Yamaha MBK YQ100 Service manual

YQ100
'00
5ME1-AE1
SERVICE
MANUAL
YQ100
SERVICE MANUAL
© 2000 by MBK INDUSTRIE
1st Edition, February 2000
All rights reserved. Any
reprinting or unauthorized use
without the written
permission of MBK INDUSTRIE
is expressly prohibited.
NOTICE
This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealers
and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and
MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in
scooter repair technology. Without such knowledge, attempted repairs or service to this model may
render it unfit to use and/or unsafe.
MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and
significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and
MBK dealers and will, where applicable, appear in future editions of this manual.
DOCUMENTATION TECHNIQUE
MBK INDUSTRIE
PARTICULARY IMPORTANT INFORMATION
This material is distinguished by the following notation :
The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or
death to the scooter operator, a bystander, or a person inspecting or
repairing the scooter.
A CAUTION indicates special precautions that must be taken to avoid
damage to the scooter.
A NOTE provides key information to make procedures easier or clearer.
EAS00007
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.
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".
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.
Sub-section titles appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates
a disassembly step.
Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS".
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
Jobs requiring more information (such as special tools and technical data) are described
sequentially.
CDI MAGNETO
ENG
CDI MAGNETO
CDI MAGNETO, ROTOR, STATOR
NOTE:
It is not necessary to remove the engine for
removing the CDI magneto
T.R
ENG
REMOVAL
CDI MAGNETO
1.Remove:
• Nut (rotor)
• Plate washer
37 Nm (3.7 m.kg)
NOTE:
Hold the rotor using flywheel holder to
loosen the nut
3
Flywheel holder:
90890-01235
4
5
6.5 Nm (0.65 m.kg)
LS
T.R
2.Remove:
• Rotor
• Woodruff key
Use the flywheel puller.
9
7
Flywheel puller:
90890-01189
8
• Stator assembly
• Gasket
1
2
Order
T.R
Job name/Part name
Q'ty
Fan cover
Fan
Nut
Washer
Magneto rotor
Woodruff key
Stator assembly
Gasket
Oil seal
INSTALLATION
1.Install:
• Gasket
Remarks
Remove the parts in the order below
CDI magneto, Rotor, Startor removal
Seat cover
Side covers
Footrest board
1
2
3
4
5
6
7
8
9
8.5 Nm (0.85 m.kg)
Refer to "COVERS" in Chapter 3.
2.Apply
• Lithium soap base grease
(to oil seal )
LS
1
1
1
1
1
1
1
1
1
3.Pass the CDI magneto lead through the
crankcase
Refer to "CDI MAGNETO REMOVAL"
section.
For installation, reverse the removal procedure
4 - 27
4 - 28
EAS00009
W
Q
GEN
INFO
SYMBOLS
SPEC
E
The following symbols are not relevant to every
vehicle.
R
INSP
ADJ
Symbols Q to I indicate the subject of each
chapter.
ENG
T
Q
W
E
R
T
Y
U
I
Y
CARB
CHAS
U
I
TRBL
SHTG
ELEC
O
Symbols O to r indicate the following.
P
{
}
q
w
O
P
{
}
q
w
e
r
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols t to p in the exploded diagrams
indicate the types of lubricants and lubrication
points.
T.
R
e
General information
Specifications
Periodic checks and adjustments
Engine
Carburetor
Chassis
Electrical system
Troubleshooting
r
t
y
u
t
y
u
i
o
p
i
o
p
Symbols [ to ] in the exploded diagrams
indicate the following.
B
[
LS
M
]
Engine oil
Gear oil
Molybdenum disulfide oil
Wheel bearing grease
Lithium soap base grease
Molybdenum disulfide grease
[ Apply locking agent (LOCTITE®)
] Replace the part
EAS00011
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
ENGINE
CARBURETOR
CHASSIS
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO
1
SPEC
2
INSP
ADJ
3
ENG
4
CARB
5
CHAS
6
ELEC
7
TRBL
SHTG
8
GEN
INFO
1
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
SCOOTER IDENTIFICATION ........................................................................ 1-1
VEHICULE IDENTIFICATION NUMBER ................................................. 1-1
ENGINE NUMBER ................................................................................... 1-1
IMPORTANT INFORMATION ...................................................................... 1-3
PREPARATION FOR REMOVAL AND DISASSEMBLY ........................ 1-3
REPLACEMENT PARTS ......................................................................... 1-3
GASKETS, OIL SEALS, AND O-RINGS ................................................. 1-3
LOCK WASHERS/PLATES AND COTTER PINS .................................... 1-4
BEARINGS AND OIL SEALS ................................................................... 1-4
CIRCLIPS ................................................................................................. 1-4
CHECKING THE CONNECTIONS ................................................................ 1-5
HOW TO USE THE CONVERSION TABLE .................................................. 1-6
SPECIAL TOOLS .......................................................................................... 1-7
GENERAL INFORMATION
GEN
INFO
EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped
on the bottom of the frame as shown.
NOTE:
The vehicle identification number is used to
identify your scooter and may be used to register
your scooter with the licensing authority in your
state.
ENGINE NUMBER
The engine serial number is stamped on the
crankcase as shown.
NOTE:
Designs and specifications are subject to change
without notice.
112
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
1.Use only genuine Yamaha/MBK parts for all
replacements. Use oil and grease
recommended by Yamaha/MBK 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
1.After removal, replace all lock washers / plates
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
1.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 base
grease. Oil bearings liberally when installing,
if appropriate.
Bearing
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing
surfaces.
Oil seal
EAS00025
CIRCLIPS
1.Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip , make sure the
sharp-edged corner is positioned opposite
the thrust that the circlip receives.
Shaft
1-3
CHECKING THE CONNECTIONS
GEN
INFO
EAS00026
2.Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several
times.
3.Check:
• all connections
Loose connection → Connect properly.
NOTE:
If the pin on the terminal is flattened, bend it
up.
4.Connect:
• lead
• coupler
• connector
NOTE:
Make sure all connections are tight.
5.Check:
• continuity
(with the pocket tester)
+
-
Pocket tester
90890-03112
NOTE:
If there is no continuity, clean the terminals.
NOTE:
When checking the wire harness, perform steps
1 to 3.
+
-
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1.Disconnect:
• lead • coupler • connector NOTE:
As a quick remedy, use a contact revitalizer
available at most part stores.
1-4
HOW TO USE THE CONVERSION TABLE
GEN
INFO
HOW TO USE THE CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex:
METRIC
MULTIPLIER
IMPERERIAL
** mm
x
0.03937
=
** in
2 mm
x
0.03937
=
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Torque
Weight
Speed
Distance
Volume/
Capacity
Miscellaneous
Metric unit
m·kg
m·kg
cm·kg
cm·kg
kg
g
km/h
km
m
m
cm
mm
cc (cm3)
cc (cm3)
lit (litre)
lit (litre)
kg/mm
kg/cm2
Centrigrade
Multiplier
7.233
86.794
0.0723
0.8679
2.205
0.03527
0.6214
0.6214
3.281
1.094
0.3937
0.03937
0.03527
0.061102
0.8799
0.2199
55.997
14.2234
9/5(°C)+32
1-5
Imperial unit
ft.lb
in.lb
ft.lb
in.lb
lb
oz
mph
mi
ft
yd
in
in
oz(IMP liq.)
cu.in
qt(IMP liq.)
gal(IMP liq.)
lb/in
psi(lb/in2)
Fahrenheit(°F)
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 N°
90890-01135
Tool name/usage
Illustration
Crankcase separating tool
This tool is used to separate the crankcase and remove the crankshaft.
90890-01189
Flywheel puller
This tool is used to remove the flywheel
magneto.
90890-01235
Rotor holding tool
This tool is used to remove the flywheel
magneto.
90890-01274
90890-01275
90890-01277
90890-01288
90890-01384
Crankshaft installer pot Crankshaft installer bolt Adapter Spacer These tools are used to install the crankshaft.
Oil seal guide
This tool is used to protect the oil seal lip
when installing the secondary sheave.
90890-01348
Locknut wrench
This tool is used when removing or
installing the secondary sheave nut.
90890-01701
Sheave holder
This tool is used to hold the secondary
sheave when removing or installing the
nut.
90890-03079
Thickness gauge
This tool is used to measure the clearance.
1-6
SPECIAL TOOLS
Tool N°
90890-01337
Tool name/usage
GEN
INFO
Illustration
Clutch spring holder.
This tool is used for compressing the
spring of the secondary sheave when
removing the nut.
90890-01409
90890-01410
Oil seal guide Oil seal installer .
This tool is used to install the left side
crankcase oil seal.
90890-01268
90890-01403
Ring nut wrench Steering nut wrench These tools are used to loosen and tighten
the steering ring nuts.
90890-01367
90890-01400
Fork seal driver weight .
Fork seal driver attachment (ø30) These tools are used when installing the
fork seals.
90890-03112
Pocket Tester
This instrument is invaluable for checking
the electrical system.
90890-03113
Engine tachometer.
This tool is needed for detecting the
engine rpm.
90890-06754
Ignition checker.
This instrument is necessary for checking
the ignition system components.
90890-01294 90890-01326 Damper rod holder.
T-handle.
This tools are used when removing the
front fork legs.
1-7
SPEC
2
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ...................................................................... 2-1
MAINTENANCE SPECIFICATIONS ............................................................. 2-4
ENGINE ................................................................................................... 2-4
TIGHTENING TORQUES (ENGINE) ....................................................... 2-7
CHASSIS ................................................................................................. 2-9
TIGHTENING TORQUES (CHASSIS) ................................................... 2-11
ELECTRICAL .........................................................................................2-13
GENERAL TORQUE SPECIFICATIONS ................................................... 2-15
LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-16
ENGINE ................................................................................................. 2-16
CHASSIS ............................................................................................... 2-17
CABLE ROUTING ....................................................................................... 2-18
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
YQ100
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
1,762 mm
690 mm
1,151 mm
812 mm
1,272 mm
157 mm
1,800 mm
Basic weight:
With oil and full fuel tank
95 kg
Engine:
Type
Cylinder arrangement
Displacement
Bore x stroke
Compression ratio
Starting system
Air-cooled-2 stroke, gasoline torque induction.
Forward- inclined single cylinder
101 cm3
52.0 x 47.6 mm
12:1 ± 0.5
Electrical and Kick starter
Lubrication system:
Separate lubrification
Oil type or grade:
Engine oil:
Transmission oil
Oil capacity:
Engine oil:
Transmission oil:
Periodic oil change
Total amount
Air filter:
Fuel:
Type
Tank capacity:
Carburetor:
Type/quantity
Manufacturer
Yamalube 2 or 2 stroke engine oil (JASO FC
grade or ISO EG-C, ISO EG-D grade).
SAE 85W140 type SE
1.3 L
0.11 L
0.13 L
Wet type element
Regular unleaded gasoline with a research
octane number of 91 or higher.
7.0 L
TK ø 16
TEIKEI
2-1
GENERAL SPECIFICATIONS
Model
YQ100
Spark plug:
Type
Manufacturer
Gap
BR8HS
NGK
0.5 ~ 0.7 mm
Clutch type:
Dry, centrifugal automatic
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission
Operation
Helical gear
47 / 15 (3.133)
Spur gear
43 / 13 (3.308)
V-belt
Automatic
Chassis:
Frame type
Caster angle
Trail
Steel tube backbone
27°
89.4 mm
Tires:
Type
Size
Manufacturer (Type)
Wear limit (Front/Rear)
Tires pressure (Cold tire):
Front (single riding)
Rear (single riding)
Front (dual riding)
Rear (dual riding)
Brakes:
Front brake type
Operation
Rear brake type
Operation
SPEC
Front
Rear
Tubeless
130 / 60 -13
140 / 60 -13
MICHELIN(BOPPER) / PIRELLI (SL 36)
0.8 mm
150 kPa (1.50 Kg/cm2, 1.50 bar)
150 kPa (1.50 Kg/cm2, 1.50 bar)
150 kPa (1.50 Kg/cm2, 1.50 bar)
150 kPa (1.50 Kg/cm2, 1.50 bar)
Disk brake
Right hand operation
Drum brake
Left hand operation
Suspension:
Front
Rear
Telescopic fork
Unit swing
Shock absorber:
Front
Rear
Coil spring/ Oil damper
Coil spring/ Oil damper
2-2
GENERAL SPECIFICATIONS
Model
YQ100
Wheel travel:
Front
Rear
80 mm
72 mm
Electrical:
Ignition system
Charging system
Battery type/model
Battery capacity
CDI
Flywheel magneto
YT4L-BS
12V 3AH
Headlight type:
Bulb
Bulb wattage x quantity:
Headlight
Position light
License light
Taillight / brake light
Flasher light
Meter light
Warning lights wattage/quantity:
"OIL"
"TURN"
"HIGH BEAM"
SPEC
Front
Rear
12V 35W/35W x 1
12V 5W x 1
12V 5W x 1
12V 5W /21W x 1
12V 10W x 2
12V 10W x 2
12V 1.2W x 2
12V 1.2W x 1
12V 1.2W x 1
12V 1.2W x 1
2-3
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Model
Cylinder head:
Warp limit
Standard
Limit
***
* Lines indicate straight edge
measurements.
0.02 mm
52.002 ~ 52.012 mm
***
***
0.05 mm
0.044 ~ 0.045
0.10 mm
51.958 ~ 51.967 mm
***
10 mm
***
52.52 mm
52.50 mm
***
***
1.2 x 2.05 mm/keystone
1.2 x 2.05 mm/keystone
***
***
0.15 ~ 0.35 mm
0.15 ~ 0.35 mm
***
***
0.03 ~ 0.05 mm
0.03 ~ 0.05 mm
***
***
13.996 ~ 14.000 mm
14.004 ~ 14.015 mm
13.975 mm
14.045 mm
Cylinder:
Bore size
Taper
Piston:
Piston clearance
Piston size
Measuring point*
Oversize:
1st
2nd
Piston rings:
Sectional sketch (BxT)/Type:
Top ring
2nd ring
T
End gap (Installed):
Top ring
2nd ring
Side clearance (Installed):
Top ring
2nd ring
B
Piston pin:
Outside diameter
Piston pin to piston clearance
2-4
MAINTENANCE SPECIFICATIONS
Model
SPEC
Standard
Limit
37.90 ~ 37.95 mm
***
79.9 ~ 80.1 mm
0.2 ~ 0.5 mm
0.4 ~0.8 mm
***
0.03 mm
4.0 mm
26.2 mm
112 mm
2800 ~ 3400 r/min
4500 ~ 5500 r/min
2.5 mm
***
112.5 mm
***
***
17.7 mm
16.0 mm
Transmission:
Main axle runout limit
Drive axle runout limit
***
***
0.08 mm
0.08 mm
Kick starter:
Type
Kick clip tension force
Ratchet type
0.15 ~ 0.25 kg
***
***
Carburetor:
I.D. mark
Main jet (M.J.)
Main air jet (M.A.J.)
Jet needle (J.N.)
Needle jet (N.J.)
Cutaway (C.A.)
Pilot jet (P.J.)
Bypass 1 (B.P.1)
Air screw (A.S.)
Valve seat size (V.S.)
Starter jet (G.S.1)
Engine idle speed
TEIKEI
TK ø16
# 76
***
# 3SOF-3/5
ø2.090
3.0
# 44
ø 0.80
1 5/8
ø 1.80
43
2000 ± 200 r/min
Crankshaft:
Crank width “A”
Runout limit “C”
Connecting rod length
Side clearance “D”
Small End Free Play
Automatic centrifugal clutch:
Clutch shoe thickness
Clutch shoe spring free length
Clutch housing inside diameter
Clutch-in revolution
Clutch-stall revolution
V-belt:
Width
2-5
***
***
***
***
***
***
***
***
***
***
***
***
***
MAINTENANCE SPECIFICATIONS
Model
SPEC
Standard
Limit
Reed valve:
Valve stopper height
Reed Valve Clearance
6.0 ~ 6.4 mm
Less than 0.2 mm
***
***
Lubrication System
Autolub Pump
Plunger diameter
Autolub pump stroke/ Manufacturer
Minimum output at 3000rpm
Maximum output at 3000rpm
2.5 mm
PLB-D39 / Dell'orto
4.5 cc/h
16 cc/h
***
2-6
***
***
MAINTENANCE SPECIFICATIONS
SPEC
TIGHTENING TORQUES
ENGINE
Part to be tightened
Spark plug
Part
name
Thread
size
Q'ty
Tightening
torque
Nm
m.kg
-
M14
1
20
2.0
Nut
M7
4
14
1.4
stud bolt
M7
4
17
1.7
Air shroud (3)
Screw
M6
3
7
0.7
Fan
Screw
M6
3
7
0.7
Air shroud (1x3)
Screw
M6
1
2
0.2
Oil pump assembly
Screw
M5
2
4
0.4
Bolt
M6
4
11
1.1
Air filter
Screw
M6
1
8.5
0.85
Air duct
Screw
M6
2
6.5
0.65
Exaust pipe/engine
Screw
M8
2
29
2.9
Exhaust pipe / Cylinder
Bolt
M6
2
8.5
0.85
Muffler protector
Bolt
M6
3
9
0.9
Cap and pipe
Bolt
M6
3
11
1.1
Exhaust Cover
Bolt
M6
3
13
1.3
Crankcase 1x2
Bolt
M6
6
12
1.2
Holder
Bolt
M6
1
7
0.7
Crankcase cover (right cover)
Bolt
M6
6
12
1.2
Crankcase cover (left cover)
Bolt
M6
12
12
1.2
Drain bolt
Bolt
M8
1
18
1.8
Plug oil
Plug oil
M14
1
3
0.3
Idle gear plate
Screw
M6
2
8
0.8
Self starting motor
Bolt
M6
2
13
1.3
Cluth housing
Nut
M10
2
40
4.0
Base magneto
Screw
M6
2
8
0.8
C.D.I. rotor
Nut
M10
1
43
4.3
Primary sheave
Nut
M12
1
45
4.5
Kick crank
Bolt
M6
1
13
1.3
Head cylinder
Cylinder
Reed valve
2-7
Remarks
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Model
Steering system:
Steering bearing type
Size of steel balls x qty:
Upper
Lower
Lock to lock angle
Left
Right
Front suspension:
Front fork travel
Optional spring
Spring rate
Stroke
Rear suspension:
Shock absorber travel
Spring free length
Spring fitting length
Spring rate
Stroke
(K1)
(K1)
Optional spring
Rim runout limit:
Front
Rear
Limit
Ball bearing
***
ø4.75 mm x 15
ø4.75 mm x 15
***
***
45°
45°
***
***
80 mm
No
5.7 N/mm
0 ~ 80 mm
***
60 mm
234 mm
199.5 mm
28 N/mm
35 N/mm
0 ~ 92 mm
92 ~ 115 mm
No
(K1)
(K2)
(K1)
(K2)
Wheels:
Front wheel type
Rear wheel type
Front wheel size/Material
Rear wheel size/Material
Standard
***
***
***
***
***
***
***
***
***
Cast wheel
Cast wheel
MT 3.00 x13 / Aluminium
MT 3.50 x 13 / Aluminium
Radial
Lateral
Radial
Lateral
***
***
***
***
2-8
1 mm
1 mm
1 mm
1 mm
MAINTENANCE SPECIFICATIONS
Model
Front disk brake:
Type
Diameter and thickness
Pad thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Rear drum brake:
Type
Drum inside diameter
Lining thickness
Spring free length
Brake lever freeplay:
Front brake lever free play
Rear brake lever free play
2-9
SPEC
Standard
Limit
Single disc
190.0 x 3.5 mm
4.5 mm
11 mm
30 mm
DOT #3 or DOT#4
***
***
2 mm
***
***
***
Leading, trailing
130 mm
4 mm
54 mm
***
130.5 mm
2 mm
***
10 ~ 20 mm
10 ~ 20 mm
***
***
MAINTENANCE SPECIFICATIONS
SPEC
TIGHTENING TORQUES
CHASSIS
Part to be tightened
Thread
size
Tightening
torque
Nm
m.kg
Remarks
Frame with engine bracket
M10
42
4.2
Engine bracket with engine
M10
50
5.0
Reinforcement tail
M8
12.5
1.25
Rear schock absorber with frame (top)
M10
31.5
3.15
Rear schock absorber with engine (bottom)
M8
17.5
1.75
Handle with steering shaft
M10
60
6.0
Upper
75
7.5
Center
-
-
Lower
38
3.8
1st tightening
22
2.2
2nd tightening
Steering nut (securing nut)
Fuel tank
M6
6.5
0.65
Seat lock assy'
M6
9.5
0.95
Box
M6
8
0.8
Cover tail / Reinforcement tail
M6
6
0.6
-
2.5
0.25
Handle seat / Reinforcement tail
M6
3.5
0.35
Front disk brake
M10
23
2.3
Front caliper
M10
23
2.3
Lever camshaft
M6
13.5
1.35
Front wheel shaft
M10
35
3.5
Rear wheel shaft
M14
125
12.5
Wheel / Hub
M10
47
4.7
Guard flap
M6
8
0.8
Oil tank
M6
5
0.5
Leg shield / Frame
M6
4
0.4
Footrest board / Frame
M6
4
0.4
Fuel tank
M6
6.5
0.65
Fuel tank / Fuel cock
2-10
MAINTENANCE SPECIFICATIONS
Part to be tightened
Thread
size
SPEC
Tightening
torque
Nm
m.kg
Screws tapping in plastic
Ø5
3.2
0.32
Screws tapping in clip
Ø5
2.2
0.22
2-11
Remarks
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Model
Voltage:
Ignition system:
Ignition timing(B.T.D.C.)
Ignition timing type
CDI:
Model/Manufacturer
Pickup coil resistance (color)
Source coil resistance (color)
Ignition coil:
Model/Manufacturer
Minimum spark length
Primary coil resistance
Secondary coil resistance
12 V
***
14° at 5000 r/min
Constant
***
***
***
***
2JN / MORYAMA
***
0.32 ~ 0.48 Ω at 20°C
5.68 ~ 8.52 kΩ at 20°C
***
***
***
***
Resin
5 kΩ at 20°C
***
Charging system / Type
Lighting coil resistance (color)
Limit
4VP / YAMAHA
400 ~ 600 Ω at 20°C (WR/WL)
(White/Red-Black)
640 ~ 960 Ω at 20°C (BR/GW)
(Black/Red-Black)
Spark plug cap:
Type
Resistance
CDI Magneto:
Model / Manufacturer
Charging coil resistance (color)
Standard
Flywheel magneto
4VP / YAMAHA
0.48 ~ 0,72 Ω at 20°C
(White-Black)
0.40 ~ 0,60 Ω at 20°C
(Yellow/Red-Black)
Voltage Regulator / Rectifier:
Type
Semi-conductor,
Short-circuit type
DUCATI
13 ~ 14 V
8A
600v
Model/Manufacturer
No load regulated voltage
Capacity
Withstand voltage
2-12
***
***
***
***
***
***
MAINTENANCE SPECIFICATIONS
Model
SPEC
Standard
Limit
1.280
***
MORYAMA
0.14 kW
0.06 ~ 0.08 Ω at 20°C
3.9 mm
563 ~ 844 g
15.8 mm
1.15 mm
***
***
0.9 mm
***
14.8 mm
***
Starter relay:
Model/Manufacturer
Amperage rating
Coil resistance
G8MS / OMRON
20 A
54 ~ 66 Ω at 20°C
***
***
Horn:
Type/Quantity
Model/Manufacturer
Maximum amperage
Plane type/1pc.
GF-12 / NIKKO or TR9 / TRANSVAL
2.5 A
***
Flasher relay:
Type
Self cancelling device
Flasher frequency
Wattage
Condenser type
No
80 ~ 160 cycles/min
10W x 2
***
***
Battery :
Specific gravity
Starter motor:
Model / Type
Output
Armature coil resistance
Brush length
Brush spring pressure
Commutator diameter
Mica undercut (depth)
Circuit breaker:
Type
Amperage for individual
circuit x Quantity
Fuel sender unit:
Model/Manufacturer
Resistance
Fuse
(Full)
(Empty)
2-13
7.5 A x 1
***
MONT. EL.
1.5 ~ 7.5 Ω at 20°C
90 ~ 100 Ω at 20°C
***
***
GENERAL TORQUE SPECIFICATIONS
SPEC
EAS00029
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special
components or assemblies are provided for each
chapter of this manual. To avoid warpage,
tighten multi-fastener assemblies in a crisscross
pattern and progressive stages until the
specified tightening torque is reached. Unless
otherwise specified, tightening torque
specifications require clean, dry threads.
Components should be at room temperature.
A
B
A: Width across flats
B: Thread diameter
2-14
A
(Nut)
B
(Bolt)
10 mm
6 mm
General torque
specifications
Nm
m.kg
60
0.6
12 mm
8 mm
15
1.5
14 mm
10 mm
30
3.0
17 mm
12 mm
55
5.5
19 mm
14 mm
85
8.5
22 mm
16 mm
130
13.0
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point
Lubricant type
Oil seal lips
LS
O-ring
LS
Crankshaft bearings
Needle bearings (connecting rod)
Main axle bearings
LS
Drive axle bearings
Secondary sheave axle bearing
Piston rings, piston pin and piston
Kick pinion gear
LS
Kick shaft
LS
Starter idle gear
Starter clutch pin
Oil pump driven gear and drive gear
LS
Secondary sliding sheave cam groove
BEL-RAY® assembly lube
Secondary fixed sheave inside diameter
BEL-RAY® assembly lube
Crankcase surface
Yamaha N°1215
2-15
LUBRICATION POINT AND GRADE OF LUBRICANT
SPEC
EAS00032
CHASSIS
Lubrication point
Front wheel oil seal (right/left)
Lubricant type
LS
Rear wheel oil seal
LS
Steering bearing and bearing race (upper/lower)
LS
Throttle grip inner surface
LS
Lever pivots and cable end
LS
Oil seal lips (front wheel)
LS
Bearing (front wheel)
LS
Speedometer gear
LS
Center stand pivot
LS
2-16
CABLE ROUTING
SPEC
EAS00035
CABLE ROUTING
햲 Taillight
햳 Rear left flasher light
햴 Seat lock assy'
햵 Band switch
햶 Clip
햷 Starter relay
햸 Fuse
햹 Battery assy'
햺 Ignition coil assy'
햻 Starter motor
햽 Rear right flasher light
햾 Oil pump wire
햿 Wire harness
헀 Seat lock cable
헁 Fuel and sunction pipe
q
R
w
}
R
U
C
Y
G
B
I
D
R
O
E
T
R
15 – 10 mm
P
A-A
e
A
A
F
R
E
w
A
W
{
H
Q
2-17
CABLE ROUTING
SPEC
A Untight the seat lock plate to give to the seat lock cable more free play. Tight the seat lock cable at 1 1/2
turn.
B Fix on the footrest board.
C Pass the wire harness through the footrest board.
D Push the wire harness to the inside.
E Place leads backwards.
F Group connections all together.
G Place the wire harness in the middle of the engine bracket.
H Tight hook end with pliers to avoid the cable way out.
q
R
w
}
R
U
C
Y
G
B
I
D
R
O
E
T
R
15 – 10 mm
P
A-A
e
A
A
F
R
E
w
A
W
{
H
Q
2-18
CABLE ROUTING
Q Fuel sender
W C.D.I. unit
E Band switch
R Oil level sender
T Wire cylinder assy'
Y Rectifier / Regulator
U Band switch cordon
I Main switch
SPEC
O Resistor
P Headlight
{ Engine assy'
} Starter wire
q Throttle cable
w Oil pump wire
e Wire harness
r Rear brake cable
A-A
C
r
I
U
e
w
q
}
Y
T
A
Q
W
E
A
E
O
A
F
{
E
2-19
R
D
B
E
P
SPEC
CABLE ROUTING
A
B
C
D
E
F
Fix the wire harness, starter motor wire and the flywheel wire all together.
Fix the wire harness.
Pass the wire harness between the regulator and the steering head pipe.
Secure the right position of the headlight protection.
Adjust the oil pump.
Turn one round the ground wire around the starter wire.
A-A
C
r
I
U
e
w
q
}
Y
T
A
Q
W
E
A
E
O
A
F
{
E
2-20
R
D
B
E
P
CABLE ROUTING
햲 Resistor assy'
햳 Horn
햴 Band switch
햵 Frame
햶 Front brake hose
햷 Speedometer cable
햸 Gear unit assy'
햹 Front mudguard
햺 Front fork assy'
SPEC
A Install the front brake hose on the front fork assy' clip.
B Pass the speedometer cable through the front
mudguard bracket.
W
Q
E
O
A
R
I
T
B
U
Y
2-21
CABLE ROUTING
햲 Right hand grip
햳 Master cylinder
햴 Speedometer assy'
햵 Left hand grip
햶 Rear brake lever
햷 Rear brake cable
햸 Starter wire
햹 Stop switch wire
햺 Front brake hose
햻 Wire harness
햽 Speedometer cable
햾 Front brake lever
햲
F
햾
SPEC
햳 G
H
햴
햵
I
햶
E
햲
햳
햴
햵
D
햶
C
햾
B
햷
A
햸
햹
햺
햽
햻
2-22
CABLE ROUTING
A
B
C
D
E
F
G
H
I
SPEC
Fix the wire harness on the frame bracket.
Group all connection in this area.
Pass the starter cable through the hole.
Tight this bolt first.
Tight this bolt first.
Stop the cap on the handlebar end. Tight at 7 Nm (0.7 m.kg).
Stop the grip on the handlebar projection.
Pass the flasher light wire through the hole.
Position the grip in regards of this switch.
햲
F
햾
햳 G
H
햴
햵
I
햶
E
햲
햳
햴
햵
D
햶
C
햾
B
햷
A
햸
햹
햺
햽
햻
2-23
CABLE ROUTING
햲 Speedometer cable
햳 Wire harness
햴 Front brake hose
햵 Rear brake cable
햶 Front handlebar cover
햷 Speedometer cover
햸 Speedometer
햹 Rear handlebar cover
햺 Handlebar switch wire
햻 Starter wire
햽 Master cylinder
햾 Throttle grip
SPEC
A Secure the installation of the clip.
B Group all connections in this area.
햾
1.5 ~ 3.0 mm
A
햸
햷
햹
햶
B
A
햽
A
B
햵
햴
햳
B
햲
햺
10¡
B-B RIGH
FR
ON
T
LE
햶
A-A
햻
햳
T
햹
햺
햻
햴
햵
5 mm
FT
2-24
CHK
ADJ
3
CHK
ADJ
CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE AND LUBRICATION ........................................ 3-1
COVERS ........................................................................................................ 3-3
SEAT AND SIDE COVERS ...................................................................... 3-3
BOX, LOWER SIDE COVERS AND MUDGUARD .................................. 3-4
FRAME REINFORCEMENT, FUEL TANK
AND REAR UNDER COVER ................................................................... 3-5
FRONT COVERS ..................................................................................... 3-6
HANDLEBAR COVERS ........................................................................... 3-7
BATTERY COVER AND LOWER COVER .............................................. 3-8
INNER PANEL AND FOOTREST BOARD .............................................. 3-9
ENGINE ....................................................................................................... 3-11
ADJUSTING THE ENGINE IDLING SPEED .......................................... 3-11
ADJUSTING THE THROTTLE CABLE FREE PLAY ............................. 3-12
CHECKING THE SPARK PLUG ............................................................ 3-13
CHECKING THE ENGINE OIL LEVEL .................................................. 3-15
CHANGING THE TRANSMISSION OIL ................................................ 3-16
AUTOLUBE PUMP AIR BLEEDING ...................................................... 3-16
CLEANING THE AIR FILTER ELEMENT .............................................. 3-17
CHECKING THE EXHAUST SYSTEM .................................................. 3-18
CHASSIS ..................................................................................................... 3-19
ADJUSTING THE FRONT BRAKE ........................................................ 3-19
ADJUSTING THE REAR BRAKE .......................................................... 3-19
CHECKING THE BRAKE FLUID LEVEL ............................................... 3-20
CHECKING THE FRONT BRAKE PADS ............................................... 3-21
CHECKING THE BRAKE SHOES ......................................................... 3-21
BLEEDING THE HYDRAULIC BRAKE SYSTEM .................................. 3-21
CHECKING AND ADJUSTING THE STEERING HEAD ........................ 3-22
CHECKING THE FRONT FORK ............................................................ 3-24
CHECKING THE TIRES ........................................................................ 3-25
CHECKING THE WHEELS .................................................................... 3-27
CHECKING AND LUBRICATING THE CABLES ................................... 3-27
LUBRICATING THE CENTERSTAND ................................................... 3-28
LUBRICATING THE REAR SUSPENSION ........................................... 3-28
ELECTRICAL SYSTEM ............................................................................... 3-29
CHECKING THE BATTERY .................................................................. 3-29
CHECKING THE FUSE ......................................................................... 3-32
REPLACING THE HEADLIGHT BULB .................................................. 3-33
ADJUSTING THE HEADLIGHT BEAM .................................................. 3-34
PERIODIC CHECKS AND ADJUSTMENTS
INSP
REG
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.
PERIODIC MAINTENANCE AND LUBRICATION
N°
ITEM
CHECKS AND MAINTENANCE JOBS
2
Spark plug
•
•
•
•
3
Air filter
• Clean or replace if necessary.
• Check electrolyte level and specific gravity.
• Correct or recharge if necessary.
• Check operation, fluid level and vehicule for fluid leakage.
(see NOTE on page 3-2)
• Correct accordingly.
• Replace brake pads if necessary.
• Check operation.
• Adjust brake lever freeplay and replace brake shoes if
necessary.
• Check for cracks and damage.
• Replace if necessary.
• Check balance, runout and for damage.
• Rebalance or replace if necessary.
• Check tread depth and damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness or damage.
• Replace if necessary.
• Check bearing play and steering for roughness.
• Correct accordingly.
• Lubricate with lithium soap base grease.
• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.
• Check operation.
• Lubricate and repair if necessary.
1
*
Fuel line
4
*
Battery
5
*
Front brake (disk)
6
*
Rear brake (drum)
7
*
Brake hose
8
*
Wheels
9
*
Tires
10 *
Wheel bearings
11 *
Steering bearings
12
Chassis fasteners
13
Centerstand
14 *
15 *
16 *
17 *
18
•
•
•
Rear shock
absorber assembly •
•
Carburetor
•
•
Autolube pump
•
•
•
Transmission oil
•
Front fork
INITIAL
(1,000 km)
6,000 km or
6 months
Annual
check
Check fuel hoses and vacuum hose for cracks and damage.
Replace if necessary.
Check condition.
Clean, regap or replace if necessary.
Every 12,000 km
Check operation and for oil leakage.
Replace if necessary.
Check operation and shock absorber for oil leakage.
Replace shock absorber assembly if necessary.
Check engine idling speed and starter operation.
Adjust if necessary.
Check operation.
Correct if necessary.
Bleed if necessary.
Check oil level and vehicle for oil leakage
Every 12,000 km
Change oil.
3-1
PERIODIC CHECKS AND ADJUSTMENTS
N°
19 *
20 *
21
22 *
ITEM
•
•
Front and rear bake •
switches
•
Moving parts and
•
cables
•
Lights, signals
•
and switches
•
V-belt
CHECKS AND MAINTENANCE JOBS
Check for wear and damage.
Replace.
Check operation.
Correct accordingly.
INITIAL
(1,000 km)
INSP
REG
6,000 km or
6 months
Annual
check
Every 20,000 km
Lubricate if necessary.
Check operation.
Correct if necessary.
Adjust headlight beam if necessary.
Items maked with an asterisk (*) require special tools, data and technical skills for servicing. Take the scooter to a Yamaha or MBK
dealer when servicing these items.
NOTE:
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Brake fluid replacement:
• When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
• Replace the brake hoses every four years, or when cracked or damaged.
3-2
INSP
REG
COVERS
SEAT AND SIDE COVERS
T.R
8 Nm (0,8 m.kg)
T.R
2
3 Nm (0,3 m.kg)
1
5
3
4
4
T.R
8 Nm (0,8 m.kg)
T.R
Order
Job/Part
Q’ty
I
1
2
3
4
Removing the seat and side covers
Remove:
Seat
Fuel tank cap
Rear seat screws and strap
Side covers (left and right)
1
1
2
2
5
Rear seat
1
2 Nm (0,2 m.kg)
Remarks
Remove the parts in the order listed.
CAUTION:
When removing the cover, be careful to
not damage the mounting clips.
For installation, reverse the removal procedure.
3-3
INSP
COVERS REG
BOX, LOWER SIDE COVERS AND MUDGUARD
T.R
T.R
3 Nm (0,3 m.kg)
8 Nm (0,8 m.kg)
4
3
5
T.R
2,5 Nm (0,25 m.kg)
2
3
1
T.R
Order
Job/Part
Q’ty
I
1
2
3
Removing the box, lower side covers
and mudguard
Remove:
Glove compartment cover
Oil cover
Lower side covers (left and right)
1
1
2
4
5
Box
Rear mudguard
1
1
6 Nm (0,6 m.kg)
Remarks
Remove the parts in the order listed.
CAUTION:
When removing the cover, be careful to
not damage the mounting clips.
For installation, reverse the removal procedure.
3-4
INSP
REG
COVERS
FRAME REINFORCEMENT, FUEL TANK AND REAR UNDER COVER
6,5 Nm (0,65 m.kg)
T.R
13 Nm (1,3 m.kg)
T.R
1
4
2
T.R
T.R
3 Nm (0,3 m.kg)
6,5 Nm (0,65 m.kg)
3
2 Nm (0,2 m.kg)
T.R
Q'ty
Job/Part
Order
Remove the parts in the order listed.
Removing the frame reinforcement,
fuel tank and rear under cover.
Rear side covers
I
1
2
3
4
Seat
Remove:
Frame reinforcement
Fuel tank
Rear under cover
Refer to "BOX,SIDE COVERS AND MUDGUARD" section.
Refer to "SEAT AND SIDE COVERS" section.
1
1
1
Rear light
Remarks
CAUTION:
When removing the cover, be careful to
not damage the mounting clips.
1
For installation, reverse the removal procedure.
3-5
COVERS
INSP
REG
FRONT COVERS
T.R
3 Nm (0,3 m.kg)
1
T.R
3 Nm (0,3 m.kg)
3
2 Nm (0,2 m.kg)
T.R
3
2
T.R
Order
I
II
1
2
3
3 Nm (0,3 m.kg)
Job/Part
Q'ty
Remarks
Remove the parts in the order listed.
Removing the front covers
Disconnect:
Headlight lead
Remove:
Front cover and headlight
Front fender
Front inner panel
1
1
1
1
CAUTION:
When removing the cover, be careful to
not damage the mounting clips.
For installation, reverse the removal procedure.
3-6
INSP
COVERS REG
HANDLEBAR COVERS
T.R
3 Nm (0,3 m.kg)
T.R
3 Nm (0,3m.kg)
3
햲
2
1
4
Order
I
II
III
1
2
3
4
T.R
3 Nm (0,3 m.kg)
Job/Part
Q'ty
Remarks
Remove the parts in the order listed.
Removing the handlebar covers
Untighten:
Handlebar under cover 햲
Disconnect:
Speedometer lead
Wires and leads
Remove:
Handlebar cover (front)
Handlebar cover (rear)
Speedometer assy'
Flasher light
1
1
1
1
1
CAUTION:
When removing the cover, be careful to
not damage the mounting clips.
For installation, reverse the removal procedure.
3-7
COVERS
INSP
REG
BATTERY COVER AND LOWER COVER
T.R
3 Nm (0,3 m.kg)
1
T.R
3 Nm (0,3 m.kg)
2
Job/Part
Order
Q'ty
Remove the parts in the order listed.
Removing the battery cover and
lower cover.
Seat
Box and side covers
Refer to “SEAT AND SIDE COVERS” section.
Refer to “BOX, SIDE COVERS AND MUDGUARD” section.
Refer to "FRONT COVERS" section.
Front covers
I
1
2
Remarks
Remove:
Battery cover
Lower cover
1
1
CAUTION:
When removing the cover, be careful to
not damage the mounting clips.
For installation, reverse the removal procedure.
3-8
COVERS
INSP
REG
INNER PANEL AND FOOTREST BOARD
T.R
4 Nm (0,4 m.kg)
1
T.R
4 Nm (0,4 m.kg)
2
Order
I
1
2
Job/Part
Q'ty
Remarks
Remove the parts in the order listed.
Removing the inner panel and
footrest board.
Remove:
Inner panel
Footrest board
1
1
NOTE:
To remove the main switch ring, turn it
counterclockwise.
CAUTION:
When removing the cover, be careful to
not damage the mounting clips.
For installation, reverse the removal procedure.
3-9
COVERS
INSP
REG
NOTE:
Correct routing of cables and wires is essential for a safe operation of this scooter. Refer to the section
“CABLE ROUTING” in Chapter 2.
NOTE:
Be careful not to pinch any wires with the covers.
NOTE:
When installing the covers, be careful to not damage the mounting clips.
3-10
ADJUSTING THE ENGINE IDLING SPEED
INSP
REG
EAS00054
ENGINE
ADJUSTING THE ENGINE IDLING SPEED
CAUTION:
For safety reasons, place the scooter on the
centerstand before starting the engine.
1.Start the engine and let it warm up for several
minutes.
2.Attach:
• engine tachometer
(onto the spark plug lead)
Engine tachometer
90890-03113
3.Measure:
• engine idling speed
Out of specification → Adjust.
Engine idling speed
2000 ± 200 r/mn
4.Adjust:
• engine idling speed
a.Turn the pilot screw 햲 in until it is lightly seated.
b.Turn the pilot screw out the specified number
of turns.
Pilot screw setting:
TEIKEI - TK ø 16
1 5/8
햳
c. Turn the throttle stop screw 햳 in direction left
or right until the specified engine idling speed
is obtained.
햲
322025(b)
Direction left
Engine idling speed is increased.
Direction right Engine idling speed is decreased.
5.Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
3-11
ADJUSTING THE THROTTLE CABLE FREE PLAY
INSP
REG
Throttle cable free play (at the /
flange of the throttle grip) @
1.5 ~ 3.0 mm
EAS00058
@
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted.
1.Check:
• throttle cable free play @
Out of specification → Adjust.
Throttle cable free play (at the
flange of the throttle grip)
1.5 ~ 3.0 mm
@
2.Adjust:
• throttle cable free play
NOTE:
When the throttle is opened, the accelerator
cable is pulled.
Carburetor side
a.Loosen the locknut on the accelerator cable.
b.Turn the adjusting nut in direction left or right
until the specified throttle cable free play is
obtained.
Direction left
Throttle cable free play is
increased.
Direction right
Throttle cable free play is
decreased.
c. Tighten the locknut.
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.
3-12
ADJUSTING THE THROTTLE CABLE FREE PLAY /
CHECKING THE SPARK PLUG
INSP
REG
Handlebar side
a.Loosen the locknut.
b.Turn the adjusting nut in direction left or rught
until the specified throttle cable free play is
obtained.
Direction left
Throttle cable free play is
increased.
Direction right
Throttle cable free play is
decreased.
c. Tighten the locknut.
WARNING
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.
EAS00060
CHECKING THE SPARK PLUG
1.Disconnect:
• spark plug cap 햲
햳
햲
2. Remove:
• spark plug 햳
CAUTION:
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.
3.Check:
• spark plug type
Incorrect → Change.
Spark plug type (manufacturer)
BR8HS (NGK)
햳
햲
4.Check:
• electrodes 햲
Damage/wear→ Replace the spark plug.
• insulator 햳
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
3-13
INSP
CHECKING THE SPARK PLUG REG
5.Clean:
•spark plug
(with a spark plug cleaner or wire brush)
햲
6.Measure:
•spark plug gap 햲
(with a wire gauge or feeler gauge)
Out of specification → Adjust.
Spark plug gap
0.5 ~ 0.7 mm
7.Install:
•spark plug
T.
R
Spark plug
20 Nm (2 m•kg)
NOTE:
• Before installing the spark plug, clean the
spark plug and gasket surface.
• First tighten by hand, then torque to
specification.
8.Connect:
•spark plug cap
3-14
CHECKING THE ENGINE OIL LEVEL
INSP
REG
EAS00070
CHECKING THE ENGINE OIL LEVEL
1.Inspect:
•oil level
Oil level low → Add oil to proper level as
follows.
햲 "OIL" indicator light.
햲
OIL LEVEL AND GAUGE CHECK
Turn main switch
to "*'
"OIL" indicator
doesn't light.
"OIL" indicator
light.
Turn main switch
to "ON".
"OIL" indicator goes
Inspect Faulty
electrical circuit,
Light bulb etc.
Engine oil level
and electric circuit
are OK.
"OIL" indicator
stays on.
Add oil.
"OIL" indicator
stays on.
Recommended oil:
Yamalube 2 or 2 stroke engine oil
(JASO FC or EG-C,EG-D grade)
Capacity:
Total:
1.3 L
NOTE:
Install the oil tank filler cap 햲 and push it fully
into the filler.
햲
CAUTION:
Always use the same type of engine oil;
mixing oils may result in a harmful chemical
reaction and lead to poor performance.
3-15
CHANGING THE TRANSMISSION OIL/
AUTOLUBE PUMP AIR BLEEDING
INSP
REG
CHANGING THE TRANSMISSION OIL
1.Remove:
•drain plug 햲
•oil filler plug 햳
Drain the transmission oil.
햳
2.Check:
•gasket (drain plug)
•O-ring (oil filler plug)
Damage → Replace.
햲
3.Install:
•gasket
•drain plug
T.
R
Drain plug:
18 Nm (1.8 m•kg)
4.Fill:
•transmision case
Transmission oil:
SAE 85W/140 type SE.
Capacity:
0.11 L
Total amount:
0.13 L
NOTE:
Wipe off any oil spilt on the crankcase, tire or
wheel.
햳
5.Install:
•O-ring 햲
•oil filler plug 햳.
햲
AUTOLUBE PUMP AIR BLEEDING
1.Remove:
•fan cover 햲
3-16
AUTOLUBE PUMP AIR BLEEDING/
CLEANING THE AIR FILTER ELEMENT
INSP
REG
2.Bleed:
•Pump housing and oil hose
햲
a.Place a rag under the pump.
b.Remove the bleed screw 햲
c. Let oil run until there are no more air bubbles
in it.
d.When there are no more bubbles, tighten the
bleed screw.
NOTE:
Check the condition of bleed screw gasket. If it
is damaged, replace it with a new one.
e.Start the engine.
f. Let engine run two or three minutes at 2000
rpm. This will force out any air in the hose.
EAS00089
CLEANING THE AIR FILTER ELEMENT
1.Remove:
•air cleaner case cover 햲
CAUTION:
Never operate the engine with the air cleaner
element removed. Unfiltered air will cause
rapid wear of engine parts and possible engine
damage.
햲
2.Remove:
•air filter case cover
•air filter element
햲
3.Inspect:
•air filter element 햲
Damage → Replace
3.Clean:
•air filter element
(with solvent)
a.Wash the element gently but thoroughly in a
solvent.
WARNING
Never use low flash point solvents, such as
gasoline, to clean the air filter element. Such
solvents may cause a fire or an explosion.
3-17
CLEANING THE AIR FILTER ELEMENT/
CHECKING THE EXHAUST PIPE SYSTEM
INSP
REG
b. Squeeze excess solvent out of the element
and let dry.
CAUTION:
Do not twist the element.
c. Apply foam air filter oil or motor oil on the
element.
d.Squeeze out the excess oil.
NOTE:
The element should be wet but not dripping.
EAS00100
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the
exhaust pipes, mufflers and gaskets.
1.Remove:
• exhaust pipe bolt (cylinder)
• exhaust pipe bolt (engine)
T.R
햵
햳
29 Nm (2,9 m.kg)
LT
햲
2.Check:
• exhaust pipe 햲
• muffler 햳
Cracks/damage → Replace.
• gasket 햴
Exhaust gas leaks → Replace.
3. Install:
• exhaust pipe bolt (engine)
• exhaust pipe bolt (cylinder)
햴
T.R
8.5 Nm (0,85 m.kg)
4.Tighten:
• exhaust pipe bolt (cylinder) 햶
• exhaust pipe bolt (engine) 햵
햶
T.
R
3-18
Exhaust pipe bolt (engine)
29 Nm (2.9 m•kg)
Exhaust pipe bolt (cylinder)
8.5 Nm (0.85 m•kg)
ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
INSP
REG
EAS00108
CHASSIS
@
ADJUSTING THE FRONT BRAKE
1.Check:
•brake lever free play @
Out of specification → Adjust.
Brake lever free play (at the end of
the brake lever)
10 ~ 20 mm
WARNING
A soft or spongy feeling in the brake lever can
indicate the presence of air in the brake
system. This air must be removed by bleeding
the brake system before the scooter is
operated. Air in the system will reduce brake
performance and can result in lost of control
and an accident. Inspect and bleed the system
if necessary.
EAS00114
ADJUSTING THE REAR BRAKE
1.Check:
•brake lever free play
Out of specification → Adjust.
Brake lever free play
10 ~ 20 mm
2.Adjust:
•brake lever free play
Rear wheel side
a.Turn the adjusting nut 햲 in direction 햳 or 햴 until
the specified brake lever free play is obtained.
햲
Direction 햳 Brake lever free play is
decreased.
햳
햴
Direction 햴 Brake lever free play is
increased.
CAUTION:
After adjusting the brake lever free play, make
sure there is no brake drag.
3-19
CHECKING THE BRAKE FLUID LEVEL
INSP
REG
EAS00116
CHECKING THE BRAKE FLUID LEVEL
1.Stand the scooter on a level surface.
NOTE:
• Place the scooter on a suitable stand.
• Make sure the scooter is upright.
• In order to ensure a correct reading of the
brake fluid level, make sure the top of the
reservoir is horizontal.
햲
2.Check:
brake fluid level
Below the minimum level mark 햲 → Add the
recommended brake fluid to the proper level.
Recommended brake fluid
DOT #3 or DOT #4
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor brake
performance.
• 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.
• When refilling, be careful that water does
not enter the reservoir. Water will
significantly lower the boiling point of the
brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
3-20
CHECKING THE FRONT BRAKE PADS/
CHECKING THE BRAKE SHOES/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
INSP
REG
EAS00123
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the
brake pads.
1.Operate the brake.
2.Check:
• brake pad
Out of specification → Replace.
NOTE:
Replace the brake pad and spring as a set when
replacing the brake pads.
햲
Wear limit 햲 :
0.5 mm
Refer to "FRONT BRAKE" in chapter 6.
EAS00126
CHECKING THE BRAKE SHOES
1.Operate the brake.
햲
햳
2.Check:
• wear indicator 햲
Reaches the wear limit line 햳 → Replace the
brake shoes as a set.
Refer to “REAR WHEEL” in chapter 6.
EAS00133
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
1.Bleed:
• brake fluid.
햲
346002(a)
a.Add proper brake fluid into the reservoir.
b.Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir overflow.
c. Connect a clear plastic tube 햲 tightly to the
caliper bleed screw.
d.Place the other end of the tube into a container.
e.Slowly apply the brake lever several times.
f. Pull the lever as far as possible and hold it
there.
g.Loosen the bleed screw and pull the lever all
the way.
h.When the lever is completely pulled, tighten
the bleed screw, then release the lever.
3-21
BLEEDING THE HYDRAULIC BRAKE SYSTEM /
CHECKING AND ADJUSTING THE STEERING HEAD
INSP
REG
i. Repeat steps (e) to (h) until all air bubbles
have been removed from the system.
j. Add brake fluid to proper level.
WARNING
Check the operation of the brake after
bleeding the brake system.
EAS00148
CHECKING AND ADJUSTING THE
STEERING HEAD
1.Stand the scooter on a level surface.
WARNING
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:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering head.
385
햲
햳
햴
햵
햶
3.Remove:
• front cover
Refer to "FRONT COVER"
• handlebar
Refer to "REMOVING THE HANDLEBAR" in
chapter 6.
4.Adjust:
• steering head
a.Remove the upper ring nut 햲, the lock washer
햳 , the center ring nut 햴 and the rubber
washer 햵.
b.Loosen the lower ring nut 햶 and then tighten
it to specification with the ring nut wrench.
NOTE:
Set the torque wrench at a right angle to the ring
nut wrench.
3-22
CHECKING AND ADJUSTING THE STEERING HEAD
INSP
REG
Steering nut wrench
90890-01403
T.
R
Lower ring nut (initial tightening
torque)
38 Nm (3.8 m•kg)
c. Loosen the lower ring nut 햶 of 1/4 turn and
then tighten it to specification with a steering
nut wrench .
햲
CAUTION:
Do not overtighten the lower ring nut.
햳
T.
R
Lower ring nut (final tightening
torque)
22 Nm (2.2 m•kg)
햴
햵
햶
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 6.
e.Install the rubber washer.
f. Install the center ring nut.
g.Finger tighten the center ring nut 햴, then align
the slots of both ring nuts. If necessary, hold
the lower ring nut and tighten the center ring
nut until their slots are aligned.
h.Install the lock washer 햲.
NOTE:
Make sure the lock washer tabs a sit correctly in
the ring nut slots.
i. Hold the lower and center ring nuts with a ring
nut wrench and tighten the upper ring nut with
a steering nut wrench.
Steering nut wrench
90890-01403
Ring nut wrench
90890-01268
T.
R
3-23
Upper ring nut
75 Nm (7.5 m•kg)
CHECKING AND ADJUSTING THE STEERING HEAD /
CHECKING THE FRONT FORK
INSP
REG
5.Install:
•front cover
Refer to "FRONT COVER"
•Handlebar
Refer to "HANDLEBAR" in chapter 6.
T.
R
Handlebar holder bolt
60 Nm (6.0 m•kg)
EAS00151
CHECKING THE FRONT FORK
1.Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
2.Check:
•inner tube
Damage/scratches→ Replace.
•oil seal
Oil leakage → Replace.
3.Hold the scooter upright and apply the front
brake.
4.Check:
•front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to "FRONT FORK" in chapter 6.
3115
3-24
CHECKING THE TIRES
INSP
REG
EAS00165
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1.Measure:
•tire pressure
Out of specification → Regulate.
WARNING
The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
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.
Operation of an overloaded scooter could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE SCOOTER.
Cold tire pressure
Up to 90 kg load*
90 kg ~ maximum
load*
Basic weight
(with oil and a full fuel tank)
95 kg
Maximum load*
280 kg
Front
Rear
150 kPa
(1.50 kg/cm2)
150 kPa
(1.50 kg/cm2)
150 kPa
(1.50kg/cm2)
150 kPa
(1.50 kg/cm2)
* total of cargo, rider, passenger and accessories
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
2.Check:
tire surfaces
Damage/wear → Replace the tire.
3101
3-25
CHECKING THE TIRES
Minimum tire tread depth
0.8 mm
햲
햳
INSP
REG
햴
3103
햲 Tire tread depth
햳 Side wall
햴 Wear indicator
WARNING
Do not use a tubeless tire on a wheel designed
only for tube tires to avoid tire failure and
personal injury from sudden deflation.
When using tube tires, be sure to install the
correct tube.
Always replace a new tube tire and a new
tube as a set.
To avoid pinching the tube, make sure the
wheel rim band and tube are centered in the
wheel groove.
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.
Tube wheel
Tube tire only
Tubeless wheel
Tube or tubeless tire
WARNING
After extensive tests, the tires listed below
have been approved by MBK industrie 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
MBK is used on this scooter.
Front tire
Manufacturer MICHELIN / PIRELLI
Model
Size
BOPPER / SL 36
130/60 - 13
Rear tire
Manufacturer MICHELIN / PIRELLI
Model
Size
3-26
BOPPER / SL 36
140/60 - 13
CHECKING THE WHEELS/
CHECKING AND LUBRICATING THE CABLES
INSP
REG
EAS00168
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1.Check:
• wheel
Damage/out-of-round → Replace.
WARNING
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
cable sheaths and cables.
WARNING
Damaged cable sheaths may cause the cable
to corrode and interfere with its movement.
Replace damaged cable sheaths and cables
as soon as possible.
E
1.Check:
• cable sheath
Damage → Replace.
2.Check:
• cable operation
Rough movement → 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.
3-27
LUBRICATING THE CENTERSTAND/
LUBRICATING THE REAR SUSPENSION
INSP
REG
EAS00173
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-tometal moving parts of the centerstand.
Recommended lubricant
Engine oil
EAS00174
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Molybdenum disulfide grease
3-28
CHECKING THE BATTERY
INSP
REG
EAS00177
ELECTRICAL SYSTEM
CHECKING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling or
working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or handling
batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• SKIN - Wash with water.
• EYES - Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk
followed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
1.Remove:
• battery cover
2.Disconnect:
• battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative battery lead ,
and the positive battery lead .
3.Remove:
• battery
3-29
INSP
CHECKING THE BATTERY REG
햲
UPPER
LOWER
+
햳
4.Check:
•electrolyte level
The electrolyte level should be between the
minimum level mark 햳 and the maximum
level mark 햲.
Below the minimum level mark → Add distilled
water to the proper level.
CAUTION:
Add only distilled water. Tap water contains
minerals which are harmful to the battery.
5.Check:
•specific gravity
Less than 1.280 → Recharge the battery.
Specific gravity
1.280 at 20°C
6.Charge:
•battery
Battery charging amperage and
time
0.3 amps/10 hrs
WARNING
Do not quick charge a battery.
CAUTION:
• Loosen the battery sealing caps.
• To ensure maximum performance, always
charge a new battery before using it.
• Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• 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.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
3-30
INSP
CHECKING THE BATTERY REG
• 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.
• 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!
NOTE:
Replace the battery whenever:
• battery voltage does not rise to specification
or bubbles fail to rise during charging,
• sulphation of one or more battery cells occurs
(as indicated by the battery plates turning
white or material accumulating in the bottom
of the battery cell),
• specific gravity readings after a long, slow
charge indicate that one battery cell’s charge
is lower than the rest,
• warpage or buckling of the battery plates or
insulators is evident.
햲
7.Install:
• battery 햲
8.Check:
• battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
햳
햲
UPPER
LOWER
+
9.Connect:
• battery leads
(to the battery terminals)
CAUTION:
First, connect the positive battery lead 햲,
and then the negative battery lead 햳.
3-31
CHECKING THE BATTERY/
CHECKING THE FUSE
INSP
REG
10.Lubricate:
•battery terminals
Recommended lubricant
Dielectric grease
11.Install:
•battery cover
Refer to "BATTERY COVER AND LOWER
COVER".
EAS00181
CHECKING THE FUSE
The following procedure applies to all of the
fuses.
CAUTION:
To avoid a short circuit, always set the main
switch to "OFF" when checking or replacing
a fuse.
1.Remove:
•battery cover
Refer to "BATTERY COVER AND LOWER
COVER".
2.Check:
•continuity
햳
a.Connect the pocket tester to the fuse 햲 and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω x 1”.
Pocket tester
90890-03112
sm3245
b.If the pocket tester indicates “∞”, replace the
fuse.
3-32
CHECKING THE FUSE/
REPLACING THE HEADLIGHT BULB
INSP
REG
3.Replace:
• blown fuse 햲
a.Set the main switch to “OFF”.
b.Install a new fuse of the correct amperage.
c. Set on the switches to verify if the electrical
circuit is operational.
d.If the fuse immediately blows again, check the
electrical circuit.
햳
Fuse
main circuit : 7.5 A
WARNING
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:
• battery cover
Refer to "BATTERY COVER AND LOWER
COVER"
EAS00182
REPLACING THE HEADLIGHT BULB
1.Disconnect:
• front cover 햲
Refer to "FRONT COVERS"
햲
햲
햳
2.Detach:
• headlight bulb holder 햲
3.Remove:
• headlight bulb 햳
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
3-33
REPLACING THE HEADLIGHT BULB/
ADJUSTING THE HEADLIGHT BEAM
INSP
REG
4.Install:
• headlight bulb
Secure the new headlight bulb with the
headlight bulb holder.
CAUTION:
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.
5.Attach:
• headlight bulb holder
6.Connect:
• headlight bulb
7.Install:
• front cover
Refer to “FRONT COVERS"
EAS00184
ADJUSTING THE HEADLIGHT BEAM
1.Adjust:
• headlight beam
a.Turn the adjusting screw 햲 in higher or lower
position.
햲
3-34
Higher
Turn out screw.
Lower
Turn in screw.
ENG
4
ENG
CHAPTER 4.
OVERHAULING THE ENGINE
ENGINE ......................................................................................................... 4-1
LEADS AND HOSES ............................................................................... 4-1
EXHAUST PIPE ....................................................................................... 4-3
ENGINE ................................................................................................... 4-4
INSTALLING THE ENGINE ..................................................................... 4-5
CYLINDER HEAD, CYLINDER AND PISTON .............................................. 4-6
PISTON PIN AND PISTON REMOVAL ................................................... 4-7
CYLINDER HEAD INSPECTION ............................................................. 4-7
CYLINDER AND PISTON INSPECTION ................................................. 4-8
PISTON RINGS INSPECTION .............................................................. 4-10
PISTON PIN AND PISTON PIN BEARING INSPECTION ..................... 4-10
PISTON PIN AND PISTON INSTALLATION ......................................... 4-11
CYLINDER AND CYLINDER HEAD ...................................................... 4-12
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ..................... 4-14
CRANKCASE COVER (LEFT) ............................................................... 4-14
KICK STARTER ..................................................................................... 4-15
KICK STARTER INSTALLATION .......................................................... 4-16
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ................. 4-17
SECONDARY SHEAVE ......................................................................... 4-18
PRIMARY SHEAVE REMOVAL ............................................................. 4-19
SECONDARY SHEAVE REMOVAL ...................................................... 4-19
CLUTCH INSPECTION .......................................................................... 4-20
V-BELT INSPECTION ............................................................................ 4-21
PRIMARY SHEAVE INSPECTION ........................................................ 4-22
SECONDARY SHEAVE INSPECTION .................................................. 4-23
SECONDARY SHEAVE INSTALLATION .............................................. 4-24
PRIMARY SHEAVE INSTALLATION ..................................................... 4-25
STARTER CLUTH AND STARTER MOTOR .............................................. 4-27
STARTER CLUTCH AND GEARS ......................................................... 4-29
C.D.I. MAGNETO .........................................................................................4-30
C.D.I. MAGNETO REMOVAL ................................................................ 4-31
C.D.I. MAGNETO INSTALLATION ........................................................ 4-31
AUTOLUBE PUMP ...................................................................................... 4-32
AUTOLUBE PUMP INSTALLATION ...................................................... 4-33
TRANSMISSION .......................................................................................... 4-34
CHECKING THE TRANSMISSION ........................................................ 4-36
ENG
CRANKCASE AND REED VALVE ............................................................. 4-37
CRANKCASE (RIGHT) REMOVAL ........................................................ 4-39
CRANKCASE (RIGHT) INSTALLATION ................................................ 4-40
CRANKSHAFT ............................................................................................ 4-42
CRANKSHAFT REMOVAL .................................................................... 4-43
CRANKSHAFT INSPECTION ................................................................ 4-43
CRANKSHAFT INSTALLATION ............................................................ 4-44
OVERHAULING THE ENGINE
ENG
EAS00188
OVERHAULING THE ENGINE
ENGINE
LEADS AND HOSES
1
8
9
11
7
10
2
3
5
6
4
Order
I
1
II
2
3
4
5
6
Job/Part
Q’ty
Removing the leads and hoses
Seat
Upper side covers
Glove compartment cover
Oil cover
Lower side covers
Rear mudguard
Remove:
Air shroud
Remove:
Autolube delivery hose
Autolube pump cable
Spark plug cap
Battery lead (-)
CDI magneto leads coupler
Remarks
Remove the parts in the order listed.
Refer to "SEAT AND SIDE COVERS"
in chapter 3.
Refer to "BOX, SIDE COVERS AND
MUDGUARD" in chapter 3.
1
1
1
1
1
2
4-1
OVERHAULING THE ENGINE
ENG
1
8
9
11
7
10
2
3
5
6
4
Order
Job/Part
Q’ty
7
III
8
Starter motor lead coupler
Untighten :
Rear wheel nut
1
IV
9
10
11
Remove :
Rear brake adjuster
Rear brake cable
Pin
1
1
1
Remarks
1
Note:
Loosen the rear wheel nut.
For installation, reverse the removal procedure.
4-2
OVERHAULING THE ENGINE
ENG
EXHAUST PIPE
LT
T.R
29 Nm (2,9 m.kg)
2
3
5
1
T.R
8.5 Nm (0,85 m.kg)
4
Order
Job/Part
Q’ty
Removing the exhaust pipe
Lower cover
I
II
1
2
3
III
4
5
Untighten:
Bolt (from cylinder)
Remove:
Gasket
Bolt
Spacer/damper
Remove:
Bolt (from cylinder)
Exhaust pipe
Remarks
Remove the parts in the order listed.
Refer to "BATTERY COVER AND
LOWER COVER" in chapter 3.
2
1
2
1/1
2
1
For installation, reverse the removal procedure.
4-3
OVERHAULING THE ENGINE
ENG
EAS00192
ENGINE
2
1
3
Order
Job/Part
Q’ty
Removing the engine
Leads and hoses
Exhaust pipe
I
Remove:
1
2
II
3
• Rear shock absorber bolt (lower)
• Engine mounting bolt
Remove:
• Engine
Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
1
1
1
Refer to "INSTALLING THE ENGINE".
For installation, reverse the removal procedure.
4-4
ENG
EAS00192
INSTALLING THE ENGINE
T.R
T.R
17.5 Nm (1,75 m.kg)
1
50 Nm (5,0 m.kg)
4
8
3
4
4
4
4
4
4
Order
I.
Job/Part
Q’ty
Remarks
Install:
Engine mounting bolt Rear shock absorber bolt (lower) 1
1
II.
1
2
Tighten the bolts in the following order.
Rear shock absorber bolt
Engine mounting bolt
1
1
III.
3
4
Install:
Rear brake cable
Leads and hoses
NOTE:
Do not fully tighten the bolts.
17.5 Nm (1.75 m•kg)
50 Nm (5.0 m•kg)
Refer to "ENGINE (LEADS AND HOSES)"
4-5
CYLINDER HEAD
ENG
EAS00222
CYLINDER HEAD, CYLINDER AND PISTON
4
5
3
2
6
8
1
T.R
14 Nm (1,4 m.kg)
9
7
E
Order
Job/Part
Q’ty
Removing the cylinder head
and piston
Lower cover
I
1
2
3
4
5
6
7
8
9
Remarks
Remove the parts in the order listed.
Exhaust pipe
Remove :
Air shroud (cylinder head)
Spark plug
Cylinder head/ Cylinder head gasket
Cylinder
Cylinder gasket
Piston pin clip
Piston pin/Piston bearing
Piston
Piston rings
Refer to "BATTERY COVER AND
LOWER COVER" in chapter 3.
Refer to "EXHAUST PIPE".
1
1
1/1
1
1
2
1/1
1
2
For installation, reverse the removal procedure.
4-6
CYLINDER HEAD, CYLINDER, PISTON
ENG
PISTON PIN AND PISTON REMOVAL
1. Remove:
• Piston pin clip NOTE:
Before removing the piston pin clip, cover the
crankcase with a clean rag so you will not
accidentally drop the clip into the crankcase.
2. Remove:
• Piston pin • Piston • Piston pin bearing CAUTION:
Do not use a hammer to drive the piston
pin out.
CYLINDER HEAD INSPECTION
1. Eliminate:
• Carbon deposits
Use a rounded scrapper .
2. Inspect:
• Cylinder head warpage
Out of specification→Re-surface.
*****************************************************
Warpage measurement and resurfacement
steps:
• Attach a straight edge and a thickness
gauge on the cylinder head.
• Measure the warpage limit.
Warpage limit:
0.05 mm
• If the warpage is out of specification, reface
the cylinder head.
NOTE:
Rotate the head several times to avoid removing
too much material from one side.
******************************************************
4-7
CYLINDER HEAD, CYLINDER, PISTON
ENG
CYLINDER AND PISTON INSPECTION
1. Eliminate :
• Carbon deposits
Use a rounded scraper .
2. Inspect :
• Cylinder wall
Wear/Scratches→Rebore or replace.
3. Eliminate :
• Carbon deposits From the piston crown and ring grooves .
4. Remove :
• Score markes and lacquer deposits
From the sides of piston.
5. Inspect :
• Piston wall
Wear/Scratches/Damage→Replace.
6. Measure :
• Piston-to cylinder clearance
*****************************************************
Piston to cylinder clearance measurement
steps: First step:
• Measure the cylinder bore “C” with a cylinder
bore gauge.
NOTE:
Measure the cylinder bore “C” in parallel to and
at right angles to the crankshaft. Then, find the
average of the measurements.
4-8
CYLINDER HEAD, CYLINDER, PISTON
ENG
Standard
D1
D3
D5
Cylinder bore 52.002~52.012mm
“C”
D2
D4
Wear limit
52.10 mm
Taper “T”
–
0.05 mm
Out of round
“R”
–
0.03 mm
C = Maximum D
T=( Maximum D1 or D2 ) - ( Maximum D5 or
D6 )
R=( Maximum D1 D3 or D5 ) - ( Maximum
D2 D4 or D6 )
D6
• If out of specification, rebore or replace
cylinder, and replace piston and piston rings
as a set.
2nd step:
• Measure the piston skirt diameter “p” with a
micrometer.
a 10 mm from the piston bottom edge.
Piston size P
a
Standard
Oversize 1
Oversize 2
51.958~51.967 mm
52.52 mm
52.50 mm
• If out of specification, replace piston and
piston rings as a set.
3rd step:
• Calculate the piston-to cylinder clearance
with following formula:
Piston-to cylinder clearance =
Cylinder bore “ C ”- Piston skirt diameter “p”
• If out of specification, rebore or replace
cylinder, and replace piston and piston rings
as a set.
Piston-to cylinder clearance:
0.044 ~ 0.045mm
Limit : 0.1 mm
4-9
CYLINDER HEAD, CYLINDER, PISTON
ENG
PISTON RINGS INSPECTION
1. Measure:
• Side clearance
Out of specification→Replace piston and
/or rings.
Use a feeler gauge Standard
Limit
Top ring
0.03 ~ 0.05 mm
0.10 mm
2nd ring
0.03 ~ 0.05 mm
0.10 mm
2. Install :
• Piston ring
Into the cylinder
Push the ring with the piston crown.
3. Measure :
• End gap
Out of specification→Replace rings
as a set.
Use a feeler gauge .
a
Standard
Limit
Top ring
0.15 ~ 0.35 mm
0.60 mm
2nd ring
0.15 ~ 0.35 mm
0.60 mm
a Measuring Point 20 mm
PISTON PIN AND PISTON PIN BEARING
INSPECTION
1. Inspect :
• Piston pin
Blue discoloration/GrooveÆReplace, then
inspect lubrication system.
4-10
CYLINDER HEAD, CYLINDER, PISTON
ENG
2. Measure :
• Outside diameter @ (piston pin)
Out of specification→Replace.
Outside diameter (piston pin) :
13.996~14.000 mm
3. Measure:
• Piston pin-to-piston clearance
Out of specification→Replace piston.
@
Piston pin-to-piston clearance =
Bore size (piston pin)
Outside diameter (piston pin)
Piston pin-to-piston clearance :
0.004~0.019 mm
4. Inspect :
• Bearing(piston pin)
Pitting/Damage→Replace.
PISTON PIN AND PISTON INSTALLATION
1. Apply :
• Engine oil
(to the crankshaft bearing, connecting rod big
end bearing, small end bearing, piston pin,
piston ring grooves and piston skirt areas.)
E
E
R.
4-11
T.
2. Install :
• Reed valve gasket
• Reed valve
• Carburetor joint 11Nm(1.1 m.kg)
CYLINDER HEAD, CYLINDER, PISTON
ENG
3. Install :
• Small end bearing
• Piston • Piston pin • Piston pin clip a
NOTE:
• The arrow a on the piston to the exhaust side.
• Before installing the piston pin clip, cover the
crankcase with a clean towel or rag so you will
not accidentally drop the pin clip material into
the crankcase.
• Always use a new piston pin clip.
CYLINDER AND CYLINDER HEAD
1. Install :
• Cylinder gasket (new gasket)
2. Check :
• Piston rings
1st ring
2nd ring
NOTE:
Make sure the ring ends are properly fitted
around the ring locating pins in the piston
grooves.
3. Install :
• Cylinder NOTE:
Install the cylinder with one hand while
compressing the piston rings with the other
hand.
4-12
CYLINDER HEAD, CYLINDER, PISTON
ENG
4. Install :
• Cylinder head gasket (new gasket)
5. Install :
• Cylinder head 14Nm(1.4m.kg)
• Spark plug 20Nm(2.0m.kg)
• Air shroud
T.
R.
T.
R.
NOTE:
Tighten the cylinder head holding nuts in stage,
using a crisscross pattern.
4-13
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE
CRANKCASE COVER (LEFT)
6
5
4
T.
R.
T.
R.
1
12Nm(1.2kg.m)
9 Nm(0.9kg.m)
T.
R.
13 Nm(1.3kg.m)
3
2
Order
Job name/Part name
Q’ty
Remove the parts in order.
Crankcase cover (left) removal
1
2
3
4
5
6
Remarks
Air cleaner assembly mounting screw
Screw(Bind)
Kick starter
Crankcase (left)
Gasket
Pin
1
1
1
1
1
2
Reverse the removal procedure for installation.
4-14
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
KICK STARTER
B
Order
Job name/Part name
Kick starter removal
Kickstarter pinion gear
Kickstarter pinion gear clip
Circlip/Plain washer
Kick shaft
Return spring
Collar
Q’ty
Remarks
Remove the parts in order.
1
1
1/1
1
1
1
Reverse the removal procedure for installation.
4-15
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
KICK STARTER INSTALLATION
1. Install :
• Return spring • Kick shaft • Collar • Plain washer • Circlip ******************************************************
Installation steps :
a. Install return spring and kick shaft as
shown.
b. Install collar, plain washer and clip .
c. Hook the spring onto the crankcase
projection .
d. Install the kick starter pinion gear and the
kick starter.
******************************************************
4-16
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE
3
2
7
6
1
5
4
T.
R.
9
R.
Order
8
T.
10
Job name/Part name
Q’ty
V-belt, clutch and secondary/primary
sheave removal
Lower rear cover
Air shroud 3
1
2
3
4
5
6
7
8
9
10
Crankcase (left)
Clutch housing
Secondary sheave assembly
V-belt
Conical washer/One-way clutch
Crow washer
Primary fixed sheave
Collar/Washer
Primary sliding sheave
Cam/ Slider
Weight
40Nm(4.0kg.m)
45Nm(4.5kg.m)
Remarks
Remove the parts in order.
Refer to “BATTERY COVER AND
LOWER COVER” section in chapter 3.
1
1
1
1/1
1
1
1/1
1
1/3
6
Refer to “CRANCKCASE COVER” section.
Refer to “SECONDARY SHEAVE
REMOVAL ” section.
Refer to “PRIMARY SHEAVE REMOVAL
INSTALLATION” section.
Reverse the removal procedure for installation
4-17
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
SECONDARY SHEAVE
SECONDARY SHEAVE
T.
R.
50Nm(5.0kg.m)
LS
LS
Order
Job name/Part name
Q’ty
Secondary sheave disassembly
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 order.
1
1
3
1
1
2
1
2
2
1
Refer to “SECONDARY SHEAVE
INSTALLATION” section.
Refer to “SECONDARY SHEAVE
INSTALLATION” section.
Reverse the disassembly procedure for
assembly.
4-18
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
PRIMARY SHEAVE REMOVAL
1. Remove :
• Fan
2. Remove :
• Nut (primary sheave)
NOTE:
When loosening the nut (primary sheave), hold
the C.D.I. magneto using flywheel holding tool
.
Flywheel holding tool :
90890-01235
3. Remove :
• Conical spring washer • One-way clutch • Crow washer • Primary fixed sheave • Shim • V-Belt
4. Remove :
• Collar • Primary sheave assembly SECONDARY SHEAVE REMOVAL
1. Remove :
• Nut (secondary sheave)
NOTE:
Hold the secondary sheave using sheave holder .
Sheave holder :
90890-01701
2. Remove :
• Clutch housing
• Secondary sheave assembly
• Dowel pins
4-19
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
3. Loosen :
• Nut(Clutch carrier) NOTE:
Install the secondary sheave to primary drive shaft
as shown, and hold the secondary sheave by
Universal Roter Holder to loosen the nut .
Flywheel holding tool :
90890-01235
CAUTION:
Do not remove the clutch securing nut yet.
If the nut is removed without compressing
the secondary sheave, it may jump and cause
injury.
4. Attach :
• Clutch spring holder Clutch spring holder :
90890-01337
5. Remove :
• Clutch securing nut 6. Remove:
• Clutch assembly • Clutch spring • Secondary sliding sheave assy' • Guide pins
CLUTCH INSPECTION
1. Inspect:
• Clutch shoes
Glazed parts→Sand with coarse sandpaper.
NOTE:
After using the sand paper, clean of the polished
particles with cloth.
4-20
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
2. Measure :
• Clutch shoe thickness a
Out of specification→Replace.
Clutch shoe thickness :
4 mm
< Wear limit> :
2.5 mm
V-BELT INSPECTION
1. Inspect :
• V-belt Crack→Replace.
NOTE:
Replace the V-belt smeared with a lot of oil or
grease.
a
2. Measure :
• V-belt width a
Out of specification→Replace.
V-belt width :
17.7 mm
<Wear limit> :
16.0 mm
4-21
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
PRIMARY SHEAVE INSPECTION
1. Inspect :
• Primary sliding sheave • Primary fixed sheave Wear/Cracks/Scratch/Damage
→Replace.
2. Check :
• Free movement
Insert the collar into the primary sliding
sheave , and check for free movement.
Stick or excessive play → Replace the sheave
or collar.
3. Measure :
• Outside diameter (weight)
Out of specification → Replace.
Outside diameter (weight)
15.0 mm
<Limit 14.5 mm>
4-22
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
SECONDARY SHEAVE INSPECTION
1. Inspect :
• Secondary fixed sheave • Secondary sliding sheave Scratch/Crack/Damage→Replace as a set.
• Oil seal Damage→Replace
2. Inspect :
• Torque cam grove • Guide pin Wear/Damage→Replace as a set.
• O-rings Damage→Replace.
3. Measure :
• Clutch spring free length
Out of specification→Replace.
Clutch spring free length :
81 mm
<Limit> :
73 mm
4. Inspect :
• Clutch housing inner surface
Oil/Scratches→Remove.
Oil
a
Scratches
Use a rag soaked in lacquer
thinner or solvent.
Use an emery cloth (lightly
and evenly polishing).
5. Measure :
• Clutch housing inside diameter a
Out of specification→Replace.
Clutch housing inside diameter :
112.0 mm
<Wear limit> :
112.5 mm
a
4-23
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
SECONDARY SHEAVE INSTALLATION
When assembling the secondary sheave, reverse the disassembly procedure. Note the
following points.
E
1. Apply :
• BEL-RAY assembly lube®
(to the inside of the sliding/fixed sheave)
E
2. Install :
• Sliding sheave NOTE:
Be careful so that the oil seal lips are not
turned over when installing the sheave.
3. Apply :
• BEL-RAY assembly lube®
(to the torque cam grooves and O-rings)
4. Install :
• Guide pin 1
5. Check :
• Sliding sheave
Unsmooth operation→Repair.
6. Install :
• Clutch securing nut Use clutch spring holder Clutch spring holder :
90890-01337
T.
7. Tighten :
• Clutch securing nut 50 Nm(5.0 m.kg)
Use Flywheel holding tool R.
Flywheel holding tool :
90890-01235
4-24
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
8. Install :
• Secondary sheave assembly
• Clutch housing • V-belt NOTE:
The V-belt must be installed with the arrow
frontward.
R.
T.
9. Tighten :
• Nut (secondary sheave)
Use sheave holder 40 Nm(4.0 m.kg)
Sheave holder :
90890-01701
PRIMARY SHEAVE INSTALLATION
1. Clean :
• Primary sliding sheave face • Primary fixed sheave face • Collar • Weight • Primary sliding sheave cam surface 2. Install :
• Weight • Cam • Slider • Collar 3. Check :
• Cam operation
Not smooth→Repair.
4. Install :
• Primary sheave assembly • Collar 5. Install :
• V-belt
4-25
V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
ENG
6. Install :
• Shim • Primary fixed sheave • Crow washer • One-way clutch • Conical spring washer • Nut T.
7. Tighten :
• Nut (primary sheave)
45 Nm(4.5 kg.m)
R.
NOTE:
When tightening the nut (primary sheave), hold
the C.D.I. magneto using Flywheel Holding Tool
.
Flywheel holding tool :
90890-01235
8. Adjust :
• V-belt Tense the V-belt by turning the primary sheave
several times.
R.
4-26
T.
9. Install :
• Fan
7 Nm (0.7 kg.m)
STARTER CLUTCH AND STARTER MOTOR
ENG
STARTER CLUTCH AND STARTER MOTOR
STARTER CLUTCH AND STARTER MOTOR
10
9
T.
R.
13Nm(1.3kg.m)
4
3
2
1
8
T.
R.
8Nm(0.8kg.m)
B
6
7
5
Order
Job name/Part name
Q’ty
Remarks
Starter clutch and starter motor
removal
Left/Right lower side cover
Left/right upper side cover
Oil cover
Air shroud 3
Cooling fan
Remove the parts in order.
Crankcase cover (left)
Refer to “CRANKCASE COVER (LEFT) ”
section.
Refer to “COVERS” in chapter 3.
Refer to “C.D.I. MAGNETO ” section
Primary sheave
1
2
3
4
Plate
Plain washer
Idle gear
Plain washer
1
1
1
1
4-27
Refer to “V-BELT, PRIMARY SHEAVE ”
section.
STARTER CLUTCH AND STARTER MOTOR
ENG
10
9
T.
R.
13Nm(1.3kg.m)
4
3
2
1
8
T.
R.
8Nm(0.8kg.m)
B
6
7
5
Order
5
6
7
8
9
10
Job name/Part name
Starter clutch
Plain washer
Starter wheel gear
Collar
Starter motor
Starter motor connector
Q’ty
Remarks
1
2
1
1
2
1
Reverse the removal procedure for instalation
4-28
INSPECTION AND REPAIR
ENG
STARTER CLUTCH AND GEARS
1. Inspect :
• Starter clutch
Push the dowel pin to arrow direction.
Unsmooth operation→Replace starter clutch
assembly.
2. Inspect :
• Starter wheel gear teeth • Idle gear teeth Burrs/Chips/Roughness/Wear→Replace.
3. Inspect :
• Starter clutch operation
******************************************************
Clutch operation checking steps:
• Install the starter wheel gear to the starter
clutch, and hold the starter clutch.
• When turning the wheel gear counterclockwise A the starter clutch and the wheel
gear should be engaged.
If not the starter clutch is faulty. Replace it.
• When turning the wheel gear clockwise B, the
wheel gear should turn freely. If not, the starter
clutch is faulty. Replace it.
*******************************************************
4-29
C.D.I. MAGNETO
ENG
C.D.I. MAGNETO
C.D.I. MAGNETO
5
4
7
8
R.
T.
8Nm(0.8kg.m)
6
3
T.
R.
43Nm(4.3kg.m)
2
T.
R.
7Nm(0.7kg.m)
1
Order
Job name/Part name
Q’ty
C.D.I. magneto removal
Lower cover
1
2
3
4
5
6
7
8
Oil cover
Air shroud 3
Fan /O-ring
Magneto rotor
Bind
Couplers (magneto leads)
Stator coil
Woodruff key
Gasket (Magneto cover)
Remarks
Remove the parts in order.
Refer to “BATTERY COVER AND
LOWER COVER” section in chapter 3.
1
1/1
1
1
2
1
1
1
Reverse the removal procedure for installation.
4-30
ENGINE DISASSEMBLY
ENG
C.D.I. MAGNETO REMOVAL
1. Remove :
• Nut (rotor)
• Plain washer
NOTE:
Hold the rotor to loosen the nut by the flywheel
holding tool .
Flywheel holding tool :
90890-01235
2. Remove :
• Rotor • Woodruff key
Use the flywheel magneto puller .
Flywheel magneto puller :
90890-01189
• Stator assembly
• Gasket
C.D.I. MAGNETO INSTALLATION
1. Install :
• Gasket 2. Apply :
• Lithium soap base grease
(to oil seal)
3. Pass the C.D.I. magneto lead through the
crankcase hole.
4. Install :
• Stator assembly
8 Nm(0.8 kg.m)
5. Install :
• Woodruff key
• C.D.I. magneto Rotor • Plain washer
• Nut
43Nm(4.3 kg.m)
B
T.
R.
T.
R.
4-31
AUTOLUBE PUMP
ENG
AUTOLUBE PUMP
AUTOLUBE PUMP
5
1
6
4
R.
3
T.
2
4Nm(0.4kg.m)
8
7
Order
1
2
3
4
5
6
7
8
Job name/Part name
Autolube pump removal
C.D.I. magneto
Air shroud 2.
Circlip
Pump drive gear
Pin
Oil hose
Oil delivery hose
Autolube pump cable
Autolube pump ass’y
Q’ty
Remarks
Remove the parts in order.
Refer to “C.D.I. MAGNETO” section.
1
1
1
1
1
1
1
1
Refer to “AUTOLUBE PUMP INSTALLATION” section
Reverse the removal procedure for installation.
4-32
AUTOLUBE PUMP
ENG
AUTOLUBE PUMP INSTALLATION
CAUTION:
After installing autolube pump, it must be
bleeded.
1. Install :
• Pin • Pump drive gear • Circlip 2. Apply :
• Lithium soap base grease
(to O-ring)
3. Install :
• Autolube pump 4 Nm(0.4m.kg)
LS
T.
R.
4. Apply:
• Lithium soap base grease
(to autolube pump gear ,)
15 cc (0.92 cu • in)
LS
4-33
ENG
TRANSMISSION
TRANSMISSION
TRANSMISSION
3
10
8
7
9
6
5
2
T.
R.
18Nm(1.8kg.m)
1
4
T.
R.
12Nm(1.2kg.m)
B
Order
Job name/Part name
Q’ty
Remove the parts in order.
Refer to “REAR WHEEL AND REAR
BRAKE ” section in chapter 6.
Refer to “V-BELT, CLUTCH, SECONDARY/
PRIMARY SHEAVE” section
Refer to “CHANGING THE TRANSMISSION OIL ” section in chapter 3.
Transmission removal
Rear wheel
Secondary sheave
Drain the transmission oil.
1
2
3
4
5
6
7
Transmission case cover
Gasket (transmission case cover)
Dowel pin
Secondary sheave axle
Plain washer
Conical spring washer
Drive gear
Remarks
1
1
2
1
1
1
1
4-34
ENG
TRANSMISSION
TRANSMISSION
TRANSMISSION
3
10
8
7
9
6
5
2
T.
R.
18Nm(1.8kg.m)
1
4
T.
R.
12Nm(1.2kg.m)
B
Order
8
9
10
Job name/Part name
Circlip
Main axle
Drive axle
Q’ty
Remarks
1
1
1
Reverse the removal procedure for installation.
4-35
TRANSMISSION
ENG
EAS00423
CHECKING THE TRANSMISSION
1.Measure:
•main axle runout (with a centering device and dial gauge)
Out of specification → Replace the main axle.
T.
R
319005(a)
Main axle deflection limit
0.08 mm
2.Measure:
•drive axle runout (with a centering device and dial gauge)
Out of specification → Replace the drive axle.
T.
R
Drive axle deflection limit
0.08 mm
319005(b)
3.Check:
•secondary sheaveaxle bearing •main axle bearing •drive axle bearing Spin the bearing inner race.
Excessive play/Roughness → Replace.
Pitting/Damage → Replace.
319038
4-36
CRANKCASE AND REED VALVE
ENG
CRANKCASE AND REED VALVE
CRANKCASE AND REED VALVE
T.
T.
R.
R.
9Nm(0.9kg.m)
12Nm(1.2kg.m)
7
4
8
5
6
B
1
9
10
2
3
Order
Job name/Part name
Q’ty
Remarks
Crankcase and Reed valve removal
Remove the parts in order.
Engine removal
Cylinder head, cylinder, piston
Refer to “ENGINE REMOVAL” section.
Refer to “CYLINDER HEAD CYLINDER
AND PISTON” section.
Refer to “CRANKCASE COVER (LEFT) ”
section.
Refer to “V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE ” section.
Refer to “C.D.I. MAGNETO” section.
Refer to “STARTER CLUTCH AND STARTER MOTOR” section.
Refer to “AUTOLUBE PUMP” section.
Refer to “REAR WHEEL AND BRAKE”
section in chapter 6.
Refer to “TRANSMISSION” section.
Crankcase cover (left)
V-belt, clutch, secondary/primary
sheave
C.D.I . magneto
Starter clutch, starter motor
Autolube pump
Rear wheel
Transmission
4-37
CRANKCASE AND REED VALVE
ENG
CRANKCASE AND REED VALVE
CRANKCASE AND REED VALVE
T.
T.
R.
R.
9Nm(0.9kg.m)
12Nm(1.2kg.m)
7
4
8
5
6
B
1
9
10
2
3
Order
Job name/Part name
Q’ty
1
2
3
4
5
Intake manifold
Reed valve
Valve seat gasket
Stopper
Crankcase 2
1
1
1
1
1
6
7
8
9
10
Dowel pin
Engine mount spacer
Circlip
Bearing
Oil seal
2
1
1
1
1
Remarks
Refer to “CRANCKCASE REMOVEL” and
“CRANCKCASE INSTALLATION”
Reverse the removal procedure for installation.
4-38
CRANKCASE AND REED VALVE
ENG
T.
CRANKCASE (RIGHT) REMOVAL
1. Remove :
• Oil seal stopper • Screws (crankcase)
9Nm(0.9 kg.m)
R.
NOTE:
Loosen each screw 1/4 turn, and remove them
after all are loosened.
2. Attach :
• Crankcase separating tool Crankcase separating tool :
90890-01135
NOTE:
Fully tighten the tool holding bolts, but make
sure the tool body is parallel with the case. If
necessary, one screw may be backed out slightly
to level tool body.
3. Remove :
• Crankcase (right)
As pressure is applied, alternately tap on the
engine mounting bosses.
CAUTION:
Use a soft hammer to tap on the case. Tap
only on reinforced spots of the case. Never
tap on the gasket mating surfaces. Work
slowly and carefully. Make sure the cases
separate evently. If one end “hand up” take
the pressure off the push screw, realign the
cases and the tool and start again. If the
cases do not separate at all, check for
remaining case screw or fitting. Do not force.
4-39
CRANKCASE AND REED VALVE
ENG
CRANKCASE (RIGHT) INSTALLATION
1. Install :
• Dowel pins • Engine mount spacer 2. Apply :
• Yamaha Bond No.1215 To the mating surfaces of both case helves.
Yamaha bond No.1215:
90890-85505
3. Attach :
• Crankshaft installing tools
Crankshaft installing tool:
90890-01274
90890-01275
90890-01277 90890-01288 T.
4. Tighten :
• Crankcase holding screws
12 Nm(1.2 kg.m)
R.
NOTE:
Tighten the crankcase holding screws in stage,
using a crisscross pattern.
5. Check :
• Crankshaft operation
Unsmnoth operation → Repair.
6. Install :
• Oil seal (right crank case) Apply grease onto oil seal lip.
B
T.
7. Install:
• Oil seal stopper plate 9 Nm (0.9 kg.m)
R.
4-40
ENG
CRANKCASE AND REED VALVE
R.
4-41
T.
8. Install :
• Gasket
• Reed valve 11 Nm(1.1 kg.m)
CRANKSHAFT
ENG
CRANKSHAFT
CRANKSHAFT
B
2
3
4
1
2
3
B
Order
Job name/Part name
Q’ty
Crankshaft removal
Right crankcase removal
1
2
3
4
Crankshaft
Bearing
Oil seal
Crankcase cover (left)
Remarks
Remove the parts in order.
Refer to “CRANKCASE AND REED
VALVE” section.
1
2
2
1
Reverse the removal procedure for installation.
4-42
CRANKSHAFT
ENG
CRANKSHAFT REMOVAL
1. Attach :
• Crankcase separating tool Crankcase separating tool :
90890-01135
2. Remove :
• Crankshaft F
C
C
CRANKSHAFT INSPECTION
1. Measure :
• Runout limit “ C”
• Connecting rod big end side clearance “D”
• Small end free play limit “F”
Out of specification→Replace.
Use V-blocks, dial gauge and thickness
gauge.
D
Runout limit “C” :
0.03 mm
Connecting rod big end side
clearance “D”:
0.2 ~ 0.5 mm
Small end free play “ F” :
0.4 ~ 0.8 mm
2. Inspect:
• Bearings (crankshaft)
Spin the bearing inner race.
Excessive play/Roughness→Replace.
Pitting/Damage→Replace.
4-43
CRANKSHAFT
ENG
CRANKSHAFT INSTALLATION
1. Attach :
• Crankshaft Installing Tool
Crankshaft installing tool:
90890-01274
90890-01275
90890-01277
90890-01288
2. Install :
• Crankshaft (to the crankcase )
3. Install :
• Oil seal • Apply lithium soap base grease onto
the oil seal lip.
Use the guide and seal driver to install
the oil seal
Oil seal installer
90890-01410
Oil seal guide
90890-01409
4-44
CARB
5
CARB
CHAPTER 5.
CARBURETOR
CARBURETOR .............................................................................................. 5-1
CARBURETOR ........................................................................................ 5-1
TEIKEI CARBURETOR DISASSEMBLY ................................................. 5-2
CHECKING THE CARBURETOR ............................................................ 5-4
ASSEMBLING THE CARBURETOR ....................................................... 5-5
INSTALLING THE CARBURETOR .......................................................... 5-6
FUEL COCK .................................................................................................. 5-7
INSPECTING THE FUEL COCK ............................................................. 5-7
CLEANING THE FUEL FILTER ............................................................... 5-7
REED VALVE ................................................................................................ 5-8
CHECKING THE REED VALVE .............................................................. 5-9
INSTALLING THE REED VALVE ............................................................ 5-9
CARBURETOR
CARB
EAS00480
CARBURETOR
CARBURETOR
3
4
6
2
5
1
7
T.
R.
Order
Job/Part
Remarks
Q'ty
Remove the parts in the order listed.
Removing the carburetor
Air filter box
1
2
3
4
5
6
7
9Nm(0.9kg.m)
Fuel hose
Vacuum hose
Oil delivery hose
Choke cable
Air filter joint
Throttle cable
Carburetor
1
1
1
1
1
1
1
Unhook
For installation, reverse the removal
procedure.
5-1
CARBURETOR
CARB
EAS000483
TEIKEI CARBURETOR DISASSEMBLY
Q
U
W
E
Y
R
P
I
O
T
{
o
}
i
u
y
t
r
e
w
q
Order
Job/Part
Q'ty
Remove the parts in the order listed.
Carburetor disassembly
Q
W
E
R
T
Y
U
I
O
P
{
}
q
Remarks
Carburetor top
Gasket
Throttle valve spring
Needle set
Throttle valve
Starter retaining plate
Starter top cover
Starter plunger O'ring
Starter plunger spring
Starter plunger
Air screw set
Throttle stop screw
Drain screw
1
1
1
1
1
1
1
1
1
1
1
1
1
5-2
CARBURETOR
CARB
EAS000483
TEIKEI CARBURETOR DISASSEMBLY
Q
U
W
E
Y
R
P
I
O
T
{
o
}
i
u
y
t
r
e
w
q
Order
w
e
r
t
y
u
i
o
Job name/Part name
Float chamber
Float chamber gasket
Float pin
Float / Needle valve
Main jet
Main nozzle
Pilot jet
Carburetor body
Q'ty
Remarks
1
1
1
1/1
1
1
1
1
For installation, reverse the removal
procedure.
5-3
CARBURETOR
CARB
EAS00485
CHECKING THE CARBURETOR
1.Check :
• carburetor body 햲
• float chamber
• jet housing
• fuel passages
Durt/Obstruction → Clean
Cracks/damage → Replace.
햲
322006
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.
2.Check :
• float chamber rubber gasket
Cracks/damage/wear → Replace.
3.Check :
• main jet 햲
• needle jet 햳
• pilot jet 햴
Contamination → Clean.
햳
햴
햲
322012
4.Check :
• float 햳
Damage → Replace.
• needle valve 햲
Wear/Contamination → Replace
• gasket
Damage → Replace.
햳
햲
322013
햲
5.Check :
• Throttle valve 햲
Damage/Wear → Replace.
322014
5-4
CARBURETOR
햲
CARB
6.Check :
•Throttle valve free movement
Unsmooth/Stickiness → Replace.
Insert the throttle valve 햲 into the carburetor
body 햳 and check for smooth movement.
햳
322015
7.Check :
•throttle stop screw 햲
•air screw 햳
•needle 햴
•starter plunger 햵
Damage/Wear → Replace.
햳
햲
햴
햵
322016
NOTE:
The float height is factory-adjusted. Never try to
adjust it yourself.
EAS00487
ASSEMBLING THE CARBURETOR
CAUTION:
Before assembling the carburetor, wash all
of the parts in a petroleum-based solvent.
Always use a new gasket.
햳
햴
1.Install :
• needle 햳
• clip 햴
• throttle valve 햲
• spring seat 햵
• spring
햵
햴
햳
Jet needle clip position :
3/5
햲
322018
5-5
CARBURETOR
햲
햳
CARB
2.Install :
• throttle valve 햲
• starter plunger
NOTE:
Align the groove 햳 of the throttle valve with the
projection 햴 of the carburetor.
햴
322019
3.Install :
• Carburetor
햲
NOTE:
Align projection 햲 with projection 햳.
햳
322020
EAS00492
INSTALLING THE CARBURETOR
1. Adjust:
• engine idling speed
Engine idling speed
1800 ~ 2200 r/min
Refer to "ADJUSTING THE ENGINE IDLING
SPEED" in chapter 3.
2. Adjust:
• throttle cable free play
Throttle cable free play (at the
flange of the throttle grip)
1.5 ~ 3.0 mm
Refer to "ADJUSTING THE THROTTLE
CABLE FREE PLAY" in chapter 3.
5-6
FUEL COCK
CARB
FUEL COCK
INSPECTING THE FUEL COCK
1.Stop the engine.
2.Remove:
• Side covers
Refer to "COVERS" in Chapter 3.
3.Inspect:
•Fuel cock
햲
*******************************************************
Fuel cock inspection steps:
• Disconnect the fuel hose 햲.
• Place the receptacle under the fuel hose end.
• If fuel stops flowing out in a few seconds, the
fuel cock is in good condition.
If not, clean or replace the fuel cock.
• Disconnect the vaccum hose and breathe in
through the vaccum hose, for vaccum.
• If fuel flows out of the fuel hose under vaccum
and stops under non-vaccum, the fuel cock is
in good condition.
If not, clean or replace the vaccum hose, fuel
hose and fuel cock.
322031
*******************************************************
CLEANING THE FUEL FILTER
The fuel filter 햲 is fitted inside the fuel tank. It is
accessible when the fuel hose (between the fuel
tank and the fuel cock) is disconnected.
햲
352001
5-7
REED VALVE
CARB
REED VALVE
T.R
11 Nm (1.1 m.kg)
1
2
Order
Job/Part
Q'ty
Removing the reed valve
Carburetor
1
2
Remarks
Remove the parts in the order listed.
Refer to "CARBURETOR" section.
Carburetor joint
Reed valve assembly
1
1
For installation, reverse the removal
procedure.
5-8
REED VALVE
CARB
YP600051
CHECKING THE REED VALVE
1.Inspect :
• Caburetor joint
Damage/Cracks → Replace.
• Reed valve
Fatigue/Cracks → Replace.
*****************************************************
Inspection steps :
• Visually inspect the reed valve.
NOTE:
Correct reed valve should fit flush or nearly flush
against valve seat.
• If in doubt as to sealing ability, apply suction to
carburetor side of assembly.
• Leakage should be slight to moderate.
*****************************************************
2.Measure :
• Valve stopper height 햲
Out of specification → Replace valve stopper.
햲
Valve stopper height 햲:
6.0 ~ 6.4 mm
322023
3.Measure :
• Reed valve clearance 햲
Out of specification → Replace reed valve.
햲
Reed valve clearance 햲:
Less than 0.2 mm
322024
INSTALLING THE REED VALVE
Reserve the removal procedure.
Note the following points.
1. Install :
• Gasket
2.Tighten :
• Reed valve securing bolts
11Nm (1.1 m•kg)
NOTE:
Tighten the bolts gradually to avoid warping.
T.R
5-9
CHAS
6
CHAS
CHAPTER 6.
CHASSIS
FRONT WHEEL AND BRAKE DISC ............................................................. 6-1
FRONT WHEEL AND BARKE DISC ........................................................ 6-1
FRONT WHEEL ....................................................................................... 6-2
REMOVING THE FRONT WHEEL .......................................................... 6-3
DISASSEMBLING THE FRONT WHEEL ................................................ 6-3
CHECKING THE FRONT WHEEL ........................................................... 6-4
CHECKING THE BRAKE DISC ............................................................... 6-6
CHECKING THE SPEEDOMETER GEAR UNIT ..................................... 6-7
ASSEMBLING THE FRONT WHEEL ...................................................... 6-7
INSTALLING THE FRONT WHEEL ......................................................... 6-8
ADJUSTING THE FRONT WHEEL STATIC BALANCE .......................... 6-9
REAR WHEEL AND BRAKE ...................................................................... 6-11
CHECKING THE REAR WHEEL ........................................................... 6-13
CHECKING THE BRAKE ....................................................................... 6-13
INSTALLING THE REAR BRAKE .......................................................... 6-14
INSTALLING THE REAR WHEEL ......................................................... 6-15
FRONT BRAKE ........................................................................................... 6-16
FRONT BRAKE PADS ........................................................................... 6-16
BRAKE PADS REPLACEMENT ............................................................ 6-18
FRONT BRAKE MASTER CYLINDER .................................................. 6-19
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............ 6-21
CHECKING THE FRONT BRAKE MASTER CYLINDER ...................... 6-21
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER ............................................................................................. 6-22
FRONT BRAKE CALIPER ..................................................................... 6-24
DISASSEMBLING THE FRONT BRAKE CALIPER ............................... 6-26
CHECKING THE FRONT BRAKE CALIPER ......................................... 6-27
INSTALLING THE FRONT BRAKE CALIPER ....................................... 6-28
CHAS
FRONT FORK .............................................................................................. 6-30
REMOVING THE FRONT FORK LEGS ................................................ 6-32
DISASSEMBLING THE FRONT FORK LEGS ....................................... 6-32
CHECKING THE FRONT FORK LEGS ................................................. 6-33
ASSEMBLING THE FRONT FORK LEGS ............................................. 6-34
HANDLEBAR .............................................................................................. 6-37
REMOVING THE HANDLEBAR ............................................................ 6-39
CHECKING THE HANDLEBAR ............................................................. 6-39
INSTALLING THE HANDLEBAR ........................................................... 6-40
STEERING HEAD ........................................................................................ 6-42
REMOVING THE LOWER BRACKET ................................................... 6-44
CHECKING THE STEERING HEAD ...................................................... 6-44
INSTALLING THE STEERING HEAD .................................................... 6-45
REAR SHOCK ABSORBER ASSEMBLY .................................................. 6-46
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................. 6-47
FRONT WHEEL AND BRAKE DISC
EAS00513
CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISC
FRONT WHEEL AND BRAKE DISC
1
4
2
6
LT
8
23 Nm (2,3 m.kg)
T.R
7
3
7
5
D
FW
Order
T.R
Q'ty
Job/Part
Removing the front wheel and brake
disc
I
1
II
2
3
4
5
6
7
8
Disconnect:
Speedometer cable
Remove:
Front brake caliper
Wheel axle nut
Wheel axle
Front wheel assembly
Speedometer gear
Collar
Brake disc
35 Nm (3,5 m.kg)
Remarks
Remove the parts in the order listed.
WARNING
Securely support the scooter so there is
no danger of it falling over.
1
NOTE:
Place the scooter on a suitable stand so
that the front wheel is elevated.
1
1
1
1
1
2
1
Refer to "INSTALLING THE FRONT WHEEL"
For installation, reverse the removal procedure.
6-1
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00518
FRONT WHEEL
2
3
2
1
D
FW
Order
Job/Part
Q'ty
Disassembling the front wheel
I
1
2
3
Remarks
Remove the parts in the order listed.
Remove:
Oil seal
Bearing
Collar
1
2
1
Refer to "DISASSEMBLING/ASSEMBLING THE FRONT WHEEL" section.
For assembly, reverse the disassembly
procedure.
6-2
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00520
REMOVING THE FRONT WHEEL
1.Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there
is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2.Disconnect:
• Speedometer cable
3.Remove:
• Front brake caliper
4.Loosen:
• Axle nut
5.Remove:
• Axle nut
• Front wheel axle • Front wheel assembly
• Speedometer gear • Collar
• Front wheel
• Brake disc
NOTE:
Never depress the brake lever when the wheel
is off the scooter. Otherwise the brake pads will
be forced out.
CAUTION:
Handle the wheel with care not to damage the
brake disc. If the brake disc is damaged,
replace it.
EAS00523
DISASSEMBLING THE FRONT WHEEL
1.Remove:
• Oil seal
• Wheel bearings
6-3
FRONT WHEEL AND BRAKE DISC
CHAS
a.Clean the outside of the front wheel hub.
b.Remove the oil seal with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag between the screwdriver and the wheel surface.
c. Remove the wheel bearings with a general
bearing puller .
2.Remove:
• Collar
EAS00525
CHECKING THE FRONT WHEEL
1.Check:
• Wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
Do not attempt to straighten a bent wheel
axle.
2.Check:
• Tire
• Front wheel
Damage/wear → Replace.
Refer to "CHECKING THE TIRES" and
"CHECKING THE WHEELS" in chapter 3.
;
;
;;
3.Measure:
• Radial wheel runout • Lateral wheel runout Over the specified limits → Replace.
Radial wheel runout limit
1.0 mm
Lateral wheel runout limit
1.0 mm
6-4
FRONT WHEEL AND BRAKE DISC
CHAS
4.Check:
• Wheel bearings
Front wheel turns roughly or is loose → Replace
the wheel bearings.
• Oil seals
Damage/wear → Replace.
@
@
5.Replace:
• Wheel bearings
• Oil seals
a.Clean the outside of the front wheel hub.
b.Remove the oil seals with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag between the screwdriver and the wheel surface.
c. Remove the wheel bearings with a general
bearing puller .
d.Install the new wheel bearings and oil seals in
the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing inner race
or balls . Contact should be made only
with the outer race .
NOTE:
Use a socket that matches the diameter of the
wheel bearing outer race and oil seal.
6.Inspect:
• Collar
Wear/Damage → Replace collar and oil seal
as set.
6-5
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00528
CHECKING THE BRAKE DISC
1.Check:
• Brake disc
Damage/galling → Replace.
2.Measure:
• Brake disc deflection
Out of specification → Inspect wheel runout.
If wheel runout is in good condition, correct the
brake disc deflection or replace the brake disc.
Brake disc deflection limit
(maximum)
0.2 mm
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 below the
edge of the brake disc.
347001
3.Measure:
• Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
Brake disc thickness limit
(minimum)
3.2 mm
347002
4.Adjust:
• 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.
6-6
FRONT WHEEL AND BRAKE DISC
Brake disc bolt
23 Nm (2.3 m • kg)
LT
T.R
CHAS
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.
23 Nm (2,3 m.kg)
EAS00535
CHECKING THE SPEEDOMETER GEAR
UNIT
1.Check:
• Speedometer clutch
Bends/damage/wear → Replace.
2.Check:
• Speedometer drive gear • Speedometer driven gear Damage/wear → Replace the speedometer
gear unit.
340004(a)
EAS00539
ASSEMBLING THE FRONT WHEEL
1.Install:
• Wheel bearings
• Oil seals
a.Install the new wheel bearings and oil seals in
the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing inner race
or balls . Contact should be made only
with the outer race .
NOTE:
Use a socket that matches the diameter of the
wheel bearing outer race and oil seal.
6-7
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00542*
INSTALLING THE FRONT WHEEL
1.Lubricate:
• Wheel axle
• Wheel bearings
• Oil seal lips
• Speedometer drive gear
• Speedometer driven gear
Recommended lubricant
Lithium soap base grease
2.Install:
• Brake disc
LT
Brake disc bolt
23 Nm (2.3 m • kg)
T.R
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
23 Nm (2,3 m.kg)
3.Install:
• Speedometer gear unit
NOTE:
Make sure the speedometer gear unit and the
wheel hub are installed with the two projections
meshed into the two slots respectively.
4.Install:
• Front wheel
A
B
WARNING
Be sure to assemble the front wheel as shown.
Difference between A and B < 3 mm
6-8
FRONT WHEEL AND BRAKE DISC
CHAS
5.Tighten:
• Wheel axle
• Brake caliper bolts
Wheel axle
35 Nm (3.5 m • kg)
Brake caliper bolt
23 Nm (2.3 m • kg)
WARNING
Make sure the brake hose is routed properly.
CAUTION:
Before tightening the axle nut, stroke the
front fork several times to check for proper
fork operation.
EAS00548
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
1.Remove:
• Balancing weight(s)
2.Find:
• Front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
a.Spin the front wheel.
b.When the front wheel stops, put an “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 (c) 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”.
X1
X1
X2
6-9
FRONT WHEEL AND BRAKE DISC
CHAS
3.Adjust:
• Front wheel static balance
a.Install a balancing weight onto the rim
exactly opposite the heavy spot “X”.
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.
X
4.Check:
• Front wheel static balance
X
X
X
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.
X
6-10
CHAS
REAR WHEEL AND BRAKE
EAS00555
REAR WHEEL AND BRAKE
2
T.R
9.75 Nm (0,98 m.kg)
3
1
11
9
4
10
T.R
125 Nm (12,5 m.kg)
5
8
7
6
FW
D
Order
Job/Part
Q'ty
Remove the parts in the order listed.
Removing the rear wheel and
the rear brake
Lower cover
Refer to "BATTERY COVER AND LOWER
COVER" in chapter 3.
Refer to "EXHAUST PIPE" in Chapter 4.
Exhaust pipe
I
1
2
3
4
5
6
7
Remove:
Rear axle nut (Nylstop)
Rear wheel
Brake shoe/brake shoe spring
Plate washer
Adjuster
Brake cable
Compression spring
Remarks
NOTE:
Place the scooter on a suitable stand so
that the rear wheel is elevated.
1
1
2/2
1
1
1
1
6-11
Refer to "INSTALLING THE REAR
WHEEL" section.
CHAS
REAR WHEEL AND BRAKE
2
T.R
9.75 Nm (0,98 m.kg)
3
1
11
9
4
10
T.R
125 Nm (12,5 m.kg)
5
8
7
6
FW
D
Order
8
9
10
11
Job/Part
Pin
Camshaft lever
Wear indicator
Brake camshaft
Q'ty
1
1
1
1
Remarks
Refer to "INSTALLING THE REAR
BRAKE" section.
For installation, reverse the removal procedure.
6-12
REAR WHEEL AND BRAKE
CHAS
EAS00565
CHECKING THE REAR WHEEL
1.Check:
• Wheel axle
• Rear wheel
Refer to "FRONT WHEEL".
2.Check:
• Tire
• Rear wheel
Damage/wear → Replace.
Refer to "CHECKING THE TIRES" and
"CHECKING THE WHEELS" in chapter 3.
;
;
;;
3.Measure:
• Radial wheel runout • Lateral wheel runout Refer to "FRONT WHEEL".
Radial wheel runout limit
1.0 mm
Lateral wheel runout limit
1.0 mm
EAS00569
CHECKING THE BRAKE
The following procedure applies to all of the
brake shoes.
1.Check:
• Brake shoe lining
Glazed areas → Repair.
Sand the glazed areas with course sandpaper.
NOTE:
After sanding the glazed areas, clean the brake
shoe with a cloth.
2.Measure:
• Brake shoe lining thickness @
Out of specification → Replace.
Brake shoe lining thickness limit
(minimum)
2.0 mm
WARNING
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.
346007
6-13
REAR WHEEL AND BRAKE
CHAS
3.Measure:
• Brake drum inside diameter a
Out of specification → Replace the wheel.
a
Brake drum inside diameter limit
(maximum)
130.5 mm
346008
4.Check:
• Brake drum inner surface
Oil deposits → Clean.
Remove the oil with a rag soaked in lacquer thinner or solvent.
Scratches → Repair.
Lightly and evenly polish the scratches with an
emery cloth.
5.Check:
• Brake camshaft
Damage/wear → Replace.
WARNING
When inspecting the brake lining, do not spill
oil or grease on the brake lining.
INSTALLING THE REAR BRAKE
Reverse the removal procedure.
Note the following points.
1.Install:
• Brake camshaft NOTE:
Apply lithium soap base grease onto the brake
camshaft and pin .
LS
CAUTION:
After installing the brake camshaft, remove
the excess of grease.
346009
2.Install:
•Tension springs •Brake shoes NOTE:
The punch mark must point outwards.
346010
CAUTION:
When installing the springs and the brake
shoes, take care not to damage the springs.
6-14
REAR WHEEL AND BRAKE
CHAS
3.Install:
• Wear indicator • Camshaft lever a.Align the projection on the wear indicator
with the camshaft notch and install.
b.Align the punch marks .
c. Check the proper position of the brake shoe.
346011(a)
4.Install:
• Plain washer • Pin
• Compression spring
• Brake cable
• Adjuster
346012
INSTALLING THE REAR WHEEL
Reverse the removal procedure.
Note the following points.
1.Clean:
• Rear wheel axle
346013
2.Install:
• Rear wheel
• Plain washer • Axle nut T.
R
Rear axle nut:
125 Nm (12.5 m • kg)
NOTE:
Make sure the splines on the wheel hub fit onto
the rear drive axle.
3.Install:
• Muffler
T.
R
Bolt (exhaust pipe):
8.5 Nm (0.85 m • kg)
Bolt (muffler):
29 Nm (2.9 m • kg)
4.Adjust:
• Rear brake lever free play
Refer to "REAR BRAKE LEVER FREE PLAY
ADJUSTMENT" in Chapter 3.
6-15
FRONT BRAKE
CHAS
EAS00576
FRONT BRAKE
FRONT BRAKE PADS
1
T.R
6 Nm (0.6 m.kg)
6
4
2
5
3
T.R
Order
I
1
2
3
4
5
6
Job/Part
Removing the front brake pads
Remove:
Plastic cap
Retaining clip
Retaining pin
Pad spring
Brake pad
Bleed screw
Q'ty
31 Nm (3.1 m.kg)
Remarks
Remove the parts in the order listed.
1
1
1
1
2
1
Refer to "BRAKE PAD REPLACEMENT" section.
For installation, reverse the removal procedure.
6-16
FRONT BRAKE
CHAS
EAS00579
CAUTION:
Disc brake components rarely require disassembly.
Therefore, always follow these preventive
measures:
• Never disassemble brake components
unless absolutely necessary.
• 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.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
Flush with water for 15 minutes and get
immediate medical attention.
Recommanded brake component replacement
schedule:
Brake pads
If necessary
Brake hose
Every two years
Brake fluid
Every two years or whenever the brake is disassembled
WARNING
All internal parts should be cleaned in new
brake fluid only. Do not use solvents as they
will cause seals to swell and distort.
6-17
FRONT BRAKE
CHAS
BRAKE PADS REPLACEMENT
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1.Remove:
• Brake pads
NOTE:
• Do not depress the brake lever when the
wheel is off the scooter otherwise the brake
pads will be forced shut.
• Install new brake pad springs when the brake
pads have to be replaced.
• Replace the pads as a set if either is found to
be worn to the wear limit @.
Wear limit @:
0.5 mm
2.Push the caliper piston into the brake caliper
by finger.
@
CAUTION:
When pushing the caliper piston into the
brake caliper, brake fluid level in reservoir
tank is increasing higher.
3.Install:
• Brake pads
• Pad spring
4.Inspect:
• Brake fluid level
Refer to "CHECKING THE BRAKE FLUID
LEVEL" section in Chapter 3.
5.Check:
• Brake lever operation
Soft spongy feeling - Bleed the brake system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" section in Chapter 3.
6-18
FRONT BRAKE
CHAS
EAS00584
FRONT BRAKE MASTER CYLINDER
T.R
8.5 Nm (0.85 m.kg)
5
2
T.R
6
6 Nm (0.6 m.kg)
1
3
T.R
23 Nm (2.3 m.kg)
4
Order
Job/Part
Q'ty
Remove the parts in the order listed.
Removing the front brake master
cylinder
Drain the brake fluid
Handlebar covers
I
1
2
3
4
5
Remove:
Brake switch
Brake lever
Union bolt
Copper washer/Brake hose
Master cylinder bracket
II
6
Remove:
Master cylinder
Remarks
Refer to “HANDLEBAR COVERS” in
chapter 3
1
1
1
2/1
1
1
For installation, reverse the removal procedure.
6-19
FRONT BRAKE
CHAS
EAS00585
T.R
1.2 Nm (0.12 m.kg)
Order
Q'ty
Job/Part
Disassembling the master cylinder
Remarks
Remove the parts in the order listed.
NOTE:
Drain completely before removing the
master cylinder.
I
Q
W
Remove:
Master cylinder cap
Diaphragm
1
1
II
E
R
T
Y
U
Remove:
Dust boot
Actuator
Actuator spring
Master cylinder piston
Piston return spring
1
1
1
1
1
6-20
For installation, reverse the removal procedure.
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.
• To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
EAS00590
347006
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1.Check:
• brake master cylinder
Damage/scratches/wear → Replace.
• brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
2.Check:
• brake master cylinder kit Damage/scratches/wear → Replace.
3.Check:
• brake master cylinder reservoir Cracks/damage → Replace.
• brake master cylinder reservoir diaphragm Damage/wear → Replace.
4.Check:
• brake hoses Cracks/damage/wear → Replace.
346014(a)
6-21
FRONT BRAKE
CHAS
EAS00596
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNING
• Before installation, all internal brake
components should be cleaned and
lubricated with clean or new brake fluid.
• Never use solvents on internal brake
components.
Recommended brake fluid
DOT #3 or DOT #4
1.Install:
• master cylinder kit
In the master cylinder.
2.Install:
• brake master cylinder
• brake master cylinder bracket
3.Install:
• copper washers
• brake hose
• union bolt
T.
R
Union bolt
23 Nm (2.3 m • kg)
WARNING
Proper brake hose routing is essential to
insure safe scooter operation. Refer to
"CABLE ROUTING" in Chapter 2.
10¡
NOTE:
• While holding the brake hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and to the right
to make sure the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
6-22
FRONT BRAKE
CHAS
4.Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended
brake fluid)
Recommended brake fluid
DOT #3 or DOT #4
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor brake
performance.
• 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.
• When refilling, be careful that water does
not enter the brake master cylinder
reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5.Bleed:
• brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" in chapter 3.
6.Check:
• brake fluid level
Below the minimum level mark → Add the
recommended brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" in chapter 3.
7.Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" in chapter 3.
6-23
FRONT BRAKE
CHAS
EAS00612
FRONT BRAKE CALIPER
23 Nm (2.3 m.kg)
T.R
5
1
3
2
4
LT
LT
T.R
Order
Job name/Part name
Q'ty
31 Nm (3.1 m.kg)
Remarks
Remove the parts in the order listed.
Removing the front brake caliper
Drain the brake fluid
I
1
2
3
4
Remove:
Union bolt
Copper washer
Brake hose
Copper washer
1
1
1
1
II
5
Remove:
Brake caliper
1
For installation, reverse the removal procedure.
6-24
CHAS
FRONT BRAKE
EAS00614
6 Nm (0.6 m.kg)
T.R
23 Nm (2.3 m.kg)
T.R
T.R
23 Nm (2.3 m.kg)
Order
Job/Part
Q'ty
Caliper disassembly
Brake pads
I
Q
W
E
R
T
Y
Remove:
Caliper
O-ring
Caliper piston
Dust seal
Piston seal
Bleed screw
Remarks
Remove the parts in the order listed.
Refer to "REMOVING THE FRONT
BRAKE PADS".
1
1
2
2
2
1
Refer to "DISASSEMBLING THE FRONT
BRAKE CALIPER".
For installation, reverse the removal procedure.
6-25
FRONT BRAKE
CHAS
EAS00620
DISASSEMBLING THE FRONT BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1.Remove:
• Union bolt • Copper washers • Brake hose NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2.Remove:
• Brake caliper pistons • Brake caliper piston seals and a.Secure the right side brake caliper piston with
a piece of wood.
b.Blow compressed air into the brake hose joint
opening to force out the left side piston from
the brake caliper.
WARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolts.
CAUTION:
Carefully remove the caliper piston to prevent
damage.
346004
c. Remove the brake caliper piston seals.
CAUTION:
• Do not use a sharp instrument. Remove
seals by your finger.
• Do not re-use removed parts.
d.Repeat the previous steps to force out the right
side piston from the brake caliper.
6-26
FRONT BRAKE
CHAS
EAS00631
CHECKING THE FRONT BRAKE CALIPER
Recommanded brake component replacement
schedule:
Brake pads
If necessary
Brake hose
Every two years
Brake fluid
Every two years or whenever the brake is disassembled
1.Check:
• brake caliper pistons Rust/scratches/wear → Replace the brake
caliper.
• brake caliper cylinders Scratches/wear → Replace the brake caliper.
• Dust/piston seals
Damaged → Replace the brake caliper.
• brake caliper body Cracks/damaged → Replace the brake caliper.
• brake fluid delivery passages (brake caliper body)
Obstruction → Blow out with compressed air.
2.Check:
• brake caliper bracket Cracks/damage → Replace the brake caliper.
6-27
FRONT BRAKE
CHAS
EAS00635
INSTALLING THE FRONT BRAKE CALIPER
WARNING
Before installation, all internal brake
components should be cleaned and
lubricated with clean or new brake fluid.
Recommended brake fluid
DOT #3 or DOT #4
1.Install:
• brake caliper (temporarily)
• copper washers
• brake hose • union bolt T.
R
Union bolt
23 Nm (2.3 m • kg)
WARNING
Proper brake hose routing is essential to
insure safe scooter operation. Refer to
"CABLE ROUTING".
2.Remove:
• brake caliper
3.Install:
• brake pads • brake pads springs • brake pads retaining pin • brake pads retaining clip • Brake pads cap • brake caliper Refer to "REPLACING THE BRAKE PADS".
T.
R
6-28
Brake caliper bolt
31 Nm (3.1 m • kg)
FRONT BRAKE
CHAS
4.Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended
brake fluid)
Recommended brake fluid
DOT #3 or DOT #4
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor brake
performance.
• 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.
• When refilling, be careful that water does
not enter the brake master cylinder
reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5.Bleed:
• brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" in chapter 3.
6.Check:
• brake fluid level
Below the minimum level mark → Add the
recommended brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" in chapter 3.
7.Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" in chapter 3.
6-29
CHAS
FRONT FORK
EAS00646
FRONT FORK
FRONT FORK
3
T.R
3 Nm (0,3 m.kg)
4
T.R
30 Nm (3,0 m.kg)
2
T.R
31 Nm (3,1 m.kg)
1
5
D
FW
Job/Part
Order
Q'ty
Removing the front fork
Front wheel
I
1
2
II
3
4
5
Remove:
Caliper assembly
Front fender
Remove:
Clip
Pinch bolt
Front fork leg
Remarks
Remove the parts in the order listed.
Refer to "FRONT WHEEL AND BRAKE
DISC".
1
1
Refer to "REMOVING THE FRONT FORK
LEGS".
2
2
2
For installation, reverse the removal procedure.
6-30
FRONT FORK
CHAS
EAS00648
LS
Order
Job/Part
I
Q
W
E
R
Disassembling the front fork
Remove:
Spring seat clip
Spring seat
O-ring
Fork spring
II
T
Y
U
I
O
P
{
Remove:
Dust seal
Retaining clip
Damper rod bolt / gasket
Oil seal
Inner tube
Damper rod / damper rod spring
Oil flow stopper
T.R
23 Nm (2,3 m.kg)
Q'ty
Remarks
Remove the parts in the order listed.
2
2
2
2
2
2
2/2
2
2
2/2
1
Refer to "ASSEMBLING THE FRONT
FORK LEGS".
For installation, reverse the removal procedure.
6-31
FRONT FORK
CHAS
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1.Stand the scooter on a level surface.
WARNING
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.
EAS00654
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
• spring seat clip • spring seat • o-ring • fork spring a.Hold the inner tube vertically.
b.Securely clamp the inner tube in a vise with
soft jaws.
CAUTION:
Do not scratch the inner tube.
c. Press down on the spring seat with a suitable
bar.
d.While pressing down on the spring seat,
remove the spring seat clip with a thin, flathead screwdriver.
e.Remove the spring seat, the o-ring and spring.
2.Drain:
• fork oil
3.Remove:
• dust seal • oil seal clip (with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
6-32
FRONT FORK
4.Remove:
• damper rod assembly bolt
NOTE:
While holding the damper rod assembly with the
damper rod holder and T-handle , loosen
the damper rod assembly bolt .
CHAS
Damper rod holder
90890-01294
T-Handle
90890-01326
342010
5.Remove:
• inner tube
a.Hold the front fork leg horizontally.
b.Securely clamp the brake caliper bracket in a
vise with soft jaws.
c. Separate the inner tube from the outer tube by
pulling the inner tube forcefully but carefully.
CAUTION:
Avoid bottoming the inner tube into the outer
tube during the above procedure, as the oil
flow stopper will be damaged.
EAS00656
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1.Check:
• inner tube • outer tube Bends/damage/scratches → Replace.
WARNING
Do not attempt to straighten a bent inner tube
as this may dangerously weaken it.
2.Inspect:
• fork spring Damage → Replace.
342011
6-33
FRONT FORK
CHAS
3.Check:
• damper rod Damage/wear → Replace.
Obstruction → Blow out all of the oil passages
with compressed air.
• oil flow stopper Damage → Replace.
EAS00659
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
NOTE:
When assembling the front fork leg, be sure to
replace the following parts:
- oil seals
- dust seals
Before assembling the front fork leg, make sure
all of the components are clean.
1.Install:
• damper rod assembly CAUTION:
Allow the damper rod assembly to slide slowly
down the inner tube until it protrudes from
the bottom of the inner tube. Be careful not to
damage the inner tube.
2.Lubricate:
• inner tube’s outer surface
Recommended lubricant
Fork oil
(ISO 6743/4-LHV 46 or SAE 10)
3.Tighten:
• damper rod assembly bolt
T.
R
342010
Damper rod assembly bolt
23 Nm (2.3 m • kg)
NOTE:
While holding the damper rod assembly with the
damper rod holder and T-handle , tighten
the damper rod assembly bolt .
6-34
FRONT FORK
CHAS
Damper rod holder
90890-01294
T-handle
90890-01326
4.Install:
• oil seal (with the fork seal driver weight and fork
seal driver attachment )
Fork seal driver weight
90890-01367
Fork seal driver attachment
90890-01400
CAUTION:
Make sure the numbered side of the oil seal
faces up.
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium soap base grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
5.Install:
• oil seal clip
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
6.Install:
• dust seal (with the fork seal driver weight)
Fork seal driver weight
90890-01367
7.Fill:
• front fork leg
(with the specified amount of the recommended
fork oil)
Fork oil type
ISO 6743/4-LHV 46 or SAE 10
Quantity (left front fork leg only)
75 cc/ leg
6-35
FRONT FORK
LS
CHAS
NOTE:
• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
8. Install:
• spring • o-ring • spring seat • spring seat clip NOTE:
Before installing the spring seat, lubricate its
O-ring with grease.
6-36
HANDLEBAR
CHAS
HANDLEBAR
3
1
3
6
2
5
9
6
10
4
T.R
60 Nm (6,0 m.kg)
7
8
Order
I
II
1
2
3
4
5
Job/Part
Q'ty
Remarks
Removing the handlebar
Remove the parts in the order listed.
Handlebar covers
Refer to "COVERS" in Chapter 3.
Disconnect:
Stop switch
Handlebar switch
2
2
Remove:
Rear view mirror
Stop switch
Front master cylinder
Handlebar switch (right)
Throttle cable
Throttle grip assembly
1
2
1
1
1
1
6-37
Refer to "MASTER CYLINDER".
Refer to "INSTALLING THE HANDLEBAR".
HANDLEBAR
CHAS
3
1
3
6
2
5
9
6
10
4
T.R
60 Nm (6,0 m.kg)
7
8
Order
6
7
8
9
10
Job/Part
Handlebar switch (left)
Rear brake cable
Starter cable
Left grip
Handlebar
Q'ty
Remarks
1
1
1
1
1
Refer to "INSTALLING THE HANDLEBAR".
For installation, reverse the removal procedure.
6-38
HANDLEBAR
CHAS
EAS00666
REMOVING THE HANDLEBAR
1.Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
2. Remove:
• handlebar grip
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
EAS00668
CHECKING THE HANDLEBAR
1.Check:
• handlebar
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handlebar
as this may dangerously weaken it.
2.Install:
• handlebar grip
a.Apply a thin coat of rubber adhesive onto the
left end of the handlebar.
b.Slide the handlebar grip over the left end of the
handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
6-39
HANDLEBAR
CHAS
EAS00673
INSTALLING THE HANDLEBAR
1.Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
2.Install:
• handlebar
NOTE:
Install the handlebar onto the steering shaft
notch.
CAUTION:
• Before installing the handlebar, wipe off
any trace of oil from the inserted section of
the shaft with solvent.
• Insert the bolt from the left as shown.
3.Tighten:
• handlebar holder
T.
R
Handlebar holder bolt
60 Nm (6.0 m • kg)
4.Fasten:
• wire harness
(to the handlebar bracket)
Refer to "CABLE ROUTING" in chapter 2.
5.Install:
• left handlebar switch
NOTE:
Align the projection on the left handlebar switch
with the hole in the handlebar.
LS
6.Install:
• throttle cable • throttle grip
NOTE:
• Lubricate the inside of the throttle grip with a
thin coat of lithium soap base grease and
install it onto the handlebar.
• Apply lithium soap base grease onto the cable
end and throttle cable support.
6-40
HANDLEBAR
CHAS
7.Install:
• right handlebar switch
WARNING
Make sure the throttle grip operates smoothly.
NOTE:
Align the projection on the right handlebar switch
with the hole in the handlebar.
8.Adjust:
• 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)
1.5 ~ 3.0 mm
9.Install:
• master cylinder
• master cylinder bracket
10.Install:
• stop switches
11.Connect:
• stop switches connectors
• Handlebar switches connectors
12.Fasten:
• cables and wires
Refer to "CABLE ROUTING" in chapter 2.
6-41
STEERING HEAD
CHAS
EAS00675
STEERING HEAD
1
2
3
4
5
6
7
9
T.R
T.R
LS
11
10
LS
75 Nm (7.5 m.kg)
Fisrt step:
38 Nm (3.8 m.kg)
2nd step:
Loosen the ring nut
1/4 turn.
3rd step:
22 Nm (2.2 m.kg)
12
8
Order
Job/Part
Q'ty
Removing the lower bracket
Remarks
Remove the parts in the order listed.
WARNING
Securely support the scooter so that
there is no danger of it falling over.
Front fork
Handlebar
I
1
2
3
4
5
6
Refer to "FRONT FORK".
Refer to "HANDLEBAR".
Remove:
Ring nut (upper)
Lock washer
Ring nut (center)
Rubber washer
Ring nut (lower)
Ball race cover
1
1
1
1
1
1
6-42
Refer to "REMOVING THE LOWER
BRACKET".
STEERING HEAD
1
2
3
4
5
6
7
9
T.R
T.R
LS
11
10
LS
CHAS
75 Nm (7.5 m.kg)
Fisrt step:
38 Nm (3.8 m.kg)
2nd step:
Loosen the ring nut
1/4 turn.
3rd step:
22 Nm (2.2 m.kg)
12
8
Order
7
8
9
10
11
12
Job/Part
Ball race (upper)
Lower bracket
Ball
Bearing
Ball race
Ball race (lower)
Q'ty
Remarks
1
1
22
1
2
1
Refer to "REMOVING THE LOWER
BRACKET".
For installation, reverse the removal procedure.
6-43
STEERING HEAD
CHAS
EAS00680
REMOVING THE LOWER BRACKET
1.Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
2.Remove:
• upper ring nut • lock washer 3.Remove:
• center ring nut • rubber washer • lower ring nut NOTE:
Hold the lower ring nut with the steering nut
wrench , and then remove the center ring nut
with the ring nut wrench.
Ring nut wrench
90890-01268
Steering nut wrench
90890-01403
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS00682
CHECKING THE STEERING HEAD
1.Wash:
• bearing balls
• bearing races
Recommended cleaning solvent
Kerosene
2.Check:
• bearing balls • bearing races Damage/pitting → Replace.
6-44
STEERING HEAD
CHAS
3.Replace:
• bearing balls
• bearing races
a.Remove the bearing races from the steering
head pipe with a long rod and hammer.
354007
b.Remove the bearing race from the lower
bracket with a floor chisel and hammer.
c. Install a new dust seal and new bearing races.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
354008
NOTE:
• Always replace the bearing balls and bearing
races as a set.
• Whenever the steering head is disassembled,
replace the dust seal.
4.Check:
• lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
354009
EAS00684
LS
INSTALLING THE STEERING HEAD
1.Lubricate:
• upper bearing
• lower bearing
• bearing races
Recommended lubricant
Lithium soap base grease
2.Install:
• lower ring nut
• rubber washer
• center ring nut
• lock washer
• upper ring nut
Refer to “CHECKING AND ADJUSTING THE
STEERING HEAD” in chapter 3.
6-45
CHAS
REAR SHOCK ABSORBER ASSEMBLY
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
1
T.R
31.5 Nm (3,15 m.kg)
2
T.R
FW
17.5 Nm (1,75 m.kg)
D
Order
Q'ty
Job/Part
Removing the rear shock absorber
assembly
Rear covers
Remarks
Remove the parts in the order listed.
Refer to "COVERS" in chapter 3.
I
1
Remove:
Rear under cover
1
II
2
Remove:
Rear shock absorber
1
For installation, reverse the removal procedure.
6-46
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• rear shock absorber
Oil leaks → Replace the rear shock absorber
assembly.
• spring
Damage/wear → Replace the rear shock
absorber assembly.
• bushings
Damage/wear → Replace.
• dust seals
Damage/wear → Replace.
• bolts
Bends/damage/wear → Replace.
6-47
ELEC
7
ELEC
CHAPTER 7.
ELECTRICAL
CIRCUIT DIAGRAM ...................................................................................... 7-1
ELECTRICAL COMPONENTS ...................................................................... 7-3
SWITCH INSPECTION .................................................................................. 7-5
SWITCH INSPECTION ............................................................................ 7-5
SWITCH CONTINUITY INSPECTION ............................................................ 7-5
IGNITION AND STARTING SYSTEM ........................................................... 7-7
CIRCUIT DIAGRAM ................................................................................. 7-7
TROUBLESHOOTING ............................................................................. 7-8
STARTER MOTOR ...................................................................................... 7-14
INSPECTION .........................................................................................7-15
CHARGING SYSTEM .................................................................................. 7-17
CIRCUIT DIAGRAM ............................................................................... 7-17
TROUBLESHOOTING ........................................................................... 7-18
LIGHTING SYSTEM .................................................................................... 7-21
CIRCUIT DIAGRAM ............................................................................... 7-21
TROUBLESHOOTING ........................................................................... 7-22
LIGHTING SYSTEM CHECK ................................................................. 7-24
SIGNAL SYSTEM ........................................................................................ 7-28
CIRCUIT DIAGRAM ............................................................................... 7-28
TROUBLESHOOTING ........................................................................... 7-29
SIGNAL SYSTEM CHECK ..................................................................... 7-31
ELEC
CIRCUIT DIAGRAM
ELECTRICAL
CIRCUIT DIAGRAM
(RED)
T
A
(RED)
Br R
Gy B
Gy B
Br R
B
B
R
R
Gy Br R B BW
LOCK
OFF
MAIN HARNESS STARTER MOTOR
CHECK
BW
ON
BW
W
W
YR
YR
B
R W B YR
R
W
I
Q
RAR
LW
GY
U
LW
LW
GY
GY
GW
BR
WR
WL
WR
WL
BR GW
GW BR
WR WL
WL WR
W
Or
B
E
Or
R
M
P
B
B
BAB
R
R
GW
BR
YR
O
Br
[
W
YR
B
Y
Or
B
BW
R
Br
Gy
BW
YR
B
Gy
LW
{
B
A
YR YB LR L
LW B
OFF
ON
OFF
B YB L
LW YR LR
PO
LW YR LR
B YB L
S
ON
L
LR
B
B
Br
Br
Br
i
I
D
B P
J
H
o
OFF
12V 1.2W
LOW
B
Y
B
B
-
L Dg Y
BrW
BrW
GB Ch P
R
12V 1.2W
Ch
Y Dg L
N
Ch
Dg
Ch BrW Dg
L
HI
Ch
B
Y
E
GB L Y
ON
Dg
p
B
C
G
12V 1.2W
12V 1.2W
-
B
P Ch GB
GY
LR
Br
LR
K
Gy
GY
LR
12V 5W
P
}
L
B
G
D
Br
Dg
Br
BrW
BrW
Br
Gy
LR
u
A
LR
LR
GY
LR
GY
Ch
Dg
Ch
Dg
B
B
B
B
B
B
y
Ch
Dg
Ch
Dg
B
B
B
B
YR
B LR
Y GB
LR B
GB Y
G
B
Y
q
LR
M
GB
Br
G
B
]
G
B
G
12V
35W / 35W
B
12V
21W / 5W
12V 5W
F
12V10W
12V10W
12V10W
12V10W
w
e
r
t
B
B
YR
B
B
7-1
B
B
B
CIRCUIT DIAGRAM
Q CDI magneto
W CDI unit
E Ignition coil
R Spark plug
T Main switch
Y Fuse
U Battery
I Rectifier/regulator
O Starter relay
P Starter motor
{ Right handle switch
A Starter switch
B Light switch
} Left handle switch
C Horn switch
D "HI/LO" switch
E Flasher switch
q Head light assy
F Head light
G Position light
w Front flasher light (left)
e Front flasher light (right)
r Rear flasher light (left)
t Rear flasher light (right)
y Tail / "STOP" light
u Horn
i Flasher relay
o Front brake switch
p Rear brake switch
[ Oil level gauge
] Fuel sender
A Meter assembly
H Meter light
I Oil indicator light
J Flasher indicator light
K High beam indicator light
L Fuel meter
M Tachometer
S Resistor
D License light
COLOR CODE
B
Br
Ch
Dg
G
Gy
L
Or
P
R
W
Y
Black
Brown
Chocolate
Dark green
Green
Grey
Blue
Orange
Pink
Red
White
Yellow
ELEC
B/R
B/W
Br/W
G/B
G/W
G/Y
L/R
L/W
W/L
W/R
Y/B
Y/R
7-2
Black/Red
Black/White
Brown/White
Green/Black
Green/White
Green/Yellow
Blue/Red
Blue/White
White/Blue
White/Red
Yellow/Black
Yellow/Red
ELECTRICAL COMPONENTS
ELEC
ELECTRICAL COMPONENTS
Q Wire harness
W Fuel sender
E Starter relay
R Ignition coil
T CDI unit
Y Oil sender
U Battery
I Resistance
햳
햲
햴
햵
햶
햹
햸
;;
;
햷
7-3
ELECTRICAL COMPONENTS
ELEC
Q Main switch
W Flasher relay
E Horn
R Rectifier/Regulator
햲
햳
;;;;;;;
;;;
;;;;;;;
;;;;
;;;;
;;;
;;;;
;;;
;;;;
햴
햵
7-4
SWITCH INSPECTION
ELEC
SWITCH INSPECTION
"0"
SWITCH INSPECTION
Use a pocket tester to check the terminals for
continuity. If the continuity is faulty as any point,
replace the switch.
"∞"
"Ω x 1"
Pocket tester:
90890-03112
NOTE:
• Set the pocket tester to "O" before starting the
test.
• The pocket tester should be set to the "x1" Ω
range when testing the switch for continuity.
• Turn the switch on and off a few times when
checking it.
R
Br
B
SWITCH CONTINUITY INSPECTION.
The terminal connections for switches (main
switch, handlebar switch, engine stop switch,
light switch,etc.) are shown in a chart similar to
the one on the left.
This chart shows the switch positions in the
column and the switch lead colors in the top row.
For each switch position, "
" indicates the
terminals with continuity.
햲
B/W
OFF
ON
햳
B
Br
R
The example chart shows that:
햲 There is continuity between the "Black" and
"Black/White" leads when the switch is set
to "OFF".
햳 There is continuity between the "Red" and
"Brown" leads when the switch is set to "ON".
7-5
ELEC
SWITCH INSPECTION
SWITCH CONTINUITY INSPECTION
Before checking a switch refer to the checking
switches as shown in the page 7-5 and check
for the correct terminal connections (closed circuit) according to color combinations shown in
the chart.
Poor connection, fault → Repair or replace.
Dimmer switch
GB L Y
HI
Start switch
LOW
LW B
OFF
B YB L
ON
LW YR LR
Horn switch
B P
Light switch
Y Dg L
B
OFF
-
BrW
GB Ch P
ON
YR YB LR L
OFF
Flasher switch
PO
ON
Ch BrW Dg
L
N
R
Br
GY
Br
Front brake
switch
GY
Rear brake
switch
Main switch
Gy Br R B BW
LOCK
OFF
CHECK
ON
BW
Gy B
Br R
Fuse
7-6
ELEC
IGNITION AND STARTING SYSTEM
IGNITION AND STARTING SYSTEM
CIRCUIT DIAGRAM
(RED)
T
A
(RED)
Br R
Gy B
Gy B
Br R
B
B
R
R
Gy Br R B BW
LOCK
OFF
MAIN HARNESS STARTER MOTOR
CHECK
BW
ON
BW
W
W
YR
YR
B
R W B YR
R
W
I
GY
LW
GY
GY
GW
BR
WR
WL
WR
WL
BR GW
GW BR
WR WL
WL WR
W
Or
B
E
Or
R
M
P
B
B
BAB
R
U
LW
GW
BR
YR
RAR
R
Br
YR
B
LW
{
B
A
YR YB LR L
LW B
OFF
ON
OFF
B YB L
LW YR LR
PO
LW YR LR
B YB L
L
LR
B
Br
Br
B
G
12V 1.2W
12V 1.2W
I
o
D
B P
J
H
OFF
12V 1.2W
Y
B
Ch BrW Dg
LOW
Y
Y Dg L
B
N
B
-
L Dg Y
BrW
BrW
GB Ch P
R
12V 1.2W
Ch
B
L
HI
Ch
B
p
E
GB L Y
ON
Dg
Ch
Dg
12V 5W
C
B
G
D
Br
P
}
L
BrW
BrW
Br
LR
Gy
A
Br
LR
i
u
Br
S
ON
-
B
P Ch GB
GY
Dg
Gy
LR
Br
LR
K
Gy
YR
GY
LR
Q
YR
O
LW
[
W
B
Y
Or
B
BW
R
Br
Gy
BW
LR B
GB Y
G
B
Y
q
B LR
Y GB
LR
M
YR
GB
Br
G
B
]
G
B
F
G
Ch
Dg
B
B
B
B
Ch
Dg
Ch
Dg
B
B
B
B
12V
21W / 5W
12V10W
12V10W
12V10W
12V10W
w
e
r
t
B
B
Q
W
E
R
T
Y
U
Dg
12V 5W
12V
35W / 35W
B
Ch
B
B
B
B
B
CDI magneto
CDI unit
Ignition coil
Spark plug
Main switch
Fuse
Battery
O Starter relay
P Starter motor
{ Handle switch (right)
A Starter switch
o Front brake switch
p Rear brake switch
7-7
LR
GY
LR
GY
B
B
y
IGNITION AND STARTING SYSTEM
ELEC
TROUBLESHOOTING
THE STARTING SYSTEM DOES NOT
WORK (NO SPARK OR IRREGULAR
SPARKS)
Procedure:
Check:
1. Fuse (main)
2. Battery
3. Spark plug
4. Spark check
5. Spark plug cap resistance
6. Ignition coil resistance
7. Pickup coil resistance
8. Source coil resistance
9. Main switch
10. Connections
NOTE:
Remove the following parts before proceeding
with the troubleshooting:
1) Battery cover
2) Side covers (right and left)
For accurate troubleshooting use the following
special tools:
Ignition tester:
90890-06754
Pocket tester:
90890-03112
NO CONTINUITY
1.Fuse
Refer to "SWITCH INSPECTION" section.
Replace the fuse.
CONTINUITY
DOES NOT MEET SPECIFICATION
2.Battery
• Check the condition of the battery.
Refer to "CHECKING THE BATTERY" in
chapter 3.
• Clean battery terminals.
• Charge or replace the battery.
CONTINUITY
3.Spark plug
Spark plug standard:
BR8HS/NGK
• Check the spark plug type.
• Check the condition of the spark plug.
• Check the spark plug gap.
Refer to "CHECKING THE SPARK PLUG"
in chapter 3.
DOES NOT MEET SPECIFICATION
Spark plug gap:
0.5 ~ 0.7 mm
Adjust it or replace the spark plug.
7-8
IGNITION AND STARTING SYSTEM
ELEC
햳
햲
4.Spark check
a
• Remove the spark plug cap.
• Connect the ignition checker 햲
햳 Ground
a Spark plug gap
• Turn the main switch to "ON".
• Start the engine.
• Check the length of the spark gap.
• Increase the spark length until the engine
begins to misfire.
MEETS SPECIFICATION
Ignition system in good condition.
Minimum spark gap:
6 mm
OUT OF
SPECIFICATION
OR NO SPARK
5.Spark plug cap resistance
• Disconnect the spark plug cap.
• Connect the pocket tester (Ωx1k) to the
ignition coil.
• Check the resistance of the spark plug cap.
DOES NOT MEET SPECIFICATION
Spark plug cap resistance:
5kΩ (20°C)
Replace the spark plug cap.
CORRECT
7-9
IGNITION AND STARTER SYSTEM
ELEC
Ωx1
6.Ignition coil resistance
• Disconnect the ignition coil leads.
• Connect the pocket tester (Ωx1) to the ignition coil.
Pocket tester (+) lead → Orange
Pocket tester (-) lead → Black
• Check the primary coil resistance.
Primary coil resistance:
0.32 ~ 0.48 Ω (20°C)
Ω x 1k
• Connect the pocket tester (Ωx1k) to the
ignition coil.
Pocket tester (+) lead → Ground
Pocket tester (-) lead → Spark plug lead
• Check the secondary coil resistance.
Secondary coil resistance:
5,68 ~ 8,52 kΩ (20°C)
DOES NOT MEET SPECIFICATION
Defect. Replace the ignition coil.
MEETS
SPECIFICATION
7.Pickup coil resistance
• Disconnect the pickup coil coupler.
• Connect the pocket tester (Ωx100) to the
pickup coil.
W
YR
GW
BR BR GW
WR WR
WL
WL
햲
Pocket tester (+) lead → White/Red 햲
Pocket tester (-) lead → White/Blue 햳
• Check the pickup coil resistance.
Pickup coil resistance:
400 ~ 600 Ω at 20°C
DOES NOT MEET SPECIFICATION
MEETS
SPECIFICATION
Replace the pickup coil.
7-10
햳
IGNITION AND STARTING SYSTEM
ELEC
MEETS
SPECIFICATION
8.Source coil resistance
햲
• Disconnect the source coil coupler from the
wire harness.
• Connect the pocket tester (Ωx100) to the
source coil.
W
YR
Pocket tester (+) lead → Black/Red 햲
Pocket tester (-) lead → Green/white 햳
• Check the source coil resistance.
Source coil resistance:
640 ~ 960 Ω at 20°C
Replace the source coil.
MEETS
SPECIFICATION
9.Main switch
Refer to "SWITCH INSPECTION" section.
NO CONTINUITY
CONTINUITY
Replace the main switch.
10.Connections
• Check all connections in the ignition system.
Refer to "WIRING DIAGRAM".
POOR CONNECTIONS
GOOD
CONNECTIONS
Repair
Replace the CDI unit.
7-11
GW
BR BR GW
WR WR
WL
WL
햳
IGNITION AND STARTING SYSTEM
ELEC
TROUBLESHOOTING
STARTER MOTOR DOES NOT WORK
Procedure
Check:
1. Fuse (main)
2. Battery
3. Starter motor
4. Starter relay
5. Main switch
6. Starter motor switch
7. Connections
NOTE:
• Remove the following parts before proceeding with the troubleshooting:
1) Side covers (right and left)
2) Footrest board/Leg shields
• For accurate troubleshooting use the following special tools:
Pocket tester:
90890-03112
NO CONTINUITY
1.Fuse.
Refer to "SWITCH INSPECTION" section.
Replace the fuse.
CONTINUITY
DOES NOT MEET SPECIFICATION
2.Battery
• Check the condition of the battery.
Refer to "CHECKING THE BATTERY" in
the Chapter 3.
MEETS
SPECIFICATIONS
3.Starter motor
• Use a jumper lead 햴 to connect the (+) 햲
terminal of the battery to the starter motor
terminal 햳.
햳
햴
• Clean battery terminals.
• Charge or replace the battery.
CAUTION:
• If the gauge of the jumper lead is smaller
than that of the battery leads, the jumper
lead might melt or burn.
• This test could cause sparks. Never perform
it near a gas source or near flammable
products.
햲
+
-
7-12
IGNITION AND STARTER SYSTEM
• Check the starter motor operation
ELEC
DOES NOT WORK
WORKS
Starter defect → Repair or replace
4.Starter relay
• Disconnect Blue/White lead from the wire
harness.
• Connect the (-) terminal of the battery to the
Blue/White lead.
• Check the starter motor operation.
+
-
DOES NOT WORK
LW
Replace the starter relay.
WORK
5.Main switch.
DOES NOT MEET SPECIFICATION
Refer to "SWITCH INSPECTION" section.
MEETS
SPECIFICATION
6.Starter motor switch.
Replace the main switch.
DOES NOT MEET SPECIFICATION
Refer to "SWITCH INSPECTION" section.
MEETS
SPECIFICATION
7.Connections.
Replace the right handlebar switch.
POOR CONNECTIONS
• Check all connections in the starter system.
Refer to "WIRING DIAGRAM" section.
Repair.
7-13
STARTER MOTOR
ELEC
STARTER MOTOR
T.R
13 Nm (1.3 m.kg)
햷
햶
햵
햴
햳
햲
LS
Order
Job name/Part name
Q'ty
Starter motor removal
햲
햳
햴
햵
햶
햷
Stater motor disassembly
O-ring
Front bracket
Rubber seal
Brush holder assembly
Armature
Rubber seal
Remarks
Refer to "STARTER CLUTCH AND
GENERATOR" in Chapter 4.
Disassemble the parts in the order below
1
1
1
1
1
1
For the assembly, reverse
disassembling procedure.
7-14
the
STARTER MOTOR
ELEC
INSPECTION
1.Check:
• Commutator
Dirty → Clean it with #600 grit sandpaper.
2.Measure:
• Commutator diameter @
Out of specification → Replace starter motor
@
Commutator wear limit:
14.8 mm
@
3.Measure:
• Mica undercut @
Out of specification → Scrape the mica to
proper value using a hacksaw blade can be
ground to fit.
Mica undercut @:
1.15 mm
N.B.:
The mica insulation of the commutator must be
undercut to ensure proper operation of
commutator.
4.Inspect:
• Armature coil (insulation/continuity)
Defects → Replace starter motor.
**********************************************************
Inspecting steps:
• Connect the pocket tester for continuity check
햲 and insulation check 햳.
• Measure the armature resistances.
Armature coil resistance:
Continuity check 햲:
0.06 ~ 0.08 Ω at 20°C
Insulation check 햳:
More than 1 MΩ
햲
햳
• If the resistance is incorrect, replace the starter
motor.
********************************************************
7-15
STARTER MOTOR
ELEC
5.Measure:
• Brush length @
Out of specification → Replace.
Brush length limit @:
0.9 mm
@
6.Measure:
• Brush spring force
Fatigue/Out of specification → Replace as a
set.
Brush spring force:
563 ~ 844 g
7-16
ELEC
CHARGING SYSTEM
CHARGING SYSTEM
CIRCUIT DIAGRAM
(RED)
T
A
(RED)
Br R
Gy B
Gy B
Br R
B
B
R
R
Gy Br R B BW
LOCK
OFF
MAIN HARNESS STARTER MOTOR
CHECK
BW
ON
BW
W
W
YR
YR
B
R W B YR
R
W
I
GY
LW
GY
GY
GW
BR
WR
WL
WR
WL
BR GW
GW BR
WR WL
WL WR
W
Or
B
E
Or
R
M
P
B
B
BAB
R
U
LW
GW
BR
YR
RAR
R
LW
YR
B
LW
{
B
A
YR YB LR L
LW B
OFF
ON
OFF
B YB L
LW YR LR
PO
LW YR LR
B YB L
L
LR
B
Br
Br
B
G
12V 1.2W
12V 1.2W
I
H
o
D
B P
J
OFF
12V 1.2W
ON
Dg
Dg
B
Ch BrW Dg
Y Dg L
B
N
LOW
Y
B
-
L Dg Y
BrW
BrW
GB Ch P
R
12V 1.2W
Ch
B
L
Ch
B
p
E
GB L Y
HI
Ch
Y
12V 5W
C
B
G
D
Br
P
}
L
BrW
BrW
Br
LR
Gy
A
Br
LR
i
u
Br
S
ON
-
B
P Ch GB
GY
Dg
Gy
LR
Br
LR
K
Gy
GY
LR
Q
O
Br
[
W
YR
B
Y
Or
B
BW
R
Br
Gy
BW
LR
GY
LR
GY
Ch
Dg
Ch
Dg
B
B
B
B
B
B
y
Ch
Dg
Ch
Dg
B
B
B
B
YR
B LR
Y GB
LR B
GB Y
G
B
Y
q
LR
M
GB
Br
YR
G
B
]
G
B
12V 5W
F
G
12V
35W / 35W
12V10W
12V10W
12V10W
12V10W
w
e
r
t
B
B
B
12V
21W / 5W
B
B
Q CDI magneto
Y Fuse
U Battery
I Rectifier/Regulator
7-17
B
B
B
CHARGING SYSTEM
ELEC
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED
Procedure
Check:
1. Fuse (main)
2. Battery
3. Charging voltage
4. Charging coil resistance
5. Connections
NOTE:
• Remove the following parts before proceeding with the troubleshooting:
1) Battery cover
2) Side covers (right and left)
• For accurate troubleshooting special
tools:
Inductive tachometer:
90890-03113
Pocket tester:
90890-03112
NO CONTINUITY
1.Fuse.
Refer to "SWITCH INSPECTION" section.
Replace the fuse.
CONTINUITY
DOES NOT MEET SPECIFICATION
2.Battery
• Check the condition of the battery.
Refer to "CHECKING THE BATTERY" in
the Chapter 3.
• Clean battery terminals.
• Charge or replace the battery.
MEETS
SPECIFICATION
7-18
CHARGING SYSTEM
ELEC
3. Charging voltage
-
• Connect the engine tachometer to the spark
plug lead.
• Connect the pocket tester (DC20V) to the
battery terminals.
Pocket tester (+) lead →
Battery (+) terminals
Pocket tester (-) lead →
Battery (-) terminals
• Start the engine and accelerate to about
5.000 rpm.
• Check the charging voltage.
MEETS SPECIFICATION
Charging voltage:
14 ~ 15V at 5.000 r/min
NOTE:
Use a fully charged battery.
Charging circuit is OK.
OUT OF
SPECIFICATION
7-19
+
CHARGING SYSTEM
ELEC
햲
4. Charging coil resistance
W
YR
• Disconnect the CDI magneto coupler from
the wire harness.
• Connect the pocket tester (Ω x 1) to the
charging coil.
GW
BR BR GW
WR WR
WL
WL
햳
Pocket tester (+) lead → White 햲
Pocket tester (-) lead → Ground 햳
• Check the charging coil resistance.
OUT OF SPECIFICATION
Charging coil resistance:
0.48 ~ 0.72 Ω at 20°C
Charging coil defect → Replace.
MEETS
SPECIFICATION
5.Connections
• Check all connections in the charging system.
Refer to "WIRING DIAGRAM".
POOR CONNECTIONS
Repair.
MEETS
SPECIFICATION
Replace the rectifier/regulator.
7-20
ELEC
LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM
(RED)
T
A
(RED)
Br R
Gy B
Gy B
Br R
B
B
R
R
Gy Br R B BW
LOCK
OFF
MAIN HARNESS STARTER MOTOR
CHECK
BW
ON
BW
W
W
YR
YR
B
R W B YR
R
W
I
GY
LW
GY
GY
GW
BR
WR
WL
WR
WL
BR GW
GW BR
WR WL
WL WR
W
Or
B
E
Or
R
M
P
B
B
BAB
R
U
LW
GW
BR
YR
RAR
R
LW
{
YR
B
Gy
LW
B
A
LW B
OFF
ON
YR YB LR L
OFF
B YB L
LW YR LR
PO
LW YR LR
B YB L
L
LR
Br
Br
B
12V 1.2W
o
D
B P
J
H
12V 5W
OFF
12V 1.2W
Ch BrW Dg
Y Dg L
L
HI
B
N
LOW
Ch
B
Y
E
GB L Y
ON
Dg
p
B
C
G
12V 1.2W
I
D
Br
P
}
L
B
G
BrW
BrW
Br
LR
Gy
A
Br
LR
i
u
Br
S
ON
B
-
L Dg Y
BrW
BrW
GB Ch P
R
B
-
B
P Ch GB
GY
B
12V 1.2W
Ch
Dg
Y
Dg
Ch
LR
Br
LR
K
Gy
GY
LR
Q
O
Br
[
W
YR
B
Y
Or
B
BW
R
Br
Gy
BW
LR
GY
LR
GY
Ch
Dg
Ch
Dg
B
B
B
B
B
B
y
Ch
Dg
Ch
Dg
B
B
B
B
YR
B LR
Y GB
LR B
GB Y
G
B
Y
q
LR
M
GB
Br
YR
G
B
]
G
B
12V 5W
F
G
12V
35W / 35W
12V10W
12V10W
12V10W
12V10W
w
e
r
t
B
B
B
12V
21W / 5W
B
B
B
B
B
Q CDI magneto
{ Right handle switch
B Lighting switch
} Left handle switch
D "HI/LO" switch
q Head light assy
F Head light
G Position light
A Meter assembly
H Meter light
K High beam indicator light
y Taillight
S Resistor
D License light
7-21
LIGHTING SYSTEM
TROUBLESHOOTING
THE HEADLIGHT, HEADLIGHT
INDICATOR, POSITION LIGHT, METER
LIGHT, LICENSE LIGHT AND/OR
TAILLIGHT DO NOT WORK
Procedure
Check:
1. "LIGHTS" switch
2. Lighting coil resistance
3. "HI/LO" switch
4. Connections
NOTE:
• Remove the following parts before proceeding with the troubleshooting:
1) Side covers
2) Handlebar covers
3) Front panel
• For accurate troubleshooting use the following special tools.
Pocket tester:
90890-03112
7-22
ELEC
LIGHTING SYSTEM
ELEC
YP802018
NO CONTINUITY
1."LIGHTS" switch
Refer to "SWITCH INSPECTION" section.
Replace the right handlebar switch.
CONTINUITY
2.Lighting coil resistance
• Disconnect the lighting coil coupler from the
wire harness.
• Connect the pocket tester (Ω x 0,1) to the
lighting coil.
W
YR
햲
Pocket tester (+) lead → Yellow/Red 햲
Pocket tester (-) lead → Ground 햳
• Check the lighting coil resistance.
GW
BR BR GW
WR WR
WL
WL
햳
OUT OF SPECIFICATION
Lighting coil resistance:
0.40 ~ 0.60 Ω at 20°C
Lighting coil defect → Replace.
MEETS
SPECIFICATION
NO CONTINUITY
3."HI/LO" switch
Refer to "SWITCH INSPECTION".
Replace the "HI/LO" switch .
CONTINUITY
POOR CONNECTIONS
4.Connections
• Check all connections in the lighting system.
Refer to "WIRING DIAGRAM"
Repair.
CORRECT
Circuit is in good condition.
7-23
ELEC
LIGHTING SYSTEM
LIGHTING SYSTEM CHECK
1.Headlight and high beam indicator light do not
work.
NO CONTINUITY
1.Bulb and socket.
Refer to "SWITCH INSPECTION".
햲
• Connect the pocket tester (AC20V) to the
headlight and the high beam indicator light
couplers.
12V
35W / 35W
Headlight:
• "LO":
Pocket tester (+) lead → Green/Black 햲
Pocket tester (-) lead → Black 햴
• "HI":
Pocket tester (+) lead → Yellow 햳
Pocket tester (-) lead → Black 햴
• High beam indicator light:
Pocket tester (+) lead → Yellow 햵
Pocket tester (-) lead → Black 햶
•
•
•
•
•
Set the main switch to "ON".
Start the engine.
".
Set the light switch to "
Switch from " " to " " and back.
Check for voltage (12 V) to the bulb socket
connector.
햳
Y
2.Voltage
GB
Replace the bulb or socket.
CONTINUITY
햴
햶
Br
I
12V 1.2W
LR
G
12V 1.2W
J
H
12V 1.2W
Dg
Ch
B
Y
Dg
B
Y
12V 1.2W
Ch
K
Gy
Br
YR
Br
M
YR
B
OUT OF SPECIFICATION
MEETS
SPECIFICATION
There is a defect in the wire harness between
the main switch and the bulb socket connector
→ Repair.
Circuit is in good condition.
3.The front position light does not work.
1.Bulb and socket.
L
B
G
햵
Br
Gy
LR
B
NO CONTINUITY
Refer to " SWITCH INSPECTION " section.
Replace bulb or socket.
CONTINUITY
7-24
ELEC
LR
LIGHTING SYSTEM
2.Voltage
햴
햲
• Connect the pocket tester (AC 20 V) to the
front position light connectors.
12V 5W
Pocket tester (+) lead → Blue/Red 햲
Pocket tester (-) lead → Black 햳
햳
Pocket tester (+) lead → Blue/Red 햴
Pocket tester (-) lead → Black 햵
•
•
•
•
Set the main switch to "ON".
Start the engine.
" or "
".
Set the light switch to "
Check for voltage (12 V) to the front position
light terminals.
햵
B
OUT OF SPECIFICATION
There is a defect in the wire harness between
the main switch and the bulb socket connector
→ Repair.
MEETS
SPECIFICATION
Circuit is in good condition.
3.The meter light does not work.
1.Bulb and socket.
NO CONTINUITY
Refer to " SWITCH INSPECTION " section.
2.Voltage
햳
• Connect the pocket tester (AC 20 V) to the
meter light coupler.
Br
I
12V 1.2W
LR
G
12V 1.2W
J
H
12V 1.2W
•
•
•
•
Set the main switch to "ON".
Start the engine.
" or "
".
Set the light switch to "
Check for voltage (12 V) to the meter light
coupler.
Dg
Ch
B
Y
Dg
Pocket tester (+) lead → Blue/Red 햲
Pocket tester (-) lead → Black 햳
L
B
G
햲
Br
Gy
LR
Replace bulb or socket.
CONTINUITY
B
Y
12V 1.2W
Ch
K
Gy
Br
YR
Br
M
YR
B
OUT OF SPECIFICATION
MEETS
SPECIFICATION
There is a defect in the wire harness between
the main switch and the meter light coupler
→ Repair.
Circuit is in good condition.
7-25
LIGHTING SYSTEM
ELEC
4.The taillight does not work.
1.Bulb and socket.
NO CONTINUITY
Refer to " SWITCH INSPECTION " section.
CONTINUITY
Replace bulb or socket.
LR
• Connect the pocket tester (AC 20 V) to the
taillight connectors.
GY
2.Voltage
햲
LR
GY
LR
GY
B
B
12V
21W / 5W
Pocket tester (+) lead → Blue/Red 햲
Pocket tester (-) lead → Black 햳
•
•
•
•
Set the main switch to "ON".
Start the engine.
" or "
".
Set the light switch to "
Check for voltage (12 V) to the taillight
coupler.
햳
B
OUT OF SPECIFICATION
MEETS
SPECIFICATION
There is a defect in the wire harness between
the main switch and the taillight connectors
→ Repair.
Circuit is in good condition.
4.The license light does not work.
1.Bulb and socket.
NO CONTINUITY
Refer to " SWITCH INSPECTION " section.
CONTINUITY
Replace bulb or socket.
7-26
LIGHTING SYSTEM
ELEC
2.Voltage
LR
햲
• Connect the pocket tester (AC 20 V) to the
license light coupler.
12V 5W
Pocket tester (+) lead → Blue/Red 햲
Pocket tester (-) lead → Black 햳
•
•
•
•
Set the main switch to "ON".
Start the engine.
" or "
".
Set the light switch to "
Check for voltage (12 V) to the license light
coupler.
햳
B
OUT OF SPECIFICATION
MEETS
SPECIFICATION
There is a defect in the wire harness between
the main switch and the bulb socket connector
→ Repair.
Circuit is in good condition.
7-27
ELEC
SIGNAL SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM
(RED)
T
A
(RED)
Br R
Gy B
Gy B
Br R
B
B
R
R
Gy Br R B BW
LOCK
OFF
MAIN HARNESS STARTER MOTOR
CHECK
BW
ON
BW
W
W
YR
YR
B
R W B YR
R
W
I
GY
LW
GY
GY
GW
BR
WR
WL
WR
WL
BR GW
GW BR
WR WL
WL WR
W
Or
B
E
Or
R
M
P
B
B
BAB
R
U
LW
GW
BR
YR
RAR
R
Br
YR
B
Gy
LW
{
B
A
LW B
OFF
ON
YR YB LR L
OFF
B YB L
LW YR LR
PO
LW YR LR
B YB L
L
LR
Br
Br
B
G
12V 1.2W
12V 1.2W
I
o
D
B P
J
H
12V 5W
OFF
12V 1.2W
Y
Ch BrW Dg
Y Dg L
L
HI
B
N
LOW
Ch
B
E
GB L Y
ON
Dg
p
B
C
B
G
D
Br
P
}
L
BrW
BrW
Br
LR
Gy
A
Br
LR
i
u
Br
S
ON
B
R
B
-
L Dg Y
BrW
BrW
GB Ch P
-
B
P Ch GB
GY
Y
B
12V 1.2W
Ch
Dg
Dg
Ch
LR
Br
LR
K
Gy
YR
GY
LR
Q
YR
O
LW
[
W
B
Y
Or
B
BW
R
Br
Gy
BW
LR B
GB Y
G
B
Y
q
B LR
Y GB
LR
M
GB
Br
YR
G
B
]
G
B
G
Ch
Dg
B
B
B
B
Ch
Dg
Ch
Dg
B
B
B
B
12V
21W / 5W
LR
GY
LR
GY
B
B
y
12V10W
12V10W
12V10W
12V10W
w
e
r
t
B
B
T Main switch
Y Fuse
U Battery
} Left handle switch
C Horn switch
E Flasher switch
w Front flasher light (left)
e Front flasher light (right)
Dg
12V 5W
F
12V
35W / 35W
B
Ch
B
B
B
B
B
r Rear flasher light (left)
t Rear flasher light (right)
y "STOP" light
u Horn
i Flasher relay
o Front brake switch
p Rear brake switch
[ Oil level gauge
7-28
] Fuel sender
A Meter assembly
I Oil indicator light
J Flasher indicator light
L Fuel meter
M Tachometer
SIGNAL SYSTEM
ELEC
TROUBLESHOOTING
FLASHER LIGHTS, TAIL/BRAKE LIGHT,
"OIL" WARNING LIGHT DO NOT WORK.
HORN DOES NOT SOUND, FUEL METER
DOES NOT WORK.
Procedure
Check:
1. Fuse (main)
2. Battery
3. Main switch
4. Connections
NOTE:
• Remove the following parts before proceeding
with the troubleshooting:
1) Side covers and footrest board
2) Handlebar covers
3) Front panel
• For accurate troubleshooting use the following
special tools:
Pocket tester:
90890-03112
1.Fuse.
Refer to "SWITCH INSPECTION" section.
NO CONTINUITY
CONTINUITY
Replace the fuse.
2.Battery
• Check the condition of the battery.
Refer "CHECKING THE BATTERY" in the
Chapter 3.
DOES NOT MEET SPECIFICATION
• Clean battery terminals.
• Charge or replace the battery.
Battery voltage:
12.8 or more at 20°C
MEETS
SPECIFICATION
3.Main switch
NO CONTINUITY
Refer to "SWITCH INSPECTION" in the
Chapter 7.
CONTINUITY
Replace the main switch.
7-29
SIGNAL SYSTEM
4.Connections
• Check all connections in the signal system.
Refer to "WIRE DIAGRAM".
POOR CONNECTIONS
Repair.
CONTINUITY
Check the condition of each circuit of the
signal system.
Refer to "SIGNAL SYSTEM CHECK".
7-30
ELEC
SIGNAL SYSTEM
ELEC
SIGNAL SYSTEM CHECK
1. Horn does not sound.
1."HORN" switch
NO CONTINUITY
Refer to "SWITCH INSPECTION".
Replace the horn switch.
CONTINUITY
2.Voltage
햲
• Connect the pocket tester (DV20 V ) to the
horn lead.
Pocket tester (+) lead → Brown 햲
Pocket tester (-) lead → Ground 햳
• Turn the main switch to "ON".
• Check for voltage (12 V) between "Brown"
and the ground.
OUT OF SPECIFICATION
Defect in the wire harness between the main
switch and the horn → Repair.
3.Horn
HORN SOUNDS
Horn is in good condition.
HORN DOES
NOT SOUND
4.Horn
• Connect the pocket tester (DC20 V) to the
horn lead.
Br
P
햲
Pocket tester (+) lead → Pink 햲
Pocket tester (-) lead → Ground
• Turn the main switch to "ON".
• Press the "HORN" switch.
• Check the voltage (12V) between "Pink"
and ground.
P
햳
MEETS
SPECIFICATION
• Disconnect the "Pink" lead at the horn terminal.
• Ground the horn terminal with a jumper lead.
• Set the main switch to "ON".
Br
NO CONTINUITY
MEETS
SPECIFICATON
Replace Horn.
Adjust Horn.
7-31
SIGNAL SYSTEM
ELEC
2. The brake light does not work.
NO CONTINUITY
1.Bulb and socket.
Refer to "SWITCH INSPECTION".
Replace bulb or socket.
CONTINUITY
NO CONTINUITY
2.Brake switch
Refer to "SWITCH INSPECTION".
Brake switch is defect → Replace.
CONTINUITY
3.Voltage
• Connect the pocket tester (DC 20 V ) to the
bulb socket connectors.
LR
GY
Pocket tester (+) lead → Green/Yellow 햲
Pocket tester (-) lead → Black 햳
LR
GY
LR
GY
B
B
햲
12V
21W / 5W
햳
B
OUT OF SPECIFICATION
• Turn the main switch to "ON".
• Pull the brake lever.
• Check the voltage (12V) between Green/
Yellow and Black.
4.Connections
• There is a defect in the wire harness between the main switch and the taillight bulb
socket connector → Repair.
Refer to "CIRCUIT DIAGRAM OF THE SIGNAL SYSTEM".
MEETS
SPECIFICATION
Circuit is in good condition.
7-32
ELEC
SIGNAL SYSTEM
3.Flashers and flasher indicator do not work.
NO CONTINUITY
1.Bulb and socket
Refer to "SWITCH INSPECTION".
Replace buld and/or socket.
CONTINUITY
NO CONTINUITY
2.Flasher switch
Refer to "SWITCH INSPECTION".
Replace the left handlebar switch.
Br
CONTINUITY
3.Voltage
BrW
• Connect the pocket tester (DC 20 V ) to the
flasher relay.
BrW
Pocket tester (+) lead → Brown 햲
Pocket tester (-) lead → Ground 햳
• Turn the main switch to "ON".
• Check the voltage (12 V) between the
"Brown" lead and the Ground.
햲
OUT OF SPECIFICATION
Defect in the wire harness between the main
switch and the flasher relay → Repair.
Br
MEETS
SPECIFICATION
햲
4.Voltage
BrW
• Connect the pocket tester (DC20 V) to the
flasher connector.
Br
BrW
Pocket tester (+) lead → Brown/White 햲
Pocket tester (-) lead → Ground 햳
• Turn the main switch to "ON".
• Check the voltage (12 V) between
"Brown/White" and the ground.
햳
Br
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Flasher relay defect → Replace.
7-33
햳
SIGNAL SYSTEM
햲
햳
5.Voltage
• Connect the pocket tester (DC 20 V) to the
flasher coupler.
ELEC
햴
햵
Ch
B
Dg
B
Ch
Dg
B
B
12V10W
Left flasher bulb
Pocket tester (+) lead → Chocolate 햲
Pocket tester (-) lead → Black 햳
12V10W
B
B
Right flasher bulb
Pocket tester (+) lead → Dark green 햴
Pocket tester (-) lead → Black 햵
• Turn the main switch "ON".
• Set the "TURN" switch to "L", then to "R".
• Check the voltage (12 V) between
"chocolate" and the ground, then "Dark
green" and the ground.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
6.Connections
This circuit is in good condition.
• Defect in the wire harness between the
main switch and the flasher bulb socket
→ Repair.
Refer to "WIRING DIAGRAM".
4.The "Oil" indicator light does not work.
NO CONTINUITY
1.Bulb and socket
Refer to "SWITCH INSPECTION".
Replace buld and/or socket.
CONTINUITY
OUT OF SPECIFICATION
2.Oil level switch
Refer to "SWITCH INSPECTION".
Replace oil level switch is defect.
MEETS
SPECIFICATION
7-34
ELEC
Br
Gy
LR
SIGNAL SYSTEM
Br
3. Voltage
I
J
H
12V 1.2W
B
Y
Dg
햲
Pocket tester (+) lead → Grey 햲
Pocket tester (-) lead → Black 햳
• Turn the main switch to "CHECK"
• Check the voltage (12V) between "Grey"
and "Black"
12V 1.2W
G
LR
• Connect the pocket tester (DC20V) to the
bulb socket connector
L
B
12V 1.2W
햳
B
12V 1.2W
Ch
K
Gy
Br
Br
M
YR
B
OUT OF SPECIFICATION
MEETS
SPECIFICATION
6.Connections
• Check all connections in the signal system.
Refer to "WIRING DIAGRAM".
This circuit is in good condition.
5.The fuel meter does not work.
1. Voltage
• Disconnect the fuel sender leads.
• Connect the pocket tester (Ω x 100) then
(Ωx10) to the fuel sender.
• Drain the fuel tank.
• Measure the resistance.
Sender unit resistance
(empty tank):
90 ~ 100 Ω at 20°C
• Fill the tank
• Measure the resistance.
Sender unit resistance
(fuel tank):
1.5 ~ 7.5 Ω at 20°C
DOES NOT MEET SPECIFICATION
MEETS
SPECIFICATION
Replace the fuel sender.
This circuit is in good condition.
7-35
TRBL
SHTG
8
TRBL
SHTG
CHAPTER 8.
TROUBLESHOOTING
STARTING FAILURE/ HARD STARTING .................................................... 8-1
FUEL SYSTEM ........................................................................................ 8-1
ELECTRICAL SYSTEM ........................................................................... 8-1
COMPRESSION SYSTEM ...................................................................... 8-2
POOR IDLE SPEED PERFORMANCE ......................................................... 8-2
POOR IDLE SPEED PERFORMANCE ................................................... 8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE ................................ 8-3
FUEL SYSTEM ........................................................................................ 8-3
ELECTRICAL SYSTEM ........................................................................... 8-3
COMPRESSION SYSTEM ...................................................................... 8-3
FAULTY AUTOMATIC (V-BELT TYPE) ........................................................ 8-3
MOTORCYCLE DOES NOT MOVE WHILE ENGINE IS OPERATING ... 8-3
CLUTCH -OUT FAILURE ......................................................................... 8-4
POOR STANDING START (LOW CLIMBING ABILITY) .......................... 8-4
POOR ACCELERATION (POOR HIGH SPEED) .................................... 8-4
OVER HEATING ............................................................................................ 8-4
OVER HEATING ...................................................................................... 8-4
IMPROPER KICKING .................................................................................... 8-5
SLIPPING ................................................................................................. 8-5
HARD KICKING ....................................................................................... 8-5
KICK CRANK NOT RETURNING ............................................................ 8-5
FAULTY BRAKE ........................................................................................... 8-5
POOR BRAKING EFFECT ...................................................................... 8-5
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION ......... 8-6
OIL LEAKAGE .......................................................................................... 8-6
MALFUNCTION ....................................................................................... 8-6
INSTABLE HANDLING ................................................................................. 8-6
INSTABLE HANDLING ............................................................................ 8-6
FAULTY SIGNAL AND LIGHTING SYSTEM ................................................ 8-7
STARTING FAILURE/HARD STARTING
TRBL
SHTG
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection,
adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING
FUEL SYSTEM
Fuel tank
• Empty
• Clogged fuel filter
• Deteriorated fuel or fuel containing water or
foreign material
• Clogged fuel tank cap
Fuel cock
• Clogged fuel hose
• Clogged vacuum
• Faulty diaphragm
Air filter
• Clogged air filter
Carburetor
• Deteriorated fuel, fuel containing water or
foreign material
• Clogged pilot jet
• Clogged pilot air passage
• Sucked-in air
• Deformed float
• Groove-worn needle valve
• Improperly sealed valve seat
• Improperly adjusted fuel level
• Improperly set pilot jet
• Clogged starter jet
• Starter plunger malfunction
• Improperly adjusted pilot air screw
ELECTRICAL SYSTEM
Spark plug
• Improper plug gap
• Worn electrodes
• Wire between terminals broken
• Improper heat range
• Faulty spark plug cap
Ignition coil
• Broken or shorted primary/secondary coil
• Faulty spark plug lead
• Broken body
Starter motor
• Faulty starter motor
• Faulty starter relay
CDI unit system
• Faulty CDI unit
• Faulty source coil
• Faulty pick-up coil
Switches and wiring
• Faulty main switch
• Broken or shorted wiring
• Faulty brake switch (front or rear)
8-1
STARTING FAILURE/HARD STARTING/
POOR IDLE SPEED PERFORMANCE
COMPRESSION SYSTEM
Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Broken cylinder head gasket
• Broken cylinder gasket
• Worn, damaged or seized cylinder
Piston and piston rings
• Improperly installed piston ring
• Worn, fatigued or broken piston ring
• Seized piston ring
• Seized or damaged piston
TRBL
SHTG
Crankcase and crankshaft
• Improperly seated crankcase
• Improperly sealed crankcase
(damaged oil seal)
• Seized crankshaft
Reed valve
• Deformed reed valve stopper
• Improperly seated reed valve
• Loose intake manifold
• Broken gasket
• Broken reed valve
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
Carburetor
• Improperly returned starter plunger
• Clogged or loose pilot jet
• Clogged pilot air jet
• Improperly adjusted idle speed ( throttle stop screw)
• Improper throttle cable play
• Flooded carburetor
8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE/
FAULTY AUTOMATIC
TRBL
SHTG
POOR MEDIUM AND HIGH SPEED PERFORMANCE
FUEL SYSTEM
Fuel tank
• Clogged fuel filter
• Deteriorated fuel or fuel containing water or
foreign material
• Clogged fuel tank cap
Fuel cock
• Clogged fuel hose
• Clogged vacuum hose
• Faulty diaphragm
Air filter
• Clogged air filter
Carburetor
• Deteriorated fuel, fuel containing water or
foreign material
• Sucked-in air
• Deformed float
• Groove-worn needle valve
• Improperly sealed valve seat
• Improperly set clip position of jet needle
• Improperly adjusted fuel level
• Clogged or loose main jet
• Clogged or loose main nozzle
• Clogged main air passage
ELECTRICAL SYSTEM
Spark plug
• Improper plug gap
• Worn electrodes
• Wire between terminals broken
• Improper heat range
• Faulty spark plug cap
CDI unit system
• Faulty CDI unit
• Faulty source coil
• Faulty pick-up coil
COMPRESSION SYSTEM
Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Broken cylinder head gasket
• Broken cylinder gasket
• Worn, damaged or seized cylinder
Piston and piston rings
• Improperly installed piston ring
• Worn, fatigued or broken piston ring
• Seized piston ring
• Seized or damaged piston
Crankcase and crankshaft
• Improperly seated crankcase
• Improperly sealed crankcase
(damaged oil seal)
• Seized crankshaft
Reed valve
• Deformed reed valve stopper
• Improperly adjusted reed valve stopper height
• Improperly sealing reed valve
• Loose intake manifold
• Broken gasket
• Broken reed valve
FAULTY AUTOMATIC (V-BELT TYPE)
MOTORCYCLE DOES NOT MOVE WHILE ENGINE IS OPERATING.
V-belt
Secondary pulley
• Worn, damaged or slippery v-belt
• Broken compression spring
Primary pulley
• Pealed lining from clutch shoe
• Worn or damaged cam plate
• Worn spline of clutch housing
• Worn or damaged slider bushing
8-3
FAULTY AUTOMATIC/
OVER HEATING
CLUTCH-OUT FAILURE
Primary pulley
• Seized primary sliding pulley and collar
TRBL
SHTG
Secondary pulley
• Broken or fatigued clutch shoe spring
POOR STANDING START (LOW CLIMBING ABILITY)
V-belt
Secondary pulley
• Worn, damaged or slippery v-belt
• Fatigued compression spring
Primary pulley
• Improper operation of secondary sliding pulley
• Worn or improper operation of weight
POOR ACCELERATION (POOR HIGH SPEED)
V-belt
• Worn or greasy V-belt
Secondary pulley
• Worn or greasy clutch shoe
• Improper operation of secondary sliding pulley
OVER HEATING
OVER HEATING
Ignition system
• Improper spark plug gap
• Improper spark plug heat range
• Faulty ignitor unit
Engine oil
• Improper engine oil quality (high viscosity)
• Low engine oil quality
Brakes
• Dragging brake
Fuel system
• Improper carburetor setting
• Improper fuel level adjustment
• Clogged air cleaner element
• Lean mixture (Air in the autolube pump)
Cooling fan
• Damaged cooling fan
• Damaged air shrouds
Compression system
• Heavy carbon deposit build-up
8-4
IMPROPER KICKING/
FAULTY BRAKE
TRBL
SHTG
IMPROPER KICKING
SLIPPING
Kick axle assembly
• Low tension of kick clip
• Worn kick axle
• Worn or damaged kick gear
• Damaged kick clip
• Kick clip coming off
• Damaged kick clip stopper
Transmission oil
• Improper quality (low viscosity)
• Deterioration
HARD KICKING
Kick axle assembly
• High tension of kick clip
• Seized kick gear
Crankcase and crankshaft
• Improperly seated crankcase
• Improperly seated crankshaft
• Damaged or seized crankshaft
• Damaged or seized crankshaft bearing
Cylinder, piston and piston ring
• Damaged or seized cylinder
• Damaged or seized piston
• Damaged or seized piston ring
KICK CRANK NOT RETURNING
Kick axle assembly
• Damaged kick return spring
• Kick return spring coming off
• Kick clip coming off
• Damaged kick return spring stopper
FAULTY BRAKE
POOR BRAKING EFFECT
Front disc brake
• Worn brake pads
• Worn disc
• Air in brake fluid
• Leaking brake fluid
• Wrong brake fluid
• Seized main cylinder piston
• Faulty caliper seal kit
• Loose union bolt
• Broken brake hose
• Oily or greasy disc/brake pads
• Improper brake fluid level
• Excessive free play (brake lever)
Rear drum brake
• Worn brake shoe
• Worn or rusty brake drum
• Improperly adjuster brake play
• Improper brake cam lever
• Improper brake shoe position
• Fatigue/damaged return spring
• Oily or greasy brake shoe
• Oily or greasy brake drum
• Broken brake cable
8-5
FRONT FORK OIL LEAKAGE AND FRONT FORK
MALFUNCTION/
INSTABLE HANDLING
TRBL
SHTG
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION
OIL LEAKAGE
• Bent, damaged or rusty inner tube
• Damaged or cracked outer tube
• Damaged oil seal lip
• Improperly installed oil seal
• Improper oil level (too much)
• Loose damper rod holding bolt
• Broken cap bolt O-ring
• Loose drain bolt or damaged drain bolt gasket
MALFUNCTION
• Bent, deformed or damaged inner tube
• Bent or deformed outer tube
• Damaged fork spring
• Worn or damaged slide metal
• Bent or damaged damper rod
• Improper oil viscosity
• Improper oil level
INSTABLE HANDLING
INSTABLE HANDLING
Handlebar
• Improperly installed or bent
Wheels
• Damaged bearing
• Bent or loose wheel axle
• Excessive wheel run-out
Steering
• Improperly installed steering column
(Improperly tightened ring nut)
• Bent steering column
• Damaged ball bearing or bearing race
Frame
• Twisted
• Damaged head pipe
• Improperly installed bearing race
Front forks
• Broken damper spring
• Bent or deformed suspension arm and pivots
• Oil level
Engine bracket
• Bent or damaged
Tires
• Incorrect tire pressure
• Uneven tire pressures on both sides
• Unevenly worn tires
Rear shock absorber
• Fatigued spring
• Oil leakage
8-6
FAULTY SIGNAL AND LIGHTING SYSTEM
TRBL
SHTG
FAULTY SIGNAL AND LIGHTING SYSTEM
Headlight dark
• Improper bulb
• Too many electric accessories
• Hard charging (broken charging coil)
• Incorrect connection
• Improperly grounded
• Poor contacts (main or light switch)
• Bulb life expired (high internal resistance)
Flasher does not light
• Improperly grounded
• Discharged battery
• Faulty flasher switch
• Faulty flasher relay
• Broken wire harness
• Loosely connected coupler
• Bulb burnt out
• Faulty fuse
Bulb burnt out
• Improper bulb
• Improperly grounded
• Faulty main and/or light switch
• Bulb life expired
Flasher keeps on
• Faulty flasher relay
• Insufficient battery capacity
(nearly discharged)
Flasher winks slower
• Faulty flasher relay
• Insufficient battery capacity (nearly discharged)
• Improper bulb
• Faulty main and/or flasher switch
Horn is inoperative
• Faulty battery
• Faulty fuse
• Faulty main and/or horn switch
• Improperly adjusted horn
• Faulty horn
• Broken wire harness
Flasher winks quicker
• Improper bulb
• Faulty flasher relay
8-7
Br R
T
(RED)
Gy B
Gy B
Br R
Q
W
E
R
T
Y
U
I
O
P
{
A
(RED)
YQ100 WIRING DIAGRAM
B
B
R
R
Gy Br R B BW
LOCK
OFF
MAIN HARNESS STARTER MOTOR
CHECK
BW
ON
BW
R W B YR
R
Q
RAR
GY
U
LW
LW
GY
GY
Or
B
GW
BR
WR
WL
WR
WL
BR GW
GW BR
WR WL
WL WR
Or
B
E
W
Or
}
R
M
P
q
B
B
BAB
R
LW
GW
BR
YR
O
R
Br
[
W
YR
B
Y
w
e
r
t
y
u
i
o
p
[
]
A
YR
B
Gy
LW
{
B
A
YR YB LR L
LW B
OFF
COLOR CODE
ON
OFF
B YB L
LW YR LR
PO
LW YR LR
B YB L
S
ON
L
LR
B
B
Br
Br
Br
G
12V 1.2W
I
H
D
B P
J
OFF
12V 1.2W
ON
Dg
Y
Dg
B
Ch BrW Dg
Y Dg L
B
N
LOW
Y
-
S
D
L Dg Y
BrW
BrW
GB Ch P
R
B
12V 1.2W
Ch
B
L
HI
Ch
B
p
E
GB L Y
Ch
-
B
P Ch GB
GY
LR
Gy
Br
LR
K
YR
GY
LR
o
C
B
G
12V 5W
P
}
L
D
Br
Dg
Br
BrW
BrW
Br
LR
Gy
A
LR
i
u
12V 1.2W
B LR
Y GB
LR B
GB Y
G
B
LR
q
Y
M
YR
GB
Br
G
B
]
G
B
F
G
12V
35W / 35W
B
Ch
Dg
Ch
Dg
B
B
B
B
Ch
Dg
Ch
Dg
B
B
B
B
12V
21W / 5W
12V 5W
12V10W
12V10W
12V10W
12V10W
w
e
r
t
B
B
Black
Brown
Chocolate
Dark green
Green
Grey
Blue
Orange
Pink
Red
White
Yellow
Black/Red
Black/White
Brown/White
Green/Black
Green/White
Green/Yellow
Blue/Red
Blue/White
White/Blue
White/Red
Yellow/Black
Yellow/Red
W
YR
W
I
B
Br
Ch
Dg
G
Gy
L
Or
P
R
W
Y
B/R
B/W
Br/W
G/B
G/W
G/Y
L/R
L/W
W/L
W/R
Y/B
Y/R
W
YR
B
BW
R
Br
Gy
BW
B
B
B
B
B
LR
GY
LR
GY
B
B
y
C.D.I. magneto
C.D.I. unit
Ignition coil
Spark plug
Main switch
Fuse
Battery
Rectifier / regulator
Starter relay
Starter motor
Right handle switch
A Starter switch
B Light switch
Left handle switch
C "HORN" switch
D "Hi / Lo" switch
E Flasher switch
Head light assy
F Head light
G Position light
Left front flasher
Right front flasher
Left rear flasher
Right rear flasher
Tail / "STOP" light
Horn
Flasher relay
Front stop switch
Rear stop switch
Oil level gauge
Fuel sender
Meter assembly
H Meter light
I Oil indicator light
J Flasher indicator light
K High beam indicator light
L Fuel meter
M Tachometer
Resistor
License light