User manual YAMAHA YP211

[. . . ] It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. Repairs attempted by anyone without this knowledge are likely to render the scooter unsafe and unfit for use. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. [. . . ] Replace. 4-33 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE YP****** ENG PRIMARY SHEAVE ASSEMBLY 1. Clean: S Primary sliding sheave face 1 S Primary fixed sheave face 2 S Collar 3 S Weight 4 S Primary sliding sheave cam face 5 NOTE: Remove any excess grease. Install: S Weight 1 S Collar 2 NOTE: D Apply Shell BT grease No. 3 (90890-69927) to the all of the outside of the weight and install. 3 (90890-69927) to the inside of the collar. Install: S Spacer 1 S Slider 2 S Cam 3 S Primary sliding sheave cap. 3 Nm (0. 3 mSkg) SECONDARY SHEAVE INSTALLATION 1. Apply: S BEL-RAY assembly lube® (to the secondary sliding sheave 1 inner surface, grease nipple groove, and oil seals) S BEL-RAY assembly lube® (to the bearings, oil seals and inner surface of the secondary fixed sheave 2 ) 2. Install: S Secondary sliding sheave 1 NOTE: Install the secondary sliding sheave 1 using the oil seal guide 2 to the secondary fixed sheave 3 . Oil seal guide: 90890-01384 4-34 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 3. Apply: S BEL-RAY assembly lube® (to the guide pin sliding groove 1 , and ) and oil seal 2 5. Install: S Secondary sheave complete 1 S Compression spring S Clutch carrier 2 NOTE: Temporarily tighten the nut 5 while attaching the clutch spring holder 3 and clutch spring holder arm 4 and compress the spring. CAUTION: Use the spacer 6 (ø 30 mm, thickness: X 3 mm). Clutch spring holder: 90890-01337 Clutch spring holder arm: 90890-01464 6. If necessary, one holding bolt maybe turned out slightly to adjust the flywheel puller's position. CAUTION: Cover the crankshaft end with the box wrench for protection. Flywheel puller: 90890-01362 4-39 A. C. MAGNETO AND STARTER CLUTCH YP402163 ENG STARTER DRIVE GEAR INSPECTION 1. Inspect: S Starter idle gear teeth S Starter drive gear teeth S Starter wheel gear teeth Burrs/chips/roughness/wear !Check: S Starter clutch operation Push the dowel pins to the arrow direction. ***************************************************** Checking steps: D Hold the starter clutch. D When turning the starter wheel gear clockwise A , the starter clutch and the starter wheel gear should be engaged. D When turning the starter wheel gear counterclockwise, B , it should turn freely. ***************************************************** YP404131 A. C. Install: S Starter wheel gear 1 S Woodruff key 2 NOTE: Install the starter wheel gear 1 , then install the woodruff key 2 . Install: S Plain washer S Rotor 1 NOTE: D Clean the tapered portion of the crankshaft and the rotor hub. D When installing the magneto rotor, make sure the woodruff key is properly seated in the key way of the crankshaft. 4-40 A. C. [. . . ] Never subject it to strong shocks or allow it to be dropped. Should it be dropped, it must be replaced. S Do not touch the thermo switch to bottom of the heated vessel. OUT OF SPECIFICATION More than 68_C 75"3_C A Thermo switch on. B Thermo switch off. Replace the thermo switch. CORRECT : 8-46 AUTO CHOKE SYSTEM : YP****** ELEC 6. [. . . ]