Yamaha YW50P User manual

2002 - 2005
MOTORCYCLE
SERVICE MANUAL
Model : YW50P, YW50R, YW50S, YW50T
5PNF81972000 *5PNF81972000*
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EBO00000
YW50BP
SERVICE MANUAL
©2001 by Yamaha Motor Taiwan Co,.Ltd.
First edition, November 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Taiwan Co,.Ltd.
is expressly prohibited.
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EB001000
NOTICE
This manual was produced bythe Yamaha Motor Company, Ltd. primarily for use byYamaha deal-
ers 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
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications
and significant changes in specifications or procedures will be forwarded to all authorized Yamaha
deal-ers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
ZL
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
~'~,WARNING
Failure to folIowWARNING instructions could result in severe injury or death
to the scooter operator, a bystander or a person checking or repairing the
scooter.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the scooter.
NOTE: A NOTE provides key information to make procedures easier or clearer.
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HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
(~ The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter. Refer to "SYMBOLS".
(~ Each chapter is divided into sections. The current section title is shown at the top of each
page, except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-sec-
tion title(s) appears.
(~ Sub-section titles appear in smaller print than the section title.
(~ To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
(~ Numbers are given in the order of the jobs in the exploded diagram. A circled number indi-
cates a disassembly step.
(~ Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS".
(~) A job instruction chart accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
(~ Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
®
®
Cvlinder head. Cylinder and piston
removal
Engine
1 Muffler/Gasket
2 Air ~hroud (cylTnder head)
3 SparkIJlug
4 Cylinder head/Cylinder head gasket
Cylinder
6 Piston pin clip
7 Piston pin/Bearing
8 Piston
9 Piston ring set
10 CyITnder gasket
Q'ty Rurllark~
Remove the pa~s Enthe order
Refer to the "ENGINEREMOVAL" sec-
tion
1/1
1
1
1/1
1
2
1
1
1
Reverse the removal procedure for in
stallatien.
CYLINDEB HEAD" CYF~:N::R: P~~
1. Remove:
• san nc
NoTE PI t pT IIp~)
Begore removing tha piston pin celt,, cover the
' crankcase witha clean rag so you will not acci
Z. Ro,,,ovo:
• Piston pTn 1~
• Piston®
• Piston pin bearing ~
GA~ON~
Donot use a hammer to drive the piston pin
out_
CYUNDER HEAD INSPECTION
~. Elhxlin~te:
• Carbon deposits
Use a rounded ~crapper @
• Cylinder head war~3age
Out ofspecification >Re8ur'0ce.
Warpage measurement and re surfacement
• Attach a =traight edge ~ and a thickness
gauge (~ on the cylinder head.
• Measure the warpage limit.
I
• If the warpage is out of specification, reface
the cylinder head.
NOTE:
Rotate the head severaT tTres to avoid remov-
ing too much moteriol from one side.
4-4 ..................................... --
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Q ®
®
®
GEN
INFO
INSP
CARB
ELEC ~=]
®
®
@
@
-n~
SPEC
®
ENG ~)~
®
CHAS (~®
®
TRBL w.~
SHTG •
@
©
@
@
® i i 1
® ® @
@ @
EAS00009
SYMBOLS
The following symbols are not relevant to ev-
ery vehicle.
Symbols (~to (~ are designed as thumb tabs
to indicate the chapter's number and content.
(~ General information
(~ Specifications
(~ Periodic inspection and adjustment
Engine
(~) Carburetor(s)
(~ Chassis
(~ Electrical system
(~ Troubleshooting
Symbols (~ to (~)
®
@
@
@
@
@
@
@
indicate the following.
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols @to @ in the exploded diagrams in-
dicate the types of lubricants and lubrication
points.
(~ Engine oil
@ Gear oil
(~) Molybdenum disulfide oil
(~ Wheel bearing grease
(~ Lithium soap base grease
(~) Molybdenum disulfide grease
Symbols@ to @ in the exploded diagrams
indicate the following.
(~ Apply locking agent (LOCTITE ®)
(~ Replace the part
I~lew
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INDEX
GENERAL INFORMATION
SPECIFICATIONS
1
g,=.
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE OVERHAUL
CARBURETION
CHASSIS
~o
ELECTRICAL
TROUBLESHOOTING
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CHAPTER 1.
GENERAL INFORMATION
SCOOTER INDENTIFICATION ........................................................................................................... 1-1
VEHICLE IDENTIFICATION NUMBER ........................................................................................... 1-1
MODEL CODE ................................................................................................................................ 1-1
IMPORTANT INFORMATION ............................................................................................................ 1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY ................................................................ 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 ......................................................................................................... 1-3
CIRCLIPS ........................................................................................................................................ 1-3
CHECKING OF CONNECTIONS ........................................................................................................ 1-4
HOW TO USE THE CONVERSION TABLE ....................................................................................... 1-5
CONVERSION TABLE .................................................................................................................... 1-5
SPECIAL TOOLS ................................................................................................................................ 1-6
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CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATION ............................................................................................................... 2-1
MAINTENANCE SPECIFICATION ..................................................................................................... 2-4
ENGINE .......................................................................................................................................... 2-4
TIGHTENING TORQUES ............................................................................................................... 2-6
ENGINE .......................................................................................................................................... 2-6
MAINTENANCE SPECIFICATION ..................................................................................................... 2-7
CHASSIS ........................................................................................................................................ 2-7
TIGHTENING TORQUES ............................................................................................................... 2-8
CHASSIS ........................................................................................................................................ 2-8
MAINTENANCE SPECIFICATION ..................................................................................................... 2-9
ELECTRICAL ................................................................................................................................... 2-9
GENERAL TORQUE SPECIFICATIONS ........................................................................................... 2-1 1
LUBRICATION POINTS AND LUBRICATION TYPE ....................................................................... 2-12
ENGINE ........................................................................................................................................ 2-12
CHASSIS ...................................................................................................................................... 2-13
CABLE ROUTING ............................................................................................................................. 2-14
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CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION ................................................................................................................................ 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ................................................................ 3-1
COVER AND PANEL ..........................................................................................................................3-3
SIDECOVER AND SEAT ................................................................................................................3-3
LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD ..................... 3-4
HANDLEBAR COVER(FRONT AND REAR) ...................................................................................3-5
ENGINE ..............................................................................................................................................3-6
IDLE SPEED ADJUSTMENT ..........................................................................................................3-6
THROTTLE CABLE FREE ADJUSTMENT .....................................................................................3-7
AUTOLUBE PUMP AIR BLEEDING ............................................................................................... 3-8
SPARK PLUG INSPECTION ........................................................................................................... 3-9
ENGINE OIL LEVEL INSPECTION ...............................................................................................3-10
TRANSMISSION OIL REPLACEMENT ........................................................................................3-11
AIR FILTER ELEMENT CLEANING ..............................................................................................3-12
V-BELT INSPECTION ...................................................................................................................3-14
CHASSIS ..........................................................................................................................................3-15
FRONT BRAKE LEVER FREE PLAY CHECK ................................................................................ 3-15
REAR BRAKE LEVER FREE PLAY CHECK ................................................................................... 3-15
BRAKE PAD INSPECTION ...........................................................................................................3-15
BRAKE SHOE INSPECTION ........................................................................................................3-16
BRAKE FLUID LEVEL INSPECTION ............................................................................................3-16
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ........................................................................ 3-17
STEERING ADJUSTMENT ..........................................................................................................3-18
TIRE INSPECTION ........................................................................................................................3-19
WHEEL INSPECTION ...................................................................................................................3-22
FRONT FORK INSPECTION .........................................................................................................3-22
REAR SHOCK ABSORBER INSPECTION ....................................................................................3-22
SEAT LOCK CABLE ADJUSTMENT ...........................................................................................3-22
CABLE CHECKING AND LUBRICATING ..................................................................................... 3-23
LEVERS LUBRICATING ...............................................................................................................3-23
CENTERSTAND LUBRICATING ..................................................................................................3-23
ELECTRICAL .....................................................................................................................................3-24
BATTERY INSPECTION ...............................................................................................................3-24
FUSE INSPECTION ......................................................................................................................3-29
HEADLIGHT BEAM ADJUSTMENT ............................................................................................3-30
HEADLIGHT BULB REPLACEMENT ............................................................................................3-30
TURN SIGNAL AND TAILLIGHT BULB REPLACEMENT ........................................................... 3-31
TAILLIGHT BULB REPLACEMENT .............................................................................................. 3-32
LICENSE LIGHT BULB REPLACEMENT ...................................................................................... 3-32
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CHAPTER 4.
ENGINE
ENGINE OVERHAUL ......................................................................................................................... 4-1
WlREHARNESS AND CABLES ...................................................................................................... 4-1
CYLINDER HEAD, CYLINDER AND PISTON .................................................................................... 4-3
CYLINDER HEAD, CYLINDER AND PISTON ................................................................................ 4-3
PISTON PIN AND PISTON REMOVAL .......................................................................................... 4-4
CYLINDER HEAD INSPECTION ..................................................................................................... 4-4
CYLINDER AND PISTON INSPECTION ........................................................................................ 4-5
PISTON RINGS INSPECTION ........................................................................................................ 4-7
PISTON PIN AND PISTON PIN BEARING .................................................................................... 4-7
PISTON PIN AND PISTON INSTALLATION ................................................................................. 4-8
CYLINDER AND CYLINDER HEAD ................................................................................................ 4-9
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ........................................................... 4-1 1
KICK STARTER AND CRANKCASE COVER(LEFT) ..................................................................... 4-1 1
KICK STARTER ............................................................................................................................. 4-12
KICK STARTER INSTALLATION ................................................................................................. 4-13
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ........................................................ 4-14
SECONDARY SHEAVE ................................................................................................................ 4-15
PRIMARY SHEAVE REMOVAL .................................................................................................... 4-16
SECONDARY SHEAVE REMOVAL .............................................................................................. 4-16
CLUTCH INSPECTION ................................................................................................................. 4-17
V-BELT INSPECTION ................................................................................................................... 4-18
PRIMARY SHEAVE INSPECTION ................................................................................................ 4-19
SECONDARY SHEAVE ................................................................................................................ 4-20
SECONDARY SHEAVE INSTALLATION ..................................................................................... 4-21
PRIMARY SHEAVE ...................................................................................................................... 4-22
STARTER CLUTCH AND STARTER MOTOR ................................................................................. 4-24
STARTER CLUTCH AND STARTER MOTOR .............................................................................. 4-24
STARTER CLUTCH AND GEARS INSPECTION ......................................................................... 4-26
C.D.I. MAGNET ................................................................................................................................ 4-27
C.D.I. MAGNETO ......................................................................................................................... 4-27
C.D.I. MAGNETO REMOVAL ....................................................................................................... 4-28
C.D.I. MAGNETO INSTALLATION .............................................................................................. 4-28
AUTOLUBE PUMP ........................................................................................................................... 4-29
AUTOLUBE PUMP ....................................................................................................................... 4-29
AUTOLUBE PUMP INSTALLATION ........................................................................................... 4-30
TRANSMISSION .............................................................................................................................. 4-31
TRANSMISSION .......................................................................................................................... 4-31
CRANKCASE AND REED VALVE .................................................................................................... 4-33
CRANKCASE AND REED VALVE ................................................................................................ 4-33
CRANKCASE(RIGHT) REMOVAL ................................................................................................ 4-35
CHECKING THE CRANKCASE .................................................................................................... 4-35
CHECKING THE BEARINGS AND OIL SEALS ............................................................................ 4-35
REED VALVE INSPECTION ......................................................................................................... 4-36
CRANKCASE (RIGHT) INSTALLATION ...................................................................................... 4-36
CRANKSHAFT .................................................................................................................................. 4-38
CRANKSHAFT .............................................................................................................................. 4-38
CRANKSHAFT REMOVAL ........................................................................................................... 4-39
CRANKSHAFT INSPECTION ....................................................................................................... 4-39
CRANKSHAFT INSTALLATION ................................................................................................... 4-40
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CHAPTER 5
CARBURETION
CARBURETION .................................................................................................................................. 5-1
CARBURETOR ................................................................................................................................ 5-1
CABURETOR DISASSEMBLY ....................................................................................................... 5-2
CABURETOR INSPECTION ........................................................................................................... 5-3
CARBURETOR ASSEMBLY ........................................................................................................... 5-5
FUEL LEVEL ADJUSTMENT ......................................................................................................... 5-6
AUTO CHOKE INSPECTION .......................................................................................................... 5-7
FUEL COCK INSPECTION ............................................................................................................. 5-8
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CHAPTER 6
CHASSIS
FRONT WHEEL AND BRAKE DISC ................................................................................................... 6-1
FRONT WHEEL AND BRAKE DISC ............................................................................................... 6-1
FRONT WHEEL DISASSEMBLY .................................................................................................... 6-2
FRONT WHEEL DISASSEMBLY .................................................................................................... 6-3
FRONT WHEEL INSPECTION ........................................................................................................ 6-3
BRAKE DISC INSPECTION ............................................................................................................ 6-4
FRONT WHEEL ASSEMBLY .......................................................................................................... 6-4
FRONT WHEEL INSTALLATION ................................................................................................... 6-5
WHEEL STATIC BALANCE ADJUSTMENT .................................................................................. 6-6
FRONT BRAKE ................................................................................................................................... 6-8
BRAKE PAD .................................................................................................................................... 6-8
BRAKE PAD REPLACEMENT ........................................................................................................ 6-9
MASTER CYLINDER ........................................................................................................................ 6-12
MASTER CYLINDER DISASSEMBLY ............................................................................................. 6-13
MASTER CYLINDER INSPECTION .............................................................................................. 6-14
MASTER CYLINDER ASSEMBLY ................................................................................................ 6-14
MASTER CYLINDER INSTALLATION ......................................................................................... 6-15
CALIPER ........................................................................................................................................... 6-17
CALIPER DISASSEMBLY ................................................................................................................. 6-18
BRAKE CALIPER DISASSEMBLY ................................................................................................ 6-19
CALIPER INSPECTION ................................................................................................................. 6-19
BRAKE CALIPER ASSEMBLY ...................................................................................................... 6-20
BRAKE CALIPER INSTALLATION ............................................................................................... 6-20
REAR WHEEL AND REAR BRAKE .................................................................................................. 6-21
REAR WHEEL ............................................................................................................................... 6-21
REAR BRAKE ................................................................................................................................ 6-22
REAR WHEEL INSPECTION ........................................................................................................ 6-23
REAR BRAKE INSPECTION ......................................................................................................... 6-23
REAR BRAKE INSTALLATION .................................................................................................... 6-24
HANDLEBAR .................................................................................................................................... 6-25
HANDLEBAR ................................................................................................................................ 6-25
HAN DLE BAR INSTALLATIO N ..................................................................................................... 6-27
STEERING ........................................................................................................................................ 6-29
STEERING .................................................................................................................................... 6-29
STEERING REMOVAL ................................................................................................................. 6-30
STEERING INSPCTION ................................................................................................................ 6-31
STEERING INSTALLATION ......................................................................................................... 6-31
FRONT FORK ................................................................................................................................... 6-34
FRONT FORK ............................................................................................................................... 6-34
FRONT FORK DISASSEMBLY ..................................................................................................... 6-35
FRONT FORK REMOVAL ............................................................................................................. 6-36
FRONT FORK DISASSEMBLY ..................................................................................................... 6-36
FRONT FORK INSPECTION ......................................................................................................... 6-37
FRONT FORK ASSEMBLY ........................................................................................................... 6-37
FRONT FORK INSTALLATION .................................................................................................... 6-39
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CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS ............................................................................................................ 7-1
ELECTRICAL COMPONENTS ........................................................................................................ 7-1
CIRCUIT DIAGRAM ........................................................................................................................ 7-2
CHECKING SWITCHES ...................................................................................................................... 7-4
CHECKING STEPS ......................................................................................................................... 7-4
SWITCH CONNECTION AS SHOWN IN THIS MANUAL ............................................................. 7-4
SWITCH POSITION AND TERMINAL CONNECTION ...................................................................... 7-5
CHECKING THE BLUBS AND BULB SOCKETS ............................................................................... 7-5
CHECKING THE BULBS AND BULB SOCKETS ........................................................................... 7-6
TYPES OF BULBS .......................................................................................................................... 7-6
CHECKING THE CONDITION OF THE BULBS .............................................................................. 7-7
CHECKING THE CONDITION OF THE BULB SOCKETS .............................................................. 7-8
IGNITION SYSTEM ............................................................................................................................ 7-9
CIRCUIT DIAGRAM ........................................................................................................................ 7-9
TROUBLESHOOTING .................................................................................................................. 7-10
CHARGING SYSTEM ....................................................................................................................... 7-14
CIRCUIT DIAGRAM ...................................................................................................................... 7-14
TROUBLESHOOTING .................................................................................................................. 7-15
ELECTRIC STARTING SYSTEM ...................................................................................................... 7-18
CIRCUIT DIAGRAM ...................................................................................................................... 7-18
TROUBLESHOOTING .................................................................................................................. 7-19
STARTER MOTOR ....................................................................................................................... 7-22
STARTER MOTOR DISASSEMBLY ............................................................................................. 7-23
INSPECTION AND REPAIR .......................................................................................................... 7-24
LIGHTING SYSTEM ......................................................................................................................... 7-26
CIRCUIT DIAGRAM ...................................................................................................................... 7-26
TROUBLESHOOTING .................................................................................................................. 7-27
LIGHTING SYSTEM CHECK ........................................................................................................ 7-29
SIGNAL SYSTEM ............................................................................................................................. 7-33
CIRCUIT DIAGRAM ...................................................................................................................... 7-33
TROUBLESHOOTING .................................................................................................................. 7-34
SIGNAL SYSTEM CHECK ............................................................................................................ 7-36
AUTO CHOKE SYSTEM .................................................................................................................. 7-42
CIRCUIT DIAGRAM ...................................................................................................................... 7-42
TROUBLESHOOTING .................................................................................................................. 7-43
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CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ........................................................................................... 8-1
FUEL SYSTEM ............................................................................................................................... 8-1
IGNITION SYSTEM ........................................................................................................................ 8-2
COMPRESSION SYSTEM ............................................................................................................. 8-2
POOR IDLE SPEED PERFORMANCE ................................................................................................ 8-3
POOR IDLE SPEED PERFORMANCE ............................................................................................ 8-3
POOR MIDIUM AND HIGH SPEED PERFORMANCE ....................................................................... 8-3
POOR MIDIUM AND HIGH SPEED PERFORMANCE ................................................................... 8-3
FULTY AUTOMATIC(V-BELT TYPE) ................................................................................................. 8-4
SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING .................................................. 8-4
CLUTCH OUT FAILURE ................................................................................................................. 8-4
POOR STANDING START(LOW CLIMBING ABILITY) ................................................................. 8-4
POOR ACCELERATION(POOR HIGH SPEED) .............................................................................. 8-4
OVER HEAT ........................................................................................................................................ 8-5
OVERHEAT ..................................................................................................................................... 8-5
POOR SPEED ..................................................................................................................................... 8-5
POOR SPEED ................................................................................................................................. 8-5
IMPROPER KICKING .......................................................................................................................... 8-6
SLIPPING ........................................................................................................................................ 8-6
HARD KICKING .............................................................................................................................. 8-6
KICK CRANK NOT RETURNING ................................................................................................... 8-6
FAULTY BRAKE ................................................................................................................................. 8-7
POOR BRAKING EFFECT ............................................................................................................... 8-7
MALFUNCTION ............................................................................................................................. 8-7
INSTABLE HANDLING ...................................................................................................................... 8-8
INSTABLE HANDLING .................................................................................................................. 8-8
FAULTY SIGNAL AND LIGHTING SYSTEM .................................................................................... 8-9
HEADLIGHT DARK ......................................................................................................................... 8-9
BULB BURNT OUT ........................................................................................................................ 8-9
FLASHER DOES NOT BLINK ......................................................................................................... 8-9
FLASHER KEEPS ON ..................................................................................................................... 8-9
FLASHER BLINKS SLOWER ........................................................................................................ 8-10
FLASHER BLINKS QUICKER ....................................................................................................... 8-10
HORN DOES NOT SOUND ......................................................................................................... 8-10
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SCOOTER INDENTIFICATION
I GEN
f
f EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number (~) is stamped
into the frame.
EAS00018
MODEL CODE
The model code label ~) is affixed to the loca-
tion shown in the figure. Record the informa-
tion on this label in the space provided. This
information will be needed to order spare parts.
1-1
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IMPORTANT INFORMATION I GEN
300-008
300-016
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISAS-
SEMBLY
1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to "SPECIAL TOOLS".
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have
been
"mated" through normal wear. Mated
parts must always be reused or replaced
as an assembly.
4. During disassembly, clean all ofthe parts
and place them in trays in the order of dis-
assembly. This will speed up assembly
and allow for the correct installation of all
parts.
5. Keep all parts away from any source of
fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recom-mended by
Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mat-
ing parts and bearings and lubricate the
oil seal lips with grease.
EAS00023
LOCK WASHERS/PLATES AND COTTER PINS
After removal, replace all lock washers/plates
~)and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat ofthe bolt or nut.
1-2
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IMPORTANT INFORMATION I GEN
,NFOI I
~\\\\\\\\~1
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu
facturer's marks or numbers are visible. When
installing oil seals, lubricate the oil seal lipswith
a light coat of lithium soap base grease.
Oil bearings liberally when installing, if appro
priate.
~) Oil seal
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
(~ Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips,
Always replace piston pin clips after one use.
When installing a circlip (~), make sure the
sharp-edged corner (~) is positioned opposite
the thrust ~ that the circlip receives.
(~ Shaft
1-3
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IMPORTANT INFORMATION I GEN
EB801000
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
• Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two
or three.
4. Pull the read to checkthat it will not come
off.
5. If the terminal comes off, bend up the pin
(~ and reinsert the terminal into the con-
Rector.
6. Connect:
• Connector
NOTE:
The two connectors "click" together.
7. Check for continuity with a tester.
NOTE:
• If there is no continuity, clean the termi-
nals.
• Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
• For a field remedy, use a contact revitalizer
available on the market.
• Use the tester on the connector as shown.
1-4
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HOW TO USE THE CONVERSION TABLE
I GEN
EB201000
HOW TO USE THE CONVERSION TABLE
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.
Ex.
METRIC MULTIPLIER IMP
** mm x 0.03937 = ** in
2 mm x 0.03937 = 0.083 in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
m.kg 7.233 ft.lb
Torque m.kg 86.794 in.lb
cm.kg 0.0723 ft.lb
cm.kg 0.8679 in.lb
Weight kg 2.205 Ib
g 0.03527 oz
Distance
Volume/
Capacity
Miscellaneous
km/h
km
m
m
ca
mm
cc(cm3)
cc(cm3)
lit(liter)
lit(liter)
kg/mm
kg/cm2
Centigrade
0.6214
0.6214
3.281
1.094
0.3937
0.03937
0.03527
0.06102
0.8799
0.2199
55.997
14.2234
9/5(°C)+32
mph
mi
ft
yd
in
in
oz (IMP liq.)
cu.in
qt(IMP liq.)
gal(IMP liq.)
Ib/in
psi(Ib/in2)
Fahrenheit (°F)
1-5
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