CS50/Z 2002 5RW1-AE1 SERVICE MANUAL
EAS00001 CS50/Z SERVICE MANUAL © 2002 by Yamaha Motor España, S.A. 1st Edition, September 2002 Any reprinting or use of this material without the prior authorisation of Yamaha Motor España, S.A. is expressly prohibited. Printed in Spain.
EAS00002 NOTICE This manual was produced by the Yamaha Motor España, S.A., primarily for use by Yamaha/MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha/MBK vehicles should have a basic understanding of the mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL FORMAT OF THIS MANUAL This manual consists of chapters for the main subject categories (See “Illustrated Symbols”). First heading : This is a chapter with a symbol at the top right-hand side of each page. Second heading : This title appears at the top of each page to the left of the chapter symbol. (For the “Inspection and periodic adjustments”, chapter the third heading appears.) Third heading : This is a final heading.
EAS00008 GEN INFO ILLUSTRATED SYMBOLS (See illustration) The symbols from to are designed as thumb indices, to indicate the chapter number and index. SPEC CHK ADJ ENG COOL CARB CHAS ELEC 10 The illustrated symbols from 10 to 16 are used to identify the specifications that appear in the text.
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM CARBURETOR CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 CHK ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9
GEN INFO 1
GEN INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION……………………………………………………1-1 FRAME SERIAL NUMBER ……………………………………………………1-1 ENGINE SERIAL NUMBER……………………………………………………1-1 IMPORTANT INFORMATION …………………………………………………1-2 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 …………………………………………………………………1-4
IDENTIFICATION OF SCOOTER GEN INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION FRAME SERIAL NUMBER The frame serial number is stamped on the chassis. ENGINE SERIAL NUMBER The serial number of the engine is stamped on the raised portion of the rear left section of the transmission box. NOTE: The first three digits of these numbers are for identifying the model; the remaining digits constitute the production number of the unit.
IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION EAS00021 REPLACEMENT PARTS 1. Use only genuine Yamaha/MBK parts for all replacements. Use the oil and/or grease recommended by Yamaha/MBK for assembly and adjustment. EAS00022 GASKETS, OIL SEALS AND O-RINGS 1. Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
IMPORTANT INFORMATION GEN INFO EAS00025 CIRCLIPS 1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip , make sure that the sharp-edged corner is positioned opposite the thrust it receives. See sectional view. Shaft.
SPECIAL TOOLS GEN INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. Tool name / Usage Illustration 90890-01235 Rotor holding tool 90890-01337 This tool is used to remove the flywheel magneto.
SPECIAL TOOLS Tool No. Tool name / Usage Illustration 90890-03112 Pocket tester 90890-03113 This instrument is very important for checking the electrical system. Engine tachometer 90890-01409 This tool is necessary for detecting the engine rpm. Oil seals guide 90890-01410 This tool is used to install the left oil guide of the crankcase. Oil seals installer 90890-06754 This tool is used to install the left oil seal of the crankcase.
SPEC 2
SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS …………………………………………………2-1 MAINTENANCE SPECIFICATIONS ……………………………………………2-3 ENGINE …………………………………………………………………………2-3 CHASSIS ………………………………………………………………………2-5 ELECTRICAL SYSTEM ………………………………………………………2-6 CONVERSION TABLE……………………………………………………………2-7 GENERAL TIGHTENING TORQUE SPECIFICATIONS ……………………2-7 TIGHTENING TORQUES ………………………………………………………2-8 ENGINE TIGHTENING TORQUES …………………………………………2-8 CHASSIS TIGHTENING TORQUES …………………………………………2-9 COOLING SYSTEM (CS50Z only) …
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model Dimensions: Overall lenght Overall widht Overall height Seat height Wheelbase Minimum ground clearance Basic weight (With oil and full fuel tank): Engine: Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system: Oil type or grade: Engine oil Transmission oil Oil capacity: Oil tank (motor oil) Transmission fluid Periodic fluid change Total amount Cooling system capacity: (Total
GENERAL SPECIFICATIONS Model Chassis: Frame type Front axle incline angle Steering angle base Tire: Size/Type (Front) Size/Type (Rear) Tire pressure (cold tire): Front Rear Maximum Load: Front Rear Brake: Type of front brake Activation Type of rear brake Activation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type or model Battery capacity Type of h
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Model Cylinder head: Warp limit Cylinder: Bore size Taper limit Out of round limit Piston: Piston size Measuring point Piston clearance On measurement 1st Piston rings: Cut-away section (BXT)/TYPE Top ring 2nd ring End gap (installed) Top ring 2nd ring Sice clearance Top ring 2nd ring Crankshaft: Crank width “A” Runout limit “C” Large end of rod side clearance “D” Small end of rod clerance “F” CS50 CS50Z 0,02 mm * The
MAINTENANCE SPECIFICATIONS Model Automatic centrifugal clutch: Clutch shoe thickness Clutch shoe spring free length Clutch - in revolution Clutch - stall revolution 2,0 mm <1,0 mm> 29,9 mm 3.350 - 3.850 r/min. 5.200 - 6.000 r/min.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Model Steering system: Steering bearing type Upper Lower Ball bearing Ball bearing Front suspension: Front fork travel Fork spring free length 70 mm 224 mm Spring rate (K1) (K2) Oil capacity Oil grade Rear suspension: Shock absorber stroke Spring free length Spring rate (K1) (K2) Wheels: Type of front wheel Type of rear wheel Size/material of front tyre Size/material of rear tyre Rim runout limit Radial Lateral CS50 1,33 Kgf/mm 2,0 Kgf/mm 45 cc ± 1 Fork oil
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL SYSTEM Model Ignition system: Type Ignition timing (B.T.D.C.) Pickup coil resistance (colour) Igntion coil: Minimum spark gap Primary winding resistance Secondary winding resistance Charging system: Normal output Source coil resistance (colour) Lighting system: Lighting output Lighting coil resistance (colour) CS50 CS50Z DC-CDI 14°/5.000 r/min 400 ~ 600 Ω at 20 °C (68 °F) (Black-White/Blue) 6.0 mm 0.56 ~ 0.84 Ω at 20 °C 5.68 ~ 8.52 KΩ at 20 °C 0.
CONVERSION TABLE / GENERAL TIGHTENING TORQUES SPECIFICATIONS SPEC EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.
TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Part to be tightened Spark plug Cylinder head and cylinder Cylinder Air protector 2 (A/C) Air protector 3 (A/C) Fan (A/C) Automatic lubrication pump Reed valve Air filter Carburettor cover Exhaust pipe Muffler Exhaust pipe protector Exhaust pipe cover Crankcase Cover of crankcase 2 Cover of crankcase 1 Air conduct (A/C) Crankcase bracket Drain bolt Oil plug Intermediate gear plate Kickstarter Starter motor Clutch housing Primary pulley
TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Part to be tightened Frame, Engine and Parts Frame with bracket 3 Engine bracket 3 with the engine Cushion and related parts Rear shock absorber (bracket side) Rear shock absorber (engine side) Forks, handlebar and parts Handlebar or grip with axle guide Axle guide Brake tube joint screw Seats and related parts Seat lock unit Hook bracket Case Covers and related parts Plastic parts, plastic covers Frame footrest plate Leg protector 2/frame Front and re
COOLING SYSTEM COOLING SYSTEM (L/C VERSION ONLY) Radiator Water pump Cylinder Reservoir tank 2-10 SPEC
CABLE ROUTING SPEC CABLE ROUTING A Insert the three tubes through the clamp B Connect the oil hose to the carburettor C Set the intake hose under the reinforcement Front brake hose Rear brake cable Front brake calliper Front mudguard Taillight Vacuum pipe Fuel pipe Intake hose (L/C) Wire harness 10 Engine breather 11 Throttle cable 12 Seat lock cable 13 Coolant hose (L/C) 14 DC-CDI 15 Coolant hoses - Carburetor (L/C) (L/C) D Clamp the fuel pipe to the carburettor E T
CABLE ROUTING SPEC CABLE ROUTING A Clamp the wire harness, brake cable and Rectifier / Regulator Main switch Fuel level gauge Horn Ignition coil Spark plug wire Oil level gauge Oil tank Speedometer cable throttle to the frame B Clamp the oil hose to the tank C Connect the oil hose to the pump D Tie both ends E Tighten together the ground cable and the ignition coil F Pass the speedometer cable through the guide G Insert the seat lock cable throught the orifice of the fram
CABLE ROUTING SPEC CABLE ROUTING A Throttle tension cable.
CHK ADJ 3
CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS……3-1 REAR BODYWORK AND MUDGUARD ………………………………………3-2 REMOVAL ………………………………………………………………………3-2 INSTALLATION …………………………………………………………………3-3 FRONT COWLING AND FOOTREST …………………………………………3-4 REMOVAL ………………………………………………………………………3-4 INSTALLATION …………………………………………………………………3-5 HANDLEBAR COVERS …………………………………………………………3-6 REMOVAL ………………………………………………………………………3-6 INSTALLATION …………………………………………………………………3-7 ENGINE ……………………………
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all the information necessary to perform the recommended inspections and adjustments. These preventive maintenance procedures, if followed correctly, will ensure more reliable operation of the vehicle and a longer life of service. The need for costly revision and repair work will be greatly reduced.
REAR BODYWORK, MUDGUARD CHK ADJ REAR BODYWORK, MUDGUARD REMOVAL 1. Remove: • seat 2. Remove: • central panel NOTE: Slide the panel to the front. 3. Remove: • rear fender 4.
REAR BODYWORK, MUDGUARD CHK ADJ 5. Remove: • side covers (4 bolts) NOTE: Remove carefully the hook between side cover and tail light. 6. Remove: • battery cover , leads and battery • oil tank fixing bolt NOTE: Fix the oil tank to the frame with a band. • helmet box 7. Remove: • rear mudguard (4 bolts) INSTALLATION Reverse the removal process. NOTE: After installing all plastic parts, check that all hooks are properly attached.
FRONT COWLING AND FOOTREST CHK ADJ FRONT COWLING AND FOOTREST REMOVAL 1. Remove: • front upper cowling NOTE: Disconect front light and indicator light couplers. 2. Remove: • front middle cowling 3. Remove: • lower cowling 4.
FRONT COWLING AND FOOTREST CHK ADJ 5. Remove: • legshield NOTE: Remove first the main switch cover 6. Remove: • hook bracket 7. Remove: • footrest INSTALLATION Reverse the removal process NOTE: After installing all plastic parts, check that all hooks are properly attached.
HANDLEBAR COVERS CHK ADJ HANDLEBAR COVERS REMOVAL 1. Remove: • upper handlebar cover NOTE: Disconect panel meter couplers 2. Remove: • front master cylinder (2 bolts) • handlebar switch couplers • stop switch couplers • rear brake wire from lever side • throttle wire from throttle grip 3. Remove: • handlebar fixing bolt 4.
HANDLEBAR COVERS CHK ADJ 5. Slide dow the lower handlebar cover 6. Remove the wiring harness rubber band from the handlebar 7. Remove: • handlebar • lower handlebar cover INSTALLATION Reverse the removal process. NOTE: • For handlebar installation refer to chapter 7. • After installing all plastic parts, check that all hooks are properly attached.
CHK ADJ ADJUSTING THE ENGINE IDLING SPEED ENGINE EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine shoud have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Connect: • engine tachometer (onto the spark plug lead) Engine tachometer 90890-03113 3. Check: • engine idling speed Out of specification Adjust. Engine idling speed 1.650 ~ 1.950 r/min 4.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: • throttle cable free play a Out of specification Adjust. Throttle cable free play (at the flange of the throttle grip) 2 ~ 5 mm 2. Remove: • center panel • grip bar • battery • right side cover • helmet box Refer to BODYWORK 3.
CHK ADJ CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1. Disconnect: • spark plug cap 2. Remove: • spark plug CAUTION: Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 3. Check: • spark plug type Incorrect Change. Spark plug type (manufacturer) BR8HS (NGK) 4. Check: • electrode Damage/wear Replace the spark plug. • insulator Abnormal color Replace the spark plug.
CHECKING THE ENGINE OIL LEVEL CHK ADJ CHECKING THE ENGINE OIL LEVEL 1. Inspect: • engine oil level Low oil level Add sufficient oil. Oil indicator light “OIL CAUTION” Visual inspection steps for engine oil level Place main switch in position (h) The “OIL CAUTION” indicator light is not lit. The “OIL CAUTION” indicator light is lit. Place the main switch in position “f” Inspect for defective electric circuit, bulbs, etc. The “OIL CAUTION” indicator light is not lit.
CHANGING THE TRANSMISSION OIL/ AUTOLUBE PUMP AIR BLEEDING CHANGING THE TRANSMISSION OIL 1. Remove: • drain bolt Drain the transmission oil. • oil filler cap 2. Inspect: • gasket (drain bolt) • o-ring (filler cap) Damaged Replace 3. Install: • gasket • drain bolt 2 4 CHK ADJ Drain bolt 18 Nm (1.8 m • kg) 4.
CHK ADJ CLEANING THE AIR FILTER ELEMENT EAS00089 CLEANING THE AIR FILTER ELEMENT Carburetor side 1. Remove: • center cover • grip bar • battery • right side cover • helmet box • air filter box assembly 2. Remove: • air filter box cover • air filter CAUTION: Never start up the engine with the air filter removed. This will allow the entry of unfiltered air, causing rapid wear and possible damage to the engine.
CHECKING THE COOLANT LEVEL CHK ADJ EAS00103 CHECKING THE COOLANT LEVEL (CS50Z only) 1. Stand the scooter on a level surface. NOTE: • Place the scooter on a suitable stand. • Make sure the scooter is upright. 40 c 30 20 10 0 2. Check: • coolant level The coolant level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Remove the front upper cowling and add the recommended coolant to the proper level.
CHANGING THE COOLANT CHK ADJ EAS00105 CHANGING THE COOLANT (CS50Z only) 1. Remove: • water pump cover • coolant filler cap s WARNING Do not remove the water pump cover when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, remove the water pump cover. 2. Drain: • coolant (from the engine and radiator) 3. Check: • o-ring (water pump cover) Damage Replace 4. Install: • water pump cover 7 Nm (0.7 m • kg) 5.
CHANGING THE COOLANT CHK ADJ Handling notes for coolant Coolant is potentially harmful and should be handled with special care. s WARNING • If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. • If coolant is swallowed, induce vomiting and get immediate medical attention. CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant.
CHANGING THE COOLANT CHK ADJ 6. Install: • coolant filler cap 7. Warm it up for several minutes, and then stop it. 8. Check: • coolant level Refer to “CHECKING THE COOLANT LEVEL”. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. NOTE: For a quick air bleeding, lift up the front wheel 1metre with the engine at idle speed. This will provide a effective and air quick bleeding from the head cylinder to the radiator. 9.
ADJUSTMENT THE FRONT BRAKE LEVER/ ADJUSTMEN THE REAR BRAKE LEVER/ CHECKING THE FRONT BRAKE PADS CHK ADJ EAS00109 CHASSIS a ADJUSTMENT THE FRONT BRAKE LEVER 1. Check: • free play of the front brake lever a. Brake lever free play (at the end of the brake lever) 2 ~ 5 mm s WARNING The soft or spongy feeling of the brake lever may indicate the presence of air in the brake system. This air should be extracted by bleeding the brake system before using the vehicle.
CHECKING THE REAR BRAKE SHOES/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ EAS00126 CHECKING THE REAR BRAKE SHOES 1. Activate the brake lever 2. Check: • wear indicator Indicator on wear limit line Replace the brake shoes. EAS00116 CHECKING THE BRAKE FLUID LEVEL NOTE: Place the scooter upright when inspecting the fluid level. 1. Check: • brake fluid level. The brake fluid level is below the minimum level line Refill up to correct level.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00133 BLEEDING THE HYDRAULIC BRAKE SYSTEM s WARNING Bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replace. • the brake fluid level is very low. • brake operation is faulty. NOTE: • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ EAS00148 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the scooter on a level surface. s WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Check: • steering head Grasp the bottom of the front fork legs and gently rock the front fork. Blinding/looseness Adjust the steering head. 3.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ Lower ring nut (final tightening torque) 6.5 Nm (0.65 m • kg) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to “STEERING HEAD” in chapter 7. e. Install the rubber washer. f. Install the center ring nut. g. Finger tighten the center ring nut , then align the slots of both ring nuts.
CHECKING THE TIRES / CHECKING THE WHEELS/ CHECKING THE FRONT FORK CHK ADJ EAS00163 CHECKING THE TIRES 1. Measure: • air pressure Outside specified value Maximum load*: Pressure cold Up to 90 kg 90 kg to maximum load Adjust 158.3 kg (CS50Z) 161.5 kg (CS50) Front Rear 175kpa. 200kpa. (1.75kg/cm2) (2.0kg/cm2) 175kpa. 225kpa. (1.75kg/cm2) (2.25kg/cm2) * Total weight of rider, passenger, cargo and accessories 2. Inspect: • tyre surface Worn/Damaged Change Minimum depth of thread of tyres 0.
REAR SHOCK ABSORBER INSPECTION CHK ADJ REAR SHOCK ABSORBER INSPECTION 1. Inspect: • rear shock absorber Oil leaks/Damage Replace 2. Check • tightening torque 3-24 Upper (nut) 31.5 Nm (3.15 m • kg) Lower (bolt) 17.5 Nm (1.
CHECKING AND CHARGING THE BATTERY CHK ADJ EAS00179 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY s WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHK ADJ CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: • battery cover 2. Disconnect: • battery leads (from the battery terminals) CAUTION: First, disconnect the negative battery lead , and then the positive battery lead . 3. Remove: • battery 4.
CHECKING AND CHARGING THE BATTERY CHK ADJ 5. Charge: • battery (refer to the appropriate charging method illustration) s WARNING Do not quick charge a battery. CAUTION: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. • If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery.
CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a variable-current (voltage) charger Measure the open-circuit voltage prior to charging. NOTE: Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and AMP meter to the battery and start charging. YES NOTE: Set the charging voltage at 16 ~ 17 V. (If the setting is lower, charging will be insufficient. If too high, the battery will be over-charged.
CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. NOTE: Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and AMP meter to the battery and start charging. YES Make sure that the current is higher than the standard charging current written on the battery. Charge the battery until the battery’s charging voltage is 15 V.
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSE CHK ADJ 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead , and then the negative battery lead . 8. Check: • battery terminals Dirt Clean with a wire brush. Loose connection Connect properly. 9. Lubricate: • battery terminals Recommended lubricant Dielectric grease 10. Install: • battery cover EAS00181 CHECKING THE FUSE 1.
REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM CHK ADJ EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: • front upper cowling 2. Remove: • headlight bulb holder 3. Remove: • headlight bulb B Y G s WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install: • headlight bulb NEW Secure the new headlight bulb with the headlight bulb holder.
ENG 4
ENG CHAPTER 4 ENGINE ENGINE REMOVAL ………………………………………………………………4-1 COVER REMOVAL ……………………………………………………………4-1 COOLING SYSTEM (CS50Z only)……………………………………………4-1 CABLES, LEADS AND HOSES ………………………………………………4-1 ENGINE REMOVAL ……………………………………………………………4-2 ENGINE DISASSEMBLY…………………………………………………………4-3 REMOVING THE REAR WHEEL ……………………………………………4-3 REMOVING THE CYLINDER HEAD AND CYLINDER ……………………4-3 REMOVING THE PISTON PIN AND PISTON ………………………………4-3 REMOVING THE KICKSTARTER SYSTEM …………………………………4-4 REMOVING THE PRIMARY SHEAVE ……
ENGINE REMOVAL ENG ENGINE ENGINE REMOVAL COVER REMOVAL 1. Remove: • center cover • helmet box Refer to “REAR BODYWORK, MUDGUARD” in chapter 3. COOLING SYSTEM (CS50Z only) 1. Disconnect: • coolant hose (on water pump cover) Drain the coolant • coolant hose (on cylinder head) CABLES, LEADS AND HOSES 1. Loosen: • rear axle nut 2. Disconnect: • rear brake cable 3. Disconnect: • starter motor leads (positive/negative leads) 4.
ENGINE REMOVAL ENG ENGINE REMOVAL 1. Place a suitable stand under the frame. 2. Remove: • rear shock absorber bolt (lower) • engine mounting bolt 3. Remove: • engine NOTE: Lift up the frame and remove the engine. 4. Place the frame on a suitable stand.
ENGINE DISASSEMBLY ENG ENGINE DISASSEMBLY REMOVING THE REAR WHEEL 1. Remove: • rear wheel Refer to “REMOVING THE REAR WHEEL” in chapter 7 • brake shoes • flat washer EAS00222 REMOVING THE CYLINDER HEAD AND CYLINDER 1. Remove: • cylinder covers (CS50 only) • carburator coolant hoses (CS50Z only) • cylinder head • cylinder head gasket NOTE: • Before loosening the cylinder head, loosen the spark plug .
ENGINE DISASSEMBLY ENG 2. Remove: • piston pin • piston • piston pin bearing CAUTION: Do not use a hammer to take out the piston pin. REMOVING THE KICKSTARTER SYSTEM 1. Remove: • clamp (air filter) • air filter 2. Remove: • oil hose delivery • carburator 3. Remove: • kick crank • crankcase cover (left) 4. Remove: • kick pinion gear NOTE: When the kick pinion gear removed, move the pedal axle. 5.
ENGINE DISASSEMBLY ENG 6. Remove: • circlip • flat washer • kick shaft EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: • fan (CS50 only) • right cranckcase cover (CS50Z only) 2. Remove: • nut (primary sheave) NOTE: To loos nut (primary sheave), support the magnetic flywheel using Fly wheel holder . Fly wheel holder 90890-01235 3. Remove: • conical spring washer • one-way clutch • special washer • fixed primary sheave • shim • v-belt 4.
ENGINE DISASSEMBLY ENG EAS00319 DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: • nut (secondary sheave) NOTE: Hold the secondary sheave with a sheave holder to loosen the nut. Sheave holder 90870-01701 2. Remove: • clutch drum • secondary sheave • crankcase cover gasket • dowel pins 3. Attach: • sheave holder • nut spanner (41 mm) Sheave holder 90870-01701 4. Loosen: • clutch securing nut CAUTION: Do not remove the clutch positioning nut yet. 5.
ENGINE DISASSEMBLY ENG REMOVING THE STARTER SYSTEM 1. Remove: • plate (intermediate gearing) • intermediate gearing • starter clutch assembly • starter wheel gear 2. Remove: • spacer • bearing • washer • starter motor TRANSMISSION 1. Remove: • transmission box cover • gasket • dowel pins NOTE: Before proceeding to disassemble the transmission cover, empty the oil. 2. Remove: • main shaft • drive shaft • flat washer • conical spring washer 3.
ENGINE DISASSEMBLY ENG DC-CDI MAGNETO 1. Remove: • bolts (CS50Z only) 2. Remove: • nut (rotor) • flat washer NOTE: Support the rotor to loosen the nut with the engine flywheel holder . Flywheel holder 90890-01235 3. Remove: • rotor • woodruff key Use the flywheel puller Flywheel puller 90890-01362 • stator assembly • gasket NOTE: Attach the flywheel puller using the flywheel thread holes.
ENGINE DISASSEMBLY ENG AUTOLUBE OIL PUMP 1. Remove: • autolube oil pump 2. Remove: • circlip • pump drive gear • pin • circlip 3. Remove: • carburetor joint • reed valve • reed valve gasket REMOVING THE CENTERSTAND 1. Remove: • clip • rubber washer • axle • spring • central stand DISASSEMBLING THE CRANKCASE AND CRANKSHAFT 1. Remove: • oil seal stopper • screws (crankcase) NOTE: Loosen each screw 1/4 of a turn and remove them after loosening them.
ENGINE DISASSEMBLY ENG 2. Attach: • crankcase puller Crankcase puller 90890-01135 NOTE: Fully tighten the positioning bolts of the tool, but ensure that the tool body is parallel with the box. If necessary, slightly loosen one of the bolts to level the body of the tool. 3. Remove: • crankcase (right) As pressure is applied, keep taping carefully on the engine mounting bosses. CAUTION: Tap on one side of the crankcase with a soft-face hammer.
INSPECTION AND REPAIR ENG INSPECTION AND REPAIR EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug bore threads 2. Check: • cylinder head Damage/scratches Replace. • cylinder head water jacket (CS50Z only) Mineral deposits/ruts Eliminate. 3. Measure: • cylinder head warpage Out of specification Resurface the cylinder head. Maximum cylinder head warpage 0.
INSPECTION AND REPAIR ENG EAS00258 CHECKING THE CYLINDER AND PISTON 1. Eliminate: • carbon deposits Use a rounde scraper 2. Inspect: • cylinder wall Wear/striping Rectify or change 3. Eliminate: • carbon deposits From the piston crown and ring groovers . 4. Remove: • cracking marks and carbon deposits on piston sides. 5. Inspect: • piston wall Wear/striping/damage Replace. 6.
ENG INSPECTION AND REPAIR a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder.Then, find the average of the measurements. Standard Wear limit Cylinder bore “C” 39.99 ~ 40.01 mm 40.1 mm Taper Limit “T” – 0.05 mm Out of round “R” – 0.
INSPECTION AND REPAIR ENG EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification Replace the piston and piston rings as a set. Use a Feeler Gauge NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.03 ~ 0.05 mm : 0.1 mm 2nd ring 0.03 ~ 0.05 mm : 0.1 mm 2.
INSPECTION AND REPAIR ENG EAS00265 CHECKING THE PISTON PIN AND PISTON PIN BEARING 1. Check: • piston pin Blue discoloration/grooves Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification Replace the piston pin. Piston pin outside diameter 9.996 ~ 10.000 mm 3. Calculate: • piston-pin-to-piston clearance Out of specification Replace the piston pin and piston as a set.
INSPECTION AND REPAIR ENG EAS00339 CHECKING THE KICKSTARTER 1. Check: • kick gear teeth • kick pinion gear teeth Damage/wear Replace. 2. Check: • mating dogs (kick pinion gear and one-way clutch) Rounded edges/Damage Replace. 3. Measure: • kickstarter pinion gear clip force (with the spring gauge) Out of specification Replace the kickstarter pinion gear clip. Kickstarter pinion gear clip force 150 ~ 250 gr (5.3 ~ 8.8 oz) TRANSMISSION 1.
INSPECTION AND REPAIR ENG AUTOLUBE OIL PUMP Internal wear or poor operation may cause the pump to deviate from its factory adjustment. However, this is very uncommon. If incorrect operation is suspected, inspect the following: 1. Inspect: • supply line Obstruction Apply air under pressure. Wear/Damage Replace. 2. Inspect: • drive gear teeth of the autolube oil pump • gear teeth driven by autolube oil pump Pitting/Wear/Damage Replace EAS00394 CHECKING THE CRANKSHAFT 1.
INSPECTION AND REPAIR ENG EAS00401 CHECKING THE BEARINGS 1. Check: • bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement Replace. EAS00321 CHECKING THE PRIMARY SHEAVE 1. Inspect: • primary sliding pulley wheel • primary fixed pulley wheel Wear/Crackjs/Striping/Damage Replace 2. Check: • free movement Insert the collar in the primary sliding sheave and check if there is free movement.
INSPECTION AND REPAIR ENG EAS00322 CHECKING THE SECONDARY SHEAVE 1. Inspect: • secondary fixed sheave • secondary sliding sheave Striping/Cracks/Damage Replace as a set. • oil seal Damage Replace. 2. Inspect: • torque cam groove • guide pin Wear/Damage Replace as a set • o-ring Damaged Replace 3. Measure: • clutch spring free length Outside specified value Replace Clutch spring free length 121.7 mm : 106.7 mm 4.
ENG INSPECTION AND REPAIR 6. Inspect: • clutch shoes Shiny parts Polish with sand paper. NOTE: After using sand paper, clean off the polished particles with a cloth. 7. Measure: • clutch shoe thickness a Outside specified value Replace Clutch shoe thickness 2.0 mm : 1.0 mm EAS00320 CHECKING THE V-BELT 1. Check: • v-belt Cracks/damage/wear Replace Grease/oil Clean the primary and secondary sheave. 2.
INSPECTION AND REPAIR ENG STARTER CLUTCH AND GEARS 1. Inspect: • starter clutch Press the conical pin in the direction of the arrow. Unsmooth operaton Replace starter clutch assembly 2.
ENG ENGINE ASSEMBLY AND ADJUSTMENT ENGINE ASSEMBLY AND ADJUSTMENT EAS00381 CRANKSHAFT AND CRANKCASE Oil seal Oil seal catch Crankcase (right) Dowel pin Bearing Crankshaft (right) Bearing Crankshaft pin Connecting rod Crankshaft (left) Bearing Engine mounting spacer Crankcase (left) Oil seal 9 Nm (0.9 m • kg) 13 Nm (1.3 m • kg) Crankshaft: A: 37.90 ~ 37.95 mm C: 0.03 mm D: 0.2 ~ 0.5 mm E: 0.004 ~ 0.017 mm F: 0.4 ~ 0.8 mm 17.5 Nm (1.
ENGINE ASSEMBLY AND ADJUSTMENT ENG EAS00407 INSTALLING THE CRANKSHAFT 1. Place: • crankshaft installation tool Crankshaft installation tool : 90890-01411 : 90890-01274 : 90890-01275 : 90890-01277 2. Install: • crankshaft: (in left crankcase) 3. Install: • dowell pins 4. Apply: • Yamaha Nº 1215 adhesive on the corresponding surfaces of both halves of the crankcase Yamaha Nº 1215 adhesive 90890-85505 5.
ENGINE ASSEMBLY AND ADJUSTMENT EAS00360 AUTOLUBE OIL PUMP AND DC-CDI MAGNETO Fan (CS50 only) Flat washer Rotor assembly Charge coil Lighting coil Pickup coil Stator plate Oil seal Gasket Oil hose Oil delivery hose Bushing Autolube pump O-ring Circlip Oil pump drive gear Pin 7 Nm (0.7 m • kg) 43 Nm (4.3 m • kg) 9 Nm (0.9 m • kg) 4 Nm (0.
ENGINE ASSEMBLY AND ADJUSTMENT ENG INSTALLING THE AUTOLUBE OIL PUMP 1. Install: • circlip • pin • pump drive gear • circlip 2. Apply: • grease with lithium soap base (on the o-ring ) 3. Install: • autolubrication pump Screw (autolubrication pump) 4 Nm (0.4 m • kg) 4. Apply: • grease with lithium soap base (on the autolubrication pump gear , ) Lithium soap base grease 15 cc (0.92 cu • in) INSTALLING THE DC-CDI MAGNETO 1. Install: • gasket 2.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 6. Tighten: • nut (magneto rotor) Use the flywheel holding tool . Flywheel holding tool 90890-01235 Nut (Flywheel magneto) 43 Nm (4.
ENGINE ASSEMBLY AND ADJUSTMENT EAS00419 TRANSMISSION Circlip Bearing Oil seal Drive axle Bearing Main axle Conical spring washer Flat washer Secondary sheave axle Bearing Dowel pin Gasket Transmission case cover Bearing Oil seal 9 Nm (0.
ENGINE ASSEMBLY AND ADJUSTMENT ENG EAS00428 INSTALLING THE TRANSMISSION 1. Apply: • SE engine oil type 10W30 (on the tansmission box cover bearing) 2. Install: • secondary sheave axle (on transmission case cover) 3. Install: • circlip • oil seal NOTE: Apply grease with lithium soap based onto the oil seal lips. 4. Check: • rotation of secondary sheave axle Rough rotation Repair. 5. Apply: • SE type 10W30 engine oil (on bearing of main axle and drive axle bearing) 6.
ENGINE ASSEMBLY AND ADJUSTMENT ENG STARTER SYSTEM Collar Starter wheel gear Bearing Starter clutch Plate Shaft Flat washer Idle gear O-ring Starter motor 8 Nm (0.8 m • kg) 13 Nm (1.
ENGINE ASSEMBLY AND ADJUSTMENT ENG INSTALLING THE STARTER SYSTEM 1. Install: • bushing • bearing • starter wheel gear • starter clutch NOTE: • Apply grease with a lithium soap base on the bearing . • Apply molybdenum disulphide oil on the pin (starter clutch) . 2. Install: • flat washer • idle gear • flat washer • plate (intermediate gear) Screw (intermediate gear plate) 8 Nm (0.8 m • kg) NOTE: Apply engine oil on the intermediate gear . 3.
ENGINE ASSEMBLY AND ADJUSTMENT ENG PRIMARY AND SECONDARY SHEAVE Nut Clutch drum Clutch plate Clutch spring Spring Spring seat Oil seal O-ring Secondary sliding sheave V-belt Guide pin Secondary fixed sheave Conical washer One-way clutch Special washer Primary fixed sheave Shim Collar Primary sliding sheave Weight 21 Slider 22 Cam *: Apply assembly lube Free length limit of spring: 29.9 mm 40 Nm (4.0 m • kg) Waste limit of clutch housing: 107.4 mm 50 Nm (5.
ENGINE ASSEMBLY AND ADJUSTMENT EAS00338 KICKSTARTER Kick shaft Return spring Collar Flat washer Circlip Kick crank Kick pinion gear clip Kick pinion gear 10 Nm (1.
ENGINE ASSEMBLY AND ADJUSTMENT ENG EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: • secondary fixed sheave’s inner surface • secondary sliding sheave’s inner surface Recommended lubricant assembly lube 2. Install: • secondary sliding sheave NOTE: Take care that the lips of the oil seals do not turn when the pulley wheel is installed. 3. Install: • guide pin 4. Lubricate: • guide pin groove • oil seal (with the recommended lubricant) 5.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 6. Tighten: • clutch securing nut use sheave holder spanner (41 mm) Sheave holder 90890-01701 Clutch securing nut 50 Nm (5.0 m • kg) 7. Install: • dowel pin • gasket • secondary assembly • clutch housing 8. Tighten: • nut (secondary sheave) Use sheave holder Sheave holder 90890-01701 Nut (secondary sheave) 40 Nm (4.0 m • kg) EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 3. Check: • cam operation Unsmooth operation Repair 4. Install: • primary sheave assembly • collar 5. Install: • v-belt NOTE: The v-belt should be installed with the arrow facing towards the front. 6. Install: • shim • primary fixed sheave • special washer • one-way clutch • conical spring washer • nut 7. Tighten: • nut (primary sheave) Nut (Primary sheave) 33 Nm (3.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 8. Adjust: • v-belt Tense the V-belt by turning the primary sheave several times. 9. Install: • fan (CS50 only) Side right Screw (fan) 7 Nm (0.7 m • kg) INSTALLING THE KICKSTARTER 1. Install: • return spring • kick shaft • collar • flat washer • circlip 2. Hook on: • return spring (on kick gear and hub) 3. Install: • kick pinion gear 4. Install: • crankcase cover Screw (crankcase cover) 9 Nm (0.9 m • kg) 5.
ENGINE ASSEMBLY AND ADJUSTMENT ENG PISTON, CYLINDER AND CYLINDER HEAD (CS50 A/C) Carburetor joint Reed valve Gasket Cylinder head Cylinder head gasket Cylinder Cylinder gasket Piston rings Piston Piston pin Piston pin clips Bearing CS50 Piston-to-cylinder clearance: 0.034 ~ 0.047 mm : 0.1 mm End gap (installed): Top ring 0.15 ~ 0.35 mm : 0.60 mm Second ring 0.15 ~ 0.35 mm : 0.60 mm 11 Nm (1.1 m • kg) Ring side clearance: Top ring 0.03 ~ 0.05 mm Second ring 0.
ENGINE ASSEMBLY AND ADJUSTMENT ENG PISTON, CYLINDER AND CYLINDER HEAD (CS50Z L/C) Carburetor joint Reed valve Gasket Cylinder head Cylinder head gaskets Cylinder Cylinder gasket Piston rings Piston Piston pin Piston pin clips Bearing Thermo switch Thermostat CS50Z Piston-to-cylinder clearance: 0.029 ~ 0.042 mm : 0.1 mm End gap (installed): Top ring 0.15 ~ 0.35 mm : 0.60 mm Second ring 0.15 ~ 0.35 mm : 0.60 mm 11 Nm (1.1 m • kg) Ring side clearance: Top ring 0.
ENGINE ASSEMBLY AND ADJUSTMENT ENG PISTON AND PISTON PIN 1. Apply: • engine oil (in the crankshaft bearing, big end bearing, small end bearing, piston pin, piston ring grooves and piston skirt areas). 2. Install: • reed valve gasket • reed valve • carburetor joint Carburetor joint 9 Nm (0.9 m • kg) 3. Install: • small end bearing • piston • piston pin • piston circlips NOTE: • The arrow of the piston should point to the exhaust side.
ENGINE ASSEMBLY AND ADJUSTMENT ENG • Check that the manufacturers symbols or numbers printed on the rings are on the upper side. 3. Intall: • cylinder NOTE: Install the cylinder with one hand while compressing the piston rings with the other. • coolant pipe (CS50Z only) 4. Install: • cylinder head gasket (new gasket) 5. Install: • thermostat (CS50Z only) on cylinder head 5 Nm (0.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 6. Install: • central stand • spring • axle • clasp • rubber washer • strap loop 7. Install: • brake shoes • flat washer • rear wheel • rear brake cable ENGINE REMOUNTING When the engine is being assembled, reverse the removal procedure. 1. Install: • engine assembly bolt • rear shock absorber bolt (lower) Engine mounting bolt 84 Nm (8.4 m • kg) Rear shock absorber bolt (lower) 18 Nm (1.8 m • kg) 2.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 4. Bleed the air: • autolubrication pump Refer to chapter 3, “BLEEDING OF AIR FROM THE AUTOLUBRICATION PUMP” section. 5. Tighten: • rear wheel axle nut NOTE: When the rear wheel axle nut is tightened, apply the rear brake. Rear wheel axle bolt 125 Nm (12.5 m • kg) 6. Install: • muffler • fan cover (CS50 only) Bolt (muffler) 26 Nm (2.6 m • kg) Bolt (exhaust pipe) 9 Nm (0.
COOL 5
COOL CHAPTER 5 COOLING SYSTEM (CS50Z only) RADIATOR AND WATER PUMP ………………………………………………5-1 REMOVING THE RADIATOR …………………………………………………5-2 REMOVING THE WATER PUMP ……………………………………………5-2 CHECKING THE RADIATOR …………………………………………………5-3 CHECKING THE WATER PUMP ……………………………………………5-3 INSTALLING THE WATER PUMP ……………………………………………5-4 INSTALLING THE RADIATOR…………………………………………………5-5 THERMOSTAT ……………………………………………………………………5-5 REMOVING THE THERMOSTAT ……………………………………………5-5 CHECKING THE THERMOSTAT ……………………………………………5-6 INSTALLING THE THE
COOL RADIATOR AND WATER PUMP EAS00454 COOLING SYSTEM (CS50Z only) RADIATOR AND WATER PUMP Water pump outlet hose O-ring 10 Reservoir tank 11 Reservoir tank hose 12 Thermostatic valve 13 Thermo switch Radiator Radiator inlet hose Radiator outlet hose Carburetor inlet hose Carburetor outlet hose Impeller Water pump cover 9 Nm (0.9 m • kg) 10 7 Nm (0.7 m • kg) 11 12 13 16 Nm (1.6 m • kg) 5-1 5 Nm (0.
RADIATOR AND WATER PUMP COOL REMOVING THE RADIATOR 1. Remove: • front upper cowling • front middle cowling • front lower cowling Refer to “FRONT COWLING AND FOOTREST” in chapter 3. 2. Drain: • coolant (from cooling system) Refer to “CHANGING THE COOLANT” in chapter 3. 3. Remove: • hose clamp NOTE: Remove the hose clamp with a thin flattedhead screwdirver. 4. Remove: • radiator hoses • radiator EAS00470 REMOVING THE WATER PUMP 1.
RADIATOR AND WATER PUMP COOL EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator. Damage Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: • radiator hoses • radiator pipes Cracks/damage Replace. EAS00473 CHECKING THE WATER PUMP 1.
RADIATOR AND WATER PUMP COOL EAS00477 INSTALLING THE WATER PUMP NOTE: Always replace the entire water pump assembly. 1. Install: • impeller • pin • water pump drive pulley • circlip New NOTE: After installation, check that the impeller shaft rotates smoothly. 2. Install: • crankcase cover (right) 3. Install: • o-ring New NOTE: Lubricate the O-ring with a thin coat of lithiumsoap-based grease. 4. Install: • water pump cover 7 Nm (0.
RADIATOR AND WATER PUMP / THERMOSTAT COOL EAS00456 INSTALLING THE RADIATOR 1. Install: • hose clamp NOTE: Install the hose clamp with a pliers . 2. Fill: • cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks Repair or replace any faulty part. THERMOSTAT REMOVING THE THERMOSTAT 1. Drain: • coolant Refer to “CHANGING COOLANT” in chapter 3. 2.
THERMOSTAT COOL EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat Does not open at 70.0°C ~ 82.0°C Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
CARB 6
CARB CHAPTER 6 CARBURETOR CARBURETOR ……………………………………………………………………6-1 REMOVING THE CARBURETOR ……………………………………………6-2 DISASSEMBLING THE CARBURETOR ……………………………………6-2 CHECKING THE CARBURETOR ……………………………………………6-3 ASSEMBLING THE CARBURETOR …………………………………………6-5 CHECKING THE AUTOCHOKE UNIT ………………………………………6-6 INSTALLING THE CARBURETOR……………………………………………6-7 FUEL COCK ………………………………………………………………………6-7 CHECKING THE FUEL COCK ………………………………………………6-7 REED VALVE ………………………………………………………………………6-8 REMOVING THE REED VALVE ………………………………………
CARBURETOR CARB EAS00480 CARBURETOR CARBURETOR Pilot jet Throttle valve spring Spring catch Throttle valve Jet needle Pilot air screw Throttle stop screw Needle jet Main jet 10 Float 11 Float gasket 12 Drain screw 13 Needle valve 14 Float chamber Main jet: #65 Jet needle A20 - 3/5, A35 - 4/5 (CS50Z) Main air jet: ø 2.5 Pilot jet: #36 Starter jet: #50 Pilot air screw: 1 3/4 ± 1/8 (CS50Z), 2 - 1/4 Idling speed: 1.
CARBURETOR REMOVING THE CARBURETOR 1. Remove: • air filter box • helmet box Refer to “REAR BODYWORK, MUDGUARD” in chapter 3 2. Drain: • fuel (from drain screw ) • coolant Refer to “CHANGING THE COOLANT” in chapter 3. 3. Disconnect: • autochoke lead coupler • coolant hoses • fuel hose • vacuum hose • oil delivery hose • throttle cable (with throttle valve) • clamp (fixing clip) 4. Remove: • carburetor CARB DISASSEMBLING THE CARBURETOR 1. Remove: • float chamber 2.
CARBURETOR CARB 4. Remove: • throttle stop screw (with spring, washer and o-ring) • pilot air screw (with spring) 5. Remove: • spring seat • jet needle • throttle valve • throttle valve spring EAS00485 CHECKING THE CARBURETOR 1. Check: • carburetor body Dirty Clean NOTE: For cleaning, use a petrol based solvent. Clean the pipes and jets with compressed air 2. Check: • main jet • needle jet • pilot jet Dirty Clean 3.
CARBURETOR CARB 4. Check: • throttle valve Wear/Damage Change 5. Check: • throttle valve displacement Irregular movement/Catches Change Insert the throttle valve in the body and check its displacement. 6. Check: • throttle stop screw • pilot air screw • jet needle • starter plunger Wear/Damage Change 7. Measure: • Float height a Outside specifications float and valve seat Check valve, Float height a 15.0 mm ~ 17.
CARBURETOR CARB NOTE: The arm of the float should be supported on the valve without compressing it. • If the height of the float is not within the specified limits, inspect the valve and its seat. • Substitute both parts if any part of them is worn. • If both are in good condition, replace the float. • Check the height of the float again. NOTE: The height of the float is adjusted in the factory. Do not try to modify it under any circumstances.
CARB CARBURETOR EAS00503 CHECKING THE AUTOCHOKE UNIT NOTE: When checking the autochoke unit, the ambient temperature must be lower than 45°C (113°F). 1. Remove: • carburetor 2. Check: • autochoke unit a. Connect a 3.3 mm hose to the starter air passage and blow into the hose. NOTE: When the starter plunger is open, air should come out of the other side of the starter air passage.
CARBURETOR/ FUEL COCK CARB EAS00492 INSTALLING THE CARBURETOR 1. Adjust: • engine idling speed Engine idling speed 1.650 ~ 1.950 r/min (CS50) 1.850 ~ 2.150 r/min (CS50Z) Refer to “ADJUSTING HE ENGINE IDLING SPEED” in chapter 3. 2. Adjust: • throttle cable free play Throttle cable free play (at the flange of the throttle grip) 2 ~ 5 mm Refer to “ADJUSTING HE ENGINE IDLING SPEED” in chapter 3. EAS00505 FUEL COCK CHECKING THE FUEL COCK 1. Stop the engine. 2.
REED VALVE CARB REED VALVE REMOVING THE REED VALVE 1. Remove: • helmet box Refer to “REAR BODYWORK, MUDGUARD” in chapter 3. • air filter box assembly 2. Remove: • carburetor See section “REMOVING THE CARBURETOR” 3. Remove: • carburetor joint • reed valve assembly CHECKING THE REED VALVE 1. Inspect: • carburetor joint Damage/Cracks Change • reed valve Fatigue/Cracks Change Inspection steps: • Visually inspect the reed valve.
REED VALVE CARB 2. Measure: • valve stopper height Out of specification Adjust the stopper/Replace the valve stopper. Height of valve stopper 6.0 ~ 6.4 mm 3. Measure: • clearance of reed valve Out of specification Replace the reed valve. Clearance of reed valve Less than 0.2 mm INSTALLING THE REED VALVE When the reed valve assembly is installed, reverse the removal procedure. Bear in mind the following points. 1. Install: • gasket New 2.
CHAS 7
CHAS CHAPTER 7 CHASSIS FRONT WHEEL …………………………………………………………………7-1 REMOVING THE FRONT WHEEL ……………………………………………7-2 CHECKING THE FRONT WHEEL ……………………………………………7-3 CHECKING HE SPEED SENSOR UNIT ……………………………………7-4 CHECKING THE BRAKE DISC ………………………………………………7-4 INSTALLING THE FRONT WHEEL …………………………………………7-6 FRONT BRAKE……………………………………………………………………7-7 REPLACING THE FRONT BRAKE PADS……………………………………7-8 REMOVING THE BRAKE HOSE ……………………………………………7-10 CHECKING THE BRAKE HOSE ……………………………………………7-10 INSTALLING THE BRAKE HOSE …………………
CHAS FRONT WHEEL EAS00518 CHASSIS FRONT WHEEL Tyre Front rim Oil seal Spacer 10 Nut Wheel axle Speed sensor unit Bearing Collar Valve Tyre: Size: 110/70-12 Type: 47 L Rim runout limit: Vertical: 1.0 mm Lateral: 1.0 mm Wheel axle bend limit: 0.25 mm 47.5 Nm (4.
FRONT WHEEL CHAS EAS00520 REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface. s WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Remove: • brake caliper • axle nut NOTE: Do not apply the brake lever when removing the brake caliper. 3. Elevate: • front wheel NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 4.
FRONT WHEEL CHAS EAS00525 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends Replace. s WARNING Do not attempt to straighten a bent wheel axle. 2. Check: • tire • front wheel Damage/wear Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: • radial wheel runout • lateral wheel runout Over the specified limits Replace. Rim runout limit Radial: 1.0 mm Rim runout limit Lateral: 1.0 mm 4.
FRONT WHEEL CHAS CAUTION: Do not contact the wheel bearing inner race or balls . Contact should be made only with the outer race . NOTE: Use a socket that matches the diameter of the wheel bearing outer race and oil seal. EAS00535 CHECKING THE SPEED SENSOR UNIT 1. Check: • speedometer sensor Bends/damage/wear Replace. 2. Check: • speedometer drive gear • speedometer driven gear Damage/wear Replace. EAS00528 CHECKING THE BRAKE DISC 1.
FRONT WHEEL CHAS 3. Measure: • brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification Replace. Brake disc thickness limit (minimum) 3.0 mm 4. Adjust: • brake disc deflection a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 23 Nm (2.3 m•kg) LOCTITE® d.
CHAS FRONT WHEEL EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: • wheel axle • wheel bearings • oil seal lips • speedometer drive gear • speedometer driven gear Recommended lubricant Lithium-soap-based grease 2. Install: • speed sensor unit NOTE: Make sure the speed sensor unit and the wheel hub are installed with the two projections engaged into the flat surface of the wheel. 3.
CHAS FRONT BRAKE EAS00576 FRONT BRAKE Retaining bolt Air bleed screw Caliper assembly Pad spring Pad set Retaining pin Brake pad cover Brake disc Master cylinder cap 10 Diaphragm 11 Brake hose 12 Brake pump assy 13 Front brake lever 14 Copper washers 15 Union bolt 16 Brake light switch cable Type of brake fluid: DOT #4 12 Wear limit of brake pads: 0.5 mm Wear limit of brake disc: 3.0 mm 13 10 14 15 16 23 Nm (2.3 m • kg) 11 23 Nm (2.
FRONT BRAKE CHAS EAS00583 REPLACING THE FRONT BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Remove: • brake pad cover • brake pad clip • brake pad pin • brake pad spring 2. Remove: • brake pads (along with the brake pad shims ) 3. Measure: • brake pad wear limit a Out of specification Replace the brake pads as a set. Brake pad wear limit 0.5 mm 4.
FRONT BRAKE CHAS NOTE: b The triangle mark a on the brake pad shim must point in the direction of disc rotation. e. Install new brake pads and a new brake pad spring . NOTE: The arrow mark b of the brake pad spring must point in the direction of disc rotation. 5. Install: • brake pad pins • brake pad clips • brake pad cover 6. Check: • brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level.
FRONT BRAKE CHAS REMOVING THE BRAKE HOSE NOTE: Before replacing the brake hose, drain the brake fluid from the entire brake system. 1. Remove: • union bolt • copper washers • brake hose NOTE: To collect any remaining brake fluid, place a container under the end of the brake hose. CHECKING THE BRAKE HOSE 1. Check: • brake hoses cracks/damage/wear Replace.
FRONT BRAKE CHAS EAS00596 INSTALLING THE BRAKE HOSE s WARNING • Never use solvents on internal brake components. Recommended brake fluid DOT #4 1. Install: • copper washers • brake hose • union bolt New 23 Nm (2.3 m • kg) s WARNING Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING”. NOTE: • While holding the brake hose, tighten the union bolt. • Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g.
FRONT BRAKE CHAS s WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the brake master cylinder reservoir.
CHAS REAR WHEEL EAS00560 REAR WHEEL Nut Washer Rear rim Valve Return springs Brake shoes Brake camshaft Wear indicator Bolt 10 Brake camshaft lever 11 Axle 12 O-ring 13 Nut Tyre: Size: 130/70-12 Type: 56 L Size: 120/70 - 12 Type: 51 L (Spain) Brake drum wear limit: 110.5 mm Brake shoe wear limit: 2.0 mm Wheel runout limit: Vertical: 1.0 mm Lateral: 1.0 mm 13 Nm (1.3 m • kg) 11 10 12 13 12 Nm (1.
REAR WHEEL CHAS EAS00564 REMOVING THE REAR WHEEL 1. Remove: • exhaust pipe assembly 2. Loosen: • rear axle nut NOTE: When the axle nut is loosened, apply rear brake. 3. Remove: • rear wheel 4. Remove: • rear brake cable • brake shoes • plain washer EAS00565 CHECKING THE REAR WHEEL 1. Inspect: • wheel See “CHECKING THE FRONT WHEEL” section 2. Measure: • wheel runout See “CHECKING THE FRONT WHEEL” section Rim runout limits Vertical: 1.0 mm Lateral: 1.0 mm 3.
REAR WHEEL CHAS 5. Measure: • Thickness of brake shoes a Outside specified value Change Brake shoes thickness 4.0 mm : 2.0 mm 6. Inspect: • Drum brake inner surface Oil/Scratches Replace 7. Measure • Drum brake inner diameter a : Out of specification Replace Wear limit of brake drum 110.5 mm EAS00570 ASSEMBLING THE BRAKE SHOES When the brake shoe carrier plate is assembled, reverse the removal procedure. Bear in mind the following points. 1.
REAR WHEEL CHAS Bolt (cam lever) 10 Nm (1.0 m • kg) 4. Install: • plain washer • brake cable EAS00574 INSTALLING THE REAR WHEEL When installing the rear wheel, reverse the removal procedure. The following points should be remembered. 1. Install: • rear wheel • plain washer • nut Nut (Rear wheel axle) 125Nm (12.5 m • kg) 2. Install: • muffler Bolt (exhaust pipe side) 9 Nm (0.9 m • kg) Bolt (muffler side) 26 Nm (2.6 m • kg) 3.
CHAS FRONT FORK EAS00646 FRONT FORK 11 Spring 12 Piston 13 Rebound spring 14 Circlip 15 Inner tube 16 Oil lock piece 17 Outer tube 18 Washer 19 Bolt Steering bracket Bolt Rubber cap Circlip Spring stopper O-ring Collar Dust seal Oil seal circlip 10 Oil seal Fork spring free lenght: 224 mm Fork oil capacity: 45 cc ± 1 cc Oil grade: SAE 10 W oil fork or equivalent 13 14 15 10 16 11 17 12 18 19 7-17
FRONT FORK CHAS EAS00651 REMOVING THE FRONT FORK LEGS 1. Place the scooter on its central stand and place an adequate support under the engine 2. Remove: • brake calipers Refer to “FRONT BRAKE REMOVAL” section. 3. Remove: • front fender • front wheel See “FRONT WHEEL REMOVAL” section. 4. Remove: • front upper cowling Refer to “FRONT BODYWORK, MUDGUARD” in chapter 3. 5. Loosen: • pinch bolt (fork) 6. Remove: • circlip • front fork EAS00652 DISASSEMBLING THE FRONT FORK LEGS 1.
CHAS FRONT FORK 4. Remove: • bolt (hydraulic rod) • copper washer NOTE: Remove the bolt (hydraulic rod) while the hydraulic rod is held with the T-handle and a support T-handle: 90890-01326 Support: 90890-01294 5. Remove: • inner tube • piston (hydraulic rod) • rebound spring • oil lock piece • oil seal (outer tube) EAS00657 CHECKING THE FRONT FORK LEGS 1.
FRONT FORK CHAS EAS00658 ASSEMBLING THE FRONT FORK LEGS Reverse the disassembly procedure. Bear in mind the following points. NOTE: • When assembling the fork, ensure that the following new parts are used. • Oil seal • Circlips • Ensure that all components are clean before assembly. 1. Install: • oil lock piece • piston (hydraulic rod) • inner tube • copper washer (new) • bolt (hydraulic rod) Bolt (hydraulic rod) 23 Nm (2.
FRONT FORK CHAS 3. Install: • circlip • dust seal NOTE: Couple the circlip correctly on the groove of the outer tube . 4. Fill: • fork oil Quantity (each front fork leg) 45 cc Recommended oil SAE 10W or equivalent From fork leg oil level (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) 105 mm NOTE: Place the fork in a vertical position. 5.
FRONT FORK CHAS EAS00663 INSTALLING THE FRONT FORK LEGS Reverse the removal procedure. The following points should be remembered 1. Install: • front fork • circlip NOTE: Attach the circlip correctly on the inner tube groove. 2. Tighten: • pinch bolt (steering bracket): Pinch bolt (steering bracket) 30 Nm (3.0 m • kg) 3. Install: • front wheel • brake calliper • brake hose holder • speed sensor coupler See “FRONT WHEEL” section • front mudguard Refer to “FRONT BODYWORK MUDGUARD” in chapter 3.
HANDLEBAR AND STEERING CHAS EAS00664 HANDLEBAR AND STEERING 11 Lock washer 12 Center ring nut 13 Rubber washer 14 Lower ring nut 15 Bearing cover 16 Upper bearing race 17 Bearing cage 18 Bearing race 19 Lower bracket Handlebar Grip cap Throttle grip Throttle grip guide Grip Nut Bolt Throttle cable Brake cable 10 Upper ring nut 10 11 13 15 17 16 18 12 14 16 18 17 19 7-23
HANDLEBAR AND STEERING CHAS EAS00666 REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface. s WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: • front upper cowling • front middle cowling • legshield • handlebar cover (upper) 3. Disconnect: • meter coupler • flasher relay 4. Disconnect • handlebar switch couplers (left and right) • brake switch connectors (front and rear) • rear brake cable 5.
HANDLEBAR AND STEERING CHAS EAS00678 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. s WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: • handlebar 3. Remove: • brake caliper • brake hose holder 4. Disconnect: • speed sensor coupler 5. Remove: • clamp 6. Remove: • ring nut (upper) (with the ring nut wrench) Ring nut wrench 90890-01403 7.
HANDLEBAR AND STEERING CHAS EAS00682 CHECKING THE STEERING HEAD 1. Wash: • bearing balls • bearing races Recommended cleaning solvent Kerosene 2. Check: • bearing races Damage/pitting Replace. • bearing balls Damage/pitting Replace. 3. Replace: • bearing balls • bearing races a. Remove the bearing races from the steering head pipe with a long rod and hammer. b. Remove the bearing race from the lower bracket with a floor chisel and hammer. c.
HANDLEBAR AND STEERING CHAS EAS00668 CHECKING THE HANDLEBAR 1. Check: • handlebar Bends/cracks/damage Replace. s WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken it. 2. Install: • handlebar grip a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.
CHAS HANDLEBAR AND STEERING EAS00673 INSTALLING THE HANDLEBAR 1. Stand the scooter on a level surface. s WARNING Securely support the scooter so that there is no danger of it falling over. 2. Install: • handlebar a NOTE: Align the slot a on the steering with the pin on the handlebar. 3. Tighten: • handlebar securing nut 42.5 Nm (4.25 m • kg) 4.
ELEC 8
ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS …………………………………………………8-1 CHECKING SWITCH CONTINUITY……………………………………………8-3 CHECKING THE SWITCHES……………………………………………………8-4 CHECKING THE BULBS AND BULB SOCKETS ……………………………8-5 TYPS OF BULBS ………………………………………………………………8-5 CHECKING THE CONDITION OF THE BULBS ……………………………8-5 CHECKING THE CONDITION OF THE BULB SOCKETS…………………8-6 IGNITION SYSTEM ………………………………………………………………8-8 CIRCUIT DIAGRAM ……………………………………………………………8-8 TROUBLESHOOTING …………………………………………………………8-9 ELECTRIC ST
ELECTRICAL COMPONENTS ELEC EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS Ignition coil Temperature sender (CS50Z only) Wire harness Starter motor DC-CDI Unit Engine oil level gauge Starter relay Fuel sender gauge Battery Ignition coil: Primary coil resistance: 0.56 ~ 0.84 Ω at 20 °C Secondary coil resistance: 5.68 ~ 8.
ELECTRICAL COMPONENTS Main switch/seat closure Indicator relay Rectifier/regulator Horn 8-2 ELEC
CHECKING SWITCH CONTINUTY ELEC EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. TOP VIEW B P Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch.
CHECKING THE BULBS AND BULB SOCKETS ELEC EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. No continuity Repair or replace the bulb, bulb socket or both. b a TYPES OF BULBS The bulbs used on this scooter are shown in the illustration on the left.
CHECKING THE BULBS AND BULB SOCKETS ELEC • Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 2. Check: • bulb (for continuity) (with the pocket tester) No continuity Replace.
CHECKING THE BULBS AND BULB SOCKETS ELEC b. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket.
IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Fuse Battery DC-CDI magneto (pickup coil) DC-CDI unit Ignition coil Spark plug 8-8 ELEC
IGNITION SYSTEM ELEC EAS00740 EAS00736 TROUBLESHOOTING 1. Spark plug The ignition system fails to operate (no spark or intermittent spark). • Check the condition of the spark plug. • Check the spark plug type. • Measure the spark plug gap. Refer to “CHECKING THE SPARK PLUG” in chapter 3. Check: 1. Spark plug 2. Ignition spark gap 3. Spark plug cap resistance 4. Ignition coil resistance 5. Main switch 6. Pickup coil resistance 7. Main fuse 8. Battery 9.
ELEC IGNITION SYSTEM EAS00744 • Connect the pocket tester (Ω x 1k) to the ignition coil as shown. 3. Spark plug cap resistance • Remove the spark plug cap from the spark plug lead. • Connect the pocket tester (“Ω x 1k” range) to the spark plug cap as shown. • Measure the spark plug cap resistance. Negative tester probe spark plug lead Positive tester probe ground • Measure the secondary coil resistance. Secondary coil resistance 5.68 ~ 8.
IGNITION SYSTEM EAS00748 ELEC EAS00739 6. Pickup coil resistance 8. Battery • Disconnect the pickup coil coupler from the wire harness. • Connect the pocket tester (Ω x 100) to the pickup coil terminal as shown. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20°C Positive tester probe white/blue Negative tester probe ground • Is the battery OK? YES • Recharge or replace the battery.
ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Fuse Battery Starter relay Starter motor Start switch Front brake switch Rear brake switch 8-12 ELEC
ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON” the starter motor can only operate if at least one of the following conditions is met: • The front brake switch is ON. • The rear brake switch is ON. When at least one of the above conditions has been met the starter relay is closed and the engine can be started by pressing the starter switch.
ELECTRIC STARTING SYSTEM EAS00757 ELEC EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The starter motor fails to turn. Check: 1. main fuse 2. battery 3. starter motor 4. starter relay 5. main switch 6. start switch 7. wiring connections (of the entire starting system) Minimum open-circuit voltage 12.8 V or more at 20°C • Is the battery OK? YES NO • Recharge or replace the battery.
ELECTRIC STARTING SYSTEM EAS00761 ELEC EAS00766 4. Starter relay 7. Wiring • Disconnect the starter relay coupler from the coupler. • Connect the pocket tester (Ω x 1) and battery (12 V) to the starter relay coupler as shown. • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? YES 4 - The starting system circuit is OK.
ELECTRIC STARTING SYSTEM ELEC EAS00767 STARTER MOTOR O-ring Starter motor front cover Rubber seal Brush holder / brushes Armature assembly Starter motor rear cover Wiring Brush wear limit: 0.9 mm Commutator wear limit: 14.8 mm Mica lower cut-off: 1.
ELECTRIC STARTING SYSTEM ELEC REMOVING THE STARTER MOTOR 1. Remove: • exhaust pipe assembly • rear wheel • starter motor EAS00769 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification Replace the starter motor. Commutator wear limit 14.8 mm a 3. Measure: • armature assembly resistances (commutator and insulation) Out of specification Replace the starter motor. a.
ELEC ELECTRIC STARTING SYSTEM EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: • brush set • rubber seal • starter motor front cover 2. Install: • starter motor rear cover 3. Install: • Starter motor bolts a 13 Nm (1.3 m • kg) NOTE: When install the starter motor the ground terminal a is installed with upper side bolt.
CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM DC-CDI Magneto Main fuse Battery Rectifier/regulator 8-19 ELEC
ELEC CHARGING SYSTEM EAS00774 EAS00738 TROUBLESHOOTING 2. Main fuse The battery is not being charged. • Check the fuse for continuity. Refer to “CHECKING THE FUSES” in chapter 3. • Is the fuse OK? Check: 1. charging voltage 2. main fuse 3. battery 4. charging coil resistance 5. wiring connections (of the entire charging system) YES NO Replace the fuse. NOTE: EAS00739 • Before troubleshooting, remove the following part(s): 1.Front upper cowling 2.
CHARGING SYSTEM Positive tester probe white Negative tester probe black • Measure the charging coil resistance. Charging coil resistance 0.288 ~ 0.432 Ω at 20°C • Is the charging coil OK? YES NO Replace the charging coil assembly. EAS00779 5. Wiring • Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly connected and without defects? YES Replace the rectifier/ regulator.
LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM DC-CDI magneto (lighting coil) Tail/brake light License light (for UK only) Auxiliary light 24 Dimmer switch 25 Headlight 35 High beam indicator light 37 Meter light 8-22 ELEC
LIGHTING SYSTEM EAS00782 ELEC EAS00784 TROUBLESHOOTING 2. Dimmer switch • Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the dimmer switch OK? Any of the following fail to light: headlight, high beam indicator light, taillight, position light, and meter light. Check: 1. lighting coil resistance 2. dimmer switch 3. wiring connections (of the entire charging system) YES The dimmer switch is faulty. Replace the left handlebar switch.
ELEC LIGHTING SYSTEM EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. Meter light coupler (wire harness side) • Set the main switch to “ON”. • Start the engine. • Set the dimmer switch to “HI” or “LO”. • Measure the voltage (DC 12 V) of yellow or green on the headlight coupler (wire harness side). • Is the voltage within specification? 1. Headlight bulb and socket • Check the headlight bulb and socket for continuity.
ELEC LIGHTING SYSTEM • Set the main switch to “ON”. • Start the engine. • Measure the voltage (DC 12 V) of blue on the meter light coupler (wire harness side). • Is the voltage within specification? YES • Set the main switch to “ON”. • Start the engine. • Measure the voltage (DC 12 V) of blue on the tail/brake light coupler (tail/brake light side). • Is the voltage within specification? NO YES This circuit is OK.
LIGHTING SYSTEM • Set the main switch to “ON”. • Start the engine. • Measure the voltage (DC 12 V) of blue on the position light coupler (positionlight side). • Is the voltage within specification? YES This circuit is OK. NO Wiring circuit from the main switch to the position light coupler is faulty and must be repaired.
SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM Main switch Fuse Battery 13 Front brake switch 14 Rear brake switch 15 Tail/brake light 18 Turn signal relay 19 Turn signal switch 20 Front turn signal light (left) 21 Front turn signal light (right) 22 Rear turn signal light (left) 23 Rear turn signal light (right) 26 Horn 27 Horn switch 28 Fuel sender 29 Thermo switch (CS50Z only) 30 Engine oil level switch 31 Water temperature warning light (CS50Z only) 32 Fuel
SIGNALING SYSTEM EAS00794 ELEC EAS00749 TROUBLESHOOTING 3. Main switch •Any of the following fail to light: flasher light, brake light or an indicator light. •The horn fails to sound. • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? Check: 1. main fuse 2. battery 3. main switch 4. wiring connections (of the entire signaling system) YES NO Replace the main switch. EAS00795 NOTE: 4. Wiring • Before troubleshooting, remove the following part(s): 1.
ELEC SIGNALING SYSTEM EAS00796 CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. 3. Horn • Disconnect the pink connector at the horn terminal. • Connect a jumper lead to the horn terminal and ground the jumper lead. • Set the main switch to “ON”. • Does the horn sound? 1. Horn switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? YES NO YES NO Replace the left handlebar switch. Replace the horn. 2. Voltage 4.
SIGNALING SYSTEM ELEC EAS00798 • Set the main switch to “ON”. • Pull in the brake levers. • Measure the voltage (DC 12 V) of green/yellow on the tail/brake light coupler (wire harness side). • Is the voltage within specification? 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” • Are the tail/brake light bulb and socket OK? YES YES NO This circuit is OK.
ELEC SIGNALING SYSTEM 3. Voltage • Set the main switch to “ON”. • Set the turn signal switch to “L” or “R”. • Measure the voltage (DC 12 V) on brown/white at the turn signal relay coupler (wire harness side). • Is the voltage within specification? • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. Positive tester probe brown Negative tester probe ground YES Br/ W NO The turn signal relay is faulty and must be replaced. Br 1 - + 5.
ELEC SIGNALING SYSTEM • Set the main switch to “ON”. • Set the turn signal switch to “L” or “R”. • Measure the voltage (DC 12 V) of the chocolate or dark green 2 at the turn signal light connector (wire harness side). • Is the voltage within specification? YES 3. Voltage • Connect the pocket tester (DC 20 V) to the meter coupler (wire harness side) as shown. Positive tester probe green/yellow Negative tester probe black NO This circuit is OK.
SIGNALING SYSTEM • Measure the fuel sender resistances. 3. Fuel level gauge • Set the main switch to “ON”. • Move the float up or down. • Check that the display segments of the fuel level gauge increase or decrease to “E” or “F”. Fuel sender resistance (up position “F”) (Ω x 1) 1.5 ~ 7.5 Ω at 20°C (68°F) Fuel sender resistance (down position “E”) (Ω x 10) 90 ~ 100 Ω at 20°C (68°F) NOTE: Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes.
SIGNALING SYSTEM ELEC EAS00802 • Set the main switch to “ON”. • Measure the voltage (DC 12 V) of red/yellow on the multi-function meter coupler (wire harness side). • Is the voltage within specification? YES 7. The water temperature warning light fails to come on (CS50Z only). 1. Water temperature warning light bulb and socket • Check the water temperature warning light bulb and socket for continuity.
SIGNALING SYSTEM s WARNING • Handle the thermo switch with special care. • Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it. Thermo switch 16 Nm (1.6m • kg) Three bond sealock® 10 • Does the thermo switch operate properly as described above? YES NO Replace the thermo switch 3. Voltage • Connect the pocket tester (DC 20 V) to the meter coupler (wire harness side) as shown.
? TRBL SHTG 9
TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURE / HARD STARTING ……………………………………9-1 ENGINE …………………………………………………………………………9-1 FUEL SYSTEM …………………………………………………………………9-1 ELECTRICAL SYSTEM ………………………………………………………9-2 INCORRECT ENGINE IDLING SPEED ………………………………………9-2 ENGINE …………………………………………………………………………9-2 FUEL SYSTEM …………………………………………………………………9-2 ELECTRICAL SYSTEM ………………………………………………………9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ……………………9-3 ENGINE …………………………………………………………………………9-3 FUEL SYSTEM …………………………………………………………………9-3
STARTING FAILURE/HARD STARTING TRBL SHTG EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING FAILURE/HARD STARTING / INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery • Discharged battery • Faulty battery TRBL SHTG Switches and wiring • Faulty main switch • Faulty engine stop switch • Broken or shorted wiring • Faulty front, rear or both brake light switches • Faulty start switch • Faulty sidestand switch • Improperly grounded circuit • Loose connections Fuse(s) • Blown, damaged or incorrect fuse • Improperly installed fuse Spark plug(s) • Incorrect spark plug gap • Incorrect spa
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY CLUTCH TRBL SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”.
OVERHEATING / OVERCOOLING / POOR BRAKING PERFORMANCE TRBL SHTG EAS00855 OVERHEATING ENGINE Clogged coolant passages • Cylinder head(s) and piston(s) • Heavy carbon buildup Engine oil • Incorrect oil level • Incorrect oil viscosity • Inferior oil quality COOLING SYSTEM (CS50Z only) Coolant • Low coolant level Radiator • Damaged or leaking radiator • Bent or damaged radiator fin Water pump • Damaged or faulty water pump • Thermostat • Thermostat stays closed • Oil cooler • Clogged or damaged oil cooler • H
FAULTY FRONT FORK LEGS / UNSTABLE HANDLING TRBL SHTG EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL • Bent, damaged or rusty inner tube • Cracked or damaged outer tube • Improperly installed oil seal • Damaged oil seal lip • Incorrect oil level (high) • Loose damper rod assembly bolt • Damaged damper rod assembly bolt copper washer • Cracked or damaged cap bolt O-ring MALFUNCTION • Bent or damaged inner tube • Bent or damaged outer tube • Damaged fork spring • Worn or damaged outer tube bushing • Bent or d
FAULTY LIGHTING OR SIGNALING SYSTEM TRBL SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON • Wrong headlight bulb • Too many electrical accessories • Hard charging • Incorrect connection • Improperly grounded circuit • Poor contacts (main or light switch) • Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT • Wrong headlight bulb • Faulty battery • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Faulty light switch • Headlight bulb life expired TA
CS50/Z 2002 WIRING DIAGRAM COLOR CODE B. ..............................BLACK R. ..............................RED L................................BLUE G...............................GREEN O...............................ORANGE Y................................YELLOW P................................PINK Br. .............................BROWN Ch. ............................CHOCOLATE Sb. ............................SKY BLUE Dg. ............................DARK GREEN B/Br...........................
