Yamaha VINO 125 Service manual

YJ125S

SERVICE MANUAL

LIT-11616-17-43 5YR-28197-10

EAS00000

YJ125S 2003

SERVICE MANUAL

©2003 by Yamaha Motor Taiwan Co., Ltd.

First edition, November 2003

All rights reserved.

Any reproduction or unauthorized use without the written permission of

Yamaha Motor Taiwan Co., Ltd.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-17-43

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers 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 Taiwan 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 dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

c

Q w

C

NOTE:

The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander or a person inspecting or repairing the scooter.

A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.

A NOTE provides key information to make procedures easier or clearer.

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.

1 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”.

2 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-section title(s) appears.

3 Sub-section titles appear in smaller print than the section title.

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.

6 Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described sequentially.

4

5

6 2 1

CYLINDER AND PISTON

ENG

EAS00251


4

8 10

9

8

11

12

13

14

13

7

5

4

2

1

4

6

2

3

1


ENG

EAS00253

REMOVING THE CYLINDER AND PISTON

1. Remove:

8piston pin clip 1

8piston pin 2

8piston 3 c C

Do not use a hammer to drive the piston pin out.

NOTE:

8 Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.

8 Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area.

3

8

2. Remove:

8top ring

82nd ring

8oil ring

NOTE:

When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.

7

4

12Nm(1.2m

• kg, 8.7 ft

• lb)

3

5

6

7

3

4

1

2

Order Job/Part

Removing the cylinder and piston

Cylinder head

Clamp

Pipe

Timing chain guide (exhaust side)

Cylinder

O-ring

Dowel pin

Cylinder gasket

8

9

10

11

12

13

14

Piston pin clip

Piston pin

Piston

Top ring

2nd ring

Oil ring

Expander

5-28

Q’ty Remarks

Remove the parts in the order listed.

Refer to “CYLINDER HEAD”.

1

2

1

1

1

1

1

Refer to “ INSTALLING THE PISTON

AND CYLINDER”

2

1 Refer to “ REMOVING THE CYLINDER

AND PISTON”

1

1 Refer to “ INSTALLING THE PISTON

AND CYLINDER”

1

2

1

For installation, reverse the removal procedure.

5-29

1

GEN

INFO

3

CHK

ADJ

5

ENG

7

CARB

9

TRBL

SHTG q

2

SPEC

4

CHAS

6

COOL

8

ELEC -

0

+

EAS00008

SYMBOLS

The following symbols are not relevant to every vehicle.

Symbols 1 to 9 indicate the subject of each chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Chassis

5 Engine

6 Cooling system

7 Carburetor(s)

8 Electrical system

9 Troubleshooting w

Symbols 0 to u indicate the following.

0 Serviceable with engine mounted q Filling fluid w Lubricant e Special tool r Tightening torque t Wear limit, clearance y Engine speed u Electrical data e r t y u

.

T

R

.

i a f

B

E

LT o

G s

LS p d

M

M g

New

Symbols i to d in the exploded diagrams indicate the types of lubricants and lubrication points.

i Engine oil o Gear oil p Molybdenum-disulfide oil a Wheel-bearing grease s Lithium-soap- based grease d Molybdenum-disulfide grease

Symbols f to g in the exploded diagrams indicate the following.

f Apply locking agent (LOCTITE ® ) g Replace the part

EAS00011

TABLE OF CONTENTS

GENERAL INFORMATION

GEN

INFO

1

SPECIFICATIONS

SPEC

2

PERIODIC CHECKS AND

ADJUSTMENTS

CHK

ADJ

3

CHASSIS

CHAS

4

ENGINE

ENG

5

CARBURETOR

ELECTRICAL SYSTEM

CARB

6

+

ELEC

7

TROUBLESHOOTING

TRBL

SHTG

8

GEN

INFO

CHAPTER 1


SCOOTER IDENTIFICATION ................................................................... 1-1

VEHICLE IDENTIFICATION NUMBER ............................................. 1-1

MODEL LABEL .................................................................................. 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 ............................. 1-3

BEARINGS AND OIL SEALS ............................................................ 1-3

CIRCLIPS ........................................................................................... 1-3

CHECKING THE CONNECTIONS ........................................................... 1-4

SPECIAL TOOLS ...................................................................................... 1-5

1-8

1

1

SCOOTER IDENTIFICATION

GEN

INFO

EAS00015


SCOOTER IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the steering head pipe.

EAS00018

MODEL LABEL

The model label 1 is affixed to the seat. This information will be needed to order spare parts.

1-1

IMPORTANT INFORMATION

GEN

INFO

EAS00020


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 the “SPECIAL TOOLS”.

3. When disassembling, always keep mated parts together. This includes gears, cylinders, 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 of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

1-2

EAS00021

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replacements. Use oil and grease recommended 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 surfaces, oil seal lips and O-rings must be cleaned.

2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.


GEN

INFO

EAS00023

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

EAS00024

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manufacturer’s marks or numbers are visible.

When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

1 Oil seal c C

Do not spin the bearing with compressed air because this will damage the bearing surfaces.

1 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 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives.

4 Shaft

1-3

CHECKING THE CONNECTIONS

GEN

INFO

EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc.

1. Disconnect:

8 lead

8 coupler

8 connector

2. Check:

8 lead

8 coupler

8 connector

Moisture J Dry with an air blower.

Rust/stains

J Connect and disconnect several times.

3. Check:

8 all connections

Loose connection J Connect properly.

NOTE:

If the pin 1 on the terminal is flattened, bend it up.

1-4

4. Connect:

8 lead

8 coupler

8 connector

NOTE:

Make sure all connections are tight.

5. Check:

8 continuity

(with the pocket tester)

Pocket tester

90890-03132 (YU-03112-C)

NOTE:

8 If there is no continuity, clean the terminals.

When checking the wire harness, perform steps (1) to (3).

8 As a quick remedy, use a contact revitalizer available at most part stores.

SPECIAL TOOLS

GEN

INFO

EAS00027

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.

When placing an order, refer to the list provided below to avoid any mistakes.

Tool NO.

90890-01083(M6)

YU-01083-1

90890-01085(M8)

YU-01083-2

90890-01084

YU-01083-3

90890-01235

YU-01235

Tool name / Function

Rocker arm shaft puller bolt1

Weight2

These tools are used when removing or installing the rocker arm shafts.

Rotor holding tool

1

Illustration

2

90890-01268

YU-01268

This tool is used to remove the flywheel magneto.

Ringnut wrench

90890-01311

YM-08035-A

This tool is used to loosen and tighten the exhaust and steering ring nut.

Valve adjusting tool

90890-01312

YM-01312-A

This tool is necessary for adjusting valve clearance.

Fuel level gauge

90890-01326

YM-01326

90890-01294

YM-01300-1

This gauge is used to measure the fuel level in the float chamber.

T-handle1

Damper rod holder2

These tool are used for holding the Damper rod holder when removing or installing the damper rod holder.

Clutch spring holder

1 2

90890-01337

YM-33285

YM-33285-6

90890-01348

YM-01348

These tool are used for removing the nut with holding the compression spring.

Lock nut wrench

41

46

90890-01189

YM-01189

This tool is used when removing or installing the secondary sheave nut.

Flywheel puller

This tool is used for removing the

A.C. magneto rotor.

1-5

Tool NO.

90890-01367

YM-A9409-7

90890-01400

YM-A9409-3

90890-01384

YM-33299

90890-01403

YU-33975

90890-01701

YS-01880-A

90890-03079

YM-34483

90890-03081

YU-33223

90890-03132

YU-03112-C

90890-03113

YU-08036-C

90890-03141

YU-03141

90890-04019

YM-04019

90890-04108

YM-04108


Fork seal driver weight 1

SPECIAL TOOLS

GEN

INFO

Illustration

Fork seal driver attachment(Ø30mm) 2

This tool is used when installing the fork seal.

Oil seal guide

This tool is used for protecting the oil seal lip when installing the secondary sliding sheave.

Ring nut wrench

1 2

This tool is used to loosen and tighten the steering ring nut.

Sheave holder

This tool is used for holding the secondary sheave.

Thickness gauge

This tool is used to measure the valve cleanance.

Compression gauge

These tool are used to measure the engine compression.

Pocket tester

This instrument is invaluable for checking the electrical system.

Engine tachometer

This tool is needed for detecting engine rpm.

Timing light

This tool is needed for detecting ignition timing.

Valve spring compressor

Attachment(Ø19mm)

These tools are used when removing or installing the valve and the valve spring.

1-6


Ignition checker

SPECIAL TOOLS

GEN

INFO

Illustration Tool NO.

90890-06754

YM-34487

90890-85505

ACC-11001-05-01

This instrument is necessary for checking the ignition system components.

Yamaha bond NO.1215

80890-04116

YM-04116

This sealant (bond) is used for crankcase mating surface, etc.

Valve guide remover (4.5 mm)

90890-04117

YM-04117

This tool is used to remove or install the valve guides.

Valve guide installer (4.5 mm)

90890-04099

YM-04099

This tool is used to install the valve guides.

Valve guide reamer (5.0 mm)

This tool is used to rebore the new valve guides.

1-7

SPEC

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ................................................................. 2-1

ENGINE SPECIFICATIONS ..................................................................... 2-2

CHASSIS SPECIFICATIONS ................................................................. 2-11

ELECTRICAL SPECIFICATIONS .......................................................... 2-14

CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICA-

TIONS ................................................................................................. 2-18

TIGHTENING TORQUES........................................................................ 2-19

ENGINE TIGHTENING TORQUES ................................................. 2-19

CHASSIS TIGHTENING TORQUES ............................................... 2-21

LUBRICATION POINTS AND LUBRICANT TYPES ............................. 2-22

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ....... 2-22

CHASSIS LUBRICATION POINTS AND LUBRICATION TYPES .. 2-24

OIL FLOW DIAGRAMS .......................................................................... 2-25

CABLE ROUTING .................................................................................. 2-27

2-31

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model code

Item Standard

5YR1 (for USA)

5YR2 (for CAN)

…

…

Limit

Dimensions

Overall length

Overall width

Overall height

Seat height

Wheelbase

Ground clearance

Minimum turning radius

Weight

Wet (without oil and a full fuel tank)

Dry (without oil and fuel)

Maximun load (total of cargo, rider,

passenger, and accessories)

1755 mm (69.1 in)

699 mm (27.5 in)

1063 mm (41.8 in)

759 mm (29.8 in)

1230 mm (48.4 in)

95 mm (3.8 in)

1800mm (72 in)

109 kg (240 lb)

104kg (229 lb)

253kg (558 lb)

…

…

…

…

…

…

…

…

…

…

2-1

ENGINE SPECIFICATIONS

SPEC


Item Standard

Engine

Engine type

Displacement

Cylinder arrangement

Forced Air cooled 4-stroke,

SOHC

0.125L(125.0 cm 3 )

…

…

Forward inclined single cylinder …

Bore × stroke

Compression ratio

Engine idle speed

Vacuum pressure at engine idle speed

51.5 × 60.0 mm

9.8±0.4 :1

1600~1700 r/min

30.0 kpa(238.6 mmHg)

…

…

…

…

Standard compression pressure (at sea level) 950 kPa(9.5kg/cm 2 ) / 300 r/min …

Fuel

Recommended fuel

Fuel tank capacity

Total (including reserve)

Regular unleaded gasoline …

4.5L (0.98lmp gal, 1.18 USgal) …

Engine oil

Lubrication system

Recommended oil

Wet sump …

-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚

SAE20W40SE

Yamaha 4-cycle oil

EFERO X, Z, BX

…

…

SAE 10W-30

SAE 10W-40

SAE 20W-40

SAE 20W-50

Limit

Quantity

Periodic oil change

With oil filter replacement

Total amount

Final gear oil

Recommended oil

Periodic oil change

Total amount

1.0L(0.92 lmp qt, 1.09 US qt) …

1.2L(1.10 lmp qt, 1.31 US qt) …

1.2L(1.10 lmp qt, 1.31 US qt) …

SAE85W140S Ehypoid gear oil …

0.13L(0.12 lmp qt, 0.14 US qt) …

0.15L(0.14 lmp qt, 0.16 US qt) …

2-2


SPEC

Standard Item

Oil filter

Oil filter type

Oil pump

Oil pump type

Inner rotor to outer rotor tip clearance

Outer rotor to pump housing clearance

Oil pump housing to inner rotor and outer

rotor clearance

Starting system type

Spark plug

Model (manufacturer) × quantity

Spark plug gap

Cylinder head

Volume

Max. warpage

Wire mesh

Trochoid

0.15 mm

0.013-0.036 mm

0.06-0.10 mm

Electric and kick starter

CR7E (NGK) × 1

0.7~0.8mm

12.3~12.7cm³

…

…

…

0.23mm

0.106mm

0.17mm

…

…

…

Limit

…

0.03 mm

2-3

Item

Camshaft

Drive system

Intake camshaft lobe dimensions


SPEC

Standard Limit

Chain drive (left) …

C

A

B

Measurement A

Measurement B

Measurement C

Exhaust camshaft lobe dimensions

C

A

26.153~26.253 mm

21.015~21.115 mm

5.203mm

Measurement A

Measurement B

Measurement C

Max. camshaft runout

B

26.153~26.253 mm

21.056~21.156 mm

5.203 mm

…

26.053 mm

20.915 mm

…

26.053 mm

20.956 mm

…

0.03 mm

2-4

Item

Timing chain

Model/number of links

Tensioning system

Valve, valve seats, valve guides

Valve clearance (cold)

Intake

Exhaust

Valve dimensions


SPEC

Standard Limit

Morse 92RH2005 / 88

Automatic

0.08~0.12 mm

0.13~0.17 mm

…

…

…

…

B

A

Head Diameter Face Width

Valve head diameter A

Intake

Exhaust

Valve face width B

Intake

Exhaust

Valve seat width C

Intake

Exhaust

Valve margin thickness D

Intake

Exhaust

Valve stem diameter

Intake

Exhaust

Valve guide inside diameter

Intake

Exhaust

Valve stem to valve guide clearance

Intake

Exhaust

Valve stem runout

Seat Width

C

23.9~24.1 mm

20.9~21.1 mm

1.69~2.40 mm

1.69~2.40 mm

0.9~1.1 mm

0.9~1.1 mm

0.85~1.15 mm

0.85~1.15 mm

4.475~4.490 mm

4.460~4.475 mm

4.500~4.512 mm

4.500~4.512 mm

0.010~0.037 mm

0.025~0.057 mm

…

D

Margin Thickness

…

…

…

…

1.6mm

1.6mm

…

…

4.445 mm

4.430 mm

4.550 mm

4.550 mm

0.080 mm

0.100 mm

0.010 mm

Valve seat width

Intake

Exhaust

2-5

0.9~1.1 mm

0.9~1.1 mm

1.6mm

1.6mm

Item

Valve springs

Free length

Intake

Exhaust

Installed length (valve closed)

Intake

Exhaust

Compressed spring force (installed)

Intake

Exhaust

Spring tilt


SPEC

Standard Limit

37.30 mm

37.30 mm

25.77mm

25.77mm

35.40 mm

35.40 mm

…

…

147±11N (15.0 ± 1.1 kgf/mm) …

147±11N (15.0 ± 1.1 kgf/mm) …

Intake

Exhaust

Winding direction (top view)

Intake

Exhaust

Valve seat reformed

Cylinder

Cylinder arrangement

Bore × stroke

Compression ratio

Bore

Max. taper

Max. out-of-round

…

…

Clockwise

Clockwise

2.5°/1.6 mm

2.5°/1.6 mm

…

…

Yes …

Forward inclined single cylinder …

51.5 × 60mm

9.8 ± 0.4:1

51.49~51.53 mm

…

…

…

…

…

0.05 mm

0.05 mm

2-6

Item

Piston

Piston-to-cylinder clearance

Diameter D


SPEC

Standard Limit

0.010~0.030 mm

51.470~51.510 mm

0.150mm

…

H

D

Height H

Piston pin bore (in the piston)

Diameter

Offset

Offset direction

Piston pin

Outside diameter

Piston rings

Top ring

Ring type

Dimensions (B × T)

End gap (installed)

Ring side clearance

2nd ring

Ring type

Dimensions (B × T)

End gap (installed)

Ring side clearance

Oil ring

Dimensions (B × T)

End gap (installed)

Ring side clearance

3.5 mm

13.002~13.013 mm

0.35~0.65mm

Intake side

12.996~13.000 mm

B

T

Barrel

1.0 × 2.1mm

0.10~0.20 mm

0.02~0.08 mm

T

T

B

Plain

1.0 × 2.1mm

0.20~0.30 mm

0.02~0.06 mm

B

2.0 × 2.2 mm

0.2~0.7 mm

0.06~0.15 mm

…

…

…

…

13.043 mm

…

…

12.976 mm

…

…

0.45mm

0.13 mm

…

…

0.65mm

0.12mm

2-7

Item

Rocker arm/rocker arm shaft

Rocker arm inside diameter

Rocker arm shaft outside diameter

Arm-to-shaft clearance

Connecting rod

Connecting rod length

Small end inside diameter

Crankshaft


SPEC

Standard Limit

10~10.015mm

9.981~9.991 mm

0.009~0.034 mm

97.95~98.05 mm

13.015~13.028mm

…

…

…

…

…

Width A

Max. runout C

Big end side clearance D

Big end radial clearance E

45.15~45.20 mm

…

0.10~0.40 mm

0~0.010mm

…

0.03mm

1.00mm

…

2-8

Item

Clutch

Clutch type

Clutch shoe thickness

Clutch shoe spring free length

Clutch housing inside diameter

Compression spring free length

Weight outside diameter

Clutch-in revolution

Clutch-stall revolution

V-belt

V-belt width

Transmission

Transmission type

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Max. main axle runout

Max. drive axle runout

Carburetor

Model (manufacturer) × quantity

ID mark

Venturi tube bore

Main jet

Main air jet

Jet needle

Needle jet

Pilot air jet 1

Pilot outlet

Pilot jet

Bypass 1

Bypass 2

Bypass 3

Valve seat size

Starter jet 1

Starter jet 2

Throttle valve size

Fuel level ( using fuel level gauge )

Engine idle speed

CO% (air induction system ON)

CO% (air induction system OFF)

Oil temperature (°C)


SPEC

Standard Limit

Automatic centrifugal

3.4 ± 0.1 mm

28.0 ± 0.4 mm

120 ± 0.1 mm

113.6 mm

20 ± 0.1 mm

3200±300 r/min

5500±500 r/min

21.6 mm

V-belt automatic

Helical gear

40/15 (2.667)

Spur gear

38/13 (2.923)

…

…

160

0.81

22.5

Ø0.8

Ø1.0

Ø1.1

BS26 (MIKUNI) × 1

5YR 00

Ø22.3

#97.5

0.5

4D×16-1

0-4M

2.0

40

0.8

115

6.5~7.5mm

1600~1700 r/min

0.2~1.4 %

4.0~5.0 %

70~80 °C

…

2.0mm

…

120.3mm

…

…

…

…

19.5mm

…

…

…

…

…

0.02 mm

0.02 mm

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

2-9


SPEC

Item Standard

Throttle bodys

Model (manufacturer) × quantity 5YR (SAFETY CONTROL

CABLE) × 2

Intake vacuum pressure 30.0kpa (238.6mmHg)

Throttle cable free play (at the flange of the 3~5mm

throttle grip)

ID mark 5YR1

…

…

…

…

Limit

2-10

Item

Frame

Frame type

Caster angle

Trail

Front wheel

Wheel type

Rim

Size

Material

Wheel travel

Wheel runout

Max. radial wheel runout

Max. lateral wheel runout

Rear wheel

Wheel type

Rim

Size

Material

Wheel travel

Wheel runout

Max. radial wheel runout

Max. lateral wheel runout

Front tire

Tire type

Size

Model (manufacturer)

Tire pressure (cold)

0~90 kg

90~197 kg

Min. tire tread depth

Rear tire

Tire type

Size


Tire pressure (cold)

0~90 kg

90~197 kg

Min. tire tread depth

CHASSIS SPECIFICATIONS


SPEC

Standard Limit

Steel tube underbone

32 °

75 mm

Cast wheel

10 × MT2.15

Aluminum

59mm

…

…

Cast wheel

10 × MT2.15

Aluminum

54mm

…

…

Tubeless

3.50-10 51J

C-922L (CHENG SHIN)

150kpa (1.5 kg/cm², 22 psi)

150kpa (1.5 kg/cm², 22 psi)

…

Tubeless

3.50-10 51J

C-6007 (CHENG SHIN)

…

…

…

200kpa (2.0 kg/cm², 29 psi) …

225kpa (2.25 kg/cm², 32 psi) …

… 0.8mm

…

…

…

…

…

…

…

1.0 mm

1.0 mm

…

…

…

…

1.0 mm

1.0 mm

…

…

…

…

…

0.8mm

2-11

Item

Front disc brake

Brake type

Operation

Brake lever free play (at lever end)

Recommended fluid

Brake disc

Diameter x thickness

Min. thickness

Max. deflection

Brake pad lining thickness-inner

Brake pad lining thickness-outer

Master cylinder inside diameter

Caliper cylinder inside diameter


SPEC

Standard

Single disc brake

Right-hand operation

3~5mm

DOT 4

180.0 × 4.0 mm

…

…

6.0 mm

6.0 mm

11mm

34.93mm

…

…

…

…

Limit

180.0 × 3.5 mm

3.5mm

0.10 mm

0.8mm

0.8mm

…

…

2-12


SPEC

Standard Item

Rear drum brake

Brake type

Operation

Brake lever free play (at lever end)

Brake drum inside diameter

Lining thickness

Front suspension

Suspension type

Front fork type

Front fork travel

Spring

Free length

Installed length

Spring rate (K1)

Spring stroke (K1)

Spring rate (K2)

Spring stroke (K2)

Optional spring available

Fork oil

Recommended oil

Quantity (each front fork leg)

Inner tube outer diameter

Inner tube bending limit

Steering system

Steering bearing type

Lock to lock angle (left)

Lock to lock angle (Right)

Rear suspension

Suspension type

Rear shock absorber assembly type

Rear shock absorber assembly travel

Spring

Free length

Installed length

Spring rate (K1)

Spring stroke (K1)

Optional spring available

Drum brake

Left-hand operation

10~20mm

110 mm

4.0mm

Telescopic

Coil spring/oil damper

80 mm

257.5 mm

245.5mm

12.7N/mm (1.27 kg/mm)

0~50mm

19.6N/mm (1.96kg/mm)

50~80mm

No

Fork oil G10 or equivalent

126 ± 2.5cc

33 mm

…

Angular bearing

47.5 °

47.5 °

Swingarm

Coil spring/oil damper

65mm

208mm

198mm

43N/mm (4.3kg/mm)

0~65mm

No

…

…

…

…

…

…

…

…

…

…

…

…

…

…

Limit

…

…

…

111mm

2mm

252.4mm

…

…

…

…

…

…

…

…

…

0.2 mm

2-13

Item

System voltage

Ignition system

Ignition system type

Ignition timing (B.T.D.C.)

Advancer type

Pickup coil resistance /color

C.D.I. unit model (manufacturer)

Ignition coil


Minimum ignition spark gap

Primary coil resistance

Secondary coil resistance

Spark plug cap

Material

Resistance

Charging system

System type


Nominal output

Lighting coil resistance /color

Lighting coil resistance /color

Voltage regulator

Regulator type


No load regulated voltage(DC)

Rectifier


Rectifier capacity(DC)

Withstand voltage

Battery

Battery type (manufacturer)

Battery voltage capacity

Specific gravity

Ten hour rate amperage

Headlight type

Indicator light

(voltage/wattage×quantity)

Turn signal indicator light

High beam indicator light

ELECTRICAL SPECIFICATIONS

SPEC


Standard

12V

C.D.I.

5 °/1650 r/min (IDL)

Digital

304~456

Ω / WR-WL

5YR00(T-MORIC)

2JN (T-MORIC)

6mm

0.184~0.276

Ω at 20 ° C

6.32~9.48 k

Ω at 20 ° C

Resin

8~12 k

Ω

…

…

C.D.I. magneto

5NW 01 (T-MORIC)

14V 120W / 5000 r/min

0.28~0.42

Ω/B-YR

0.32~0.48

Ω/B-W

Semiconductor, short circult …

SH671-12 (XIN DIAN YUAN) …

14~15 V …

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

Limit

SH671-12 (XIN DIAN YUAN) …

8A …

200V …

GTX7A-BS (GS)

12V 6AH

1.330

6 AH

Krypton bulb

…

…

…

…

…

12 V 1.7 W × 1

14 V 3W × 1

…

…

2-14


SPEC

Standard Item

Bulbs (voltage/wattage × quantity)

Headlight

Tail/brake light

Front turn signal light

Rear turn signal light

Speedometer light

Fuel lever meter light

12 V 60 W/55 W × 1

12 V 8W/27 W × 1

12 V 10 W × 2

12 V 10 W × 2

14 V 3 W ×1

14 V 3 W ×1

…

…

…

…

…

…

Limit

2-15

Item

Electric starting system

System type

Starter motor


Suction voltage

Power output

Brushes

Overall length

Quantity

Spring force

Commutator diameter

Commutator resistance

Mica undercut (depth)

Starter relay


Amperage

Coil resistance

Suction voltage

Horn

Horn type



SPEC

Standard Limit

Constant mesh

4TE1 (T-MORIC)

12V

0.3 kW

10.0 mm

2

5.52~8.28 N

22 mm

0.0306~0.0374

Ω at 20 °C

1.5 mm

3UH1 (SHI LIN)

100 A

3.6-4.4

Ω

Below DC8V

…

…

…

…

…

…

…

…

3.5mm

…

…

21mm

…

…

… Plane

AH-368

(ASIA TRAFFIC)

1.5 A

95~105db/2m

4.05~4.55

Ω

…

…

…

…

Max. amperage

Performance

Coil resistance

Turn signal relay

Relay type


Self-cancelling device built-in

Turn signal blinking frequency

Wattage

Fuel sender


Sender unit resistance-full

Sender unit resistance-empty

Starting circuit cut-off relay


Coil resistance

Thermostat switch


Carburetor heater

Manufacturer

Coil resistance

Semi transistor

5CA9 (TA YOUNG)

NO

75~95 cycles/min

10 W × 2 + 1.7 W+ AP

5YR1 (CHAO LONG)

4-10

Ω

90-100 Ω

09-N (SHI LIN)

54~66

Ω

1AJ (NATIONAL)

MIKUNI

30

Ω 20°C

…

…

…

…

…

…

…

…

…

…

…

…

…

2-16

Item

Fuel lever meter

Type( manufacturer )

Fuse (amperage × quantity)

Main fuse

Reserve fuse


SPEC

Standard Limit

Moving magneto (CHAO LONG) …

10A×1

10A×1

…

…

2-17

CONVERTION TABLE / GENERAL TIGHTENING

TORQUE SPECIFICATIONS

SPEC

EB201000

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

** mm

2 mm

MULTIPLIER IMPERIAL

0.03937

** in

0.03937

0.08 in

CONVERSION TABLE

Tightening torque

Weight

Speed

Distance

Volume/

Capacity

Misc.

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit m·kg m·kg cm·kg cm·kg kg g

7.233

86.794

0.0723

0.8679

2.205

0.03527

ft·lb in·lb ft·lb in·lb lb oz km/hr km m m cm mm cc (cm 3 ) cc (cm 3 ) lt (liter) lt (liter) kg/mm kg/cm 2

Centigrade

(°C)

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+32 mph mi ft yd in in oz (IMP liq.) cu-in qt (IMP liq.) gal (IMP liq.) lb/in psi (lb/in 2 )

Fahrenheit (°F)

EAS00030

GENERAL TIGHTENING TORQUE

SPECIFICATIONS

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.

Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.

A: Width across flats

B: Thread diameter

A

(nut)

B

(bolt)

10 mm

12 mm

6 mm

8 mm

14 mm 10 mm

17 mm 12 mm

19 mm 14 mm

22 mm 16 mm

General tightening torques

Nm m•kg ft•lb

6 0.6

4.3

15

30

55

85

1.5

3.0

5.5

8.5

130 13.0

11

22

40

61

94

2-18

TIGHTENING TORQUES

SPEC

ENGINE TIGHTENING TORQUES

Part to be tightened

Cylinder head and cylinder

Spark plug

Cylinder head(timing chain side)

Mainfold stud bolt

Exhaust pipe stud bolt

Breather assembly

Stopper plate

Guide stopper2

Valve clearance adjusting screw lock nut

Camshaft sprocket

Timing chain tensioner (body)

Timing chain tensioner (plug)

Air shroud 1and 2

Air shroud 1

Air shroud 1

Fan

Oil pump assembly

Cover element

Cover element inside drain bolt

Delivery pipe

Delivery pipe

Engine oil drain

Mainfold

Air filter assembly

Air filter case and air filter cap

Element cap

Carburetor overflow drain plug

Muffler

Muffler

Protector

Air induction system assembly

AI bracket and muffler

AI pipe

AI pipe clamp

AI filter

Crankcase 1and 2

Crankcase cover1

Crankcase cover2

Cover1(magneto)

Drain bolt(transmission oil)

Nut

Bolt

Screw

Screw

Screw

Bolt

Hose clamp

Bolt

Bolt

Bolt

Bolt

Screw

Bolt

Bolt

Screw

Screw

Bolt

_

Union bolt

Bolt plug

Nut

Screw

Screw

Screw plug

Bolt

_

Bolt

Bolt plug

Screw

Screw

Nut

_

Bolt

_

_

Bolt

Bolt

M6

M5

M8

M6

M8

M8

M10

M6

M6

M6

M6

M6

M6

M6

M6

M6

M8

M6

M5

M5

M6

M6

M6

M6

M6

M6

M6

M8

M6

M35

M6

M6

M6

M6

M6

M6

M6

M8

Part name

Thread size

Q ’ ty

Tightening torque

Nm m•kgf ft•lb

5

1

1

1

2

2

1

1

2

1

1

3

2

5

2

2

1

1

2

1

2

2

1

2

2

4

1

5

3

1

2

8

10

1

1

4

4

2

2

2

Remarks

23.1

5.1

5.1

5.1

5.1

1.4

5.8

5.1

5.1

5.8

5.1

7.2

5.8

5.1

5.1

21.7

7.2

5.8

1.1

5.1

15.9

9

8.7

5.1

5.1

5.1

5.1

1.1

8.7

7.2

8.7

5.1

16.6

7.2

22.4

5.1

2.9

2.9

5.8

3.3

3.2

0.7

0.7

0.7

0.7

0.2

0.8

0.7

0.7

0.8

0.7

1.0

0.8

0.7

0.7

3.0

1.0

0.8

0.15

0.7

2.2

1.25

1.2

0.7

0.7

0.7

0.7

0.45

0.15

1.2

1.0

1.2

0.7

2.3

1.0

3.1

0.7

0.4

0.4

0.8

4

And AI pipe tighten

And air shroud tighten

7

7

2

32

7

7

8

7

10

8

8

7

7

7

7

30

10

8

1.5

7

22

12.5

12

7

7

7

7

4.5

1.5

12

10

12

7

23

4

4

8

10

31

7

2-19


Drain bolt(engine oil )

V-belt case air filter element holder

Oil pipe

Cylinder stud bolt (case1)

Cylinder stud bolt (case2)

Crankcase cover3

Plate (V-belt guide)

Idle gear plate

Kick crank assembly

Clutch housing

Clutch carrier assembly

Primary fixed sheave

Starter motor assembly

C.D.I. rotor

Cylinder head tightening sequence


SPEC

Part name

Thread size

Q ’ ty

Tightening torque

Nm m•kgf ft•lb

_

Screw

Bolt

_

_

Screw

Screw

Screw

Bolt

Nut

Nut

Nut

Bolt

Nut

M8

M6

M6

M8

M8

M6

M6

M6

M8

M14

M36

M12

M6

M12

1

1

1

3

2

2

3

1

2

1

1

1

1

2

23

7

10

12.5

12.5

7

9

7

23

60

90

55

7

70

16.6

5.1

7.2

9

9

5.1

6.5

5.1

16.6

43.4

65.1

39.8

5.1

50.6

2.3

0.7

1.0

1.25

1.25

0.7

0.9

0.7

2.3

6.0

9.0

5.5

0.7

7.0

Remarks

3

2

1

5

4

6

2-20


SPEC

CHASSIS TIGHTENING TORQUES


Thread size

Tightening torque

Nm m•kgf ft•lb

Remarks

Frame and engine bracket 2

Engine bracket 2 and engine bracket 3

Engine bracket, engine and centerstand

Rear shock absorber and frame

Rear shock absorber and engine

Rear arm

Sidestand (bolt)

Sidestand (nut)

Steering shaft(upper nut)

Handlebar holder bracket and steering shaft

Handlebar holder and handlebar lower holder

Handlebar lower holder and handlebar upper holder

Master cylinder assembly

Brake hose and master cylinder

Fuel sender

Rear carrier

Rear carrier(upper)

Front wheel shaft

Rear wheel shaft

Rear brake camshaft lever

Front brake caliper pad(bolt)

Front brake caliper and front fork

Front brake disc rotor

Front brake hose and brake caliper

Front brake caliper and bleed screw

M12

M14

M6

M10

M10

M8

M10

M7

M8

M6

M10

M5

M8

M6

M10

M10

M10

M10

M8

M8

M8

M8

M25

M10

M10

42

55

32

30

18

28

1

19

75

60

47.5

30

9

26

7

23

10

70

105

10

22

35

20

23

6

4.2

5.5

3.2

3.0

1.8

2.8

0.1

1.9

7.5

6.0

4.75

3.0

0.9

2.6

0.7

2.3

1.0

7.0

10.5

1.0

2.2

3.5

2.0

2.3

0.6

30.4

39.8

23.1

21.7

13.0

20.3

0.7

13.7

54.2

43.4

34.4

21.7

6.5

18.8

5.1

16.6

7.2

50.6

75.9

7.2

15.9

25.3

14.5

16.6

4.3

See”NOTE”

LT

NOTE:

1. First, tighten the ring nut (lower) approximately 28 Nm (2.8m•kg, 20.3ft•lb) by using the torque wrench, then loosen the ring nut 1/4 turn.

2. Second, tighten the ring nut (lower) approximately 9 Nm (0.9m•kg, 6.5ft•lb) by using the torque wrench.

3. Installing the rubber washer.

4. Then finger tighten the center ring nut and touch rubber washer. Align the slots both ring nut and install the lock washer.

5. Final, hold the ring nuts (lower and center) and tighten the ring nut (upper) 75Nm (7.5 m•kg,

54.2ft•lb) by using the torque wrench.

3

2

1

4

5

1 Lower ring nut

2 Rubber washer

3 Center ring nut

4 Lock washer

5 Upper ring nut

2-21

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication Point

Oil seal lips

O-ring (Except V-belt drive unit)

Cylinder head tightening nut mounting surface

Cylinder head stud bolt thread

Cylinder head gasket dowel pin

Crankshaft pin outside surface

Connecting rod

Piston outside and ring groove

Piston pin outside surface surface and bolt thread

Crankshaft journal

Piston (balancer) outside surface

Piston pin (balancer) outside surface

Camshaft profile journal

Valve stem (IN, EX)

Valve stem seal

Valve stem end (IN, EX)

Valve lifter

Oil pump assembly inside

Oil pipe union bolt thread and surface

Gasket (Oil pump assembly)

Idle gear 1 thrust surfaces

Idle gear 2

Drive shaft serration (Sprocket)

Drive shaft taper rollor bearing

Transmission bearing

Secondary shaft bearing (right)

Primary sheave oil seal

Lubricant

LS

LS

LS

M

M

M

4

4

4

4

4

4

4

4

4

4

4

M

4

4

4

4

4

LS

LS

G

LS

LS

2-22


SPEC

Lubrication Point

Primary sheave inside, Collar, Solid bush,

Secondary fixed inner surface

Secondary sheave torque cam ditch

Gasket (Cylinder head cover)

Stopper guide (Cylinder head cover)

Crankcase mating surfaces

Oil pipe

C.D.I. magneto lead grommet

Lubricant

LS

BEL-RAY asembly lube

BEL-RAY asembly lube

Sealant

Sealant

Sealant

Sealant

Sealant

2-23


SPEC

EAS00032

CHASSIS LUBRICATION POINTS AND LUBRICATION TYPES

Lubrication Point

Front wheel oil seal lips

Frame head pipe bearing (upper and lower)

Frame head pipe dust seal lips ( lower)

Tube guide (throttle grip) inner surface

Brake lever and lever holder bolt sliding surface

Sidestand and frame sliding surface

Centerstand sliding surface and mounting bolt

Rear footrest (pin) outside surface

Rear shock absorber backward, bush inner surface and spacer sliding surface

Seat lock cable and cylinder inner surface

Engine bracket and engine mound bolt sliding surface

Lubricant

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

M

2-24

OIL FLOW DIAGRAMS

1 Oil strainer

2 Oil pump

3 Oil filter

4 Oil delivery pipe

5 Oil delivery pipe union bolt


SPEC

2-25

1 Connecting rod big end bearing


SPEC

2-26

CABLE ROUTING

1 Turn signal relay

2 Main switch assembly

3 Seat lock cable

4 Horn

5 Rectifier / regulator assembly

6 Starter motor negative lead

7 Wire (negative lead)

8 Starter motor positive lead

9 C.D.I. magneto lead

0 C.D.I. unit q Pipe 2 w AI. filter assembly e Clamp r Vacuum sensing hose t Wire harness y Side cover (right) u Frame Comp.

i Speedometer cable o Front brake hose p Throttle cable 1,2

CABLE ROUTING

SPEC a Rear brake cable s Speedometer lead d Auto choke lead

A Fasten the wire harness, rear brake cable and throttle cable 1,2 to the frame and cut the end to be shorter than

5mm.

B Route the front brake hose through the under fender and inner fender right side hole.

C Route the front brake hose through the front brake hose holder.

D Colar white mark to the outside.

E The seat lock cable pass the frame right side hole into frame inside, protector part to the hole position.

F Clamp the wire harness, wire positive lead and wire negative lead to the frame, clamp position to the white mark and press to tighten.

G Fasten the wire harness, wire positive lead and starter motor negative lead to the frame with a plastic locking tie, point the band tip to forward.

H Fasten the C.D.I. magneto lead and wire harness to the frame with a plastic locking tie, point the band tip to upper and the trunk surface.

I Secure the ground lead and the ignition coil base to the ignition coil stay.

O

N

M

L K w e q

J

B

0

1

2

I

6

H

9

8

7

T

G

B

F

3

B

C

F

F

4

5

A

Q r

8

7

T d s p a

BACKWARD

F-F t

E D u i t u

BACKWARD

FORWARD t y

FORWARD

P

7

6

B-B o

2-27

CABLE ROUTING

SPEC

J Fasten the C.D.I. unit lead and wire harness to the frame with a plastic locking tie, point the band tip to upper and the trunk surface.

K Fasten the wire harness to the frame and cut the end to be shorter than 5mm.

L Pass the seat lock cable along the outside of the reinf tail.

M Installing the bend hose 5 to the AI. Filter assembly, into the frame inside.

N Route the trail light lead and rear turn signal light lead through the rear cover hole.

O The tail light through the base hole.

O

N

M

L K w e q

J

B

0

1

2

I

6

H

9

8

7

T

G

B

F

3

B

C

F

F

4

5

A

Q r

8

7

T d s p a

BACKWARD

F-F t

E D u i t u

BACKWARD

FORWARD t

B-B y

FORWARD

P

7

6 o

2-28

1 Lever holder assembly (left side)

2 Rear brake cable

3 Throttle cable 1 (left turn side)

4 Throttle cable2 (right turn side)

5 Breather hose

6 Carburetor air vent hose

7 Spacer

8 Fuel overflow pipe

9 Crankcase cover 3

0 Starter air vent hose q Head light unit w Front turn signal light e Turn signal relay r Fuel lever meter t Main switch assembly y Horn

CABLE ROUTING

SPEC

A Pass the speedometer cable left side the inner fender and front fender hole.

B Pass the speedometer cable through the speedometer cable holder.

C Pass the rear brake cable through the rear brake cable holder.

D Pass the rear brake cable over the engine bracket cross tube bar.

E Route the vacuum sensing hose between throttle cable

1 and throttle cable 2.

F Clamp the canister pipe, breather hose and fuel cock vacuum hose, the end of down.

G Clamp the canister pipe, fuel hose and fuel cock vacuum hose.

H The filler cover and fuel overflow hose into the spacer.

I Pass the fuel overflow hose outside the rear bracket.

J Pass the fuel overflow hose through license bracket holder.

K Pass the carburetor overflow hose through shroud and crankcase cover 3 breach.

L The fuel lever meter lead terminal through the leg shield

2.

M Clamp the wire harness and head light lead to the turn signal bracket.

G

A

1

2

6

F

5

4

E

D

3 t y

B

M

C q

K

0 9

L r e w

7 H

8

I

J

2-29

1 Seat lock cable

2 Carburetor heater lead

3 Carburetor autochoke lead

4 Starter switch lead

5 Starter motor positive lead

6 Starter motor negative lead

7 High tension cord

8 Clamp

9 C.D.I. magneto lead

0 Vacuum sensing hose q Joint w Carburetor air vent hose e Starter air vent hose r Wire (positive lead)

A Pass the sidestand switch lead under the rear brake cable and throttle cable 1,2.

B Pass the sidestand switch lead under the frame.

CABLE ROUTING

SPEC

C Pass the throttle cable, wire harness and rear brake cable under the frame cross tube.

D Pass the thermo switch lead under the frame.

E Pass the positive and negative battery leads through the slot in the footrest board.

F Fasten the autochoke lead and heater lead to the cross tube and cut the end to be shorter than 5mm.

G Fasten the vacuum sensing hose, starter motor positive lead, C.D.I. magneto lead and high tension cord, and the vacuum sensing hose to the over position and cut the end.

H Clamp the starter motor lead and C.D.I. magneto lead.

I Pass the fuel overflow hose along the left side of the fuel tank.

J Route the autochoke lead and heater lead between vacuum sensing hose and fuel cock vacuum hose.

K Pass the breather hose right side the throttle cable.

L Fasten the breather hose, autochoke lead, heater lead and throttle cable 1, 2.

Breather hose to the over position and cut the end.

M Pass the throttle cable, wire harness and rear brake cable outside the inner fender rib.

B

1

C

D

E

F

4

2

3

5

6 7

G

8

9

0

H

A

M r

L K

J e w q

1

I

2-30

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

CHK

ADJ

INTRODUCTION ....................................................................................... 3-1

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM ............................................................................................... 3-2

Periodic maintenance chart for the emission control system ........... 3-2

GENERAL MAINTENANCE AND LUBRICATION CHART ................... 3-3

General maintenance and lubrication chart ...................................... 3-3

COVER AND PANEL ................................................................................ 3-4

SEAT AND SIDE COVERS ................................................................ 3-4

FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE

........................................................................................................ 3-5

LEG SHIELD 1 , 2 .............................................................................. 3-6

ADJUSTING THE VALVE CLEARANCE ................................................. 3-7

ENGINE ..................................................................................................... 3-7

ADJUSTING THE VALVE CLEARANCE ........................................... 3-7

ADJUSTING THE ENGINE IDLING SPEED ......................................... 3-10

ADJUSTING THE ENGINE IDLING SPEED .................................. 3-10

CHECKING THE EXHAUST GAS AT IDLE ........................................... 3-11

CHECKING THE EXHAUST GAS AT IDLE .................................... 3-11

ADJUSTING THE THROTTLE CABLE FREE PLAY ............................ 3-13

ADJUSTING THE THROTTLE CABLE FREE PLAY ...................... 3-13

CHECKING THE SPARK PLUG ............................................................ 3-15

CHECKING THE SPARK PLUG ...................................................... 3-15

CHECKING THE IGNITION TIMING ....................................................... 3-16

CHECKING THE IGNITION TIMING ............................................... 3-16

MEASURING THE COMPRESSION PRESSURE ................................ 3-17

MEASURING THE COMPRESSION PRESSURE ......................... 3-17

CHECKING THE ENGINE OIL LEVEL .................................................. 3-20

CHECKING THE ENGINE OIL LEVEL ........................................... 3-20

CHECKING THE ENGINE OIL ............................................................... 3-21

CHANGING THE ENGINE OIL ........................................................ 3-21

CHANGING THE ENGINE OIL FILTER ELEMENT .............................. 3-22

CHANGING THE ENGINE OIL FILTER ELEMENT ....................... 3-22

CHANGING THE TRANSMISSION OIL ................................................. 3-24

CHANGING THE TRANSMISSION OIL .......................................... 3-24

MEASURING THE ENGINE OIL PRESSURE ....................................... 3-25

MEASURING THE ENGINE OIL PRESSURE ................................ 3-25

3-56

CHK

ADJ

CLEANING THE AIR FILTER ELEMENT/CLEANING THE V-BELT

CASE AIR FILTER ELEMENT ............................................................... 3-26

CLEANING THE AIR FILTER ELEMENT ....................................... 3-26

CLEANING THE V-BELT CASE AIR FILTER ELEMENT ............... 3-26

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD .. 3-28

CHECKING THE CARBURETOR JOINT AND INTAKE

MANIFOLD ................................................................................... 3-28

CHECKING THE FUEL AND VACUUM HOSES/CHECKING THE

CRANKCASE BREATHER HOSE .................................................... 3-29

CHECKING THE FUEL AND VACUUM HOSES ............................ 3-29

CHECKING THE CRANKCASE BREATHER HOSE ..................... 3-29

CHECKING THE EXHAUST SYSTEM .................................................. 3-30

CHECKING THE EXHAUST SYSTEM ........................................... 3-30

ADJUSTING THE FRONT BRAKE/ADJUSTING THE REAR

BRAKE .................................................................................................... 3-31

CHASSIS ................................................................................................. 3-31

ADJUSTING THE FRONT BRAKE ................................................. 3-31

ADJUSTING THE REAR BRAKE.................................................... 3-31

CHECKING THE BRAKE FLUID LEVEL .............................................. 3-32

CHECKING THE BRAKE FLUID LEVEL ........................................ 3-32

CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE

SHOES/CHECKING THE FRONT BRAKE HOSE ........................... 3-33

CHECKING THE FRONT BRAKE PADS ........................................ 3-33

CHECKING THE REAR BRAKE SHOES ....................................... 3-33

CHECKING THE FRONT BRAKE HOSE ....................................... 3-33

BRAKE FLUID CHANGE ....................................................................... 3-34

BRAKE FLUID CHANGE ................................................................. 3-34

BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................. 3-36

BLEEDING THE HYDRAULIC BRAKE SYSTEM........................... 3-36

CHECKING AND ADJUSTING THE STEERING HEAD ...................... 3-38

CHECKING AND ADJUSTING THE STEERING HEAD ................ 3-38

CHECKING THE FRONT FORK ............................................................ 3-40

CHECKING THE FRONT FORK ..................................................... 3-40

CHECKING THE TIRES .......................................................................... 3-41

CHECKING THE TIRES .................................................................. 3-41

CHECKING THE WHEELS/CHECKING AND LUBRICATING THE

CABLES ............................................................................................. 3-44

CHECKING THE WHEELS.............................................................. 3-44

CHECKING AND LUBRICATING THE CABLES ............................ 3-44

3-57

CHK

ADJ

LUBRICATING THE SIDESTAND/LUBRICATING THE

CENTERSTAND ..................................................................................... 3-45

LUBRICATING THE SIDESTAND ................................................... 3-45

LUBRICATING THE CENTERSTAND ............................................ 3-45

CHECKING AND CHARGING THE BATTERY ..................................... 3-46

ELECTRICAL SYSTEM ......................................................................... 3-46

CHECKING AND CHARGING THE BATTERY............................... 3-46

CHECKING AND CHARGING THE BATTERY/

CHECKING THE FUSES ........................................................................ 3-52

CHECKING THE FUSES ................................................................. 3-52

REPLACING THE HEADLIGHT BULB ................................................. 3-54

REPLACING THE HEADLIGHT BULB ........................................... 3-54

ADJUSTING THE HEADLIGHT BEAMS............................................... 3-55

ADJUSTING THE HEADLIGHT BEAMS ........................................ 3-55

3-58

INTRODUCTION

CHK

ADJ

EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and adjustments.

If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.

NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.

From 30,000 km, repeat the maintenance intervals starting from 6,000 km.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

3-1

PERIODIC MAINTENANCE CHART FOR THE

EMISSION CONTROL SYSTEM

CHK

ADJ

EAU17560*

Periodic maintenance chart for the emission control system

NO.

1 * Fuel line

2 * Valves

3 * Spark plug

ITEM

4 * Air filter element

5

6

*

Crankcase breather system

* Carburetor

7 * Exhaust system

8 *

Evaporative emission control system

9 * Air induction system

ROUTINE

• Check fuel hoses and vacuum hose for cracks or damage.

• Check valve clearance.

• Adjust if necessary.

• Check condition.

• Clean and regap.

• Replace.

• Clean.

• Replace.

• Check breather hose for cracks or damage.

• Replace if necessary.

• Adjust engine idling speed.

• Check for leakage.

• Tighten if necessary.

• Replace gaskets if necessary.

• Checkcontrol system for damage.


• Check the air cut-off valve, reed valve, and hose for damage.

• Replace any damaged.

ODOMETER READING

600 mi

(1,000 km) or

1 month

2,000 mi

(4,000 km) or

6 months

4,000 mi 6,000 mi

(7,000 km) or

12 months

(10,000 km) or

18 months

8,000 mi

(13,000 km) or

24 months

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

NOTE:

From 10000 mi (16000 km) or 30 months, repeat the maintenance intervals starting from 2000 mi

(4000 km) or 6 months.

3-2

GENERAL MAINTENANCE AND LUBRICATION

CHART

CHK

ADJ

EAU32121

General maintenance and lubrication chart

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

NOTE:

From 12000 mi (18000 km) or 36 months, repeat the maintenance intervals starting from 4000 mi

(7000 km) or 12 months.

NO.

ITEM ROUTINE

1

2

3

4

*

*

*

*

V-belt case air filter elements

Front brake

Rear brake

Brake hose

• Clean.

• Replace.

• Check operation, fluid level and vehicle for fluid leakage.

(See NOTE)

• Replace brake pads.

• Check operation and adjust brake lever free play.

• Replace brake shoes.

• Check for cracks or damage.

• Replace. (See NOTE)

• Check runout and for damage.

5 * Wheels

6 * Tires

• Check tread depth and for damage.


• Check air pressure.

• Correct if necessary.

• Check bearing for looseness or damage.

7 * Wheel bearings

8 * Steering bearings

• Check bearing play and steering for roughness.

• Lubricate with lithium-soap-based grease.

• Make sure that all nuts, bolts and screws are properly tightened.

9 * Chassis fasteners

10

11

12

13

14

Sidestand, centerstand

• Check operation.

• Lubricate.

* Sidestand switch

* Front fork


• Check operation and for oil leakage.

* Shock absorber assembly • Check operation and shock absorber for oil leakage.

Engine oil

• Change.

• Check oil level and vehicle for oil leakage.

• Clean.

15

16

17

* Engine oil filter element

* Engine oil strainer

Final transmission oil

• Clean.

• Change.

18

19

* V-belt

*

Front and rear brake switches

20

21

22

*

*

• Replace.


Moving parts and cables • Lubricate.

Throttle grip housing and cable

Lights, signals and switches

• Check operation and free play.

• Adjust the throttle cable free play if necessary.

• Lubricate the throttle grip housing and cable.


• Adjust headlight beam.

ODOMETER READING

600 mi

(1,000 km) or

1 month

2,000 mi

(4,000 km) or

6 months

4,000 mi 6,000 mi

(7,000 km) or

12 months

(10,000 km) or

18 months

8,000 mi

(13,000 km) or

24 months

Whenever worn to the limit

Whenever worn to the limit

Every 4 years

Every 16,000 mi (24,000 km)

Every 1,900 mi (3,000 km)

Every 12,000 mi (18,000 km)

EAU17620

NOTE:

8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

8 Hydraulic brake system

9 When disassembling the master cylinder or caliper cylinder, always replace the brake fluid.

Check the brake fluid level regularly and fill as required.

9 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.

9 Replace the brake hoses every four years or if cracked or damaged.

3-3

COVER AND PANEL

CHK

ADJ

COVER AND PANEL

SEAT AND SIDE COVERS

4

1

6

23Nm(2.3m

• kg, 16.6 ft • lb)

13

5

2

9

10

11

7 12

8

3

7

8

9

5

6

1

2

3

4

10

11

12

13

Order Job/Part

Removing the seat and side covers

Seat

Rear carrier

Side cover( left )

Side cover( right )

Hook( left )

Hook( right )

Cover

Front cover

Fuel tank cap

Rear cover

Tail / brake light

License plate

Trunk

Q’ty Remarks


1

1

1

1

1

1

1

1

1

1

1

1

1


3-4

COVER AND PANEL

CHK

ADJ

FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE

1

3

4

7

5

8

2

6

7

8

5

6

1

2

3

4

Order Job/Part

Removing the footrest board and footrest board side cover mole

Side covers( left and right )

Mat

Battery cover

Battery negative(-) lead

Battery positive(+) lead

Battery

Footrest board side cover mole( left )

Footrest board side cover mole( right )

Footrest board

Q’ty

1

1

1

1

1

1

1

1

Remarks


Refer to “SEAT AND SIDE COVERS”

c C

First, disconnect the negative battery lead, and then the positive battery lead.


3-5

LEG SHIELD 1 , 2

2

COVER AND PANEL

CHK

ADJ

5

6

3

7

4

1

Order Job/Part

Removing the leg shield 1,2

Footrest board

6

7

4

5

1

2

3

Headlight cover

Headlight assembly

Front turn signal light bracket

Leg shield 1

Main switch cover

Fuel lever meter

Leg shield 2

1

1

1

1

1

1

1

Q’ty Remarks


Refer to “FOOTREST BOARD AND

FOOTREST BOARD SIDE COVER

MOLE”


3-6

ADJUSTING THE VALVE CLEARANCE

CHK

ADJ

EAS00049

ENGINE


The following procedure applies to all of the valves.

NOTE:

8 Valve clearance adjustment should be made on a cold engine, at room temperature.

8 When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.

1. Remove:

8 cover

8 rear carrier

8 side cover (right,left )

8 hook

8 front cover

8 spark plug cap

Refer to “COVER AND PANEL”.

1

2. Remove:

8 spark plug

8 engine oil cap

8 valve cover (exhaust )

8 cap1

3-7

3. Measure:

8 valve clearance

Out of specification J Adjust.

Valve clearance (cold)

Intake valve

0.08 ~ 0.12 mm (0.003 ~ 0.005 in)

Exhaust valve

0.13 ~ 0.17 mm (0.005 ~ 0.007 in)

1


2

CHK

ADJ

***************************************************** a. Turn the crankshaft counterclockwise.

b. When the piston is at TDC on the compression stroke, align the punch mark in the camshaft sprocket with the stationary on the cylinder head.

c. Align the TDC mark 1 on the magneto rotor with the stationary pointer 2 on the crankcase.

d. Measure the valve clearance with a thickness gauge.

Out of specification

J Adjust.

***************************************************** a

3

2 b

1

4. Adjust:

8 valve clearance

***************************************************** a. Loosen the locknut 1.

b. Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip.

c. Turn the adjusting screw 3 in direction a or b until the specified valve clearance is obtained.

Direction a Valve clearance is increased.

Direction b Valve clearance is decreased.

3-8

Tappet adjusting tool

90890-01311 (YM-08035-A) d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specification.

8 locknut

T

R

7 Nm (0.7 m • kg, 5.1 ft • lb) e. Measure the valve clearance again.

f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.

*****************************************************


CHK

ADJ

5. Install:

8 cap

8 spark plug

T

R

12.5 Nm (1.25 m • kg, 9 ft • lb)

8 valve cover (exhaust )

8 engine oil cap

6. Install:

8 spark plug cap

8 front cover

8 hook


8 rear carrier

8 cover


3-9

ADJUSTING THE ENGINE IDLING SPEED

CHK

ADJ

EAS00054

ADJUSTING THE ENGINE IDLING SPEED

NOTE:

Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression.

1. Start the engine and let it warm up for several minutes.

1

2. Connect:

8engine tachometer 1

(onto the spark plug lead of cylinder)

Engine tachometer

90890-03113 (YU-08036-C) a b 1

3. Check:

8engine idling speed

Out of specification J Adjust

Engine idling speed

1600 ~ 1700 r/min

4. Adjust:

8engine idling speed

***************************************************** a. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained.

Direction a Engine idling speed is increased.

Direction b Engine idling speed is decreased.

*****************************************************

5. Adjust:

8throttle cable free play

Refer to “ADJUSTING THE THROTTLE

CABLE FREE PLAY”.

Throttle cable free play (at the flange of the throttle grip)

3 ~ 5 mm (0.12 ~ 0.20 in)

3-10

CHECKING THE EXHAUST GAS AT IDLE

CHK

ADJ


(Measuring the exhaust gas at idle[when air induction system is operation])

1. Stand the scooter on a level surface.

NOTE:

8 Place the scooter on a suitable stand.

8 Make sure the scooter is upright.

1

2. Install:

8pocket tester1.

(onto the engine oil drain bolt)

8engine tachometer

(onto the spark plug lead )

Pocket tester

90890-03132 (YU-03112-C)


90890-03113 (YU-08036-C)

3. Start the engine and warm it up until the specified oil temperature is reached.

Oil temperature

70~80°C

4. Measure:

8 engine idling speed


J Adjust.

Refer to “ADJUSTING THE ENGINE

IDLING SPEED”


1600 ~ 1700 r/min

3

1

2

3-11

5. Install:

8 carbon monoxide and hydrocarbon tester1.

8 sampling probe2.

8 engine tachometer3.


CHK

ADJ

NOTE:

8 Since it is necessary to insert the sampling probe 600mm into the exhaust pipe, be sure to use a heat-resisant rubber tube as shown in the illustration.

8 Be sure to set the heat-resistant rubber tube so that exhaust gas does not leak out.

8 Before using the carbon monoxide and hydrocarbon tester, be sure to read the user,s manual.

6. Measure:

8 carbon monoxide density

8 hydrocarbon density

Carbon monoxide density ( when air induction system is operating )

0.2%~1.4%

hydrocarbon density ( when air induction system is operating )

1000ppm below


J Check air induction system.

Refer to “AIR INDUCTION SYSTEM” in chapter 6.

3-12

ADJUSTING THE THROTTLE CABLE FREE PLAY

CHK

ADJ

EAS00057

ADJUSTING THE THROTTLE CABLE FREE

PLAY

NOTE:

Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly.

a

1. Check:

8 throttle cable free play a



3 ~ 5 mm (0.12 ~ 0.20 in)

2. Remove:

8 cover

8 rear carrier

8 side cover (right )


3. Adjust:

8 throttle cable free play a

2

1 b

3-13

*****************************************************

Carburetor side a. Loosen the locknut 1.

b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained.

Direction a Throttle cable free play is increased.

Direction b Throttle cable free play is decreased.

c. Tighten the locknuts.

NOTE:

If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar side.

ADJUSTING THE THROTTLE CABLE FREE PLAY

CHK

ADJ

Handlebar side a. Loosen the locknut 1.

b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained.

b a

1

2

Direction a Throttle cable free play is increased.

Direction b Throttle cable free play is decreased.

c. Tighten the locknut.

w

After adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.

*****************************************************

4. Install:

8side cover (right )

8rear carrier

8cover


3-14

a

2

CHECKING THE SPARK PLUG

CHK

ADJ

EAS00060

CHECKING THE SPARK PLUG

1. Remove:

8 cover


2. Disconnect:

8 spark plug cap

3. Remove:

8 spark plug c C

Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder.

4. Check:

8 spark plug type

Incorrect

J Change.

Spark plug type (manufacturer)

CR7E (NGK)

1

5. Check:

8 electrode 1

Damage/wear J Replace the spark plug.

8 insulator 2

Abnormal color

J Replace the spark plug.

Normal color is medium-to-light tan.

6. Clean:

8 spark plug

(with a spark plug cleaner or wire brush)

7. Measure:

8 spark plug gap a

(with a wire Thickness gauge)

Out of specification J Regap.

Spark plug gap

0.7 ~ 0.8 mm (0.028 ~ 0.032 in)

8. Install:

8 spark plug

T

R

12.5 Nm (1.25 m • kg, 9 ft • lb)

NOTE:

Before installing the spark plug, clean the spark plug and gasket surface.

3-15

9. Connect:

8 spark plug cap

10.Install:

8 cover


1

2

CHECKING THE IGNITION TIMING

CHK

ADJ

EAS00062

CHECKING THE IGNITION TIMING

1

NOTE:

Prior to checking the ignition timing, check the wiring connections of the entire ignition system.

Make sure all connections are tight and free of corrosion.

1. Remove: cap 1

2. Attach: timing light engine tachometer

(onto the spark plug lead of cylinder)

Timing light

90890-03141 (YU-03141)


90890-03113 (YU-08036-C)

3. Check: ignition timing

***************************************************** a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed.

Oil temperture

70~80°C


1600 ~ 1700 r/min b. Check that the mark 1 on the magneto rotor is within the firing range 2 on the crankcase .

Incorrect firing range

J Check the ignition system.

NOTE:

The ignition timing is not adjustable.

*****************************************************

4. Remove:

8 timing light

8 engine tachometer

5. Install:

8 cap

3-16

MEASURING THE COMPRESSION PRESSURE

CHK

ADJ

EAS00067

MEASURING THE COMPRESSION PRES-

SURE

NOTE:

Insufficient compression pressure will result in a loss of performance.

1. Measure:

8 valve clearance

Out of specification J Adjust

Refer to “ADJUSTING THE VALVE

CLEARANCE”.

2. Start the engine, warm it up for several minutes, and then turn it off.

3. Remove:

8 cover

8 rear carrier


8 hook

8 front cover


4. Disconnect:

8 spark plug cap

5. Remove:

8 spark plug c C

Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling into the cylinder.

1

3-17

6. Install:

8 compression gauge 1

Compression gauge

90890-03081

YU-33223


CHK

ADJ

7. Measure:

8 compression pressure


J Refer to steps (c) and (d).

Compression pressure (at sea level)

Minimum

827 kPa (8.27 kg/cm 2 , 400r/min)

Standard

950 kPa (9.5 kg/cm 2 , 400r/min)

Maximum

1064 kPa (10.64 kg/cm 2 , 400r/min)

***************************************************** a. Set the main switch to “ON”.

b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.

w

To prevent sparking, ground the spark plug lead before cranking the engine.

c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits.

Carbon deposit

J Eliminate.

d. If the compression pressure is below the minimum specification, pour a teaspoonful engine of oil into the spark plug bore and measure again.

Refer to the following table.

Compression pressure

(with oil applied into the cylinder)

Reading

Diagnosis

Higher than without oil

Piston ring wear or damage J Repair.

Same as without oil

Piston, valves, cylinder head gasket or piston possibly defective J Repair.

*****************************************************

8. Remove:

8 compression gauge

9. Install:

8 spark plug

T

R

12.5 Nm (1.25 m • kg, 9ft • lb)

10. Connect:

8 spark plug cap

3-18


CHK

ADJ

11. Install:

8 front cover

8 hook


8 rear carrier

8 cover


3-19

b a

1

-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚

SAE 10W-30

SAE 10W-40

SAE 20W-40

SAE 20W-50

CHECKING THE ENGINE OIL LEVEL

CHK

ADJ

EAS00069

CHECKING THE ENGINE OIL LEVEL


NOTE:




3. Check:

8 engine oil level 1

The engine oil level should be between the minimum level mark a and maximum level mark b.

Below the minimum level mark J Add the recommended engine oil to the proper level.

Recommended oil

Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures.

API standard

SE or higher grade c C the crankcase.

NOTE:

Before checking the engine oil level, wait a few minutes until the oil has settled.


5. Check the engine oil level again.

NOTE:

Before checking the engine oil level, wait a few minutes until the oil has settled.

3-20

CHECKING THE ENGINE OIL

1

CHK

ADJ

EAS00076

CHANGING THE ENGINE OIL


2. Place a container under the engine oil drain bolt.

3. Remove:

8 engine oil filler cap 1

8 engine oil drain bolt 2

(along with the gasket)

4. Drain:

8 engine oil

(completely from the crankcase)

2

3 2

1

5. If the oil filter element is also to be cleaned,

8 perform the following procedure.

***************************************************** a. Remove the oil strainer cover 1 and oil filter element 2.

b. Replace the O-ring 3 c. Install the oil strainer cover.

T

.

R

.

Oil strainer cover

32 Nm (3.2 m • kg, 23.1 ft • lb)

*****************************************************

6. Install:

8 engine oil drain bolt


T

R

23 Nm (2.3 m • kg, 16.6 ft • lb)

7. Fill:

8 crankcase

(with the specified amount of the recommended engine oil)

Periodic oil change

1.0 L(0.92 lmp qt, 1.09 US qt)

8.

Install:

8 engine oil filler cap

9.

Start the engine, warm it up for several minutes, and then turn it off.

3-21

10. Check:

8 engine

(for engine oil leaks)

CHANGING THE ENGINE OIL FILTER ELEMENT

CHK

ADJ

11. Check:

8 engine oil level

Refer to “CHECKING THE ENGINE OIL

LEVEL”.

12. Check:

8 engine oil pressure


PRESSURE”.

1

CHANGING THE ENGINE OIL FILTER ELE-

MENT

1. Drain:

8 engine oil

2. Remove:

8 oil delivery pipe bolt 1

8 copper washers

3. Remove:

8 oil filter element cover1

8 o-ring2

8 oil filter element 3

1

2

3

3

2

1

4. Install: c C

Be careful because it causes an engine trouble when the attachment direction of the oil filter element is mistaken.

8 oil filter element 1

8 o-ring2

New

8 oil filter element cover3

T

R

8 Nm (0.8 m • kg, 5.8 ft • lb)

8 copper washers

8 oil delivery pipe bolt

T

R

10 Nm (1.0 m • kg, 7.2 ft • lb)

3-22

CHANGING THE ENGINE OIL FILTER ELEMENT

CHK

ADJ c C

Check it under the condition that a check bolt is surely loosened because oil erupts when a check bolt is removed and an engine is started.

5. Fill:

8 crankcase


“.

Quantity

Total amount

1.2L (1.10 Imp qt, 1.31 US qt)

Without oil filter element replacement

1.2L (1.10 Imp qt, 1.31 US qt)


1.0 L (0.92 Imp qt, 1.09 US qt)

3-23

2

1

CHANGING THE TRANSMISSION OIL

CHK

ADJ

CHANGING THE TRANSMISSION OIL


NOTE:

8 Stand the scooter on a suitable stand.

8 Make sure that the scooter up right.


3. Place a container under the transmission.

2

4. Remove:

8 Oil filler cap

8 Transmission oil drain bolt 1

8 Completely drain the transmission oil

5. Install:

8 transmission oil drain bolt

T

R

23 Nm (2.3 m • kg, 16.6 ft • lb)

6. Fill:

8 transmission oil

( with the specified amount of the recommended transmission oil )

Total amount

0.15L(0.14 Imp qt, 0.16 US.qt)


0.13L(0.12 Imp qt, 0.14 US.qt)

Recommended oil

SAE85W140SE

7. Install:

8 o-ring1

8 oil filler cap2

8. Start the engine for several minutes to warm it up and check for the oil leakage.

1

3-24

1

MEASURING THE ENGINE OIL PRESSURE

CHK

ADJ

EAS00077

MEASURING THE ENGINE OIL PRESSURE

1. Check:

8 engine oil level

Below the minimum level mark J Add the recommended engine oil to the proper level.


LEVEL”.


c C

When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine.

3. Remove:

8 cover


4. Lossen:

8 gallery bolt 1 w

The engine, muffler and engine oil are extremely hot.

5. Check:

8 engine oil pressure

***************************************************** a. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt.

If no engine oil comes out after one minute, turn the engine off so that it will not seize.

b. Check the engine oil passages, the oil filter and oil pump for damage or leakage.Refer

to”OIL PUMP” in chapter 5.

c. Start the engine after solving the problem(s) and check the engine oil pressure again.

*****************************************************

6. Install:

8 gallery bolt

3-25

CLEANING THE AIR FILTER ELEMENT/

CLEANING THE V-BELT CASE AIR FILTER ELEMENT

1

2

CHK

ADJ

EAS00086

CLEANING THE AIR FILTER ELEMENT

1. Remove:

8 air filter case cover 1

8 air filter element2

2. Check:

8 air filter element

Damage

J Replace.

EAS00091

CLEANING THE V-BELT CASE AIR

FILTER ELEMENT

1. Remove:

8 kick starter 1

8 damper cover 2

1

2

2

1

2. Remove:

8 V-belt case air filter element holder1

8 V-belt case air filter element 2

NOTE:

When assembling the element, the yellow side

(the coarser side) must face the case cover side of the air cleaner. Wrong side assembling will result in failure of filtering. Moreover, the element should be tightly sealed with the case cover of the crank to prevent from air leakage.

3. Check:

8 V-belt case air filter element 1

Damage

J Replace.

1

1

3-26

4. Clean:

8 V-belt case air filter element 1 (with solvent) w

Never use low flash point solvents, such as gasoline, to clean the air filter element. Such solvents may cause a fire or an explosion.

CLEANING THE V-BELT CASE AIR FILTER ELEMENT

CHK

ADJ

NOTE:

After cleaning, gently squeeze the V-belt case air filter element to remove the excess solvent.

c C

Do not twist the V-belt case air filter element when squeezing it.

5. Apply the recommended oil to the entire surface of the air filter element and squeeze out the excess oil. The air filter element should be wet but not dripping.

Recommanded oil

Engine oil

6. Install:

8 element 1

1

2

7. Install:

8 element holder1

T

R

7 Nm (0.7 m • kg, 5.1 ft • lb)

1

1

3-27

8. Install:

8 damper cover 1

8 kick starter 2

T

R

23 Nm (2.3 m • kg, 16.6 ft • lb)

CHECKING THE CARBURETOR JOINT

AND INTAKE MANIFOLD

CHK

ADJ

EAS00094

CHECKING THE CARBURETOR JOINT AND

INTAKE MANIFOLD

1. Remove:

8 cover

8 rear carrier


8 seat

8 hook

8 front cover

8 fuel tank cap

8 rear cover

8 trunk


2

1

2. Check:

8 carburetor joint 1

8 intake manifold 2

Cracks/damage

J Replace.

Refer to “CARBURETOR” in chapter 6.

3. Install:

8 trunk

8 rear cover

8 fuel tank cap

8 front cover

8 hook

8 seat


8 rear carrier

8 cover


3-28

CHECKING THE FUEL AND VACUUM HOSES/

CHECKING THE CRANKCASE BREATHER HOSE

CHK

ADJ

EAS00096

CHECKING THE FUEL AND VACUUM

HOSES

The following procedure applies to all of the fuel and vacuum hoses.

1. Remove:

8cover

8rear carrier

8side cover (left )


1

2

2. Check:

8vacuum hose 1

8fuel hose 2

Cracks/damage J Replace.


3. Install:

8side cover (left )

8rear carrier

8cover


EAS00098

CHECKING THE CRANKCASE BREATHER

HOSE

1. Remove:

8 cover


1

2. Check:

8 crankcase breather hose 1

Cracks/damage

J Replace.


c C

Make sure the crankcase breather hose is routed correctly.

3. Install:

8 cover


3-29

4

3

CHECKING THE EXHAUST SYSTEM

CHK

ADJ

EAS00099

CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the muffler assembly and gaskets.

1. Remove:

8 hose(from air fi/ter)

8 vacuum hose

8 hose(to cylinder head)

8 air cut-off valve assembly

Refer to “AIR INDUCTION SYSTEM”in chapter 6.

2. Check:

8 muffler assembly 1


8 gasket

Exhaust gas leaks J Replace.

2

1

3. Check:

8 tightening torque

T

.

R

.

Muffler assembly nut 2

10 Nm (1.0 m • kg, 7.2 ft • lb)

Muffler and rear arm bolt 3

31 Nm (3.1 m • kg, 22.4 ft • lb)

Protector screw 4

7 Nm (0.7 m • kg, 5.1 ft • lb)

4.

Install:

8 air cut-off valve assembly

8 hose(to cylinder head)

8 vacuum hose

8 hose(from air fi/ter)

Refer to “AIR INDUCTION SYSTEM”in chapter 6.

3-30

a

1 a b

ADJUSTING THE FRONT BRAKE/

ADJUSTING THE REAR BRAKE a

CHK

ADJ

EAS00108

CHASSIS

ADJUSTING THE FRONT BRAKE

1. Check:

8 brake lever free play a

Brake lever free play (at the end of the brake lever)

3 ~ 5mm (0.12 ~ 0.20 in) w

A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Therefore, check and, if necessary, bleed the brake system.

EAS00114

ADJUSTING THE REAR BRAKE

1. Check:

8 brake lever free playa


Brake lever free play

10~20 mm(0.4~0.8 in)

2. Adjust:

8 brake lever free play

*****************************************************

Rear wheel side a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained.

Direction a Brake lever free play is increased.

Direction b Brake lever free play is decreased.

c C

After adjusting the brake lever free play, make sure there is no brake drag.

*****************************************************

3-31

CHECKING THE BRAKE FLUID LEVEL

CHK

ADJ

EAS00116

CHECKING THE BRAKE FLUID LEVEL


NOTE:



a

2. Check:

8 brake fluid level

Below the minimum level mark a J Add the recommended brake fluid to the proper level.

Recommended brake fluid

DOT 4 w

Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

c C

Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.

NOTE:

In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal.

3-32

2

1

CHECKING THE FRONT BRAKE PADS/

CHECKING THE REAR BRAKE SHOES/

CHECKING THE FRONT BRAKE HOSE

CHK

ADJ

EAS00117

CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the brake pads.

1. Remove:

8 cap 1

2. Operate the brake.

3. Check:

8 front brake pad

Wear indicators 2 almost touch the brake disc J Replace the brake pads as a set.

Refer to “REPLACING THE FRONT

BRAKE PADS” in chapter 4.

1

1

2

3-33

EAS00126

CHECKING THE REAR BRAKE SHOES

1. Operate the brake.

2. Check:

8 wear indicator 1

Reaches the wear limit line 2

J Replace the brake shoes as a set.

Refer to “REAR WHEEL AND REAR

BRAKE” in chapter 4.

EAS00130

CHECKING THE FRONT BRAKE HOSE

1. Check:

8 brake hose 1

Cracks/damage/wear J Replace.

2. Check:

8 brake hose clamp

Loose connection J Tighten the clamp bolt.

3. Hold the scooter upright and apply the front

8 brake several times.

4. Check:

8 brake hose

Brake fluid leakage J Replace the damaged hose.

Refer to “FRONT AND REAR BRAKES” in chapter 4.

1

1

2

BRAKE FLUID CHANGE

CHK

ADJ

BRAKE FLUID CHANGE w

Should you feel loose when pulling Brake, it is possibly due to leaking of Brake fluid of mixing with air which led to the ineffectiveness of Brake. Since poor performance of Brake caused by mixing with air may trigger accidents, therefore inspection must be carried out prior to riding, and expel the air if necessary.

1. Place the scooter in standing position vertically on a flat floor.

NOTE:

8 Use the main stand to place the scooter in upright position.

8 During change, be sure the scooter is standing vertically.

2. Remove:

8 reservoir cap 1

Remove the reservoir cap of the master cylinder at horizontal condition.

3. Bleed.

8hydraulic brake system.

3-34

***************************************************** a. Securely connect the transparent vinyl hose

1 to the fluid screw 2.

b. Place the other end of the hose in the oil pan (receiving pan).

c. Slowing operate the brake lever for several times.

Repeat the procedures until no more brake fluid overflows from the fluid screw.

c C

Brake fluid can cause damages to painting or plastic surfaces, so be sure to wipe clean the spilled brake fluid.

d. Tighten:

8bleed screw

T

R

6Nm (0.6m • kg, 4.3 ft • lb)

BRAKE FLUID CHANGE

CHK

ADJ e. Remove the reservoir diaphragm.

f. Fill proper volume of designated brake fluid into the reservoir of the master cylinder.

Refer to “CHECKING THE BRAKE FLUID

LEVEL”.

g. Operate brake lever slowly for several times.

Repeat the procedures until the small amount of air (air bubbles) in the reservoir tank disappears, and the brake lever feels heavy.

h. Bleed:

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM”.

w

Following air expelling for the hydraulic brake, please verify the actuating condition of the brake.

*****************************************************

4. Install:

8 reservoir cap

T

R

1.6Nm (0.16m • kg, 1.2 ft • lb)

3-35

BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK

ADJ

EAS00133

BLEEDING THE HYDRAULIC BRAKE SYS-

TEM w

Bleed the hydraulic brake system whenever: or replaced.

1. Remove:

8reservoir cap

NOTE:

8 Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow.

8 When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure.

8 If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours.

Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared.

1

2

3-36

2. Bleed:

8 hydraulic brake system

***************************************************** a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.

b. Install the brake master cylinder reservoir diaphragm.

c. Connect a clear plastic hose 1 tightly to the bleed screw 2.

d. Place the other end of the hose into a container.

e. Slowly apply the brake lever several times.

f. Fully pull the brake lever without releasing it.

g. Loosen the bleed screw.

NOTE:

Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip.

BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK

ADJ h. Tighten the bleed screw and then release the brake lever.

i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.

j. Tighten the bleed screw to specification.

T

.

R

.

Bleed screw

6 Nm (0.6 m • kg, 4.3 ft • lb) k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.


LEVEL”.

w

After bleeding the hydraulic brake system, check the brake operation.

*****************************************************

3.

Install: reservoir cap

T

R

1.6 Nm (0.16 m • kg, 1.2 ft • lb)

3-37

CHECKING AND ADJUSTING THE STEERING HEAD

CHK

ADJ

EAS00148

CHECKING AND ADJUSTING THE STEER-

ING HEAD


w

Securely support the scooter so that there is no danger of it falling over.

NOTE:

Place the scooter on a suitable stand so that the front wheel is elevated.

2. Check:

8 steering head

Grasp the bottom of the front fork legs and gently rock the front fork.

Binding/looseness J Adjust the steering head.

3. Remove:

8 head light cover

8 front turn signal light bracket

8 leg shield 1


6

1

2

3

4

5

4. Adjust:

8 steering head

***************************************************** a. Remove the upper ring nut 1, the lock washer 2, the center ring nut 3 and the rubber washer 4.

b. Loosen the lower ring nut 5 and then tighten it to specification with the steering nut wrench 6.

NOTE:

Set the torque wrench at a right angle to the steering nut wrench.

3-38

Steering nut wrench

90890-01403

YU-33975

T

.

R

.

Lower ring nut (initial tightening torque)

28 Nm (2.8 m • kg, 20.3 ft • lb)

CHECKING AND ADJUSTING THE STEERING HEAD

CHK

ADJ c. Loosen the lower ring nut completely and then tighten it to specification with a steering nut wrench .

w

Do not overtighten the lower ring nut.

b

7 a

8

T

.

R

.

Lower ring nut (final tightening torque)

9 Nm (0.9 m • kg, 6.5 ft • lb) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings.

Refer to “STEERING HEAD” in chapter 4.

e. Install the rubber washer.

f. Install the center ring nut.

g. Finger tighten the center ring nut 7, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the center ring nut until their slots are aligned.

h. Install the lock washer 8.

NOTE:

Make sure the lock washer tabs a sit correctly in the ring nut slots b.

i. Hold the lower and center ring nuts with a ring nut wrench and tighten the upper steering nut with a ring nut wrench.

Ring nut wrench

90890-01268

YU-01268

T

.

R

.

Upper ring nut

75 Nm (7.5 m • kg, 54.2 ft • lb)

*****************************************************

5. Install:

8 leg shield 1

8 front turn signal light bracket

8 head light cover


3-39

CHECKING THE FRONT FORK

CHK

ADJ

EAS00151

CHECKING THE FRONT FORK


w


2. Check:

8 inner tube

Damage/scratches J Replace.

8 oil seal

Oil leakage J Replace.

3. Hold the scooter upright and apply the front brake.

4. Check:

8 front fork operation

Push down hard on the handlebar several times and check if the front fork rebounds smoothly.

Rough movement

J Repair.

Refer to “FRONT FORK” in chapter 4.

3-40

CHECKING THE TIRES

CHK

ADJ

EAS00163


The following procedure applies to both of the tires.

1. Check:

8tire pressure


J Regulate.

w checked and regulated when the tire temperature equals the ambient air temperature.

must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.

could cause tire damage, an accident or an injury.

Basic weight

(with oil and a full fuel tank)

Maximum load*

Cold tire pressure

Up to 90 kg load*

97 kg (214 lb)

253 kg (558 lb)

Front Rear

150 kPa (1.5

kgf/cm 2 , 22 psi)

200 kPa (2.00

kgf/cm 2 , 29 psi)

90 kg ~ maximum load*

150 kPa (1.5

kgf/cm 2 , 22 psi)

225 kPa (2.25

kgf/cm 2 , 32 psi)

* Total weight of rider, passenger, cargo and accessories w

It is dangerous to ride with a worn-out tire.

When the tire tread reaches the wear limit, replace the tire immediately.

3-41

3

2

1


CHK

ADJ

2.

Check:

8tire surfaces

Damage/wear

J Replace the tire.

Minimum tire tread depth

0.8 mm (0.03 in)

1 Tire tread depth

2 Sidewall

3 Wear indicator w designed only for tube tires to avoid tire failure and personal injury from sudden deflation.

the correct tube.

tube as a set.

the wheel rim band and tube are centered in the wheel groove.

mended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement.

A Tire

B Wheel

Tube wheel

Tubeless wheel

Tube tire only

Tube or tubeless tire low have been approved by Yamaha

Motor Taiwan Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this scooter.

Front tire

Manufacturer Model Size

CHENG SHIN C-922L 3.50-10 51J

Rear tire

3-42

Manufacturer Model Size

CHENG SHIN C- 6007 3.50-10 51J

2

1


CHK

ADJ w

New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.

NOTE:

For tires with a direction of rotation mark 1:

8 Install the tire with the mark pointing in the direction of wheel rotation.

8 Align the mark 2 with the valve installation point.

3-43

CHECKING THE WHEELS/

CHECKING AND LUBRICATING THE CABLES

CHK

ADJ

EAS00168

CHECKING THE WHEELS

The following procedure applies to both of the wheels.

1. Check:

8 wheel

Damage/out-of-round

J Replace.

w

Never attempt to make any repairs to the wheel.

NOTE:

After a tire or wheel has been changed or replaced, always balance the wheel.

3-44

EAS00170

CHECKING AND LUBRICATING THE

CABLES

The following procedure applies to all of the inner and outer cables.

w

Damaged outer cable may cause the cable to corrode and interfere with its movement.

Replace damaged outer cable and inner cables as soon as possible.

1. Check:

8 outer cable

Damage

J Replace.

2. Check:

8 cable operation

Rough movement J Lubricate.

Recommended lubricant

Engine oil or a suitable cable lubricant

NOTE:

Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device.

LUBRICATING THE SIDESTAND/

LUBRICATING THE CENTERSTAND

CHK

ADJ

EAS00172

LUBRICATING THE SIDESTAND

Lubricate the pivoting point and metal-to-metal moving parts of the sidestand.


Lithium-soap-based grease

EAS00173

LUBRICATING THE CENTERSTAND

Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.



3-45

CHECKING AND CHARGING THE BATTERY

CHK

ADJ

EAS00179

ELECTRICAL SYSTEM

CHECKING AND CHARGING THE BATTERY w

Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid.

Therefore, always follow these preventive measures: or working near batteries.

area.

open flames (e.g., welding equipment, lighted cigarettes).

dling batteries.

OUT OF REACH OF CHILDREN.

it can cause severe burns or permanent eye injury.

FIRST AID IN CASE OF BODILY CONTACT:

EXTERNAL and get immediate medical attention.

INTERNAL followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.

c C the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate.

charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.

3-46


CHK

ADJ

NOTE:

Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte.

Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.

1. Remove:

8 mat

8 battery cover


1

1

2

2. Disconnect:

8 battery leads

(from the battery terminals) c C

First, disconnect the negative battery lead

3. Remove:

8 battery

4. Check:

8 battery charge

***************************************************** a. Connect a digital pocket tester 1 to the battery terminals.

Pocket tester

90890-03132 (YU-03112-C)

3-47

Positive tester probe J positive battery terminal

Negative tester probe J negative battery terminal

NOTE:

8 The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected).

8 No charging is necessary when the opencircuit voltage equals or exceeds 12.8 V.

13.0

12.5

12.0

11.5


Relationship between the open-circuit voltage and the charging time at 20 C

CHK

ADJ b. Check the charge of the battery, as shown in the charts and the following example.

5 6.5

10

Charging time (hours)

These values vary with the temperature, the condition of the battery plates, and the electrolyte level.

Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 <-> 30%

*****************************************************

Ambient temperature

20 C

Charging condition of the battery (%)

3-48

5.

Charge:

8 battery

(refer to the appropriate charging method illustration) w

Do not quick charge a battery.

c C caps.

since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.

ing current on the battery charger, be careful not to overcharge the battery.

move it from the scooter. (If charging has to be done with the battery mounted on the scooter, disconnect the negative battery lead from the battery terminal.) plug in the battery charger until the battery charger leads are connected to the battery.

lead clips from the battery terminals, be sure to turn off the battery charger.


CHK

ADJ are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.

at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it.

Hot batteries can explode!

the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.

3-49


CHK

ADJ

Charging method using a variable-current (voltage) charger

Charger

Ammeter

Measure the open-circuit voltage prior to charging.

NOTE:

Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage.

Connect a charger and ammeter to the battery and start charging.

NOTE:

Set the charging voltage to 16-17 V.

(If the charging voltage is lower charging will be insufficient, if it is higher, the battery will be over-charged.)

NO

YES

Is the amperage higher than the standard charging amperage written on the battery?

NO

Adjust the voltage to obtain the standard charging amperage.

YES

Adjust the char ging voltage to

20 ~ 25V.

Monitor the amperage for 3 ~ 5 minutes. Is the standard charging amperage exceeded?

NO

Set the timer to the charging time determined by the opencircuit voltage.

Refer to “CHECKING AND

CHARGING THE BATTERY”.

If the amperage does not exceed the standard charging amperage after 5 minutes, replace the battery.

If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage.

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

12.8 V ~ Charging is complete.

12.0 ~ 12.7 V ~ Recharging is required.

Under 12.0 V ~ Replace the battery.

3-50


CHK

ADJ

Charging method using a constant voltage charger

Measure the open-circuit voltage prior to charging.

NOTE:

Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage.

Connect a charger and ammeter to the battery and start charging.

YES

Is the amperage higher than the standard charging amperage written on the battery?

NO

Charge the battery until the charging voltage reaches 15 V.

NOTE:

Set the charging time to a maximum of 20 hours.

This type of battery charger cannot charge an MF batter y. A variablevoltage charger is recommended.

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

12.8 V ~ Charging is complete.

12.0 ~ 12.7 V ~ Recharging is required.

Under 12.0 V ~ Replace the battery.

CAUTION:

Constant amperage chargers are not suitable for charging MF batteries.

Voltmeter

Charger

Ammeter

3-51

CHECKING AND CHARGING THE BATTERY/

CHECKING THE FUSES

2

1

CHK

ADJ

6. Install:

8 battery

7. Connect:

8 battery leads

(to the battery terminals) c C

First, connect the positive battery lead 1 and then the negative battery lead 2

8. Check:

8 battery terminals

Dirt

J Clean with a wire brush.

Loose connection

J Connect properly.

9. Lubricate:

8 battery terminals


Dielectric grease

10. Install:

8 battery cover

8 mat


EAS00181


The following procedure applies to all of the fuses.

c C

To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse.

1. Remove:

8 mat

8 battery cover


3-52


CHK

ADJ

2. Check:

8 fuse

***************************************************** a. Connect the pocket tester to the fuse and check the continuity.

NOTE:

Set the pocket tester selector to “

Ω × 1”.

Pocket tester

90890-03132 (YU-03112-C) b. If the pocket tester indicates “ ∞”, replace the fuse.

*****************************************************

3. Replace:

8 blown fuse

***************************************************** a. Set the main switch to “OFF”.

b. Install a new fuse of the correct amperage rating.

c. Set on the switches to verify if the electrical circuit is operational.

d. If the fuse immediately blows again, check the electrical circuit.

Fuses Amperage rating Q’ty

Main 10A 1

Reserve 10A 1 w

Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

*****************************************************

4. Install:

8 battery cover

8 mat


3-53

REPLACING THE HEADLIGHT BULB

CHK

ADJ

EAS00182

REPLACING THE HEADLIGHT BULB

1. Remove:

8 headlight cover

2

1

2. Disconnect:

8 headlight coupler 1

3. Remove:

8 headlight bulb holder rubber2

1

2

4. Remove :

8 headlight bulb holder 1

8 headlight bulb 2 w

Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

5. Install:

8 headlight bulb New

Secure the new headlight bulb with the headlight bulb holder.

c C

Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

3-54

6. Install :

8 headlight bulb holder

8 headlight bulb holder rubber

7. Connect:

8 headlight coupler

8. Install:

8 headlight cover

1

ADJUSTING THE HEADLIGHT BEAMS a b

CHK

ADJ

EAS00185

ADJUSTING THE HEADLIGHT BEAMS

The following procedure applies to both of the headlight.

1. Adjust:

8 headlight beam (vertically) a. Loosen the adjusting screw 1and press headlight in direction a or b.

*****************************************************

Direction a Headlight beam is raised.

Direction b Headlight beam is lowered.

***************************************************** a

1 b

2. Adjust:

8 headlight beam (horizontally)

***************************************************** a. Turn the adjusting knob 1 in direction a or b.

Direction a Headlight beam moves to the right.

Direction b Headlight beam moves to the left.

*****************************************************

3-55

CHAS

CHAPTER 4

CHASSIS

FRONT WHEEL AND BRAKE DISC ....................................................... 4-1

FRONT WHEEL ................................................................................. 4-2

REMOVING THE FRONT WHEEL .................................................... 4-3

CHECKING THE FRONT WHEEL .................................................... 4-4

CHECKING THE BRAKE DISC ......................................................... 4-5

ASSEMBLING THE FRONT WHEEL ................................................ 4-7

INSTALLING THE FRONT WHEEL .................................................. 4-8

ADJUSTING THE FRONT WHEEL STATIC BALANCE ................... 4-9

REAR WHEEL AND REAR BRAKE ...................................................... 4-11

CHECKING THE REAR WHEEL ..................................................... 4-12

CHECKING THE BRAKE ................................................................ 4-13

ASSEMBLING THE BRAKE SHOE PLATE .................................... 4-14

ADJUSTING THE REAR WHEEL STATIC BALANCE ................... 4-14

FRONT BRAKE ...................................................................................... 4-15

FRONT BRAKE PADS ..................................................................... 4-15

REPLACING THE FRONT BRAKE PADS ...................................... 4-16

FRONT BRAKE MASTER CYLINDER ........................................... 4-19

DISASSEMBING THE FRONT BRAKE MASTER CYLINDER ...... 4-20

DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ... 4-21

CHECKING THE FRONT BRAKE MASTER CYLINDER .............. 4-21

ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER

CYLINDER ................................................................................... 4-23

FRONT BRAKE CALIPER............................................................... 4-26

DISASSEMBING THE FRONT BRAKE CALIPER ......................... 4-27

DISASSEMBLING THE FRONT BRAKE CALIPER ....................... 4-28

CHECKING THE FRONT BRAKE CALIPER .................................. 4-29

ASSEMBLING AND INSTALLING THE FRONT BRAKE

CALIPER ...................................................................................... 4-30

FRONT FORK ......................................................................................... 4-33

DISASSEMBING THE FRONT FORK LEGS ................................. 4-34

REMOVING THE FRONT FORK LEGS.......................................... 4-35

DISASSEMBLING THE FRONT FORK LEGS ............................... 4-36

CHECKING THE FRONT FORK LEGS .......................................... 4-38

ASSEMBLING THE FRONT FORK LEGS ..................................... 4-39

INSTALLING THE FRONT FORK LEGS ........................................ 4-42

4-55

CHAS

HANDLEBAR .......................................................................................... 4-43

REMOVING THE HANDLEBAR ...................................................... 4-44

CHECKING THE HANDLEBAR ...................................................... 4-44

INSTALLING THE HANDLEBAR..................................................... 4-45

STEERING HEAD ................................................................................... 4-47

LOWER FENDER COVER AND HANDLEBAR LOWER

HOLDER ....................................................................................... 4-47

LOWER BRACKET .......................................................................... 4-48

REMOVING THE LOWER BRACKET ............................................. 4-50

CHECKING THE STEERING HEAD ............................................... 4-51

INSTALLING THE STEERING HEAD ............................................. 4-52

REAR SHOCK ABSORBER .................................................................. 4-53

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY .......... 4-53

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .......... 4-53

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ........ 4-54

4-56

FRONT WHEEL AND BRAKE DISC

CHAS

EAS00513

CHASSIS


1

4

LS

6

2

3

5

70Nm(7.0m

• kg, 50.6 ft • lb)

20Nm(2.0m

• kg, 14.5 ft • lb)

LT

7

8

3

4

1

2

5

6

Order Job/Part

Removing the front wheel and brake disc

Q’ty Remarks


NOTE:


Speedometer cable

Front brake caliper assembly

Wheel axle nut

Wheel axle

Front wheel

Speedometer gear unit assembly

1

1

1

1

1

1 Refer to”REMOVING THE FRONT

WHEEL and INSTALLING THE FRONT

WHEEL”

7

8

Spacer

Front brake disc

1

1


4-1

EAS00518

FRONT WHEEL


CHAS

4

3

B

B

1

2

Order

1

2

3

4

Job/Part

Disassembling the front wheel

Oil seal

Bearing

Collar

Bearing

Q’ty Remarks


1

1

1

1 Refer to”REMOVING THE FRONT

WHEEL” and “INSTALLING THE FRONT

WHEEL”

For assembly, reverse the disassembly procedure.

4-2


CHAS

EAS00520

REMOVING THE FRONT WHEEL


w


NOTE:


2. Remove:

8 speedometer cable

8 brake hose holder

Refer to” REMOVING THE FRONT

WHEEL AND BRAKE DISC” .

1

3. Remove:

8 brake caliper1

8 front wheel axle

8 front wheel

8 speedometer gear unit assembly

NOTE:

Do not apply the brake lever when removing the brake caliper.

4. Elevate:

8 front wheel

NOTE:


4-3


CHAS

EAS00525

CHECKING THE FRONT WHEEL

1. Check:

8 wheel axle

Roll the wheel axle on a flat surface.

Bends J Replace.

w

Do not attempt to straighten a bent wheel axle.

2. Check:

8 tire

8 front wheel

Damage/wear

J Replace.

Refer to “CHECKING THE TIRES” and

“CHECKING THE WHEELS” in chapter

3.

3. Measure:

8 radial wheel runout 1

8 lateral wheel runout 2

Over the specified limits J Replace.

Radial wheel runout limit

1.0 mm (0.04 in)

Lateral wheel runout limit

1.0 mm(0.04 in)

4-4

4. Check:

8 wheel bearings

Front wheel turns roughly or is loose J

Replace the wheel bearings.

8 oil seals

Damage/wear

J Replace.

5. Replace:

8 wheel bearings New

8 oil seal New

*****************************************************

2

1


CHAS a.

Clean the outside of the front wheel hub.

b.

Remove the oil seals 1 with a flat-head screwdriver.

NOTE:

To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface.

c. Remove the wheel bearings 3 with a general bearing puller.

d. Install the new wheel bearings and oil seals in the reverse order of disassembly.

*****************************************************

3 a b

EAS00528

CHECKING THE BRAKE DISC

1. Check:

8 brake disc

Damage/galling J Replace.

2. Measure:

8 brake disc deflection a


J Correct the brake disc deflection or replace the brake disc.

Brake disc deflection limit (maximum)

0.10 mm (0.04 in)

***************************************************** a. Place the scooter on a suitable stand so that the front wheel is elevated.

b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary.

c. Remove the brake caliper.

d. Hold the dial gauge at a right angle against the brake disc surface.

e. Measure the deflection 2 ~ 3 mm (0.08 ~

0.12 in) below the edge of the brake disc.

*****************************************************

4-5

LT


CHAS

3. Measure:

8 brake disc thicknessb

Measure the brake disc thickness at a few different locations.

Out of specification J Replace.

Brake disc thickness limit (minimum)

3.5 mm (0.14 in)

4. Adjust:

8 brake disc deflection

***************************************************** a. Remove the brake disc.

b. Rotate the brake disc by one bolt hole.

c. Install the brake disc.

NOTE:

Tighten the brake disc bolts in stages and in a crisscross pattern.

T

.

R

.

Brake disc bolt

20 Nm (2.0 m • kg, 14.5 ft • lb)

LOCTITE ® d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification.

f. If the brake disc deflection cannot be brought within specification, replace the brake disc.

*****************************************************

4-6


CHAS

EAS00539

ASSEMBLING THE FRONT WHEEL

1. Install:

8 wheel bearings

8 oil seals New

***************************************************** a. Install the new wheel bearings and oil seals in the reverse order of disassembly.

c C

Do not contact the wheel bearing inner race with the outer race 3

NOTE:

Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal.

*****************************************************

4-7

1

3

3


CHAS

EAS00542

INSTALLING THE FRONT WHEEL

1. Lubricate:

8 wheel axle

8 wheel bearings

8 oil seal lips



2

2. Install:

8 speedometer gear unit 1

NOTE:

Make sure the speedometer gear unit and the wheel hub are installed with the two projections

2meshed into the two slots3 respectively.

1

2

3. Install:

8 front wheel 1

NOTE:

Make sure the slot2 in the speedometer gear unit fits over the stopper 3on the outer tube.

4. Tighten:

8 wheel axle

T

R

70 Nm (7.0 m • kg, 50.6 ft • lb) c C

Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly.

1

2

4-8

5. Install:

8 brake caliper 1

8 brake caliper bolts 2

T

R

35 Nm (3.5 m • kg, 25.3 ft • lb) w

Make sure the brake hose is routed properly.


CHAS

EAS00548

ADJUSTING THE FRONT WHEEL STATIC

BALANCE

NOTE:

8 After replacing the tire, wheel or both, the front wheel static balance should be adjusted.

8 Adjust the front wheel static balance with the brake disc installed.

1. Remove:

8 balancing weight(s)

X

1

X 2

2. Find:

8 front wheel’s heavy spot

NOTE:

Place the front wheel on a suitable balancing stand.

***************************************************** a. Spin the front wheel.

b. When the front wheel stops, put an “X 1 ” mark at the bottom of the wheel.

c. Turn the front wheel 90° so that the “X 1 ” mark is positioned as shown.

d. Release the front wheel.

e. When the wheel stops, put an “X 2 ” mark at the bottom of the wheel.

f. Repeat steps (d) through (f) several times until all the marks come to rest at the same spot.

g. The spot where all the marks come to rest is the front wheel’s heavy spot “X”.

*****************************************************

4-9

X


CHAS

1

3. Adjust:

8 front wheel static balance

***************************************************** a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”.

NOTE:

Start with the lightest weight.

b.

Turn the front wheel 90° so that the heavy spot is positioned as shown.

c.

If the heavy spot does not stay in that position, install a heavier weight.

d.

Repeat steps (b) and (c) until the front wheel is balanced.

*****************************************************

4. Check:

8 front wheel static balance

***************************************************** a. Turn the front wheel and make sure it stays at each position shown.

b. If the front wheel does not remain stationary at all of the positions, rebalance it.

*****************************************************

4-10

REAR WHEEL AND REAR BRAKE

CHAS


1

LS

11

9

10

3

LS

4

2

6

8

7

5

105Nm(10.5m

• kg, 75.9 ft • lb)

7

8

9

10

11

3

4

5

6

1

2

Order Job/Part

Removing the rear wheel and rear brake

Q’ty Remarks


NOTE:


Refer to “MAINFOLD, AIR FILTER AND

MUFFLER ASSEMBLY “in chapter 5.

Muffler assembly

Rear arm

Brake adjuster

Brake cable

Compression spring

Pin

Rear wheel

Brake shoe

Tension spring

Plate washer

Camshaft lever

Indicator plate

Brake camshaft

1

1

1

1

1

2

2

1

1

1

1


4-11


CHAS

EAS00565

CHECKING THE REAR WHEEL

1. Check:

8 wheel axle

8 rear wheel

Refer to “CHECKING THE FRONT

WHEEL”.

2. Check:

8 tire

8 rear wheel

Damage/wear J Replace.

Refer to “CHECKING THE TIRES” and

“CHECKING THE WHEELS” in chapter

3.

3. Measure:

8radial wheel runout

8lateral wheel runout

Refer to “CHECKING THE FRONT

WHEEL”.

4-12

b


CHAS

EAS00569

CHECKING THE BRAKE

The following procedure applies to all of the brake shoes.

1. Check:

8 brake shoe lining

Glazed areas

J Repair.

Sand the glazed areas with course sandpaper.

a

NOTE:

After sanding the glazed areas, clean the brake shoe with a cloth.

2. Measure:

8 brake shoe lining thickness a


J Replace.

Brake shoe lining thickness limit

(minimum)

2.0 mm(0.08 in) w

Do not allow oil or grease to contact the brake shoes.

NOTE:

Replace the brake shoes as a set, if either is worn to the wear limit.

4-13

3. Measure:

8 brake drum inside diameter b

Out of specification J Replace the wheel.

Brake drum inside diameter limit

(maximum)

111 mm(4.37 in)

4. Check:

8 brake drum inner surface

Oil deposits

J Clean.

Remove the oil with a rag soaked in lacquer thinner or solvent.

Scratches J Repair.

Lightly and evenly polish the scratches with an emery cloth.

5. Check:

8 brake camshaft


1 a

2


CHAS

EAS00570

ASSEMBLING THE BRAKE SHOE PLATE

1. Install:

8 brake camshaft 1

8 brake shoe wear indicator 2 b

***************************************************** a.

Install the brake camshaft so its punch mark a is positioned as shown.

b.

Align the projection b on the brake shoe wear indicator with the notch in the brake shoe camshaft.

c.

Check that the brake shoes are properly positioned.

*****************************************************

2. Check:

8 rear brake level free play

Refer to “CHECKING AND ADJUSTING

THE REAR BRAKE “ in chapter 3.

EAS00575

ADJUSTING THE REAR WHEEL STATIC BAL-

ANCE

NOTE:

8 After replacing the tire, wheel or both, the rear wheel static balance should be adjusted.

8 Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.

1. Adjust:

8 rear wheel static balance

Refer to “ADJUSTING THE FRONT

WHEEL STATIC BALANCE”.

4-14

FRONT BRAKE

CHAS

EAS00576

FRONT BRAKE

FRONT BRAKE PADS

5

5

LS

1

35Nm(3.5m

• kg, 25.3 ft • lb)

6

1

3

3

4

7

1

2

3

4

5

Order Job/Part

Removing the front brake pads

Caliper brake bracket bolt

Caliper brake pad bolt

Brake pad

Brake pad plate

Brake pad spring

6

7

Caliper brake bracket

Caliper assembly

2

22Nm(2.2m

• kg, 15.9 ft • lb)

Q’ty Remarks


2

1

2

1

2 Refer to “REPLACING THE FRONT

BRAKE PADS”.

1

1


4-15

1

4-16

FRONT BRAKE

CHAS

EAS00579 c C

Disc brake components rarely require disassembly.

Therefore, always follow these preventive measures: unless absolutely necessary.

system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.

components.

cleaning brake components.

faces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.

with the eyes as it can cause serious injury.

FIRST AID FOR BRAKE FLUID ENTERING

THE EYES: immediate medical attention.

EAS00581

REPLACING THE FRONT BRAKE PADS

NOTE:

When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.

1. Loosen:

8 brake pad bolt

2. Remove:

8 brake caliper 1

2

2

FRONT BRAKE

CHAS

3. Remove:

8 brake pad bolt

8 brake pad spring 1

8 brake pads 2

8 brake pad plate 3

3

1 a

4. Measure:

8 brake pad wear limit a

Out of specification J Replace the brake pads as a set.

Brake pad wear limit

0.8 mm(0.03 in)

1

2

3

1

3

4

4-17

5. Install:

8 brake pad plate 1

8brake pads 2

8brake pad spring 3

NOTE:

Always install new brake pads and a new brake pad spring as a set.

***************************************************** a. Connect a clear plastic hose 2 tightly to the bleed screw 1. Put the other end of the hose into an open container.

b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.

c. Tighten the bleed screw.

T

.

R

.

Bleed screw

6 Nm (0.6 m • kg, 4.3 ft • lb) d. Install new brake pads3 and new brake pad springs4.

NOTE:

8 Make sure the brake pad spring is installed correctly as shown.

LS a

FRONT BRAKE

CHAS

6.

Lubricate:

8brake caliper guide bar


Lithium-soap-based grease c C pads.

7. Install:

8brake pad bolt

T

R

22 Nm (2.2 m • kg, 15.9 ft • lb)

8brake caliper bolt

T

R

35 Nm (3.5 m • kg, 23.5 ft • lb)

8. Check:

8brake fluid level

Below the MIN level mark a J Add the recommended brake fluid to the proper level.


LEVEL” in chapter 3.

9. Check:

8brake lever operation

Soft or spongy feeling J Bleed the brake system.

` Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

4-18

FRONT BRAKE

CHAS

EAS00584

FRONT BRAKE MASTER CYLINDER

9Nm(0.9m • kg, 6.5 ft • lb)

1.6Nm(0.16m • kg, 1.2 ft • lb)

LS 6

7

1

2

26Nm(2.6m • kg, 18.8 ft • lb)

3

4

5

4

3

4

1

2

5

6

7

Order Job/Part

Removing the front brake master cylinder

Brake fluid

Brake lever / Compress spring

Front brake light switch

Union bolt

Copper washer

Brake hose

Master cylinder bracket

Master cylinder assembly

Q’ty

1/1

1

1

2

1

1

1

Remarks


Drain.


4-19

FRONT BRAKE

CHAS

EAS00585

DISASSEMBING THE FRONT BRAKE MASTER CYLINDER

2

3

4

1

5

Order

1

2

3

4

5

Job/Part

Disassembling the front brake master cylinder

Reservoir diaphragm

Dust boot

Circlip / Washer

Master cylinder kit

Spring

Q’ty

1

1

1/1

1

1

Remarks



4-20

FRONT BRAKE

CHAS

EAS00588

DISASSEMBLING THE FRONT BRAKE MAS-

TER CYLINDER

NOTE:

Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system.

1

2

3

1. Disconnect:

8 brake switch coupler

(from the brake switch)

2. Remove:

8 union bolt 1

8 copper washer 2

8 brake hose 3

NOTE:

To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

2

1

1

EAS00590

CHECKING THE FRONT BRAKE MASTER

CYLINDER

1. Check:

8 brake master cylinder 1

8 Damage/scratches/wear J Replace.

8 brake fluid delivery passages 2

(brake master cylinder body)

Obstruction J Blow out with compressed air.

2. Check:

8 brake master cylinder kit 1

Damage/scratches/wear J Replace.

4-21

1

1

FRONT BRAKE

CHAS

3. Check:

8 brake master cylinder reservoir

Cracks/damage

J Replace.

brake master cylinder reservoir diaphragm

1

Damage/wear

J Replace.

4. Check: brake hoses 1


4-22

2

1

2

1

2

1 a b

4-23

FRONT BRAKE

CHAS

EAS00597

ASSEMBLING AND INSTALLING THE FRONT

BRAKE MASTER CYLINDER w components should be cleaned and lubricated with clean or new brake fluid.

components.


DOT 4

1. Install:

8 spring 1

Install the spring with its smaller diameter to the master cylinder kit.

8 master cylinder kit 2

2. Install:

8 circlip1 New

8 dust boot2

3. Install:

8 brake switch

8 brake lever

4. Install:

8 master cylinder1

8 master cylinder bracket2

T

R

9 Nm (0.9 m • kg, 6.5 ft • lb) c C with the “UP” mark a der holder with the punch mark b the handlebar.

lower bolt.

3

1

2

FRONT BRAKE

CHAS

5. Install:

8 copper washers1

New

8 brake hose2

8 union bolt3

T

R

26 Nm (2.6 m • kg, 18.8 ft • lb) w

Proper brake hose routing is essential to insure safe scooter operation. Refer to

“CABLE ROUTING”.

NOTE:

8 While holding the brake hose, tighten the union bolt as shown.

8 Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary.

6. Fill:

8 brake master cylinder reservoir

(with the specified amount of the recommended brake fluid)


DOT 4 w



not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

c C


4-24

a

FRONT BRAKE

CHAS

7. Bleed:

8 brake system



8. Check:

8 brake fluid level




9. Check:

8 brake lever operation

Soft or spongy feeling

J Bleed the brake system.



4-25

FRONT BRAKE

CHAS

EAS00612

FRONT BRAKE CALIPER

35Nm(3.5m • kg, 25.3 ft • lb)

4

3

1

23Nm(2.3m • kg, 16.6 ft • lb)

2

5

3

4

1

2

5

Order Job/Part

Removing the front brake caliper

Brake fluid

Union bolt

Copper washer

Brake hose

Front brake caliper bracket bolt


Q’ty Remarks


Drain.

1

2

1

2

1


4-26

EAS00614

DISASSEMBING THE FRONT BRAKE CALIPER

2

5 3 1

FRONT BRAKE

CHAS

6Nm(0.6m • kg, 4.3 ft • lb)

9

3

LS

4

7

6

8

22Nm(2.2m • kg, 15.9 ft • lb)

1

2

3

4

5

6

7

8

9

Order Job/Part

Disassembling the front brake caliper

Cap

Caliper bracket

Brake pad

Brake pad plate

Brake spring

Dust seal

Piston seal

Caliper piston

Bleed screw / Cap

Q’ty

2

1

1

1

1/1

2

1

1

1

Remarks



4-27

FRONT BRAKE

CHAS

EAS00619

DISASSEMBLING THE FRONT BRAKE CALI-

PER

NOTE:

Before disassembling the brake caliper, drain the brake fluid from the entire brake system.

1

2

3

5

4

6

3

1. Remove:

8 union bolt 1

8 copper washers 2

8 brake hose 3

8 brake caliper pad bolt 4

8 brake caliper bracket bolts 5

8 brake caliper assembly6

NOTE:

Put the end of the brake hose into a container and pump out the brake fluid carefully.

2. Remove:

8 brake caliper piston 1

8 brake caliper piston seal 2

8 brake caliper dust seal 3

2 1 a

***************************************************** a. Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper.

w rag. Be careful not to get injured when the piston are expelled from the brake caliper.

ton.

b. Remove the brake caliper piston seal.

*****************************************************

4-28

1

3

2

FRONT BRAKE

CHAS

EAS00631

CHECKING THE FRONT BRAKE CALIPER

Recommended brake component replacement schedule

Brake pads

Piston seal

Brake fluid

If necessary

Every 2 years

Every 2 year and whenever the brake is disassembled

1. Check:

8 brake caliper piston 1

Rust/scratches/wear J Replace the brake caliper piston assembly.

8 brake caliper cylinder 2

Scratches/wear J Replace the brake caliper assembly.

8 brake caliper body 3

Cracks/damage

J Replace the brake caliper assembly.

8 brake fluid delivery passages

(brake caliper body)


w

Whenever a brake caliper is disassembled, replace the piston seal.

2. Check:

8 brake caliper bracket

Cracks/damage

J Replace.

4-29

FRONT BRAKE

CHAS

EAS00637

ASSEMBLING AND INSTALLING THE FRONT

BRAKE CALIPER w components should be cleaned and lubricated with clean or new brake fluid.

components as they will cause the piston seals to swell and distort.

sembled, replace the brake caliper piston seals.


DOT 4

2

1. Install:

8 brake caliper piston seal 1

New

8 brake caliper dust seal 2

New

1

2. Install:

8 brake caliper piston1 c C piston.

1

6

5

4

2

3

1

4-30

3. Install:

8 brake pads

8 brake springs

8 brake caliper assembly1

8 brake caliper bracket bolt2

T

R

35 Nm (3.5 m • kg, 25.3 ft • lb)

FRONT BRAKE

CHAS

8brake caliper pad bolt 3

T

R

22 Nm (2.2 m • kg, 15.9 ft • lb)

8brake hose 4

8copper washers 5

New

8union bolt 6

T

R

23 Nm (2.3 m • kg, 16.6 ft • lb) w

Proper brake hose routing is essential to insure safe scooter operation. Refer to

“CABLE ROUTING”.

a b

1 c C

When installing the brake hose onto the brake caliper 1 caliper.

4-31

4. Fill:

8 brake fluid reservoir

(with the specified amount of the recommended brake fluid)


DOT 4 w



not enter the brake fluid reservoir. Wa-

a

FRONT BRAKE

CHAS ter will significantly lower the boiling point of the brake fluid and could cause vapor lock.

c C


5. Bleed:

8 brake system



6. Check:

8 brake fluid level




7. Check:

8 brake lever operation

Soft or spongy feeling

J Bleed the brake system.



4-32

FRONT FORK

CHAS

EAS00646

FRONT FORK

45Nm(4.5m • kg, 32.5 ft • lb)

5

2

4

23Nm(2.3m • kg, 16.6 ft • lb)

7

6

3

1

5

6

7

1

2

3

4

Order Job/Part

Removing the front fork legs

Front wheel

Leg shield 1

Front fork protect cover

Brake hose holder 1

Speedometer cable guide


Cap bolt/O-ring

Pinch bolt

Front fork leg

1

1

1

1

1

1

1

Q’ty Remarks


Refer to “FRONT WHEEL AND BRAKE

DISC”.

Refer to “COVER AND PANEL” in chapter 3.


4-33

EAS00648

DISASSEMBING THE FRONT FORK LEGS

FRONT FORK

CHAS

2 1

8

7

9

5

0

6

30Nm(3.0m • kg, 21.7 ft • lb)

4

3

3

LT

1

2

3

4

5

6

Order Job/Part

Disassembling the front fork legs

Fork oil

Fork spring

Clamp / Boot

Damper rod bolt / Gasket

Inner tube

Damper rod

Rebound spring

7

8

9

0

Oil flow stopper

Oil seal clip

Oil seal

Outer tube

1

1

1

1

Q’ty Remarks


Drain.

1

1/1

1/1

1

1

1 Refer to “DISASSEMBLING AND IN-

STALLING THE FRONT FORK LEGS “


4-34

1

3

2

FRONT FORK

CHAS

EAS00651

REMOVING THE FRONT FORK LEGS

The following procedure applies to both of the front fork legs.


w


NOTE:


2. Loosen:

8pinch bolt 1

3. Remove:

8 cap bolt 2

(with a 10-mm hexagonal wrench3) w cap bolt.

w

Before loosening the upper and lower bracket pinch bolts, support the front fork leg.

5. Remove:

8front fork leg

4-35

1

FRONT FORK

CHAS

EAS00653

DISASSEMBLING THE FRONT FORK LEGS


1. Remove:

8fork spring 1

2. Drain:

8fork oil

3

2

1

3. Remove:

8damper rod assembly bolt 1

8damper rod assembly

NOTE:

While holding the damper rod with the damper rod holder 2 and T- handle3, loosen the damper rod assembly bolt.

Damper rod holder

90890-01294 (YM-01300-1)

T- handle

90890-01326 (YM-01326)

1

2

4-36

4. Remove:

8damper rod 1

8spring

8inner tube 2

1

1

2

FRONT FORK

CHAS

5. Remove:

8oil seal clip 1

(with a flat-head screwdriver) c C

Do not scratch the inner tube.

6. Remove:

8oil seal 1 c C

Never reuse the oil seal.

8 Rag 2

4-37

1

2

FRONT FORK

CHAS

EAS00656

CHECKING THE FRONT FORK LEGS


1. Check:

8 inner tube 1

8 outer tube 2

Bends/damage/scratches J Replace.

w

Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

1 a

2

1

2

2. Measure:

8 spring free length a


J Replace.

Spring free length

257.5 mm (10.14 in)

<Limit> : 252.4 mm (9.94 in)

3. Check:

8 damper rod 1


Obstruction J Blow out all of the oil passages with compressed air.

8 oil flow stopper 2

Damage

J Replace.

4. Check:

8 cap bolt 1


8 O-ring2

New

4-38

2

1

3

FRONT FORK

CHAS

EAS00658

ASSEMBLING THE FRONT FORK LEGS


w legs are equal.

dling and a loss of stability.

NOTE:

8 When assembling the front fork leg, be sure to replace the following parts:

- oil seal

- dust seal

8 Before assembling the front fork leg, make sure all of the components are clean.

1. Install:

8 damper rod assembly 1

8 rebound spring 2 c C

Allow the damper rod assembly to slide slowly down the inner tube 3 protrudes from the bottom of the inner tube.

Be careful not to damage the inner tube.

2. Lubricate:

8 inner tube’s outer surface


Fork oil 10W or equivalent

3.

Tighten:

8 damper rod assembly bolt 1

T

.

R

.

30 Nm (3.0 m • kg, 21.7 ft • lb)

LOCTITE ® 204

4-39

NOTE:

While holding the damper rod assembly with the damper rod holder 2 and T-handle 3, tighten the damper rod assembly bolt.

FRONT FORK

CHAS

Damper rod holder

90890-01294(YM-01300-1)

T-handle

90890-01326(YM-01326)

2

3

1

4

342-034

4. Install:

8oil seal 1

New

(with the fork seal driver weight 2 and adapter 3)

Fork seal driver weight

90890-01367(YM-A9409-7)

Adapter

90890-01400(YM-A9409-3) c C

Make sure the numbered side of the oil seal faces up.

NOTE:

8 Before installing the oil seal, lubricate its lips with lithium soap base grease.

8 Lubricate the outer surface of the inner tube with fork oil.

8 Before installing the oil seal, cover the top of the front fork leg with a plastic bag 4 to protect the oil seal during installation.

4-40

5. Install:

8oil seal clip 1

NOTE:

Adjust the oil seal clip so that it fits into the outer tube’s groove.

1

FRONT FORK

CHAS

6. Install:

8fork boot 1

7. Fill:

8 front fork leg

(with the specified amount of the recommended fork oil)

Quantity (each front fork leg)

0.126 L (0.11 lmp qt, 0.13 US qt)

Recommended oil

Fork oil 10W or equivalent

NOTE:

8 While filling the front fork leg, keep it upright.

8 After filling, slowly pump the front fork leg up and down to distribute the fork oil.

1

8. Install:

8 fork spring 1

NOTE:

8 Install the spring with the smaller pitch facing up.

8 Before installing the cap bolt, lubricate its

O-ring with grease.

8 Temporarily tighten the cap bolt.

4-41

2

1

FRONT FORK

CHAS

EAS00663

INSTALLING THE FRONT FORK LEGS


1. Install:

8front fork leg

NOTE:

Pull up the inner tube until it stops, then install the cap bolt.

2. Tighten:

8cap bolt 1

T

R

45 Nm (4.5 m • kg, 32.5 ft • lb)

8 pinch bolt 2

T

R

23 Nm (2.3 m • kg, 16.6 ft • lb)

4-42

HANDLEBAR

CHAS

EAS00664

HANDLEBAR

6

LS

LS

5

1

5

4

9Nm(0.89m • kg, 6.5 ft • lb)

3

30Nm(3.0m • kg, 21.7 ft • lb)

11

7

2

12

11

12

7

13

1

9

10

8

LS

6

7

8

9

10

11

12

13

1

2

3

4

5

Order Job/Part

Removing the handlebar

Rear view mirror ( left and right )

Brake master cylinder bracket

Brake master cylinder assembly

Handlebar switch assembly (right)

Throttle cable

Throttle grip assembly

Band

Rear brake cable

Handlebar switch assembly ( left )

Handlebar grip

Cap

Handlebar upper holder

Handlebar assembly

Q’ty Remarks


1

2

1

1

1

4

2

1

2

1

1

1

2


4-43

HANDLEBAR

CHAS

EAS00666

REMOVING THE HANDLEBAR


w


1

3

1

2

2. Remove:

8handlebar switch assembly (right)1

8throttle grip assembly 2

8brake master cylinder assembly 3

NOTE:

While removing the handlebar switch assembly

(right), pull back the rubber cover.

3. Remove:

8handlebar grip 1

NOTE:

Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

EAS00668

CHECKING THE HANDLEBAR


w


4-44

2. Check:

8handlebar 1

Bends/cracks/damage J Replace.

w

Do not attempt to straighten a bent handlebar as this may dangerously weaken it.

1

2 b

HANDLEBAR

CHAS

EAS00671

INSTALLING THE HANDLEBAR


w


2. Install:

8 handlebar 1

8 upper handlebar holders 2

T

R

30 Nm (3.0 m • kg, 21.7 ft • lb) c C of the handlebar holder, and then on the rear side.

4-45

NOTE:

8The upper handlebar holders should be installed with the arrow marks a facing forward A.

8Align the match marks b on the handlebar with the upper surface of the lower handlebar holders.

3. Install:

8 handlebar grip

NOTE:

Before installing the handlebar grip, apply the bond.

1 a b

1

2

3 a b

1 a

HANDLEBAR

CHAS

4. Install:

8 left handlebar switch 1

NOTE:

Align the projection a on the left handlebar switch with the hole b in the handlebar.

5. Install:

8 throttle grip 1

8 right handlebar switch2

8 throttle cables 3

4-46

NOTE:

8 Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar4.

8 Align the projection a on the right handlebar switch with the hole b in the handlebar.

w

Make sure the throttle grip operates smoothly.

6. Install:

8 front brake master cylinder 1

NOTE:

8 Align the mating surfaces of the front brake master cylinder with the punch mark a on the handlebar.

7. Adjust:

8 throttle cable free play


CABLE FREE PLAY” in chapter 3.


3 ~ 5 mm(0.12 ~ 0.20 in)

STEERING HEAD

CHAS

EAS00675

STEERING HEAD

LOWER FENDER COVER AND HANDLEBAR LOWER HOLDER

47.5Nm(4.75m • kg, 34.4 ft • lb)

6

8

9

5

2

1

4

3

7

7

8

9

3

4

5

6

1

2

Order Job/Part

Removing the lower fender cover and handlebar lower holder

Front wheel

Q’ty

Leg shield 1

Remarks



DISC”.


Refer to “FRONT FORK”.

Refer to “HANDLEBAR”.

Front fork legs

Handlebar assembly

Brake hose holder 1

Brake hose holder 2

Lower fender bracket

Lower fender cover (front)

Lower fender cover (inner)

Handlebar cover

Speedometer cable

Speedometer assembly

Handlebar lower holder

1

1

1

1

1

1

1

1

1


4-47

STEERING HEAD

CHAS

EAS00675

LOWER BRACKET

9

60Nm(6.0m • kg, 43.4 ft • lb)

75Nm(7.5m • kg, 54.2 ft • lb)

1st 28Nm(2.8m • kg, 20.3 ft • lb)

2nd 9Nm(0.9m • kg, 6.5 ft • lb)

8

10

12

6

5

4

7

3

2

LS

1

LS

7

8

9

5

6

10

11

12

13

14

1

2

3

4

Order Job/Part

Removing the lower bracket

Front wheel

Handlebar lower holder

Handlebar holder bracket

Upper ring nut

Lock washer

Center ring nut

Rubber washer

Lower ring nut

Bearing race cover

Upper bearing inner race

Lower bracket

Upper bearing

Lower bearing

Upper bearing outer race

Lower bearing outer race

Lower bearing inner race

13

11

14

15

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Q’ty Remarks



DISC”.

Refer to “LOWER FENDER COVER AND

HANDLEBAR LOWER HOLDER”.

4-48

9

Order

15 Rubber washer

Job/Part

LS

STEERING HEAD

CHAS

60Nm(6.0m • kg, 43.4 ft • lb)

75Nm(7.5m • kg, 54.2 ft • lb)

1st 28Nm(2.8m • kg, 20.3 ft • lb)

2nd 9Nm(0.9m • kg, 6.5 ft • lb)

8

10

12

6

5

4

7

3

2

LS

1

13

11

14

15

Q’ty

1

Remarks


4-49

1

2

1

2

STEERING HEAD

CHAS

EAS00678

REMOVING THE LOWER BRACKET


w


2. Remove:

8 handlebar holder bracket 1

NOTE:

8 Remove the handlebar holder bracket by loosening the upper ring nut2 gradually.

3. Remove:

8ring nut 1

(with the ring nut wrench 2)

Ring nut wrench

90890-01268(YU-01268) w

Securely support the lower bracket so that there is no danger of it falling.

4-50

2

1

2

STEERING HEAD

CHAS

EAS00682

CHECKING THE STEERING HEAD

1. Wash:

8bearings

8bearing races

Recommended cleaning solvent

Kerosene

2. Check:

8bearings 1

8bearing races 2

Damage/pitting J Replace.

4-51

3. Replace:

8bearings

8bearing races

***************************************************** a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer.

b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer.

c. Install a new rubber washer and new bearing races.

c C

If the bearing race is not installed properly, the steering head pipe could be damaged.

NOTE:

8Always replace the bearings and bearing races as a set.

8Whenever the steering head is disassembled, replace the rubber washer.

*****************************************************

4. Check:

8handlebar lower holder

8lower bracket

(along with the steering stem)

Bends/cracks/damage J Replace.

3

2

1

2

3

4

1

STEERING HEAD

CHAS

EAS00684

INSTALLING THE STEERING HEAD

1. Lubricate:

8 upper bearing

8 lower bearing

8 bearing races



2. Install:

8 lower ring nut 1

8 rubber washer 2

8 center ring nut 3

8 lock washer 4

8 upper ring nut 5

Refer to “CHECKING THE STEERING

HEAD” in chapter 3.

3. Install:

8 handlebar holder bracket 1

T

R

60 Nm (6.0 m • kg, 43.4 ft • lb)

NOTE:

Align the handlebar holder bracket across rod

2 on the lower bracket concave3.

4-52

1

2

REAR SHOCK ABSORBER

CHAS

EAS00692

REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY


w


NOTE:

Place the scooter on a suitable stand so that the rear wheel is elevated.

2. Remove:

8 rear carrier

8 side cover( left )


3. Remove:

8 rear shock absorber nut (upper)1

8 rear shock absorber bolt (lower)2

4-53

EAS00695

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY

1. Check:

8rear shock absorber rod

Bends/damage

J Replace the rear shock absorber assembly.

8rear shock absorber

Oil leaks J Replace the rear shock absorber assembly.

8spring

Damage/wear

J Replace the rear shock absorber assembly.

8bushings


8dust seals

Damage/wear

J Replace.

8bolts

Bends/damage/wear J Replace.

1

2

REAR SHOCK ABSORBER

CHAS

EAS00698

INSTALLING THE REAR SHOCK ABSORBER

ASSEMBLY

1. Lubricate:

8 spacer

8 bush


Molybdenum disulfide grease

2. Install:

8 rear shock absorber assembly

3. Tighten:

8 rear shock absorber assembly upper nut1

T

R

30 Nm (3.0 m • kg, 21.7 ft • lb)

8 rear shock absorber assembly lower bolt2

T

R

18 Nm (1.8 m • kg, 13.0 ft • lb)

4. Install:

8 side cover( left )

8 rear carrier


4-54

ENG

CHAPTER 5

ENGINE

ENGINE ..................................................................................................... 5-1

LEADS, HOSES AND REAR BRAKE ............................................... 5-1

INSTALLING THE ENGINE ............................................................... 5-3

MAINFOLD, AIR FILTER AND MUFFLER ASSEMBLY ................... 5-4

CYLINDER HEAD ..................................................................................... 5-5

CYLINDER HEAD .............................................................................. 5-5

REMOVING THE CYLINDER HEAD................................................. 5-7

CHECKING THE CYLINDER HEAD ................................................. 5-9

INSTALLING THE CYLINDER HEAD ............................................. 5-10

THE ROCKER ARMS AND CAMSHAFT .............................................. 5-13

THE ROCKER ARMS AND CAMSHAFT ....................................... 5-13

REMOVING THE ROCKER ARMS AND CAMSHAFT ................... 5-14

CHECKING THE ROCKER ARMS AND ROCKER ARM

SHAFTS........................................................................................ 5-15

CHECKING THE CAMSHAFT......................................................... 5-16

CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND

TIMING CHAIN GUIDES .............................................................. 5-17

CHECKING THE TIMING CHAIN TENSIONER ............................. 5-17

INSTALLING THE CAMSHAFT AND ROCKER ARMS ................. 5-18

VALVES AND VALVE SPRINGS ............................................................ 5-19

VALVES AND VALVE SPRINGS ..................................................... 5-19

REMOVING THE VALVES ............................................................... 5-20

CHECKING THE VALVES AND VALVE GUIDES ........................... 5-21

CHECKING THE VALVE SEATS ..................................................... 5-23

CHECKING THE VALVE SPRINGS ................................................ 5-25

INSTALLING THE VALVES .............................................................. 5-26

CYLINDER AND PISTON....................................................................... 5-28

CYLINDER AND PISTON ................................................................ 5-28

REMOVING THE CYLINDER AND PISTON .................................. 5-29

CHECKING THE CYLINDER AND PISTON ................................... 5-30

CHECKING THE PISTON RINGS ................................................... 5-31

CHECKING THE PISTON PIN ........................................................ 5-32

CHECKING THE TIMING CHAIN GUIDE ....................................... 5-33

INSTALLING THE PISTON AND CYLINDER ................................. 5-33

5-65

ENG

BELT DRIVE............................................................................................ 5-35

CRANKCASE COVER ..................................................................... 5-35

KICKSTARTER ................................................................................ 5-36

INSTALLING THE KICKSTARTER .................................................. 5-37

V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE ......... 5-38

DISASSEMBLING THE SECONDARY SHEAVE ........................... 5-39

REMOVING THE PRIMARY SHEAVE ............................................ 5-40

REMOVING THE SECONDARY SHEAVE AND V-BELT................ 5-40

DISASSEMBLING THE SECONDARY SHEAVE ........................... 5-41

CHECKING THE CLUTCH SHOE .................................................. 5-41

CHECKING THE V-BELT ................................................................. 5-42

CHECKING THE PRIMARY SHEAVE ............................................ 5-42

CHECKING THE PRIMARY SHEAVE WEIGHTS .......................... 5-42

CHECKING THE SLIDER ................................................................ 5-43

CHECKING THE SECONDARY SHEAVE ...................................... 5-43

ASSEMBLING THE PRIMARY SHEAVE ........................................ 5-43

ASSEMBLING THE SECONDARY SHEAVE ................................. 5-45

INSTALLING THE BELT DRIVE ...................................................... 5-46

STARTER CLUTCH AND STARTER MOTOR ...................................... 5-48

STARTER CLUTCH AND STARTER MOTOR ................................ 5-48

CHECKING THE STARTER WHEEL GEAR ................................... 5-49

C.D.I. MAGNETO ..................................................................................... 5-50

C.D.I. MAGNETO .............................................................................. 5-50

REMOVING THE C.D.I. MAGNETO ................................................. 5-51

INSTALLING THE C.D.I. MAGNETO ............................................... 5-52

OIL PUMP ............................................................................................... 5-53

OIL PUMP ........................................................................................ 5-53

CHECKING THE OIL PUMP ........................................................... 5-54

INSTALLING THE OIL PUMP .......................................................... 5-55

TRANSMISSION ..................................................................................... 5-56

TRANSMISSION .............................................................................. 5-56

CHECKING THE TRANSMISSION ................................................. 5-57

CRANKCASE AND CRANKSHAFT ..................................................... 5-58

CRANKCASE AND CRANKSHAFT................................................ 5-58

DISASSEMBLING THE CRANKCASE ........................................... 5-60

REMOVING THE CRANKSHAFT ASSEMBLY ............................... 5-61

CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES .. 5-61

CHECKING THE CRANKSHAFT AND CONNECTING ROD ........ 5-62

INSTALLING THE CRANKSHAFT .................................................. 5-63

ASSEMBLING THE CRANKCASE ................................................. 5-64

5-66

EAS00188

ENGINE

LEADS, HOSES AND REAR BRAKE

ENGINE

ENGINE

ENG

18Nm(1.8m • kg, 13.0 ft • lb)

9

10

3

5

6

2

1 11

12

13

4

15

LS

7

42Nm(4.2m • kg, 30.4 ft • lb) 14

8

6

7

8

9

10

1

2

3

4

5

11

12

13

14

15

Order Job/Part

Removing the leads, hoses and rear brake

Seat/Rear carrier

Side cover ( left / right )/Fuel tank cap

Rear cover/Hook( left and right )

Front cover/Trunk

Spark plug cap

Starting motor lead / Earth lead

Auto choke lead

C.D.I. magneto lead / Stator lead

Carburetor heater positive lead

Carburetor heater negative lead

Throttle cable

Brake cable (adjuster / pin)

Air inlet hose

Fuel hose

Carburetor inlet hose

Fuel cock vacuum pipe

Rear shock absorber bolt

Self lock nut

Engine mounting bolt

Q’ty Remarks


Refer to “COVER AND PANEL”in chapter 3.

1

2

1

1

1

1

1/1

1

1/1

1

1

1

1

1

1

c C

First, disconnect the negative lead, and then the positive lead.

Refer to “ INSTALLING THE ENGINE “.

5-1

ENGINE

ENG

18Nm(1.8m • kg, 13.0 ft • lb)

9

Order

15

LS

1

10

5

3

6

2

11

12

13

4

Job/Part

7

42Nm(4.2m • kg, 30.4 ft • lb) 14

8

Q’ty Remarks


5-2

ENGINE

ENG

NOTE:

Make sure to reset the oil change indicator when the oil is changed.

1

EAS00192

INSTALLING THE ENGINE

1. Install:

8 engine bracket bolt 1

NOTE:

Do not fully tighten the bolts.

2. Tighten:

8 engine bracket bolt1

T

R

55Nm(5.5 m • kg, 39.8 ft • lb)

8 engine

5-3

ENGINE

ENG

MAINFOLD, AIR FILTER AND MUFFLER ASSEMBLY

31Nm(3.1m • kg, 22.4 ft • lb)

7Nm(0.7m • kg, 5.1 ft • lb)

1

6

5

4

2

10Nm(1.0m • kg, 7.2 ft • lb)

3

1

2

3

4

5

6

Order Job/Part

Removing the mainfold, air filter and muffler assembly

Starting motor lead / Earth lead

Auto choke lead

C.D.I. magneto lead / Stator lead

Throttle cable

Rear brake cable (adjuster / pin)

Hose( from AI air filter )

Vacuum hose (from mainfold)

Hose(to cylinder head )

Muffler assembly

AI pipe

Air filter / Breather hose

Carburetor

Mainfold / O-ring

Joint / Gasket

Q’ty Remarks


1

1

1/1

1

1/1

1/1

Refer to “LEADS, HOSES AND REAR

BRAKE”.

Refer to “AIR INDUCTION SYSTEM” in chapter 6.


5-4

EAS00221

CYLINDER HEAD

10Nm(1.0m • kg,7.2 ft • lb)

5

8Nm(0.8m • kg, 5.8 ft • lb)

CYLINDER HEAD

ENG

8Nm(0.8m • kg, 5.8 ft • lb)

10Nm(1.0m • kg, 7.2 ft • lb)

10

2

3

1

16

17

6

8

14 13

17

9

22Nm(2.2m • kg, 15.9 ft • lb)

12

11

15 7

12Nm(1.2m • kg, 8.7 ft • lb)

7

4

30Nm(3.0m • kg, 21.7 ft • lb)

8

9

10

11

12

3

4

5

1

2

6

7

Order Job/Part

Removing the cylinder head

Muffler assembly

Air filter

Mainfold

Unit bolt

Cooper washer

Oil delivery pipe / O-ring

Air shroud 1

Air shroud 2

Spark plug

Breather / O-ring

Engine oil cap / O-ring

Valve cover / O-ring

Timing chain tensioner assembly

Camshaft sprocket plate

Camshaft sprocket

13

14

15

16

Nut / Washer

Plate

Cylinder head

Cylinder head gasket

5-5

Q’ty Remarks


Refer to “MAINFOLD, AIR FILTER AND

MUFFLER ASSEMBLY”.

1/1

1/1

1

1

1

1

2

1/1

1

1

1

1/1

Refer to “ REMOVING THE CYLINDER

HEAD”.

4/2

1

1

1

CYLINDER HEAD

ENG

10Nm(1.0m • kg,7.2 ft • lb)

5

8Nm(0.8m • kg, 5.8 ft • lb)

8Nm(0.8m • kg, 5.8 ft • lb)

10Nm(1.0m • kg, 7.2 ft • lb)

10

2

3

1

16

17

6

8

14 13

17

9

22Nm(2.2m • kg, 15.9 ft • lb)

12

11

15 7

12Nm(1.2m • kg, 8.7 ft • lb)

7

Order

17 Dowel pin

Job/Part

4

30Nm(3.0m • kg, 21.7 ft • lb)

Q’ty

2

Remarks


5-6

d c

1

4

3 a b

CYLINDER HEAD

ENG

EAS00225

REMOVING THE CYLINDER HEAD

1. Remove :

8 oil delivery pipe

8 engine oil cap

8 valve cover

8 Air shroud 1

8 Air shroud 2

8 breather

2. Align:

8 “I” mark a on the magneto

(with the stationary pointer b on the crankcase cover)

***************************************************** a. Turn the primary sheave counterclockwise.

b. When the piston is at TDC on the compression stroke, align the “I” mark c on the camshaft sprocket with the mark d on the cylinder head.

*****************************************************

3. Loosen:

8 timing chain tensioner bolt

8 camshaft sprocket plate bolt 1

While holding the crank bolt with a wrench, remove the camshaft sprocket plate bolt 1.

2

4. Remove:

8 timing chain tensioner


8 camshaft sprocket plate 2

8 camshaft sprocket 3

8 timing chain 4

5-7

5

4

3

1

6

2

CYLINDER HEAD

ENG

NOTE:

8 To prevent the timing chain from falling into the crankcase, fasten it with a wire.

8 While holding the C.D.I. magneto bolt with a wrench, remove the camshaft sprocket plate bolt 1.

5. Remove:

8cylinder head

NOTE:

8 Loosen the nuts in the proper sequence as shown.

8 Loosen each nut 1/2 of a turn at a time.

After all of the nuts are fully loosened, remove them.

5-8

5-9

CYLINDER HEAD

ENG

EAS00227

CHECKING THE CYLINDER HEAD

1. Eliminate:

8 combustion chamber carbon deposits

(with a rounded scraper)

NOTE:

Do not use a sharp instrument to avoid damaging or scratching:

8 spark plug bore thread

8 valve seats

2. Check:

8 cylinder head

Damage/scratches J Replace.

3. Measure:

8 cylinder head warpage

Out of specification J Resurface the cylinder head.

Maximum cylinder head warpage

Less than0.05 mm(0.002 in)

***************************************************** a. Place a straightedge and a thickness gauge across the cylinder head.

b. Measure the warpage.

c. If the limit is exceeded, resurface the cylinder head as follows.

d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern.

NOTE:

To ensure an even surface, rotate the cylinder head several times.

*****************************************************

4

3

2

1

5

4

6

4

CYLINDER HEAD

ENG

EAS00231

INSTALLING THE CYLINDER HEAD

1. Install:

8 gasket New

8 dowel pins

2. Install:

8 cylinder head

3. Tighten:

8 cylinder head nuts

T

R

22 Nm (2.2 m • kg, 15.9 ft • lb)

8 cylinder head bolts

T

R

12 Nm (1.2 m • kg, 8.7 ft • lb)

NOTE:

8 Lubricate the cylinder head nuts with engine oil.

8 Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages.

2 d c

1 a b

4. Install:

8 camshaft sprocket 1

8 timing chain 2

***************************************************** a. Turn the primary pulley counterclockwise.

b. Align the “I” mark a on the C.D.I. magneto rotor with the stationary pointer b on the crankcase cover.

c. Align the “I” mark c on the camshaft sprocket with the stationary pointer d on the cylinder head.

d. Install the timing chain onto the camshaft sprocket, and then install the camshaft sprocket onto the camshaft.

5-10

NOTE:

8 When installing the camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side.

8 Align the pin on the camshaft with the slot in the camshaft sprocket.

CYLINDER HEAD

ENG c C

Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing.

e. While holding the camshaft, temporarily tighten the camshaft sprocket bolts.

f. Remove the wire from the timing chain.

*****************************************************

5. Install

8camshaft sprocket plate 1

8camshaft sprocket plate bolt 2 1

2

5

4

3

2

1

6. Install:

8timing chain tensioner gasket New

8timing chain tensioner

***************************************************** a. Remove the cap bolt 1 and spring 2.

b. Release the timing chain tensioner one-way cam 3 and push the timing chain tensioner rod 4 all the way into the timing chain tensioner housing.

c. Install the timing chain tensioner and gasket 5 onto the cylinder.

T

.

R

.

Timing chain tensioner bolt

10 Nm (1.0 m • kg, 7.2 ft • lb) d. Install the springs 2 and cap bolt 1.

T

.

R

.

Cap bolt

8 Nm (0.8 m • kg, 5.8 ft • lb)

*****************************************************

5-11

CYLINDER HEAD

ENG

7. Turn:

8crankshaft

(several turns counterclockwise) d c a b

8. Check:

8“I” mark a

Align the “I” mark on the C.D.I. magneto rotor with the stationary pointer b on the crankcase cover.

8“I” mark c

Align the “I” mark on the camshaft sprocket with the stationary pointer d on the cylinder head.

Out of alignment J Correct.

Refer to the installation steps above.

9. Tighten:

8camshaft sprocket bolt

T

R

30 Nm (3.0 m • kg, 21.7 ft • lb) c C

Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine.

10. Measure:

8valve clearance


J Adjust.

Refer to “ADJUSTING THE VALVE

CLEARANCE” in chapter 3.

5-12

THE ROCKER ARMS AND CAMSHAFT

ENG


7Nm(0.7m • kg, 5.1 ft • lb)

2

3

5

4

5

4

LS

4

6

6

M

7

M

M

2

3

M

1

7Nm(0.7m • kg, 5.1 ft • lb)

4

Order

1

2

3

4

5

6

7

Job/Part

Removing the rocker arms and camshaft

Cylinder head

Stopper plate

Locknut

Adjusting screw

Rocker arm shaft

Q’ty

2

2

1

2

Remarks



Refer to “ REMOVING THE ROCKER

ARMS AND CAMSHAFT” and “INSTALL-

ING THE ROCKER ARMS AND CAM-

SHAFT.

O-ring

Rocker arm

Camshaft

2

2

1 Refer to”INSTALLING THE CAMSHAFT

AND ROCKER ARMS”


5-13

1

2


ENG

EAS00202

REMOVING THE ROCKER ARMS AND CAM-

SHAFT

1. Remove:

8 locknut 1

8 stopper plate 2

1

2

2. Remove:

8 intake rocker arm shaft

8 exhaust rocker arm shaft

8 intake rocker arm

8 exhaust rocker arm

NOTE:

Remove the rocker arm shafts with the slide hammer bolt 1 and weight2 .

Slide hammer bolt

90890-01083 (YU-01083-1)

90890-01085 (YU-01083-2)

Weight

90890-01084 (YU-01083-3)

2

1

3. Remove:

8 camshaft1

Screw 8-mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft.

Slide hammer bolt

90890-01085 (YU-01083-2)

Weight

90890-01084 (YU-01083-3)

5-14

a


ENG

EAS00206

CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS

The following procedure applies to all of the rocker arms and rocker arm shafts.

1. Check:

8 rocker arm

Damage/wear

J Replace.

2. Check:

8 rocker arm shaft

Blue discoloration/excessive wear/pitting/ scratches

J Replace or check the lubrication system.

3. Check:

8 camshaft lobe

Excessive wear J Replace the camshaft.

4. Measure:

8 rocker arm inside diameter a


Rocker arm inside diameter

10 ~ 10.015 mm(0.393~0.394 in) a

5. Measure:

8 rocker arm shaft outside diameter a


J Replace.

Rocker arm shaft outside diameter

9.981 ~ 9.991 mm(0.392~0.393 in)

5-15

6. Calculate:

8 rocker-arm-to-rocker-arm-shaft clearance

NOTE:

Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter.

Above 0.034 mm(0.001 in)

J Replace the defective part(s).

a


ENG

Rocker-arm-to-rocker-arm-shaft clearance

0.009 ~ 0.034 mm(0.0004~0.001 in) b

EAS00205

CHECKING THE CAMSHAFT

1. Check:

8 camshaft bushings


2. Check:

8 camshaft lobes

Blue discoloration/pitting/scratches

J

Replace the camshaft.

3. Measure:

8 camshaft lobe dimensions a and b

Out of specification J Replace the camshaft.

Camshaft lobe dimension limit

Intake

1.034 in)

<Limit>:26.053mm

0.831 in)

<Limit>:20.915mm

Exhaust

1.034 in)

<Limit>:26.053mm

0.833 in)

<Limit>:20.956mm

4. Check:

8 camshaft oil passage


5-16

a


ENG

EAS00208

CHECKING THE TIMING CHAIN, CAMSHAFT

SPROCKETS, AND TIMING CHAIN GUIDES

The following procedure applies to all of the camshaft sprockets and timing chain guides.

1. Check:

8 timing chain 1

Damage/stiffness J Replace the timing chain and camshaft sprockets as a set.

1 b

2

2. Check:

8 camshaft sprocket

More than 1/4 tooth wear a J Replace the camshaft sprockets and the timing chain as a set.

a 1/4 tooth b Correct

1 Timing chain roller

2 Camshaft sprocket

3. Check:

8 timing chain guide (exhaust side)

8 timing chain guide (intake side)

8 timing chain guide (top side)

Damage/wear J Replace the defective part(s).

5-17

EAS00210

CHECKING THE TIMING CHAIN TENSIONER

1. Check:

8 timing chain tensioner


2. Check:

8 one-way cam operation

Rough movement

J Replace the timing chain tensioner housing.

3. Check:

8 cap bolt

8 copper washer O-ring

New

8 spring

8 one-way cam

8 gasket

New

8 timing chain tensioner rod

Damage/wear J Replace the defective part(s).

M


ENG

4

EAS00220

INSTALLING THE CAMSHAFT AND ROCKER

ARMS

1. Lubricate:

8 camshaft 1

1

M


Camshaft

Molybdenum disulfide oil

Camshaft bearing

Engine oil

2. Lubricate:

8 rocker arm shafts



2

1

2

1

1

2

5-18

3. Install:

8 exhaust rocker arm 1

8 exhaust rocker arm shaft 2

NOTE:

Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head.

4. Install:

8 intake rocker arm 1

8 intake rocker arm shaft 2

NOTE:

Make sure the intake rocker arm shaft is completely pushed into the cylinder head.

c C

Make sure the threaded part of the rocker arm shaft faces out.

5. Install:

8 stopper plate 1

8 locknut 2

T

R

7 Nm (0.7 m • kg, 5.1 ft • lb)

EAS00236

VALVES AND VALVE SPRINGS


ENG

1 2

6

M

3

7

4

M

5

M

3

7

M

2

6

1

5

6

7

1

2

3

4

Order Job/Part

Removing the valves and valve springs

Cylinder head

Rocker arm and rocker arm shaft

Q’ty Remarks



Refer to “ ROCKER ARMS AND

ROCKER ARMS SHAFTS”.

Valve cotter

Valve spring retainer

Valve spring

Valve (intake)

Valve (exhaust)

Valve stem seal

Valve stem seat

1

2

2

4

2

2

1 Refer to “ INSTALLING THE VALVES

AND VALVE SPRINGS “.


5-19

2

1


ENG

EAS00237

REMOVING THE VALVES

The following procedure applies to all of the valves and related components.

NOTE:

Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.

1. Check:

8 valve sealing

Leakage at the valve seat J Check the valve face, valve seat, and valve seat width.

Refer to “CHECKING THE VALVE

SEATS”.

***************************************************** a. Pour a clean solvent a into the intake and exhaust ports.

b. Check that the valves properly seal.

NOTE:

There should be no leakage at the valve seat

1.

*****************************************************

3

2. Remove:

8 valve cotters 1

NOTE:

Remove the valve cotters by compressing the valve spring with the valve spring compressor

2 and the valve spring compressor attachment

3.

Valve spring compressor

90890-04109 (YM-04109)

Valve spring compressor attachment

90890-04108 (YM-04108)

5-20

1

2

4

3 a

5 b

6


ENG

3. Remove:

8 valve cotter 1

8 valve spring retainer 2

8 valve spring 3

8 valve stem seal 4

8 lower spring seat 5

8 valve 6

NOTE:

Identify the position of each part very carefully so that it can be reinstalled in its original place.

EAS00239

CHECKING THE VALVES AND VALV E

GUIDES

The following procedure applies to all of the valves and valve guides.

1. Measure:

8 valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =

Valve guide inside diameter a -

Valve stem diameter b

Out of specification J Replace the valve guide.

Valve-stem-to-valve-guide clearance

Intake

0.010 ~ 0.037 mm(0.0004~0.0015 in)

<Limit>: 0.08 mm(0.003 in)

Exhaust

0.025 ~ 0.057 mm(0.001~0.002 in)

<Limit>: 0.10 mm(0.004 in)

2. Replace:

8 valve guide

NOTE:

To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100°C (212°F) in an oven.

***************************************************** a. Remove the valve guide with the valve guide remover 1.

b. Install the new valve guide with the valve guide installer 2 and valve guide remover

1.

c. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valveguide clearance.

5-21


ENG

NOTE:

After replacing the valve guide, reface the valve seat.

Valve guide remover (4.5 mm)

90890-04116 (YM-04116)

Valve guide installer (4.5 mm)

90890-04117 (YM-04117)

Valve guide reamer (5.0 mm)

90890-04099

*****************************************************

3. Eliminate:

8 carbon deposits

(from the valve face and valve seat)

4. Check:

8 valve face

Pitting/wear J Grind the valve face.

8 valve stem end

Mushroom shape or diameter larger than the body of the valve stem

J Replace the valve.

a

5-22

5. Measure:

8 valve margin thickness a

Out of specification J Replace the valve.

Valve margin thickness

0.85~1.15 mm(0.033~0.045 in)

6. Measure:

8 valve stem runout


J Replace the valve.

NOTE:

8 When installing a new valve, always replace the valve guide.

8 If the valve is removed or replaced, always replace the oil seal.

Valve stem runout

0.01 mm(0.0004 in)


ENG

EAS00240

CHECKING THE VALVE SEATS

The following procedure applies to all of the valves and valve seats.

1. Eliminate:

8 carbon deposits

(from the valve face and valve seat)

2. Check:

8 valve seat

Pitting/wear J Replace the cylinder head.

3. Measure:

8 valve seat width a

Out of specification J Replace the cylinder head.

b

Valve seat width

Intake: 0.9 ~ 1.1 mm(0.035 ~ 0.043

in)

<Limit>: 1.6 mm(0.063 in)

Exhaust: 0.9 ~1.1 mm(0.035~0.043

in)

<Limit>: 1.6 mm(0.063 in)

***************************************************** a. Apply Mechanic’s blueing dye (Dykem) b onto the valve face.

b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and onto the valve seat to make a clear impression.

d. Measure the valve seat width.

NOTE:

Where the valve seat and valve face contacted one another, the blueing will have been removed.

*****************************************************

4. Lap:

8 valve face

8 valve seat

NOTE:

After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

5-23

*****************************************************


ENG a a. Apply a coarse lapping compound a to the valve face.

c C

Do not let the lapping compound enter the gap between the valve stem and the valve guide.

b b. Apply molybdenum disulfide oil onto the valve stem.

c. Install the valve into the cylinder head.

d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound.

NOTE:

For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

e. Apply a fine lapping compound to the valve face and repeat the above steps.

f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat.

g. Apply Mechanic’s blueing dye (Dykem) b onto the valve face.

h. Install the valve into the cylinder head.

i. Press the valve through the valve guide and onto the valve seat to make a clear impression.

j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat.

*****************************************************

5-24

a


ENG

EAS00241

CHECKING THE VALVE SPRINGS

The following procedure applies to all of the valve springs.

1. Measure:

8 valve spring free length a


J Replace the valve spring.

Valve spring free length

37.30 mm(1.469 in)

<Limit>: 35.40 mm(1.394 in) b a

2. Measure:

8 compressed valve spring force a

Out of specification J Replace the valve spring.

b Installed length

Compressed valve spring force (installed)

147±11N(15.0±1.1 kg) at 25.77 mm

(33.075 ± 2.426 lb at 1.015 in) a

5-25

3. Measure:

8 valve spring tilt a

Out of specification J Replace the valve spring.

Spring tilt limit

1.6 mm ( 2.5°)(0.063 in)


ENG

EAS00245

INSTALLING THE VALVES

The following procedure applies to all of the valves and related components.

1. Deburr:

8valve stem end

(with an oil stone)

2. Lubricate:

8valve stem

8valve stem seal

(with the recommended lubricant)



5 3

4

6

M

2

1 b

M a

3. Install:

8 valve 1

8valve spring seat 2

8valve stem seal 3

New

8valve spring 4

8valve spring retainer 5

8 valve cotter 6

(into the cylinder head)

NOTE:

Install the valve spring with the larger pitch a facing up.

b Smaller pitch

2

1

3

4. Install:

8valve cotters 1

NOTE:

Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3.

5-26


ENG

Valve spring compressor

90890-04109 (YM-04109)

Valve spring compressor attachment

90890-04108 (YM-04108)

5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer.

c C

Hitting the valve tip with excessive force could damage the valve.

5-27


ENG

EAS00251


4

8 10

11

12

13

13

14

7

5

4

9

8

2

1

4

6

4

12Nm(1.2m • kg, 8.7 ft • lb)

3

3

4

1

2

5

6

7

Order Job/Part

Removing the cylinder and piston

Cylinder head

Clamp

Pipe

Timing chain guide (exhaust side)

Cylinder

O-ring

Dowel pin

Cylinder gasket

8

9

10

11

12

13

14

Piston pin clip

Piston pin

Piston

Top ring

2nd ring

Oil ring

Expander

5-28

Q’ty Remarks



1

1

1

1

1

2


AND CYLINDER”

2

1 Refer to “ REMOVING THE CYLINDER

AND PISTON”

1


AND CYLINDER”

1

2

1


2

3

1


ENG

EAS00253

REMOVING THE CYLINDER AND PISTON

1. Remove:

8 piston pin clip 1

8 piston pin 2

8 piston 3 c C

Do not use a hammer to drive the piston pin out.

NOTE:

8 Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.

8 Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area.

2. Remove:

8 top ring

8 2nd ring

8 oil ring

NOTE:

When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.

5-29

a

P


ENG

EAS00261*

CHECKING THE CYLINDER AND PISTON

1. Check:

8 piston wall

8 cylinder wall

Vertical scratches J Replace the cylinder, and the piston and piston rings as a set.

2. Measure:

8 piston-to-cylinder clearance

***************************************************** a. Please carry out the following inspections:

8 cylinder

Measure the piston pin in both of its horizontal axis direction a and its right angle direction b at six positions of A, B, C, etc.

with a cylinder gauge.

Abrasion = Max. value - min. value as measured at those six positions

When abrasion is beyond limit J Replace it

Standard value of cylinder inner diameter

52.40~52.41mm (2.063~2.064 in)

Service limit of cylinder inner diameter

52.5mm (2.067 in) b. If out of specification, replace the cylinder, and the piston and piston rings as a set.

c. Measure piston skirt diameter “P” with the micrometer.

a 3.5 mm(0.138 in) from the bottom edge of the piston

Piston size “P”

51.470 ~ 51.510 mm(2.026~ 2.028 in) d. If out of specification, replace the piston and piston rings as a set.

e. Calculate the piston-to-cylinder clearance with the following formula.

Piston-to-cylinder clearance =

Cylinder bore “C” - Piston skirt diameter “P”

Piston-to-cylinder clearance

0.01 ~ 0.03 mm(0.0004~0.0012 in)

<Limit>: 0.15 mm(0.006 in) f. If out of specification, replace the cylinder, and the piston and piston rings as a set.

5-30

*****************************************************

a


ENG

EAS00263

CHECKING THE PISTON RINGS

1. Measure:

8 piston ring side clearance

Out of specification J Replace the piston and piston rings as a set.

NOTE:

Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

Piston ring side clearance

Top ring

0.02 ~ 0.08 mm(0.0008~0.0031 in)

<Limit>: 0.13mm(0.0051 in)

2nd ring

0.02 ~ 0.06 mm(0.0008~0.0024 in)

<Limit>:0.12 mm(0.0047 in)

5-31

2. Install:

8 piston ring

(into the cylinder)

NOTE:

Level the piston ring into the cylinder with the piston crown.

a 20 mm (0.79 in)

3. Measure:

8 piston ring end gap

Out of specification J Replace the piston ring.

NOTE:

The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.

Piston ring end gap

Top ring

0.10 ~ 0.20 mm (0.004 ~ 0.008 in)

<Limit>: 0.45 mm (0.018 in)

2nd ring

0.20 ~ 0.30 mm (0.008 ~ 0.012 in)

<Limit>: 0.65 mm (0.026 in)

Oil ring

0.06 ~ 0.15 mm (0.002 ~ 0.006 in)

b


ENG

EAS00265

CHECKING THE PISTON PIN

1. Check:

8 piston pin

Blue discoloration/grooves J Replace the piston pin and then check the lubrication system.

a

2. Measure:

8 piston pin outside diameter a

Out of specification J Replace the piston pin.

Piston pin outside diameter

12.996 ~ 13.000 mm

(0.5117~0.5118 in)

<Limit>:12.976 mm (0.5109 in)

3. Measure:

8 piston pin bore diameter b

Out of specification J Replace the piston.

Piston pin bore diameter

13.002 ~ 13.013 mm

(0.5119 ~ 0.5123 in)

<Limit>:13.043 mm (0.5135 in)

4. Calculate:

8 piston-pin-to-piston-pin-bore clearance

Out of specification J Replace the piston pin and piston as a set.

Piston-pin-to-piston-pin-bore clearance =

Piston pin bore diameter b -

Piston pin outside diameter a

Piston-pin-to-piston clearance

<Limit>:0.067 mm(0.0026 in)

5-32


ENG

CHECKING THE TIMING CHAIN GUIDE

1. Check:

8 timing chain guide (exhaust side)

Damage/wear J Replace

2

3

1

EAS00267

INSTALLING THE PISTON AND CYLINDER

1. Install:

8 oil ring expander 1

8 oil ring rail 2

8 2nd ring 3

8 top ring 4

NOTE:

Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.

4

3

2

1

2 a

2. Install:

8 piston 1

8 piston pin 2

8 piston pin clip

New

3

NOTE:

8 Apply engineoil the piston pin.

8 Make sure the arrow mark a on the piston points towards the exhaust side of the cylinder.

8 Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase.

5-33

1

2


ENG

3. Install:

8 gasket New 1

8 dowel pins 2 a b c

A d

1

4. Lubricate:

8 piston

8 piston rings

8 cylinder



Engine oil

5. Offset:

8 piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring

A Exhaust side

6. Install:

8 cylinder 1

NOTE:

8 While compressing the piston rings with one hand, install the cylinder with the other hand.

8 Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.

5-34

BELT DRIVE

ENG

EAS00316

BELT DRIVE

CRANKCASE COVER

6

5

10Nm(1.0m • kg, 7.2 ft • lb)

2

7

6

8

9

4

3

1

2

3

4

5

6

7

8

9

Order Job/Part

Removing the belt drive

Kickstarter

Crankcase cover - 3

V-belt case air filter element holder

V-belt case filter element

Crankcase cover - 1

Dowel pin

O-ring

Dowel pin

O-ring

7Nm(0.7m • kg, 5.1 ft • lb)

1

23Nm(2.3m • kg, 16.6 ft • lb)

Q’ty Remarks


1

1

1

1

1

1

1

1

1


5-35

BELT DRIVE

ENG

EAS00338

KICKSTARTER

7

6

9Nm(0.9m • kg, 6.5 ft • lb)

1

2

8

5

3

4

1

2

5

6

7

8

Order Job/Part

Removing the kickstarter

Crankcase cover

Plate (V-belt guide)

Gasket

Kick pinion gear

Kick pinion gear clip

Circlip / Plate washer

Kick shaft assembly

Torsion spring

Solid bush

4

3

Q’ty Remarks


Refer to “CRANKCASE COVER “.

1

1

1

1

1/1

1

1

1

Refer to “INSTALLING THE KICKSTARTER“.


5-36

1

2

2

3

BELT DRIVE

ENG

EAS00340

INSTALLING THE KICKSTARTER

1. Install:

8 solid bush 1

8 kickstarter shaft 2

8 kickstarter spring 3

1 b a

2 d c

2. Hook:

8 kickstarter spring

NOTE:

Hook the spring end a on the kickstarter shaft b as shown, and hook the other end c on the projection d .

3. Install:

8 plain washer1

8 circlip2

New

1

4. Install:

8 kick pinion gear1

8 kick pinion gear clip 2

NOTE:

Install the clip at the position shown.

1

5. Install:

8 gasket1

New

8 plate2

2

5-37

V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE

BELT DRIVE

ENG

60Nm(6.0m • kg, 43.4 ft • lb)

5

4

13

10

8

3

6

2

1

LS

11

12

9

12

55Nm(5.5m • kg, 39.8 ft • lb)

LS

7

8

9

10

11

12

13

Order

1

2

3

4

5

6

Job/Part

Removing the V-belt, clutch, primary and secondary sheave

Primary sheave nut / Plate washer

Oneway clutch

Q’ty

1/1

1

Remarks


Refer to “ REMOVING AND INSTALLING

THE SECONDARY SHEAVE “

Primary fixed sheave

Secondary sheave nut

Clutch housing

Secondary sheave assembly

1

1

1

1 Refer to “ REMOVING AND INSTALLING

THE PRIMARY SHEAVE “

V-belt

Washer / Collar

Primary sliding sheave

Cam / Weight

Slider

Oil seal

Gasket

3

2

1

1

1/1

1

1/6


5-38

DISASSEMBLING THE SECONDARY SHEAVE

5

4

LS

3

BELT DRIVE

ENG

2

1

90Nm(9.0m

• kg, 65.1 ft • lb) 0

6

9

7

LS

8

9

LS

1

2

3

4

5

6

7

8

9

0

Order Job/Part

Disassembling the secondary sheave

Clutch carrier nut

Clutch carrier

Clutch shoe spring

Compression spring

Spring seat

Guide pin

Secondary sliding sheave

O-ring

Oil seal

Secondary fixed sheave

Q’ty

3

1

1

1

1

3

1

2

2

1

Remarks

Disassemble the parts in the order listed.

Refer to “ REMOVING AND INSTALLING

THE SECONDARY SHEAVE “


5-39

2

3

1

BELT DRIVE

ENG

EAS00317

REMOVING THE PRIMARY SHEAVE

1. Remove:

8 primary sheave nut 1

8 plate washer

8 primary fixed sheave 2

NOTE:

While holding the primary fixed sheave with the rotor holding tool 3, loosen the primary fixed sheave nut.

Rotor holding tool:

90890-01235 (YU-01235)

1

3

2

EAS00318

REMOVING THE SECONDARY SHEAVE AND

V-BELT

1. Remove:

8 secondary sheave nut 1

8 clutch housing 2

NOTE:

While holding the clutch housing with the sheave holder 3, loosen the secondary sheave nut.

Sheave holder:

90890-01701 (YS-01880-A)

2. Loosen:

8 clutch carrier nut 1 c C

Do not remove the clutch carrier nut at this stage.

NOTE:

While holding the clutch carrier with the rotor holding tool 2, loosen the clutch carrier nut one full turn with the locknut wrench 3.

Roter holding tool:

90890-01235 (YU-01235)

Locknut wrench:

90890-01348 (YM-01348)

5-40

BELT DRIVE

ENG

3. Remove:

8 secondary sheave assembly 1

8 V-belt 2

NOTE:

Remove the V-belt and clutch assembly from the primary sheave side.

2 1

2

3

1

EAS00319

DISASSEMBLING THE SECONDARY SHEAVE

1. Remove:

8 clutch carrier nut 1

NOTE:

Install the clutch spring holder 2 and clutch spring holder arm 3 onto the secondary sheave as shown. Then, compress the spring, and remove the clutch carrier nut 1.

Clutch spring holder

90890-01337 (YM-33285)

(YM-33285-6) a a a

CHECKING THE CLUTCH SHOE

1. Measure:

8 Clutch shoe

Scratches

J Glaze using coares sandpaper.


Clutch shoe thickness

3.5 mm (0.138 in)

<Limit>: 2.0 mm (0.079 in)

NOTE:

8 Inspect clutch shoes a.

8 After removing the clutch weight spring, do not use them again.

8 Replace the all three as a set.

5-41

1

1

BELT DRIVE

ENG

EAS00320

CHECKING THE V-BELT

1. Check:

8 V-belt 1


Grease/oil J Clean the primary and secondary sheave.

a

2. Measure:

8 V-belt width a


V-belt width

21.6 mm (0.0850 in)

<Limit>: 19.5 mm (0.768 in)

CHECKING THE PRIMARY SHEAVE

1. Check:

8 Primary sliding sheave1

8 Primary fixed sheave2

Cracks/damage/wear

J Replace the primary sliding sheave, primary fixed sheave and V-belt.

2 a

5-42

EAS00321

CHECKING THE PRIMARY SHEAVE WEIGHTS

The following procedure applies to all of the primary sheave weights.

1. Check:

8 primary sheave weight


2. Measure:

8 primary sheave weight outside diameter a


J Replace.

Primary sheave weight outside diameter

19.9~20.1 mm (0.783~0.791 in)

BELT DRIVE

ENG

CHECKING THE SLIDER

1.

Check:

slider 1


2

1

2

5

1 3

4

1

2

EAS00322

CHECKING THE SECONDARY SHEAVE

1. Check:

8secondary fixed sheave

8secondary sliding sheave

Cracks/damage/wear

J Replace the secondary fixed and sliding sheaves as a set.

2. Check:

8torque cam groove 1

Damage/wear J Replace the secondary fixed and sliding sheaves as a set.

3. Check:

8guide pin 2

Damage/wear J Replace the secondary fixed and sliding sheaves as a set.

EAS00323

ASSEMBLING THE PRIMARY SHEAVE

1. Clean:

8primary fixed sheave 1

8primary sliding sheave 2

8collar 3

8primary sheave weights 4

NOTE:

Use thinner to clean up grease, dirt on the primary sliding sheave cam side 5.

2. Install:

8primary sheave weights 1

8collar 2

5-43

3

2

1

BELT DRIVE

ENG

3. Install:

8 slider 1

8 primary sliding sheave 2

8 cam 3

5-44

2 1

BELT DRIVE

ENG

EAS00324

ASSEMBLING THE SECONDARY SHEAVE

1. Lubricate:

8 secondary fixed sheave’s inner surface 1

8 secondary sliding sheave’s inner surface

2

8 torque cam groove

8 oil seals

8 bearings



BEL-RAY assembly lube

3

1

2

2. Install:

8 secondary sliding sheave 1

NOTE:

Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide

3.

Oil seal guide

90890-01384 (YM-33299)

3

2

1

5-45

3. Install:

8 guide pin 1

4. Lubricate:

8 guide pin groove 2

8 o-ring

New

3



BEL-RAY assembly lube

3

1

4

2

5

BELT DRIVE

ENG

5. Install:

8 secondary sheave 1

8 spring

8 clutch carrier 2

NOTE:

Attach the clutch spring holder 3 and clutch spring holder arm 4 onto the secondary sheave as shown. Then, compress the spring, and tighten the clutch carrier nut 5.

Clutch spring holder

90890-01337 (YM-33285)

( YM-33285-6)

1

2

EAS00325

INSTALLING THE BELT DRIVE

1. Install:

8 V-belt 1

8 clutch assembly 2 c C

Do not allow grease to contact the V-belt, secondary sheave assembly.

NOTE:

Install the V-belt onto the primary sheave side.

5-46

3

1

2

2

BELT DRIVE

ENG

2. Install:

8 clutch carrier nut 1

T

R

90 Nm (9.0 m • kg, 65.1 ft • lb)

NOTE:

While holding the clutch carrier with the rotor holding tool 2, tighten the clutch carrier nut with the locknut wrench 3.

Rotor holding tool

90890-01235

Locknut wrench

90890-01348 (YM-01348)

1

3

3. Install:

8 clutch housing 1

8 secondary sheave nut2

T

R

60 Nm (6.0 m • kg, 43.4 ft • lb)

NOTE:

Tighten the secondary sheave nut with the sheave holder 3.

Sheave holder

90890-01701 (YS-01880-A)

2

1 3

5-47

4.

Position:

8 V-belt 1

NOTE:

Position the V-belt in the primary sheave 2

(when the pulley is at its widest position) and in the secondary sheave 3 (when the pulley is at its narrowest position), and make sure the Vbelt is tight.

STARTER CLUTCH AND STARTER MOTOR

ENG


7Nm(0.7m • kg, 5.1 ft • lb)

9

10

6

7

2

3

7Nm(0.7m • kg, 5.1 ft • lb)

B

2

11

8

1

5

4

LS

3

4

5

1

2

6

7

8

9

10

11

Order Job/Part

Removing the starter clutch and starter motor

Primary sheave

Q’ty Remarks


Refer to “ REMOVING THE PRIMARY

SHEAVE “

Idle gear plate

Plate washer

Idle gear

Starter clutch

Washer

Circlip

Bearing

Starter wheel gear

Starter motor

O-ring

Shaft

1

1

1

1

2

1

1

1

1

1

1


5-48

A

B


ENG

CHECKING THE STARTER WHEEL GEAR

1. Check:

8 starter wheel gear 1

8 idle gear2

Burrs/chips/roughness/wear J Replace

2

1

2. Check:

8 starter clutch operation

***************************************************** a. Install the starter clutch gear 1 onto the starter clutch2 and hold the starter clutch.

b. When turning the starter wheel gear clockwise A, the starter clutch and the starter wheel gear should engage, otherwise the starter clutch is faulty and must be replaced.

c. When turning the starter wheel gear counterclockwise B, it should turn freely. otherwise the starter clutch is faulty and must be replaced.

*****************************************************

5-49

C.D.I. MAGNETO

C.D.I. MAGNETO

ENG

3

7Nm(0.7m • kg, 5.1 ft • lb)

2

1

4

70Nm(7.0m • kg, 50.6 ft • lb)

Order

1

2

3

4

Job/Part

Removing the C.D.I. magneto

Air shroud 1

Fan

C.D.I. magneto rotor

Woodruff key

Stator coil assembly

1

1

1

1

Q’ty Remarks


Refer to “CYLINDER HEAD”in chapter 3.

c C

Disconnect the C.D.I. magneto lead coupler.


5-50

2

1

C.D.I. MAGNETO

ENG

REMOVING THE C.D.I. MAGNETO

1. Remove:

8 nut 1

8 plate washer

NOTE:

8 While holding the C.D.I. magneto rotor with the holding tool 2, loosen the C.D.I. magneto nut1.

8 Do not allow the sheave holder to touch the projection on the C.D.I. magneto rotor.


90890-01235 (YU-01235)

2

1

2. Remove:

8 C.D.I. magneto rotor1

8 (with flywheel puller 2 )

Flywheel puller

90890-01189 (YM-01189)

5-51

3

2

1

C.D.I. MAGNETO

ENG

INSTALLING THE C.D.I. MAGNETO

1. Install:

8 C.D.I. magneto rotor 1

NOTE:

8 Clean the tapered portion of the crankshaft and the magneto rotor hub.

8 When installing the magneto rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft.

2. Tighten:

8 nut 2

T

R

70 Nm (7.0 m • kg, 50.6 ft • lb)

NOTE:

8 While holding the C.D.I. magneto with the holding tool 3, tighten the C.D.I. magneto rotor nut 2.

8 Do not allow the sheave holder to touch the projection on the C.D.I. magneto rotor.


90890-01235 (YU-01235)

5-52

OIL PUMP

ENG

EAS00360

OIL PUMP

1

2

3

4

LS

7Nm(0.7m • kg, 5.1 ft • lb)

7Nm(0.7m • kg, 5.1 ft • lb)

8

11

12

14

13

6

10

9

7

5

6

7

8

9

3

4

1

2

10

11

12

13

14

Order Job/Part

Disassembling the oil pump

C.D.I. magneto

Cover

O-ring

Gasket

Oil seal

Dowel pin

Circlip / Plate washer

Oil pump driven gear

Dowel pin

Oil pump body

Outer rotor

Inner rotor

Oil pump shaft

Oil pump housing cover

Gasket

5

Q’ty Remarks


Refer to “ C.D.I. MAGNETO “

1

1/1

1

1

1

1

1

1

1

1

1

1

1

1


5-53

a

3 b

1

OIL PUMP

ENG

EAS00364

CHECKING THE OIL PUMP

1. Check:

8 oil pump driven gear 1

Cracks/damage/wear J Replace the defective part(s).

c

1

2

2. Measure:

8 inner-rotor-to-outer-rotor-tip clearance a

8 outer-rotor-to-oil-pump-housing clearance b

8 oil-pump-housing-to-inner-rotor-andouter-rotor clearance c


J Replace the oil pump.

1 Inner rotor

2 Outer rotor

3 Oil pump housing

Inner-rotor-to-outer-rotor-tip clearance

0.15 mm (0.006 in)

<Limit>: 0.23 mm (0.009 in)

Outer-rotor-to-oil-pump-housing clearance

0.013 ~ 0.036 mm

(0.0005~0.0014 in)

<Limit>: 0.106 mm (0.0042 in)

Oil-pump-housing-to-inner-rotorand-outer-rotor clearance

0.06 ~ 0.10 mm (0.002~0.004 in)

<Limit>: 0.17 mm (0.0067 in)

5-54

OIL PUMP

ENG

3. Check:

8 oil pump operation

Rough movement

J Repeat steps (1) and

(2) or replace the defective part(s).

2

1

EAS00376

INSTALLING THE OIL PUMP

1. Install:

8 gasket 1

New

8 oil pump assembly2

8 oil pump bolt

T

R

7 Nm (0.7 m • kg, 5.1 ft • lb) c C

After tightening the bolts, make sure the oil pump turns smoothly.

5-55

TRANSMISSION

ENG

EAS00419

TRANSMISSION

B

7

G

6

5

6

3

2

1

4

G

G

12Nm(1.2m • kg, 8.7 ft • lb)

B

3

4

1

2

5

6

7

Order Job/Part

Removing the transmission, shift drum assembly, and shift forks

Transmission oil

Rear wheel

Crankcase cover

Belt drive

Secondary sheave

Crankcase cover- 2

Crankcase cover gasket- 2

Dowel pin

Primary drive gear shaft

Plate washer

Main axle

Drive axle

Q’ty Remarks


1

1

2

1

1

1

1

Drain.

Refer to “REAR WHEEL AND REAR

BRAKE “ in chapter 4.

Refer to “BELT DRIVE “.

Refer to “V-BELT, CLUTCH, PRIMARY

AND SECONDARY SHEAVE “.


5-56

5-57

TRANSMISSION

ENG

EAS00425

CHECKING THE TRANSMISSION

1. Measure:

8 main axle runout

(with a centering device and dial gauge )

Out of specification J Replace the main axle.

Main axle runout limit

0.02 mm (0.0008 in)

2. Measure:

8 primary drive gear shaft runout


Out of specification J Replace the drive axle.

Primary drive gear shaft runout limit

0.02 mm (0.0008 in)

3. Measure:

8 drive axle runout



J Replace the drive axle.

Drive axle runout limit

0.02 mm (0.0008 in)

4. Check:

8 transmission gears

Blue discoloration/pitting/wear J Replace the defective gear(s).

8 transmission gear dogs

Cracks/damage/rounded edges J Replace the defective gear(s).

5. Check:

8 transmission gear engagement

(each pinion gear to its respective wheel gear)

Incorrect J Reassemble the transmission axle assemblies.

6. Check:

8 transmission gear movement

Rough movement J Replace the defective part(s).

CRANKCASE AND CRANKSHAFT

ENG

EAS00381


12Nm(1.2m • kg, 8.7 ft • lb)

11

10

7

8

9

18

19

11

17

16

12

15

4

14

LS

13

8Nm(0.8m • kg, 5.8 ft • lb)

1

2 3

6

5 4

3

2

1

32Nm(3.2m • kg, 23.1 ft • lb)

32Nm(3.2m • kg, 23.1 ft • lb)

6

7

8

9

10

1

2

3

4

5

Order Job/Part

Removing the crankshaft assembly

Engine

Cylinder head

Cylinder piston

V-belt, clutch, primary / Secondary sheave

Starter clutch

Q’ty Remarks


Refer to “ ENGINE “

Refer to “CYLINDER HEAD “

Refer to “CYLINDER PISTON “

Refer to “V-BELT, CLUTCH, PRIMARY

AND SECONDARY SHEAVE “.

Refer to “STARTER CLUTCH AND

STARTER MOTOR“

Refer to “C.D.I. MAGNETO “

Refer to “OIL PUMP “

Refer to “REAR WHEEL “

C.D.I. magneto

Oil pump

Rear wheel

Bolt

Collar

Plate washer

Spring

Centerstand

Engine bracket

Oil elemet cover

O-ring

Oil elemet

Crankcase (right )

2

2

2

1

1

1

1

1

1

1

5-58


ENG

12Nm(1.2m • kg, 8.7 ft • lb)

11

10

7

8

9

18

19

11

17

16

12

15

4

14

LS

13

8Nm(0.8m • kg, 5.8 ft • lb)

1

2 3

6

Order

11

12

Dowel pin

Crankshaft

13

14

15

16

17

18

19

Timing chain

Crankcase ( left )

Bolt

O-ring

Timing chain guide

Oil pipe

O-ring

Job/Part

5 4

3

2

1

32Nm(3.2m • kg, 23.1 ft • lb)

32Nm(3.2m • kg, 23.1 ft • lb)

1

1

1

1

1

Q’ty

2

1

Remarks

Refer to “DISASSEMBLING THE

CRANKCASE “

1

1 Refer to “INSTALLING THE CRANK-

SHAFT “


5-59


ENG

DISASSEMBLING THE CRANKCASE

1. Remove:

8 centerstand assembly

1

1

2

2. Remove:

8 crankcase bolts 1

NOTE:

Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

3.

Remove:

8 right crankcase1

NOTE:

Tap on one side of the crankcase with a softface hammer2. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly.

5-60

2

1


ENG

EAS00389

REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:

8 crankshaft assembly 1

8 timing chain 2

NOTE:

8 Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket.

8 The crankshaft assembly cannot be removed if the timing chain is attached onto the crankshaft sprocket.

EAS00207

CHECKING THE TIMING CHAIN AND TIMING

CHAIN GUIDES

1. Check:

8 timing chain

Damage/stiffness J Replace the timing chain.

2. Check:

8 timing chain guide

Damage/wear J Replace the timing chain guide.

5-61


ENG

EAS00394

CHECKING THE CRANKSHAFT AND CON-

NECTING ROD

1. Measure:

8 crankshaft runout

Out of specification J Replace the crankshaft, bearing or both.

NOTE:

Turn the crankshaft slowly.

Maximum crankshaft runout

0.03 mm (0.0012 in)

3

2

2

1

2. Measure:

8 big end side clearance

Out of specification J Replace the big end bearing, crankshaft pin, or connecting rod.

Big end side clearance

0.10~0.40 mm (0.004~0.016 in)

3. Measure:

8 crankshaft width


J Replace the crankshaft.

Crankshaft width

45.15~45.20 mm (1.778~1.780 in)

5-62

4. Check:

8 crankshaft sprocket 1

Damage/wear


8 bearing 2

Cracks/damage/wear J Replace the crankshaft.

8 oil pump drive gear 3

Damage/wear


3

2

1


ENG

5. Check:

8 crankshaft journal

Scratches/wear


8 crankshaft journal oil passage

Obstruction

J Blow out with compressed air.

EAS00408

INSTALLING THE CRANKSHAFT

1. Install:

8 crankshaft assembly 1

8 crankcase2

8 timing chain3 c C

To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.

NOTE:

Put the timing chain in parallel into the crank case, then use hands to place the crank shaft

Ass’y into the crank case. Manually rotate the crank shaft to check whether it is tightly engaged with the timing chain. (if not, install again)

5-63

2

1

1


ENG

EAS00418

ASSEMBLING THE CRANKCASE

1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.

2. Apply:

8 sealant

(onto the crankcase mating surfaces)

Yamaha bond No. 1215

90890-85505 (ACC-11001-05-01)

NOTE:

Do not allow any sealant to come into contact with the oil gallery.

a

3. Install:

8 dowel pins

8 timing chain 1

NOTE:

Install the timing chain so it is not visible through the opening a in the left crankcase 2.

4. Install:

8 crankshaft 1

8 crankcase (right )

5. Tighten:

8 crankcase

T

R

12 Nm (1.2 m • kg, 8.7 ft • lb)

5-64

CARB

CHAPTER 6

CARBRETOR

CARBURETOR ......................................................................................... 6-1

CHECKING THE CARBURETOR ..................................................... 6-3

ASSEMBLING THE CARBURETOR................................................. 6-5

INSTALLING THE CARBURETOR ................................................... 6-6

MEASURING AND ADJUSTING THE FUEL LEVEL ....................... 6-7

CHECKING THE FUEL COCK .......................................................... 6-8

CHECKING THE AUTOCHOKE UNIT .............................................. 6-8

AIR INDUCTION SYSTEM ..................................................................... 6-10

CHECKING THE AIR INDUCTION SYSTEM ................................. 6-11

6-12

EAS00483

CARBURETOR

4

1

2 q p o a w e

CARBURETOR

CARB

CARBURETOR

3 i

5

6

0 u y t r

8

7

9

1

2

3

4

5

6 q w e r t

7

8

9

0 y u i o

Order Job/Part

Disassembling the carburetor

Auto choke unit

Auto choke holder

Throttle stop screw / Spring

Bracket

Clamp

Vacuum chamber cover / Piston valve spring

Piston valve

Jet needle kit

Float chamber

Gasket

Accelerator pump assembly

Float pin

Float

Needle valve

Needle valve seat

Main jet

Main nozzle

Main air jet

Pilot jet

Q’ty Remarks


1

1

1/1

1

1

1/1

1

1

1

1

1

1

1

1

1

1

1

1

1

6-1

CARBURETOR

CARB

3 i

4

1

2 q p o a w e

0 u y t r

9

8

7

6

5

Order p a

Job/Part

Carburetor heater

Ground terminal

Q’ty

1

1

Remarks


6-2

2

1

CARBURETOR

CARB

EAS00485

CHECKING THE CARBURETOR

1. Check:

8 carburetor body

8 float chamber


2. Check:

8 fuel passages

Obstruction J Clean.

***************************************************** a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution.

b. Blow out all of the passages and jets with compressed air.

*****************************************************

3. Check:

8 float chamber body 1

Dirt J Clean.

4. Check:

8 float chamber rubber gasket 2

Cracks/damage/wear

J Replace.

6-3

5. Check:

8 float

Damage

J Replace.

3

2

1

CARBURETOR

CARB

6. Check:

8 needle valve 1

8 needle valve seat 2

Damage/obstruction/wear J Replace the needle valve, needle valve seat and Oring as a set.

7. Check:

8 O-ring 3

Damage/wear J Replace the needle valve, needle valve seat and O-ring as a set.

8. Check:

8 piston valve 1

Damage/scratches/wear J Replace.

8 piston valve diaphragm 2

Cracks/tears

J Replace.

1

2

2

1

9. Check:

8 vacuum chamber cover 1

8 piston valve spring 2

Cracks/damage

J Replace.

5

4 3

2

1

10. Check:

8jet needle1

8main jet2

8main nozzle3

8pilot jet4

8main air jet5

Bends/damage/wear J Replace.

Obstruction

J Clean.

Blow out the jets with compressed air.

6-4

11. Check:

8 piston valve movement

Insert the piston valve into the carburetor body and move it up and down.

Tightness J Replace the piston valve.

12. Check:

8 vacuum hoses

8 fuel hoses

Cracks/damage/wear

J Replace.

Obstruction J Clean.

Blow out the hoses with compressed air.

3

2

1

CARBURETOR

CARB

EAS00487

ASSEMBLING THE CARBURETOR c C all of the parts in a petroleum-based solvent.

1. Install:

8 main nozzle 1

8 main jet 2

8 pilot jet 3

3

5

4

1

2

2. Install:

8 needle valve seat 1

8 float 2

8 needle valve 3

8 float pin 4

8 screw 5

3. Install:

8 accelerator pump assembly

6-5

4. Install:

8piston valve

8jet needle

8piston valve spring

8vacuum chamber cover

6-6

CARBURETOR

CARB

EAS00492

INSTALLING THE CARBURETOR

1. Adjust:

8 engine idling speed


1,600 ~ 1,700r/min

Refer to “ADJUSTING THE ENGINE

IDLING SPEED” in chapter 3.

2. Adjust:

8 throttle cable free play


3 ~ 5 mm (0.12 ~ 0.20 in)


CABLE FREE PLAY” in chapter 3.

3

1 a

1

2

CARBURETOR

CARB

EAS00498

MEASURING AND ADJUSTING THE FUEL

LEVEL

1. Measure:

8 fuel level a


Fuel level (below the float chamber mating surface)

6.5 ~ 7.5 mm (0.26 ~ 0.30 in)

***************************************************** a. Stand the motorcycle on a level surface.

b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up.

c. Install the fuel level gauge 1 onto the fuel drain pipe 2

Fuel level gauge

90890-01312 (YM-01312-A) d. Loosen the fuel drain screw e. Hold the fuel level gauge vertically next to the float chamber 3.

f. Measure the fuel level a.

***************************************************** a

2.

Adjust:

8 fuel level

***************************************************** a. Remove the carburetor.

b. Check the needle valve seat and needle valve.

c. If either is worn, replace them as a set.

d. If both are fine, adjust the float level by slightly bending the float tang 1.

e. Install the carburetor.

f. Measure the fuel level a again.

g. Repeat steps (a) to (f) until the fuel level is within specification.

*****************************************************

6-7

CARBURETOR

CARB

EAS00505

CHECKING THE FUEL COCK

1. Check:

8fuel cock


2

1

1

2. Check:

8fuel cock strainer 1 obstruction J clean.

Blow out the jets with compressed air.

Damage J Replace.

6-8

EAS00503

CHECKING THE AUTOCHOKE UNIT

NOTE:

When checking the autochoke unit, the ambient temperature must be lower than 45°C (113°F).

1. Remove:

8carburetor

2. Check:

8autochoke unit

***************************************************** a. Connect a 3.3-mm hose 1 to the starter air passage 2 and blow into the hose.

NOTE:

When the starter plunger is open, air should come out of the other side of the starter air passage.

Starter plunger opens

Perform step (3).

Starter plunger closes

Replace the autochoke unit.

*****************************************************

3

B B

2

1

4

CARBURETOR

CARB

3. Check:

8 autochoke unit

***************************************************** a. Connect the autochoke unit leads to a 12.0-

V battery for five minutes.

Positive battery lead 1

J black

Negative battery lead 2

J black b. Connect a 3.3-mm hose 3 to the starter air passage 4 and blow into the hose.

Starter plunger opens.

Replace the autochoke unit.

Starter plunger closes.

Autochoke is OK.

*****************************************************

6-9

AIR INDUCTION SYSTEM


CARB

1

2

4Nm(0.4m • kg, 2.9 ft • lb)

7

6

5

3

4

31Nm(3.1m • kg, 22.4 ft • lb)

6

7

4

5

1

2

3

Order Job/Part

Removing the air induction system

Hose (from AI air filter)

Vacuum hose( from mainfold )

Hose (to cylinder head)

Muffler assembly

Gasket

Air cut-off valve bracket

Air cut-off valve assembly

Q’ty Remarks


1

1

1

1

1

1

1


6-10

1


CARB

EAS00510

CHECKING THE AIR INDUCTION SYSTEM

1. Check:

8 hoses



8 pipe

Cracks/damage

J Replace.

2. Check:

8 air cut-off valve


NOTE:

When the negative pressure is applied to the part 1, check that the continuity in the direction of arrow mark is completely lost. If the negative pressure is not loaded, the continuity can be obtained.

6-11

ELEC +

CHAPTER 7

ELECTRICAL

ELECTRICAL COMPONENTS ................................................................ 7-1

WIRING DIAGRAM ................................................................................... 7-2

CHECKING SWITCH CONTINUITY ........................................................ 7-4

CHECKING THE SWITCHES ................................................................... 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

ELECTRIC STARTING SYSTEM ........................................................... 7-14

CIRCUIT DIAGRAM ......................................................................... 7-14

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ................ 7-15


STARTER MOTOR ........................................................................... 7-20

CHECKING THE STARTER MOTOR .............................................. 7-21

ASSEMBLING THE STARTER MOTOR ......................................... 7-23

CHARGING SYSTEM ............................................................................. 7-24

CIRCUIT DIAGRAM ......................................................................... 7-24


LIGHTING SYSTEM ............................................................................... 7-27

CIRCUIT DIAGRAM ......................................................................... 7-27


CHECKING THE LIGHTING SYSTEM ........................................... 7-29

SIGNALING SYSTEM ............................................................................ 7-33

CIRCUIT DIAGRAM ......................................................................... 7-33


CHECKING THE SIGNALING SYSTEM ......................................... 7-35

CRABURETOR HEATING SYSTEM ..................................................... 7-41

CIRCUIT DIAGRAM ......................................................................... 7-41


AUTO CHOKE SYSTEM ........................................................................ 7-45

CIRCUIT DIAGRAM ......................................................................... 7-45


7-48

ELECTRICAL COMPONENTS

ELEC

EAS00729

ELECTRICAL COMPONENTS

ELECTRICAL

1 Wire harness

2 Battery

3 C.D.I. unit

4 Carburetor heater

5 Sidestand switch

6 Horn

7 Rectifier/Regulator

8 Ignition coil

9 Rear brake light switch

0 Main switch q Thermo switch w Fuel sender e Starter relay r Turn signal relay t Front brake light switch y Starting circuit cut-off relay

+

0 t r

9 w

6 q

7 y

2

8

5

1

4

3 e

7-1

WIRING DIAGRAM

ELEC +

WIRING DIAGRAM

B

Sb

L Y

BW

YR

L Y

LW

LW

RW

Br

B

Sb

GY

BW

BW

Br

B

B

R

Br

R

B

10A

R R

R

R

B B

B B

Y Y B

Br GY

BrW

P

L

Br

Br

BrW

GY

L

GY

12V 27/8W

Dg

12V 10W

Ch

12V 10W

G

Y

B

Y

B

G

B

Ch

Dg

12V 60W/55W

L

Br

L

14V3W

HI BEAM 12V3W

(ILLUM) 12V3W

TURN 12V3W

Dg

Ch

B

Dg

Ch

B

G G

B

B

12V 10W

12V 10W

B

B

B

B

B

7-2

1 Main switch

2 C.D.I. magneto


4 Battery

5 Main fuse

6 Battery (+) lead

7 Battery (-) lead

8 Wire lead

9 Starter relay

0 Starter motor q C.D.I. unit w Ignition coil e Auto choke unit r Front brake light switch t Rear brake light switch y Start switch u Engine stop switch i Starting circuit cut-off relay o Sidestand switch p Horn a Horn switch s Turn signal switch d Turn signal relay f Speedometer light g Tail/brake light h Dimmer switch j High beam indicator light k Turn signal indicator light l Fuel lever meter

; Fuel sender z Headlight x Front turn signal light (left) c Front turn signal light (right) v Rear turn signal light (left) b Rear turn signal light (right) n Thermo switch m Carburetor heater

WIRING DIAGRAM

ELEC +

Color Cod

B Black

Br Brown

Ch Chocolate

Dg Dark green

G Green

L Blue

Or Orange

P Pink

R Red

Sb Sky blue

W White

Y Yellow

B/W Black/White

B/R Black/Red

Br/W Brown/White

G/Y Green/Yellow

G/W Green/White

L/Y Blue/Yellow

L/W Blue/White

W/R White/Red

R/W Red/White

W/L White/Blue

Y/R Yellow/Red

7-3

a

OFF

ON

Br R b

Br R

+

CHECKING SWITCH CONTINUITY

ELEC

EAS00730

CHECKING SWITCH CONTINUITY

Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.

c C

Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

Pocket tester

90890-03132 (YU-03112-C)

NOTE:

8 Before checking for continuity, set the pocket tester to “0” and to the “

Ω × 1” range.

8 When checking for continuity, switch back and forth between the switch positions a few times.

The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left.

The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration.

NOTE:

“ c-c” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position).

The example illustration on the left shows that:

There is continuity between red and brown when the switch is set to “ON”.

7-4

+

CHECKING THE SWITCHES

ELEC

EAS00731

CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.

Damage/wear

J Repair or replace.

Improperly connected J Properly connect.

Incorrect continuity reading J Replace the switch.

Rear barake light switch

Main switch

Br R B B/W

LOCK

OFF

ON

R

B

Br

B

B Front barake light switch

Br

G/Y

Dimmer switch

Y L G

HI

LO

Horn switch

P B

OFF

PUSH

Turn signal light switch

Ch

Br/

W

Dg

L

N

R

Dg

Ch

L

B

L

P

B

Ch

Br/W

Dg

Sidestand switch

L/Y

Start switch

OFF

START

L/

W

L/

W

Engine stop switch

B/ B/

W W

L/

W

Br

OFF

RUN

B/W B/W

L/W Br

B

Main fuse

7-5

+

CHECKING THE BULBS AND BULB SOCKETS

ELEC

EAS00733

CHECKING THE BULBS AND BULB

SOCKETS

Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals.

Damage/wear

J Repair or replace the bulb, bulb socket or both.

Improperly connected J Properly connect.

No continuity

J Repair or replace the bulb, bulb socket or both.

C

A B

D E

TYPES OF BULBS

The bulbs used on this scooter are shown in the illustration on the left.

8 Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb. The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise.

8 Bulbs C is used for turn signal and tail/ brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise.

8 Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out.

7-6

+


ELEC

CHECKING THE CONDITION OF THE

BULBS

The following procedure applies to all of the bulbs.

1. Remove:

8 bulb w

Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

c C removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.

headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

2.

Check:

8 bulb (for continuity)


No continuity

J Replace.

Pocket tester

90890-03132 (YU-03112-C)

NOTE:

Before checking for continuity, set the pocket tester to “0” and to the “ Ω × 1” range.

3

1

2

1

3

2

7-7

***************************************************** a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity.

b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity.

c.

If either of the readings indicate no continuity, replace the bulb.

*****************************************************


ELEC +

CHECKING THE CONDITION OF THE BULB

SOCKETS

The following procedure applies to all of the bulb sockets.

1.

Check:

8 bulb socket (for continuity)


No continuity J Replace.

Pocket tester

90890-03132 (YU-03112-C)

NOTE:

Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following.

***************************************************** a. Install a good bulb into the bulb socket.

b. Connect the pocket tester probes to the respective leads of the bulb socket.

c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket.

*****************************************************

7-8

IGNITION SYSTEM

ELEC +

IGNITION SYSTEM

CIRCUIT DIAGRAM

B

R

Br

R

B

Sb

L Y

BW

L Y

YR

LW

RW

LW

Br

B

BW

BW

Br

Sb

GY

B

Y Y

BrW

P

L

Br

Br

Br

1 Main switch

B 2 Pickup coil

4 Battery

5 Main fuse

6 Battery (+) lead

8 Wire lead q C.D.I. unit w Ignition coil

GY

L B

BrW

Dg

12V 10W

Ch

12V 10W

B

B

G

Y

B

Y

B

G

B

12V 60W/55W

Ch

Dg

Dg

Ch

B

Dg

Ch

HI BEAM 12V3W

TURN 12V3W

12V 10W

12V 10W

L

(ILLUM) 12V3W

B

B

Br

L

14V3W

B

G G

B

B

10A

R R

R

R

B B

B B B

7-9

EAS00736

TROUBLESHOOTING

The ignition system fails to operate (no spark or intermittent spark).

Check:

1. Main Fuse

2. Battery

3. Spark plug

4. Ignition spark gap

5. Spark plug cap resistance

6. Ignition coil resistance

7. Main switch

8. Engine stop switch

9. Sidestand switch

10. Pickup coil resistance

11. Wiring connections (of the entire ignition system)

NOTE:

8 Before troubleshooting, remove the following part(s):

1. Head light cover

2. Front turn signal light bracket

3. Leg shield 1

4. Rear carrier

5. Side cover (right )

6. Cover

7. Battery cover

8 Troubleshoot with the following special tool(s).

Ignition checker

90890-06754 (YM-34487)

Pocket tester

90890-03132 (YU-03112-C)

+

IGNITION SYSTEM

ELEC

EAS00738

1.

Main Fuse

8 Check the fuse for continuity.

Refer to “CHECKING THE FUSE” in chapter 3.

8 Is the fuse OK?

YES NO

Replace the fuse.

EAS00739

2. Battery

8 Check the condition of the battery.

Refer to “CHECKING AND CHARGING

THE BATTERY” in chapter 3.

Minimum open-circuit voltage

12.8 V or more at 20°C

8 Is the battery OK?

YES NO

8 Clean the battery terminals.

8 Recharge or replace the battery.

EAS00740

3. Spark plug

8 Check the condition of the spark plug.

8 Check the spark plug type.

8 Measure the spark plug gap.

Refer to “CHECKING THE SPARK

PLUG” in chapter 3.

Standard spark plug

CR7E (NGK)

Spark plug gap

0.7 ~ 0.8 mm(0.028 ~ 0.032 in)

8 Is the spark plug in good condition, is it of the correct type, and is its gap within specification?

YES NO

Re-gap or replace the spark plug.

7-10

EAS00742

4. Ignition spark gap

8 Disconnect the spark plug cap from the spark plug.

8 Connect the ignition checker 1 as shown.

2 Spark plug cap

8 Set the main switch to “ON”.

8 Measure the ignition spark gap a.

8 Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.

+

IGNITION SYSTEM

ELEC

EAS00744

5. Spark plug cap resistance

8Remove the spark plug cap from the spark plug lead.

8Connect the pocket tester (“ Ω × 1k” range) to the spark plug cap as shown.

8Measure the spark plug cap resistance.

Spark plug cap resistance

8~12 k Ω

8Is the spark plug cap OK?

YES NO

Minimum ignition spark gap

6 mm(0.24 in)

8 Is there a spark and is the spark gap within specification?

NO YES

The ignition system is OK.

Replace the spark plug cap.

EAS00746

6. Ignition coil resistance

8Disconnect the ignition coil connectors from the ignition coil terminals.

8Connect the pocket tester ( Ω × 1) to the ignition coil as shown.

Positive tester probe J

Negative tester probe J

7-11

+

IGNITION SYSTEM

ELEC

EAS00749

7. Main switch

8 Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES”.

8 Is the main switch OK?

YES NO

8 Measure the primary coil resistance.

Primary coil resistance

0.184 ~ 0.276 Ω

8 Connect the pocket tester ( Ω × 1k) to the ignition coil as shown.



1

2

EAS00750


8 Check the engine stopswitch for continuity.


8 Is the engine stop switch OK?

YES

Replace the main switch.

NO

Replace the right handlebar switch.

EAS00752

9. Sidestand switch

8 Check the sidestand switch for continuity.


8 Is the sidestand switch OK?

YES NO

Replace the sidestand switch.

8 Measure the secondary coil resistance.

Secondary coil resistance

6.32 ~ 9.48 k

Ω

8 Is the ignition coil OK?

YES NO

Replace the ignition coil.

7-12

EAS00748

10.Pickup coil resistance

8Disconnect the pickup coil coupler from the wire harness.

8Connect the pocket tester ( Ω × 100) to the pickup coil terminal as shown.

Positive tester probe

J


1

W/R

W/L

2

IGNITION SYSTEM

ELEC +

8Measure the pickup coil resistance.

Pickup coil resistance

304 ~456

Ω

8Is the pickup coil OK?

YES NO

Replace the pickup coil.

EAS00754

11.Wiring

8Check the entire ignition system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

8Is the ignition system’s wiring properly connected and without defects?

YES NO

Replace the C.D.I.

unit.

Properly connect or repair the ignition system’s wiring.

7-13

ELECTRIC STARTING SYSTEM

ELEC


CIRCUIT DIAGRAM

+

B

Sb

L Y

BW

L Y

YR

LW

Br

RW

LW Sb

GY

B

BW

BW

Br

B

B

R

Br

R

B

10A

R R

R

R

B B

B B

Y Y B

Br GY

B

Br GY

L

GY

12V 27/8W

B

B

Br

BrW

Dg

12V 10W

Ch

12V 10W

B

BrW

P

L

Dg

Ch

1 Main switch

G

Y

12V 60W/55W

B B 6 Battery (+) lead

7 Battery (-) lead

9 Starter relay

0 Starter motor q C.D.I. unit

Dg

L

12V 10W t Rear brake light switch

TURN 12V3W

Ch

Ch y Start switch

HI BEAM 12V3W

B

12V 10W u Engine stop switch

(ILLUM) 12V3W i Starting circuit cut-off relay o Sidestand switch

B

B

L B

14V3W

G Br G B

7-14

q

0

1

2

6

3

7

+


ELEC

EAS00756

STARTING CIRCUIT CUT-OFF SYSTEM OP-

ERATION

If the main switch is set to “ON” (switchis closed), the starter motor can only operate if at least one of the following conditions is met:

8 The sidesatnd switch is up (the side stand switch is closed), and the brake lever ( front or rear) is pulled to the handlebar

(the brake light switch is closed)

9

1 Battery

2 Main fuse

3 Main switch

4 Front brake light switch

5 Rear brake light switch

6 Engine stop switch

7 Starting circuit cut-off relay

8 Sidestand switch

9 Start switch

0 Starter relay q Starter motor w C.D.I. unit w

8

5 4

7-15

EAS00757

TROUBLESHOOTING

The starter motor fails to turn.

Check:

1. Main fuse

2. Battery

3. Starter motor

4. Starting circuit cut-off relay

5. Starter relay

6. Main switch

7. Brake light switch (front, rear)


9. Sidestand switch

10. Start switch

11. Wiring connections

(of the entire starting system)

YES NO

-

Replace the fuse.

+


ELEC

EAS00738

1. Main fuse

8 Check the fuse for continuity.


8 Is the fuse OK?

NOTE:


1. Head light cover


3. Leg shield 1

4. Rear carrier


6. Cover

7. Battery cover


EAS00739

2. Battery

8 Check the condition of the battery.




12.8 V or more at 20°C

8 Is the battery OK?

YES NO

Pocket tester

90890-03132 (YU-03112-C)

8 Clean the battery terminals.


7-16

+


ELEC

EAS00758

3. Starter motor

8 Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead3.

EAS00759

4. Starting circuit cut-off relay

8Disconnect the starting circuit cut-off relay coupler from the wire harness.

8Connect the pocket tester ( Ω × 1) and battery (12 V) to the starting circuit cutoff relay coupler as shown.

Positive battery terminal J

Negative battery terminal J



w have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn.

therefore make sure nothing flammable is in the vicinity.

8Does the starter motor turn?

YES NO

Repair or replace the starter motor.

3 1

× 1Ω

4

2

12V

8Does the starting circuit cut-off relay have continuity between green/yellow3 and sky blue4?

YES NO

Replace the starting circuit cut-off relay.

7-17

+


ELEC

EAS00761

5. Starter relay

8 Disconnect the starter relay coupler from the coupler.

8 Connect the pocket tester ( Ω × 1) and battery (12 V) to the starter

8 relay coupler as shown.

EAS00751

7. Brake light switch(front and rear)

8 Check the brake light switch for continuity.


8 Is the brake light switch OK?

YES NO

Positive battery terminal J

Negative battery terminal J



Replace the brake light switch.

L/W

R/W

2

1

3

4

Starter relay

EAS00750


8 Check the engine stop switch for continuity.


8 Is the engine stop switch OK?

YES NO

8 Does the starter relay have continuity between red3 and red 4?

YES NO

Replace the starter relay.


EAS00752

9. Sidestand switch

8 Check the sidestand switch for continuity.


8 Is the sidestand switch OK?

YES NO

EAS00749

6. Main switch

8Check the main switch for continuity.


8Is the main switch OK?

YES NO

Replace the sidestand switch.


EAS00764

10.Start switch

8 Check the start switch for continuity.


8 Is the start switch OK?

YES NO


7-18


ELEC

EAS00766

11. Wiring

8 Check the entire starting system’s wiring.


8 Is the starting system’s wiring properly connected and without defects?

-

YES NO

+

The starting system circuit is OK.

Properly connect or repair the star ting system’s wiring or replace the C.D.I.

unit.

7-19

STARTER MOTOR


ELEC +

1

2

Order

1

2

5

6

7

8

9

0 q

1

2

3

4

5

6

0

9

3

2

7

7

8

3.5Nm(0.35m • kg, 2.5 ft • lb)

8

3

4

Starter motor

Starter motor disassembly

O-ring

Rear bracket

Gasket

Stator assembly

Armature coil

Circlip

Brush

Brush spring

Brush seat

Plate washer

Front bracket

Job/Part

Starter motor removal

Air filter case

Starter motor lead q

1

LS

7-20

1

1

1

2

2

2

1

1

1

1

1

Q’ty Remarks


Refer to“LEADS, HOSES AND REAR

BRAKE ”in chapter 5.

1

1




+


ELEC

EAS00769

CHECKING THE STARTER MOTOR

1. Check:

8 commutator

Dirt J Clean with 600-grit sandpaper.

2. Measure:

8 commutator diameter a


J Replace the starter motor.

Commutator wear limit

21 mm (0.83 in)

3.

Measure:

8 mica undercut a

Out of specification J Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.

Mica undercut

1.5 mm (0.06 in)

NOTE:

The mica of the commutator must be undercut to ensure proper operation of the commutator.

4. Measure:

8 armature assembly resistances (commutator and insulation)


J Replace the starter motor.

***************************************************** a. Measure the armature assembly resistances with the pocket tester.

Pocket tester

90890-03132 (YU-03112-C)

Armature coil

Commutator resistance 1

0.0306 ~ 0.0374 Ω

Insulation resistance 2

Above 1 M

Ω b. If any resistance is out of specification, replace the starter motor.

7-21

*****************************************************

+


ELEC

5. Measure:

8 brush length a


J Replace the brushes as a set.

Brush length wear limit

3.5 mm (0.14 in)

6. Measure:

8 brush spring force

Out of specification J Replace the brush springs as a set.

Brush spring force

5.52 ~ 8.28 N

7. Check:

8 gear teeth

Damage/wear

J Replace the gear.

7-22

2

3

1

1

2 b a

1

2


ELEC

EAS00772

ASSEMBLING THE STARTER MOTOR

1. Install:

8 brush spring 1

8 brush 2

8 armature coil

+

2. Install:

8 gasket 1

8 starter motor front bracket 2

8 starter motor rear bracket 3

NOTE:

Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear brackets.

2

1

3 . Install:

T

R

8 O-ring

New

1

8 washer

8 bolts 2

3.5 Nm (0.35 m • kg, 2.5 ft • lb)

7-23

CHARGING SYSTEM

ELEC +

EAS00773

CHARGING SYSTEM

CIRCUIT DIAGRAM

Br

Y Y

Br

B

2 C.D.I. magneto


4 Battery

5 Main fuse

6 Battery (+) lead

Sb

L Y

BW

L Y

LW

RW

Sb

GY

B

B

YR

LW

B

BW

BW

Br

B

R

Br

R

B

10A

R R

R

R

B B

B B

BrW

P

L

Br

Br

BrW

GY

L

GY

12V 27/8W

Dg

12V 10W

Ch

12V 10W

G

Y

B

Y

B

G

B

12V 60W/55W

Ch

Dg

L

Br

L

14V3W

HI BEAM 12V3W

(ILLUM) 12V3W

TURN 12V3W

Dg

Ch

B

Dg

Ch

B

G G

B

B

B

B

B

12V 10W

12V 10W

B

B

7-24

EAS00774

TROUBLESHOOTING

The battery is not being charged.

Check:

1. main fuse

2. battery

3. charging voltage

4. stator coil resistance

5. wiring connections

(of the entire charging system)

NOTE:


1. Rear carrier


3. Cover

4. Battery cover



90890-03113 (YU-08036-C)

Pocket tester

90890-03132 (YU-03112-C)

+

CHARGING SYSTEM

ELEC

EAS00739

2. Battery

8Check the condition of the battery.




12.8 V or more at 20°C

8Is the battery OK?

YES NO

8Clean the battery terminals.

8Recharge or replace the battery.

EAS00775

3. Charging voltage

8Connect the engine tachometer to the spark plug lead of cylinder.

8Connect the pocket tester (DC 20 V) to the battery as shown.

Positive tester probe J terminal

Negative tester probe J terminal

DC20V

EAS00738

1. Main fuse

8Check the fuse for continuity.


8Is the fuse OK?

YES NO

Replace the fuse.

8Start the engine and let it run at approximately 5,000 r/min.

8Measure the charging voltage.

Charging voltage

14 V at 5000r/min

7-25

NOTE:

Make sure the battery is fully charged.

8Is the charging voltage within specification?

YES NO

+

CHARGING SYSTEM

ELEC

EAS00754

5. Wiring

8Check the entire charging system’s wiring.


8Is the charging system’s wiring properly connected and without defects?

YES NO

The charging circuit is OK.

Replace the unit rectifier/regulator.

EAS00776

4. Stator coil resistance

8 Remove the C.D.I magneto couplers from wireharness.

8Connect the pocket tester ( Ω × 1) to the stator coils as shown.



Properly connect or repair the charging system’s wiring.

2

1

B/R G/W

W/R W/L

G/W B/R

W/L W/R

8Measure the stator coil resistances.

Stator coil resistance

688 ~ 1032

Ω

8Is the stator coil OK?

YES NO

Replace the stator coil assembly.

7-26

LIGHTING SYSTEM

ELEC +

EAS00780

LIGHTING SYSTEM

CIRCUIT DIAGRAM

B

R

Br

R

B

Sb

L Y

BW

L Y

YR

LW

RW

LW

Br

B

BW

BW

Br

Sb

GY

B

Y Y

BrW

P

L

Br

Br f Speedometer light h Dimmer switch j High beam indicator light

Br z Headlight

BrW

GY

L

GY

12V 27/8W

Dg

12V 10W

Ch

12V 10W

G

Y

B

Y

B

G

B

12V 60W/55W

Ch

Dg

B

B

B

Dg

Ch

B

Dg

Ch

HI BEAM 12V3W

TURN 12V3W

12V 10W

12V 10W

L

(ILLUM) 12V3W

B

B

Br

L

14V3W

B

G G B

B

10A

R R

R

R

B B

B B B

7-27

EAS00781

TROUBLESHOOTING

Any of the following fail to light: headlight, high beam indicator light, fuel level meter light or meter light.

Check:

1.

main fuse

2.

battery

3.

main switch

4.

dimmer switch

5.

wiring connections

(of the entire lighting system)

NOTE:

8Before troubleshooting, remove the following part(s):

1.

Head light cover

2.

Front turn signal light bracket

3.

Leg shield 1

4.

Rear varrier

5.

Side cover (right )

6.

Cover

7.

Battery cover

8Troubleshoot with the following special tool(s).

+

LIGHTING SYSTEM

ELEC

EAS00739

2. Battery




`


12.8 V or more at 20°C

8Is the battery OK?

YES NO



EAS00749

3. Main switch




YES NO

Pocket tester

90890-03132 (YU-03112-C) Replace the main switch.

EAS00738

1. Main fuse

8Check the fuses for continuity.

Refer to “CHECKING THE FUSES” in chapter 3.

8Is the fuse OK?

YES NO

Replace the fuse.

EAS00784

4. Dimmer switch

8Check the dimmer switch for continuity.


8Is the dimmer switch OK?

YES NO

The dimmer switch is faulty.

Replace the left handlebar switch.

7-28

EAS00787

5. Wiring

8 Check the entire lighting system’s wiring.


8 Is the lighting system’s wiring properly connected and without defects?

YES NO

Check the condition of each of the lighting system’s circuits.

Refer to “CIRCUIT

DIAGRAM”.

Properly connect or repair the lighting system’s wiring.

+

LIGHTING SYSTEM

ELEC

EAS00788

CHECKING THE LIGHTING SYSTEM

1. The headlight and the high beam indicator light fail to come on.

1. Headlight bulb and socket

8 Check the headlight bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND

BULB SOCKETS”

8 Are the headlight bulb and socket OK?

YES NO

Replace the headlight bulb, socket or both.

2. High beam indicator light bulb and socket

8 Check the high beam indicator light bulb and socket for continuity.


BULB SOCKETS”

8 Are the high beam indicator light bulb and socket OK?

YES NO

Replace the high beam indicator light bulb , socket or both.

7-29

3. Voltage

8 Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown.

When the dimmer switch is set to “%”

When the dimmer switch is set to “&”

Headlight coupler (wire harness side)

Headlight





LIGHTING SYSTEM

ELEC

YES NO

+

This circuit is OK.

The wiring circuit from the main switch to the headlight coupler and hight beam indicator light are faulty and must be repaired.

1

G

Y B

2 3

G

Y B

4

EAS00754

4. Wiring

8 Check the entire lighting system’s wiring.


8 Is the lighting system’s wiring properly connected and without defects?

YES NO

High beam indicator light


Negative tester probe

J

Check the condition of each of the lighting system’s circuits.

Refer to “CIRCUIT

DIAGRAM”.

Properly connect or repair the lighting system’s wiring.

Y

1

Dg

Ch

L

B

2

L Dg

B Ch

8Set the main switch to “ON”.

8Start the engine

8Set the dimmer switch to “%” or “&”.

8Measure the voltage (DC 12 V) on the headlight coupler (wire harness side).

8Measure the voltage (DC 12 V) on the dimmer switch coupler (wire harness side) when the dimmer switch is set to

“&”.

8Is the voltage within specification?

7-30

EAS00789

2. The meter light fails to come on.

1. Meter light bulb and socket

8 Check the meter light bulb and socket for continuity.


BULB SOCKETS”

8 Are the meter light bulb and socket OK?

YES NO

Replace the meter light bulb, socket or both.

+

LIGHTING SYSTEM

ELEC

EAS00841

3. Fuel level meter light

8 Check the fuel level meter light bulb and socket for continuity.

8 Are the fuel level meter light bulb and socket OK?

YES NO

Replace the fuel level meter light bulb, socket or both.

2. Voltage

8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown.



1

Dg

Ch

L

B

L Dg

B Ch

Y

2


8Measure the voltage (DC 12 V) of blue

1 on the meter light coupler (wire harness side).


YES NO

This circuit is OK.

The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired.

Refer to “CIRCUIT

DIAGRAM”.

7-31

EAS00748

4. Lighting coil resistance

8 Disconnect the lighting coil coupler from the wire harness.

8 Connect the pocket tester ( Ω × 1) to the lighting coil terminal as shown.



J

LIGHTING SYSTEM

ELEC +

Y/R

W

1

8 Measure the lighting coil resistance.

Lighting coil resistance

0.28 ~0.42

Ω

(between yellow/red and ground)

8 Connect the pocket tester ( Ω × 1)to the lighting coil terminal as shown.



J

Y/R

W

1



0.32 ~0.48

Ω

(between white and ground)

8 Is the lighting coil OK?

YES NO

Replace the lighting coil.

7-32

SIGNALING SYSTEM

ELEC +

EAS00793


CIRCUIT DIAGRAM

1 Main switch

4 Battery

5 Main fuse

6 Battery (+) lead

7 Battery (-) lead

8 Wire lead r Front brake light switch t Rear brake light switch p Horn a Horn switch L Y

L Y

Sb

Br d Turn signal relay g Tail/brake light k Turn signal indicator light

LW l Fuel level meter

RW

; Fuel sender x Front turn signal light(left) c Front turn signal light(right) v Rear turn signal light(left)

B

Sb

GY

B

Y Y

Br

Br

Br

B

BrW

GY

GY

L

GY

12V 27/8W

Dg

12V 10W

Ch

12V 10W

B

B

B

B

BrW

L

G

Y

B

Y

B

G

B

Ch

Dg

12V 60W/55W

BW

BW

Br P

LW

HI BEAM 12V3W

TURN 12V3W

Dg

Ch

B

Dg

Ch

12V 10W

12V 10W

B

B

L

(ILLUM) 12V3W

Br

L

14V3W

B

G G B

B

R

Br

R

B

10A

R R

R

R

B B

B B B

7-33

EAS00794

TROUBLESHOOTING signal light, brake light or an indicator light.

+


ELEC

EAS00739

2. Battery





12.8 V or more at 20°C

Check:

1. mainfuse

2. battery

3. main switch

4. wiring connections

(of the entire signaling system)

8Is the battery OK?

YES NO



NOTE:


1. Head light cover


3. Leg shield 1

4. Rear carrier


6. Cover

7. Battery cover


EAS00749

3. Main switch




YES NO


Pocket tester

90890-03132 (YU-03112-C)

EAS00738

1. Main fuse

8Check the main fuse for continuity.


8Is the fuse OK?

YES NO

Replace the fuse.

EAS00795

4. Wiring

8Check the entire signal system’s wiring.


8Is the signaling system’s wiring properly connected and without defects?

YES NO

Check the condition of each of the signaling system’s circuits.

Refer to “CHECKING

THE SIGNALING

SYSTEM”.

Properly connect or repair the signaling system’s wiring.

7-34

EAS00796

CHECKING THE SIGNALING SYSTEM

1.

The horn fails to sound.

1. Horn switch

8 Check the horn switch for continuity.


8 Is the horn switch OK?

YES NO


ELEC +

3. Horn

8Disconnect the pink connector at the horn terminal.

8Connect a jumper lead 1 to the horn terminal and ground the jumper lead.


8Push the horn switch.

8Does the horn sound?

P

Br


1

2. Voltage

8Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown.



J

1

Br P

NO YES

The horn is OK.

4. Voltage

8Connect the pocket tester (DC 20 V) to the horn connector at the pink terminal as shown.



Br P

1


8Push the horn switch.

8Measure the voltage (DC 12 V) of brown at the horn terminal.


YES NO

The wiring circuit from the main switch to the horn connector is faulty and must be repaired.

Refer to “CIRCUIT DIA-

GRAM”.


8Measure the voltage (DC 12 V) of pink

1 at the horn terminal.


YES NO

Repair or replace the horn.

Replace the horn.

7-35

EAS00798

2.

The tail/brake light fails to come on.

1. Tail/brake light bulb and socket

8 Check the tail/brake light bulb and socket for continuity.


BULB SOCKETS”

8 Are the tail/brake light bulb and socket

OK?


ELEC +

3. Voltage

8 Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.



YES NO

Replace the tail/brake light bulb, socket or both.

2. Brake light switches

8 Check the brake light switches for continuity.


8 Is the brake light switch OK?

YES NO

2

1

B

B

Y L

G/Y L


8 Pull in the brake levers.

8 Measure the voltage (DC 12 V) of yellow green/yellow 1 on the tail/brake light coupler (wire harness side).

8 Is the voltage within specification?

YES NO

The wiring circuit from the main switch to the tail/brake light bulb connector is faulty and must be repaired.

Refer to “CIRCUIT

DIAGRAM”.

Replace the brake light switch.

This circuit is OK.

The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.

Refer to “CIRCUIT

DIAGRAM”.

7-36

EAS00799

3. The turn signal light, turn signal indicator light or both fail to blink.

1. Turn signal light and turn signal indicator light bulbs and sockets

8 Check the turn signal light bulb and socket for continuity.


BULB SOCKETS”

8 Check the turn signal indicator light bulb and socket for continuity.


BULB SOCKETS”

8 Are the turn signal light bulb and socket

OK?


ELEC +

3. Voltage

8Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.



1

B Br/W Br

YES NO

Replace the turn signal light and/or turn signal indicator light bulb, socket or both.


8Measure the voltage (DC 12 V) on brown

1 at the turn signal relay coupler (wire harness side).


YES NO

2. Turn signal switch

8Check the turn signal switch for continuity.


8Is the turn signal switch OK?

The wiring circuit from the main switch to the turn signal relay coupler is faultyand must be repaired.


GRAM”.

YES NO


7-37

4. Voltage

8Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.



J

1

B Br/W Br


ELEC +

5. Voltage

8Connect the pocket tester (DC 20 V) to the turn signal light connector or meter assembly coupler (wire harness side) as shown.

Turn signal light

Turn signal indicator light

Left turn signal light



Right turn signal light


J



8Set the turn signal switch to “4” or “6”.

8Measure the voltage (DC 12 V) on brown/ white 1 at the turn signal relay coupler

(wire harness side).


YES NO

The turn signal relay is faulty and must be replaced.

Ch B

1

Ch B

Dg B

2

Dg B


8Set the turn signal switch to “4” or “6”.

8Measure the voltage (DC 12 V) of the chocolate 1 or dark green 2 at the turn signal light connector (wire harness side).


YES NO

This circuit is OK.

The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.

7-38

EAS00804

4. The fuel level meter fails to operate.

1. Fuel sender

8 Remove the fuel sender from the fuel tank.

8 Connect the pocket tester ( Ω × 1) to the fuel sender coupler (wire harness side) as shown.




ELEC +

2. Voltage

8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown.



1

L

B

Br

G

Br

G

L

B

2

(F)

1

G

B

(E)

2

8 Measure the fuel sender resistances.

Fuel sender resistance (up position

F)( Ω

4~10

Ω

Fuel sender resistance (down position E)(

Ω ××××× 10)

90~100 Ω

8Is the fuel sender OK?

YES NO

Replace the fuel sender.


8 Measure the voltage (DC 12 V) of brown

1 on the meter light coupler (wire harness side).

8 Is the voltage within specification?

YES NO

Check the wiring connections of the entire signaling system.


GRAM”.

7-39

3. Fuel level meter


8 Move the float up 1 or down 2.

1

2


ELEC +

8 Check that the fuel level meter needle moves to “F” or “E”.

NOTE:

Before reading the fuel level meter, leave the float in one position (either up or down) for at

least three minutes.

8 Does the fuel level meter needle move appropriately?

YES NO

This circuit is OK.

Replace the fuel level meter.

4.

Wiring

8 Check the entire signaling system’s wiring

7-40

CRABURETOR HEATING SYSTEM

ELEC

EAS00820

C ARBURETOR HEATING SYSTEM

CIRCUIT DIAGRAM

+

Y Y B

Br

B

Sb

L Y

BW

L Y

YR

LW

RW

LW Sb

GY

B

BW

BW

Br

B

B

R

Br

R

B

10A

R R

R

R

B B

B B

BrW

P

L

Br GY

1 Main switch

4 Battery

5 Main fuse

Br

Br GY

7 Battery (-) lead L

8 Wire lead n Thermo switch m Carburetor heater

BrW

Dg

12V 27/8W

12V 10W

Ch

12V 10W

G

Y

B

Y

B

G

B

12V 60W/55W

Ch

Dg

Dg

Ch

B

Dg

Ch

HI BEAM 12V3W

TURN 12V3W

L

(ILLUM) 12V3W

Br

L

14V3W

B

G G

B

B

B

B

12V 10W

12V 10W

B

B

B

7-41

EAS00821

TROUBLESHOOTING

The carburetor heating system fails to operate.

+


ELEC

EAS00739

2. Battery




Check:

1. Main fuse

2. Battery

3. Main switch

4. Thermo switch

5. Carburetor heater


(of the entire carburetor heating system)

NOTE:


1. Head light cover


3. Leg shield 1

4. Cover

5. Battery cover

6. Footrest board side cover mole(right)




EAS00749

3. Main switch




YES NO

Pocket tester

90890-03132 (YU-03112-C)


12.8 V or more at 20°C

8Is the battery OK?

YES NO


EAS00738

1. Main fuse

8Check the fuse for continuity.


8Is the fuse OK?

YES NO

Replace the fuse.

7-42

+


ELEC

EAS00823

4. Thermo switch

8 Remove the thermo switch from the thermo switch plate wire harness.

8 Connect the pocket tester to the ( Ω × 1) to the thermo switch 1 as shown.

NOTE:

Make sure that the thermo switch terminals do not get wet.

A The coolant temperature sensor circuit is closed.

B The coolant temperature sensor circuit is open.

OFF

ON

8 Immerse the thermo switch in a container filled with coolant 2.

8 Place a thermometer3 in the coolant.

8 Slowly heat the coolant, then let it cool down to the specified temperature.

8 Check the thermo switch for continuity at the temperature indicated below.

Continuity Test step

1

2

3*

4*

C o o l a n t temperature

0 ~11 ± 3 °C

More than16 ± 3 °C

16 ± 3 ~ 11±3 °C

Less than11 ± 3 °C

YES

NO

NO

YES

Steps 1 & 2: Heating phase

Steps 3 & 4: Cooling phase

11 ± 3 ˚ C

B

16 ± 3 ˚ C

A

8 Does the thermo switch operate properly?

YES NO

Replace the thermo switch.

3

2

1

EAS00824

5. Carburetor heater

8Remove the carburetor heating element from the carburetor.

8Connect the pocket tester to the carburetor heating element as shown.


J

Negative tester probe J body 2

8Measure the carburetor heater resistance.

w care.

strong shocks. If the thermo switch is dropped, replace it.

2

1

7-43

Carburetor heating element resistance

30

Ω

8Is the carburetor heating element OK?

YES NO

Replace the carburetor heating element.


ELEC

EAS00826

6. Wiring

8 Check the entire carburetor heating system’s wiring.


8 Is the carburetor heating system’s wiring properly connected and without defects?

-

NO

+

Properly connect or repair the carburetor heating system’s wiring.

7-44

AUTO CHOKE SYSTEM

ELEC +


CIRCUIT DIAGRAM

Br

Y Y

Br

B

2 C.D.I. magneto e Auto choke unit

GY

Sb

L Y

BW

L Y

LW

RW

Sb

GY

B

B

YR

LW

B

BW

BW

Br

B

R

Br

R

B

10A

R R

R

R

B B

B B

BrW

P

L

Br

Br

BrW

GY

L

GY

12V 27/8W

Dg

12V 10W

Ch

12V 10W

G

Y

B

Y

B

G

B

Ch

Dg

12V 60W/55W

L

Br

L

14V3W

HI BEAM 12V3W

(ILLUM) 12V3W

TURN 12V3W

Dg

Ch

B

Dg

Ch

B

G G

B

B

12V 10W

12V 10W

B

B

B

B

B

7-45

TROUBLESHOOTING

The auto choke system fails to operate.

Check:


2. Auto choke unit resistance


(of the entire auto choke system)

+


ELEC

EAS00748


8 Disconnect the lighting coil coupler from the wire harness.

8 Connect the pocket tester ( Ω × 1) to the lighting coil terminal as shown.



J

NOTE:


1. Cover

2. Rear carrier


Troubleshoot with the following special tool(s).

Y/R

W

1

Pocket tester

90890-03132 (YU-03112-C)



0.28 ~0.42

Ω

(between yellow/red and ground)

8 Connect the pocket tester ( Ω × 1)to the lighting coil terminal as shown.



J

Y/R

W

1



0.32 ~0.48

Ω

(between white and ground)

8 Is the lighting coil OK?

YES NO

Replace the lighting coil.

7-46

2. Auto choke unit resistance

8Disconnect the auto choke unit coupler from wire harness.

8Connect the Pocket tester( Ω × 1) to the

Auto choke unit coupler as shown.




ELEC +

B B

8Measure the auto choke unit resistance.

Auto choke unit resistance

30

Ω

8Is the auto choke unit OK?

YES NO

Replace the auto choke unit.

EAS00826

3. Wiring

8 Check the entire auto choke system’s wiring.


8 Is the auto choke system’s wiring properly connected and without defects?

YES NO

Properly connect or repair the auto choke system’s wiring.

7-47

TRBL

SHTG

CHAPTER 8

TROUBLE SHOOTING

STARTING FAILURES ............................................................................. 8-1

ENGINE .............................................................................................. 8-1

FUEL SYSTEM .................................................................................. 8-1

ELECTRICAL SYSTEMS .................................................................. 8-1

STARTING FAILURES/INCORRECT ENGINE IDLING SPEED ............ 8-2

INCORRECT ENGINE IDLING SPEED ................................................... 8-2

ENGINE .............................................................................................. 8-2

FUEL SYSTEM .................................................................................. 8-2


POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY

CLUTCH .................................................................................................... 8-3

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 8-3

ENGINE .............................................................................................. 8-3

FUEL SYSTEM .................................................................................. 8-3

FAULTY CLUTCH ..................................................................................... 8-3

ENGINE OPERATES BUT SCOOTER WILL NOT MOVE ............... 8-3

CLUTCH SLIPS ................................................................................. 8-3

POOR STARTING PERFORMANCE ................................................ 8-3

OVERHEATING/POOR BRAKING PERFORMANCE/FAULTY FRONT

FORK LEGS ......................................................................................... 8-4

POOR SPEED PERFORMANCE ..................................................... 8-4

OVERHEATING......................................................................................... 8-4

ENGINE .............................................................................................. 8-4

FUEL SYSTEM .................................................................................. 8-4

CHASSIS ............................................................................................ 8-4


POOR BRAKING PERFORMANCE ........................................................ 8-4

FAULTY FRONT FORK LEGS ................................................................. 8-4

LEAKING OIL ..................................................................................... 8-4

MALFUNCTION ................................................................................. 8-4

8-7

TRBL

SHTG

UNSTABLE HANDLING/FAULTY LIGHTING OR SIGNALING

SYSTEM .................................................................................................... 8-5

UNSTABLE HANDLING ........................................................................... 8-5

FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 8-5

HEADLIGHT DOES NOT COME ON ................................................ 8-5

HEADLIGHT BULB BURNT OUT ..................................................... 8-5

TAIL/BRAKE LIGHT DOES NOT COME ON .................................... 8-5

TAIL/BRAKE LIGHT BULB BURNT OUT ......................................... 8-5

TURN SIGNAL DOES NOT COME ON ............................................ 8-5

TURN SIGNAL BLINKS SLOWLY ..................................................... 8-5

TURN SIGNAL REMAINS LIT ........................................................... 8-6

TURN SIGNAL BLINKS QUICKLY .................................................... 8-6

HORN DOES NOT SOUND .............................................................. 8-6

8-8

STARTING FAILURES

TRBL

SHTG

EAS00844

TROUBLESHOOTING

NOTE:

The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.

STARTING FAILURES

ENGINE

Cylinder and cylinder head

8 Loose spark plug

8 Loose cylinder head or cylinder

8 Damaged cylinder head gasket

8 Damaged cylinder gasket

8 Worn or damaged cylinder

8 Incorrect valve clearance

8 Improperly sealed valve

8 Incorrect valve-to-valve-seat contact

8 Incorrect valve timing

8 Faulty valve spring

8 Seized valve

Piston and piston ring

8Improperly installed piston ring

8Damaged, worn or fatigued piston ring

8Seized piston ring

8Seized or damaged piston

Air filter

8Improperly installed air filter

8Clogged air filter element

Crankcase and crankshaft

8Improperly assembled crankcase

8Seized crankshaft

FUEL SYSTEM

Fuel tank

8Empty fuel tank

8Clogged fuel filter

8Clogged fuel tank cap breather hole

8Clogged or damaged fuel hose

8Deteriorated or contaminated fuel

Fuel cock

8Clogged or damaged fuel hose

Carburetor

8Deteriorated or contaminated fuel

8Clogged pilot jet

8Clogged pilot air passage

8Sucked-in air

8Damaged float

8Worn needle valve

8Improperly installed needle valve seat

8Incorrect fuel level

8Improperly installed pilot jet

8Clogged starter jet

8Clogged emulsion tube

8Improperly adjusted pilot screw

Auto choke unit

8Faulty starter plunger

8Faulty thermo switch

ELECTRICAL SYSTEMS

Battery

8Discharged battery

8Faulty battery

Fuse

8Blown, damaged or incorrect fuse

8Improperly installed fuse

Spark plug

8Incorrect spark plug gap

8Incorrect spark plug heat range

8Fouled spark plug

8Worn or damaged electrode

8Worn or damaged insulator

8Faulty spark plug cap

Ignition coil

8Cracked or broken ignition coil body

8Broken or shorted primary or secondary coils

8Faulty spark plug lead

8-1

STARTING FAILURES/

INCORRECT ENGINE IDLING SPEED

TRBL

SHTG

Ignition system

8Faulty C.D.I unit

8Faulty pickup coil

8Broken magneto rotor woodruff key

EAS00846

INCORRECT ENGINE IDLING

SPEED

Switches and wiring

8Faulty main switch

8Faulty engine stop switch

8Broken or shorted wiring

8Faulty front and rear brake light switch

8Faulty start switch

8Faulty sidestand switch

8Improperly grounded circuit

8Loose connections

ENGINE

Cylinder and cylinder head

8Incorrect valve clearance

8Damaged valve train components

Air filter


Starting system

8Faulty starter motor

8Faulty starter relay

8Faulty starting circuit cut-off relay

8Faulty starter clutch

FUEL SYSTEM

Carburetor

8Faulty starter plunger

8Loose or clogged pilot jet

8Loose or clogged pilot air jet

8Damaged or loose carburetor joint

8Improperly adjusted engine idling speed

(throttle stop screw)

8Improper throttle cable free play

8Flooded carburetor


Battery

8Discharged battery

8Faulty battery

Spark plug



8Fouled spark plug

8Worn or damaged electrode

8Worn or damaged insulator

8Faulty spark plug cap

Ignition coil

8Broken or shorted primary or secondary coils

8Faulty spark plug lead

8Cracked or broken ignition coil

Ignition system

8Faulty C.D.I. unit

8Faulty pickup coil

8Broken magneto rotor woodruff key

8-2

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/

FAULTY CLUTCH

TRBL

SHTG

EAS00849

POOR MEDIUM-AND-HIGH-SPEED

PERFORMANCE

EAS00853

FAULTY CLUTCH

ENGINE OPERATES BUT SCOOTER WILL

NOT MOVE

Refer to “STARTING FAILURES”.

ENGINE

Air filter


V-belt

8Bent, damaged or worn V-belt

8Slipping V-belt

Air intake system

8Bent, clogged or disconnected carburetor air vent hose

8Clogged or leaking air duct

Primary pulley cam and primary pulley slider

8Damaged or worn primary pulley cam

8Damaged or worn primary pulley slider

Clutch spring(s)

8Damaged clutch spring

FUEL SYSTEM

Carburetor

8Faulty diaphragm


8Loose or clogged main jet

8Faulty accelerating pump

Transmission gears

8Damaged transmission gear

Fuel cock

8Faulty fuel cock

CLUTCH SLIPS

Clutch shoe springs

8Damaged, loose or worn clutch shoe spring

Clutch shoes

8Damaged or worn clutch shoe

Primary sliding sheave

8Seized primary sliding sheave

POOR STARTING PERFORMANCE

V-belt

8V-belt slips

8Oil or grease on the V-belt


8Faulty operation

8Worn pin groove

8Worn pin

Clutch shoes

8Bent, damaged or worn clutch shoe

8-3

OVERHEATING/POOR BRAKING PERFORMANCE/

FAULTY FRONT FORK LEGS

TRBL

SHTG

POOR SPEED PERFORMANCE

V-belt

8Oil or grease on the V-belt

EAS00859

POOR BRAKING PERFORMANCE

Primary pulley weight(s)

8Faulty operation

8Worn primary pulley weight

Primary fixed sheave

8Worn primary fixed sheave


8Worn primary sliding sheave

Secondary fixed sheave

8Worn secondary fixed sheave

Disc brake

8Worn brake pad

8Worn brake disc

8Air in hydraulic brake system

8Leaking brake fluid

8Faulty brake caliper kit

8Faulty brake caliper seal

8Loose union bolt

8Damaged brake hose

8Oil or grease on the brake disc

8Oil or grease on the brake pad

8Incorrect brake fluid level

Secondary sliding sheave

8Worn secondary sliding sheave

EAS00854

OVERHEATING

ENGINE

Cylinder head and piston

8Heavy carbon buildup

Drum brake

8Worn brake shoe

8Worn or rusty brake drum

8Incorrect brake camshaft lever position

8Incorrect brake shoe position

8Damaged or fatigued brake shoe spring

8Oil or grease on the brake shoe

8Oil or grease on the brake drum

8Broken brake torque rod

EAS00860

FAULTY FRONT FORK LEGS Engine oil

8Incorrect oil level

8Incorrect oil viscosity

8Inferior oil quality

FUEL SYSTEM

Carburetor

8Incorrect main jet setting


8Damaged or loose carburetor joint

Air filter


LEAKING OIL

8Bent, damaged or rusty inner tube

8Cracked or damaged outer tube

8Improperly installed oil seal

8Damaged oil seal lip

8Incorrect oil level (high)

8Loose damper rod assembly bolt

8Damaged damper rod assembly bolt copper washer

8Cracked or damaged cap bolt O-ring

CHASSIS

Brakes

8Dragging brake


Spark plug



MALFUNCTION

8Bent or damaged inner tube

8Bent or damaged outer tube

8Damaged fork spring

8Bent or damaged damper rod

8Incorrect oil viscosity

8Incorrect oil level

Ignition system

8Faulty C.D.I. unit

8-4

UNSTABLE HANDLING/

FAULTY LIGHTING OR SIGNALING SYSTEM

TRBL

SHTG

EAS00862

UNSTABLE HANDLING

EAS00866

FAULTY LIGHTING OR SIGNALING

SYSTEM

Handlebar

8Bent or improperly installed handlebar

Steering head components

8Improperly installed upper bracket

8Improperly installed lower bracket

(improperly tightened ring nut)

8Bent steering stem

8Damaged ball bearing or bearing race

HEADLIGHT DOES NOT COME ON

8Wrong headlight bulb

8Too many electrical accessories

8Hard charging

8Incorrect connection


8Poor contacts (main or light switch)

8Burnt-out headlight bulb

Front fork leg(s)

8Uneven oil levels (both front fork legs)

8Unevenly tensioned fork spring (both front fork legs)

8Broken fork spring

8Bent or damaged inner tube

8Bent or damaged outer tube

HEADLIGHT BULB BURNT OUT

8Wrong headlight bulb

8Faulty battery

8Faulty rectifier/regulator


8Faulty main switch

8Headlight bulb life expired

Rear shock absorber assembly

8Faulty rear shock absorber spring

8Leaking oil

Tire(s)

8Uneven tire pressures (front and rear)

8Incorrect tire pressure

8Uneven tire wear

TAIL/BRAKE LIGHT DOES NOT COME ON

8Wrong tail/brake light bulb

8Too many electrical accessories


8Burnt-out tail/brake light bulb

TAIL/BRAKE LIGHT BULB BURNT OUT

8Wrong tail/brake light bulb

8Faulty battery

8Tail/brake light bulb life expired

Wheel(s)

8Incorrect wheel balance

8Deformed cast wheel

8Damaged wheel bearing

8Bent or loose wheel axle

8Excessive wheel runout

Frame

8Bent frame

8Damaged steering head pipe

8Improperly installed bearing race

TURN SIGNAL DOES NOT COME ON

8Faulty turn signal switch

8Faulty turn signal relay

8Burnt-out turn signal bulb


8Damaged or faulty wire harness


8Faulty battery


TURN SIGNAL BLINKS SLOWLY


8Faulty main switch

8Faulty turn signal switch

8Incorrect turn signal bulb

8Faulty battery

8-5

FAULTY LIGHTING OR SIGNALING SYSTEM

TRBL

SHTG

TURN SIGNAL REMAINS LIT



TURN SIGNAL BLINKS QUICKLY

8Incorrect turn signal bulb



HORN DOES NOT SOUND

8Improperly adjusted horn

8Damaged or faulty horn

8Faulty main switch

8Faulty horn switch

8Faulty battery


8Faulty wire harness

8-6

YAMAHA MOTOR TAIWAN CO., LTD

Yamaha VINO 125 Service manual

SERVICE MANUAL

NOTICE

HOW TO USE THIS MANUAL

TABLE OF CONTENTS

GENERAL INFORMATION

GEN

INFO

SPECIFICATIONS

SPEC

PERIODIC CHECKS AND

ADJUSTMENTS

CHK

ADJ

CHASSIS

CHAS

ENGINE

ENG

CARBURETOR

ELECTRICAL SYSTEM

CARB

ELEC

TROUBLESHOOTING

TRBL

SHTG

GENERAL INFORMATION

SPECIFICATIONS

CONVERSION TABLE

GENERAL TIGHTENING TORQUE

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHECKING THE FRONT BRAKE PADS/

CHECKING THE REAR BRAKE SHOES/

CHECKING THE FRONT BRAKE HOSE

CHASSIS

ENGINE

CHAPTER 7

ELECTRICAL

ELECTRICAL

CRABURETOR HEATING SYSTEM

C ARBURETOR HEATING SYSTEM

TROUBLESHOOTING

OVERHEATING/POOR BRAKING PERFORMANCE/

FAULTY FRONT FORK LEGS

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Table of contents