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!
Q
The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOUR
SAFETY IS INVOLVED!
w
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.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.
NOTE:
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.
6 2
1
CYLINDER AND PISTON
ENG
CYLINDER AND PISTON
CYLINDER AND PISTON
REMOVING THE CYLINDER AND PISTON
1. Remove:
8 piston pin clip 1
8 piston pin 2
8 piston 3
1
2
8
2
4
11
12
Do not use a hammer to drive the piston pin
out.
1
8
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.
13
14
13
7
4
5
5
4
6
2. Remove:
8 top ring
8 2nd ring
8 oil ring
3
4
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.
12Nm(1.2m • kg, 8.7 ft • lb)
7
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
Removing the cylinder and piston
Cylinder head
Clamp
Pipe
Timing chain guide (exhaust side)
Cylinder
O-ring
Dowel pin
Cylinder gasket
1
1
1
1
1
2
1
8
9
Piston pin clip
Piston pin
2
1
10
11
Piston
Top ring
1
1
12
13
14
2nd ring
Oil ring
Expander
1
2
1
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “ INSTALLING THE PISTON
AND CYLINDER”
Refer to “ REMOVING THE CYLINDER
AND PISTON”
Refer to “ INSTALLING THE PISTON
AND CYLINDER”
For installation, reverse the removal procedure.
5-28
3
cC
10
4
9
ENG
EAS00253
3
EAS00251
5-29
8
EAS00008
1
2
GEN
INFO
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
SPEC
3
4
CHK
ADJ
1
2
3
4
5
6
7
8
9
CHAS
5
6
ENG
COOL
7
8
CARB
ELEC
9
0
-
w
e
r
+
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
TRBL
SHTG
q
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Carburetor(s)
Electrical system
Troubleshooting
T.
R.
t
y
i
u
o
E
a
p
G
s
B
d
M
LS
f
M
g
LT
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
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
CARBURETOR
GEN
INFO
1
SPEC
2
CHK
ADJ
3
CHAS
4
ENG
5
CARB
6
-
ELECTRICAL SYSTEM
TROUBLESHOOTING
+
ELEC
7
TRBL
SHTG
8
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
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
SCOOTER IDENTIFICATION
GEN
INFO
EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped
into the steering head pipe.
1
EAS00018
MODEL LABEL
The model label 1 is affixed to the seat. This
information will be needed to order spare parts.
1
1-1
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
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.
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.
1-2
IMPORTANT INFORMATION
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
cC
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.
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.
1-4
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
90890-01268
YU-01268
90890-01311
YM-08035-A
90890-01312
YM-01312-A
90890-01326
YM-01326
90890-01294
YM-01300-1
90890-01337
YM-33285
YM-33285-6
90890-01348
YM-01348
90890-01189
YM-01189
Tool name / Function
Illustration
Rocker arm shaft puller bolt1
1
Weight2
These tools are used when removing or installing the rocker arm shafts.
2
Rotor holding tool
This tool is used to remove the flywheel
magneto.
Ringnut wrench
This tool is used to loosen and tighten the
exhaust and steering ring nut.
Valve adjusting tool
This tool is necessary for adjusting valve
clearance.
Fuel level gauge
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
These tool are used for removing the nut
with holding the compression spring.
Lock nut wrench
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
2
41
46
SPECIAL TOOLS
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
Tool name / Function
GEN
INFO
Illustration
Fork seal driver weight 1
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
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
1
2
SPECIAL TOOLS
Tool NO.
90890-06754
YM-34487
90890-85505
ACC-11001-05-01
80890-04116
YM-04116
90890-04117
YM-04117
90890-04099
YM-04099
Tool name / Function
Ignition checker
This instrument is necessary for checking
the ignition system components.
Yamaha bond NO.1215
This sealant (bond) is used for crankcase
mating surface, etc.
Valve guide remover (4.5 mm)
This tool is used to remove or install the valve
guides.
Valve guide installer (4.5 mm)
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
GEN
INFO
Illustration
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 SPECIFICATIONS ................................................................................................. 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
Standard
Item
Model code
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)
Limit
5YR1 (for USA)
5YR2 (for CAN)
…
…
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
ENGINE SPECIFICATIONS
Item
Standard
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Engine idle speed
Vacuum pressure at engine idle speed
Standard compression pressure (at sea level)
Forced Air cooled 4-stroke,
SOHC
0.125L(125.0 cm3)
Forward inclined single cylinder
51.5 × 60.0 mm
9.8±0.4 :1
1600~1700 r/min
30.0 kpa(238.6 mmHg)
950 kPa(9.5kg/cm2) / 300 r/min
…
…
…
…
…
…
…
Regular unleaded gasoline
…
Engine
Engine type
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Engine oil
Lubrication system
Recommended oil
-20˚ -10˚
0˚
10˚
20˚ 30˚
40˚ 50˚
SAE 10W-30
Limit
…
4.5L (0.98lmp gal, 1.18 USgal) …
Wet sump
…
SAE20W40SE
Yamaha 4-cycle oil
EFERO X, Z, BX
…
…
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)
…
…
…
SAE 10W-40
SAE 20W-40
SAE 20W-50
Quantity
Periodic oil change
With oil filter replacement
Total amount
Final gear oil
Recommended oil
Periodic oil change
Total amount
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
ENGINE SPECIFICATIONS
Standard
Item
Oil filter
Oil filter type
SPEC
Limit
Wire mesh
…
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
Trochoid
0.15 mm
0.013-0.036 mm
0.06-0.10 mm
…
0.23mm
0.106mm
0.17mm
Starting system type
Electric and kick starter
…
Spark plug
Model (manufacturer) × quantity
Spark plug gap
CR7E (NGK) × 1
0.7~0.8mm
…
…
Cylinder head
Volume
Max. warpage
12.3~12.7cm³
…
…
0.03 mm
2-3
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Camshaft
Drive system
Intake camshaft lobe dimensions
Limit
Chain drive (left)
…
26.153~26.253 mm
21.015~21.115 mm
5.203mm
26.053 mm
20.915 mm
…
26.153~26.253 mm
21.056~21.156 mm
5.203 mm
…
26.053 mm
20.956 mm
…
0.03 mm
C
A
B
Measurement A
Measurement B
Measurement C
Exhaust camshaft lobe dimensions
C
A
B
Measurement A
Measurement B
Measurement C
Max. camshaft runout
2-4
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Timing chain
Model/number of links
Tensioning system
Valve, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Limit
Morse 92RH2005 / 88
Automatic
…
…
0.08~0.12 mm
0.13~0.17 mm
…
…
B
C
D
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
Valve seat width
Intake
Exhaust
Seat Width
Margin Thickness
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
1.6mm
1.6mm
0.85~1.15 mm
0.85~1.15 mm
…
…
4.475~4.490 mm
4.460~4.475 mm
4.445 mm
4.430 mm
4.500~4.512 mm
4.500~4.512 mm
4.550 mm
4.550 mm
0.010~0.037 mm
0.025~0.057 mm
…
0.080 mm
0.100 mm
0.010 mm
0.9~1.1 mm
0.9~1.1 mm
1.6mm
1.6mm
2-5
ENGINE SPECIFICATIONS
Standard
Item
Valve springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force (installed)
Intake
Exhaust
Spring tilt
SPEC
Limit
37.30 mm
37.30 mm
35.40 mm
35.40 mm
25.77mm
25.77mm
…
…
147±11N (15.0 ± 1.1 kgf/mm)
147±11N (15.0 ± 1.1 kgf/mm)
…
…
Intake
Exhaust
Winding direction (top view)
Intake
Exhaust
…
…
2.5°/1.6 mm
2.5°/1.6 mm
Clockwise
Clockwise
…
…
Valve seat reformed
Yes
…
Forward inclined single cylinder
51.5 × 60mm
9.8 ± 0.4:1
51.49~51.53 mm
…
…
…
…
…
…
0.05 mm
0.05 mm
Cylinder
Cylinder arrangement
Bore × stroke
Compression ratio
Bore
Max. taper
Max. out-of-round
2-6
ENGINE SPECIFICATIONS
Standard
Limit
0.010~0.030 mm
51.470~51.510 mm
0.150mm
…
3.5 mm
…
13.002~13.013 mm
0.35~0.65mm
Intake side
13.043 mm
…
…
12.996~13.000 mm
12.976 mm
Barrel
1.0 × 2.1mm
0.10~0.20 mm
0.02~0.08 mm
…
…
0.45mm
0.13 mm
Plain
1.0 × 2.1mm
0.20~0.30 mm
0.02~0.06 mm
…
…
0.65mm
0.12mm
2.0 × 2.2 mm
0.2~0.7 mm
0.06~0.15 mm
…
…
…
Item
Piston
Piston-to-cylinder clearance
Diameter D
SPEC
H
D
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pin
Outside diameter
Piston rings
Top ring
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
2nd ring
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
Ring side clearance
2-7
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Limit
Rocker arm/rocker arm shaft
Rocker arm inside diameter
Rocker arm shaft outside diameter
Arm-to-shaft clearance
10~10.015mm
9.981~9.991 mm
0.009~0.034 mm
…
…
…
Connecting rod
Connecting rod length
Small end inside diameter
97.95~98.05 mm
13.015~13.028mm
…
…
45.15~45.20 mm
…
0.10~0.40 mm
0~0.010mm
…
0.03mm
1.00mm
…
Crankshaft
Width A
Max. runout C
Big end side clearance D
Big end radial clearance E
2-8
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Limit
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
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
…
2.0mm
…
120.3mm
…
…
…
…
V-belt
V-belt width
21.6 mm
19.5mm
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Max. main axle runout
Max. drive axle runout
V-belt automatic
Helical gear
40/15 (2.667)
Spur gear
38/13 (2.923)
…
…
…
…
…
…
…
0.02 mm
0.02 mm
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)
BS26 (MIKUNI) × 1
5YR 00
Ø22.3
#97.5
0.5
4D×16-1
0-4M
160
0.81
22.5
Ø0.8
Ø1.0
Ø1.1
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
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
2-9
ENGINE SPECIFICATIONS
Standard
Item
Throttle bodys
Model (manufacturer) × quantity
Intake vacuum pressure
Throttle cable free play (at the flange of the
throttle grip)
ID mark
SPEC
Limit
5YR (SAFETY CONTROL
CABLE) × 2
30.0kpa (238.6mmHg)
3~5mm
…
…
5YR1
…
2-10
…
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Standard
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
Model (manufacturer)
Tire pressure (cold)
0~90 kg
90~197 kg
Min. tire tread depth
Limit
Steel tube underbone
32 °
75 mm
…
…
…
Cast wheel
…
10 × MT2.15
Aluminum
59mm
…
…
…
…
…
1.0 mm
1.0 mm
Cast wheel
…
10 × MT2.15
Aluminum
54mm
…
…
…
…
…
1.0 mm
1.0 mm
Tubeless
3.50-10 51J
C-922L (CHENG SHIN)
…
…
…
150kpa (1.5 kg/cm², 22 psi)
150kpa (1.5 kg/cm², 22 psi)
…
…
…
0.8mm
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
2-11
CHASSIS SPECIFICATIONS
Standard
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
Limit
Single disc brake
Right-hand operation
3~5mm
DOT 4
…
…
…
…
180.0 × 4.0 mm
…
…
6.0 mm
6.0 mm
11mm
34.93mm
180.0 × 3.5 mm
3.5mm
0.10 mm
0.8mm
0.8mm
…
…
2-12
CHASSIS SPECIFICATIONS
Standard
Item
Rear drum brake
Brake type
Operation
Brake lever free play (at lever end)
Brake drum inside diameter
Lining thickness
SPEC
Limit
Drum brake
Left-hand operation
10~20mm
110 mm
4.0mm
…
…
…
111mm
2mm
Telescopic
Coil spring/oil damper
80 mm
…
…
…
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
257.5 mm
245.5mm
12.7N/mm (1.27 kg/mm)
0~50mm
19.6N/mm (1.96kg/mm)
50~80mm
No
252.4mm
…
…
…
…
…
…
Fork oil G10 or equivalent
126 ± 2.5cc
33 mm
…
…
…
…
0.2 mm
Steering system
Steering bearing type
Lock to lock angle (left)
Lock to lock angle (Right)
Angular bearing
47.5 °
47.5 °
…
…
…
Swingarm
Coil spring/oil damper
65mm
…
…
…
208mm
198mm
43N/mm (4.3kg/mm)
0~65mm
No
…
…
…
…
…
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
2-13
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Standard
Item
Limit
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)
12V
…
C.D.I.
5 °/1650 r/min (IDL)
Digital
304~456 Ω / WR-WL
5YR00(T-MORIC)
…
…
…
…
…
Ignition coil
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
2JN (T-MORIC)
6mm
0.184~0.276 Ω at 20 ° C
6.32~9.48 kΩ at 20 ° C
…
…
…
…
Spark plug cap
Material
Resistance
Resin
8~12 kΩ
…
…
Charging system
System type
Model (manufacturer)
Nominal output
Lighting coil resistance /color
Lighting coil resistance /color
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
…
…
…
…
…
Voltage regulator
Regulator type
Model (manufacturer)
No load regulated voltage(DC)
Semiconductor, short circult
SH671-12 (XIN DIAN YUAN)
14~15 V
…
…
…
Rectifier
Model (manufacturer)
Rectifier capacity(DC)
Withstand voltage
SH671-12 (XIN DIAN YUAN)
8A
200V
…
…
…
Battery
Battery type (manufacturer)
Battery voltage capacity
Specific gravity
Ten hour rate amperage
GTX7A-BS (GS)
12V 6AH
1.330
6 AH
…
…
…
…
Headlight type
Krypton bulb
…
Indicator light
(voltage/wattage×quantity)
Turn signal indicator light
High beam indicator light
12 V 1.7 W × 1
14 V 3W × 1
…
…
2-14
ELECTRICAL SPECIFICATIONS
Standard
Item
Bulbs (voltage/wattage × quantity)
Headlight
Tail/brake light
Front turn signal light
Rear turn signal light
Speedometer light
Fuel lever meter light
SPEC
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
2-15
Limit
…
…
…
…
…
…
ELECTRICAL SPECIFICATIONS
Standard
Item
Electric starting system
System type
Starter motor
Model (manufacturer)
Suction voltage
Power output
Brushes
Overall length
Quantity
Spring force
Commutator diameter
Commutator resistance
Mica undercut (depth)
Starter relay
Model (manufacturer)
Amperage
Coil resistance
Suction voltage
SPEC
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
3.5mm
…
…
21mm
…
…
3UH1 (SHI LIN)
100 A
3.6-4.4 Ω
Below DC8V
…
…
…
…
Plane
AH-368
(ASIA TRAFFIC)
1.5 A
95~105db/2m
4.05~4.55 Ω
…
…
…
…
…
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Semi transistor
5CA9 (TA YOUNG)
NO
75~95 cycles/min
10 W × 2 + 1.7 W+ AP
…
…
…
…
…
Fuel sender
Model (manufacturer)
Sender unit resistance-full
Sender unit resistance-empty
5YR1 (CHAO LONG)
4-10 Ω
90-100 Ω
…
…
…
Starting circuit cut-off relay
Model (manufacturer)
Coil resistance
09-N (SHI LIN)
54~66 Ω
…
…
Thermostat switch
Model (manufacturer)
1AJ (NATIONAL)
…
Carburetor heater
Manufacturer
Coil resistance
MIKUNI
30 Ω 20°C
…
…
Horn
Horn type
Model (manufacturer)
Max. amperage
Performance
Coil resistance
2-16
ELECTRICAL SPECIFICATIONS
SPEC
Standard
Item
Limit
Fuel lever meter
Type( manufacturer )
Moving magneto (CHAO LONG) …
Fuse (amperage × quantity)
Main fuse
Reserve fuse
10A×1
10A×1
2-17
…
…
CONVERTION TABLE / GENERAL TIGHTENING
TORQUE SPECIFICATIONS
SPEC
EB201000
EAS00030
CONVERSION TABLE
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
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.
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.
Ex.
METRIC
MULTIPLIER
IMPERIAL
** mm
0.03937
** in
2 mm
0.03937
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
m·kg
Tightening torque m·kg
cm·kg
cm·kg
Multiplier
Imperial unit
7.233
86.794
0.0723
0.8679
ft·lb
in·lb
ft·lb
in·lb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu-in
qt (IMP liq.)
gal (IMP liq.)
kg/mm
kg/cm2
Centigrade
(°C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit (°F)
Misc.
A: Width across flats
B: Thread diameter
A
(nut)
2-18
B
(bolt)
General tightening
torques
Nm
m•kg
ft•lb
10 mm
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
TIGHTENING TORQUES
SPEC
ENGINE TIGHTENING TORQUES
Part to be tightened
Part name
Thread ’
Q ty
size
Tightening
torque
Remarks
Nm m•kgf ft•lb
Cylinder head and cylinder
Nut
M8
Spark plug
_
M10
Cylinder head(timing chain side)
Bolt
M6
Mainfold stud bolt
_
M6
Exhaust pipe stud bolt
_
M6
Breather assembly
Bolt
M6
Stopper plate
Bolt
M6
Guide stopper2
Bolt
M6
Valve clearance adjusting screw lock nut
_
M5
Camshaft sprocket
Bolt
M8
Timing chain tensioner (body)
Bolt
M6
Timing chain tensioner (plug)
plug
M8
Air shroud 1and 2
Screw
Air shroud 1
Screw
M6
Air shroud 1
Bolt
M6
Fan
Screw
M6
Oil pump assembly
Screw
M6
Cover element
Bolt
M6
Cover element inside drain bolt
_
M6
Delivery pipe
Union bolt M8
Delivery pipe
Bolt
M6
Engine oil drain
plug
M35
Mainfold
Nut
M6
Air filter assembly
Screw
M6
Air filter case and air filter cap
Screw
M6
Element cap
Screw
M6
Carburetor overflow drain plug
plug
M6
Muffler
Nut
M6
Muffler
Bolt
M8
Protector
Screw
M6
Air induction system assembly
Screw
M5
AI bracket and muffler
Screw
M5
AI pipe
Bolt
M6
AI pipe clamp
Hose clamp
AI filter
Bolt
M6
Crankcase 1and 2
Bolt
M6
Crankcase cover1
Bolt
M6
Crankcase cover2
Bolt
M6
Cover1(magneto)
Screw
M6
Drain bolt(transmission oil)
Bolt
M8
2-19
4
1
2
2
2
2
1
1
2
1
2
1
5
2
1
3
2
2
1
1
1
1
2
2
5
1
1
2
2
2
4
4
1
1
2
8
10
5
3
1
22
12.5
12
7
7
7
7
7
7
30
10
8
1.5
7
8
7
7
8
7
10
8
32
7
7
7
7
2
10
31
7
4
4
8
4.5
1.5
12
10
12
7
23
2.2
1.25
1.2
0.7
0.7
0.7
0.7
0.7
0.7
3.0
1.0
0.8
0.15
0.7
0.8
0.7
0.7
0.8
0.7
1.0
0.8
3.2
0.7
0.7
0.7
0.7
0.2
1.0
3.1
0.7
0.4
0.4
0.8
0.45
0.15
1.2
1.0
1.2
0.7
2.3
15.9
9
8.7
5.1
5.1
5.1
5.1
5.1
5.1
21.7
7.2
5.8
1.1
5.1
5.8
5.1
5.1
5.8
5.1
7.2
5.8
23.1
5.1
5.1
5.1
5.1
1.4
7.2
22.4
5.1
2.9
2.9
5.8
3.3
1.1
8.7
7.2
8.7
5.1
16.6
4
And AI pipe tighten
And air shroud tighten
TIGHTENING TORQUES
Part to be tightened
Part name
Thread ’
Q ty
size
SPEC
Tightening
torque
Nm m•kgf ft•lb
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
_
Screw
Bolt
_
_
Screw
Screw
Screw
Bolt
Nut
Nut
Nut
Bolt
Nut
Cylinder head tightening sequence
3
1
5
2
4
6
2-20
M8
M6
M6
M8
M8
M6
M6
M6
M8
M14
M36
M12
M6
M12
1
1
1
2
2
3
3
2
1
1
1
1
2
1
23 2.3 16.6
7
0.7 5.1
10 1.0 7.2
12.5 1.25 9
12.5 1.25 9
7
0.7 5.1
9
0.9 6.5
7
0.7 5.1
23 2.3 16.6
60 6.0 43.4
90 9.0 65.1
55 5.5 39.8
7
0.7 5.1
70 7.0 50.6
Remarks
TIGHTENING TORQUES
SPEC
CHASSIS TIGHTENING TORQUES
Part to be tightened
Thread
size
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
M10
M10
M10
M10
M8
M8
M8
M8
M25
M10
M10
M8
M6
M10
M5
M8
M6
M12
M14
M6
M10
M10
M8
M10
M7
Handlebar lower holder and handlebar upper holder
Tightening
torque
Nm
m•kgf ft•lb
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
Remarks
30.4
39.8
23.1
21.7
13.0
20.3
0.7
13.7
54.2 See”NOTE”
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
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
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.
4
1
2
3
4
5
5
3
2
1
2-21
Lower ring nut
Rubber washer
Center ring nut
Lock washer
Upper ring nut
LT
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication Point
Lubricant
Oil seal lips
LS
O-ring (Except V-belt drive unit)
LS
Cylinder head tightening nut mounting surface
4
Cylinder head stud bolt thread
4
Cylinder head gasket dowel pin
4
Crankshaft pin outside surface
4
Connecting rod
4
Piston outside and ring groove
4
Piston pin outside surface
4
surface and bolt thread
4
Crankshaft journal
4
Piston (balancer) outside surface
4
Piston pin (balancer) outside surface
4
Camshaft profile journal
M
Valve stem (IN, EX)
M
Valve stem seal
M
Valve stem end (IN, EX)
M
Valve lifter
4
Oil pump assembly inside
4
Oil pipe union bolt thread and surface
4
Gasket (Oil pump assembly)
LS
Idle gear 1 thrust surfaces
4
Idle gear 2
4
Drive shaft serration (Sprocket)
LS
Drive shaft taper rollor bearing
LS
Transmission bearing
G
Secondary shaft bearing (right)
LS
Primary sheave oil seal
LS
2-22
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication Point
SPEC
Lubricant
Primary sheave inside, Collar, Solid bush,
LS
Secondary fixed inner surface
BEL-RAY asembly lube
Secondary sheave torque cam ditch
BEL-RAY asembly lube
Gasket (Cylinder head cover)
Sealant
Stopper guide (Cylinder head cover)
Sealant
Crankcase mating surfaces
Sealant
Oil pipe
Sealant
C.D.I. magneto lead grommet
Sealant
2-23
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00032
CHASSIS LUBRICATION POINTS AND LUBRICATION TYPES
Lubrication Point
Lubricant
Front wheel oil seal lips
LS
Frame head pipe bearing (upper and lower)
LS
Frame head pipe dust seal lips ( lower)
LS
Tube guide (throttle grip) inner surface
LS
Brake lever and lever holder bolt sliding surface
LS
Sidestand and frame sliding surface
LS
Centerstand sliding surface and mounting bolt
LS
Rear footrest (pin) outside surface
LS
Rear shock absorber backward, bush inner surface and spacer sliding surface
M
Seat lock cable and cylinder inner surface
LS
Engine bracket and engine mound bolt sliding surface
LS
2-24
OIL FLOW DIAGRAMS
OIL FLOW DIAGRAMS
1
2
3
4
5
Oil strainer
Oil pump
Oil filter
Oil delivery pipe
Oil delivery pipe union bolt
2-25
SPEC
OIL FLOW DIAGRAMS
1 Connecting rod big end bearing
2-26
SPEC
CABLE ROUTING
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
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.
SPEC
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.
1
L
K q
2
J
N M
O
4
I
0
3
H
98
7
T
6
w e
F
5
F
A
B
C
G
B
F
B
t
r
E
D
Q
t
a
d
8
7
u
i
y
P
u
t
s
p
BACKWARD
FORWARD
BACKWARD
T
o
F-F
2-27
FORWARD
6
7
B-B
SPEC
CABLE ROUTING
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.
1
L
K q
2
J
N M
O
4
I
0
3
H
98
7
T
6
w e
F
5
F
A
B
C
G
B
F
B
t
r
E
D
Q
t
a
d
8
7
u
i
y
P
u
t
s
p
BACKWARD
FORWARD
BACKWARD
T
F-F
2-28
o
FORWARD
6
7
B-B
CABLE ROUTING
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
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.
SPEC
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
1
7H
8
A
2
6
F
I
5
E
4
3
D
B
J
C
K 09
M
q
w
e
t
y
L
r
2-29
CABLE ROUTING
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)
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.
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.
D
C
1
F
E
2
G
4
3
5
6
7
8
9
0
SPEC
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.
H
B
1
A
M
I
r
L
K
J
e
2-30
w
q
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
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
ODOMETER READING
NO.
1
2
3
*
*
*
ITEM
ROUTINE
600 mi 2,000 mi 4,000 mi 6,000 mi 8,000 mi
(1,000 (4,000 (7,000 (10,000 (13,000
km)
km)
km)
km)
km)
or
or
or
or
or
1
6
12
18
24
month months months months months
Fuel line
• Check fuel hoses and vacuum hose for cracks or damage.
—
—
—
—
Valves
• Check valve clearance.
• Adjust if necessary.
—
—
—
—
• Check condition.
• Clean and regap.
—
—
—
—
Spark plug
—
• Replace.
—
• Clean.
*
Air filter element
5
*
Crankcase breather
system
• Check breather hose for cracks or damage.
• Replace if necessary.
6
*
Carburetor
• Adjust engine idling speed.
4
—
• Replace.
—
—
—
—
—
—
—
—
—
—
—
—
7
*
Exhaust system
8
*
Evaporative emission
control system
• Checkcontrol system for damage.
• Replace if necessary.
—
Air induction system
• Check the air cut-off valve, reed valve, and hose for damage.
• Replace any damaged.
—
*
—
—
• Check for leakage.
• Tighten if necessary.
• Replace gaskets if necessary.
9
—
—
—
—
—
—
* 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.
ODOMETER READING
NO.
1
2
*
*
ITEM
V-belt case air filter
elements
Front brake
ROUTINE
600 mi 2,000 mi 4,000 mi 6,000 mi 8,000 mi
(1,000 (4,000 (7,000 (10,000 (13,000
km)
km)
km)
km)
km)
or
or
or
or
or
1
6
12
18
24
month months months months months
—
• Clean.
—
—
• Replace.
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE)
—
• Replace brake pads.
—
—
—
—
—
Whenever worn to the limit
• Check operation and adjust brake lever free play.
—
—
3
*
Rear brake
4
*
Brake hose
5
*
Wheels
• Check runout and for damage.
—
• Replace brake shoes.
—
—
—
Whenever worn to the limit
—
• Check for cracks or damage.
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
• Replace. (See NOTE)
—
Every 4 years
6
*
Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
7
*
Wheel bearings
• Check bearing for looseness or damage.
• Check bearing play and steering for roughness.
—
8
*
Steering bearings
9
*
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
—
—
—
—
Sidestand, centerstand
• Check operation.
• Lubricate.
—
—
—
—
Sidestand switch
• Check operation.
Front fork
• Check operation and for oil leakage.
10
11
12
13
*
*
*
• Lubricate with lithium-soap-based grease.
Every 16,000 mi (24,000 km)
—
Shock absorber assembly • Check operation and shock absorber for oil leakage.
—
—
—
—
—
—
—
—
—
—
—
—
Engine oil
• Change.
• Check oil level and vehicle for oil leakage.
—
Engine oil filter element
• Clean.
—
—
—
Engine oil strainer
• Clean.
—
—
—
17
Final transmission oil
• Change.
—
—
—
18
*
V-belt
• Replace.
19
*
Front and rear brake
switches
• Check operation.
20
Moving parts and cables
• Lubricate.
21
*
• Check operation and free play.
Throttle grip housing and
• Adjust the throttle cable free play if necessary.
cable
• Lubricate the throttle grip housing and cable.
22
*
Lights, signals and
switches
14
15
16
*
*
Every 1,900 mi (3,000 km)
Every 12,000 mi (18,000 km)
—
• Check operation.
• Adjust headlight beam.
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
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
CHK
ADJ
COVER AND PANEL
COVER AND PANEL
SEAT AND SIDE COVERS
23Nm(2.3m•kg, 16.6 ft•lb)
9
2
13
4
11
6
5
10
1
7
12
8
3
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
11
12
13
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
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
3-4
COVER AND PANEL
CHK
ADJ
FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE
3
1
4
7
5
8
2
6
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
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
Remarks
Remove the parts in the order listed.
Refer to “SEAT AND SIDE COVERS”
1
1
1
1
1
1
1
1
cC
First, disconnect the negative battery
lead, and then the positive battery
lead.
For installation, reverse the removal procedure.
3-5
COVER AND PANEL
CHK
ADJ
LEG SHIELD 1 , 2
5
6
3
7
2
4
1
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “FOOTREST BOARD AND
FOOTREST BOARD SIDE COVER
MOLE”
Removing the leg shield 1,2
Footrest board
1
2
3
4
5
6
7
Remarks
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
For installation, reverse the removal procedure.
3-6
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EAS00049
ENGINE
ADJUSTING THE VALVE CLEARANCE
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”.
2. Remove:
8 spark plug
8 engine oil cap
8 valve cover (exhaust )
8 cap1
1
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)
3-7
ADJUSTING THE VALVE CLEARANCE
*****************************************************
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.
*****************************************************
2
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.
2
b
1
a
CHK
ADJ
3
Direction a
Direction b
Valve clearance is increased.
Valve clearance is decreased.
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.
*****************************************************
3-8
ADJUSTING THE VALVE CLEARANCE
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 side cover (right,left )
8 rear carrier
8 cover
Refer to “COVER AND PANEL”.
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.
2. Connect:
8engine tachometer 1
(onto the spark plug lead of cylinder)
1
Engine tachometer
90890-03113 (YU-08036-C)
3. Check:
8engine idling speed
Out of specification J Adjust
Engine idling speed
1600 ~ 1700 r/min
4. Adjust:
8engine idling speed
b
*****************************************************
a. Turn the throttle stop screw 1 in direction
a or b until the specified engine idling
speed is obtained.
1
a
Direction a
Direction b
Engine idling speed is increased.
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
CHECKING THE EXHAUST GAS AT IDLE
(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.
2. Install:
8pocket tester1.
(onto the engine oil drain bolt)
8engine tachometer
(onto the spark plug lead )
Pocket tester
90890-03132 (YU-03112-C)
Engine tachometer
90890-03113 (YU-08036-C)
1
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
Out of specification J Adjust.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED”
Engine idling speed
1600 ~ 1700 r/min
3
1
5. Install:
8 carbon monoxide and hydrocarbon
tester1.
8 sampling probe2.
8 engine tachometer3.
2
3-11
CHECKING THE EXHAUST GAS AT IDLE
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
Out of specification 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.
1. Check:
8 throttle cable free play a
Out of specification J Adjust.
a
Throttle cable free play (at the flange
of the throttle grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Remove:
8 cover
8 rear carrier
8 side cover (right )
Refer to “COVER AND PANEL”.
3. Adjust:
8 throttle cable free play
a
2
*****************************************************
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.
b
1
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.
3-13
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
1
a
Direction a
Throttle cable free play is increased.
Direction b
Throttle cable free play is decreased.
2
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
Refer to “COVER AND PANEL”.
3-14
CHECKING THE SPARK PLUG
CHK
ADJ
EAS00060
CHECKING THE SPARK PLUG
1. Remove:
8 cover
Refer to “COVER AND PANEL”.
2. Disconnect:
8 spark plug cap
3. Remove:
8 spark plug
cC
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)
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.
1
a
2
Spark plug gap
0.7 ~ 0.8 mm (0.028 ~ 0.032 in)
T.
8. Install:
8 spark plug
12.5 Nm (1.25 m • kg, 9 ft • lb)
R.
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
8 spark plug cap
10.Install:
8 cover
Refer to “COVER AND PANEL”.
3-15
CHECKING THE IGNITION TIMING
CHK
ADJ
EAS00062
CHECKING THE IGNITION TIMING
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
1. Remove:
cap 1
2. Attach:
timing light
engine tachometer
(onto the spark plug lead of cylinder)
Timing light
90890-03141 (YU-03141)
Engine tachometer
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
Engine idling speed
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 rangeJ Check the ignition
system.
2
1
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 PRESSURE
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 side cover (right,left )
8 hook
8 front cover
Refer to “COVER AND PANEL”.
4. Disconnect:
8 spark plug cap
5. Remove:
8 spark plug
cC
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.
6. Install:
8 compression gauge 1
1
Compression gauge
90890-03081
YU-33223
3-17
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
7. Measure:
8 compression pressure
Out of specification J Refer to steps (c)
and (d).
Compression pressure (at sea level)
Minimum
827 kPa (8.27 kg/cm2, 400r/min)
Standard
950 kPa (9.5 kg/cm2, 400r/min)
Maximum
1064 kPa (10.64 kg/cm2, 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.
12.5 Nm (1.25 m • kg, 9ft • lb)
10. Connect:
8 spark plug cap
R.
3-18
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
11. Install:
8 front cover
8 hook
8 side cover (right,left )
8 rear carrier
8 cover
Refer to “COVER AND PANEL”.
3-19
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the scooter on a level surface.
NOTE:
8 Place the scooter on a suitable stand.
8 Make sure the scooter is upright.
2. Start the engine, warm it up for several minutes, and then turn it off.
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.
b
a
1
-20˚ -10˚
0˚
10˚
20˚ 30˚
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
40˚ 50˚
SAE 10W-30
SAE 10W-40
SAE 20W-40
SAE 20W-50
cC
8 Do not allow foreign materials to enter
the crankcase.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
4. Start the engine, warm it up for several minutes, and then turn it off.
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
CHK
ADJ
EAS00076
1
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
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
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.
2
1
T.
R.
Oil strainer cover
32 Nm (3.2 m • kg, 23.1 ft • lb)
*****************************************************
6. Install:
8 engine oil drain bolt
(along with the gasket)
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.
10. Check:
8 engine
3-21
(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
Refer to “CHECKING THE ENGINE OIL
PRESSURE”.
CHANGING THE ENGINE OIL FILTER ELEMENT
1. Drain:
8 engine oil
2. Remove:
8 oil delivery pipe bolt 1
8 copper washers
1
3. Remove:
8 oil filter element cover1
8 o-ring2
8 oil filter element 3
3
2
1
4. Install:
cC
Be careful because it causes an engine
trouble when the attachment direction of the
oil filter element is mistaken.
1
2
8 oil filter element 1
8 o-ring2 New
8 oil filter element cover3
3
T.
8 Nm (0.8 m • kg, 5.8 ft • lb)
R.
8 copper washers
8 oil delivery pipe bolt
T.
R.
3-22
10 Nm (1.0 m • kg, 7.2 ft • lb)
CHANGING THE ENGINE OIL FILTER ELEMENT
CHK
ADJ
cC
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
Refer to “CHECKING THE ENGINE OIL
“.
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)
Periodic oil change
1.0 L (0.92 Imp qt, 1.09 US qt)
3-23
CHANGING THE TRANSMISSION OIL
CHK
ADJ
CHANGING THE TRANSMISSION OIL
1. Stand the scooter on a level surface.
NOTE:
8 Stand the scooter on a suitable stand.
8 Make sure that the scooter up right.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Place a container under the transmission.
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
1
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)
Periodic oil change
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.
2
2
1
3-24
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.
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
2. Start the engine, warm it up for several minutes, and then turn it off.
cC
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
Refer to “COVER AND PANEL”.
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
1
3-25
CLEANING THE AIR FILTER ELEMENT/
CLEANING THE V-BELT CASE AIR FILTER ELEMENT
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.
2
1
EAS00091
CLEANING THE V-BELT CASE AIR
FILTER ELEMENT
1. Remove:
8 kick starter 1
8 damper cover 2
1
2
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.
2
1
3. Check:
8 V-belt case air filter element 1
Damage J Replace.
1
4. Clean:
8 V-belt case air filter element 1 (with solvent)
w
1
Never use low flash point solvents, such as
gasoline, to clean the air filter element. Such
solvents may cause a fire or an explosion.
3-26
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.
cC
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
7. Install:
8 element holder1
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • lb)
1
T.
8. Install:
8 damper cover 1
8 kick starter 2
23 Nm (2.3 m • kg, 16.6 ft • lb)
R.
2
1
3-27
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 side cover (right,left )
8 seat
8 hook
8 front cover
8 fuel tank cap
8 rear cover
8 trunk
Refer to “COVER AND PANEL”.
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 side cover (right,left )
8 rear carrier
8 cover
Refer to “COVER AND PANEL”.
1
2
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 )
Refer to “COVER AND PANEL”.
2. Check:
8vacuum hose 1
8fuel hose 2
Cracks/damage J Replace.
Loose connection J Connect properly.
3. Install:
8side cover (left )
8rear carrier
8cover
Refer to “COVER AND PANEL”.
2
1
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
8 cover
Refer to “COVER AND PANEL”.
2. Check:
8 crankcase breather hose 1
Cracks/damage J Replace.
Loose connection J Connect properly.
1
cC
Make sure the crankcase breather hose is
routed correctly.
3. Install:
8 cover
Refer to “COVER AND PANEL”.
3-29
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
EAS00099
4
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
Cracks/damage J Replace.
8 gasket
Exhaust gas leaks J Replace.
3
2
1
3. Check:
8 tightening torque
T.
R.
4.
3-30
Muffler assembly nut2
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)
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.
ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
CHK
ADJ
EAS00108
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Check:
8 brake lever free play a
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
Out of specification J Adjust.
a
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
Direction b
b
1
a
Brake lever free play is increased.
Brake lever free play is decreased.
cC
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
1. Stand the scooter on a level surface.
NOTE:
8 Place the scooter on a suitable stand.
8 Make sure the scooter is upright.
2. Check:
8 brake fluid level
Below the minimum level mark a J Add
the recommended brake fluid to the
proper level.
a
Recommended brake fluid
DOT 4
w
8 Use only the designated brake fluid.
Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
8 Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
8 When refilling, be careful that water does
not enter the brake fluid reservoir. Water will significantly lower the boiling
point of the brake fluid and could cause
vapor lock.
cC
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
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
2
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.
1
2
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
3-33
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.
1
2. Remove:
8 reservoir cap 1
Remove the reservoir cap of the master
cylinder at horizontal condition.
3. Bleed.
8hydraulic brake system.
*****************************************************
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.
2
1
cC
Brake fluid can cause damages to painting
or plastic surfaces, so be sure to wipe clean
the spilled brake fluid.
T.
d. Tighten:
8bleed screw
6Nm (0.6m • kg, 4.3 ft • lb)
R.
3-34
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.
T.
*****************************************************
4. Install:
8 reservoir cap
1.6Nm (0.16m • kg, 1.2 ft • lb)
R.
3-35
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EAS00133
BLEEDING THE HYDRAULIC BRAKE SYSTEM
w
Bleed the hydraulic brake system whenever:
8 the system is disassembled.
8 a brake hose is loosened, disconnected
or replaced.
8 the brake fluid level is very low.
8 brake operation is faulty.
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.
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.
2
1
NOTE:
Loosening the bleed screw will release the pressure and cause the brake lever to contact the
throttle grip.
3-36
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.
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)
R.
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
w
After bleeding the hydraulic brake system,
check the brake operation.
T.
*****************************************************
3. Install:
reservoir cap
1.6 Nm (0.16 m • kg, 1.2 ft • lb)
R.
3-37
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
EAS00148
CHECKING AND ADJUSTING THE STEERING HEAD
1. Stand the scooter on a level surface.
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
Refer to “COVER AND PANEL”.
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.
1
2
3
4
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
6
Steering nut wrench
90890-01403
YU-33975
5
T.
R.
3-38
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.
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.
8
a
h. Install the lock washer 8.
7
NOTE:
Make sure the lock washer tabs a sit correctly
in the ring nut slots b.
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
Refer to “COVER AND PANEL”.
3-39
CHECKING THE FRONT FORK
CHK
ADJ
EAS00151
CHECKING THE FRONT FORK
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
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
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
8tire pressure
Out of specification J Regulate.
w
8 The tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air temperature.
8 The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger and accessories) and the anticipated
riding speed.
8 Operation of an overloaded scooter
could cause tire damage, an accident or
an injury.
8 NEVER OVERLOAD THE SCOOTER.
Basic weight
(with oil
and a full
fuel tank)
97 kg (214 lb)
Maximum
load*
253 kg (558 lb)
Cold tire
pressure
Front
Rear
Up to 90 kg
load*
150 kPa (1.5 200 kPa (2.00
kgf/cm2, 22 psi) kgf/cm2, 29 psi)
90 kg ~ maximum load*
150 kPa (1.5 225 kPa (2.25
kgf/cm2, 22 psi) kgf/cm2, 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
CHECKING THE TIRES
2.
1
CHK
ADJ
Check:
8tire surfaces
Damage/wear J Replace the tire.
Minimum tire tread depth
0.8 mm (0.03 in)
3
1 Tire tread depth
2 Sidewall
3 Wear indicator
2
w
8 Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
8 When using tube tires, be sure to install
the correct tube.
8 Always replace a new tube tire and a new
tube as a set.
8 To avoid pinching the tube, make sure
the wheel rim band and tube are centered in the wheel groove.
8 Patching a punctured tube is not recommended. 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
8 After extensive tests, the tires listed below 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
CHENG SHIN C-922L
Size
3.50-10 51J
Rear tire
Manufacturer
Model
CHENG SHIN C- 6007
3-42
Size
3.50-10 51J
CHECKING THE TIRES
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.
2
1
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.
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.
3-44
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.
Recommended lubricant
Lithium-soap-based grease
EAS00173
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
Recommended lubricant
Lithium-soap-based grease
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:
8 Wear protective eye gear when handling
or working near batteries.
8 Charge batteries in a well-ventilated
area.
8 Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
8 DO NOT SMOKE when charging or handling batteries.
8 KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
8 Avoid bodily contact with electrolyte as
it can cause severe burns or permanent
eye injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
8 Skin — Wash with water.
8 Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
8 Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg or vegetable oil. Get immediate
medical attention.
cC
8 This is a sealed battery. Never remove
the sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
8 Charging time, charging amperage and
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
CHECKING AND CHARGING THE BATTERY
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
Refer to “COVER AND PANEL”.
2. Disconnect:
8 battery leads
(from the battery terminals)
1
cC
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
2
3. Remove:
8 battery
4. Check:
8 battery charge
*****************************************************
a. Connect a digital pocket tester 1 to the
battery terminals.
1
Pocket tester
90890-03132 (YU-03112-C)
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.
3-47
Open-circuit voltage (V)
CHECKING AND CHARGING THE BATTERY
13.0
CHK
ADJ
b. Check the charge of the battery, as shown
in the charts and the following example.
Relationship between the open-circuit voltage
and the charging time at 20 C
12.5
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 <-> 30%
*****************************************************
12.0
11.5
5 6.5
10
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level.
Open-circuit voltage (V)
Ambient
temperature
20 C
Charging condition of the battery (%)
5.
Charge:
8 battery
(refer to the appropriate charging method
illustration)
w
Do not quick charge a battery.
cC
8 Never remove the MF battery sealing
caps.
8 Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
8 If it is impossible to regulate the charging current on the battery charger, be
careful not to overcharge the battery.
8 When charging a battery, be sure to remove 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.)
8 To reduce the chance of sparks, do not
plug in the battery charger until the battery charger leads are connected to the
battery.
8 Before removing the battery charger
lead clips from the battery terminals, be
sure to turn off the battery charger.
3-48
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
8 Make sure the battery charger lead clips
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.
8 If the battery becomes hot to the touch
at any time during the charging process,
disconnect the battery charger and let
the battery cool before reconnecting it.
Hot batteries can explode!
8 As shown in the following illustration,
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
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Charging method using a variable-current (voltage) charger
Charger
Ammeter
Measure the open-circuit
voltage prior to charging.
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?
NOTE:
Leave the battery unused for more
than 30 minutes before measuring its
opencircuit voltage.
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
Adjust the char ging voltage to
20 ~ 25V.
NO
Adjust the voltage to obtain the
standard charging amperage.
YES
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
CHECKING AND CHARGING THE BATTERY
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
This type of battery charger cannot
charge an MF battery. A
variablevoltage charger is recommended.
Charge the battery until the charging
voltage reaches 15 V.
NOTE:
Set the charging time to a maximum
of 20 hours.
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.
Charger
Ammeter
Voltmeter
CAUTION:
Constant amperage chargers are not
suitable for charging MF batteries.
3-51
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
CHK
ADJ
6. Install:
8 battery
7. Connect:
8 battery leads
(to the battery terminals)
2
cC
First, connect the positive battery lead 1,
and then the negative battery lead 2.
1
8. Check:
8 battery terminals
Dirt J Clean with a wire brush.
Loose connection J Connect properly.
9. Lubricate:
8 battery terminals
Recommended lubricant
Dielectric grease
10. Install:
8 battery cover
8 mat
Refer to “COVER AND PANEL”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
cC
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
Refer to “COVER AND PANEL”.
3-52
CHECKING THE FUSES
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
Main
Reserve
Amperage rating
10A
10A
Q’ty
1
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
Refer to “COVER AND PANEL”.
3-53
REPLACING THE HEADLIGHT BULB
CHK
ADJ
EAS00182
REPLACING THE HEADLIGHT BULB
1. Remove:
8 headlight cover
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
2
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
1
5. Install:
8 headlight bulb New
Secure the new headlight bulb with the
headlight bulb holder.
cC
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.
6. Install :
8 headlight bulb holder
8 headlight bulb holder rubber
7. Connect:
8 headlight coupler
8. Install:
8 headlight cover
3-54
ADJUSTING THE HEADLIGHT BEAMS
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.
*****************************************************
a
b
1
Direction a
Direction b
Headlight beam is raised.
Headlight beam is lowered.
*****************************************************
2. Adjust:
8 headlight beam (horizontally)
*****************************************************
a. Turn the adjusting knob 1 in direction a or
b.
1
b
Direction a
Direction b
a
Headlight beam moves to the right.
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
FRONT WHEEL AND BRAKE DISC
4
1
LS
6
5
2
3
70Nm(7.0m•kg, 50.6 ft•lb)
7
20Nm(2.0m•kg, 14.5 ft•lb)
8
LT
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand so
that the front wheel is elevated.
Removing the front wheel and brake
disc
1
2
3
4
5
6
Speedometer cable
Front brake caliper assembly
Wheel axle nut
Wheel axle
Front wheel
Speedometer gear unit assembly
1
1
1
1
1
1
7
8
Spacer
Front brake disc
1
1
Refer to”REMOVING THE FRONT
WHEEL and INSTALLING THE FRONT
WHEEL”
For installation, reverse the removal procedure.
4-1
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00518
FRONT WHEEL
4
3
B
B
2
1
Order
1
2
3
4
Job/Part
Q’ty
Disassembling the front wheel
Oil seal
Bearing
Collar
Bearing
Remarks
Remove the parts in the order listed.
1
1
1
1
4-2
Refer to”REMOVING THE FRONT
WHEEL” and “INSTALLING THE FRONT
WHEEL”
For assembly, reverse the disassembly
procedure.
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00520
REMOVING THE FRONT WHEEL
1. Stand the scooter on a level surface.
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. Remove:
8 speedometer cable
8 brake hose holder
Refer to” REMOVING THE FRONT
WHEEL AND BRAKE DISC” .
3. Remove:
8 brake caliper1
8 front wheel axle
8 front wheel
8 speedometer gear unit assembly
1
NOTE:
Do not apply the brake lever when removing the
brake caliper.
4. Elevate:
8 front wheel
NOTE:
Place the scooter on a suitable stand so that
the front wheel is elevated.
4-3
FRONT WHEEL AND BRAKE DISC
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. 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
*****************************************************
4-4
FRONT WHEEL AND BRAKE DISC
CHAS
a.
b.
Clean the outside of the front wheel hub.
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.
2
1
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
EAS00528
CHECKING THE BRAKE DISC
1. Check:
8 brake disc
Damage/galling J Replace.
2. Measure:
8 brake disc deflection a
Out of specification J Correct the brake
disc deflection or replace the brake disc.
b
Brake disc deflection limit (maximum)
0.10 mm (0.04 in)
a
*****************************************************
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
FRONT WHEEL AND BRAKE DISC
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)
LT
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
FRONT WHEEL AND BRAKE DISC
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.
cC
Do not contact the wheel bearing inner race
1 or balls 2. Contact should be made only
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
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00542
INSTALLING THE FRONT WHEEL
1. Lubricate:
8 wheel axle
8 wheel bearings
8 oil seal lips
Recommended lubricant
Lithium-soap-based grease
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.
13
2
3. Install:
8 front wheel 1
1
2
NOTE:
Make sure the slot2 in the speedometer gear
unit fits over the stopper 3on the outer tube.
3
T.
4. Tighten:
8 wheel axle
70 Nm (7.0 m • kg, 50.6 ft • lb)
R.
cC
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
5. Install:
8 brake caliper 1
8 brake caliper bolts 2
35 Nm (3.5 m • kg, 25.3 ft • lb)
1
T.
R.
w
2
Make sure the brake hose is routed properly.
4-8
FRONT WHEEL AND BRAKE DISC
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)
2. Find:
8 front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
X1
*****************************************************
a. Spin the front wheel.
b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
c. Turn the front wheel 90° so that the “X1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” 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”.
*****************************************************
X2
4-9
FRONT WHEEL AND BRAKE DISC
CHAS
3. Adjust:
8 front wheel static balance
*****************************************************
a. Install a balancing weight 1 onto the rim
exactly opposite the heavy spot “X”.
1
NOTE:
Start with the lightest weight.
X
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
REAR WHEEL AND REAR BRAKE
LS
7
8
11
9
2
10
3
1
LS
6
4
5
105Nm(10.5m•kg, 75.9 ft•lb)
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Q’ty
Remarks
Removing the rear wheel and rear
brake
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand so
that the front wheel is elevated.
Muffler assembly
Refer to “MAINFOLD, AIR FILTER AND
MUFFLER ASSEMBLY “in chapter 5.
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
For installation, reverse the removal procedure.
4-11
REAR WHEEL AND REAR BRAKE
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
REAR WHEEL AND REAR BRAKE
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.
NOTE:
After sanding the glazed areas, clean the brake
shoe with a cloth.
2. Measure:
8 brake shoe lining thickness a
Out of specification J Replace.
Brake shoe lining thickness limit
(minimum)
2.0 mm(0.08 in)
a
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.
3. Measure:
8 brake drum inside diameter b
Out of specification J Replace the wheel.
b
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
Damage/wear J Replace.
4-13
REAR WHEEL AND REAR BRAKE
CHAS
EAS00570
ASSEMBLING THE BRAKE SHOE PLATE
1. Install:
8 brake camshaft 1
8 brake shoe wear indicator 2
1
2
*****************************************************
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.
*****************************************************
b
a
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 BALANCE
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
35Nm(3.5m•kg, 25.3 ft•lb)
1
6
1
5
7
3
3
5
4
LS
2
22Nm(2.2m•kg, 15.9 ft•lb)
Order
Job/Part
Q’ty
1
2
3
4
5
Removing the front brake pads
Caliper brake bracket bolt
Caliper brake pad bolt
Brake pad
Brake pad plate
Brake pad spring
2
1
2
1
2
6
7
Caliper brake bracket
Caliper assembly
1
1
Remarks
Remove the parts in the order listed.
Refer to “REPLACING THE FRONT
BRAKE PADS”.
For installation, reverse the removal procedure.
4-15
FRONT BRAKE
CHAS
EAS00579
cC
Disc brake components rarely require
disassembly.
Therefore, always follow these preventive
measures:
8 Never disassemble brake components
unless absolutely necessary.
8 If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
8 Never use solvents on internal brake
components.
8 Use only clean or new brake fluid for
cleaning brake components.
8 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.
8 Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
8 Flush with water for 15 minutes and get
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
1
4-16
FRONT BRAKE
CHAS
3. Remove:
8 brake pad bolt
8 brake pad spring 1
8 brake pads 2
8 brake pad plate 3
2
3
1
4. Measure:
8 brake pad wear limit a
Out of specification J Replace the brake
pads as a set.
a
Brake pad wear limit
0.8 mm(0.03 in)
5. Install:
8 brake pad plate 1
8brake pads 2
8brake pad spring 3
1
2
NOTE:
Always install new brake pads and a new brake
pad spring as a set.
3
*****************************************************
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.
2
1
T.
R.
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)
d. Install new brake pads3 and new brake pad
springs4.
3
NOTE:
8 Make sure the brake pad spring is installed
correctly as shown.
4
4-17
FRONT BRAKE
6.
CHAS
Lubricate:
8brake caliper guide bar
Recommended lubricant
Lithium-soap-based grease
cC
LS
8 Do not allow grease to contact the brake
pads.
8 Remove any excess grease.
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.
Refer to “CHECKING THE BRAKE FLUID
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.
a
4-18
CHAS
FRONT BRAKE
EAS00584
FRONT BRAKE MASTER CYLINDER
9Nm(0.9m • kg, 6.5 ft • lb)
1.6Nm(0.16m • kg, 1.2 ft • lb)
6
LS
7
1
2
4
26Nm(2.6m • kg, 18.8 ft • lb)
3
5
4
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
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
Remarks
Remove the parts in the order listed.
Drain.
1/1
1
1
2
1
1
1
For installation, reverse the removal procedure.
4-19
FRONT BRAKE
CHAS
EAS00585
DISASSEMBING THE FRONT BRAKE MASTER CYLINDER
2
3
4
1
5
Order
Job/Part
Q’ty
1
2
3
4
5
Disassembling the front brake master cylinder
Reservoir diaphragm
Dust boot
Circlip / Washer
Master cylinder kit
Spring
Remarks
Remove the parts in the order listed.
1
1
1/1
1
1
For assembly, reverse the disassembly
procedure.
4-20
FRONT BRAKE
CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Disconnect:
8 brake switch coupler
(from the brake switch)
2
2. Remove:
8 union bolt 1
8 copper washer 2
8 brake hose 3
3
1
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
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.
1
2
2. Check:
8 brake master cylinder kit 1
Damage/scratches/wear J Replace.
1
4-21
FRONT BRAKE
CHAS
3. Check:
8 brake master cylinder reservoir
Cracks/damage J Replace.
brake master cylinder reservoir diaphragm
1
Damage/wear J Replace.
1
4. Check:
brake hoses 1
Cracks/damage/wear J Replace.
1
4-22
FRONT BRAKE
CHAS
EAS00597
ASSEMBLING AND INSTALLING THE FRONT
BRAKE MASTER CYLINDER
w
8 Before installation, all internal brake
components should be cleaned and lubricated with clean or new brake fluid.
8 Never use solvents on internal brake
components.
Recommended brake fluid
DOT 4
2
1
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
2
1
4. Install:
8 master cylinder1
8 master cylinder bracket2
1
T.
R.
a
9 Nm (0.9 m • kg, 6.5 ft • lb)
cC
8 Install the brake master cylinder holder
with the “UP” mark a facing up.
8 Align the end of the brake master cylinder holder with the punch mark b on
the handlebar.
8 First, tighten the upper bolt, then the
lower bolt.
2
b
4-23
FRONT BRAKE
1
CHAS
5. Install:
8 copper washers1 New
8 brake hose2
8 union bolt3
2
T.
R.
26 Nm (2.6 m • kg, 18.8 ft • lb)
w
3
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)
Recommended brake fluid
DOT 4
w
8 Use only the designated brake fluid.
Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
8 Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
8 When refilling, be careful that water does
not enter the brake fluid reservoir. Water will significantly lower the boiling
point of the brake fluid and could cause
vapor lock.
cC
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4-24
FRONT BRAKE
CHAS
7. Bleed:
8 brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
8. Check:
8 brake fluid level
Below the MIN level mark a J Add the
recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
9. Check:
8 brake lever operation
Soft or spongy feeling J Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
a
4-25
FRONT BRAKE
CHAS
EAS00612
FRONT BRAKE CALIPER
35Nm(3.5m • kg, 25.3 ft • lb)
4
3
5
2
1
23Nm(2.3m • kg, 16.6 ft • lb)
Order
1
2
3
4
5
Job/Part
Q’ty
Removing the front brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Front brake caliper bracket bolt
Front brake caliper assembly
Remarks
Remove the parts in the order listed.
Drain.
1
2
1
2
1
For installation, reverse the removal procedure.
4-26
FRONT BRAKE
CHAS
EAS00614
DISASSEMBING THE FRONT BRAKE CALIPER
6Nm(0.6m • kg, 4.3 ft • lb)
2
5
9
3 1
3
LS
4
7
6
22Nm(2.2m • kg, 15.9 ft • lb)
8
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
Disassembling the front brake caliper
Cap
Caliper bracket
Brake pad
Brake pad plate
Brake spring
Dust seal
Piston seal
Caliper piston
Bleed screw / Cap
Remarks
Remove the parts in the order listed.
1
1
2
1
2
1
1
1
1/1
For assembly, reverse the disassembly
procedure.
4-27
FRONT BRAKE
CHAS
EAS00619
DISASSEMBLING THE FRONT BRAKE CALIPER
NOTE:
Before disassembling the brake caliper, drain the
brake fluid from the entire brake system.
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.
5
3
1
6
2
4
2. Remove:
8 brake caliper piston 1
8 brake caliper piston seal 2
8 brake caliper dust seal 3
3
2
1
*****************************************************
a. Blow compressed air into the brake hose
joint opening a to force out the pistons from
the brake caliper.
a
w
8 Cover the brake caliper pistons with a
rag. Be careful not to get injured when
the piston are expelled from the brake
caliper.
8 Never try to pry out the brake caliper piston.
b. Remove the brake caliper piston seal.
*****************************************************
4-28
FRONT BRAKE
CHAS
EAS00631
CHECKING THE FRONT BRAKE CALIPER
Recommended brake component replacement
schedule
Brake pads
If necessary
Piston seal
Every 2 years
Brake fluid
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)
Obstruction J Blow out with compressed
air.
1
3
2
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
8 Before installation, all internal brake
components should be cleaned and lubricated with clean or new brake fluid.
8 Never use solvents on internal brake
components as they will cause the piston seals to swell and distort.
8 Whenever a brake caliper is disassembled, replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
8 brake caliper piston seal 1 New
8 brake caliper dust seal 2 New
2
1
2. Install:
8 brake caliper piston1
cC
8 Do not force.
8 Use care to prevent damage on caliper
piston.
1
4
3. Install:
8 brake pads
8 brake springs
8 brake caliper assembly1
8 brake caliper bracket bolt2
2
6
1
T.
5
R.
3
4-30
35 Nm (3.5 m • kg, 25.3 ft • lb)
FRONT BRAKE
CHAS
T.
8brake caliper pad bolt 3
22 Nm (2.2 m • kg, 15.9 ft • lb)
8brake hose 4
8copper washers 5 New
8union bolt 6
23 Nm (2.3 m • kg, 16.6 ft • lb)
R.
T.
R.
w
Proper brake hose routing is essential to
insure safe scooter operation. Refer to
“CABLE ROUTING”.
cC
a
When installing the brake hose onto the
brake caliper 1, make sure the brake pipe
a touches the projection b on the brake
caliper.
b
1
4. Fill:
8 brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
w
8 Use only the designated brake fluid.
Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
8 Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
8 When refilling, be careful that water does
not enter the brake fluid reservoir. Wa4-31
FRONT BRAKE
CHAS
ter will significantly lower the boiling
point of the brake fluid and could cause
vapor lock.
cC
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
8 brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:
8 brake fluid level
Below the MIN level mark a J Add the
recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
a
7. Check:
8 brake lever operation
Soft or spongy feeling J Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-32
FRONT FORK
CHAS
EAS00646
FRONT FORK
45Nm(4.5m • kg, 32.5 ft • lb)
5
2
4
3
6
23Nm(2.3m • kg, 16.6 ft • lb)
7
1
Order
Job/Part
Q’ty
Removing the front fork legs
Front wheel
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISC”.
Refer to “COVER AND PANEL” in chapter 3.
Leg shield 1
1
2
3
4
5
6
7
Remarks
1
1
1
1
1
1
1
Front fork protect cover
Brake hose holder 1
Speedometer cable guide
Front brake caliper assembly
Cap bolt/O-ring
Pinch bolt
Front fork leg
For installation, reverse the removal procedure.
4-33
FRONT FORK
CHAS
EAS00648
DISASSEMBING THE FRONT FORK LEGS
1
2
7
8
9
5
0
6
30Nm(3.0m • kg, 21.7 ft • lb)
4
3
3
LT
Order
Job/Part
1
2
3
4
5
6
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
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
1/1
1/1
1
1
1
Refer to “DISASSEMBLING AND INSTALLING THE FRONT FORK LEGS “
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-34
FRONT FORK
CHAS
EAS00651
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the scooter on a level surface.
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. Loosen:
8pinch bolt 1
3. Remove:
8 cap bolt 2
(with a 10-mm hexagonal wrench3)
3
w
2
8Fork spring will jump out after removing
cap bolt.
1
w
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
5. Remove:
8front fork leg
4-35
FRONT FORK
CHAS
EAS00653
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
8fork spring 1
1
2. Drain:
8fork oil
3. Remove:
8damper rod assembly bolt 1
8damper rod assembly
2
3
NOTE:
While holding the damper rod with the damper
rod holder 2 and T- handle3, loosen the
damper rod assembly bolt.
1
Damper rod holder
90890-01294 (YM-01300-1)
T- handle
90890-01326 (YM-01326)
4. Remove:
8damper rod 1
8spring
8inner tube 2
1
2
4-36
FRONT FORK
CHAS
5. Remove:
8oil seal clip 1
(with a flat-head screwdriver)
cC
Do not scratch the inner tube.
1
6. Remove:
8oil seal 1
2
cC
Never reuse the oil seal.
1
8 Rag 2
4-37
FRONT FORK
CHAS
EAS00656
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1
1. Check:
8 inner tube 1
8 outer tube 2
Bends/damage/scratches J Replace.
2
w
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
8 spring free length a
Out of specification J Replace.
Spring free length
257.5 mm (10.14 in)
<Limit> : 252.4 mm (9.94 in)
a
3. Check:
8 damper rod 1
Damage/wear J Replace.
Obstruction J Blow out all of the oil passages with compressed air.
8 oil flow stopper 2
Damage J Replace.
1
2
4. Check:
8 cap bolt 1
Damage/wear J Replace.
8 O-ring2 New
1
2
4-38
FRONT FORK
CHAS
EAS00658
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
w
8 Make sure the oil levels in both front fork
legs are equal.
8 Uneven oil levels can result in poor handling 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.
2
1. Install:
8 damper rod assembly 1
8 rebound spring 2
1
cC
Allow the damper rod assembly to slide
slowly down the inner tube 3 until it
protrudes from the bottom of the inner tube.
Be careful not to damage the inner tube.
3
2. Lubricate:
8 inner tube’s outer surface
Recommended lubricant
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
NOTE:
While holding the damper rod assembly with the
damper rod holder 2 and T-handle 3, tighten
the damper rod assembly bolt.
4-39
FRONT FORK
CHAS
Damper rod holder
90890-01294(YM-01300-1)
T-handle
90890-01326(YM-01326)
4. Install:
8oil seal 1 New
(with the fork seal driver weight 2 and
adapter 3)
2
3
1
Fork seal driver weight
90890-01367(YM-A9409-7)
Adapter
90890-01400(YM-A9409-3)
cC
Make sure the numbered side of the oil seal
faces up.
4
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.
342-034
5. Install:
8oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
4-40
FRONT FORK
CHAS
6. Install:
8fork boot 1
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.
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.
1
4-41
FRONT FORK
CHAS
EAS00663
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
8front fork leg
NOTE:
Pull up the inner tube until it stops, then install
the cap bolt.
T.
2. Tighten:
8cap bolt 1
45 Nm (4.5 m • kg, 32.5 ft • lb)
R.
T.
8 pinch bolt 2
23 Nm (2.3 m • kg, 16.6 ft • lb)
R.
1
2
4-42
HANDLEBAR
CHAS
EAS00664
HANDLEBAR
1
4
9Nm(0.89m • kg, 6.5 ft • lb)
6
30Nm(3.0m • kg, 21.7 ft • lb)
1
LS
11
7
2
11
12
12
LS
5
5
9
7
3
13
10
8
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Part
Q’ty
LS
Remarks
Remove the parts in the order listed.
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
2
1
1
1
2
1
2
1
1
1
4
2
1
For installation, reverse the removal procedure.
4-43
HANDLEBAR
CHAS
EAS00666
REMOVING THE HANDLEBAR
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2. Remove:
8handlebar switch assembly (right)1
8throttle grip assembly 2
8brake master cylinder assembly 3
3
NOTE:
While removing the handlebar switch assembly
(right), pull back the rubber cover.
2
1
1
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
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2. Check:
8handlebar 1
Bends/cracks/damage J Replace.
w
Do not attempt to straighten a bent
handlebar as this may dangerously weaken
it.
4-44
HANDLEBAR
CHAS
EAS00671
INSTALLING THE HANDLEBAR
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2. Install:
8 handlebar 1
8 upper handlebar holders 2
T.
R.
1
30 Nm (3.0 m • kg, 21.7 ft • lb)
2
cC
8 First, tighten the bolts on the front side
of the handlebar holder, and then on the
rear side.
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.
b
3. Install:
8 handlebar grip
NOTE:
Before installing the handlebar grip, apply the
bond.
4-45
HANDLEBAR
4. Install:
8 left handlebar switch 1
b
a
CHAS
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
1
a
2
3
b
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
1
NOTE:
8 Align the mating surfaces of the front brake
master cylinder with the punch mark a on
the handlebar.
a
7. Adjust:
8 throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the flange
of the throttle grip)
3 ~ 5 mm(0.12 ~ 0.20 in)
4-46
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
7
3
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the lower fender cover and
handlebar lower holder
Front wheel
Refer to “FRONT WHEEL AND BRAKE
DISC”.
Refer to “COVER AND PANEL” in chapter 3.
Refer to “FRONT FORK”.
Refer to “HANDLEBAR”.
Leg shield 1
1
2
3
4
5
6
7
8
9
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
Remarks
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
4-47
STEERING HEAD
CHAS
EAS00675
LOWER BRACKET
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)
1
2
3
4
5
6
7
8
9
LS
10
12
LS
13
11
14
15
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISC”.
Refer to “LOWER FENDER COVER AND
HANDLEBAR LOWER HOLDER”.
Removing the lower bracket
Front wheel
Handlebar lower holder
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Remarks
1
1
1
1
1
1
1
1
1
1
1
1
1
1
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
4-48
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)
1
2
3
4
5
6
7
8
9
LS
10
12
LS
13
11
14
15
Order
15
Job/Part
Q’ty
Rubber washer
Remarks
1
For installation, reverse the removal procedure.
4-49
STEERING HEAD
CHAS
EAS00678
REMOVING THE LOWER BRACKET
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2. Remove:
8 handlebar holder bracket 1
NOTE:
8 Remove the handlebar holder bracket by
loosening the upper ring nut2 gradually.
1
2
3. Remove:
8ring nut 1
(with the ring nut wrench 2)
1
Ring nut wrench
90890-01268(YU-01268)
2
w
Securely support the lower bracket so that
there is no danger of it falling.
4-50
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.
2
1
2
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.
cC
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.
4-51
STEERING HEAD
CHAS
EAS00684
INSTALLING THE STEERING HEAD
1. Lubricate:
8 upper bearing
8 lower bearing
8 bearing races
Recommended lubricant
Lithium-soap-based grease
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.
1
2
3
4
3. Install:
8 handlebar holder bracket 1
2
T.
R.
3
60 Nm (6.0 m • kg, 43.4 ft • lb)
1
NOTE:
Align the handlebar holder bracket across rod
2 on the lower bracket concave3.
4-52
REAR SHOCK ABSORBER
CHAS
EAS00692
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the scooter on a level surface.
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 rear wheel is elevated.
2. Remove:
8 rear carrier
8 side cover( left )
Refer to “COVER AND PANEL” in chapter 3.
3. Remove:
8 rear shock absorber nut (upper)1
8 rear shock absorber bolt (lower)2
1
2
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
Damage/wear J Replace.
8dust seals
Damage/wear J Replace.
8bolts
Bends/damage/wear J Replace.
4-53
REAR SHOCK ABSORBER
CHAS
EAS00698
INSTALLING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Lubricate:
8 spacer
8 bush
Recommended lubricant
Molybdenum disulfide grease
2. Install:
8 rear shock absorber assembly
3. Tighten:
8 rear shock absorber assembly upper
nut1
1
T.
R.
30 Nm (3.0 m • kg, 21.7 ft • lb)
8 rear shock absorber assembly lower
bolt2
2
T.
R.
18 Nm (1.8 m • kg, 13.0 ft • lb)
4. Install:
8 side cover( left )
8 rear carrier
Refer to “COVER AND PANEL” in chapter 3.
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
ENGINE
ENG
EAS00188
ENGINE
ENGINE
LEADS, HOSES AND REAR BRAKE
18Nm(1.8m • kg, 13.0 ft • lb)
9
2
6
10
1
5
3
11
12
13
4
15
7
LS
8
42Nm(4.2m • kg, 30.4 ft • lb)
Order
Job/Part
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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
14
Q’ty
5-1
Remarks
Remove the parts in the order listed.
Refer to “COVER AND PANEL”in chapter 3.
1
1/1
1
1/1
1
1
2
1
1
1
1
1
1
1
1
cC
First, disconnect the negative lead,
and then the positive lead.
Refer to “ INSTALLING THE ENGINE “.
ENGINE
ENG
18Nm(1.8m • kg, 13.0 ft • lb)
9
2
6
10
1
5
3
11
12
13
4
15
7
LS
8
42Nm(4.2m • kg, 30.4 ft • lb)
Order
Job/Part
Q’ty
14
Remarks
For installation, reverse the removal procedure.
5-2
ENGINE
ENG
NOTE:
Make sure to reset the oil change indicator when
the oil is changed.
EAS00192
INSTALLING THE ENGINE
1. Install:
8 engine bracket bolt 1
NOTE:
Do not fully tighten the bolts.
1
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
7Nm(0.7m • kg, 5.1 ft • lb)
31Nm(3.1m • kg, 22.4 ft • lb)
1
5
6
4
2
10Nm(1.0m • kg, 7.2 ft • lb)
3
Order
Job/Part
Q’ty
1
2
3
4
5
6
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
Remarks
Remove the parts in the order listed.
Refer to “LEADS, HOSES AND REAR
BRAKE”.
Refer to “AIR INDUCTION SYSTEM” in
chapter 6.
1
1
1/1
1
1/1
1/1
For installation, reverse the removal procedure.
5-4
CYLINDER HEAD
ENG
EAS00221
CYLINDER HEAD
8Nm(0.8m • kg, 5.8 ft • lb)
8Nm(0.8m • kg, 5.8 ft • lb)
10Nm(1.0m • kg, 7.2 ft • lb)
5
10
10Nm(1.0m • kg,7.2 ft • lb)
2
3
1
17
16
6
17
8
14
13
4
15
12
11
7
22Nm(2.2m • kg, 15.9 ft • lb)
Order
30Nm(3.0m • kg, 21.7 ft • lb)
7
9
12Nm(1.2m • kg, 8.7 ft • lb)
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
11
12
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
1
2
1/1
1
1
1
1/1
1/1
1/1
1
1
1
13
14
15
16
Nut / Washer
Plate
Cylinder head
Cylinder head gasket
4/2
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “MAINFOLD, AIR FILTER AND
MUFFLER ASSEMBLY”.
5-5
Refer to “ REMOVING THE CYLINDER
HEAD”.
CYLINDER HEAD
ENG
8Nm(0.8m • kg, 5.8 ft • lb)
8Nm(0.8m • kg, 5.8 ft • lb)
10Nm(1.0m • kg, 7.2 ft • lb)
5
10
10Nm(1.0m • kg,7.2 ft • lb)
2
3
1
17
16
6
17
8
14
13
4
15
12
11
7
22Nm(2.2m • kg, 15.9 ft • lb)
Order
17
30Nm(3.0m • kg, 21.7 ft • lb)
7
9
12Nm(1.2m • kg, 8.7 ft • lb)
Job/Part
Q’ty
Dowel pin
Remarks
2
For installation, reverse the removal procedure.
5-6
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
a
2. Align:
8 “I” mark a on the magneto
(with the stationary pointer b on the
crankcase cover)
b
*****************************************************
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.
*****************************************************
d
c
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.
4. Remove:
8 timing chain tensioner
(along with the gasket)
8 camshaft sprocket plate 2
8 camshaft sprocket 3
8 timing chain 4
1
4
2
3
5-7
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
5
3
1
4
6
2
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
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.
*****************************************************
5-9
CYLINDER HEAD
ENG
EAS00231
3
1
5
4
6
INSTALLING THE CYLINDER HEAD
1. Install:
8 gasket New
8 dowel pins
2. Install:
8 cylinder head
3. Tighten:
8 cylinder head nuts
22 Nm (2.2 m • kg, 15.9 ft • lb)
4
4
2
T.
R.
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.
a
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.
b
2
d
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.
c
1
5-10
CYLINDER HEAD
ENG
cC
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
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.
5
4
2
1
3
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)
a
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.
b
9. Tighten:
8camshaft sprocket bolt
d
T.
R.
30 Nm (3.0 m • kg, 21.7 ft • lb)
cC
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
Out of specification J Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
5-12
THE ROCKER ARMS AND CAMSHAFT
ENG
THE ROCKER ARMS AND CAMSHAFT
7Nm(0.7m • kg, 5.1 ft • lb)
2
3
5
M
4
6
4
LS
7
5
4
M
6
M
1
3
2
M
4
7Nm(0.7m • kg, 5.1 ft • lb)
Order
Job/Part
Q’ty
1
2
3
4
Removing the rocker arms and camshaft
Cylinder head
Stopper plate
Locknut
Adjusting screw
Rocker arm shaft
1
2
2
2
5
6
7
O-ring
Rocker arm
Camshaft
2
2
1
5-13
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “ REMOVING THE ROCKER
ARMS AND CAMSHAFT” and “INSTALLING THE ROCKER ARMS AND CAMSHAFT.
Refer to”INSTALLING THE CAMSHAFT
AND ROCKER ARMS”
For installation, reverse the removal procedure.
THE ROCKER ARMS AND CAMSHAFT
ENG
EAS00202
REMOVING THE ROCKER ARMS AND CAMSHAFT
1. Remove:
8 locknut 1
8 stopper plate 2
1
2
1
2. Remove:
8 intake rocker arm shaft
8 exhaust rocker arm shaft
8 intake rocker arm
8 exhaust rocker arm
2
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)
3. Remove:
8 camshaft1
Screw 8-mm bolt 2 into the threaded end of
the camshaft and then pull out the camshaft.
2
Slide hammer bolt
90890-01085 (YU-01083-2)
Weight
90890-01084 (YU-01083-3)
1
5-14
THE ROCKER ARMS AND CAMSHAFT
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
Out of specification J Replace.
a
Rocker arm inside diameter
10 ~ 10.015 mm(0.393~0.394 in)
5. Measure:
8 rocker arm shaft outside diameter a
Out of specification J Replace.
Rocker arm shaft outside diameter
9.981 ~ 9.991 mm(0.392~0.393 in)
a
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).
5-15
THE ROCKER ARMS AND CAMSHAFT
ENG
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.034 mm(0.0004~0.001 in)
EAS00205
CHECKING THE CAMSHAFT
1. Check:
8 camshaft bushings
Damage/wear J Replace.
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.
a
Camshaft lobe dimension limit
Intake
a 26.153~26.253 mm (1.030
1.034 in)
<Limit>:26.053mm
b 21.015~21.115 mm (0.827
0.831 in)
<Limit>:20.915mm
Exhaust
a 26.153~26.253 mm (1.030
1.034 in)
<Limit>:26.053mm
b 21.056~21.156 mm (0.829
0.833 in)
<Limit>:20.956mm
b
~
~
~
~
4. Check:
8 camshaft oil passage
Obstruction J Blow out with compressed
air.
5-16
THE ROCKER ARMS AND CAMSHAFT
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.
a
1
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).
b
2
EAS00210
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
8 timing chain tensioner
Cracks/damage J Replace.
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).
5-17
THE ROCKER ARMS AND CAMSHAFT
ENG
EAS00220
INSTALLING THE CAMSHAFT AND ROCKER
ARMS
1. Lubricate:
8 camshaft 1
4
1
Recommended lubricant
Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil
M
M
2. Lubricate:
8 rocker arm shafts
Recommended lubricant
Molybdenum disulfide oil
3. Install:
8 exhaust rocker arm 1
8 exhaust rocker arm shaft 2
2
NOTE:
Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head.
1
4. Install:
8 intake rocker arm 1
8 intake rocker arm shaft 2
2
NOTE:
Make sure the intake rocker arm shaft is completely pushed into the cylinder head.
1
cC
Make sure the threaded part of the rocker
arm shaft faces out.
2
T.
5. Install:
8 stopper plate 1
8 locknut 2
7 Nm (0.7 m • kg, 5.1 ft • lb)
R.
1
5-18
VALVES AND VALVE SPRINGS
ENG
EAS00236
VALVES AND VALVE SPRINGS
1
2
3
4
7
6
M
5
M
M
7
3
M
6
2
1
Order
Job/Part
Q’ty
Removing the valves and valve
springs
Cylinder head
Rocker arm and rocker arm shaft
1
2
3
4
5
6
7
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “ ROCKER ARMS AND
ROCKER ARMS SHAFTS”.
4
2
2
1
1
2
2
Valve cotter
Valve spring retainer
Valve spring
Valve (intake)
Valve (exhaust)
Valve stem seal
Valve stem seat
Remarks
Refer to “ INSTALLING THE VALVES
AND VALVE SPRINGS “.
For installation, reverse the removal procedure.
5-19
VALVES AND VALVE SPRINGS
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.
*****************************************************
2. Remove:
8 valve cotters 1
2
3
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and the valve spring compressor attachment
3.
1
Valve spring compressor
90890-04109 (YM-04109)
Valve spring compressor attachment
90890-04108 (YM-04108)
5-20
VALVES AND VALVE SPRINGS
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.
6
5
ENG
3
24
1
EAS00239
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
8 valve-stem-to-valve-guide clearance
a
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a Valve stem diameter b
Out of specification J Replace the valve
guide.
b
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
VALVES AND VALVE SPRINGS
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.
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)
a
6. Measure:
8 valve stem runout
Out of specification 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)
5-22
VALVES AND VALVE SPRINGS
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.
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.
b
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
VALVES AND VALVE SPRINGS
ENG
a. Apply a coarse lapping compound a to the
valve face.
cC
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
a
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.
*****************************************************
b
5-24
VALVES AND VALVE SPRINGS
ENG
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the valve
springs.
1. Measure:
8 valve spring free length a
Out of specification J Replace the valve
spring.
a
Valve spring free length
37.30 mm(1.469 in)
<Limit>: 35.40 mm(1.394 in)
2. Measure:
8 compressed valve spring force a
Out of specification J Replace the valve
spring.
b Installed length
b
a
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)
3. Measure:
8 valve spring tilt a
Out of specification J Replace the valve
spring.
a
Spring tilt limit
1.6 mm ( 2.5°)(0.063 in)
5-25
VALVES AND VALVE SPRINGS
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)
Recommended lubricant
Molybdenum disulfide oil
4
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)
1
5 3
2
M
b
6
a
M
NOTE:
Install the valve spring with the larger pitch a
facing up.
b
Smaller pitch
4. Install:
8valve cotters 1
2
3
NOTE:
Install the valve cotters by compressing the valve
spring with the valve spring compressor 2 and
the valve spring compressor attachment 3.
1
5-26
VALVES AND VALVE SPRINGS
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.
cC
Hitting the valve tip with excessive force
could damage the valve.
5-27
CYLINDER AND PISTON
ENG
EAS00251
CYLINDER AND PISTON
1
2
8
10
4
9
11
12
8
13
14
13
7
4
5
4
6
3
4
12Nm(1.2m • kg, 8.7 ft • lb)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
Removing the cylinder and piston
Cylinder head
Clamp
Pipe
Timing chain guide (exhaust side)
Cylinder
O-ring
Dowel pin
Cylinder gasket
1
1
1
1
1
2
1
8
9
Piston pin clip
Piston pin
2
1
10
11
Piston
Top ring
1
1
12
13
14
2nd ring
Oil ring
Expander
1
2
1
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “ INSTALLING THE PISTON
AND CYLINDER”
Refer to “ REMOVING THE CYLINDER
AND PISTON”
Refer to “ INSTALLING THE PISTON
AND CYLINDER”
For installation, reverse the removal procedure.
5-28
CYLINDER AND PISTON
ENG
EAS00253
3
REMOVING THE CYLINDER AND PISTON
1. Remove:
8 piston pin clip 1
8 piston pin 2
8 piston 3
cC
Do not use a hammer to drive the piston pin
out.
2
1
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
CYLINDER AND PISTON
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)
P
a
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
CYLINDER AND PISTON
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)
2. Install:
8 piston ring
(into the cylinder)
a
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)
5-31
CYLINDER AND PISTON
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.
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)
a
3. Measure:
8 piston pin bore diameter b
Out of specificationJ Replace the piston.
b
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
CYLINDER AND PISTON
ENG
CHECKING THE TIMING CHAIN GUIDE
1. Check:
8 timing chain guide (exhaust side)
Damage/wear J Replace
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
2. Install:
8 piston 1
8 piston pin 2
8 piston pin clip New 3
1
a
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.
2
3
5-33
CYLINDER AND PISTON
1
ENG
3. Install:
8 gasket New 1
8 dowel pins 2
2
4. Lubricate:
8 piston
8 piston rings
8 cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Offset:
8 piston ring end gaps
b
a
a
b
c
d
A
c
A
Top ring
Lower oil ring rail
Upper oil ring rail
2nd ring
Exhaust side
d
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.
1
5-34
BELT DRIVE
ENG
EAS00316
BELT DRIVE
CRANKCASE COVER
6
5
10Nm(1.0m • kg, 7.2 ft • lb)
9
2
8
6
7
4
3
1
7Nm(0.7m • kg, 5.1 ft • lb)
23Nm(2.3m • kg, 16.6 ft • lb)
Order
1
2
3
4
5
6
7
8
9
Job/Part
Q’ty
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
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
5-35
BELT DRIVE
ENG
EAS00338
KICKSTARTER
7
6
9Nm(0.9m • kg, 6.5 ft • lb)
1
2
8
5
4
3
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CRANKCASE COVER “.
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
1
1
1
1
1/1
1
1
1
Refer to “INSTALLING THE KICKSTARTER“.
For installation, reverse the removal procedure.
5-36
BELT DRIVE
ENG
EAS00340
2
INSTALLING THE KICKSTARTER
1. Install:
8 solid bush 1
8 kickstarter shaft 2
8 kickstarter spring 3
3
1
2. Hook:
8 kickstarter spring
d
c
NOTE:
Hook the spring enda on the kickstarter shaft
b as shown, and hook the other end c on the
projectiond .
b
a
3. Install:
8 plain washer1
8 circlip2 New
2
1
1
4. Install:
8 kick pinion gear1
8 kick pinion gear clip 2
2
NOTE:
Install the clip at the position shown.
5. Install:
8 gasket1 New
8 plate2
1
2
5-37
ENG
BELT DRIVE
V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE
60Nm(6.0m • kg, 43.4 ft • lb)
5
4
13
6
8
3
10
2
12
1
9
11
12
LS
LS
Order
Job/Part
Q’ty
1
2
Removing the V-belt, clutch, primary
and secondary sheave
Primary sheave nut / Plate washer
Oneway clutch
3
4
5
6
Primary fixed sheave
Secondary sheave nut
Clutch housing
Secondary sheave assembly
7
8
9
10
11
12
13
V-belt
Washer / Collar
Primary sliding sheave
Cam / Weight
Slider
Oil seal
Gasket
55Nm(5.5m • kg, 39.8 ft • lb)
Remarks
Remove the parts in the order listed.
1/1
1
1
1
1
1
Refer to “ REMOVING AND INSTALLING
THE SECONDARY SHEAVE “
Refer to “ REMOVING AND INSTALLING
THE PRIMARY SHEAVE “
1
1/1
1
1/6
3
2
1
For installation, reverse the removal procedure.
5-38
BELT DRIVE
ENG
DISASSEMBLING THE SECONDARY SHEAVE
5
3
4
2
LS
1
90Nm(9.0m • kg, 65.1 ft • lb)
0
6
9
7
8
LS
9
LS
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
0
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
Remarks
Disassemble the parts in the order listed.
1
1
3
1
1
3
1
2
2
1
Refer to “ REMOVING AND INSTALLING
THE SECONDARY SHEAVE “
For assembly, reverse the disassembly
procedure.
5-39
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)
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.
3
2
Sheave holder:
90890-01701 (YS-01880-A)
1
2. Loosen:
8 clutch carrier nut 1
2
1
cC
Do not remove the clutch carrier nut at this
stage.
3
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
EAS00319
2
DISASSEMBLING THE SECONDARY SHEAVE
3
1. Remove:
8 clutch carrier nut 1
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)
CHECKING THE CLUTCH SHOE
1. Measure:
8 Clutch shoe
Scratches J Glaze using coares sandpaper.
Damage/wear J Replace
a
a
Clutch shoe thickness
3.5 mm (0.138 in)
<Limit>: 2.0 mm (0.079 in)
a
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
BELT DRIVE
ENG
EAS00320
CHECKING THE V-BELT
1. Check:
8 V-belt 1
Cracks/damage/wear J Replace.
Grease/oil J Clean the primary and secondary sheave.
2. Measure:
8 V-belt width a
Out of specification J Replace.
1
V-belt width
21.6 mm (0.0850 in)
<Limit>: 19.5 mm (0.768 in)
a
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.
1
2
EAS00321
CHECKING THE PRIMARY SHEAVE WEIGHTS
The following procedure applies to all of the primary sheave weights.
1. Check:
8 primary sheave weight
Cracks/damage/wear J Replace.
2. Measure:
8 primary sheave weight outside diameter
a
Out of specification J Replace.
Primary sheave weight outside diameter
19.9~20.1 mm (0.783~0.791 in)
a
5-42
BELT DRIVE
ENG
CHECKING THE SLIDER
1. Check:
slider 1
Damage/wearJ Replace
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.
2
1
EAS00323
2
5
1
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
8primary fixed sheave 1
8primary sliding sheave 2
8collar 3
8primary sheave weights 4
3
4
NOTE:
Use thinner to clean up grease, dirt on the primary sliding sheave cam side 5.
1
2. Install:
8primary sheave weights 1
8collar 2
2
5-43
BELT DRIVE
ENG
3. Install:
8 slider 1
8 primary sliding sheave 2
8 cam 3
3
2
1
5-44
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
(with the recommended lubricant)
1
2
Recommended lubricant
BEL-RAY assembly lube
3
2. Install:
8 secondary sliding sheave 1
1
NOTE:
Install the secondary sliding sheave onto the
secondary fixed sheave 2 with the oil seal guide
3.
2
Oil seal guide
90890-01384 (YM-33299)
3. Install:
8 guide pin 1
4. Lubricate:
8 guide pin groove 2
8 o-ring New 3
(with the recommended lubricant)
3
1
2
Recommended lubricant
BEL-RAY assembly lube
5-45
BELT DRIVE
5. Install:
8 secondary sheave 1
8 spring
8 clutch carrier 2
4
2
5
3
ENG
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.
1
Clutch spring holder
90890-01337 (YM-33285)
( YM-33285-6)
EAS00325
INSTALLING THE BELT DRIVE
1. Install:
8 V-belt 1
8 clutch assembly 2
cC
Do not allow grease to contact the V-belt,
secondary sheave assembly.
1
2
NOTE:
Install the V-belt onto the primary sheave side.
5-46
BELT DRIVE
ENG
2. Install:
8 clutch carrier nut 1
T.
R.
1
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.
3
2
Rotor holding tool
90890-01235
Locknut wrench
90890-01348 (YM-01348)
3. Install:
8 clutch housing 1
8 secondary sheave nut2
3
2
T.
R.
60 Nm (6.0 m • kg, 43.4 ft • lb)
NOTE:
Tighten the secondary sheave nut with the
sheave holder 3.
1
Sheave holder
90890-01701 (YS-01880-A)
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.
1 3
2
5-47
ENG
STARTER CLUTCH AND STARTER MOTOR
STARTER CLUTCH AND STARTER MOTOR
7Nm(0.7m • kg, 5.1 ft • lb)
9
10
7Nm(0.7m • kg, 5.1 ft • lb)
2
3
B
2
11
6
7
8
1
5
4
LS
Order
Job/Part
Q’ty
Removing the starter clutch and
starter motor
Primary sheave
1
2
3
4
5
6
7
8
9
10
11
Idle gear plate
Plate washer
Idle gear
Starter clutch
Washer
Circlip
Bearing
Starter wheel gear
Starter motor
O-ring
Shaft
Remarks
Disassemble the parts in the order listed.
Refer to “ REMOVING THE PRIMARY
SHEAVE “
1
2
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
5-48
STARTER CLUTCH AND STARTER MOTOR
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
*****************************************************
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.
*****************************************************
B
5-49
C.D.I. MAGNETO
ENG
C.D.I. MAGNETO
3
2
7Nm(0.7m • kg, 5.1 ft • lb)
1
4
70Nm(7.0m • kg, 50.6 ft • lb)
Order
1
2
3
4
Job/Part
Q’ty
Removing the C.D.I. magneto
Air shroud 1
Fan
C.D.I. magneto rotor
Woodruff key
Stator coil assembly
Remarks
Disassemble the parts in the order listed.
Refer to “CYLINDER HEAD”in chapter 3.
1
1
1
1
cC
Disconnect the C.D.I. magneto lead
coupler.
For installation, reverse the removal procedure.
5-50
C.D.I. MAGNETO
ENG
REMOVING THE C.D.I. MAGNETO
1. Remove:
8 nut 1
8 plate washer
1
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.
2
Rotor holding tool
90890-01235 (YU-01235)
2. Remove:
8 C.D.I. magneto rotor1
8 (with flywheel puller 2 )
1
Flywheel puller
90890-01189 (YM-01189)
2
5-51
C.D.I. MAGNETO
ENG
INSTALLING THE C.D.I. MAGNETO
1. Install:
8 C.D.I. magneto rotor 1
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
3
T.
2. Tighten:
8 nut 2
70 Nm (7.0 m • kg, 50.6 ft • lb)
R.
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.
Rotor holding tool
90890-01235 (YU-01235)
5-52
OIL PUMP
ENG
EAS00360
OIL PUMP
2
4
3
1
LS
14
8
7Nm(0.7m • kg, 5.1 ft • lb)
7Nm(0.7m • kg, 5.1 ft • lb)
11
12
13
5
10
6
9
7
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ C.D.I. MAGNETO “
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
1
1
1
1
1
1/1
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
5-53
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).
1
a
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
Out of specification J Replace the oil
pump.
2
1 Inner rotor
2 Outer rotor
3 Oil pump housing
3
b
c
1
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).
EAS00376
2
INSTALLING THE OIL PUMP
1. Install:
8 gasket 1 New
8 oil pump assembly2
8 oil pump bolt
7 Nm (0.7 m • kg, 5.1 ft • lb)
1
T.
R.
cC
After tightening the bolts, make sure the oil
pump turns smoothly.
5-55
ENG
TRANSMISSION
EAS00419
TRANSMISSION
B
7
G
6
5
6 3
2
1
G
4
G
12Nm(1.2m • kg, 8.7 ft • lb)
B
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the transmission, shift
drum assembly, and shift forks
Transmission oil
Rear wheel
1
2
3
4
5
6
7
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
Remarks
Drain.
Refer to “REAR WHEEL AND REAR
BRAKE “ in chapter 4.
Refer to “BELT DRIVE “.
Refer to “V-BELT, CLUTCH, PRIMARY
AND SECONDARY SHEAVE “.
1
1
2
1
1
1
1
For installation, reverse the removal procedure.
5-56
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
(with a centering device and dial gauge )
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
(with a centering device and dial gauge )
Out of specification 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).
5-57
CRANKCASE AND CRANKSHAFT
ENG
EAS00381
CRANKCASE AND CRANKSHAFT
12Nm(1.2m • kg, 8.7 ft • lb)
11
10
4
19
9
7
18
11
12
8
17
14
15
16
LS
13
8Nm(0.8m • kg, 5.8 ft • lb)
1
23
6
3
5
Order
4
Job/Part
Q’ty
Removing the crankshaft assembly
Engine
Cylinder head
Cylinder piston
V-belt, clutch, primary / Secondary
sheave
Starter clutch
1
2
3
4
5
6
7
8
9
10
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 )
32Nm(3.2m • kg, 23.1 ft • lb)
1
32Nm(3.2m • kg, 23.1 ft • lb)
Remarks
Remove the parts in the order listed.
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 “
2
2
2
1
1
1
1
1
1
1
5-58
2
CRANKCASE AND CRANKSHAFT
ENG
12Nm(1.2m • kg, 8.7 ft • lb)
11
10
4
19
18
9
7
11
12
8
17
14
15
16
LS
13
8Nm(0.8m • kg, 5.8 ft • lb)
1
23
6
3
5
Order
Job/Part
4
Q’ty
11
12
Dowel pin
Crankshaft
2
1
13
14
Timing chain
Crankcase ( left )
1
1
15
16
17
18
19
Bolt
O-ring
Timing chain guide
Oil pipe
O-ring
1
1
1
1
1
2
32Nm(3.2m • kg, 23.1 ft • lb)
1
32Nm(3.2m • kg, 23.1 ft • lb)
Remarks
Refer to “DISASSEMBLING THE
CRANKCASE “
Refer to “INSTALLING THE CRANKSHAFT “
For installation, reverse the removal procedure.
5-59
CRANKCASE AND CRANKSHAFT
ENG
DISASSEMBLING THE CRANKCASE
1. Remove:
8 centerstand assembly
2. Remove:
8 crankcase bolts 1
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.
1
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.
2
5-60
CRANKCASE AND CRANKSHAFT
ENG
EAS00389
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:
8 crankshaft assembly 1
8 timing chain 2
1
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.
2
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
CRANKCASE AND CRANKSHAFT
ENG
EAS00394
CHECKING THE CRANKSHAFT AND CONNECTING 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)
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
Out of specification J Replace the crankshaft.
Crankshaft width
45.15~45.20 mm (1.778~1.780 in)
4. Check:
8 crankshaft sprocket 1
Damage/wear J Replace the crankshaft.
8 bearing 2
Cracks/damage/wear J Replace the
crankshaft.
8 oil pump drive gear 3
Damage/wear J Replace the crankshaft.
2
3
2
1
5-62
CRANKCASE AND CRANKSHAFT
ENG
5. Check:
8 crankshaft journal
Scratches/wear J Replace the crankshaft.
8 crankshaft journal oil passage
Obstruction J Blow out with compressed
air.
EAS00408
2
3
INSTALLING THE CRANKSHAFT
1. Install:
8 crankshaft assembly 1
8 crankcase2
8 timing chain3
1
cC
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
CRANKCASE AND CRANKSHAFT
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.
3. Install:
8 dowel pins
8 timing chain 1
2
NOTE:
Install the timing chain so it is not visible through
the opening a in the left crankcase 2.
1
a
4. Install:
8 crankshaft 1
8 crankcase (right )
5. Tighten:
8 crankcase
12 Nm (1.2 m • kg, 8.7 ft • lb)
1
T.
R.
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
CARBURETOR
CARB
CARBURETOR
EAS00483
CARBURETOR
3
5
i
4
6
1
0
2
p
a
u
y
r
w
q
8
t
o
e
7
9
Order
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
i
o
Job/Part
Q’ty
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
6-1
Remarks
Remove the parts in the order listed.
1
1
1/1
1
1
1/1
1
1
1
1
1
1
1
1
1
1
1
1
1
CARBURETOR
CARB
3
5
i
4
6
1
0
2
p
a
u
y
r
w
q
8
t
o
e
7
9
Order
p
a
Job/Part
Q’ty
Carburetor heater
Ground terminal
Remarks
1
1
For assembly, reverse the disassembly
procedure.
6-2
CARBURETOR
CARB
EAS00485
CHECKING THE CARBURETOR
1. Check:
8 carburetor body
8 float chamber
Cracks/damage J Replace.
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.
2
1
5. Check:
8 float
Damage J Replace.
6-3
CARBURETOR
3
2
1
2
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/wearJ Replace.
8 piston valve diaphragm 2
Cracks/tears J Replace.
1
9. Check:
8 vacuum chamber cover 1
8 piston valve spring 2
Cracks/damage J Replace.
1
2
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.
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.
6-4
CARBURETOR
CARB
EAS00487
ASSEMBLING THE CARBURETOR
cC
8 Before assembling the carburetor, wash
all of the parts in a petroleum-based solvent.
8 Always use a new gasket.
3
1. Install:
8 main nozzle 1
8 main jet 2
8 pilot jet 3
2
1
1
3
2. Install:
8 needle valve seat 1
8 float 2
8 needle valve 3
8 float pin 4
8 screw 5
2
5
4
3. Install:
8 accelerator pump assembly
4. Install:
8piston valve
8jet needle
8piston valve spring
8vacuum chamber cover
6-5
CARBURETOR
CARB
EAS00492
INSTALLING THE CARBURETOR
1. Adjust:
8 engine idling speed
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
Throttle cable free play (at the flange
of the throttle grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
6-6
CARBURETOR
CARB
EAS00498
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
8 fuel level a
Out of specification J Adjust.
a
1
Fuel level (below the float chamber
mating surface)
6.5 ~ 7.5 mm (0.26 ~ 0.30 in)
3
2
*****************************************************
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.
*****************************************************
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.
*****************************************************
1
a
6-7
CARBURETOR
CARB
EAS00505
CHECKING THE FUEL COCK
1. Check:
8fuel cock
Cracks/damage/wear J Replace.
2. Check:
8fuel cock strainer 1
obstruction J clean.
Blow out the jets with compressed air.
Damage J Replace.
1
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.
1
NOTE:
When the starter plunger is open, air should
come out of the other side of the starter air passage.
2
Starter plunger opens
Perform step (3).
Starter plunger closes
Replace the autochoke unit.
*****************************************************
6-8
CARBURETOR
2
CARB
3. Check:
8 autochoke unit
*****************************************************
a. Connect the autochoke unit leads to a 12.0V battery for five minutes.
1
B B
3
Positive battery lead 1 J black
Negative battery lead 2 J black
4
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
AIR INDUCTION SYSTEM
4Nm(0.4m • kg, 2.9 ft • lb)
1
2
7
6
5
3
4
31Nm(3.1m • kg, 22.4 ft • lb)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
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
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
For installation, reverse the removal procedure.
6-10
AIR INDUCTION SYSTEM
CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
8 hoses
Loose connection J Connect properly.
Cracks/damage J Replace.
8 pipe
Cracks/damage J Replace.
2. Check:
8 air cut-off valve
Cracks/damage J Replace.
1
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
TROUBLESHOOTING ..................................................................... 7-16
STARTER MOTOR ........................................................................... 7-20
CHECKING THE STARTER MOTOR .............................................. 7-21
ASSEMBLING THE STARTER MOTOR ......................................... 7-23
CHARGING SYSTEM ............................................................................. 7-24
CIRCUIT DIAGRAM ......................................................................... 7-24
TROUBLESHOOTING ..................................................................... 7-25
LIGHTING SYSTEM ............................................................................... 7-27
CIRCUIT DIAGRAM ......................................................................... 7-27
TROUBLESHOOTING ..................................................................... 7-28
CHECKING THE LIGHTING SYSTEM ........................................... 7-29
SIGNALING SYSTEM ............................................................................ 7-33
CIRCUIT DIAGRAM ......................................................................... 7-33
TROUBLESHOOTING ..................................................................... 7-34
CHECKING THE SIGNALING SYSTEM......................................... 7-35
CRABURETOR HEATING SYSTEM ..................................................... 7-41
CIRCUIT DIAGRAM ......................................................................... 7-41
TROUBLESHOOTING ..................................................................... 7-42
AUTO CHOKE SYSTEM ........................................................................ 7-45
CIRCUIT DIAGRAM ......................................................................... 7-45
TROUBLESHOOTING ..................................................................... 7-46
7-48
ELECTRICAL COMPONENTS
ELEC
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
9
0
Wire harness
Battery
C.D.I. unit
Carburetor heater
Sidestand switch
Horn
Rectifier/Regulator
Ignition coil
Rear brake light switch
Main switch
q
w
e
r
t
y
t
0
Thermo switch
Fuel sender
Starter relay
Turn signal relay
Front brake light switch
Starting circuit cut-off relay
9
w
r
6
3
7
e
q
4
y
1
8
2
5
7-1
-
+
R
Br
6
4
0
8
R
B
7
(RED)
G
B
(RED)
G
B
B
LW
RW
9
l
;
(GREEN)
L Br
B G
Br L
G B
(GREEN)
B
MOTOR
B
B
B
B
RW
RW
B
f j
k
START
OFF
START
y
x
(BLACK)
Dg L
B B
Y
(BLACK)
L Dg
B Ch
OFF
RUN
E/G STOP
u
c
a
BW
(BLACK)
Ch L
P
B
BrW
Dg
(BLACK)
3
BW BW
Br LW
HI
LO
DIMMER SW
h
BW BW
LW Br
(BLUE)
L Ch
P BrW
B Dg
Y
OFF
PUSH
HORN SW
R
W B
R YR
B
R
10A
R
R
R
B
B
R
L
(ILLUM) 12V3W
LW
TURN 12V3W
L
14V3W
B
Br
G
HI BEAM 12V3W
B
s
Y B
G
(BLACK)
z
P
TURN SIGNAL SW
L
N
R
YR
W
YR
B
5
Ch
BW
BW
Dg
1
12V 10W
G
B
Ch
B
Dg
12V 10W
Br
P
B
B
B
Br
W
YR
2
B
Dg
d
B
B
(GREEN)
Dg
Ch
(BROWN)
b
Br
(GREEN)
(BLACK)
(BROWN)
B
Ch
v
B
BrW
p
(BLACK)
B
YR
(BLACK)
B
B
e
W
YR
YR
W
WR WL
BR GW
WL
B
i
Sb GY
LW RW
WL
WR WR
BR
GW
BR
GW
WL WR
GW BR
Sb
LY
o
g
B
GY
L
(RED)
(RED)
L
Y
B
Br
GY
Br
GY
r
BW
Sb
LY
BW
B
Or
B
(BLACK)
B
(BLACK)
q
Or
Or
Sb
R
B
Br
Ch
L
Y
Y
12V 60W/55W
G
G
BrW
RW
R
B
Br
Dg
LW
Sb
Br
GY
BrW
LY
LY
B
MAIN
LOCK
OFF
ON
B
Or
(RED)
B
B
t
w
(RED)
Br
GY
m
n
-
B
Ch
12V 10W
B
Dg
12V 10W
B
BW
L
12V 27/8W
Br
GY
GY
Br
GY
Br
Y
Y
B
7-2
B
WIRING DIAGRAM
ELEC
+
WIRING DIAGRAM
WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
i
o
p
a
s
d
f
g
h
j
k
l
;
z
x
c
v
b
n
m
Main switch
C.D.I. magneto
Rectifier/Regulator
Battery
Main fuse
Battery (+) lead
Battery (-) lead
Wire lead
Starter relay
Starter motor
C.D.I. unit
Ignition coil
Auto choke unit
Front brake light switch
Rear brake light switch
Start switch
Engine stop switch
Starting circuit cut-off relay
Sidestand switch
Horn
Horn switch
Turn signal switch
Turn signal relay
Speedometer light
Tail/brake light
Dimmer switch
High beam indicator light
Turn signal indicator light
Fuel lever meter
Fuel sender
Headlight
Front turn signal light (left)
Front turn signal light (right)
Rear turn signal light (left)
Rear turn signal light (right)
Thermo switch
Carburetor heater
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
ELEC
-
+
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.
cC
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)
Br R
a
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.
b
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.
OFF
ON
Br
R
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
-
ELEC
CHECKING THE SWITCHES
+
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.
Main switch
Br R B B/W
LOCK
OFF
ON
Rear barake light switch
B
B
R
B
Br
Front barake light switch
Br
G/Y
Dimmer switch
Y L G
HI
LO
Start switch
Horn switch
L/ L/
WW
Dg L
Ch B
OFF
START
P B
OFF
PUSH
Turn signal light switch
Br/
Ch Dg
W
L
N
R
B/W B/W
L/W Br
Engine stop switch
L Ch
P Br/W
B Dg
B/ B/ L/ Br
WWW
Sidestand switch
OFF
RUN
L/Y
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.
A
C
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.
B
D
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.
E
7-6
CHECKING THE BULBS AND BULB SOCKETS
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.
cC
8 Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal in the coupler.
8 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.
2.
Check:
8 bulb (for continuity)
(with the pocket tester)
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.
1
2
3
*****************************************************
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.
*****************************************************
1
3
2
7-7
CHECKING THE BULBS AND BULB SOCKETS
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)
(with the pocket tester)
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
Br
7
0
B
(RED)
G
B
(RED)
G
B
B
l
;
(GREEN)
L Br
B G
Br L
G B
(GREEN)
B
MOTOR
LW
RW
B
RW
RW
B
f j
k
START
OFF
START
y
x
(BLACK)
Dg L
B B
Y
(BLACK)
L Dg
B Ch
OFF
RUN
E/G STOP
u
c
a
BW
(BLACK)
Ch L
P
B
BrW
Dg
(BLACK)
L Ch
P BrW
B Dg
Y
OFF
PUSH
HORN SW
3
BW BW
Br LW
HI
LO
DIMMER SW
h
BW BW
LW Br
(BLUE)
Br
R
4
8
9
R
W B
R YR
B
R
10A
R
R
6
R
B
B
B
BW
R
B
B
R
L
14V3W
B
L
(ILLUM) 12V3W
s
Y B
G
(BLACK)
z
P
TURN SIGNAL SW
L
N
R
YR
W
YR
B
5
HI BEAM 12V3W
B
LW
TURN 12V3W
Br
W
YR
2
B
Dg
d
B
B
(GREEN)
Dg
Ch
(BROWN)
b
Br
(GREEN)
(BLACK)
(BROWN)
B
Ch
v
B
BrW
p
(BLACK)
B
YR
(BLACK)
B
B
e
W
YR
YR
W
WR WL
BR GW
RW
BW
Ch
1
Dg
Br
G
G
B
Ch
12V 10W
B
Dg
12V 10W
B
B
P
B
L
Y
Y
12V 60W/55W
G
G
BrW
LW
Sb
Br
WL
B
i
Sb GY
LW RW
WL
WR WR
BR
GW
BR
GW
WL WR
GW BR
Sb
LY
o
r
BW
Sb
LY
BW
B
Or
B
(BLACK)
B
(BLACK)
q
Or
Or
LY
LY
B
R
B
Br
Ch
BW
L
12V 27/8W
GY
BrW
Sb
Br
GY
B
Or
g
B
GY
L
(RED)
(RED)
L
Y
B
Br
GY
Br
GY
(RED)
B
B
t
w
Br
GY
m
n
(RED)
Main switch
Pickup coil
Battery
Main fuse
Battery (+) lead
Battery (-) lead
Wire lead
C.D.I. unit
Ignition coil
Engine stop switch
Sidestand switch
GY
R
B
Br
Dg
Br
GY
MAIN
LOCK
OFF
ON
-
B
Ch
12V 10W
B
Dg
12V 10W
B
Br
Y
Y
B
7-9
1
2
4
5
6
7
8
q
w
u
o
B
IGNITION SYSTEM
ELEC
+
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
ELEC
-
+
EAS00736
EAS00738
TROUBLESHOOTING
1. Main Fuse
8 Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter 3.
8 Is the fuse OK?
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)
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
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).
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.
Ignition checker
90890-06754 (YM-34487)
Pocket tester
90890-03132 (YU-03112-C)
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
IGNITION SYSTEM
EAS00742
ELEC
-
+
EAS00744
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.
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
Ω at 20°C
8~12 kΩ
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
Replace the spark plug cap.
YES
EAS00746
The ignition system is OK.
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 orange
Negative tester probe J black
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
Replace the main switch.
8 Measure the primary coil resistance.
EAS00750
8. Engine stop switch
8 Check the engine stopswitch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the engine stop switch OK?
Primary coil resistance
0.184 ~ 0.276 Ω at 20°C
8 Connect the pocket tester (Ω × 1k) to
the ignition coil as shown.
YES
Negative tester probe J spark plug lead
2
Positive tester probe J spark plug lead
1
NO
Replace the right handlebar
switch.
EAS00752
9. Sidestand switch
8 Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the sidestand switch OK?
2
1
YES
Replace the sidestand switch.
8 Measure the secondary coil resistance.
Secondary coil resistance
Ω at 20°C
6.32 ~ 9.48 kΩ
8 Is the ignition coil OK?
YES
NO
NO
Replace the ignition coil.
7-12
IGNITION SYSTEM
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 white/red 1
Negative tester probe J white/blue 2
1
W/R
W/L
2
8Measure the pickup coil resistance.
Pickup coil resistance
Ω at 20°C
304 ~456Ω
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
Replace the C.D.I.
unit.
NO
Properly connect or
repair the ignition
system’s wiring.
7-13
ELEC
-
+
R
R
10A
R
R
0
8
R
B
Br
(RED)
G
B
(RED)
G
B
B
LW
RW
l
;
(GREEN)
L Br
B G
Br L
G B
(GREEN)
B
MOTOR
B
B
B
7
B
B
4
R
6
B
RW
RW
B
L
START
OFF
START
y
f j
(ILLUM) 12V3W
9
HI BEAM 12V3W
k
x
B
R
LW
TURN 12V3W
5
L Dg
B Ch
OFF
RUN
E/G STOP
u
(BLACK)
Y
(BLACK)
Dg L
B B
c
Ch
L
14V3W
B
BW
OFF
PUSH
HORN SW
a
BW
BW
R
3
BW BW
Br LW
HI
LO
DIMMER SW
h
BW BW
LW Br
(BLUE)
W B
R YR
(BLACK)
Ch L
P
B
BrW
Dg
(BLACK)
L Ch
P BrW
B Dg
Y
B
1
Dg
Br
G
s
P
TURN SIGNAL SW
L
N
R
YR
W
Y B
G
(BLACK)
z
B
B
Br
W
YR
2
B
Dg
d
B
B
(GREEN)
Dg
Ch
(BROWN)
b
Br
(GREEN)
(BLACK)
(BROWN)
B
Ch
v
B
BrW
p
(BLACK)
B
YR
(BLACK)
B
B
e
W
YR
YR
W
WR WL
BR GW
WL
B
i
Sb GY
LW RW
WL
WR WR
BR
GW
BR
GW
WL WR
GW BR
Sb
LY
o
g
L
Y
B
(RED)
Br
GY
r
BW
Sb
LY
BW
B
GY
L
(RED)
Br
GY
B
Or
B
(BLACK)
B
(BLACK)
q
Or
Or
Sb
R
B
Br
Ch
12V 10W
Dg
12V 10W
G
B
Br
P
B
Y
Y
12V 60W/55W
G
G
BrW
YR
B
R
B
Br
Ch
RW
LY
LY
B
MAIN
LOCK
OFF
ON
Dg
LW
Sb
Br
GY
BrW
L
Main switch
Battery
Main fuse
Battery (+) lead
Battery (-) lead
Wire lead
Starter relay
Starter motor
C.D.I. unit
Front brake light switch
Rear brake light switch
Start switch
Engine stop switch
Starting circuit cut-off relay
Sidestand switch
B
B
Or
(RED)
B
B
t
w
(RED)
Br
GY
m
n
-
B
Ch
12V 10W
B
Dg
12V 10W
B
BW
L
12V 27/8W
Br
GY
GY
Br
GY
Br
Y
Y
B
7-14
1
4
5
6
7
8
9
0
q
r
t
y
u
i
o
B
ELECTRIC STARTING SYSTEM
ELEC
+
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
ELEC
-
+
EAS00756
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
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)
q
0
9
1
2
3
4
5
6
7
8
9
0
q
w
1
2
7
3
6
w
8
5
4
7-15
Battery
Main fuse
Main switch
Front brake light switch
Rear brake light switch
Engine stop switch
Starting circuit cut-off relay
Sidestand switch
Start switch
Starter relay
Starter motor
C.D.I. unit
ELECTRIC STARTING SYSTEM
EAS00757
ELEC
-
+
EAS00738
TROUBLESHOOTING
1. Main fuse
8 Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in
chapter 3.
8 Is the fuse OK?
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)
8. Engine stop switch
9. Sidestand switch
10. Start switch
11. Wiring connections
(of the entire starting system)
YES
NO
Replace the fuse.
EAS00739
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).
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.
Pocket tester
90890-03132 (YU-03112-C)
7-16
ELECTRIC STARTING SYSTEM
EAS00758
ELEC
-
+
EAS00759
3. Starter motor
8 Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead3.
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 red/white 1
Negative battery terminal J blue/white 2
Positive tester probe J green/yellow 3
Negative tester probe J sky blue 4
w
8 A wire that is used as a jumper lead must
have at least the same capacity or more
as that of the battery
lead, otherwise
the jumper lead may burn.
8 This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
×1Ω
1
4
2
12V
8Does the starting circuit cut-off relay have
continuity between green/yellow3 and
sky blue4?
8Does the starter motor turn?
YES
3
YES
NO
NO
Replace the starting
circuit cut-off relay.
Repair or replace the
starter motor.
7-17
ELECTRIC STARTING SYSTEM
EAS00761
ELEC
-
+
EAS00751
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.
7. Brake light switch(front and rear)
8 Check the brake light switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the brake light switch OK?
YES
Positive battery terminal J red/white 1
Negative battery terminal J blue/white 2
Positive tester probe J red 3
Negative tester probe Jred 4
NO
Replace the brake light
switch.
2
L/W
R/W
EAS00750
1
8. Engine stop switch
8 Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the engine stop switch OK?
3
4
Starter
relay
YES
8 Does the starter relay have continuity between red3 and red 4?
YES
NO
Replace the right
handlebar switch.
NO
EAS00752
9. Sidestand switch
8 Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the sidestand switch OK?
Replace the starter
relay.
EAS00749
6. Main switch
8Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8Is the main switch OK?
YES
YES
NO
Replace the sidestand
switch.
NO
EAS00764
Replace the main
switch.
10.Start switch
8 Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
7-18
ELECTRIC STARTING SYSTEM
EAS00766
11. Wiring
8 Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8 Is the starting system’s wiring properly
connected and without defects?
YES
The starting system circuit is OK.
NO
Properly connect or
repair the starting
system’s wiring or
replace the C.D.I.
unit.
7-19
ELEC
-
+
ELECTRIC STARTING SYSTEM
ELEC
-
+
STARTER MOTOR
1
2
5
6
0
3
9
LS
q
2
7 7
1
8
8
3.5Nm(0.35m • kg, 2.5 ft • lb)
3
4
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to“LEADS, HOSES AND REAR
BRAKE ”in chapter 5.
Starter motor removal
Air filter case
1
2
1
2
3
4
5
6
7
8
9
0
q
Remarks
1
1
Starter motor lead
Starter motor
For installation, reverse the removal procedure.
Remove the parts in the order listed.
Starter motor disassembly
O-ring
Rear bracket
Gasket
Stator assembly
Armature coil
Circlip
Brush
Brush spring
Brush seat
Plate washer
Front bracket
1
1
2
1
1
1
2
2
1
1
1
For assembly, reverse the disassembly
procedure.
7-20
ELECTRIC STARTING SYSTEM
ELEC
-
+
EAS00769
CHECKING THE STARTER MOTOR
1. Check:
8 commutator
Dirt J Clean with 600-grit sandpaper.
2. Measure:
8 commutator diameter a
Out of specification 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)
Out of specification 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 at 20°C
Insulation resistance 2
Ω at 20°C
Above 1 MΩ
b. If any resistance is out of specification, replace the starter motor.
7-21 *****************************************************
ELECTRIC STARTING SYSTEM
ELEC
-
+
5. Measure:
8 brush length a
Out of specification 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
ELECTRIC STARTING SYSTEM
ELEC
-
+
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
8 brush spring 1
8 brush 2
8 armature coil
2
2
1
2. Install:
8 gasket 1
8 starter motor front bracket 2
8 starter motor rear bracket 3
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.
1
1
2
b
a
3 . Install:
8 O-ring New 1
8 washer
8 bolts 2
3.5 Nm (0.35 m • kg, 2.5 ft • lb)
2
1
T.
R.
7-23
Br
7
0
B
(RED)
G
B
(RED)
G
B
B
l
;
(GREEN)
L Br
B G
Br L
G B
(GREEN)
B
MOTOR
LW
RW
B
RW
RW
B
f j
k
START
OFF
START
y
x
(BLACK)
Dg L
B B
Y
(BLACK)
L Dg
B Ch
OFF
RUN
E/G STOP
u
c
a
BW
(BLACK)
Ch L
P
B
BrW
Dg
(BLACK)
L Ch
P BrW
B Dg
Y
OFF
PUSH
HORN SW
3
BW BW
Br LW
HI
LO
DIMMER SW
h
BW BW
LW Br
(BLUE)
Br
R
4
8
9
R
W B
R YR
B
R
10A
R
R
6
R
B
B
B
BW
R
B
B
R
L
(ILLUM) 12V3W
LW
TURN 12V3W
L
14V3W
B
Br
G
HI BEAM 12V3W
B
s
Y B
G
(BLACK)
z
P
TURN SIGNAL SW
L
N
R
YR
W
YR
B
5
Ch
Br
W
YR
2
B
Dg
d
B
B
(GREEN)
Dg
Ch
(BROWN)
b
Br
(GREEN)
(BLACK)
(BROWN)
B
Ch
v
B
BrW
p
(BLACK)
B
YR
(BLACK)
B
B
e
W
YR
YR
W
WR WL
BR GW
RW
BW
Dg
1
12V 10W
G
B
Ch
B
Dg
12V 10W
B
B
P
B
L
Y
Y
12V 60W/55W
G
G
BrW
WL
B
i
Sb GY
LW RW
WL
WR WR
BR
GW
BR
GW
WL WR
GW BR
Sb
LY
o
g
B
GY
L
(RED)
(RED)
L
Y
B
Br
GY
Br
GY
r
BW
Sb
LY
BW
B
Or
B
(BLACK)
B
(BLACK)
q
Or
Or
Sb
R
B
Br
Ch
LW
Sb
Br
GY
BrW
LY
LY
B
R
B
Br
Dg
Br
GY
MAIN
LOCK
OFF
ON
B
Or
B
B
t
w
Br
GY
m
n
(RED)
(RED)
-
B
Ch
12V 10W
B
Dg
12V 10W
B
BW
L
12V 27/8W
Br
GY
GY
Br
Y
Y
B
7-24
2
3
4
5
6
7
B
CHARGING SYSTEM
ELEC
+
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
C.D.I. magneto
Rectifier/Regulator
Battery
Main fuse
Battery (+) lead
Battery (-) lead
CHARGING SYSTEM
EAS00774
ELEC
-
+
EAS00739
TROUBLESHOOTING
2. Battery
8Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
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)
Minimum open-circuit voltage
12.8 V or more at 20°C
8Is the battery OK?
YES
NOTE:
8 Before troubleshooting, remove the following part(s):
1. Rear carrier
2. Side cover (right )
3. Cover
4. Battery cover
8 Troubleshoot with the following special
tool(s).
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 positive battery
terminal
Negative tester probe J negative battery
terminal
Engine tachometer
90890-03113 (YU-08036-C)
Pocket tester
90890-03132 (YU-03112-C)
DC20V
EAS00738
1. Main fuse
8Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in
chapter 3.
8Is the fuse OK?
YES
8Start the engine and let it run at approximately 5,000 r/min.
8Measure the charging voltage.
NO
Replace the fuse.
Charging voltage
14 V at 5000r/min
7-25
CHARGING SYSTEM
NO
YES
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.
Positive tester probe Jgreen/ white 1
Negative tester probe J black/red 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 at 20°C
8Is the stator coil OK?
YES
+
5. Wiring
8Check the entire charging system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8Is the charging system’s wiring properly
connected and without defects?
8Is the charging voltage within specification?
2
-
EAS00754
NOTE:
Make sure the battery is fully charged.
YES
ELEC
NO
Replace the stator coil assembly.
7-26
NO
Properly connect or repair
the charging system’s wiring.
R
Br
6
4
0
8
R
B
7
(RED)
G
B
(RED)
G
B
B
LW
RW
9
l
;
(GREEN)
L Br
B G
Br L
G B
(GREEN)
B
MOTOR
B
B
B
B
RW
RW
B
f j
k
START
OFF
START
y
x
(BLACK)
Dg L
B B
Y
(BLACK)
L Dg
B Ch
OFF
RUN
E/G STOP
u
c
a
BW
(BLACK)
Ch L
P
B
BrW
Dg
(BLACK)
3
BW BW
Br LW
HI
LO
DIMMER SW
h
BW BW
LW Br
(BLUE)
L Ch
P BrW
B Dg
Y
OFF
PUSH
HORN SW
R
W B
R YR
B
R
10A
R
R
R
B
B
R
L
14V3W
B
L
(ILLUM) 12V3W
s
Y B
G
(BLACK)
z
P
TURN SIGNAL SW
L
N
R
YR
W
YR
B
5
HI BEAM 12V3W
B
LW
TURN 12V3W
BW
BW
Ch
1
Dg
Br
G
G
B
Ch
12V 10W
B
Dg
12V 10W
Br
P
B
B
B
Br
W
YR
2
B
Dg
d
B
B
(GREEN)
Dg
Ch
(BROWN)
b
Br
(GREEN)
(BLACK)
(BROWN)
B
Ch
v
B
BrW
p
(BLACK)
B
YR
(BLACK)
B
B
e
W
YR
YR
W
WR WL
BR GW
WL
B
i
Sb GY
LW RW
WL
WR WR
BR
GW
BR
GW
WL WR
GW BR
Sb
LY
o
(RED)
(RED)
g
B
GY
L
Br
GY
L
Y
B
B
Or
t
w
(RED)
B
B
(RED)
Br
GY
C.D.I. magneto
Speedometer light
Dimmer switch
High beam indicator light
Fuel lever meter light
Headlight
Br
GY
r
BW
Sb
LY
BW
B
Or
B
(BLACK)
B
(BLACK)
q
Or
Or
Sb
R
B
Br
Ch
L
Y
Y
12V 60W/55W
G
G
BrW
RW
LY
LY
B
R
B
Br
Dg
LW
Sb
Br
GY
BrW
Br
GY
MAIN
LOCK
OFF
ON
m
n
-
B
Ch
12V 10W
B
Dg
12V 10W
B
BW
L
12V 27/8W
Br
GY
GY
Br
Y
Y
B
7-27
2
f
h
j
l
z
B
LIGHTING SYSTEM
ELEC
+
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
EAS00781
ELEC
-
+
EAS00739
TROUBLESHOOTING
2. Battery
8Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Any of the following fail to light: headlight,
high beam indicator light, fuel level meter
light or meter light.
Minimum open-circuit voltage
12.8 V or more at 20°C
Check:
1. main fuse
2. battery
3. main switch
4. dimmer switch
5. wiring connections
(of the entire lighting system)
8Is the battery OK?
`
YES
NO
8Clean the battery terminals.
8Recharge or replace the
battery.
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).
EAS00749
3. Main switch
8Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8Is the main switch OK?
YES
Pocket tester
90890-03132 (YU-03112-C)
NO
Replace the main switch.
EAS00738
EAS00784
1. Main fuse
8Check the fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
8Is the fuse OK?
4. Dimmer switch
8Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8Is the dimmer switch OK?
YES
YES
NO
NO
The dimmer switch is faulty.
Replace the left handlebar
switch.
Replace the fuse.
7-28
LIGHTING SYSTEM
EAS00787
ELEC
-
+
EAS00788
5. Wiring
8 Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8 Is the lighting system’s wiring properly
connected and without defects?
YES
Check the condition
of each of the lighting system’s circuits.
Refer to “CIRCUIT
DIAGRAM”.
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?
NO
Properly connect or
repair the lighting
system’s wiring.
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.
Refer to “CHECKING THE BULBS AND
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
LIGHTING SYSTEM
YES
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
Positive tester probe J green 1
Negative tester probe J black 2
Positive tester probe J yellow 3
Negative tester probe J black 4
1
3
2
G
Y
G
Y
B
Y
+
NO
EAS00754
4. Wiring
8 Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8 Is the lighting system’s wiring properly
connected and without defects?
4
B
Check the condition of each of the
lighting system’s
circuits.
Refer to “CIRCUIT
DIAGRAM”.
High beam indicator light
Positive tester probe J yellow 1
Negative tester probe J black 2
L Dg
B Ch
-
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.
YES
Dg L
Ch B
ELEC
1
2
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
NO
Properly connect or
repair the lighting
system’s wiring.
LIGHTING SYSTEM
EAS00789
ELEC
-
+
EAS00841
2. The meter light fails to come on.
1. Meter light bulb and socket
8 Check the meter light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
8 Are the meter light bulb and socket OK?
YES
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.
Replace the 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.
Positive tester probe J blue 1
J black 2
Negative tester probeJ
1
Dg L
Ch B
Y
L Dg
B Ch
2
8Set the main switch to “ON”.
8Measure the voltage (DC 12 V) of blue
1 on the meter light coupler (wire harness side).
8Is the voltage within specification?
YES
This circuit is OK.
NO
NO
The wiring circuit
from the main
switch to the meter
light coupler is faulty
and must be repaired.
Refer to “CIRCUIT
DIAGRAM”.
7-31
LIGHTING SYSTEM
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.
Positive tester probe J yellow/red 1
Negative tester probe J ground
1
Y/R
W
8 Measure the lighting coil resistance.
Lighting coil resistance
0.28 ~0.42 Ω at 20°C
(between yellow/red and ground)
8 Connect the pocket tester (Ω × 1)to the
lighting coil terminal as shown.
Positive tester probe J white 1
Negative tester probe J ground
Y/R
W 1
8 Measure the lighting coil resistance.
Lighting coil resistance
0.32 ~0.48 Ω at 20°C
(between white and ground)
8 Is the lighting coil OK?
YES
NO
Replace the lighting coil.
7-32
ELEC
-
+
R
R
10A
R
Br
6
R
0
8
R
B
R
7
(RED)
G
B
(RED)
G
B
B
LW
RW
9
l
;
(GREEN)
L Br
B G
Br L
G B
(GREEN)
B
MOTOR
B
B
4
R
B
B
B
B
RW
RW
B
f j
k
START
OFF
START
y
x
(BLACK)
Dg L
B B
Y
(BLACK)
L Dg
B Ch
OFF
RUN
E/G STOP
u
c
BW
(BLACK)
Ch L
P
B
(BLACK)
BrW
Dg
R
3
BW BW
Br LW
HI
LO
DIMMER SW
h
BW BW
LW Br
(BLUE)
L Ch
P BrW
B Dg
Y
OFF
PUSH
HORN SW
a
BW
W B
R YR
B
5
L
(ILLUM) 12V3W
LW
TURN 12V3W
L
14V3W
B
Br
G
HI BEAM 12V3W
B
s
Y B
G
(BLACK)
z
P
TURN SIGNAL SW
L
N
R
YR
W
WR WL
BR GW
Br
W
YR
2
B
Dg
d
B
B
(GREEN)
Dg
Ch
(BROWN)
b
Br
(GREEN)
(BLACK)
(BROWN)
B
Ch
v
B
BrW
p
(BLACK)
B
YR
(BLACK)
B
B
e
W
YR
YR
W
RW
BW
Ch
1
Dg
Br
P
B
B
B
YR
B
WL WR
GW BR
Or
B
(BLACK)
Or
B
(BLACK)
BR
GW
BR
GW
q
WL
B
i
Sb GY
LW RW
WL
WR WR
o
Sb
R
B
Br
Ch
L
Y
Y
12V 60W/55W
G
G
BrW
LW
Sb
Br
GY
BrW
LY
LY
Sb
LY
Or
g
B
GY
L
(RED)
(RED)
L
Y
B
Br
GY
r
BW
Sb
LY
BW
B
Br
GY
B
R
B
Br
12V 10W
G
B
Ch
B
Dg
12V 10W
Ch
12V 10W
B
Dg
12V 10W
B
Br
MAIN
LOCK
OFF
ON
Or
B
w
n
(RED)
B
B
t
(RED)
Br
GY
m
-
B
BW
L
12V 27/8W
Br
GY
GY
Y
B
7-33
GY
Y
Main switch
Battery
Main fuse
Battery (+) lead
Battery (-) lead
Wire lead
Front brake light switch
Rear brake light switch
Horn
Horn switch
Turn signal switch
Turn signal relay
Tail/brake light
Turn signal indicator light
Fuel level meter
Fuel sender
Front turn signal light(left)
Front turn signal light(right)
Rear turn signal light(left)
Rear turn signal light(right)
Dg
Br
1
4
5
6
7
8
r
t
p
a
s
d
g
k
l
;
x
c
v
b
B
SIGNALING SYSTEM
ELEC
+
EAS00793
SIGNALING SYSTEM
CIRCUIT DIAGRAM
SIGNALING SYSTEM
EAS00794
ELEC
-
+
EAS00739
TROUBLESHOOTING
2. Battery
8Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
8Any of the following fail to light: turn
signal light, brake light or an indicator light.
8The horn fails to sound.
Minimum open-circuit voltage
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
8Clean the battery
terminals.
8 Recharge or replace the battery.
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).
EAS00749
3. Main switch
8Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8Is the main switch OK?
YES
NO
Replace the main
switch.
Pocket tester
90890-03132 (YU-03112-C)
EAS00738
EAS00795
1. Main fuse
8Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
8Is the fuse OK?
YES
4. Wiring
8Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8Is the signaling system’s wiring properly
connected and without defects?
NO
YES
Replace the fuse.
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING
THE SIGNALING
SYSTEM”.
7-34
NO
Properly connect or
repair the signaling
system’s wiring.
SIGNALING SYSTEM
EAS00796
The horn fails to sound.
1. Horn switch
8 Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the horn switch OK?
YES
-
+
3. Horn
8Disconnect the pink connector at the
horn terminal.
8Connect a jumper lead 1 to the horn
terminal and ground the jumper lead.
8Set the main switch to “ON”.
8Push the horn switch.
8Does the horn sound?
CHECKING THE SIGNALING SYSTEM
1.
ELEC
Br
NO
P
Replace the left
handlebar switch.
1
2. Voltage
8Connect the pocket tester (DC 20 V) to
the horn connector at the horn terminal
as shown.
Positive tester probe Jbrown 1
Negative tester probe J ground
NO
YES
The horn is OK.
1
Br
P
4. Voltage
8Connect the pocket tester (DC 20 V) to
the horn connector at the pink terminal
as shown.
Positive tester probe J pink 1
Negative tester probe J ground
Br
8Set the main switch to “ON”.
8Push the horn switch.
8Measure the voltage (DC 12 V) of brown
at the horn terminal.
8Is the voltage within specification?
YES
P
1
NO
8Set the main switch to “ON”.
8Measure the voltage (DC 12 V) of pink
1 at the horn terminal.
8Is the voltage within specification?
The wiring circuit from the
main switch to the horn connector is faulty and must be
repaired.
Refer to “CIRCUIT DIAGRAM”.
YES
Repair or replace the
horn.
7-35
NO
Replace the horn.
SIGNALING SYSTEM
EAS00798
2.
1. Tail/brake light bulb and socket
8 Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
8 Are the tail/brake light bulb and socket
OK?
NO
B
Replace the tail/brake
light bulb, socket or
both.
2
The wiring circuit from
the main switch to the
tail/brake light bulb
connector is faulty
and must be repaired.
Refer to “CIRCUIT
DIAGRAM”.
+
Y
L
1
B
G/Y
L
8 Set the main switch to “ON”.
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?
2. Brake light switches
8 Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the brake light switch OK?
YES
-
3. Voltage
8 Connect the pocket tester (DC 20 V) to
the tail/brake light coupler (wire harness
side) as shown.
Positive tester probe J green/ yellow 1
Negative tester probe J black 2
The tail/brake light fails to come on.
YES
ELEC
YES
NO
This circuit is OK.
Replace the brake
light switch.
7-36
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
Refer to “CIRCUIT
DIAGRAM”.
SIGNALING SYSTEM
EAS00799
1. Turn signal light and turn signal indicator
light bulbs and sockets
8 Check the turn signal light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
8 Check the turn signal indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
8 Are the turn signal light bulb and socket
OK?
+
B Br/W Br
1
8Set the main switch to “ON”.
8Measure the voltage (DC 12 V) on brown
1 at the turn signal relay coupler (wire
harness side).
8Is the voltage within specification?
NO
Replace the turn
signal light and/or
turn signal indicator
light bulb, socket or
both.
YES
NO
The wiring circuit from
the main switch to the
turn signal relay coupler
is faultyand must be repaired.
Refer to “CIRCUIT DIAGRAM”.
2. Turn signal switch
8Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8Is the turn signal switch OK?
YES
-
3. Voltage
8Connect the pocket tester (DC 20 V) to
the turn signal relay coupler (wire harness side) as shown.
Positive tester probe J brown 1
Negative tester probe J ground
3. The turn signal light, turn signal indicator
light or both fail to blink.
YES
ELEC
NO
Replace the left
handlebar switch.
7-37
SIGNALING SYSTEM
4. Voltage
8Connect the pocket tester (DC 20 V) to
the turn signal relay coupler (wire harness side) as shown.
J brown/white 1
Positive tester probeJ
Negative tester probe J ground
-
+
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
Positive tester probe J chocolate 1
Negative tester probe J ground
Right turn signal light
Positive tester probe J dark green 2
Negative tester probe J ground
B Br/W Br
1
8Set the main switch to “ON”.
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).
8Is the voltage within specification?
YES
ELEC
Ch B
Dg B
Ch B
Dg B
1
2
8Set the main switch to “ON”.
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).
8Is the voltage within specification?
NO
The turn signal relay is
faulty and must be replaced.
YES
This circuit is OK.
7-38
NO
The wiring circuit
from the turn signal
switch to the turn
signal light connector is faulty and must
be repaired.
SIGNALING SYSTEM
EAS00804
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.
Positive tester probe J green 1
Negative tester probe J black 2
1
L
B
1
G
B
(E)
Br
G
Br
G
L
B
2
8 Set the main switch to “ON”.
8 Measure the voltage (DC 12 V) of brown
1 on the meter light coupler (wire harness side).
8 Is the voltage within specification?
2
8 Measure the fuel sender resistances.
YES
Fuel sender resistance (up position
Ω × 1)
F)(Ω
Ω at 20°C
4~10Ω
Fuel sender resistance (down poΩ × 10)
sition E)(Ω
90~100 Ω at 20°C
NO
Check the wiring connections of the entire signaling system.
Refer to “CIRCUIT DIAGRAM”.
8Is the fuel sender OK?
YES
+
2. Voltage
8 Connect the pocket tester (DC 20 V) to
the meter light coupler (wire harness
side) as shown.
Positive tester probe J brown 1
Negative tester probe J black 2
4. The fuel level meter fails to operate.
(F)
-
ELEC
NO
Replace the fuel sender.
7-39
SIGNALING SYSTEM
3. Fuel level meter
8 Set the main switch to “ON”.
8 Move the float up 1 or down 2.
1
2
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
This circuit is OK.
4.
NO
Replace the fuel
level meter.
Wiring
8 Check the entire signaling system’s
wiring
7-40
ELEC
-
+
B
R
0
R
Br
7
(RED)
G
B
(RED)
G
B
B
LW
RW
9
l
;
(GREEN)
L Br
B G
Br L
G B
(GREEN)
B
MOTOR
B
B
4
8
R
B
B
B
B
RW
RW
B
f j
k
START
OFF
START
y
x
(BLACK)
Dg L
B B
Y
(BLACK)
L Dg
B Ch
OFF
RUN
E/G STOP
u
c
a
BW
(BLACK)
Ch L
P
B
BrW
Dg
(BLACK)
L Ch
P BrW
B Dg
Y
OFF
PUSH
HORN SW
R
3
BW BW
Br LW
HI
LO
DIMMER SW
h
BW BW
LW Br
(BLUE)
Br
R
10A
R
R
R
6
L
14V3W
B
L
(ILLUM) 12V3W
W B
R YR
B
5
HI BEAM 12V3W
B
LW
TURN 12V3W
BW
BW
Ch
1
Dg
s
Y B
G
(BLACK)
z
P
TURN SIGNAL SW
L
N
R
YR
W
YR
B
R
B
Br
B
P
B
L
Y
Y
B
12V 60W/55W
G
G
BrW
Br
W
YR
2
B
Dg
d
B
B
(GREEN)
Dg
Ch
(BROWN)
b
Br
(GREEN)
(BLACK)
(BROWN)
B
Ch
v
B
BrW
p
(BLACK)
B
YR
(BLACK)
B
B
e
W
YR
YR
W
WR WL
BR GW
RW
R
B
Br
Ch
LW
Sb
GY
Br
WL
i
Sb GY
LW RW
WL
WR WR
BR
GW
BR
GW
WL WR
GW BR
q
Sb
LY
o
BW
Sb
LY
BW
B
Or
Or
B
(BLACK)
Or
B
(BLACK)
LY
LY
B
MAIN
LOCK
OFF
ON
Dg
BW
B
L
12V 27/8W
Br
G
G
B
Ch
12V 10W
B
Dg
12V 10W
B
Ch
12V 10W
B
Dg
12V 10W
B
BrW
Sb
Br
GY
r
g
B
GY
L
(RED)
(RED)
L
Y
B
Br
GY
Br
GY
Main switch
Battery
Main fuse
Battery (+) lead
Battery (-) lead
Wire lead
Thermo switch
Carburetor heater
GY
Br
GY
B
Or
(RED)
B
B
t
w
(RED)
Br
GY
Br
Y
Y
B
7-41
1
4
5
6
7
8
n
m
B
m
n
CRABURETOR HEATING SYSTEM
ELEC
+
EAS00820
CARBURETOR HEATING SYSTEM
CIRCUIT DIAGRAM
CRABURETOR HEATING SYSTEM
EAS00821
ELEC
-
+
EAS00739
TROUBLESHOOTING
2. Battery
8Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
The carburetor heating system fails to
operate.
Check:
1. Main fuse
2. Battery
3. Main switch
4. Thermo switch
5. Carburetor heater
6. Wiring connections
(of the entire carburetor heating system)
Minimum open-circuit voltage
12.8 V or more at 20°C
8Is the battery OK?
YES
NO
8Clean the battery terminals.
8Recharge or replace the
battery.
NOTE:
8 Before troubleshooting, remove the following part(s):
1. Head light cover
2. Front turn signal light bracket
3. Leg shield 1
4. Cover
5. Battery cover
6. Footrest board side cover mole(right)
8 Troubleshoot with the following special
tool(s).
EAS00749
3. Main switch
8Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8Is the main switch OK?
YES
Pocket tester
90890-03132 (YU-03112-C)
NO
Replace the main switch.
EAS00738
1. Main fuse
8Check the fuse for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
8Is the fuse OK?
YES
NO
Replace the fuse.
7-42
CRABURETOR HEATING SYSTEM
EAS00823
-
ELEC
+
A The coolant temperature sensor circuit is
closed.
B The coolant temperature sensor circuit is
open.
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.
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.
Test step C o o l a n t
temperature
1
0 ~11 ± 3 °C
2
More than16 ± 3 °C
3*
16 ± 3 ~ 11±3 °C
4*
Less than11 ± 3 °C
11 ± 3˚C
B
8 Does the thermo switch operate properly?
Continuity
YES
YES
NO
NO
YES
NO
Replace the thermo
switch.
EAS00824
5. Carburetor heater
8Remove the carburetor heating element
from the carburetor.
8Connect the pocket tester to the carburetor heating element as shown.
Positive tester probe J heating element 1
Negative tester probe J heating element
body 2
8Measure the carburetor heater resistance.
Steps 1 & 2: Heating phase
Steps 3 & 4: Cooling phase
3
16 ± 3˚C
A
1
2
w
1
8 Handle the thermo switch with special
care.
8 Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
2
Carburetor heating element resistance
30 Ω at 20°C
8Is the carburetor heating element OK?
YES
NO
Replace the carburetor
heating element.
7-43
CRABURETOR HEATING SYSTEM
EAS00826
6. Wiring
8 Check the entire carburetor heating
system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
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
ELEC
-
+
R
Br
6
4
0
8
R
B
7
(RED)
G
B
(RED)
G
B
B
LW
RW
9
l
;
(GREEN)
L Br
B G
Br L
G B
(GREEN)
B
MOTOR
B
B
B
B
RW
RW
B
f j
k
START
OFF
START
y
x
(BLACK)
Dg L
B B
Y
(BLACK)
L Dg
B Ch
OFF
RUN
E/G STOP
u
c
a
BW
(BLACK)
Ch L
P
B
BrW
Dg
(BLACK)
3
BW BW
Br LW
HI
LO
DIMMER SW
h
BW BW
LW Br
(BLUE)
L Ch
P BrW
B Dg
Y
OFF
PUSH
HORN SW
R
W B
R YR
B
R
10A
R
R
R
B
B
R
L
(ILLUM) 12V3W
LW
TURN 12V3W
L
14V3W
B
Br
G
HI BEAM 12V3W
B
s
Y B
G
(BLACK)
z
P
TURN SIGNAL SW
L
N
R
YR
W
YR
B
5
Ch
BW
BW
Dg
1
12V 10W
G
B
Ch
B
Dg
12V 10W
Br
P
B
B
B
Br
W
YR
2
B
Dg
d
B
B
(GREEN)
Dg
Ch
(BROWN)
b
Br
(GREEN)
(BLACK)
(BROWN)
B
Ch
v
B
BrW
p
(BLACK)
B
YR
(BLACK)
B
B
e
W
YR
YR
W
WR WL
BR GW
WL
B
i
Sb GY
LW RW
WL
WR WR
BR
GW
BR
GW
WL WR
GW BR
Sb
LY
o
g
B
GY
L
(RED)
(RED)
L
Y
B
Br
GY
Br
GY
r
BW
Sb
LY
BW
B
Or
B
(BLACK)
B
(BLACK)
q
Or
Or
Sb
R
B
Br
Ch
L
Y
Y
12V 60W/55W
G
G
BrW
RW
R
B
Br
Dg
LW
Sb
Br
GY
BrW
LY
LY
B
MAIN
LOCK
OFF
ON
B
Or
(RED)
B
B
t
w
2 C.D.I. magneto
e Auto choke unit
(RED)
Br
GY
m
n
-
B
Ch
12V 10W
B
Dg
12V 10W
B
BW
L
12V 27/8W
Br
GY
GY
Br
GY
Br
Y
Y
B
7-45
B
AUTO CHOKE SYSTEM
ELEC
+
AUTO CHOKE SYSTEM
CIRCUIT DIAGRAM
AUTO CHOKE SYSTEM
ELEC
-
+
EAS00748
TROUBLESHOOTING
1. 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.
Positive tester probe J yellow/red 1
Negative tester probe J ground
The auto choke system fails to operate.
Check:
1. Lighting coil resistance
2. Auto choke unit resistance
3. Wiring connections
(of the entire auto choke system)
NOTE:
8 Before troubleshooting, remove the following part(s):
1. Cover
2. Rear carrier
3. Side cover (right )
Troubleshoot with the following special
tool(s).
1
Y/R
W
8 Measure the lighting coil resistance.
Lighting coil resistance
0.28 ~0.42 Ω at 20°C
(between yellow/red and ground)
Pocket tester
90890-03132 (YU-03112-C)
8 Connect the pocket tester (Ω × 1)to the
lighting coil terminal as shown.
Positive tester probe J white 1
Negative tester probe J ground
Y/R
W 1
8 Measure the lighting coil resistance.
Lighting coil resistance
0.32 ~0.48 Ω at 20°C
(between white and ground)
8 Is the lighting coil OK?
YES
NO
Replace the lighting coil.
7-46
AUTO CHOKE SYSTEM
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.
Positive tester probe Jblack 1
Negative tester probe Jblack 2
B B
8Measure the auto choke unit resistance.
Auto choke unit resistance
30 Ω at 20°C
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.
Refer to “CIRCUIT DIAGRAM”.
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
ELEC
-
+
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
ELECTRICAL SYSTEMS .................................................................. 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
ELECTRICAL SYSTEMS .................................................................. 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
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
Piston and piston ring
8Improperly installed piston ring
8Damaged, worn or fatigued piston ring
8Seized piston ring
8Seized or damaged piston
Auto choke unit
8Faulty starter plunger
8Faulty thermo switch
Air filter
8Improperly installed air filter
8Clogged air filter element
ELECTRICAL SYSTEMS
Battery
8Discharged battery
8Faulty battery
Crankcase and crankshaft
8Improperly assembled crankcase
8Seized crankshaft
Fuse
8Blown, damaged or incorrect fuse
8Improperly installed fuse
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
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
Fuel cock
8Clogged or damaged fuel hose
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
EAS00846
Ignition system
8Faulty C.D.I unit
8Faulty pickup coil
8Broken magneto rotor woodruff key
INCORRECT ENGINE IDLING
SPEED
ENGINE
Cylinder and cylinder head
8Incorrect valve clearance
8Damaged valve train components
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
Air filter
8Clogged air filter element
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
Starting system
8Faulty starter motor
8Faulty starter relay
8Faulty starting circuit cut-off relay
8Faulty starter clutch
ELECTRICAL SYSTEMS
Battery
8Discharged battery
8Faulty battery
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
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
EAS00849
EAS00853
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
FAULTY CLUTCH
TRBL
SHTG
Refer to “STARTING FAILURES”.
ENGINE OPERATES BUT SCOOTER WILL
NOT MOVE
ENGINE
Air filter
8Clogged air filter element
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
8Incorrect fuel level
8Loose or clogged main jet
8Faulty accelerating pump
Transmission gears
8Damaged transmission gear
CLUTCH SLIPS
Clutch shoe springs
8Damaged, loose or worn clutch shoe
spring
Fuel cock
8Faulty fuel cock
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
Primary sliding sheave
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
EAS00859
POOR SPEED PERFORMANCE
V-belt
8Oil or grease on the V-belt
POOR BRAKING PERFORMANCE
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
Primary pulley weight(s)
8Faulty operation
8Worn primary pulley weight
Primary fixed sheave
8Worn primary fixed sheave
Primary sliding sheave
8Worn primary sliding sheave
Secondary fixed sheave
8Worn secondary fixed sheave
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
Secondary sliding sheave
8Worn secondary sliding sheave
EAS00854
OVERHEATING
ENGINE
Cylinder head and piston
8Heavy carbon buildup
EAS00860
FAULTY FRONT FORK LEGS
Engine oil
8Incorrect oil level
8Incorrect oil viscosity
8Inferior oil quality
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
FUEL SYSTEM
Carburetor
8Incorrect main jet setting
8Incorrect fuel level
8Damaged or loose carburetor joint
Air filter
8Clogged air filter element
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
CHASSIS
Brakes
8Dragging brake
ELECTRICAL SYSTEMS
Spark plug
8Incorrect spark plug gap
8Incorrect spark plug heat range
Ignition system
8Faulty C.D.I. unit
8-4
UNSTABLE HANDLING/
FAULTY LIGHTING OR SIGNALING SYSTEM
EAS00862
TRBL
SHTG
EAS00866
UNSTABLE HANDLING
FAULTY LIGHTING OR SIGNALING
SYSTEM
Handlebar
8Bent or improperly installed handlebar
HEADLIGHT DOES NOT COME ON
8Wrong headlight bulb
8Too many electrical accessories
8Hard charging
8Incorrect connection
8Improperly grounded circuit
8Poor contacts (main or light switch)
8Burnt-out headlight bulb
Steering head components
8Improperly installed upper bracket
8Improperly installed lower bracket
(improperly tightened ring nut)
8Bent steering stem
8Damaged ball bearing or bearing race
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
8Improperly grounded circuit
8Faulty main switch
8Headlight bulb life expired
Rear shock absorber assembly
8Faulty rear shock absorber spring
8Leaking oil
TAIL/BRAKE LIGHT DOES NOT COME ON
8Wrong tail/brake light bulb
8Too many electrical accessories
8Incorrect connection
8Burnt-out tail/brake light bulb
Tire(s)
8Uneven tire pressures (front and rear)
8Incorrect tire pressure
8Uneven tire wear
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
TURN SIGNAL DOES NOT COME ON
8Faulty turn signal switch
8Faulty turn signal relay
8Burnt-out turn signal bulb
8Incorrect connection
8Damaged or faulty wire harness
8Improperly grounded circuit
8Faulty battery
8Blown, damaged or incorrect fuse
Frame
8Bent frame
8Damaged steering head pipe
8Improperly installed bearing race
TURN SIGNAL BLINKS SLOWLY
8Faulty turn signal relay
8Faulty main switch
8Faulty turn signal switch
8Incorrect turn signal bulb
8Faulty battery
8-5
FAULTY LIGHTING OR SIGNALING SYSTEM
TURN SIGNAL REMAINS LIT
8Faulty turn signal relay
8Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY
8Incorrect turn signal bulb
8Faulty turn signal relay
8Burnt-out turn signal bulb
HORN DOES NOT SOUND
8Improperly adjusted horn
8Damaged or faulty horn
8Faulty main switch
8Faulty horn switch
8Faulty battery
8Blown, damaged or incorrect fuse
8Faulty wire harness
8-6
TRBL
SHTG
YAMAHA MOTOR TAIWAN CO., LTD