User manual YAMAHA YN50-2002 SERVICE MANUAL

[. . . ] YN505 2002 RN-AE1 SERVICE MANUAL YN50 SERVICE MANUAL © 2002 Yamaha Motor España, S. A. First Edition, September 2002 All rights reserved. The reprinting or use of this material without the written authorisation of Yamaha Motor España, S. A is forbidden. Printed in Spain. WARNING This Manual was written by Yamaha Motor España, S. A. [. . . ] Install: · Clutch positioning bolt Use the clutch spring compressor Clutch spring compressor 90890-01337 6. Tighten: · Clutch positioning nut Use the pulley wheel clamp Spanner (41 MM). Pulley wheel clamp 90890-01701 5. 0 m · kg 4-31 ASSEMBLY AND ADJUSTMENT OF ENGINE MOT 7. Install: · Conical pin · Crankcase cover seal · Secondary pulley wheel assembly · Clutch drum 8. Tighten: · Nut (secondary pulley wheel) Use the pulley wheel support Pulley wheel clamp 90890-01701 Clutch drum nut 4. 0 m · kg 9. Install · O-ring PRIMARY PULLEY WHEEL 1. Clean: · Surface of primary sliding pulley wheel · Surface of primary fixed pulley wheel · Hubs · Rollers · Roller races 2. Install: · Counterbalance · Race · Runner · Hub 3. Check: · Operation of race Rough operation Repair. 4. Install: · Primary pulley wheel assembly · Hub 5. Install: · Trapezoidal belt NOTE: The trapezoidal belt should be installed with the arrow facing towards the front. 4-32 ASSEMBLY AND ADJUSTMENT OF ENGINE MOT 6. Install: · Shim · Primary fixed pulley wheel · Washer · One-way clutch · Conical spring washer · Nut 7. Tighten: · Nut (primary pulley wheel) Primary pulley wheel nut 3, 3 m · kg NOTE: When the nut is tightened (primary pulley wheel), support the magnetic flywheel using the engine wheel support tool Engine wheel support tool 90890-01235 8. Adjust: · Trapezoidal belt Tense the trapezoidal belt by turning the primary pulley wheel several times 9. Install: · Fan Screw (fan) 0. 7 m · kg KICKSTART PEDAL 1. Install: · Return spring · Pedal axle · Bushing · Flat washer · Elastic circlip 4-33 ASSEMBLY AND ADJUSTMENT OF ENGINE 2. Hook on: · Return spring (on pedal gear and hub) 3. Install: · Pedal pinion gear MOT 4. Install: · Crankcase cover Screw (crankcase cover) 7 Nm (0. 7 m · kg) 5. Install: · Kickstart pedal Kickstart pedal 0. 9 m · kg 4-34 ASSEMBLY AND ADJUSTMENT OF ENGINE PISTON, CYLINDER AND CYLINDER HEAD MOT Carburettor gasket Reed valve Gasket Cylinder head Cylinder head gasket Cylinder Cylinder seal Piston rings Piston k Piston pin 10 k Circlips 11 k Bearing 12 CLEARANCE FROM PISTON TO CYLINDER: 0. 034 ~ 0. 047 mm Limit: 0. 1 mm BETWEEN ENDS (INSTALLED): Top ring 0. 15 ~ 0. 35 mm Limit: 0. 60 mm Second ring 0. 15 ~ 0. 35 mm Limit: 0. 60 mm LATERAL CLEARANCE: Top ring 0. 03 ~ 0. 05 mm Limit 0. 10 mm Second ring 0. 03 ~ 0. 05 mm Limit 0. 10 mm SPARK PLUG MANUFACTURER/TYPE: NKG/BR7HS GAP BETWEEN ELECTRODES 0. 06 ~ 0. 7 mm 4-35 ASSEMBLY AND ADJUSTMENT OF ENGINE MOT 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 · Carburettor gasket Carburettor gasket 0. 9 m · kg 3. [. . . ] CONTINUITY 2. Oil level switch · Remove the oil sump oil level switch. · Connect the pocket tester (x1) on the oil level switch. Cable (+) of tester Cable (­) of tester Terminal Terminal NO CONTINUITY ELEC OUTSIDE SPECIFIED VALUE The connection circuit from the "TURN" switch to the bulb holder connector is defective, review. Change the bulb and/or bulb receptacle. · Check the oil level measurer for continuity. Switch position A Vertical position upwards B Reverse position : Continuity Good condition x Bad condition x POOR CONDITION x x Change the oil level switch. x: No continuity GOOD CONDITION 3. [. . . ]