Yamaha CE50T User manual

1987 - 1990
MOTORCYCLE
SERVICE MANUAL
Model : CE50T, CG50A, CG50U, CG50W
2YT281972000 *2YT281972000*
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CE50T
SERVICE MANUAL
©1986 by Yamaha Motor Co., Ltd.
1st Edition, November 1986
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
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D
NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to put an entire mechanic's education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha scooter
have a basic understanding of the mechanical concepts and procedures inherent in scooter repair tech-
nology. Without: such knowledge, attempted repairs or service to this model may render it unfit to
use and/or unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all Autho-
rized Yamaha dealers and will, where applicable,appear in future editions of this manual.
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLES OPERATIONS
YAMAHAMOTOR CO., LTD.
HOW TOUSE THiS MANUAL
PARTICULARLYiMPORTANT iNFORMATiON
This material is distinguished bythe following notation.
NOTE: A NOTE provides keyinformation to make procedureseasier or clearer.
ili ii i iiil ACAUTIONindicatesspecialproceduresthatmustbefollowedtoavoid
damageto thescooter.
A WARNING indicatesspecial procedures that must be followed to avoid injury
to a scooter operator or person inspecting or repairing thescooter.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format.The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of afaulty component will precede an arrow symbol and the course
of action required will follow the symbol, e.g.,
• Bearings
Pitting/Damage_ Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
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(9®iLLUSTRATED SYMBOLS
IGENINFO (Refer to the illustration)
Illustrated symbols (_) to _) are designed as
thumb tabs to indicatethe chapter's number and
(_ (_) content.
%_JDI IC _i General information
ENGOOL Periodic inspection and adjustment
_ EngineCooling system
(_ (_) _ Carburetion
@Chassis
ICARB[ ]_ 1 _"AS1_I _(_)_; pter'nCdl'ces
® ®
® ® _ Illustrated symbols (_ to(_) are used to identify
6_ _ the specifications appearing in the text.
(_) Filling fluid
(_ Lubricant
(_) Tightening
_Wear limit, clearance(_) (_) -- Engine speed
@ @
® ® @Illustrated symbols (_ to (_ in the exploded
.,1 _ jdiagram indicate grade of lubricant and location
- _ = of lubrication point.
_ _ ® Apply engine o,1
® Apply gear oil
@ (_ (_ @(_Apply molybdenum disulfide oilApply wheel bearing grease
_ _ _ _L_.._ _(_))Apply lightweightlithium-soap base grease
Apply molybdenum disulfide grease
Apply locking agent (LOCTITE ®)
®l
m
i
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INDEX
GENERAL,NFORMAT,ON
ENGINE OVERHAUL '_'%_
ENG _
CARBURETION CARB_,
CHASSISCHAS_
L..,-.-----J
ELECTRICAL ELEC_
APPENDICES APPX_
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ii
1p,
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m
GEN
CHAPTER 1
GENERAL INFORMATNON
SCOOTER IDENTIFICATION ....................................... B-3
VEHICLE IDENTIFICATION NUMBER .............................. B-3
ENGINE SERIAL NUMBER ....................................... B-3
IMPORTANT INFORMATION ...................................... B-3
ALl. REPLACEMENT PARTS ..................................... B-3
GASKETS, OIL SEALS,AND O-RINGS ............................ B-3
LOCK WASHER/PLATES AND COTTER PINS ..................... B-3
BEARINGS AND OIL SEALS ..................................... B-4
CIRCLIPS ...................................................... B-4
SPECIAL TOOLS .................................................. B-4
FOR TUNE-UP .................................................. B-4
FOR ENGINE SERVICE .......................................... B-4
FOR CHASSIS SERVICE ......................................... B-5
FOR ELECTRICAL COMPONENTS ................................ B-5
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INFO
SCOOTER IDENTIFICATION
GENERAL
INFORMATION
SCOOTER IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number (~ is stamped
into the frame.
NOTE:
The vehicle identification number is used to iden-
tify your scooter and may be used to register your
scooterwith the licensing outhority in your state.
Starting Serial Number:
JYA2UG00-~HA720101
ENGINE SERIAL NUMBER
The engine serial number (~ is stamped into the
crankcase.
NOTE:
The first three digits of these numbers are for
model identifications; the remaining digits are the
unit production number.
Starting Serial Number:
14T-720101
NOTE:
Designs and specifications are subject to change
without notice.
1-1
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I°E"
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1. Use only genuine Yamaha parts forall
replacements. Use oil and/or greaserecom-
mendedby Yamahafor assembly and adjust-
ment. Other brands may besimilar in func-
tionand 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
gasket surfaces,oil seal lips and O-rings must
be cleaned.
2. Properly oil all mating parts and bearings dur-
ing reassembly. Apply grease to the oil seal
lips.
LOCK WASHERS/PLATES AND COTTER
PINS
1.All lock washers/Plates (_ 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 pro-
perly tightened.
1-2
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INFO iMPORTANT iNFORMATiON
BEARINGSAND OIL SEALS
i. Install the bearing(s) and oil seal(s) with their
manufacturer's marks or numbers facing out-
ward. (In other words, the stamped letters
__) _ must be on the side exposed to view.) When
installing oil seal(s), apply a light coating of
light-weight lithium base grease to the seal
lip(s). Oil the bearings liberally when installing.
(_ Oil seal
Do not use compressed air to spin the bear-
(_ ings dry. This causes damage tothe bearing
surfaces.
(_ Bearing
CIRCLIPS
1.All circlips should be inspected carefully
e orereas ereoaceO ton
clips after one use. Replace distorted circlips.
_/._/7_/_////_ When installing a cirelip (_, make sure that
the sharp edged corner (_ is positioned op-
posite to the thrust (_) it receives. See the
/J sectional view.
(_) (_) Shaft
1-3
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3
I
GEN
SPECIAL TOOLS I
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or improvis-
ed techniques.
FOR TUNE-UP
1. Inductive Tachometer
P/N. YU-08036
This tool is needed for detecting engine rpm.
2. Compression Gauge
P/N. YU-33223
This gauge is used to measure engine compr-
ession.
FOR ENGINE SERVICE
1. Flywheel Holding Tool
P/N. YU-01235
Thistool is usedto the hold the flywheel magneto
and clutch assembly when removing or installing
the securing nut.
2. Flywheel Magneto Puller
P/N. YM-01189
This tool is used to remove the flywheel.
1-4
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I GEN
SPECIAL TOOLS
i ............. ir
3. Primary Sheave Holder
P/N. YS-01880
This tool is used when holding the clutch hub.
P
4. Clutch Spring Holder
P/N. YS-28891
This tool is used to disassembly and assembly the
secondary sheave.
5. Thickness Gauge
P/N. YU-03001
6. Universal Puller Set
P/N. YU-33270
This tool is used to remove the crankshaft from
the crankcase.
7. Crankcase Separating Tool
P/N. YU-01135
This tool is used to remove the crankshaft or
separate the crankcase.
1-5
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I GEN
SPECIAL TOOLS I
,.Fol l
8. Crankshaft Installation Set
P/N. YU-90050 ...................... (~)
Adapter (M10)
P/N. YM-90062 ..................... (~
Adapter (M12)
P/N. YM-90063 ..................... ~)
These tools are used to install the crankshaft.
9. Sealant (Quick Gasket~)
P/N. ACC-11001-05-01
This sealant (bond) is used for crankcase mating
surfaces.
@
FOR CHASSIS SERVICE
1. Ring Nut Wrench
P/N. YU-01268 (~
P/N. YU-33975 ..................... (~
This tool is used to loosen and tighten the steer-
ing ring nut.
FOR ELECTRICAL COMPONENTS
1. Pocket Tester
P/N. YU-03112
This instrument is invaluable for electrical system
inspection and §djustment.
!J
2. Electro Tester
P/N. YU-33260
This instrument is necessary for ignition system
inspection.
1-6
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INSP
CHAPTER 2
PERiODiC iNSPECTiONS AND ADJUSTMENTS
INTRODUCTION................................................. C-3
PERIODICMAINTENANCE/LUBRICATIONINTERVALS ............ C-3
TAIL COVER ..................................................... C-3
REMOVAL .................................................... C-3
INSTALLATION ................................................ C-4
FRONT FENDER, FRONT PANEL AND FOOTREST BOARD......... C-4
REMOVAL .................................................... C-4
INSTALLATION ................................................ C°5
HANDLEBAR COVERS ........................................... C-5
REMOVAL ..................................................... C-5
INSTALLATION ................................................ C-5
ENGINE .......................................................... C-5
ENGINE IDLE SPEED ADJUSTMENT ............................. C-5
THROTTLE CABLE FREE PLAY ADJUSTMENT ................... C-6
AUTOLUBE PUMP CABLE ADJUSTMENT ........................ C-6
AUTOLUBE PUMP AIR BLEEDING ............................... C°7
AIR CLEANER ELEMENT CLEANING ............................. C-8
FUEL COCK CLEANING ........................................ C-8
COMPRESSION PRESSURE MEASUREMENT ..................... C-9
ENGINE OIL LEVEL INSPECTION ................................ C-10
TRANSMISSION OIL REPLACEMENT .... ........................ C-10
FUEL LINE INSPECTION ........................................ C-11
CHASSIS ........................................................ C-11
FRONT BRAKE LEVER FREE PLAY CHECK ....................... C-11
REAR BRAKE LEVER FREE PLAY CHECK ....................... C-11
FRONT AND REAR BRAKE LINING INSPECTION ................ C-12
TIRE AND WHEEL INSPECTION ................................. C-12
STEERING ADJUSTMENT ...................................... C-12
ELECTRICAL ..................................................... C-13
BATTERY ..................................................... C-13
FUSE INSPECTION ............................................. C-14
SPARK PLUG INSPECTION ..................................... C-14
HEADLIGHT BEAM ADJUSTMENT .............................. C-15
IGNITION TIMING ......................................... ..... C-15
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IINSPli 1 INTRODUCTION/PERIODIC MAINTENANCE/B
ADJ LUBRICATION iNTERVALS
PERIODICINSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapterincludes all information necessaryto performrecommended inspections and adjustments.
Thesepreventiw,• maintenanceprocedures,if followed, will ensuremorereliablevehicleoperationand
a longer servicelife. The need for costlyoverhaul work willbe greatlyreduced. Thisinformation ap-
pliesto vehicles alreadyin service aswellas new vehicles thatare beingprepared for sale. All service
techniciansshould befamiliarwiththis entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
Unit: km (mi)
EVERY
BREAK-IN
ITEM REMARKS500 3,000 6,000
(300) (2,000)or (4,000) or
6 months12 months
Spark plug Check/Clean or replace. O ©O
Air filter Clean. Replace if necessary.O ©
Carburetor Check/Adjust/idle speed, starter operation.© ©
Fuel line Check fuel hose for cracks or damage. O O
Transmission oil Replace (Warm engine before draining). Replace Check Check
Every 12,000 (8,000) or 24 months.
Autolube pump Check/Adjust/Air bleeding. O O
Brake Check operation.Adjust if necessary. O O
Wheels* Check balance/damage/runout. O O
Check bearings assembly for looseness/O O
Wheel bearings damage. Replace if damaged.
Check bearings assembly for looseness.
Steering bearing Moderately repack every 12,000 (8,000) Check Check Check
or 24 months.**
Rear shock absorber Check operation. O O
Fittings/Fasteners Check all chassis fittings and fasteners. O O O
Check specific gravity.Check breather pipe O O
Battery for proper operation.
V-belt Check damage and wear. O
Replace if necessary.
**: Medium weight wheel bearing grease.
2-1
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TAILCOVERADJ
TAIL COVER
REMOVAL
1. Open the seat lock.
2. Remove:
=Seat
3.Remove:
-Cover (_
4. Remove:
,Grab bar
_ , Rear carrier
(With rear flasher lights and taillight)
5. Disconnect:
,Rear flasher light leads
•Taillight leads
6. Remove:
®Side covers (Right and left)
NOTE:
When removing the side cover, unhook it at the
front and slide it forward.
7. Remove:
=Tail cover
: !!
2-2
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INSP E
ADJ _1 TA'LCOVER INSTALLATION
When installing the tail cover,reverse the
"REMOVAL" procedure.
Note the following points.
1. Install:
®Side covers
NOTE:
After installing the side covers, make sure that
all hooks are securely fitted.
2. Connect:
eRear flasher light leads
NOTE:
The leadsof identical colors should be connected.
31install:
i_J_. ®Rear carrier
i__i 7Nm (0.7 m,kg, 5.1 ft-lb)
4. Install:
eSeat
!_ 7 Nm (0.7 5.1 ft,lb)
m,kg,
2-3
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