User manual YAMAHA YSR50T SERVICE MANUAL

[. . . ] @YAM AHA Service YS R5OT SERVICE MANUAL 01987 by Yamaha Motor Corporation, U. S. A. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U. S. A. LIT-Il616-O6-05 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 motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. [. . . ] Install: @Kickaxle assembly : 1 eMake sure that the kick stopper is sto n epf the crankcase. Hook the kick spring @). 3, Install: @Kickidle gear @Washers@ a @ @ @ Circlip Shift lever Rotor @ Return spring @ Pin Oil seal @ Kick crank @ 0 Collar @ Return spring 0 Kick axle Kick idle gear IMAWY DRIVE GEAR I . Install: primary drive gear @ oThrust washer @ ~Gonical spring washer NOTE: e sure to install the conical spring was as shown. Tighten: o N u k (Primary drive gear) NOTE: - - etween the teeth of the - 3. Install: @Thrust washer @Clutchboss Q a 13 e sure to install the conical spring washer as shown. 4. Tighten: nut (Clutch boss) niversal Clutch clutch boss. a older @ to hold 5. Install: lutch damper Q and f r i c t i ~ n plate alter- friction plate and second clutch damper. . Tighten the bolts in stages, using a crisscross pattern. @Gasket(Crankcase cover-New) @ Tighten the screws in stages, using a crisscross A @ @ @ @ Straight key @ Clutch boss @ @ @ @ @ Primary drive gear 0 Clutch damper Friction plate Clutch plate Cushion spring Conical spring washer Push rod # 1 Pressure plate Conical spring washer Push rod # 2 Ball @ Thrust washer Collar @ O-ring @ Clutch housing a @ 0 To the small end bearin bearing. the crankcase. - Asways use a new piston pin d i p . 4. Install: Install the cylinder with one ha d while compressing the piston rings wit the other hand. Tighten the nuts in stages, using a crisscross 7. Install: a Cylinder(Cylinder head) head @ Gasket @ @ @ Spark plug Cylinder Gasket (Cylinder) Vkl A Note the following points. Install: Engine assembly Q efore installing t e drive sprocket, loosen the rear wheel axle and push forward the rear wheel. - Tighten the screws in stages, using a crisscross pattern. . , p - P rive chain slack @ ENT" section. Adjust: @Throttle cable free play @ @ @ @ a Spring (Throttle valve) Jet needle assembly Throttle valve Throttle stop screw Pilot screw Starter plunger Pilot jet @ Main jet @ Valve seat assembly 0 Float @ Pin (Float) @ Float chamber @ Drain screw Float height REb?QOAk MOTE : - -- , . The fallov2;ir-g parts can be cleaned and inspected without carburetor disassern "Pilot screw 0 Lower cowling Refer s "'CHA o sectioja. 2 , Turn the fuel cock to "OFF" piaskion and disconnect the fuel hose a. 3, Loosen: Screws (Carburetor joint) 4" Eernove: srburetor assembly a DiSASSEMBL?!Remove: tarter plunger throttle stop screw @ pilot screw g ] I . Inspect: @Carburetorbody @Fuelpassage Contamination-~Clean indicated. Inspect @Float amage+ Replace. Inspect: o Needle va!ve @Valveseat @ @Gasket@ amage/Wear/Contamination+ Replace. -: - Always replace the needle valve and valve seat as a set. 4. Check: Free movement Insert the throttle valve into the carburetor body, and check for free movement. Inspect: @Clipposition 7 . Inspect: @Starterplunger @ @Throttle stop screw @ everse the disassemby procedure. Measure: ut of specification+Adjust. 5-5 _ _p __ _ _ _ n __ l _ - - Float height measurement an the carburetor in an up sition. measure the distance between the w valve, but not cormpressing the needle valve. olf h e float height is nor within specification, insped the valve seat and needle valve. [. . . ] Tester ( ) Lead-+Terminal @ Tester ( - 1 Lead-+Terminal @ + *Check the bulb for continuity 1 Bulb is faulty, replace it. I 2. Neutral switch check #Disconnect the CDI magneto coupler (Sky blue, White, Black and YellowIRed) from the wireharness. Tester ( + ) Lead+Sky blue @ Lead Tester ( - ) Lead+Black @ Lead DISPLAY SYSTEM . Shift the transmission in neutral and gear. . Check the neutral switch for continuity. 1 I ELEC I E ( l Transmission position Neutral Gear I Good condition BAD CONDITION Bad condition 0 x x x 101 x I x / 0 0 Neutral switch is faulty, replace it. I 0: Continuity : Nocontinuity GOOD CONDITION 3. [. . . ]