt:
30 Nm (3.0 m kg; 21.7 ft lb)
STEERING HEAD AND HANDLEBAR
CHAS

Q Handlebar
W Nut
E Bolt
R Grip
T Throttle grip
Y Throttle cable
U Screw
I Brake cable
O Starter cable

354004(a)
6-23
CHAS
STEERING HEAD AND

HANDLEBAR
REMOVAL
WARNING
Securely support the scooter so there is no
danger of it falling over.
354001
1. Place the scooter on an even surface.

2. Remove:
Front fender
Inner panels
Upper handlebar cover
Refer to section REMOVAL AND INSTALLATION OF COVERS in Chapter 3.
3. Drain:
Front brake system
Refer to section FRONT BRAKE in Chapter 6.
4. Remove:
Front brake master cylinder
5. Remove:
Front brake caliper mounting bolts
6. Remove:
Front wheel
7. Remove:
Rear brake cable
Throttle grip
8. Disconnect:
Ground wire
All couplers
Wire harness band
Clamp
9. Remove:
Nut Q
Bolt
Handlebar
10. Remove:
Ring nut
Washer
6-24
CHAS
11. Remove:
Upper bearing race Q
Steering head nut wrench:

9079Q-02218

354005
Steering shaft
Bearing balls
INSPECTION
1. Check:
Handlebar Q
Bends/Cracks/Damage Replace.
2. Wash the bearing balls in solvent.
3. Check:
Bearing races Q
Bearing balls
354006
NOTE:
Always replace the bearing balls and the upper
and 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.
354007
6-25
CHAS
CAUTION:
Unless installed correctly, the bearing races

will damage the frame.
Never hit the bearing races on the ball
race surface.
*********************************************************
354008
4. Check:
Steering shaft
Bend/Damage Replace.
WARNING
Never attempt to straighten a bent steering
shaft.
354009
ASSEMBLY AND INSTALLATION

Reverse the REMOVAL and DISASSEMBLY
procedure.
WARNING
Proper cable and hose routing is essential to
insure safe scooter operation. Refer to section
CABLE ROUTING in Chapter 2.
1. Install:
Bearing balls
2. Apply:
Bearing grease (onto upper and lower bearing
balls)
354010
3. Install:
Steering shaft
Bearing race (upper) Q
9079Q-02218
354003
6-26
CHAS
CAUTION:
Hold the steering shaft until it is securely
attached.
4. Install:
Washer Q
Steering shaft lock nut W

354002
NOTE:
Tighten the steering shaft lock nut with the Steering head nut wrench. Set the torque wrench to the
ring nut wrench so that they form a right angle.
9079Q-02218
T.
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.

354011
6. Install:
Throttle grip (complete)
Master cylinder
Brake hose (into the clip)
CAUTION:
Before installing the handlebar, wipe off any
trace of oil from the inserted section of the
shaft with solvent.
Insert the bolt from the left as shown.
T.
Bolt (handlebar):
60 Nm (6.0 m.kg, 43.3 ft.lb)
7. Install:
Band
Refer to section CABLE ROUTING in Chapter 2.
6-27
ELEC
ELEC
CHAPTER 7.
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS ...................................................................... 7-1
CIRCUIT DIAGRAM ....................................................................................... 7-3
IGNITION AND STARTING SYSTEM ............................................................ 7-5
CIRCUIT DIAGRAM ................................................................................. 7-5
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM .................... 7-6
TROUBLESHOOTING ............................................................................. 7-7
CHARGING SYSTEM .................................................................................. 7-13
CIRCUIT DIAGRAM ............................................................................... 7-13
TROUBLESHOOTING ........................................................................... 7-14
LIGHTING SYSTEM .................................................................................... 7-16
CIRCUIT DIAGRAM ............................................................................... 7-16
SIGNAL SYSTEM ........................................................................................ 7-21
WIRING DIAGRAM ................................................................................ 7-21
ELECTRICAL COMPONENTS
ELEC
BATTERY:
SPECIFIC GRAVITY: 1.280
IGNITION COIL
Primary coil resistance:
0.32 ~ 0.48 at 20C (68F)
Secondary coil resistance:
5.68 ~ 8.52 at 20C (68F)
Q Wire harness
W Fuel sender
E Ignition coil
R Starter relay
T Battery
Y CDI unit
U Oil sender
383002
7-1
Q Main switch
W Rectifier / Regulator
E Horn
R Flasher relay
ELEC
Starter motor coil resistance:

0.06 - 0.08 at 20C (68F)
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
7-2
ELEC
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
2
O
1
0
B
WR
LOCK
OFF
CHECK
ON
BR
BW
YR
B
5
}
YR
L G Y
OFF
LOW
HI
8
B
LW
G
Y
{
GY
B R
BW
L
t
q
B
Br
i
Ch
BrW
L
B
o
B
Dg
Gy
L
N
R
P
F
p
7-3
Gy
Dg
Ch
e
Br
H
Br
Br
u
B
[
B
]
B
Br Gy
CIRCUIT DIAGRAM
Q Spark plug
W Ignition coil
E CDI magneto
R CDI unit
T Rectifier/regulator
Y Starter motor
U Starter relay
I Battery
O Fuse
P Main switch
{ Starter switch
} "LIGHTS" switch
q Meter light
w Meter light
e Headlight
r Position light
t Tail/Stop light
ELEC
y Flasher relay
u Flasher indicator
i "TURN" switch
o Rear flasher light (left)
p Front flasher light (left)
[ Rear flasher light (right)
] Front flasher light (right)
A Front stop switch
S Rear stop switch
D Horn
F Horn switch
G Oil level indicator
H Oil level gauge
J Fuel meter
K Sender
L High beam indicator
COLOR CODE
B
Black
Br
Brown
Ch
Chocolate
Dg
Dark green
G
Green
Gy
Grey
L
Blue
O
Orange
P
Pink
R
Red
Sb
Sky blue
W
White
Y
B/R
B/W
Br/W
Br/Y
G/B
G/Y
L/W
W/R
Y/B
Y/R
7-4
Yellow
Black/Red
Black/White
Brown/White
Brown/Yellow
Green/Black
Green/Yellow
Blue/White
White/Red
Yellow/Black
Yellow/Red
ELEC
IGNITION AND STARTING SYSTEM

2
O
1
0
B
WR
BR
BW
YR
B
5
}
YR
B R
BW
LOCK
OFF
CHECK
ON
L G Y
OFF
LOW
B
B
HI
LW
G
Y
{
GY
L
t
q
B
Br
i
Ch
BrW
L
B
Q Spark plug
W Ignition coil
E CDI Magneto
o
B
R CDI unit
Y Starter motor
U Starter Relay
Dg
Gy
L
N
R
P
F
p
u
B
[
B
I Battery
O Fuse
P Main switch
7-5
Gy
Dg
Ch
e
Br
H
Br
Br
]
B
{ Starter switch
A Front brake switch
S Rear brake switch
Br Gy
ELEC
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM

} Main switch
Q Spark plug
a Source coil
t Front brake switch
W Ignition coil
b Pickup coil
y Rear brake switch
R CDI unit
c Wave-shape shaping circuit
U Starter Motor
d Condenser
I Starter relay
e Diode
O Fuse
f SCR
P Battery
g To oil level switch
{ Starter switch
B/R
e
W/R
e
d
B
B
B/W
BW B
Br Gy
LOCK
OFF
CHECK
ON
M
B
B
L/W
Br
G/Y
: Current flow in ignition control circuit

: Current flow in starter motor control circuit
374001
7-6
ELEC

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:
90890-06754
Pocket tester:
90890-03112
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 in
Chapter 3.
INCORRECT

BR8HS (NGK)
The spark plug is defective. Replace it or
adjust the spark plug gap.
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.
W Spark plug cap
E Spark
Check the length of the spark gap.
Start the engine and increase the spark
length until the engine begins to misfire.
372000
Minimum spark gap:

6.0 mm (0.24 in)
MEETS SPECIFICATION
OUT OF
SPECIFICATION
OR NO SPARK
Ignition system in good condition.
7-7
ELEC
3.Spark plug cap resistance

Disconnect the spark plug cap.
Connect the pocket tester ( x 1 k) to the
spark plug cap.
Check the resistance of the spark plug cap.
Spark plug cap resistance:
5k at 20C (68F)
DOES NOT MEET

SPECIFICATION
372001
Replace the spark plug cap

MEETS
SPECIFICATION
4.Ignition coil resistance
Disconnect the ignition coil leads.
Connect the pocket tester ( x 1) to the
ignition coil.
Ignition coil :
Pocket tester (+) lead Orange
Pocket tester (-) lead Ground
372002
Check the primary coil resistance.

0.32 ~ 0.48 at 20C (68F)
Connect the pocket tester ( x 1k) to the
ignition coil.
Pocket tester (+) lead Ground
Pocket tester (-) lead Spark plug lead
Check the secondary coil resistance.
372003

5.68 ~ 8.52 at 20C (68F)
DOES NOT MEET

SPECIFICATION
MEETS
SPECIFICATION
Defect. Replace the ignition coil.
7-8
ELEC
5.Pickup coil resistance

CDI
MAGNETO
Disconnect the pickup coil coupler.

pickup coil.
Pocket tester (+) lead Q White / Red

Pocket tester (-) lead W Ground
Y/R
W/R B/R
Check the pickup coil resistance.
372004
DOES NOT MEET

SPECIFICATION
Pickup coil resistance:

400 ~ 600 at 20C (68F)
MEETS
SPECIFICATION
Pickup coil defect Replace.
6.Source coil resistance

Disconnect the source coil coupler from the
wire harness.
source coil.
CDI
MAGNETO
Pocket tester (+) lead Q Black / Red

Y/R
W/R B/R
Check the source coil resistance.
372005
DOES NOT MEET

SPECIFICATION
Source coil resistance:

640 ~ 960 at 20C (68F)
MEETS
SPECIFICATION
Source coil defect Replace.

POOR CONNECTIONS
7.Connections
Check all connections in the ignition system.
Refer to WIRING DIAGRAM.
Repair.
GOOD
CONNECTIONS
Replace the CDI unit.
7-9
ELEC
TROUBLESHOOTING
STARTER MOTOR DOES NOT WORK
NOTE:
2) Footrest boards
3) Front panel
4) Handlebar cover
Pocket tester:
90890-03112
1.Fuse
NO CONTINUITY
Remove the fuse.

Connect the pocket tester ( x 1) to the fuse.
Check the fuse for continuity.
Defect Replace fuse.
CONTINUITY
2.Battery
Check the condition of the battery.
Refer to BATTERY INSPECTION in
CHAPTER 3.
DOES NOT MEET

SPECIFICATION
Open circuit voltage:

12.8 V or more at 20C (68F)
Clean battery terminals.

Charge or replace the battery.
MEETS
SPECIFICATION
3.Starter motor
Use a jumper lead E * to connect the (+) Q
terminal of the battery to the starter motor
terminal W.
CAUTION:
If the gauge of the jumper lead is smaller
than that of the battery leads, the jumper
lead might melt or burn.
This test could cause sparks. Never

perform it near a gas source or near
flammable products.
DOES NOT WORK
372006
Starter defect Repair or replace.
Check the starter motor operation.

WORKS
7-10
ELEC
4. Starter relay
Disconnect the Blue/White lead from the
wire harness.
Connect the (-) Q terminal of the battery to
the Blue/White lead.
DOES NOT WORK
L/W
Starter relay defect Replace.
372007
WORKS
5. Main switch
Disconnect the main switch from the wire
harness.
Check for continuity between Red Q and
Brown W.
BW B
Br Gy
LOCK
OFF
DOES NOT MEET

SPECIFICATION
CHECK
ON
R
R
B/W
Main switch defect Replace.
Br Gy B
372008
MEETS
SPECIFICATION
6.Starter switch
Disconnect the right handlebar switch coupler from the wire harness.
Check for continuity between Blue / White
Q and Black W.
7-11
ELEC
LW B
OFF
DOES NOT MEET

SPECIFICATION
ON
372009A
B YB L
LW YR LR
372009B
Starter switch defect Replace right handlebar switch.
MEETS
SPECIFICATION
POOR CONNECTIONS
7.Connections
Check all connections in the starter system.
7-12
Repair.
ELEC
CHARGING SYSTEM
CHARGING SYSTEM
WIRING DIAGRAM
2
O
1
0
B
WR
BR
BW
YR
B
B
YR
5
}
L G Y
OFF
LOW
LW
HI
G
Y
{
GY
B R
BW
LOCK
OFF
CHECK
ON
L
t
q
B
Br
i
Ch
BrW
L
B
E CDI magneto
T Rectifier / regulator
Dg
Gy
L
N
R
P
F
p
I Battery
O Fuse
7-13
Gy
Dg
Ch
e
Br
H
Br
Br
u
B
[
B
]
B
Br Gy
CHARGING SYSTEM
ELEC
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED
NOTE:
1) Side covers (left and right) and foot rest board.
90890-03113
Pocket tester:
90890-03112
1.Fuse (Main)
Remove the fuse.
NO CONTINUITY
CONTINUITY
2.Battery
Fuse defect Replace.

CHAPTER 3.
12,8 V or more at 20C (68F)
DOES NOT MEET

SPECIFICATION

3.Charging voltage
Connect the engine tachometer to the spark
plug lead.
Connect the pocket tester (DC20V) to the
battery terminals.
Pocket tester (+) lead Battery (+) terminal
Pocket tester (-) lead Battery (-) terminal
Start the engine and accelerate to about
5000 rpm.
Check the charging voltage.
Charging voltage :
14 ~ 15 V at 5.000 tr/mn
367001
MEETS SPECIFICATION
NOTE:
Use a fully charged battery.
OUT OF
SPECIFICATION
Charging circuit is OK.
7-14
372010
CHARGING SYSTEM
ELEC
4.Charging coil resistance

CDI
MAGNETO
Disconnect the CDI magneto coupler from

the wire harness.
charging coil.
Check the charging coil resistance
Tester (+) lead White Q

Tester () lead Ground W
Charging coil resistance:
0.48 ~ 0.72 at 20C (68F)
Y/R
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Charging coil defect Replace.

POOR CONNECTIONS
5.Connections
Check all connections in the charging system.
Repair.
MEETS
SPECIFICATION
Replace the rectifier/regulator.
7-15
W/R B/R
372015
ELEC
LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM
2
O
1
0
B
WR
BR
BW
YR
B
B
YR
5
}
B R
BW
LOCK
OFF
CHECK
ON
L G Y
OFF
LOW
LW
HI
G
Y
{
GY
L
t
q
B
Br
i
Ch
BrW
K G
L
B
E CDI magneto
} LIGHTS switch
q Meter light
w Meter light
Dg
Gy
L
N
R
P
F
p
u
B
e Headlight
r Position light
7-16
Gy
Dg
Ch
e
Br
H
Br
Br
[
B
]
B
t Tail/Stop light
L HIGH BEAM indicator light
Br Gy
LIGHTING SYSTEM
ELEC
TROUBLESHOOTING
THE AUXILIARY LIGHT, HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT,
TAILLIGHT OR METER LIGHT DO NOT WORK
NOTE:
Handlebar covers
Pocket tester:
90890-03112
1. LIGHTS switch
Set the switch to .
Check for continuity between
YR L G Y
OFF
P0
ON
G YR LW
Yellow / Red Q and Blue W
Yellow / Red Q and Green 3

Then set the switch to .
Check for continuity between:
372009A
NO CONTINUITY
Yellow / Red Q and Blue W

Yellow / Red Q and Yellow 4
"Light" switch defect Replace.
CONTINUITY
7-17
372013(a)
LIGHTING SYSTEM
ELEC
2. Lighting coil resistance

CDI
MAGNETO
Disconnect the lighting coil coupler from the

wire harness.
lighting coil.
Check the lighting coil resistance
Tester (+) lead Yellow / Red Q

Tester (-) lead Ground W
Lighting coil resistance:
0.32 ~ 0.48 at 20C (68F)
MEETS
SPECIFICATION
Lighting coil defect Replace.
3. Connections
Check all connections in the lighting system.
Y/R
POOR CONNECTIONS
MEETS
SPECIFICATION
Repair.
Circuit is in good condition.
7-18
W/R B/R
372036
LIGHTING SYSTEM
ELEC
LIGHTING SYSTEM INSPECTION

1. Headlight and headlight indicator do not work.
1. Bulb and socket
NO CONTINUITY
Check the bulb and socket for continuity.

Replace bulb or socket.
CONTINUITY
2. Voltage
Connect the pocket tester (AC20V) to the
headlight coupler.
Headlight:
LO:
Pocket tester (+) lead Green Q
Pocket tester (-) lead Black E
HI:
Pocket tester (+) lead Yellow W
Headlight indicator:
Pocket tester (+) lead Yellow R
Pocket 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 headlight coupler leads.
B
Y
B
Y
372017(a)
MEETS
SPECIFICATION
There is a defect in the wire harness between
the main switch and the headlight coupler
and/or between the main switch and the
headlight indicator coupler
Repair.

2. The meter light does not work.
NO CONTINUITY
1. Bulb and socket

CONTINUITY
7-19
ELEC
LIGHTING SYSTEM
2. Voltage
L Br
Dg G
Ch Gy

meter light coupler.
Pocket tester (+) lead Blue Q
Pocket tester (-) lead Black W
Start the engine.
Check the voltage (12V) between the headlight coupler leads Blue and Black.
Br L
G Dg
Gy Ch
B
Y
B
Y
372037(a)
MEETS
SPECIFICATION
the main switch and the meter light coupler
Repair.
3. The taillight does not work.

NO CONTINUITY
1. Bulb and socket

CONTINUITY
2. Voltage
110
L
Ch Dg Dg Ch
L
GY
Dg
Ch
B
GY
250
250
L L GY
- B B -
GY

Start the engine.
110
250

taillight coupler.
Dg
B
Ch
372019(a)
MEETS
SPECIFICATION

the main switch and the taillight coupler
Repair.
7-20
ELEC
SIGNAL SYSTEM
SIGNAL SYSTEM
WIRING DIAGRAM
2
O
1
0
B
WR
BR
BW
YR
B
B
YR
5
}
L G Y
OFF
LOW
HI
{
GY
L
q
B
t
r
BrW
o
B
u Flasher indicator
I Battery
i "TURN" switch
O Fuse
o Rear flasher light (left)
0 Main switch
t Tail / Stop light p Front flasher light (left)
y Flasher relay [ Rear flasher light (right)
Gy
P
F
Ch
L
Dg
L
N
R
K G
Br
i
Ch
Br
Br
Br
LW
G
Y
B R
BW
LOCK
OFF
CHECK
ON
p
B
Dg
u
B
[
B
]
B
] Front flasher light (right)

A Front stop switch
S Rear stop switch
D Horn
F "HORN" switch
7-21
Gy
G Oil level indicator

H Oil level gauge
J Fuel meter
K Sender
Br Gy
ELEC
SIGNAL SYSTEM
TROUBLESHOOTING
FLASHER LIGHTS, BRAKE LIGHT, OIL WARNING LIGHT DO NOT WORK

HORN DOES NOT SOUND
NOTE:
Handlebar cover
Pocket tester:
90890-03112
1. Fuse
Remove the fuse.
Refer to FUSE INSPECTION in Chapter 3.
NO CONTINUITY
CONTINUITY
2. Battery
DOES NOT MEET SPECIFICATION

CHAPTER 3.
Battery voltage:
MEETS
SPECIFICATION
3. Main switch
BW B

harness.
Turn the main switch to .
OFF
ON
R
R
Red Q and Brown W
Br Gy
CHECK
Red Q and Grey E

Turn the main switch to ON.
LOCK
B/W
Br Gy B
MEETS
SPECIFICATION
7-22
372040
SIGNAL SYSTEM
4. Connections
ELEC
POOR CONNECTIONS
Check all connections in the signal system.

GOOD
CONNECTIONS
Repair.
Check the condition of each circuit of the

signal system.
Refer to the section SIGNAL SYSTEM
CHECK.
SIGNAL SYSTEM CHECK

1. Horn does not sound
1. HORN switch
Disconnect the handlebar switch (left) from
the wire harness.
Black Q and Pink W.
B
OFF
ON
NO CONTINUITY
Ch - P
B BrW Dg
Horn switch is defect Replace.

372029(a)
CONTINUITY
2. Voltage
horn lead.
Pocket tester (+) lead Brown Q
Pocket tester (-) lead Ground W
Check for voltage (12V) between Brown
and the ground.
7-23
SIGNAL SYSTEM
Br
ELEC
Defect in the wire harness between the main

switch and the horn Repair.
372025
MEETS
SPECIFICATION
3. Horn
Disconnect the Pink lead at the horn terminal.
Ground the horn terminal Q with a jumper
lead.
Br
HORN SOUNDS
Horn in good condition.
372026
HORN DOES
NOT SOUND
4. Voltage
Br

Pink lead.
Pocket tester (+) lead Pink Q

Press the HORN switch.
Check the voltage (12V) between Pink and
ground.
372027
MEETS
SPECIFICATION
Horn is defect Replace.
Adjust the horn.
7-24
SIGNAL SYSTEM
ELEC
2. The brake light does not work.

1. Bulb and socket
NO CONTINUITY

CONTINUITY

2. Brake switch
Disconnect the brake switch leads from the
wire harness.
Brown Q and Green / Yellow W
Br G/Y
ON (Pull in)
OFF (Free)
NO CONTINUITY
Br G/Y
Brake switch is defect Replace.

372030
CONTINUITY
3. Voltage
socket.
Pocket tester (+) lead Green / Yellow Q
Pull the brake lever.
Check the voltage (12V) between Green /
Yellow Q and Black W.
Dg
110
110
250
Ch Dg Dg Ch
L
GY
Dg
Ch
B
GY
250
250
L L GY
- B B -
GY

the main switch and the brake light socket
Repair.
B
Ch
372019(a)
MEETS
SPECIFICATION
7-25
SIGNAL SYSTEM
ELEC
3. Flasher does not work

NO CONTINUITY
1. Bulb and socket

CONTINUITY
2. TURN switch
the wire harness.
Check for continuity between :
Left side : Brown / White Q and Chocolate W
Right side : Brown / White Q and Dark green E
Ch BrW Dg
L
N
R
NO CONTINUITY
Ch - P
B BrW Dg
Left handlebar switch is defect Replace.
372032(a)
CONTINUITY
3. Voltage
flasher relay.
Check the voltage (12V) between the Brown
lead and the ground.
Br/W
Br

switch and the flasher relay Repair.
372033
MEETS
SPECIFICATION
7-26
SIGNAL SYSTEM
ELEC
4. Voltage
flasher relay.
Pocket tester (+) lead Brown / White Q
Check the voltage (12V) between Brown /
White and the ground.

-
Br/W
Br
Flasher relay defect Replace.

372034
MEETS
SPECIFICATION
5. Voltage
flasher connector.
Left flasher bulb:
Pocket tester (+) lead Chocolate Q
Right flasher bulb:
Pocket tester (+) lead Dark green W
Set the TURN switch to L, then to R.
Check the voltage (12V) between Chocolate and the ground, then Dark green and
the ground.
Dg
110
110

250
Ch Dg Dg Ch
L
GY
Dg
Ch
B
GY
250

switch and the flasher bulb socket Repair.
250
L L GY
- B B -
GY
B
Ch
372038(a)
MEETS
SPECIFICATION 7-27
SIGNAL SYSTEM
ELEC
This circuit is in good condition.

4. The OIL indicator light does not work.
1. Bulb and socket
NO CONTINUITY

CONTINUITY
2. Oil level switch

Disconnect the oil level switch from the oil
tank.
Connect the pocket tester ( x 1) to the oil
level switch.
Pocket tester (+) lead Terminal Q
Pocket tester (-) lead Terminal Q
Check the switch for continuity.
Float
position
Good
condition
Bad
condition
HIGH
LOW
O : Continuity X : No continuity
Replace oil level switch is defect.
B
372035
MEETS
SPECIFICATION
7-28
SIGNAL SYSTEM
ELEC
3. Voltage
bulb socket connector.
Pocket tester (+) lead Grey Q
Check the voltage (12V) between Grey and
the ground.
L Br
Dg G
Ch Gy
4. Connections
372039(a)
MEET
SPECIFICATION
7-29

TRBL
SHTG
TRBL
SHTG
CHAPTER 8.
TROUBLESHOOTING
STARTING FAILURE/ HARD STARTING ..................................................... 8-1
FUEL SYSTEM ........................................................................................ 8-1
ELECTRICAL SYSTEM ........................................................................... 8-1
COMPRESSION SYSTEM ...................................................................... 8-2
POOR IDLE SPEED PERFORMANCE ......................................................... 8-2
POOR IDLE SPEED PERFORMANCE ................................................... 8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE ................................ 8-3
FUEL SYSTEM ........................................................................................ 8-3
ELECTRICAL SYSTEM ........................................................................... 8-3
COMPRESSION SYSTEM ...................................................................... 8-3
FAULTY AUTOMATIC (V-BELT TYPE) ......................................................... 8-3
MOTORCYCLE DOES NOT MOVE WHILE ENGINE IS OPERATING ... 8-3
CLUTCH -OUT FAILURE ......................................................................... 8-4
POOR STANDING START (LOW CLIMBING ABILITY) .......................... 8-4
POOR ACCELERATION (POOR HIGH SPEED) .................................... 8-4
OVER HEATING ............................................................................................ 8-4
OVER HEATING ...................................................................................... 8-4
IMPROPER KICKING .................................................................................... 8-5
SLIPPING ................................................................................................. 8-5
HARD KICKING ....................................................................................... 8-5
KICK CRANK NOT RETURNING ............................................................ 8-5
FAULTY BRAKE ............................................................................................ 8-5
POOR BRAKING EFFECT ...................................................................... 8-5
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION ........... 8-6
OIL LEAKAGE .......................................................................................... 8-6
MALFUNCTION ....................................................................................... 8-6
INSTABLE HANDLING .................................................................................. 8-6
INSTABLE HANDLING ............................................................................ 8-6
FAULTY SIGNAL AND LIGHTING SYSTEM ................................................. 8-7
STARTING FAILURE/HARD STARTING
TRBL
SHTG
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 STARTING

FUEL SYSTEM
Fuel tank
Empty
Clogged fuel filter
Deteriorated fuel or fuel containing water or
foreign material
Clogged fuel tank cap
Fuel cock
Clogged fuel hose
Clogged vacuum
Faulty diaphragm
Air cleaner
Clogged air filter
Carburetor
Deteriorated fuel, fuel containing water or
foreign material
Clogged pilot jet
Clogged pilot air passage
Sucked-in air
Deformed float
Groove-worn needle valve
Improperly sealed valve seat
Improperly adjusted fuel level
Improperly set pilot jet
Clogged starter jet
Starter plunger malfunction
Improperly adjusted pilot air screw
ELECTRICAL SYSTEM
Spark plug
Improper plug gap
Worn electrodes
Wire between terminals broken
Improper heat range
Faulty spark plug cap
Ignition coil
Broken or shorted primary/secondary coil
Faulty spark plug lead
Broken body
Starter motor
Faulty starter motor
Faulty starter relay
CDI unit system

Faulty CDI unit
Faulty source coil
Faulty pick-up coil
Switches and wiring
Faulty main switch
Broken or shorted wiring
Faulty brake switch (front or rear)
8-1
STARTING FAILURE/HARD STARTING/

POOR IDLE SPEED PERFORMANCE
COMPRESSION SYSTEM
Cylinder and cylinder head
Loose spark plug
Loose cylinder head or cylinder
Broken cylinder head gasket
Broken cylinder gasket
Worn, damaged or seized cylinder
Piston and piston rings
Improperly installed piston ring
Worn, fatigued or broken piston ring
Seized piston ring
Seized or damaged piston
TRBL
SHTG
Crankcase and crankshaft

Improperly seated crankcase
Improperly sealed crankcase
(damaged oil seal)
Seized crankshaft
Reed valve
Deformed reed valve stopper
Improperly seated reed valve
Loose intake manifold
Broken gasket
Broken reed valve

Carburetor
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
8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE/

FAULTY AUTOMATIC
TRBL
SHTG
POOR MEDIUM AND HIGH SPEED PERFORMANCE

FUEL SYSTEM
Fuel tank
Clogged fuel filter
Deteriorated fuel or fuel containing water or
foreign material
Clogged fuel tank cap
Fuel cock
Clogged fuel hose
Clogged vacuum hose
Faulty diaphragm
Air cleaner
Clogged air cleaner
Carburetor
Deteriorated fuel, fuel containing water or
foreign material
Sucked-in air
Deformed float
Groove-worn needle valve
Improperly sealed valve seat
Improperly set clip position of jet needle
Improperly adjusted fuel level
Clogged or loose main jet
Clogged or loose main nozzle
Clogged main air passage
ELECTRICAL SYSTEM
Spark plug
Improper plug gap
Worn electrodes
Wire between terminals broken
Improper heat range
Faulty spark plug cap
CDI unit system

Faulty CDI unit
Faulty source coil
Faulty pick-up coil
COMPRESSION SYSTEM
Cylinder and cylinder head
Loose spark plug
Loose cylinder head or cylinder
Broken cylinder head gasket
Broken cylinder gasket
Worn, damaged or seized cylinder
Piston and piston rings
Improperly installed piston ring
Worn, fatigued or broken piston ring
Seized piston ring
Seized or damaged piston

Improperly sealed crankcase
(damaged oil seal)
Seized crankshaft
Reed valve
Deformed reed valve stopper
Improperly adjusted reed valve stopper height
Improperly sealing reed valve
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 spring
Primary sheave
Pealed lining from clutch shoe
Worn or damaged cam plate
Worn spline of clutch housing
Worn or damaged slider bushing
8-3
FAULTY AUTOMATIC/
OVER HEATING
CLUTCH-OUT FAILURE
Primary sheave
Seized primary sliding sheave and collar
TRBL
SHTG
Secondary sheave
Broken or fatigued clutch shoe spring
POOR STANDING START (LOW CLIMBING ABILITY)

V-belt
Secondary sheave
Worn, damaged or slippery v-belt
Fatigued compression spring
Primary sheave
Improper operation of secondary sliding sheave
Worn or improper operation of weight
POOR ACCELERATION (POOR HIGH SPEED)
V-belt
Worn or greasy V-belt
Secondary sheave
Worn or greasy clutch shoe
Improper operation of secondary sliding sheave
OVER HEATING
OVER HEATING
Ignition system
Improper spark plug gap
Improper spark plug heat range
Faulty ignitor unit
Engine oil
Improper engine oil quality (high viscosity)
Low engine oil quality
Brakes
Dragging brake
Fuel system
Improper carburetor setting
Improper fuel level adjustment
Clogged air cleaner element
Lean mixture (Air in the autolube pump)
Cooling fan
Damaged cooling fan
Damaged air shrouds
Compression system
Heavy carbon deposit build-up
8-4
IMPROPER KICKING/
FAULTY BRAKE
TRBL
SHTG
IMPROPER KICKING
SLIPPING
Kick axle assembly
Low tension of kick clip
Worn kick axle
Worn or damaged kick gear
Damaged kick clip
Kick clip coming off
Damaged kick clip stopper
Transmission oil
Improper quality (low viscosity)
Deterioration
HARD KICKING
Kick axle assembly
High tension of kick clip
Seized kick gear

Improperly seated crankshaft
Damaged or seized crankshaft
Damaged or seized crankshaft bearing
Cylinder, piston and piston ring

Damaged or seized cylinder
Damaged or seized piston
Damaged or seized piston ring
KICK CRANK NOT RETURNING
Kick axle assembly
Damaged kick return spring
Kick return spring coming off
Kick clip coming off
Damaged kick return spring stopper
FAULTY BRAKE
POOR BRAKING EFFECT
Front disc brake
Worn brake pads
Worn disc
Air in brake fluid
Leaking brake fluid
Wrong brake fluid
Seized main cylinder piston
Faulty caliper seal kit
Loose union bolt
Broken brake hose
Oily or greasy disc/brake pads
Improper brake fluid level
Excessive free play (brake lever)
Rear drum brake

Worn brake shoe
Worn or rusty brake drum
Improperly adjuster brake play
Improper brake cam lever
Improper brake shoe position
Fatigue/damaged return spring
Oily or greasy brake shoe
Oily or greasy brake drum
Broken brake cable
8-5
FRONT FORK OIL LEAKAGE AND FRONT FORK

MALFUNCTION/
INSTABLE HANDLING
TRBL
SHTG
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION

OIL LEAKAGE
Bent, damaged or rusty inner tube
Damaged or cracked outer tube
Damaged oil seal lip
Improperly installed oil seal
Improper oil level (too much)
Loose damper rod holding bolt
Broken cap bolt O-ring
Loose drain bolt or damaged drain bolt gasket
MALFUNCTION
Bent, deformed or damaged inner tube
Bent or deformed outer tube
Damaged fork spring
Worn or damaged slide metal
Bent or damaged damper rod
Improper oil viscosity
Improper oil level
INSTABLE HANDLING
INSTABLE HANDLING
Handlebar
Improperly installed or bent
Wheels
Damaged bearing
Bent or loose wheel axle
Excessive wheel run-out
Steering
Improperly installed steering column
(Improperly tightened ring nut)
Bent steering column
Damaged ball bearing or bearing race
Frame
Twisted
Damaged head pipe
Improperly installed bearing race
Front forks
Broken damper spring
Bent or deformed suspension arm and pivots
Oil level
Engine bracket
Bent or damaged
Tires
Incorrect tire pressure
Uneven tire pressures on both sides
Unevenly worn tires
Rear shock absorber

Improper adjustment
Fatigued spring
Oil leakage
8-6
FAULTY SIGNAL AND LIGHTING SYSTEM
TRBL
SHTG
FAULTY SIGNAL AND LIGHTING SYSTEM

Headlight dark
Improper bulb
Too many electric accessories
Hard charging (broken charging coil)
Incorrect connection
Improperly grounded
Poor contacts (main or light switch)
Bulb life expired (high internal resistance)
Flasher does not light

Improperly grounded
Discharged battery
Faulty flasher switch
Faulty flasher relay
Broken wire harness
Loosely connected coupler
Bulb burnt out
Faulty fuse
Bulb burnt out

Improper bulb
Improperly grounded
Faulty main and/or light switch
Bulb life expired
Flasher keeps on
Insufficient battery capacity
(nearly discharged)
Flasher winks slower

Insufficient battery capacity (nearly discharged)
Improper bulb
Faulty main and/or flasher switch
Horn is inoperative
Faulty battery
Faulty fuse
Faulty main and/or horn switch
Improperly adjusted horn
Faulty horn
Broken wire harness
Flasher winks quicker

Improper bulb
8-7
CW50RS WIRING DIAGRAM
a
1
Br
GY
Br
GY
LW
OFF
ON
GY
YR
L G Y
B OFF
LOW
HI
:
Dg Dg
YR
BW
L Y B
G YR LW
Y
B
B
Gy
Dg
Ch
Or
BG
Gy
Br
Dg
110
110
B
Y
B
L
B
L
BW
Br L
G Dg
Gy Ch
B
Y
(GREEN)
L
Gy
G
Br
L
Y
Dg
L
GY
Dg
Ch
B
Ch
L L GY
- B B -
GY
Ch Dg Dg Ch
L
GY
Dg
Ch
B
GY
B
Ch
B
Ch
B B
Ch Ch
Ch
BrW Dg B Ch P
B
BrW
Br
Ch - P
B BrW Dg
BrW
Br
Br
BrW
B P Ch
BrW
W YR
WR BR
W YR
W YR
Blue
Orange
Pink
red
Sky blue
White
Y
B/R
B/W
Br/W
Br/Y
G/B
R B
R B
LW
GY
WR
Ch BrW Dg
R
R
Yellow
Black/Red
Black/White
Brown/White
Brown/Yellow
Green/Black
12V 4AH
BR
L
N
R
COLORS CODE
L
O
P
R
Sb
W
B Or
Black
Brown
Chocolate
Dark green
Green
Grey
BW
Dg
u
OFF
ON
B Or
WR
B Or
B P
LW GY
BR
P
Ch - Dg
B
Br
Ch
Dg
G
Gy
250
187.8
(BLACK)
L Br
Dg G
Ch Gy
D
S
Y G B L LW YR
Br
G
B
B G
250
H
G
YR B W R
Br B Gy
B WR
Br Gy B
Br Gy B
G YR LW
L Y B
B
L
R Br
LOCK
OFF
CHECK
ON
B G
Dg
B
B B
BW B Gy
250
B
Dg
2
Br
G/Y
L/W
W/R
Y/R
Y/R
Green/Yellow
Blue/White
White/Red
Yellow/White
Yellow/Red
Q
W
E
R
T
Y
U
I
O
P
{
}
q
w
e
r
t
y
u
i
o
p
[
]
A
S
D
F
G
H
J
K
L
:
a
Handlebar switch (right)

"START" switch
"LIGHT" switch
Main switch
Ignition coil
Spark plug
Rectifier / regulator
Fuel lever sender
Oil level gauge
Rear flasher light (right)
Tail /Stop light
Rear flasher light (left)
Starter motor
Starter switch
Battery
Fuse
CDI unit
CDI magneto
Horn
Handle switch (left)
"TURN" switch
"HORN" switch
Flasher relay
Front flasher light (left)
Head light
Meter light
Meter light
Fuel meter
Flasher indicator
Oil caution indicator
"HIGH BEAM" indicator light
Position light
Front flasher light (right)
Rear stop switch
Front stop switch
CW50RS
'00
5FX-ME2
SUPPLEMENTARY
SERVICE MANUAL
FOREWORD
This supplementary service manual has been prepared to introduce new service and data for the
CW50RS ('00). For complete service information procedures it is necessary to use this supplementary
service manual together with the following manual.
CW50RS ('99) SERVICE MANUAL : 5FX-ME1
CW50RS ('00)
SUPPLEMENTARY
SERVICE MANUAL
1999 by MBK INDUSTRIE
1st Edition, September 1999
All rights reserved. Any
reprinting or unauthorized use
without the written
permission of MBK INDUSTRIE
is expressly prohibited.
NOTICE
This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealers
and their qualified mechanics. It is not possible to put an entire mechanics education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and
MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in
scooter repair technology. Without such knowledge, attempted repairs or service to this model may
render it unfit to use and/or unsafe.
MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and
significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and
MBK dealers and will, where applicable, appear in future editions of this manual.
DOCUMENTATION TECHNIQUE
MBK INDUSTRIE
PARTICULARY IMPORTANT INFORMATION

This material is distinguished by the following notation :
The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE :
Failure to follow WARNING instructions could result in severe injury or

death to the scooter operator, a bystander, or a person inspecting or
repairing the scooter.
A CAUTION indicates special precautions that must be taken to avoid

damage to the scooter.
A NOTE provides key information to make procedures easier or clearer.
HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This 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 FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particulary important procedure 4 is placed between a line of asterisks " * " with each step
preceded 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 an
alignement 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 required
the symbol 9.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams are before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
ILLUSTRATED SYMBOLS
GEN
INFO
(REFER TO THE ILLUSTRATION)
SPEC
Illustrated symbols Q to W are designed as

thumb tabs to indicate the chapters number and
content.
INSP
ADJ
ENG
Q General information
W Specifications
E Periodic inspection and adjustment
R Engine
T Carburetion
Y Chassis
U Electrical
I Troubleshooting
CARB
CHAS
TRBL
SHTG
ELEC
O
Illustrated symbols O to e are used to identify

the specifications appearing in the text.
T.
Illustrated symbols r to [ in the exploded

diagram indicate grade of lubricant and location
of lubrication point.
r
O Filling fluid
P Lubricant
{ Special tool
} Tightening
q Wear limit, clearance
w Engine speed
e , V, A
r Apply engine oil

t Apply gear oil
y Apply molybdenum disulfide oil
u Apply wheel bearing grease
i Apply lightweight lithium-soap base
grease
o Apply molybdenum disulfide grease
p Apply locking agent (THREADLOCK )
[ Use new one
CONTENTS
ELECTRICAL COMPONENTS ......................................................................... 1
CIRCUIT DIAGRAM .......................................................................................... 3
IGNITION AND STARTING SYSTEM ............................................................... 5
CIRCUIT DIAGRAM .................................................................................... 5
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM ....................... 6
TROUBLESHOOTING ................................................................................ 7
CHARGING SYSTEM ..................................................................................... 13
CIRCUIT DIAGRAM .................................................................................. 13
TROUBLESHOOTING .............................................................................. 14
LIGHTING SYSTEM ....................................................................................... 16
CIRCUIT DIAGRAM .................................................................................. 16
SIGNAL SYSTEM ........................................................................................... 21
WIRING DIAGRAM ................................................................................... 21
ELEC
BATTERY:
SPECIFIC GRAVITY: 1.280
IGNITION COIL
0.32 ~ 0.48 at 20C (68F)
5.68 ~ 8.52 at 20C (68F)
Q Wire harness
W Fuel sender
E Ignition coil
R Starter relay
T Battery
Y CDI unit
U Oil sender
383002
-1-
Q Main switch
W Rectifier / Regulator
E Horn
R Flasher relay
ELEC
Starter motor coil resistance:

0.06 - 0.08 at 20C (68F)
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
-2-
ELEC
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
A
(BLACK)
Br Gy B
R
B
R
B
Br Gy B
Gy Br R B BW
LOCK
MAIN HARNESS STARTER MOTOR
OFF
R
CHECK
ON
BW
BW
B Or
W YR -
W YR R W B YR
R
LW
GY
BR
BR
WR
YR
WR
Or
YR
B Or
BW
Br
Gy
BW
RAR
GY
LW
Br
BAB
o
B
Gy
LW
YR
LW B
YR LR
OFF
OFF
LR/L L
YR _
L LR
_ YR
ON
ON
LW B
B LW
LR
Br
Br
Br
12V10W
]
B
L Br
Dg G
}
C
Dg
OFF
HI
ON
LOW
BrW
G Ch P
LR Dg Y
BrW
P Ch G
GY
G B
12V
35W / 35W
Ch
Dg
Ch
Dg
G B
12V10W
p
B
-3-
12V10W
12V10W
e
B
12V10W
GY
Ch
Y
(GREEN)
B
Y Dg LR
Ch
Ch BrW Dg
G LR Y
D
B P
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
Ch Gy
BrW
L Br
Br
(GREEN)
Dg G
BrW
Dg
Ch Gy
Br
Gy
(BLACK)
H
12V
21W / 5W
Ch Dg
_ B
Dg Ch
B _
GY L
L GY
CIRCUIT DIAGRAM
ELEC
e Right front flasher

r Taillight assembly
F Left rear flasher
G Right rear flasher
H Tail / Stop light
t Horn
y Flasher relay
u Front stop switch
i Rear stop switch
o Oil level gauge
p Fuel sender
[ Meter assembly
J Meter light
K Oil warning light
L Flasher indicator light
M High beam indicator light
N Fuel meter
] Position light
Q
W
E
R
T
Y
U
I
O
P
{
C.D.I. magneto
C.D.I. unit
Ignition coil
Spark plug
Main switch
Fuse
Battery
Starter relay
Starter motor
Right handle switch
A Starter switch
B Lighting switch
} Left handle switch
C "HORN" switch
D "Hi / Lo" switch
E Flasher switch
q Head light
w Left front flasher
COLOR CODE
Black
B
Brown
Br
Chocolate
Ch
Dark green
Dg
Green
G
Grey
Gy
Blue
L
Orange
O
Pink
P
Red
R
Sky blue
Sb
White
W
Y
B/R
B/W
Br/W
Br/Y
G/B
G/Y
L/R
L/W
W/R
Y/B
Y/R
-4-
Yellow
Black/Red
Black/White
Brown/White
Brown/Yellow
Green/Black
Green/Yellow
Blue/Red
Blue/White
White/Red
Yellow/Black
Yellow/Red
ELEC

CIRCUIT DIAGRAM
A
(BLACK)
Br Gy B
R
B
R
B
Br Gy B
Gy Br R B BW
LOCK
OFF
R
CHECK
ON
B Or
W YR
R
W YR R W B YR
R
LW
GY
BR
BR
WR
YR
WR
Or
YR
B Or
BW
Br
Gy
BW
BW
BW
RAR
R
R
GY
LW
Br
M
BAB
Gy
LW
YR
LW B
YR LR
OFF
YR
ON
ON
LW B
YR
B LW
LR
L LR
LR/L L
OFF
Br
Br
Br
12V10W
]
Y
L Br
L Br
Dg G
}
C
Dg
OFF
HI
ON
LOW
BrW
G Ch P
LR Dg Y
BrW
P Ch G
GY
Ch
Y
Y
G B
12V
35W / 35W
Ch
Dg
Ch
Dg
12V10W
12V10W
G B
p
B
Q
W
E
R
T
C.D.I. magneto
C.D.I. unit
Ignition coil
Spark plug
Main switch
Y
U
O
P
Fuse
Battery
Starter relay
Starter motor
-5-
12V10W
12V10W
e
B
{ Right handle switch

A Starter switch
u Front stop switch
i Rear stop switch
GY
(GREEN)
B
Y Dg LR
Ch
Ch BrW Dg
G LR Y
D
B P
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
Ch Gy
Br
BrW
(GREEN)
Dg G
BrW
Dg
Ch Gy
Br
Gy
(BLACK)
H
12V
21W / 5W
Ch Dg
_ B
Dg Ch
B _
GY L
L GY
ELEC
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM

} Main switch
Q Spark plug
a Source coil
t Front brake switch
W Ignition coil
b Pickup coil
y Rear brake switch
R CDI unit
c Wave-shape shaping circuit
U Starter Motor
d Condenser
I Starter relay
e Diode
O Fuse
f SCR
P Battery
g To oil level switch
{ Starter switch
B/R
e
W/R
e
d
B
B
B/W
BW B
Br Gy
LOCK
OFF
CHECK
ON
M
B
B
L/W
Br
G/Y
: Current flow in ignition control circuit

: Current flow in starter motor control circuit
374001
-6-
ELEC

TROUBLESHOOTING
THE STARTING SYSTEM DOES NOT WORK
(NO SPARK OR IRREGULAR SPARKS).
NOTE:
Ignition checker:
90890-06754
Pocket tester:
90890-03112
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 in
Chapter 3.
INCORRECT

BR8HS (NGK)
The spark plug is defective. Replace it or
adjust the spark plug gap.
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.
W Spark plug cap
E Spark
Check the length of the spark gap.
Start the engine and increase the spark
length until the engine begins to misfire.
372000
Minimum spark gap:

6.0 mm (0.24 in)
MEETS SPECIFICATION
OUT OF
SPECIFICATION
OR NO SPARK
Ignition system in good condition.
-7-
ELEC
3.Spark plug cap resistance

Disconnect the spark plug cap.
Connect the pocket tester ( x 1 k) to the
spark plug cap.
Check the resistance of the spark plug cap.
Spark plug cap resistance:
5k at 20C (68F)
DOES NOT MEET

SPECIFICATION
372001
Replace the spark plug cap

MEETS
SPECIFICATION
4.Ignition coil resistance
Disconnect the ignition coil leads.
ignition coil.
Ignition coil :
Pocket tester (+) lead Orange
372002
Check the primary coil resistance.

0.32 ~ 0.48 at 20C (68F)
Connect the pocket tester ( x 1k) to the
ignition coil.
Pocket tester (+) lead Ground
Pocket tester (-) lead Spark plug lead
Check the secondary coil resistance.
372003

5.68 ~ 8.52 at 20C (68F)
DOES NOT MEET

SPECIFICATION
MEETS
SPECIFICATION
Defect. Replace the ignition coil.
-8-
ELEC
5.Pickup coil resistance

CDI
MAGNETO
Disconnect the pickup coil coupler.

pickup coil.
Pocket tester (+) lead Q White / Red

Y/R
W/R B/R
Check the pickup coil resistance.
372004
DOES NOT MEET

SPECIFICATION
Pickup coil resistance:

400 ~ 600 at 20C (68F)
MEETS
SPECIFICATION
Pickup coil defect Replace.
6.Source coil resistance

Disconnect the source coil coupler from the
wire harness.
source coil.
CDI
MAGNETO
Pocket tester (+) lead Q Black / Red

Y/R
W/R B/R
Check the source coil resistance.
372005
DOES NOT MEET

SPECIFICATION
Source coil resistance:

640 ~ 960 at 20C (68F)
MEETS
SPECIFICATION
Source coil defect Replace.

POOR CONNECTIONS
7.Connections
Check all connections in the ignition system.
Repair.
GOOD
CONNECTIONS
Replace the CDI unit.
-9-
ELEC
TROUBLESHOOTING
STARTER MOTOR DOES NOT WORK
NOTE:
2) Footrest board
3) Front panel
4) Handlebar cover
Pocket tester:
90890-03112
1.Fuse
NO CONTINUITY
Remove the fuse.

Defect Replace fuse.
CONTINUITY
2.Battery
CHAPTER 3.
DOES NOT MEET

SPECIFICATION


MEETS
SPECIFICATION
3.Starter motor
Use a jumper lead E * to connect the (+) Q
terminal of the battery to the starter motor
terminal W.
CAUTION:
If the gauge of the jumper lead is smaller
than that of the battery leads, the jumper
lead might melt or burn.
This test could cause sparks. Never

perform it near a gas source or near
flammable products.
DOES NOT WORK
372006
Starter defect Repair or replace.

WORKS
-10-
ELEC
4. Starter relay
Disconnect the Blue/White lead from the
wire harness.
Connect the (-) Q terminal of the battery to
the Blue/White lead.
DOES NOT WORK
L/W
Starter relay defect Replace.
372007
WORKS
5. Main switch
harness.
Check for continuity between Red Q and
Brown W.
BW B
Br Gy
DOES NOT MEET

SPECIFICATION
LOCK
OFF
CHECK
ON
R
R
B/W
Br Gy B
372008
MEETS
SPECIFICATION
6.Starter switch
Check for continuity between Blue / White
Q and Black W.
-11-
ELEC
LW B
OFF
DOES NOT MEET

SPECIFICATION
ON
372009A
B YB L
LW YR LR
Starter switch defect Replace right handlebar switch.
372009B
MEETS
SPECIFICATION
POOR CONNECTIONS
7.Connections
Check all connections in the starter system.
Repair.
-12-
ELEC
CHARGING SYSTEM
CHARGING SYSTEM
CIRCUIT DIAGRAM
A
(BLACK)
Br Gy B
R
B
R
B
Br Gy B
Gy Br R B BW
LOCK
OFF
R
CHECK
ON
B Or
W YR
R
W YR R W B YR
R
LW
GY
BR
BR
WR
YR
WR
Or
YR
B Or
BW
Br
Gy
BW
BW
BW
RAR
R
R
GY
LW
Br
BAB
o
B
Gy
LW
YR
LW B
YR LR
OFF
YR
ON
ON
LW B
YR
B LW
LR
L LR
LR/L L
OFF
Br
Br
Br
12V10W
]
B
L Br
Dg G
}
C
Dg
OFF
HI
ON
LOW
BrW
G Ch P
LR Dg Y
BrW
P Ch G
GY
G B
12V
35W / 35W
Ch
Dg
Ch
Dg
G B
12V10W
p
B
Q
Y
U
I
C.D.I. magneto
Fuse
Battery
-13-
12V10W
12V10W
e
B
12V10W
GY
Ch
Y
L
(GREEN)
B
Y Dg LR
Ch
Ch BrW Dg
G LR Y
D
B P
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
Ch Gy
BrW
L Br
Br
(GREEN)
Dg G
BrW
Dg
Ch Gy
Br
Gy
(BLACK)
H
12V
21W / 5W
Ch Dg
_ B
Dg Ch
B _
GY L
L GY
CHARGING SYSTEM
ELEC
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED
NOTE:
1) Side covers (left and right) and footrest board.
90890-03113
Pocket tester:
90890-03112
1.Fuse (Main)
Remove the fuse.
NO CONTINUITY
CONTINUITY
2.Battery

CHAPTER 3.
DOES NOT MEET
SPECIFICATION

12,8 V or more at 20C (68F)

3.Charging voltage
Connect the engine tachometer to the spark
plug lead.
battery terminals.
Pocket tester (+) lead Battery (+) terminal
Pocket tester (-) lead Battery (-) terminal
Start the engine and accelerate to about
5000 rpm.
Check the charging voltage.
Charging voltage :
14 ~ 15 V at 5.000 tr/mn
367001
MEETS SPECIFICATION
NOTE:
Use a fully charged battery.
OUT OF
SPECIFICATION
Charging circuit is OK.
-14-
372010
CHARGING SYSTEM
ELEC
4.Charging coil resistance

CDI
MAGNETO
Disconnect the CDI magneto coupler from

the wire harness.
charging coil.
Check the charging coil resistance
Tester (+) lead White Q

Tester () lead Ground W
Y/R
Charging coil resistance:

0.48 ~ 0.72 at 20C (68F)
MEETS
SPECIFICATION
Charging coil defect Replace.

POOR CONNECTIONS
5.Connections
Check all connections in the charging system.
Repair.
MEETS
SPECIFICATION
Replace the rectifier/regulator.
-15-
W/R B/R
372015
ELEC
LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM
A
(BLACK)
Br Gy B
R
B
R
B
Br Gy B
Gy Br R B BW
LOCK
OFF
R
CHECK
ON
B Or
W YR
R
W YR R W B YR
R
LW
GY
BR
BR
WR
YR
WR
Or
YR
B Or
BW
Br
Gy
BW
BW
BW
RAR
R
R
GY
LW
Br
BAB
U
B
Gy
LW
YR
LW B
YR LR
OFF
OFF
YR
ON
ON
LW B
YR
B LW
LR
L LR
LR/L L
Br
Br
Br
12V10W
L Br
L Br
Dg G
}
C
Dg
HI
ON
LOW
BrW
G Ch P
LR Dg Y
BrW
P Ch G
GY
Ch
Y
G B
12V
35W / 35W
Ch
Dg
Ch
Dg
(GREEN)
B
Y Dg LR
Ch
Ch BrW Dg
G LR Y
OFF
D
B P
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
Ch Gy
12V10W
12V10W
G B
p
B
Q C.D.I. magneto
{ Right handle switch
B Lighting switch
} Left handle switch
D "Hi / Lo" switch
q Head light
12V10W
12V10W
e
B
H Tail / Stop light
[ Meter assembly
J Meter light
] Position light
-16-
GY
Br
BrW
(GREEN)
Dg G
BrW
Dg
Ch Gy
Br
Gy
(BLACK)
H
12V
21W / 5W
Ch Dg
_ B
Dg Ch
B _
GY L
L GY
LIGHTING SYSTEM
ELEC
TROUBLESHOOTING
THE AUXILIARY LIGHT, HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT,
TAILLIGHT OR METER LIGHT DO NOT WORK
NOTE:
Handlebar covers
Pocket tester:
90890-03112
YR LR
OFF
ON
1. LIGHTS switch
Set the switch to
.
L LR
_ YR
B LW
372009A
NO CONTINUITY
Yellow / Red Q and Blue / Red W
"Light" switch defect Replace.

CONTINUITY
G LR Y
2. HI / LO switch
Disconnect the HI / LO switch coupler (left)
from the wire harness.
Set the switch to " ".
HI
LOW
LR Dg Y
BrW
P Ch G
Blue / Red Q and Green W

372009A
Then set the switch to .

NO CONTINUITY
Blue / Red Q and Yellow E

"HI / LO" switch defect Replace.
CONTINUITY
-17-
LIGHTING SYSTEM
ELEC
2. Lighting coil resistance

CDI
MAGNETO
Disconnect the lighting coil coupler from the

wire harness.
lighting coil.
Check the lighting coil resistance
Tester (+) lead Yellow / Red Q

Tester (-) lead Ground W
Y/R
Lighting coil resistance:

0.32 ~ 0.48 at 20C (68F)
MEETS
SPECIFICATION
Lighting coil defect Replace.
3. Connections
POOR CONNECTIONS
Check all connections in the lighting system.

MEETS
SPECIFICATION
Repair.
-18-
W/R B/R
372036
LIGHTING SYSTEM
ELEC
LIGHTING SYSTEM INSPECTION

1. Headlight and headlight indicator do not work.
1. Bulb and socket
NO CONTINUITY

CONTINUITY
2. Voltage
headlight coupler.
Headlight:
LO:
Pocket tester (+) lead Green Q
HI:
Pocket tester (+) lead Yellow W
Headlight indicator:
Pocket tester (+) lead Yellow R
Pocket tester (-) lead Black T
B
Y
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 headlight coupler leads.
B
Y
372017(a)
MEETS
SPECIFICATION

the main switch and the headlight coupler
and/or between the main switch and the
headlight indicator coupler
Repair.
2. The meter light does not work.

NO CONTINUITY
1. Bulb and socket

CONTINUITY
-19-
ELEC
LIGHTING SYSTEM
2. Voltage
L Br
Dg G
Ch Gy

meter light coupler.
Br L
G Dg
Gy Ch
B
Y
Set the main switch to "ON".

Start the engine.
B
Y
372037(a)
MEETS
SPECIFICATION

the main switch and the meter light coupler
Repair.
3. The taillight does not work.

NO CONTINUITY
1. Bulb and socket

CONTINUITY

taillight coupler.
12V10W

Start the engine.
12V10W
GY
2. Voltage
Ch Dg
_ B
Dg Ch
B _
GY L
L GY
12V
21W / 5W
MEETS
SPECIFICATION

the main switch and the taillight coupler
Repair.
-20-
ELEC
SIGNAL SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM
A
(BLACK)
Br Gy B
R
B
R
B
Br Gy B
Gy Br R B BW
LOCK
OFF
R
CHECK
ON
BW
BW
B Or
W YR
R
W YR R W B YR
R
LW
GY
BR
BR
WR
YR
WR
Or
YR
B Or
BW
Br
Gy
BW
RAR
R
R
GY
LW
Br
BAB
U
B
Gy
LW
YR
LW B
YR LR
OFF
YR
ON
ON
LW B
YR
B LW
LR
L LR
LR/L L
OFF
Br
Br
Br
12V10W
]
B
L Br
Dg G
}
C
Dg
HI
ON
LOW
BrW
G Ch P
LR Dg Y
BrW
P Ch G
GY
Ch
Dg
G B
12V
35W / 35W
Ch
Dg
G B
12V10W
p
B
T
Y
U
}
Main switch
Fuse
Battery
Left handle switch
C "HORN" switch
E Flasher switch
w Left front flasher
e Right front flasher
12V10W
12V10W
F Left rear flasher
H Tail / Stop light
t Horn
y Flasher relay
u Front stop switch
i Rear stop switch
-21-
12V10W
GY
Ch
Y
L
(GREEN)
B
Y Dg LR
Ch
Ch BrW Dg
G LR Y
OFF
D
B P
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
Ch Gy
BrW
L Br
Br
(GREEN)
Dg G
BrW
Dg
Ch Gy
Br
Gy
(BLACK)
Ch Dg
_ B
Dg Ch
B _
GY L
L GY
H
12V
21W / 5W
o Oil level gauge

p Fuel sender
[ Meter assembly
K Oil warning light
N Fuel meter
ELEC
SIGNAL SYSTEM
TROUBLESHOOTING
FLASHER LIGHTS, BRAKE LIGHT, OIL WARNING LIGHT DO NOT WORK

HORN DOES NOT SOUND
NOTE:
Handlebar cover
Pocket tester:
90890-03112
1. Fuse
NO CONTINUITY
Remove the fuse.

Refer to FUSE INSPECTION in Chapter 3.
CONTINUITY
2. Battery

CHAPTER 3.
Battery voltage:
MEETS
SPECIFICATION
3. Main switch
BW B
Br Gy
LOCK

harness.
Turn the main switch to .
OFF
CHECK
ON
Red Q and Grey E

B/W
Br Gy B
Red Q and Brown W

MEETS
SPECIFICATION
-22-
372040
SIGNAL SYSTEM
4. Connections
ELEC
POOR CONNECTIONS

GOOD
CONNECTIONS
Repair.
Check the condition of each circuit of the

signal system.
Refer to the section SIGNAL SYSTEM
CHECK.
SIGNAL SYSTEM CHECK

1. Horn does not sound
1. HORN switch
the wire harness.
Black Q and Pink W.
B P
OFF
ON
NO CONTINUITY
LR Dg Y
BrW
Horn switch is defect Replace.
P Ch G
CONTINUITY
2. Voltage
horn lead.
Check for voltage (12V) between Brown
and the ground.
-23-
SIGNAL SYSTEM
Br
ELEC

switch and the horn Repair.
372025
MEETS
SPECIFICATION
3. Horn
Disconnect the Pink lead at the horn terminal.
Ground the horn terminal Q with a jumper
lead.
Br
HORN SOUNDS
Horn is in good condition.
372026
HORN DOES
NOT SOUND
4. Voltage
Br

Pink lead.
Pocket tester (+) lead Pink Q

Press the HORN switch.
Check the voltage (12V) between Pink and
ground.
372027
MEETS
SPECIFICATION
Horn is defect Replace.
Adjust the horn.
-24-
SIGNAL SYSTEM
ELEC
2. The brake light does not work.

1. Bulb and socket
NO CONTINUITY

CONTINUITY

2. Brake switch
Disconnect the brake switch leads from the
wire harness.
Brown Q and Green / Yellow W
Br G/Y
ON (Pull in)
OFF (Free)
NO CONTINUITY
Br G/Y
Brake switch is defect Replace.

372030
CONTINUITY
3. Voltage
socket.
Pocket tester (+) lead Green / Yellow Q
Pull the brake lever.
Check the voltage (12V) between Green /
Yellow Q and Black W.
L
12V10W
12V10W
GY
Ch Dg
_ B
Dg Ch
B _
GY L
L GY
12V
21W / 5W

the main switch and the brake light socket
Repair.
MEETS
SPECIFICATION
-25-
SIGNAL SYSTEM
ELEC
3. Flasher does not work

NO CONTINUITY
1. Bulb and socket

CONTINUITY
2. TURN switch
the wire harness.
Check for continuity between :
Left side : Brown / White Q and Chocolate W
Right side : Brown / White Q and Dark green E
Ch BrW Dg
L
NO CONTINUITY
N
R
LR Dg Y
BrW
Left handlebar switch is defect Replace.
P Ch G
CONTINUITY
3. Voltage
flasher relay.
Check the voltage (12V) between the Brown
lead and the ground.
Br/W
Br

switch and the flasher relay Repair.
372033
MEETS
SPECIFICATION
-26-
SIGNAL SYSTEM
ELEC
4. Voltage
flasher relay.
Pocket tester (+) lead Brown / White Q
Check the voltage (12V) between Brown /
White and the ground.

-
Br/W
Br
Flasher relay defect Replace.

372034
MEETS
SPECIFICATION
5. Voltage
flasher connector.
Left flasher bulb:
Pocket tester (+) lead Chocolate Q
Right flasher bulb:
Pocket tester (+) lead Dark green E
Pocket 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 "Chocolate" and "Black", then "Dark green" and
"Black".
Dg
Ch
GY
REAR:
12V10W
12V10W
Ch Dg
_ B
Dg Ch
B _
GY L
L GY
12V
21W / 5W
MEETS
SPECIFICATION -27-
FRONT:
Ch
Ch
Dg
Dg
Ch
12V10W
Dg
12V10W
REAR: Defect in the wire harness between

the main switch and the flasher bulb socket
Repair.
FRONT: Defect in the wire harness between the main switch and the flasher bulb
coupler Repair.
SIGNAL SYSTEM
ELEC

4. The OIL indicator light does not work.
1. Bulb and socket
NO CONTINUITY

CONTINUITY
2. Oil level switch

Disconnect the oil level switch from the oil
tank.
Connect the pocket tester ( x 1) to the oil
level switch.
Pocket tester (+) lead Terminal W
Pocket tester (-) lead Terminal Q
Check the switch for continuity.
Float
position
Good
condition
Bad
condition
HIGH
LOW
O : Continuity X : No continuity
Replace oil level switch is defect.
B
372035
MEETS
SPECIFICATION
-28-
SIGNAL SYSTEM
ELEC
3. Voltage
bulb socket connector.
Pocket tester (+) lead Grey Q
Turn the main switch to "ON".
Check the voltage (12V) between "Grey"
and "Black".
L Br
Br
L Br
Dg G
Ch Gy
(GREEN)
Dg
4. Connections
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
Gy
12V 1.2W
Ch Gy
Dg G
(BLACK)
Ch
Y

MEET
SPECIFICATION
-29-
CW50RS WIRING DIAGRAM
Q
W
E
R
T
Y
U
I
O
P
{
A
(BLACK)
Br Gy B
R
B
R
B
Br Gy B
Gy Br R B BW
LOCK
OFF
R
CHECK
ON
B Or
W YR R
W YR R W B YR
R
LW
GY
YR
BR
BR
WR
WR
RAR
R
R
GY
LW
Br
Gy
LW
LW B
OFF
OFF
ON
ON
LW B
L LR
_ YR
B LW
LR
Br
Br
Br
12V10W
]
B
L Br
Dg G
}
C
Dg
OFF
HI
ON
LOW
BrW
G Ch P
LR Dg Y
BrW
P Ch G
GY
G B
12V
35W / 35W
Ch
Dg
Ch
Dg
12V10W
12V10W
G B
p
B
12V10W
12V10W
e
B
GY
Ch
Y
L
(GREEN)
B
Y Dg LR
Ch
Ch BrW Dg
G LR Y
D
B P
12V 1.2W
12V 1.2W
12V 1.2W
12V 1.2W
Ch Gy
u
BrW
L Br
Br
(GREEN)
Dg G
BrW
Dg
Ch Gy
Br
Gy
(BLACK)
12V 1.2W
Black
Brown
Chocolate
Dark green
Green
Grey
Blue
Orange
Pink
Red
White
Yellow
Black/Red
Black/White
Brown/White
Green/Yellow
Blue/Red
Blue/White
White/Red
Yellow/Red
YR LR
LR/L L
YR _
COLOR CODE
t
y
u
i
o
p
[
YR
B
Br
Ch
Dg
G
Gy
L
Or
P
R
W
Y
B/R
B/W
Br/W
G/Y
L/R
L/W
W/R
Y/R
BAB
q
w
e
r
Or
YR
B Or
BW
Br
Gy
BW
BW
BW
H
12V
21W / 5W
Ch Dg
_ B
Dg Ch
B _
GY L
L GY
C.D.I. magneto
C.D.I. unit
Ignition coil
Spark plug
Main switch
Fuse
Battery
Starter relay
Starter motor
Right handle switch
A Starter switch
B "Light" switch
Left handle switch
C "HORN" switch
D "Hi / Lo" switch
E Flasher switch
Head light
Left front flasher
Right front flasher
Taillight assembly
F Left rear flasher
H Tail / Stop light
Horn
Flasher relay
Front stop switch
Rear stop switch
Oil level gauge
Fuel sender
Meter assembly
J Meter light
K Oil warning light
N Fuel meter
Position light

BWS NG 1998

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CW50RS

PARTICULARY IMPORTANT INFORMATION

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

Failure to follow WARNING instructions could result in severe injury or

A CAUTION indicates special precautions that must be taken to avoid

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

HOW TO USE THIS MANUAL

(REFER TO THE ILLUSTRATION)

Illustrated symbols Q to W are designed as

Illustrated symbols O to e are used to identify

Illustrated symbols r to [ in the exploded

r Apply engine oil

ENGINE SERIAL NUMBER

GASKETS, OIL SEALS, AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

Do not use compressed air to spin the

IMPORTANT INFORMATION/SPECIAL TOOLS

Flywheel magneto puller

FOR ENGINE SERVICE

Crankcase separating tool

Flywheel holding tool

Crankshaft installing tool set

Clutch serving nut wrench

Clutch spring holder

Steering Head wrench

FOR CHASSIS SERVICE

Damper rod holder

Oil seal guide

Oil seal guide adapter

1.746 mm (0.07 in)

Minimum turning radius :

1.800 mm (0.07 in)

Air-cooled 2-stroke, gasoline torque induction.

Separate lubrication (Yamaha Autolube )

Oil type or grade:

SEMI-SYNTHETIC, in accordance with

0.11 L (0.10 Imp qt, 0.12 US qt)

Wet type element

Regular unleaded gasoline with a reserch octane

Dry, centrifugal automatic

Steel tube underbone

Tire pressure (cold tire):

150 kPa (1.50 kg/cm2, 21.3 psi)

Coil spring/Oil damper

Bulb wattage / quantity:

39.993 ~ 40.012 mm (1.576 ~ 1.575 in)

39.952 ~ 39.972 mm (1.576 ~ 1.574 in)

0.034 ~ 0.047 mm (0.001 ~ 0.002 in)

1.2 1.8 mm (0.05 ~ 0.07 in)

37.90 ~ 37.95 mm (1.492 ~ 1.494 in)

Automatic centrifugal clutch:

2.0 mm (0.08 in)

16.5 mm (0.64 in)

0.08 mm (0.003 in)

4.0 ~ 4.4 mm (0.15 ~ 0.17 in)

Main air jet

Pilot air screw

1+3/8 1/8 out

1+1/2 1/4 out

Valve seat size

2000 200 rpm

2000 200 rpm