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BODYWORK DISASSEMBLY SEQUENCE 1) REMOVING SEAT (1) Unscrew and remove the nut (2) located under the seat (1) 2) REMOVING RIGHT-HAND (4) AND LEFT-HAND (5) AIR-SCOOPS Unscrew and remove the two screws (3) securing the air-scoops (4),(5). Unscrew and remove the two screws (6) connecting the air-scoops (4),(5), to the radiator grille (7). 3) REMOVING RADIATOR GRILLE (7) Unscrew and remove the screw (8) connecting the radiator grille (7) to the frame. Unscrew and remove the two screws (6) connecting the air-scoops (4),(5), to the radiator grille (7). Remove the radiator grille, (7) pulling it downwards, with the handlebars turned to one side. 4) REMOVING LEFT-HAND (9) AND RIGHT-HAND (10) SIDEPANELS Unscrew and remove the screw (11) holding the sidepanel (9),(10) to the frame. 6) REMOVING TAILPIECE (17) Remove the seat (1), following the procedure “REMOVING SEAT”. Unscrew and remove the two bolts (14), being careful of the corresponding nuts (15) on the underside. Unscrew and remove the two screws (16) securing the tailpiece (17). 7) REMOVING NUMBERPLATE BRACKET (18) Remove the seat (1), following the procedure “REMOVING SEAT”. Remove the tailpiece (17), following the procedure “REMOVING TAILPIECE”. Unscrew and remove the three screws (19) Disconnect the rear indicator connectors (Table 4) Disconnect the tail lamp connector block (Table 4) (the connector block is located above the battery). 8) REMOVING HEADLAMP COWLING (20) Unhook the two O-rings (21). Remove the headlamp cowling (20) by pulling it downwards. Disconnect the headlamp connectors (Table 4). 14) REMOVING FUEL TANK (38) Remove the seat, following the procedure “REMOVING SEAT (1)”. Remove the right-hand and left-hand air-scoops, following the procedure “REMOVING RIGHT-HAND (4) AND LEFT-HAND (5) AIRSCOOPS”. Unscrew and remove the central bolt (39) holding the tank (38) to the frame. Unscrew and remove the two side bolts (40). Turn off the fuel tap (41) located under the fuel tank (38). Disconnect the tank/carburettor fuel hose (Table 5). 17 2 46 43 16 39 19 48 19 15) REMOVING RIGHT-HAND (43), AND LEFT-HAND (44) HANDGUARDS AND RIGHT-HAND (45), AND LEFT-HAND (46) MIRRORS Unscrew and remove the nuts (47) which secure the rear view mirrors (45),(46); Remove the mirrors, followed by the handguards (43),(44). 47 20 44 47 21 21 15 38 10 16) REMOVING HANDLEBARS (48) Remove the rear view mirrors (45),(46) and the handguards (43),(44), following the procedure “REMOVING RIGHT-HAND (43), AND LEFTHAND (44) HANDGUARDS AND RIGHT-HAND (45), AND LEFTHAND (46) MIRRORS”. Remove the front brake master cylinder (Table 3). Unscrew and remove the two screws (35) (Table 5), Remove the twistgrip (34) (Table 5) Unscrew and remove the screw (36) (Table 5); remove the left-hand handlebar switch (37) (Table 5) Remove the handlebar clamps (9) after unscrewing and removing the four screws (8) (Table 2) 41 18 11 40 12 22 40 13 4 23 36 36 30 35 28 24 26 42 6 29 11) REMOVING CHAINGUARD (31) Unscrew and remove the two screws (32) 13) REMOVING SHOCKABSORBER SHROUD (35) Remove the sidepanels, following the procedure “REMOVING LEFTHAND (9) AND RIGHT-HAND (10) SIDEPANELS”. Unscrew and remove the two screws (36), taking particular note, especially when reassembling, of the earth lead (42) located under the left-hand screw. Unscrew and remove the screw (37). 14 1 10) REMOVING RIGHT-HAND (24), AND LEFT-HAND (25) FORK SHROUDS Unscrew and remove the two screws (26) In the case of the left-hand fork shroud (25) unscrew and remove the screw (27), being careful of the corresponding nut on the inside (30), to disengage the front brake hose. In the case of the right-hand fork shroud (24) unscrew and remove the screw (28) being careful of the corresponding nut on the inside (29) to disengage the tachometer cable. 12) REMOVING FRONT SPROCKET COVER (33) Unscrew and remove the two screws (34). 5) REMOVING TOOLBOX (12) Unscrew and remove the two screws securing the toolbox (12). 45 9) REMOVING FRONT FENDER (22) Unscrew and remove the four bolts (23) Remove the front fender (22) 37 27 9 7 25 REASSEMBLY 11 3 31 33 26 For reassembly, reverse the order of operations for dismantling. 8 6 3 5 34 32 RELEASE 00 2002 - 10 MX 50 BODYWORK Chap.6 TABLE 01 FRONT FORKS - SWINGING ARM DISASSEMBLY SEQUENCE 1) REMOVING FRONT FORK ASSEMBLY (1) Support the motorcycle securely to avoid the risk of personal injury and damage to the motorcycle itself. Unscrew and remove the screws and remove the right-hand and left-hand fork shrouds, following the procedure “REMOVING RIGHT-HAND (24), AND LEFTHAND (25) FORK SHROUDS” (Table 1) Remove the front brake caliper, following the first part of the procedure “REMOVING FRONT BRAKE SYSTEM (1)” (Table 3). Remove the front wheel spindle and the front wheel, following the procedure “REMOVING FRONT WHEEL (18)” (Table 3). Remove the headlamp cowling, following the procedure “REMOVING HEADLAMP COWLING (20)” (Table 1). Remove the direction indicator brackets, following the procedure “REMOVING RIGHT-HAND (16) AND LEFT-HAND (17) DIRECTION INDICATORS” (Table 4). Slack off the pinchbolt (3) in the fork top yoke (2). Slack off the pinchbolts (5) in the fork bottom yoke (4). Slide out the right-hand (6), or the left-hand (7), fork leg as necessary. Carry out the last three stages in the procedure first for one fork leg then for the other. 2) REMOVING SHOCKABSORBER (11) Remove the fuel tank, following the procedure “REMOVING FUEL TANK (38)” (Table 1). Remove the right-hand sidepanel, following the procedure “REMOVING LEFTHAND (9) AND RIGHT-HAND (10) SIDEPANELS” (Table 1). Support the rear end of the motorcycle securely to avoid the risk of personal injury and damage to the motorcycle itself. Unscrew and remove the bolt (12) holding the shockabsorber (11) to the frame (10), being careful of the corresponding nut (13) and the bush (14). Attention: when reassembling, grease the bush (14). Unscrew and remove the bolt (15) connecting the shockabsorber (11) to the suspension rocker-arm (18), being careful of the corresponding nut (16) and the needle-roller bearing (17). Attention: when reassembling, grease the needle-roller bearing (17). Remove the shockabsorber (11). 1 13 12 14 8 9 11 10 8 15 9 16 2 18 3 17 24 21 3 19 20 25 5 4 34 22 5 28 7 31 35 26 29 30 36 38 37 33 4) REMOVING SWINGING ARM (26) Support the rear end of the motorcycle securely to avoid the risk of personal injury and damage to the motorcycle itself. Slack off the rear wheel spindle (Table 3) so that the wheel can slide forward, creating enough slack in the chain to allow it to be taken off the front sprocket (Table 3). If it is necessary to remove the rear wheel, follow the procedure “REMOVING REAR WHEEL (24)” (Table 3). Unscrew and remove the centre bolt (22) of the suspension rockerarm (18), being careful of the corresponding nut (20) and the needleroller bearing (21). Attention: when reassembling, grease the needle-roller bearing (21). Unscrew and remove the bolt (24) connecting the suspension linkarm (19) to the frame (10), being careful of the nut (23) and the spacer (25). Attention: when reassembling, grease the spacer (25). Unscrew and remove the long pivot bolt (27) connecting the swinging arm (26) to the frame (10), being careful of the spacer (29) and the bushes (28). Attention: when reassembling, grease the bushes (28). Remove the swinging arm (26). 5) REMOVING SIDESTAND (30) Remove the spring assembly (31). Unscrew and remove the nut (32), being careful of the bolt (33). Attention: when reassembling, grease the bolt and apply Loctite 243 to the threads of the nut. Remove the sidestand (30). 23 6 3) REMOVING SUSPENSION ROCKER-ARM (18) AND LINK-ARM (19) Support the rear end of the motorcycle securely to avoid the risk of personal injury and damage to the motorcycle itself. Remove the shockabsorber (11), following the procedure “REMOVING SHOCKABSORBER (10)”. Unscrew and remove the centre bolt (22) of the suspension rockerarm (18), being careful of the corresponding nut (20) and the needleroller bearing (21). Attention: when reassembling, grease the needle-roller bearing (21). Unscrew and remove the bolt (24) connecting the suspension linkarm (19) to the frame (10), being careful of the nut (23) and the spacer (25). Attention: when reassembling, grease the spacer (25). Remove the suspension rocker-arm (18) and the link-arm (19) as a unit. 28 27 6) REMOVING RIGHT-HAND (34) AND LEFT-HAND (35) FRONT FOOTRESTS Unscrew and remove the bolt (36), being careful of the corresponding nut (37) and of the spring (38). Remove the front footrest (34) or (35). Repeat the procedure for the other footrest. 32 REASSEMBLY For reassembly, reverse the order of operations for dismantling. RELEASE 00 2002 - 10 MX 50 FRONT FORKS - SWINGING ARM Chap.6 TABLE 02 FRONT/REAR BRAKES - FRONT/REAR WHEEL DISASSEMBLY SEQUENCE 2) REMOVING REAR BRAKE SYSTEM (9) Remove the right-hand sidepanel, following the procedure “REMOVING LEFTHAND (9) AND RIGHT-HAND (10) SIDEPANELS” (Table 1). Remove the clip (10) connecting the rear master-cylinder (11) to the rear brake lever (12). Disconnect the stop-switch harness. Undo the hose-clips on the swinging arm. Unscrew the two screws (13). Remove the rear brake caliper (14). Unscrew and remove the screws (15) holding the rear master-cylinder reservoir (16). Unscrew the bolts (17) securing the rear master-cylinder (11). Remove the complete rear brake system (9). 1) REMOVING FRONT BRAKE SYSTEM (1) Disengage the front brake hose (2) from the upper hose guide (3) located on the indicator bracket (Table 4). Disengage the front brake hose (2) from the guide fitted to the left-hand fork shroud, and remove the shroud itself, following the procedure “REMOVING RIGHT-HAND (24), AND LEFT-HAND (25) FORK SHROUDS” (Table 1). Unscrew and remove the two bolts (4). Remove the front brake caliper (5). Remove the right-hand handguard, following the procedure “REMOVING RIGHT-HAND (43), AND LEFT-HAND (44) HANDGUARDS AND RIGHTHAND (45), AND LEFT-HAND (46) MIRRORS” Disconnect the front stop-switch harness (Table 4). Unscrew and remove the two screws (6) and remove the mounting bracket (7) for the front master-cylinder (8). Remove the complete front brake system (1). NOTE: please have the sense to keep the master-cylinder higher than the caliper at all times. NOTE: please have the sense to keep the master-cylinder higher than the caliper at all times. 3) REMOVING FRONT WHEEL (18) Remove the right-hand and left-hand fork shroud, following the procedure “REMOVING RIGHT-HAND (24), AND LEFT-HAND (25) FORK SHROUDS (25)” (Table 1). Unscrew and remove the front wheel spindle (19), paying particular attention to the order in which the following parts are fitted: speedometer drive (20), bearings (21), spacer (22), spacer (23). Attention: Grease when reassembling. Remove the front wheel (18). 4) REMOVING REAR WHEEL (24) Unscrew and remove the rear wheel spindle (25) (Table 3), paying particular attention to the order in which the following parts are fitted: self-locking nut (26), plain washers (27), chain adjusting plates (28), spacer (29), brake caliper mounting plate (30), spacer (31), bearings (32), spacer (33). Attention: Grease when reassembling. Take the chain (34) off the rear sprocket (35). Attention: Grease when reassembling. Remove the rear wheel (24). 16 8 9 15 11 17 6 7 13 25 10 14 27 28 29 31 12 24 18 30 33 19 35 20 32 21 2 22 32 3 4 1 28 5 21 27 26 23 REASSEMBLY 4 For reassembly, reverse the order of operations for dismantling. 34 RELEASE 00 2002 - 10 MX 50 FRONT/REAR BRAKES - FRONT/ REAR WHEEL Chap.6 TABLE 03 ELECTRICAL SYSTEM DISASSEMBLY SEQUENCE 3) REMOVING HEADLAMP (12) Remove the headlamp cowling, following the procedure “REMOVING HEADLAMP COWLING (20)” (Table 1). Unscrew and remove the two screws (13). Unscrew and remove screw (14) (headlamp adjustment screw). Disconnect connector (15). Remove the headlamp (12). 1) REMOVING RIGHT-HAND (1) AND LEFT-HAND REAR DIRECTION INDICATORS Unscrew and remove screw (3), being careful of the corresponding nut (4). Disconnect the connector (5). If necessary repeat the operation for the other direction indicator. NOTE: to remove just the indicator lens, unscrew the lens fitting screw. If necessary, replace the bulb after removing the indicator lens. 4) REMOVING RIGHT-HAND (16) AND LEFT-HAND (17) DIRECTION INDICATORS Unscrew and remove screw (18). Disconnect connector (19) or (20) after removing the headlamp cowling, following the procedure “REMOVING HEADLAMP COWLING (20)” (Table 1). 2) REMOVING TAIL LAMP (10) Unscrew and remove the two nuts (6) located under the numberplate bracket, being careful of the two spacers (7). Disconnect the connector block (8), after removing the seat, following the procedure “REMOVING SEAT (1)” (Table 1). Remove the tail lamp (10). NOTE: to remove just the indicator lens, unscrew the lens fitting screw. If necessary, replace the bulb after removing the indicator lens. NOTE: to remove just the tail lamp lens (11), unscrew and remove the two screws (9). If necessary, replace the bulb after removing the tail lamp lens (11). 34 38 7) REMOVING FLASHER RELAY (34) The flasher relay (34) can be removed from the right-hand side of the vehicle, without having to remove any other part. 36 15 8) REMOVING FUSE (45) AND FUSE/DIODE BOX RUBBER (35) The fuse (45) can be reached directly from the right-hand side of the vehicle, without having to remove any other part. 39 1 11 43 44 9 10 3 41 4 20 37 40 5 2 42 26 27 33 28 7 6 4 5 25 21 30 29 31 18 7 29 24 32 6) REMOVING BATTERY (33) Remove left-hand sidepanel, following the procedure “REMOVING LEFT-HAND (9) AND RIGHT-HAND (10) SIDEPANELS” (Table 1). Remove the battery cover (Table 5) after unscrewing and removing the four fixing screws (Table 5). Attention: one of the four screws has a rubber washer; pay particular attention when reassembling. Remove the battery (33), rotating it clockwise and pulling it downwards at the same time. Disconnect first the negative (-) cable, then the positive (+) cable from the battery (33), in that order. Attention: on reassembly, connect first the positive (+) cable, then the negative (-) cable, in that order. 45 35 19 5) REMOVING INSTRUMENT PANEL (21) Remove the headlamp cowling, following the procedure “REMOVING HEADLAMP COWLING (20)” (Table 1). Slack off tachometer cable guide (22) and speedometer cable guide (23). Disconnect connector (24) from the tachometer (26); disconnect connector (25) from the speedometer (27). Unscrew and remove the two screws (28) connecting the panel to the top yoke, paying particular attention to the order in which the following parts are fitted: spacers (29), dampers (30) and nuts (31). To remove just the tachometer cable (26) or the speedometer cable (27), remove the split pins (32). 3 9) REMOVING TRANSDUCER (36) AND VOLTAGE REGULATOR (37) Remove the fuel tank, following the procedure “REMOVING FUEL TANK (38)” (Table 1). Unscrew and remove the two screws (38), being careful of the nut (39). Disconnect the leads, having first labelled them to ensure correct refitting. Remove the transducer (36). Unscrew and remove the screw (40), being careful of the nut (41). Disconnect the leads, having first labelled them to ensure correct refitting. Remove the voltage regulator (37). 8 10) REMOVING HORN (42) Disconnect the connectors (44). Unscrew and remove the nut securing the horn (42) to the support bracket (43). Remove the horn (42). NOTE: the horn (42) is supplied as a spare part complete with the support bracket (43). To replace the horn/support bracket assembly, remove the radiator grille, following the procedure “REMOVING RADIATOR GRILLE (7)” (Table 1). 32 23 22 REASSEMBLY 16 18 For reassembly, reverse the order of operations for dismantling. 14 13 RELEASE 00 2002 - 10 MX 50 13 12 17 ELECTRICAL SYSTEM Chap.6 TABLE 04 ENGINE AND COMPONENTS DISASSEMBLY SEQUENCE 1) REMOVING AIR FILTER BOX (1) Remove the sidepanels, following the procedure “REMOVING LEFT-HAND (9) AND RIGHT-HAND (10) SIDEPANELS” (Table 1). Remove the battery, following the procedure “REMOVING BATTERY (33)” (Table 4). Remove the flasher relay, following the procedure “REMOVING FLASHER RELAY (34)” (Table 4) Remove the fuse/diode box rubber. Unscrew and remove the screw (4). Slack off the clamp connecting the air filter box to the inlet duct. Remove the air filter box (1). 2) REMOVING TWO-STROKE OIL TANK/EXPANSION BOTTLE (6) Remove the seat, following the procedure “REMOVING SEAT (1)” (Table 1). Remove the right-hand and left-hand air-scoops, following the procedure “REMOVING RIGHT-HAND (4) AND LEFT-HAND (5) AIR-SCOOPS” (Table 1). Remove the fuel tank, following the procedure “REMOVING FUEL TANK (38)” (Table 1). Unscrew and remove the two screws (7). Slack off the expansion pipe/silencer clamp (23). Remove the silencer (17). Slack off the clamp (8) and remove the pipe (9) from the radiator cap (10). Disconnect the connectors (11). Remove the two-stroke oil tank/expansion bottle (6). 3) REMOVING RADIATOR (12) Remove the right-hand and left-hand air-scoops, following the procedure “REMOVING RIGHT-HAND (4) AND LEFT-HAND (5) AIR-SCOOPS” (Table 1). Remove the radiator grille, following the procedure “REMOVING RADIATOR GRILLE (7)” (Table 1). Drain the coolant from the cooling system by unscrewing the screw with the copper washer on the water pump cover. Unscrew and remove the screw (13) and the screw (14). Slack off the clamps (15) and (16). Unscrew and remove the radiator cap (10). Remove the radiator (12), lifting it gently. 4) REMOVING SILENCER (17) Unscrew and remove the screw (18), paying particular attention to the order in which the following parts are fitted: washers (19), silent-block (20), spacer (21), nut (22). 4 1 35 34 3 31 2 5 3 27 36 17 29 19 18 37 30 32 6 21 20 33 28 8 9 33 11 7 10 12 26 23 16 14 25 15 24 19 22 5) REMOVING EXHAUST EXPANSION PIPE (24) Slack off the expansion pipe/silencer clamp (23) and separate the expansion pipe (24) from the silencer (17). Unhook the springs (25) from the barrel. Unscrew and remove the bolt (26). Remove the expansion pipe (24). 6) REMOVING CARBURETTOR (27) Remove the fuel tank, following the procedure “REMOVING FUEL TANK (38)” (Table 1). Disconnect the throttle cable (28) from the carburettor (27). Disconnect the oil feed pipe. Slack off the clamp (5) connecting the carburettor (27) to the inlet sleeve. Unscrew the bolt on the inlet manifold to separate the carburettor (27) from the manifold. Remove the carburettor (27). 7) REMOVING ENGINE (29) Remove the seat, following the procedure “REMOVING SEAT (1)” (Table 1). Remove the right-hand and left-hand air-scoops, following the procedure “REMOVING RIGHT-HAND (4) AND LEFT-HAND (5) AIRSCOOPS” (Table 1). Remove the fuel tank, following the procedure “REMOVING FUEL TANK (38)” (Table 1). Remove the expansion pipe, following the procedure “REMOVING EXHAUST EXPANSION PIPE (24)”. Drain the coolant from the cooling system by unscrewing the screw with the copper washer on the water pump cover. Disconnect the cooling hoses from the water pump and the cylinder head. Unscrew and remove the two oilpump cover screws. Disconnect the oilpump cable. Remove the oilpump. Disconnect the oil feed pipe to the carburettor. Disconnect the tachometer cable (Table 4). Disconnect the clutch cable (30). Separate the engine (29) from the carburettor (27) by unscrewing the bolt on the inlet manifold. Disconnect the inlet manifold heating pipe (31). Pull the sparkplug cap off the sparkplug itself. Disconnect the neutral light lead connector. Disconnect the lead to the CDI unit/coil (Table 4) Disconnect the lead to the voltage regulator (Table 4). Disconnect the engine earth lead. Remove the front sprocket cover, following the procedure “REMOVING FRONT SPROCKET COVER (33)” (Table 1). Slack off the rear wheel spindle (Table 3) so that the wheel can slide forward, creating enough slack in the chain to allow it to be taken off the front sprocket (Table 3). Remove the front sprocket (32) from the engine (29). Unscrew and remove the three long bolts (33) which hold the engine in the frame. Remove the engine (29) (preferably from the left-hand side). REASSEMBLY For reassembly, reverse the order of operations for dismantling. RELEASE 00 2002 - 10 MX 50 13 ENGINE AND COMPONENTS Chap.6 TABLE 05 WIRING DIAGRAM MX 50 23 22 21 20 17 19 15 ASD 18 V M Vi V Bi B R Az G B 15 24 B 25 26 29 57 56 31 R/V R/V Gr B/N Ar Bi / R G Vi R M G Vi R M N Bi B R N Bi B G B Ar R/V V 13 R 12 V/G G B B S T 29 V Az V Az Az B Ar R/V V G 29 B Ar R/V V G R/V Gr Bi / R Gr Bi B/N Az R G N Bi V 29 Bi / R 27 29 B Ar R/V V G M Bi Vi R Az G B R/V 29 Bi / R B/N R/V Bi / R B Ar R/V V G M Bi Vi R Az G B V Gr Bi B/N Az R G N Bi V 14 Az 11 M 2 6 29 10 R/V V/G R 8 R Bi R V 1 N 5 Bi / R ~~ G 4 FUS. 7,5 A G V B B Vi B B R/V V/G 28 V 9 31 30 LEGEND 1) 2) 4) 5) 6) 8) 9) 10) 11) 12) 13) 14) 15) 17) Generator Ignition coil Voltage regulator Fuses Battery Rear stoplight switch Mixer oil reserve sensor Neutral indicator Rear left direction indicator Rear light Rear right direction indicator Blinking Ignition switch / steering lock / light switch Left dimmer switch 18) 19) 20) 21) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) Complete dashboard Dashboard lamps Direction indicator warning light Low beam warning light ASD High beam warning light Mixer oil reserve warning light Neutral warning light Horn Front right direction indicator Low beam bulb Front parking light Front left direction indicator Multiple connectors Spark plug Front stoplight switch CABLE COLOURS Ar Az B Bi G Gr M N R V Vi Orange Light blue Blue White Yellow Gray Brown Black Red Green Violet RELEASE 00 2002 - 10 MX 50 WIRING DIAGRAM Chap.7